Servomex Servotough SpectraScan 2400 User manual

Part Number: 02400001A
Revisio : 1
La guage: US E glish
User Ma ual
SERVOTOUGH SpectraScan (2400)
Gas Analyzer
PROCESSANAL
YZERS

The SpectraSca A alyzer is ma ufactured by Precisive LLC of Bosto , MA, USA who
assume respo sibility for the product performa ce with regard to software a d set up
usi g appropriate gas mixtures for calibratio . The methodology is pate t protected
a d is the I tellectual Property of Precisive LLC.

SERVOTOUGH SpectraScan User Manual
02400001A/1 i
TABLE OF CONTENTS
1ABOUT THIS MANUAL................................................................................... 6
1.0 Introduction..................................................................................................... 6
1.1 Symbols and Notices Used in this Manual....................................................... 7
1.1.1 Hazard Notices ............................................................................................... 7
1.1.2 Hazard Labels Statement................................................................................ 7
1.1.3 IEC and ISO Symbols ..................................................................................... 8
2SYSTEM OVERVIEW..................................................................................... 9
2.0 Introduction to the Analyzer............................................................................. 9
2.1 Measurement Principle ................................................................................... 9
3SYSTEM SAFETY.........................................................................................12
3.0 General Precautions ......................................................................................13
3.1 WARNINGS AND CAUTIONS........................................................................15
3.2 Suitability of Application .................................................................................17
3.3 Operator Training...........................................................................................17
3.4 Analyzer Hazards ..........................................................................................17
3.4.1 Gases............................................................................................................17
3.4.2 Heated Equipment .........................................................................................18
3.4.3 Over Pressurizing ..........................................................................................18
3.4.4 Electrical Safety.............................................................................................19
3.4.5 Electrostatic Discharge ..................................................................................19
3.4.6 Ergonomic Considerations .............................................................................20
4UNPACKING THE ANALYZER......................................................................21
4.0 Component List .............................................................................................21
4.1 Removing the Analyzer from the Shipping Container......................................22
4.2 Inspection......................................................................................................22
5MOUNTING CONSIDERATIONS...................................................................23
5.0 Environmental Requirements .........................................................................23
5.0.1 Dimensions, Weight and Ventilation ...............................................................24
5.0.2 Operating Temperature, Humidity and Pressure.............................................25
5.0.3 Combustion Hazard .......................................................................................26
5.0.4 Power Requirements .....................................................................................26
5.0.5 Fittings Requirements ....................................................................................26
5.1 Mounting Procedure.......................................................................................26
6ELECTRICAL CONNECTIONS......................................................................29
6.0 I/O Panel Layout............................................................................................30
6.0.1 Component Layout.........................................................................................32
6.1 Electrical Power Requirements ......................................................................34
6.2 Wiring............................................................................................................35
6.2.1 Power Wiring: 24 VDC ...................................................................................36
6.2.2 Power Wiring: 120-240 VAC ..........................................................................38
6.3 Communication Connection ...........................................................................40
6.4 Spectrascan Networking and Software Configuration .....................................42

SERVOTOUGH SpectraScan User Manual
02400001A/1 ii
6.4.1 Ethernet and TCP/IP......................................................................................42
6.4.2 Finding the IP address of your instrument ......................................................42
6.4.3 Setting a static IP address..............................................................................43
6.4.4 RS-422 connection ........................................................................................46
6.4.5 Modbus register .............................................................................................48
7SAMPLE GAS CONNECTIONS.....................................................................49
7.0 Sample Line Connections ..............................................................................50
7.0.1 Sampling Ports ..............................................................................................50
7.0.2 Preparing Sample Gas Lines .........................................................................50
7.0.3 Sampling Gas from a Pressurized Source......................................................51
7.0.4 Cleanliness of Sample Stream .......................................................................51
7.0.5 Stream Switching Using External Solenoid Valves .........................................52
7.0.6 Procedure for Connecting the Sample Lines...................................................54
7.1 Enclosure Purge Connections........................................................................55
7.1.1 Purging of Enclosure Compartment................................................................55
8INSTALLATION CHECKLIST.........................................................................57
9VERIFICATION .............................................................................................59
9.0 Procedure......................................................................................................59
9.0.1 Setup.............................................................................................................59
9.0.2 Zeroing ..........................................................................................................60
9.0.3 Span Verification............................................................................................60
9.1 Re-spanning ..................................................................................................60
10 MAINTENANCE.............................................................................................61
10.0 Light Source Assembly Replacement Procedure............................................62
11 TROUBLESHOOTING...................................................................................67
12 APPENDIX A: PRODUCT SPECIFICATIONS................................................69
12.0 Measurement Specifications ..........................................................................69
12.1 Physical Specifications ..................................................................................70
12.2 Communications Specification .......................................................................70
12.3 Sampling System Specifications ....................................................................71
12.4 Electrical Specifications .................................................................................72
12.5 Environmental Specifications .........................................................................72
12.6 Manual Revision History ................................................................................72
13 INDEX ...........................................................................................................73
14 CONTACT DETAILS......................................................................................74

SERVOTOUGH SpectraScan User Manual
02400001A/1 iii
List of Figures
Figure 1 - The Servomex SpectraScan Gas Analyzer.......................................................... 23
Figure 2 - Hole Dimensions of the Servomex SpectraScan Gas Analyzer ............................ 24
Figure 3 - I/O panel of the Servomex SpectraScan Gas Analyzer ........................................ 30
Figure 4 - Analyzer with Cover Open................................................................................... 31
Figure 5 - Interior of the Servomex SpectraScan Gas Analyzer............................................ 32
Figure 6 - SpectraScan Interior Diagram ............................................................................. 33
Figure 7 - Example Rating Label ......................................................................................... 34
Figure 8 - Wiring the SpectraScan with 24 VDC .................................................................. 36
Figure 9 - Wiring the SpectraScan with 120-240Vac............................................................ 38
Figure 10 - Connecting the Ethernet TCP/IP communication cable ...................................... 40
Figure 11 - Location of the serial number tag....................................................................... 42
Figure 12 - Location of debug RS-232 connector on MPU ................................................... 44
Figure 13 - Sample session in which a static IP address is set using PuTTY to communicate
with the MPU................................................................................................................ 46
Figure 14 - Identification of RS-422 signals in instrument..................................................... 47
Figure 15 - Location of RS-422 connector on system board................................................. 47
Figure 17 – Typical Gas Connection Configuration.............................................................. 49
Figure 18 - Recommended Connections for Inlet Stream Switching..................................... 53
Figure 19 - Accessing the Light Source ............................................................................... 63
Figure 20 - The Light Source Circuit Board.......................................................................... 63
Figure 22 - Mounting Hole for Light Source ......................................................................... 64
Figure 21 - The Light Source Assembly............................................................................... 64
Figure 23 - Dimensions of SpectraScan .............................................................................. 70

SERVOTOUGH SpectraScan User Manual
02400001A/1 iv
List of Tables
Table 1 - Definition of Symbols Found on the Analyzer.......................................................... 8
Table 2 - Hazardous Location Ratings................................................................................. 12
Table 3 - Standard Fittings Used on the Servomex SpectraScan Gas Analyzer ................... 26
Table 4 - Wire Types........................................................................................................... 35
Table 5 - SpectraScan Modbus register............................................................................... 48
Table 6 - Diagnostic LED Indications................................................................................... 59
Table 7 - Troubleshooting ................................................................................................... 67
Table 8 – Measurement Specifications................................................................................ 69
Table 9 – Physical Specifications ........................................................................................ 70
Table 10 - Communications Specifications .......................................................................... 70
Table 11 - Sampling System Specifications......................................................................... 71
Table 12 - Response Time Versus Gas Flow Rate .............................................................. 71
Table 13 - Electrical Specifications...................................................................................... 72
Table 14 - Environmental Specifications.............................................................................. 72

SERVOTOUGH SpectraScan User Manual
02400001A/1 v
This page intentionally left blank.

SERVOTOUGH SpectraScan User Manual
02400001A/1 6
1 ABOUT THIS MANUAL
1.0 Introduction
This manual provides information about the Servomex SpectraScan Gas Analyzer. TCP/IP enabled,
the Servomex SpectraScan Gas Analyzer can monitor process gases remotely, unattended for
extended periods of time.
This manual presents all safety considerations of the Servomex SpectraScan Gas Analyzer first,
and then provides instructions for unpacking, mounting and connecting the unit. An installation
checklist ensures all the required tasks are performed. The verification test confirms span accuracy
upon installation, and includes the zeroing procedure which may be repeated periodically. Short
maintenance and troubleshooting sections are included in this manual. Product specifications are
given in the appendix at the end of this manual.
Before installing or operating your Servomex SpectraScan Gas Analyzer, carefully read and
familiarize yourself with System Safety. In addition, observe and obey all Hazard Notices and
Symbols provided for your safety throughout this manual.

NOTE
S
Read this manual in its entirety before attempting to perform any operations
on the Servomex SpectraScan System.

SERVOTOUGH SpectraScan User Manual
02400001A/1 7
1.1 Symbols and Notices Used in this Manual
This manual contains attention symbols and notices which should be observed to ensure personal
safety, as well as to protect the product and the connected equipment. Hazard notices are
accompanied with text that identifies the hazard, advises you to avoid the hazard, and/or the
probable consequences of NOT avoiding the hazard. Where applicable, within the notice box or
near the paragraph text, the appropriate IEC or ISO symbol is used. Attention notices provide useful
information pertinent to the operation of the analyzer.
The following notices are displayed throughout Servomex documentation:
1.1.1 Hazard Notices
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 and NOTES, 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 analyser
or to other equipment or property.

NOTE
S
This highlights information which it is useful for you to be aware of (for
example, specific operating conditions, and so on).
1.1.2 Hazard Labels Statement
Hazard labels indicate possible hazardous areas and identify the potential hazard on the analyzer.
Hazard labels are applied to the access areas of the analyzer to caution the following:
Exposure to hazardous chemicals (gases, process materials or by-products,
solvents/solutions) or physical conditions (heat or excessive cold) that may result in injuries
Exposure to electrical energy that may cause electric shock or death
Exposure to high temperatures that may cause injuries
See Table 1 IEC and ISO Symbols on page 8 for definition of symbols.

SERVOTOUGH SpectraScan User Manual
02400001A/1 8
1.1.3 IEC and ISO Symbols
The following symbols may be found on the Servomex SpectraScan Gas Analyzer and in the
documentation:
Definition of Symbols Found on the Analyzer and in this Manual
|
On (Supply)
IEC 60417, No. 5007
Off (Supply)
IEC 60417, No. 5008
Protective Earth
(Ground)
IEC 60417, No. 5017
Protective Conductor
Terminal
IEC 60417, No. 5019
Caution, hot surface
ISO 3684, No. 6043
Equipotentiality
IEC 60417, No. 5021
Frame or Chassis
Terminal
IEC 6041, No. 5020
Double or Reinforced
Insulation
IEC 6041, No. 5172
3
Direct Current
IEC 60417, No. 5031
Alternating Current
IEC 60417, No. 5032
Both Direct and
Alternating Current
IEC 60417, No. 5033
Three-phase
Alternating Current
Caution, risk of
electric shock
ISO 3864, No.B.3.6
Caution, refer to
accompanying
documents
ISO 3864, No.B.3.1
Out position of a bi-
stable push control
IEC 60417, No 5269
In position of a bi-
stable push control
IEC 60417, No 5268
Table 1 - Definition of Symbols Found on the Analyzer

SERVOTOUGH SpectraScan User Manual
02400001A/1 9
2 SYSTEM OVERVIEW
This chapter introduces the Servomex SpectraScan Gas Analyzer and explains its basic principle of
operation.
2.0 Introduction to the Analyzer
The Servomex SpectraScan Gas Analyzer is a non-contact, light absorption based gas analyzer
capable of ppm to percent level concentration monitoring of multiple gas compounds. The system
consists of a light spectrometer, a flow-through sample cell, a single-element photo-detector and the
supporting electronics. The spectrometer uses a unique tunable Fabry-Perot assembly that
provides wavelength scanning with high optical throughput. An advanced spectral processing
algorithm computed in the embedded electronics provides highly accurate and robust quantitative
measurements.
The analyzer is configured and calibrated for a specific wavelength analysis region(s) depending on
the application for which it is intended. It is designed to be a dedicated on-line monitoring system
that is “plug and play,” not requiring any on-site configuration or calibration. The specific system
configuration and calibration is denoted by the application code “-xyz” that can be found in the
Calibration Verification Sheet delivered with the analyzer.
Example applications of the Servomex SpectraScan Gas Analyzer include:
Hydrocarbon gas composition monitoring
Petrochemical process monitoring
Specialty and chemical gas process and blending monitoring
Catalysis and combustion process monitoring
2.1 Measurement Principle
When a gas sample is introduced in the gas cell, the light radiation provided by a broadband light
source is partially absorbed by the gas species present. The light absorption occurs at specific
frequencies and magnitudes depending on the gas compound and the concentration of that
compound. The Servomex SpectraScan spectrometer module scans the wavelength and measures
the true absorption spectra and compares them with the pre-loaded calibration spectra. The on-
board analysis algorithm computes the gas concentrations in real-time, which can then be output
through the MODBUS TCP/IP protocol.
In principal, the absorption spectrum of each compound is unique which acts as a “fingerprint” for
identification or speciation analysis. In addition, the magnitude of the absorption is a function of the
number of molecules of the gas. With a known path length, pressure and temperature, the
magnitudes of the absorption spectra are then used to compute volumetric concentrations. This
first principle based technique provides accurate and robust measurements with minimal span and
baseline drifts.
The analyzer employs an internal pressure transducer to measure the sample pressure in real-time
enabling pressure variation corrections. The flow cell is heated to a constant temperature (default
value is 60oC) with a sample preheat module to maintain both sample and optical sensor
temperature at a constant calibrated temperature, thereby ensuring measurement accuracy and
stability despite sample and environmental variations.

SERVOTOUGH SpectraScan User Manual
02400001A/1 10

SERVOTOUGH SpectraScan User Manual
02400001A/1 11
This page intentionally left blank.

SERVOTOUGH SpectraScan User Manual
02400001A/1 12
3 SYSTEM SAFETY
A primary concern of Servomex is to ensure a safe working environment for all users of our system.
The Servomex SpectraScan Gas Analyzer meets the following classifications;
Hazardous Location Classification:
Classification
and Rating
Class 1, Division 2, Groups A,B,C and D, T4
Class 1, Zone 2, AEx nA nC nL IIC T4 Gc
Class 1, Zone 2, Ex nA nC nL IIC T4 Gc
II 3G Ex ic nA nC IIC T4 Gc
IP66
ITS12ATEX
Ambient Temperature Rating: -20 < Tamb < 50°C (-4 to 122°F)
Table 2 - Hazardous Location Ratings
It is essential that all users become aware of the hazards associated with the start-up, operation
and maintenance of this analyzer. Servomex SpectraScan users must observe all prescribed safety
guidelines and adopt good general work practices to adequately protect themselves, fellow workers
and the unit. Only trained and experienced users should start, operate and/or maintain the
Servomex SpectraScan Gas Analyzer.
WARNING
The following general safety precautions must be observed during all phases
of installation and operation of this analyzer. Failure to comply with these
precautions or with specific warnings elsewhere in this manual violates safety
standards of intended use of the unit and may impair the protection provided
by the analyzer, exposing the user to the risk of injury or death and possibly
causing damage to the analyzer. Servomex assumes no liability for the
customer’s failure to comply with these requirements.

SERVOTOUGH SpectraScan User Manual
02400001A/1 13
3.0 General Precautions
DO NOT SUBSTITUTE PARTS OR MODIFY THIS ANALYZER
Do not install substitute parts or perform any unauthorized modification to the analyzer. Return the
analyzer to Servomex for service and repair to ensure that all safety features are maintained.
SERVICE BY QUALIFIED PERSONNEL ONLY
There are no user serviceable components in the analyzer. Component replacement and internal
adjustments must be made by qualified Servomex representatives only.
GROUNDING THE PRODUCT
This product is grounded through the grounding conductor of the power cabling to the ground lug
inside the enclosure. This grounding is essential for safe operation. Upon loss of the protective
ground connection, all accessible conductive parts (including knobs and controls that may appear to
be insulated) can render an electrical shock. Dangerous voltages are contained within this
analyzer. All electrical fittings and cables must be of the type specified, and be in good condition,
and all electrical fittings must be properly connected and grounded. All cables entering the analyzer
(24 VDC or 120/240 VAC power and communication) must be separately jacketed as they enter the
analyzer to prevent mis-wiring.
symbol for ground
USING THE PROPER POWER CABLING
This product is designed to be hardwired and has a 24 VDC model and a 120/240 VAC model. Use
only power cabling that is in good condition and which meets the input power requirements
specified in this manual. The power cabling used, whether for 24 VDC operation or for 120-240
VAC operation, must use a 3 conductor cable that is jacketed separately from the communications
cable. The ground wire in this 3 conductor cable must be electrically connected to the earth ground
lug in the analyzer. See Section 5.0.4 Power Requirements on page 26 and Table 13 - Electrical
Specifications on page 72 for more information. Also see Table 4 - Wire Types on page 35.
USING THE PROPER POWER SOURCE
This product is configured at the factory to operate from a 24 VDC or 120-240 VAC power source,
depending on the model. See labelling on the analyzer to determine which power source to use.
Ensure that the power supplied to the analyzer is appropriate for the configuration of analyzer being
installed. See Section 5.0.4 Power Requirements on page 26 for more information.

SERVOTOUGH SpectraScan User Manual
02400001A/1 14
USE THE PROPER FUSE
Use only a fuse of the correct type, voltage rating, and current rating, as specified for your product.
See Table 13 - Electrical Specifications on page 72 and Figure 6 - SpectraScan Interior Diagram
on page 33 for more information.
DO NOT OPERATE IN EXPLOSIVE ATMOSPHERES
To avoid explosion, do not operate this product in an explosive environment unless it has been
specifically certified for such operation. If it has been certified for such operation, carefully follow
the guidelines set forth in the Material Safety Data Sheets for the explosive chemical, as well as the
product labelling on the Servomex SpectraScan Gas Analyzer.
HIGH VOLTAGE DANGER
Assume high voltage is present in the cable and in the analyzer whenever a power cord is
connected.
USE PROPER FITTINGS AND TIGHTENING PROCEDURES
All connection fittings must be consistent with Servomex SpectraScan Gas Analyzer specifications,
and compatible with the intended use of the unit. Assemble and tighten fittings according to
manufacturer's directions. See Section 5.0.5 Fittings Requirements on page 26 for more
information.
CHECK FOR LEAK-TIGHT FITTINGS
Carefully check all connections to ensure leak-tight installation.
OPERATE AT SAFE INLET PRESSURES
Never operate at pressures higher than the rated maximum and minimum pressure. See Section
3.4.3 Over Pressurizing on page 18 and Table 11 - Sampling System Specifications on page 71 for
more information.
KEEP THE UNIT FREE OF CONTAMINANTS
Do not allow contaminants to enter the unit before or during use. Contamination such as dust, dirt,
lint, glass chips, or metal chips may permanently damage the unit.

SERVOTOUGH SpectraScan User Manual
02400001A/1 15
ALLOW PROPER WARM-UP TIME
The unit’s gas cell is temperature-controlled and will only meet measurement accuracy
specifications when sufficient time is allowed for the unit to meet and stabilize to the designed
operating temperature. Warm-up time for the unit is approximately 30 minutes to 2 hours depending
on the ambient temperature. The analyzer temperature shall be stable (default value is 60oC) prior
to performing any measurement. The red “Warm-up” LED on the display extinguishes and the green
“Run” LED lights when the unit has reached operating temperature.
MAINTAIN INGRESS PROTECTION
The Servomex SpectraScan unit has been tested to an Ingress Protection level of IP66, Type 4. In
order to maintain this rating, a suitable 1” conduit connector must be used that will not compromise
the existing IP Rating.
3.1 WARNINGS AND CAUTIONS
This apparatus is suitable for use in Hazardous Locations as defined in Table 2 - Hazardous
Location Ratings on page 12, or unclassified locations.
WARNING
LOSS OF SYSTEM INTEGRITY: Exposure to some chemicals may degrade
the sealing properties.
WARNING
EXPLOSION HAZARD: Do not remove or replace fuses unless power has
been disconnected or the area is known to be free of ignitable concentrations
of flammable gases or vapours.
WARNING
EXPLOSION HAZARD: The ac and dc source must be located in an
unclassified area.
WARNING
SYSTEM SAFETY: This analyzer is typed as permanently connected
equipment and as such, must include a switch or circuit–breaker in the
installation. This switch must be supplied and installed by the customer (not
provided by Servomex. It must be suitably located and easily reached, and
must be marked as the disconnecting device for the equipment.

SERVOTOUGH SpectraScan User Manual
02400001A/1 16
WARNING
EXPLOSION HAZARD: Do not disconnect while the circuit is live unless the
area is known to be free of ignitable concentrations of flammable gases or
vapours.
WARNING
EXPLOSION HAZARD: Substitution of components may impair suitability for
class 1, division 2 and class 1, zone 2 installations.
WARNING
EXPLOSION HAZARD: Do not use screws that exceed the maximum screw
penetration depth in any threaded holes.

SERVOTOUGH SpectraScan User Manual
02400001A/1 17
3.2 Suitability of Application
It is the customer’s responsibility to determine the suitability of the Servomex SpectraScan Gas
Analyzer for a given purpose. Servomex makes no representation that potential hazards presented
here or elsewhere are the only hazards associated with this product and its start-up, operation or
maintenance.
3.3 Operator Training
All users should be fully trained in all applicable safety and emergency procedures. At a minimum:
Safe work practices and procedures
Electrical safety
Chemical safety and procedures for handling hazardous materials
Proper use of personal protective equipment (PPE)
3.4 Analyzer Hazards
The Servomex SpectraScan is designed to be safe. The following hazards are unavoidably present
when operating or servicing the Servomex SpectraScan Gas Analyzer. All personnel connected to
the operation, installation or maintenance of the Servomex SpectraScan Gas Analyzer must be
familiar with the hazards intrinsic to the analyzer’s environment:
Gases
Heated Equipment
Over Pressurizing
Electrical Safety
Electrostatic Discharge
Ergonomic Considerations
3.4.1 Gases
WARNING
Imminent Danger of Personal Injury or Death: The Servomex SpectraScan
Gas Analyzer is designed and can be configured to analyze some flammable
or explosive gas mixtures. Do not use this unit with flammable or explosive
gases unless it has been specifically certified for that application.

NOTE
Consult the gas manufacturer’s Material Safety Data Sheets (MSDS) for
further details on the storage, use, and safe handling procedures applicable
for these gases.

SERVOTOUGH SpectraScan User Manual
02400001A/1 18
3.4.2 Heated Equipment
The gas cell in the Servomex SpectraScan Gas Analyzer will be heated to a temperature that is
higher than the gas being sampled to avoid condensation on the optical windows in the gas cell.
WARNING
Burn Hazard: The gas cell, though insulated, may be extremely hot. Use
caution when handling the gas cell, sample lines or other heated equipment.
3.4.3 Over Pressurizing
CAUTION
Equipment Damage: Restricting the gas flow on either the intake or the exhaust side may
cause the gas cell to over pressurize, causing damage to the analyzer. Care should be taken to
remove any port caps or other flow barriers before connecting any sample line or switching on
the analyzer. Also make sure the exhaust routing is appropriate for your specific application.
When the gas is to be sampled from a pressurized source, such as a pressurized line, a pressure
relief mechanism should be employed so as not to force or restrict the flow of gas into the unit.
CAUTION
Equipment Damage: Pressure relief mechanism should be employed when sampling gas from
a source other than the ambient in order to avoid damage to the analyzer.