Servomex SERVOTOUGH LaserExact 2950 User manual

02950001A
1
Part Number:
Rev s on:
Language: UK Engl sh
Operator Manual
SERVOTOUGH LaserExact
(Model 2950)
PROCESS ANALYSERS
(For W ndows Software v. 6.1)

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SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1
I
TABLE OF CONTENTS
1. INTRODUCTION........................................................................................................................1
1.1 SAFETY INFORMATION...............................................................................................................1
1.2 GENERAL .................................................................................................................................1
1.3 MEASURING PRINCIPLE .............................................................................................................2
1.4 INSTRUMENT DESCRIPTION........................................................................................................4
1.5 SOFTWARE...............................................................................................................................5
1.6 LASER CLASSIFICATION.............................................................................................................6
1.7 PRODUCT DATA........................................................................................................................7
2. PREPARATIONS .......................................................................................................................8
2.1 TOOLS AND OTHER EQUIPMENT .................................................................................................8
2.2 FLOW CONDITIONS....................................................................................................................8
2.3 CELL MATERIALS......................................................................................................................8
2.4 CABLES AND ELECTRICAL CONNECTIONS....................................................................................8
2.5 STICKY GASES..........................................................................................................................9
3. INSTALLATION ...................................................................................................................... 10
3.1 LABELLING ............................................................................................................................ 10
3.2 INSTALLATION AND ADJUSTMENTS........................................................................................... 11
3.2.1 SERVOTOUGH LaserExact installation ......................................................................... 12
3.2.2 Purging of laser beam alignment chamber..................................................................... 14
3.2.3 Laser module purge........................................................................................................ 15
3.3 START-UP ............................................................................................................................. 16
3.4 ALIGNMENT OF LASER BEAM................................................................................................... 16
3.5 CONNECTING A PC................................................................................................................ 19
3.6 INSTALLING A MODEM............................................................................................................. 19
4. THE SERVICE PROGRAM..................................................................................................... 20
4.1 SOFTWARE START-UP ............................................................................................................ 20
4.2 THE MEASUREMENT MENU...................................................................................................... 22
4.3 THE PROGRAM MENUS ........................................................................................................... 25
4.3.1 Plot readings................................................................................................................... 25
4.3.2 Second harmonic signal.................................................................................................. 25
4.3.3 Log readings ................................................................................................................... 26
4.3.4 View error log.................................................................................................................. 27
4.3.5 Measurement configuration ............................................................................................ 28
4.3.6 Gas specific parameters ................................................................................................. 33
4.3.7 Calibrate instrument........................................................................................................ 36
4.3.8 TCP/IP and modem configuration................................................................................... 38
4.3.9 File download / upload.................................................................................................... 39
4.3.10 Manual instrument control .......................................................................................... 40
5. OPERATION, MAINTENANCE AND CALIBRATION............................................................ 41
5.1 OPERATING MODES................................................................................................................ 41
5.2 MAINTENANCE....................................................................................................................... 43
5.2.1 Routine maintenance...................................................................................................... 43
5.2.2 Servicing the LaserExact cell.......................................................................................... 44
5.3 CALIBRATION OF THE INSTRUMENT.......................................................................................... 45
5.3.1 PROPORTIONAL versus GLOBAL calibration............................................................... 48
5.4 TROUBLESHOOTING THE INSTRUMENT..................................................................................... 48
6. ELECTRICAL CONNECTIONS .............................................................................................. 52
6.1CABINET INTERFACE .............................................................................................................. 53
6.2 POWER CABLE CONNECTIONS................................................................................................. 54
6.3 AUXILIARY CONNECTIONS....................................................................................................... 54

SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1
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6.4 RS-232 AND ETHERNET CONNECTIONS .................................................................................. 55
6.5 CURRENT LOOP (4-20 MA) INPUT CONNECTIONS (PLC)........................................................... 56
6.6 MAINS POWER CABLE CONNECTION......................................................................................... 57
6.7 TRANSMITTER BOARD -FUSES AND LED’S............................................................................... 57
6.8 RELAY INDICATIONS ............................................................................................................... 58
6.9 CONFIGURING RELAY 3OUTPUT.............................................................................................. 60
6.9.1 Normal configuration of relay-3, «Gas Alarm»................................................................ 60
6.9.2 Inverted configuration of relay-3, «Gas alarm»............................................................... 61
6.9.3 Maintenance configuration of relay-3.............................................................................. 61
6.9.4 Inverting relay-3 output by hardware switch ................................................................... 61
APPENDIX 1 COMPLIANCE AND STANDARDS INFORMATION ........................................... 62
APPENDIX 2 PRODUCT DISPOSAL/APPLICABILITY OF THE WASTE ELECTRICAL AND
ELECTRONIC EQUIPMENT (WEEE) DIRECTIVE 2002/96/EC ..................................................... 66

SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1
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FIGURES
FIGURE 1-1: MEASURING PRINCIPLE SERVOTOUGH LASEREXACT MONITOR.................................................3
FIGURE 1-2: BLOCK DIAGRAM OF INSTRUMENT ELECTRONICS ............................................................................5
FIGURE 3-1: SERVOTOUGH LASEREXACT MONITOR OVERVIEW..................................................................11
FIGURE 3-2:PURGE CONNECTIONS.....................................................................................................................15
FIGURE 3-3:ALIGNMENT CHAMBER ACCESS PANEL...........................................................................................18
FIGURE 3-4:COUPLING MIRRORS.......................................................................................................................18
FIGURE 6-1:CABINET ELECTRONIC INTERFACE..................................................................................................53
FIGURE 6-2: CURRENT LOOP INPUT,ACTIVE PROBE...........................................................................................56
FIGURE 6-3: CURRENT LOOP INPUT,PASSIVE PROBE..........................................................................................57
FIGURE 6-4: MAIN BOARD,FUSES AND LED’S LAYOUT ....................................................................................58
TABLES
TABLE 5-1 RECOMMENDED GAS CONCENTRATIONS FOR CALIBRATION.............................................................45
TABLE 5-2: INSTRUMENT LCD ERROR MESSAGES.............................................................................................51
TABLE 6-1: POWER CABLE AND SENSOR CONNECTIONS INSIDE THE CABINET....................................................54
TABLE 6-2: CABINET –AUXILIARY CONNECTIONS............................................................................................54
TABLE 6-3: CABINET –RS 232 CONNECTION ....................................................................................................55
TABLE 6-4: CABINET –ETHERNET CONNECTION...............................................................................................56
TABLE 6-5: RELAY INDICATIONS AND OUTPUTS................................................................................................59

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SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1
INSTALLATION
1
1. INTRODUCTION
1.1 Safety Information
Read this manual and ensure that you fully understand its content before you attempt
to install, use or maintain the Laser monitor. 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.
CAUTION
Cautions highlight hazards which, if not taken into account, can result in damage
to the Laser monitor 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).
1.2 General
This manual contains information of installation, operation and maintenance of the
SERVOTOUGH LaserExact Monitor. A description of the SERVOTOUGH LaserExact
Monitor and its basic features is also included.
Please read sections 3and 4carefully before using the SERVOTOUGH
LaserExact Monitor. It is a sophisticated instrument utilising state-of-the-art
electronic and laser technology. Installation and maintenance of the instrument
requires care and preparation. Failure to do so may damage the instrument and
void the warranty.
There are no user serviceable parts in the SERVOTOUGH LaserExact.
WARNING
The Laser monitor must not be used as personal protective
equipment.

SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1
2 CHAPTER 3
WARNING
The Safe Area monitor is only suitable for use in unclassified areas.
WARNING
The ATEX Zone 2 and CSA CL I Div 2 Hazardous area variant
cannot be used for oxygen enriched samples; that is, gases over
21% O2. If used with gases containing over 21% O2 the hazardous
area certification is invalidated.
WARNING
The Safe Area, GP and ATEX Zone 2 Variants are certified for use
with a flammable samples at a pressure of 0.8 to 1.1 bar absolute. If
used with a flammable sample beyond these limits, the hazardous
area certification is invalidated.
1.3 Measuring principle
The SERVOTOUGH LaserExact Monitor is an optical instrument transmitting infrared
laser light multiple times through a measurement chamber (the LaserExact cell). Two
mirrors are mounted inside the cell and the laser beam is reflected between these
many times resulting in a measurement path of between 0.7 and approximately 11m.
The measuring technique is based on measuring the absorption of light by the gas
molecules present in the cell.
The measuring principle is infrared single-line absorption spectroscopy, which is
based on the fact that each gas has distinct absorption lines at specific wavelengths.
The measuring principle is illustrated in Figure 1-1.
The laser wavelength is scanned across a chosen absorption line of the gas to be
measured. The absorption line is carefully selected to avoid cross interference from
other (background) gases. The detected light intensity varies as a function of the
laser wavelength due to absorption of the targeted gas molecules in the optical path
between the diode laser and detector. In order to increase the sensitivity the
wavelength modulation technique is employed: The laser wavelength is slightly
modulated while scanning the absorption line. The detector signal is spectrally
decomposed into frequency components at harmonics of the laser modulation
frequency. The second harmonics of the signal is used to measure the concentration
of the absorbing gas.

SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1
INSTALLATION
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The line amplitude and line width are both extracted from the second harmonics line
shape, which makes the measured concentration insensitive to line shape variations
(line broadening effect) caused by background gases.
NOTE: The SERVOTOUGH LaserExact Monitor measures the concentration of
only the FREE molecules of the specific gas, thus not being sensitive to the
molecules bound with some other molecules into complexes and to the
molecules attached to or dissolved in particles and droplets. Care should be
taken when comparing the measurements with the results from other
measurement techniques.
T ransm ission
A bsorption line
l
Figure 1-1: Measuring Principle SERVOTOUGH LaserExact Monitor
Sample
gas
Transmitter unit
Receiver unit
Coupling
mirrors
Optical window
LaserExact

SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1
4 CHAPTER 3
1.4 Instrument description
The SERVOTOUGH LaserExact Monitor consists of 3 modules:
•Cabinet
•LaserExact cell (under an optional protective cover)
•Laser beam alignment chamber (under an optional protective cover)
The cabinet is connected to the laser beam alignment chamber, which couples the
laser beam into the LaserExact cell. After multiple passes through the cell, the beam
exits back into the alignment chamber and is coupled onto the detector.
The transmitter inside the cabinet contains a temperature stabilised diode laser with
collimating optics. The laser is tuned to a specific wavelength and frequency and is
modulated to enable gas detection. The wavelength is unique for each gas to be
measured and is within the range from 0.7 to 2.4 µm (700 and 2400 nm). By varying
the DC supply current the laser wavelength is scanned over the absorption line of the
gas.
The transmitter is located within the cabinet enclosure and also contains the main
electronics board and the display. Communication with the electronics is provided
through an RS-232 connection to a PC, enabling service and calibration of the
instrument. In addition, communication via an Ethernet connector is possible.
The receiver inside the cabinet contains a detector connected to the receiver
electronics with a short cable. The detected signal is amplified and transmitted back
to the transmitter unit through electrical cables.
The laser beam alignment chamber contains two adjustable mirrors. The first mirror
controls the coupling of the beam into the cell and is adjusted to obtain the correct
angle of incidence; the second mirror controls the coupling of the beam onto the
detector and is adjusted to focus the beam on the detector centre.
The LaserExact cell with volume 0.875 litres (875 ml) is made of electro-polished
stainless steel. Two cell mirrors are mounted inside the cell volume, one at each end
of the cell. In the cell mirror next to the alignment chamber there is a slit, through
which the laser beam enters and leaves the cell volume. A wedged sapphire window
separates the cell from the alignment chamber.
A block diagram of the instrument electronics is shown in Figure 1-2. The transmitter
electronics takes care of all calculations and monitoring operations. Three relays are
integrated in the auxiliary electronics board. The integrated relays are warning, error
and gas alarm relays. The operator can set the gas alarm relay in the software. The
integrated relay functions are further explained in Section 6.8.

SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1
INSTALLATION
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The RS-232 or Ethernet service port is connected to an external PC during
installation, calibration and if service is required. Normally this port should not be in
use. Optionally a modem can be implemented, which enables long distance
communication with the instrument for service purposes.
The LCD continuously displays the gas concentration, laser beam transmission and
instrument status (warning and fault messages). In Section 5.4 an array of the
different fault messages is given.
Transmission Electronics
Receiver
electronics
4 – 20 mA out
Optic fiber (optional)
Power
supply
4 – 20 mA in
RS-232
Ethernet
Auxiliary board
Relay out
Ethernet board (optional)
Main board
CPU board
LCD display
Figure 1-2: Block diagram of instrument electronics
1.5 Software
Software for the SERVOTOUGH LaserExact Monitor consists of 2 programs:
1. A program hidden to the user and integrated in the CPU electronics, running the
micro controller on the CPU card. The program performs all necessary
calculations and self-monitoring tasks.
2. A Windows-based program running on a standard PC connected through the
RS-232 connection. The program enables communication with the instrument
during installation, service and calibration.
The operator will need to use the PC-based program only during installation and
calibration and not during normal operation of the instrument. See Chapter 4 for more
details.

SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1
6 CHAPTER 3
1.6 Laser Classification
The diode lasers used in the SERVOTOUGH LaserExact Monitors operate in the
near infrared (NIR) range between 700 and 2400 nm depending on the gas to be
measured. The lasers have an output power and optical arrangement, which
according to IEC 60825-1 2007 classifies the SERVOTOUGH LaserExact Monitors
as Laser Class 3R Laser Product.Accordingly, the product bears the following
markings:
WARNING
The laser beam is switched on when any indication is shown on the
display, or the backlight is illuminated.
WARNING
CLASS 3R LASER PRODUCT
NON VISIBLE LASER RADIATION – AVOID DIRECT EYE
CONTACT

SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1
INSTALLATION
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1.7 Product Data
Manufacturer NEO Monitors AS
Country of origin Norway
Model: SERVOTOUGH LaserExact
(LaserGasTM II Multipass)
Dimensions (L x H x W): 571 x 627 x 200mm
Mass: 28kg
Environmental conditions:
Operating temperature: -20°C to +55°C
Storage temperature -20°C to +55°C
Apparatus is suitable for indoor use
Operating pressure range: 101.3kPa, -20%, +10%
(1.013bar, -20%, +10%)
Maximum operating altitude: 2000m
Protection classification IP65
Electrical Data:
Input power supply unit (mains): 100 – 240 VAC, 50/60 Hz, 50 VA Max.
Input direct (DC): 18-36V DC, 20W Max.
4 - 20 mA output: 500 Ohm Max. isolated
Relay output: 1 A at 30 V DC/AC
Laser Class: Class 3R according to IEC 60825-1:2007
Laser power: Max 40mW at 700 to 2400nm
Approvals:
ATEX Zone 2: II 3 G Ex nA nC op is Gc IIC T4
II 3 D Ex td A22 IP65 T100°C
CSA: Class 1 Division 2 Groups A, B, C, D; T4
non-incendive

SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1
8 CHAPTER 3
2. PREPARATIONS
2.1 Tools and other equipment
No special tools are necessary to install and calibrate the equipment.
2.2 Flow conditions
The volume of the standard LaserExact cell is 875 ml. The flow of the target gas will
determine the measurement time. The complete cell volume needs to be replaced by
“new” gas before a new reasonable measurement point is logged.
2.3 Cell Materials
A list of the standard cell materials is given below. As these materials are exposed to
the gas mix; therefore, it should be verified that the gas does not adversely affect any
of them. Other cell materials may be available on request (contact SERVOMEX).
•Stainless steel, type AISI 316L
•BK7 mirrors coated with Au and SiO (optional MgF2 overcoat). NB: The Au is
protected but the BK7 is exposed to the gas.
•Sapphire window (for beam entrance)
•O-rings, Viton (other materials on request)
2.4 Cables and electrical connections
There are no constraints on the length of the optional optical fibre, but the user
should verify that the cable length for the 4-20 mA analogue current output from the
cabinet unit does not influence the measurements (due to inductance etc.). The
Service PC cable is 3 metres long, but can be extended to approximately 10 metres.
If electrical connections have to be made at installation, refer to Chapter 6 for details.
WARNING
Ensure that the electrical installation of the Laser monitor conforms to
all applicable local and national electrical safety requirements.
WARNING
Wiring to or from this device, which enters or leaves the system
enclosure, must utilize wiring methods suitable for Class 1, Division 2
and/or Zone 2 Hazardous Locations, as appropriate for the
installation.

SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1
INSTALLATION
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2.5 Sticky gases
Special care should be taken for reactive and “sticky” gases such as NH3, HCl and
H2S. Because of the nature of these gases, it is difficult to obtain the correct
concentration in the cell due to possible adsorption and desorption in the connection
tubes. Make sure that the extractive system is appropriate.

SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1
10 CHAPTER 3
3. INSTALLATION
WARNING
You must install and use the Laser monitor in accordance with the
requirements of this section and subsequent sections of the manual.
If you do not, people may be injured, the protection facilities
incorporated into the design of the Laser monitor may not operate as
intended, measurements may not be accurate, or the Laser monitor
may be damaged.
WARNING
The Laser monitors are not suitable for use in hazardous areas
unless the correct certification labels have been affixed.
Instructions Specific to Hazardous Area Installations
WARNING
The ATEX Zone 2 and CSA CL I Div 2 Hazardous area variants
cannot be used for oxygen enriched samples; that is, gases over
21% O2. If used with gases containing over 21% O2 the hazardous
area certification is invalidated.
WARNING
The ATEX Zone 2 variants are not suitable for use with a process
atmosphere that requires EPL Ga (e.g.: Zone 0). If used within this
process atmosphere, the hazardous area certification may be
invalidated.
3.1 Labelling
Versions suitable for use in Hazardous areas will be labelled with relevant markings
for:
ATEX Zone 2: II 3 G Ex nA nC op is Gc IIC T4
II 3 D Ex td A22 IP65 T100°C
CSA: GP and Class 1 Division 2 Groups A, B, C,
D; T4 non-incendive

SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1
INSTALLATION
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3.2 Installation and adjustments
The installation procedure described in this section refers to Figure 3-1.
Figure 3-1: SERVOTOUGH LaserExact Monitor Overview
1. Cabinet
2. Display
3. LaserExact cell
4. Gas inlet (std. 6 mm SS pipe)
5. Gas outlet (std. 8 mm SS pipe)
6. Laser beam alignment chamber
7. Alignment Chamber Purge gas inlet (std. 6 mm Swagelok)
8. Optional protective shroud (shown transparent for clarity)

SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1
12 CHAPTER 3
3.2.1 SERVOTOUGH LaserExact installation
WARNING
You must not modify the Laser monitor in any way (either
mechanically or electrically). If you do, the certification of the monitor
will be invalidated, and it may not operate safely.
WARNING
The Laser monitor is heavy (see section 1.7). Take care to handle
the analyser safely and securely during installation.
WARNING
The Laser monitor must be installed by a suitably skilled and
competent technician or engineer in accordance with this manual and
to the special conditions of installation contained within the manual.
WARNING
Make sure that power is disconnected or switched off before
connecting any cable.
WARNING
Obey the safety instructions given below when you install the Laser
monitor; if you do not, the monitor certification may be invalidated,
the monitor may not operate correctly, or it may be damaged.
WARNING
You must mount the Laser monitor on a structure which is capable of
supporting the mass of the Laser monitor (refer to product data).
WARNING
Sample and calibration gases may be toxic, asphyxiant or flammable.
Ensure that the external connections are leak free at full operating
pressure before use of sample or calibration gases and that they vent
to avoid exposure to personnel.

SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1
INSTALLATION
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WARNING
If using toxic, asphyxiant or flammable sample or calibration gases,
open cabinet or alignment chamber enclosures in a force ventilated
open area, or in another appropriate environment in which any
hazardous gases are directed away from the user.
WARNING
The ATEX Zone 2 and CSA CL I Div 2 Hazardous area variant
cannot be used for oxygen enriched samples; that is, gases over
21% O2. If used with gases containing over 21% O2 the hazardous
area certification is invalidated.
WARNING
Power shall only be applied to the analyser when the alignment
chamber is fully assembled in accordance with the instructions below
and the beam cannot be accessed.
CAUTION
Do not install the Laser monitor on a surface which is subject to high levels
of vibration or sudden jolts. If you do, sample measurements may not be
accurate, or the monitor may be damaged.
The environmental conditions for the SERVOTOUGH LaserExact Monitor are listed
in the product data section 1.7 of this manual.
Read thoroughly all instructions prior to installation.
All external parts are made of stainless steel or aluminium. All threads should be
lubricated using suitable grease before installation. Please note that there is no
separate mains switch on instrument.
Inspect, test and replace seals regularly to ensure that external connections
are leak free at full operating pressure at all times.
WARNING
The cabinet contains a small battery. Do not open when an
explosive atmosphere may be present.

SERVOTOUGH LaserExact Monitor, Operator Manual 02950001A_1
14 CHAPTER 3
To install the instrument follow the steps below (see also Figure 3-1).
1. Install the instrument in an upright position. Use the mounting tabs provided
with the analyser.
2. Connect the sample gas tubes as follows:
Gas INLET 6mm OD (front of unit)
Gas OUTLET 8mm OD (rear of unit)
Metric Swagelok fitting are supplied loose for use, however other
connectors may be used provided they are compatible with the inlet and
outlet pipes provided. Therefore gas inlet and outlet must not be
confused. We recommend stainless steel tubes.
3. If applicable connect a purge INLET to the alignment chamber (connection
between the inlet and outlet pipes)
4. Connect optional output signals (4-20 mA, warning relays, etc.) to the
“Auxiliary” terminals inside the cabinet (use the auxiliary cable gland, Figure
6-1). Refer to Section 6.3.
5. Connect external 4-20 mA temperature and pressure probes (ref. Section 6.2
and 6.5). This is optional as some instruments operate without probes. Input
signals are connected to the terminals inside the cabinet.
6. Open the gas lines. Check all connections for gas leaks before operating the
monitor.
The SERVOTOUGH LaserExact Monitor can now be switched on. This procedure is
described in Section 3.3.
3.2.2 Purging of laser beam alignment chamber
Note that some instruments may require purging with Nitrogen or clean dry air for
measurement purpose i.e. the target gas must be removed from the internal
measurement path to achieve sufficient measurement accuracy, or to ensure toxic or
flammable gases do not build up within the chamber. Examples are low level O2or
CO2instruments for measurement or H2S or HCl for toxic/flammable.
In this case the laser beam alignment chamber (one Swagelok connection) must be
purged (see Figure 3-2). Since there are optical surfaces inside this chamber, the
cleanness of the gas must be ensured and additional filtering may be necessary.
The purge flow must not be high to avoid overpressure inside. It is recommended
setting the flow to around 0.5 l/min. The purge flow will be vented to atmosphere
through the purge outlet port at the base of the cabinet (see Figure 3-2).