Servomex SERVOPRO Plasma User manual

Part Number: 02001001A
Revision: 9
Language: UK English
SERVOPRO Plasma
OPERATOR MANUAL

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Plasma Gas Analyzer
1 02001001A_9
CONTENTS
Section
Page
1DESCRIPTION AND DEFINITIONS............................................................... 5
1.1 Scope of this manual...................................................................................... 5
1.2 Safety information........................................................................................... 5
1.3 Description......................................................................................................6
1.3.1 Ordering options........................................................................................ 6
1.3.2 02001 Analyzer layout...............................................................................7
2SPECIFICATION............................................................................................9
2.1 General........................................................................................................... 9
2.2 Environmental limits........................................................................................ 9
2.3 Electrical data............................................................................................... 10
2.4 Sample Gases.............................................................................................. 10
2.5 Calibration gas.............................................................................................. 11
2.6 Performance................................................................................................. 11
3UNPACK THE ANALYZER...........................................................................12
4INSTALLATION AND SET-UP.....................................................................13
4.1 Mechanical installation rack mounting.......................................................... 15
4.2 Electrical Installation..................................................................................... 16
4.2.1 Electrical Safety.......................................................................................16
4.2.2 Connect the electrical supply................................................................... 17
4.2.3 Milliamp output connections.................................................................... 18
4.2.4 Alarm, remote range and status relay connections (general) ................. 19
4.2.5 Alarm output option ................................................................................. 20
4.2.6 RS232 connection (option)...................................................................... 22
4.3 Connect the sample/ auto calibration (optional) gas pipeline(s) ..................25
5GENERAL OPERATION .............................................................................. 28
5.1 Power on and start up...................................................................................28
5.2 Routine and operational verification............................................................. 29
5.3 Configuration ................................................................................................30
5.3.1 Auto ranging ............................................................................................ 30
5.3.2 Sample flow............................................................................................. 30
5.3.3 Analogue output mode ............................................................................30
5.3.4 mA failure mode.......................................................................................31
5.4 Calibration..................................................................................................... 32
5.5 Diagnosis...................................................................................................... 35
5.5.1 Error and Alarm Historic..........................................................................37
5.5.2 Serial number ..........................................................................................38
5.6 Run ............................................................................................................... 39
5.7 Special consideration about the 0 - 1 ppm range......................................... 40
5.8 Hidden Menu ................................................................................................41
5.8.1 Starting Count.......................................................................................... 41
5.8.2 Temperature Coefficient.......................................................................... 42
5.8.3 Time and date setting.............................................................................. 44
5.8.4 System Gain............................................................................................ 46
5.8.5 PID values ............................................................................................... 47
5.8.6 Lock range............................................................................................... 48

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5.8.7 Averaging Number...................................................................................49
5.8.8 Calibration done parameters................................................................... 50
6ROUTINE MAINTENANCE (STANDARD ANALYZER)............................... 51
6.1 Cleaning the analyzer................................................................................... 51
6.2 Inspecting/replacing the fuse (when necessary) ..........................................52
7SPARES.......................................................................................................53
8STORAGE AND DISPOSAL ........................................................................53
8.1 Storage .........................................................................................................53
8.2 Disposal........................................................................................................ 53
8.2.1 Product disposal in accordance with the Waste Electrical and Electronic
Equipment (WEEE) Directive .................................................................. 54
9COMPLIANCE AND STANDARDS INFORMATION.................................... 55
10 CONTACT INFORMATION..........................................................................55
APPENDIX 1: AUTOMATIC CALIBRATION OPTION ........................................................ 56
1AUTOMATIC CALIBRATION OPTION.........................................................57
1.1 Gas Circuit Description................................................................................. 57
1.2 System Operation......................................................................................... 58
1.3 Entering Zero and span gas values.............................................................. 58
1.4 Manual Calibration........................................................................................ 58
1.5 Automatic Calibration Mode .........................................................................61
APPENDIX 2: TRACE NITROGEN IN HELIUM VERSION................................................. 65
2TRACE NITROGEN IN HELIUM VERSION................................................. 66
2.1 User Manual ................................................................................................. 66
2.2 Flow Control System.....................................................................................66
2.3 Leaks ............................................................................................................66
2.4 Working with Helium..................................................................................... 66
APPENDIX 3: DUAL BACKGROUND ANALYZERS...........................................................68
3DUAL BACKGROUND ANALYZERS...........................................................69
3.1 NOTE TO THE READER..............................................................................69
3.2 User Manual ................................................................................................. 69
3.3 Flow control system...................................................................................... 69
3.4 Leaks ............................................................................................................69
3.5 Configuration and operation ......................................................................... 70
3.5.1 Introduction..............................................................................................70
3.5.2 HIDDEN menu access............................................................................. 70
3.5.3 Operating consideration .......................................................................... 72
APPENDIX 4: INTERFACE FOR EXTERNAL VALVE BOX...............................................74
4INTERFACE FOR EXTERNAL VALVE BOX (VB)....................................... 75
4.1 Description....................................................................................................75
4.2 Main Menu....................................................................................................75
4.3 Calibration Menu........................................................................................... 75
4.4 Status Data and Commands through the RS-232 Port................................76
4.5 Controlling the valves of Valve Box from the analyzer................................. 80

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Figure 1 - FRONT OF THE ANALYZER.................................................................................7
Figure 2 - REAR OF THE ANALYZER...................................................................................7
Figure 3 - INTERNAL SCHEMATIC.......................................................................................8
Figure 4 - DIMENSIONAL OUTLINE DRAWING .................................................................14
Figure 5 - INSTALL THE 02001 ANALYZER IN A PANEL................................................15
Figure 6 - REAR VIEW CUT OUT DIMENSIONS...............................................................15
Figure 7 - ANALOGUE OUTPUT INTERFACE CONNECTOR............................................18
Figure 8 - DIGITAL OUTPUT INTERFACE CONNECTOR ................................................19
Figure 9 - CONFIGURATION MENU, PAGE 2 ....................................................................20
Figure 10 - ENTERING ALARM #1 SET POINT..................................................................20
Figure 11 - RS232 CONNECTION PIN DETAILS................................................................23
Figure 12 - IDEAL INSTALLATION EXAMPLE....................................................................26
Figure 13 - POOR INSTALLATION EXAMPLE 1.................................................................26
Figure 14 - POOR INSTALLATION EXAMPLE 2.................................................................27
Figure 15 - POOR INSTALLATION EXAMPLE 3.................................................................27
Figure 16 - MAIN MENU ......................................................................................................28
Figure 17 - CONFIGURATION MENU .................................................................................30
Figure 18 - CONFIGURATION MENU - PAGE 2.................................................................31
Figure 19 - MAIN CALIBRATION.........................................................................................32
Figure 20 - DISPLAYED WHEN ENTERING ZERO VALUE................................................32
Figure 21- DISPLAYED WHEN ENTERING SPAN VALUE.................................................33
Figure 22 - CALIBRATION SUB MENU...............................................................................33
Figure 23 - DIAGNOSTIC MAIN MENU...............................................................................35
Figure 24 - DIAGNOSTIC MAIN MENU...............................................................................35
Figure 25 - DIAGNOSTIC MENU.........................................................................................36
Figure 26 - DIAGNOSTIC MENU........................................................................................37
Figure 27 - SERIAL NUMBER MENU..................................................................................38
Figure 28 - RUN MODE .......................................................................................................39
Figure 29 - HIDDEN MENU, FIRST PAGE ..........................................................................41
Figure 30 - TEMPERATURE COEFFICIENT.......................................................................42
Figure 31 - TEMPERATURE GAIN......................................................................................43
Figure 32 -TIME AND DATE SETTING (1) ..........................................................................44
Figure 33 - TIME AND DATE SETTING (2) .........................................................................44
Figure 34 - TIME AND DATE SETTING (3) .........................................................................45
Figure 35 - TIME AND DATE SETTING (4) .........................................................................45
Figure 36 - SYSTEM GAIN ..................................................................................................46
Figure 37 - GAS FLOW PID VALUES..................................................................................47
Figure 38 - CHANGING A PID VALUE.................................................................................47
Figure 39 - LOCK RANGE ...................................................................................................48
Figure 40 - AVERAGING NUMBER.....................................................................................49
Figure 41 - CALIBRATION DONE PARAMETERS..............................................................50
Figure 42 - CALIBRATION MODE SELECTION MENU ......................................................58
Figure 43: CALIBRATION FACTOR CALCULATION MENU...............................................59
Figure 44 - CALIBRATION FACTOR CALCULATION MENU..............................................60
Figure 45 - TRANSFER DELAY...........................................................................................61

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Figure 46 - FIRST PAGE OF THE HIDDEN MENU.............................................................61
Figure 47 - AUTOMATIC CALIBRATION TIMERS ..............................................................62
Figure 48 - ANALOG OUTPUT HOLD TO TRACK TRANSFER DELAY.............................62
Figure 49 - SERVOPRO PLASMA WITH AUTOMATIC CALIBRATION..............................64
Figure 50 - OPERATING PARAMETERS MENU.................................................................70
Figure 51 - BACKGROUND GAS SELECTION MENU........................................................71
Figure 52 - TEMPERATURE COEFFICIENT MENU ...........................................................71

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1 DESCRIPTION AND DEFINITIONS
1.1 Scope of this manual
This manual provides installation, operation and routine maintenance instructions for
the SERVOPRO Plasma Trace N2Analyzer, abbreviated to "analyzer" in the
remainder of this manual.
1.2 Safety information
Read this manual and ensure that you fully understand its content before you attempt
to install, use or maintain the analyzer. Important safety information is highlighted in
this manual as WARNINGs and CAUTIONs, which are used as follows:
WARNING
Warnings highlight specific hazards which, if not taken into account,
may result in personal injury or death.
Where the above symbol is marked on the equipment the manual must be consulted in order to find
out the nature of the potential hazards and any actions which have to be taken to avoid them.
CAUTION
Cautions highlight hazards which, if not taken into account, can result in
damage to the analyzer or to other equipment or property.
This manual also incorporates 'Be aware of' information, which is used as follows:

This highlights information which it is useful for you to be aware of (for
example, specific operating conditions, and so on).

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1.3 Description
WARNING
This analyzer is not a medical device as defined in the medical
devices directive 93/42/EEC and is not intended to be used on
human beings for the diagnosis, prevention, monitoring, treatment or
alleviation of disease, injury or replacement or modification of the
anatomy.
WARNING
The analyzer must not be used as personal protective equipment.
The analyzer is designed to meet the needs of the control and product quality
applications of industrial gas producers and users, who require fast, accurate and
reliable gas analysis.
Gas sample measurements are shown on the analyzer display, and can also be
output to a serial device connected to the analyzer, or as milliAmp (mA) output. The
SERVOPRO PLASMA Trace N2 Analyzer can support one gas measurement using a
plasma transducer measuring trace level nitrogen in argon or helium.
1.3.1 Ordering options
For the latest ordering options please contact your local Servomex agent or visit
www.servomex.com

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1.3.2 02001 Analyzer layout
Key
Description
1.
Keypad
2.
LCD display
3.
Power inlet
4.
Gas connections
5.
(Service port)
6.
RS-232 port
7.
IO Connector
Figure 1 - FRONT OF THE ANALYZER
Figure 2 - REAR OF THE ANALYZER
1
2
4
6
5
3
7

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Figure 3 - INTERNAL SCHEMATIC

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2 SPECIFICATION
WARNING
The protection, accuracy, operation and condition of the equipment
may be impaired if the analyzer is not installed in accordance with the
requirements of this and subsequent sections of the manual.
WARNING
Not suitable for flammable samples.
Never pressurise the analyzer.
Always remove vent plug before connecting the sample inlet.
2.1 General
Dimensions
Mass
(Height x Width x Depth):
133 mm x 483 mm x 457 mm
(5.25 ins x 19 ins x 18 ins)
15 kg
2.2 Environmental limits
Equipment is suitable for indoor use only
Ambient temperature range
Operation:
5 to 40°C
Storage:
–20 to 60°C
Operating ambient pressure range:
101.3 kPa ± 10% (1.013 bar ± 10%)
Operating ambient humidity range:
0 to 95% RH, non-condensing
Operating altitude range:
to 2000 †metres
Ingress protection:
IP20
†Above sea level.

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2.3 Electrical data
Electrical supply
Voltage:
100 - 120 Vac / 230 - 240 Vac, 50 to 60 Hz
(± 10% maximum fluctuation) (1)
Fuse rating / type:
Two fuses 1 amp / 250 V, Type “F”,
Breaking capacity 1.5kA @ 250 V AC
miniature fuses 5 x 20 mm
Maximum power consumption:
45W
Interface signal relay ratings:
30 Vrms, 42.4 V peak or 60 Vdc/ 1A
mA output (active)
Maximum load resistance:
600 Ω at 20 mA DC
Isolation voltage (to earth):
750 VDC or AC
Normal sample measurement:
4mA to 20 mA
Fault condition:
4 mA or 20 mA (can be set high or low)
(1) The analyzer is supplied configured for operation with one of these voltage ranges. You must specify the
voltage range when you order the analyzer.
2.4 Sample Gases

The sample gases must be, clean, non-corrosive, free from oil and
condensates and compatible with the materials listed in Appendix 1
Flow rate:
25 to 150 ml min-1
Pressure:
27.6 to 55.2 kPa gauge (max)
(5 to 10 Psig(max))
Dew point:
5 °C below ambient temperature (minimum)
Temperature:
5 to 40 °C
Particulate size:
< 2 µm (2 micron)
CAUTION
To retain the CE mark, do not operate above 70kPa (10psig)

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2.5 Calibration gas

The calibration gases must be clean, non-corrosive, free from oil and
condensates and compatible with the materials listed in Appendix 1
High calibration set point At least 90% FSD N2in Ar or He
Low calibration set point 6N Grade Ar or He
2.6 Performance
Detector type:
Plasma Emission Detector (PED). Material:
Quartz, single element, vacuum tight to 69 kPa (10
Psig)
Ranges:
Display Resolution:
Choice of one of the following -
0-1/0-10/0-100 ppm
0-10/0-50/0-100 ppm
0-10/0-50/0-250 ppm(3)
0-10/0-100/0-1000ppm (3)
0-1 ppm range: 10 ppb
0-10 ppm range: 0.1 ppm
0-50ppm range: 0.5 ppm
0-100, 250, 500, 1000 ppm ranges: 1ppm
Auto-zero, auto-span calibration system: (optional)
Serial port: RS-232 (optional)
Digital output: 3 range indication, 1 system status
0-1/ 0-10 /0-100
ppm
0-10 /0-50/ 0-100
ppm
0-10/ 0-50/ 0-250
ppm (3)
0-10/ 0-100/
0-1000 ppm (3)
Accuracy (1)
±1% Range (2)
±1% Range (2)
± 5% Range (2)
± 5% Range (2)
Drift over 24
hours
±1% Range(2)
±1% Range (2)
± 1% Range (2)
±1% Range (2)
Noise (1)
± 1% Range (2)
± 1% Range (2)
± 5% Range (2)
± 5% Range (2)
Zero temp
coefficient
± 0.25 ppm/10°C
± 0.25 ppm/10°C
± 0.63 ppm /10°C
± 2.5 ppm/10 °C
(1) The accuracy may be decreased by an additional 6% maximum range at some frequencies under the influence of
radiated RF fields specified for industrial environments.
(2) Calibrated Range
(3) N2 in Ar only

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3 UNPACK THE ANALYZER
WARNING
The analyzer is heavy (see Section 2.1). Care must be taken when
handling. It is recommended that they are lifted with hands positioned
on either side on the base of the chassis.
Remove the analyzer and any other equipment from its packaging.
Remove any protective caps from the sample gas inlets and outlets on the rear of
the analyzer (see Figure 1 - FRONT OF THE ANALYZER and Figure 2 - REAR
OF THE ANALY.

It is advisable that the protective caps are kept on prior to fitting.
Inspect the analyzer and the other items supplied, and check that they are not
damaged. If any item is damaged, immediately contact Servomex or your local
Servomex agent.
Check that you have received all of the items that you ordered. If any item is
missing, immediately contact Servomex or your local Servomex agent.
If you do not intend to use the analyzer immediately:
Refit any protective caps.
Place the analyzer and any other equipment supplied back in its protective
packaging.
Store the analyzer as described in Section 8.1.

Retain the shipping documentation and packaging for future use (for example,
return of the analyzer to Servomex for servicing or repair).

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4 INSTALLATION AND SET-UP
WARNING
The analyzer must be installed by a suitably skilled and
competent person. The following procedure must be followed
to prevent a hazard.
WARNING
The analyzer is only suitable for installation in unclassified areas.
CAUTION
Do not install the analyzer in a frame/rack or on a bench which is subject to
high levels of vibration or sudden jolts. If you do, sample measurements
may not be accurate, or the analyzer may be damaged.
CAUTION
Do not install analyzer in an area where a strong electromagnetic field is
present. Never use radio transmitters near the analyzer.
CAUTION
To avoid damage to analyzer, always leave the protection caps on gas
connections until clean gas is ready to flow in the analyzer.
CAUTION
The vent connection of the analyzer must be at atmospheric pressure all the
time. Pressurizing the vent side of analyzer could cause the quartz cell to
crack and also damage the flow module.
CAUTION
Do not expose the analyzer to high level of direct sunlight.

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Figure 4 - DIMENSIONAL OUTLINE DRAWING

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4.1 Mechanical installation rack mounting
CAUTION
The analyzer must not be supported by the front panel alone. You must provide an
additional support under the base of the analyzer towards the rear of the enclosure
as shown in Figure 5 - INSTALL THE 02001 ANALYZER IN A PANEL.
If you do not, the analyzer may be damaged, or may fall and damage other
equipment.
Refer to Figure 5 and Figure 6
Prepare a cut-out in a suitable panel capable of supporting 15kg.
Prepare a suitable base support and secure it in your frame or cabinet capable of supporting
15kg.
Fit the analyzer in the panel and use nuts and bolts through the fixing holes in the panel and the
mounting brackets to secure the analyzer in place.
Figure 5 - INSTALL THE 02001 ANALYZER IN A PANEL
Figure 6 - REAR VIEW CUT OUT DIMENSIONS

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4.2 Electrical Installation
4.2.1 Electrical Safety
WARNING
Ensure that the electrical installation of the analyzer conforms with all
applicable local and national electrical safety requirements.
WARNING
Obey the safety instructions given below when you install the analyzer;
if you do not, the analyzer warranty may be invalidated, the analyzer
may not operate correctly, or it may be damaged.

The electrical supply coupler or plug must be easily accessible for
disconnection from the electrical supply.

Ensure that your electrical supply can provide the necessary maximum
power consumption: refer to Section 10

All signal and electrical supply cables must be rated for temperatures
of 70 °C or higher.

Ensure that the cables that you connect to the analyzer are routed so that
they do not present a trip hazard.

When you carry out insulation testing, disconnect all cables from the
analyzer.

Ensure the analyzer is provided with a sound earth connection via the
electrical supply plug (Figure 2 Item 3).

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4.2.2 Connect the electrical supply
WARNING
Only use the power supply cord provided with the unit.
CAUTION
Ensure that the analyzer is suitable for use with your electrical supply voltage
and frequency. If the analyzer is not suitable, the analyzer may not operate
correctly, or it may be damaged when you operate it.

To comply with the relevant safety requirements the cables carrying mains power
and connected to the analyzer shall be approved to:
For EU: IEC 60227 or IEC 60245 and be designated H05VV-F.
For North America: UL817 or CSA C22.2 No. 21 and be designated SJT.

Ensure that the cables that you connect to the analyzer are routed so
that they do not present a trip hazard.
The analyzer is supplied with an electrical supply cable, configured for your electrical
supply. Connect the electrical supply to the analyzer as follows:
Fit the IEC plug on the electrical supply cable provided to the electrical supply socket
on the rear of the analyzer (Figure 2 item 3).
Check the earth (ground) continuity between your electrical supply outlet earth
(ground) and the SH (ground) terminal on the rear of the analyzer (Figure 2 item 7) or
exposed metal work.
Connect the electrical supply cable to your electrical supply outlet.

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4.2.3 Milliamp output connections
WARNING
The milliamp outputs are separated from the analyzer mains circuits by
reinforced insulation. The terminals must only be connected to circuits
that are themselves separated from mains voltages by an isolation
method that provides at least this level of protection.
CAUTION
To comply with EMC requirements, screened cables must be used to connect
the analogue outputs and the screen of the mA output shall be connected to
the analyzer enclosure. The remote end of the screen shall be open circuit.
Connect the positive and negative wires in your cable to the screw terminals on the rear
panel refer to Figure 7. Section 2.3 provides information on the rating of cable.
The screen should be connected to the SH point on the rear of the analyzer.
Figure 7 - ANALOGUE OUTPUT INTERFACE CONNECTOR