YOKOGAWA TDLS220 User manual




Tunable Diode Laser Spectroscopy Analyzer
IM 11Y01B02-01E-A
3rd Edition
Yokogawa Corporation of America
2 Dart Road, Newnan, Georgia U.S.A. 30265
Tel: [phone] Fax: [phone]
Yokogawa Corporation of America
IM 11Y01B02-01E-A

IM 11Y01B02-01E-A 3rd Edition June 19, 2012-00
PREFACE
This Instruction Manual has been compiled for Owners/Operators of the
Model TDLS220 Tunable Diode Laser Analyzer
• This manual should be passed on to the end user.
• The contents of this manual are subject to change
without prior notice.
• The contents of this manual shall not be
reproduced or copied, in part or in whole, without
permission.
• This manual explains the functions contained in
this product, but does not warrant that they are
suitable the particular purpose of the user.
• Every effort has been made to ensure accuracy in
the preparation of this manual. However, if you nd
mistaken expressions or omissions, please
contact the nearest Yokogawa Electric
representative or sales ofce.
• This manual does not cover special
modications. This manual may not reect
change of specications, construction or
parts when the change does not affect the
functions or performance of the product.
• If the product is not used in a manner specied in
this manual, the safety and performance of this
product may be impaired.
Yokogawa is not responsible for damage to the
instrument, poor performance of the instrument or
losses resulting from such, if the problems are
caused by:
• Improper operation by the user.
• Use of the instrument in improper applications
• Use of the instrument in an improper
environment
or improper utility program
• Repair or modication of the related instrument
by an engineer not authorized by Yokogawa.
Safety and Modication Precautions
• Follow the safety precautions in this manual
when using the product to ensure protection
and safety of the human body, the product and
the system containing the product.
SAFETY should be considered rst and foremost im-
portance when working on the equipment described in
this manual. All persons using this manual in conjunc-
tion with the equipment must evaluate all aspects
of the task for potential risks, hazards and dangerous
situations that may exist or potentially exist. Please
take appropriate action to prevent ALL POTENTIAL
ACCIDENTS.

AVOIDSHOCKANDIMPACTTOTHE
ANALYZERTHELASERSCANBE
PERMANENTLYDAMAGED
THELASERSCANBEPERMANENTLY
DAMAGED
“This analyzer contains a Class 1 laser source (EN
60825-1 classication; eye-safe under all operating
conditions). However, it is recommended to avoid
direct eye exposure to the laser radiation.
The Instrument is packed carefully with shock absorb-
ing materials, nevertheless, the instrument may be
damaged or broken if subjected to strong shock, such
as if the instrument is dropped. Handle with care.
Notice
Media No. IM 11Y01B02-01E-A 3rd Edition :June. 2012 (USA)
All Rights Reserved Copyright © 2012, Yokogawa Corporation of America
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IM 11Y01B02-01E-A 3rd Edition June 19, 2012-00


 In order to protect the system controlled by the product and the product itself and ensure safe operation,
observe the safety precautions described in this user’s manual. We assume no liability for safety if users
fail to observe these instructions when operating the product.
• If this instrument is used in a manner not specied in this user’s manual, the protection provided by this
instrument may be impaired.
• If any protection or safety circuit is required for the system controlled by the product or for the product
itself, prepare it separately.
• Be sure to use the spare parts approved by Yokogawa Electric Corporation (hereafter simply referred to
as YOKOGAWA) when replacing parts or consumables.
• Modication of the product is strictly prohibited.
• The following safety symbols are used on the product as well as in this manual.
Safety Precautions

Safety, Protection, and Modification of the Product
•In order to protect the system controlled by the product and the product itself and ensure safe operation,
observe the safety precautions described in this user’s manual. We assume no liability for safety if users fail
to observe these instructions when operating the product.
•If this instrument is used in a manner not specified in this user’s manual, the protection provided by this
instrument may be impaired.
•If any protection or safety circuit is required for the system controlled by the product or for the product itself
prepare it separately.
•Be sure to use the spare parts approved by Yokogawa Electric Corporation (hereafter simply referred to as
YOKOGAWA) when replacing parts or consumables.
•Modification of the product is strictly prohibited.
•The following safety symbols are used on the product as well as in this manual.
DANGER
This symbol indicates that an operator must follow the instructions laid out in this manual in
order to avoid the risks, for the human body, of injury, electric shock, or fatalities. The
manual describes what special care the operator must take to avoid such risks.
WARNING
This symbol indicates that the operator must refer to the instructions in this manual in order
to prevent the instrument (hardware) or software from being damaged, or a system failure
from occurring.
CAUTION
This symbol gives information essential for understanding the operations and functions.
Note!
This symbol indicates information that complements the present topic.
This symbol indicates Protective Ground Terminal
ThissymbolindicatesFunctionGroundTerminal(Donotusethisterminalastheprotectiveground
terminal.)
Warning and Disclaimer
The product is provided on an “as is” basis. YOKOGAWA shall have neither liability nor responsibility to any
person or entity with respect to any direct or indirect loss or damage arising from using the product or any
defect of the product that YOKOGAWA cannot predict in advance.
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

IM 11Y01B02-01E-A 3rd Edition June 19, 2012-00
SAFETY should be considered rst and foremost importance when working on the equipment described in this manual. All persons using this
manual in conjunction with the equipment must evaluate all aspects of the task for potential risks, hazards and dangerous situations that may exist
or potentially exist. Please take appropriate action to prevent ALL POTENTIAL ACCIDENTS.
1) Safe lifting and carrying
If it is necessary to relocate the analyzer, it should be lifted by at least two people wearing protective gloves and steel toe boots.
The analyzer should be always transported either in a vertical position as shown in the picture, or in a horizontal position with the mounting plate
facing down. If transported horizontally, it must be held by the mounting plate only. In vertical position, it is acceptable to hold the analyzer by the
elements in the “grip” area. Never hold the analyzer by applying force to the elements in the “Do not grip” zone or to the conecting cables and
tubes. If a winch or another hoisting device is used, it can be hooked to the upper mounting holes.
2) Electrical hazard
The areas of potentially hazardous voltage are labeled with this sign:
The analyzer is powered by either a ~220V, 50 Hz or ~120V, 60 Hz (model specic). During normal operation this voltage is not accessible from
outside of the enclosure. However, end user is responsible for connecting the mains to the analyzer terminals in the Power/Temperature Controller
box (right bottom block in the diagram above).
THE WIRES BEING CONNECTED MUST BE DISCONNECTED FROM ANY VOLTAGE SOURCES DURING THIS PROCEDURE.
PROTECTIVE GROUND WIRE MUST BE CONNECTED TO THE DESIGNATED TERMINAL LABELED BY THE CORRESPONDING SYMBOL.
DO NOT OPEN THE POWER MODULE ENCLOSURE WHEN THE ANALYZER IS ENERGIZED.
Some maintenance and troubleshooting operations require opening the Electronics Controller box (left bottom block in the diagram above) while
the analyzer is powered. The highest voltage present in this box is 24V and is not hazardous. A higher voltage (+65V, 10 mA)
is shielded with an isolating plate and labeled. .
3) Thermal hazard
The gas cell can be heated up to +120 ºC and cause thermal injury to unprotected skin at direct contact. In normal conguration the cell is wrapped
in a thermal isolation jacket that prevents such incidents. DO NOT REMOVE THERMAL JACKET WHEN THE ANALYZER IS POWERED. Prior to
performing service operations that require removal of the thermal jacket, power the analyzer down and wait 30 minutes to let the temperature drop
to a safe level.
Areas of a potentially hazardous temperature are labeled with the following symbol:


IM 11Y01B02-01E-A 3rd Edition June 19, 2012-00
4) Chemical hazard
Analyzer can measure a wide variety of chemical species in various gas mixtures. CHEMICAL COMPOSITION OF SAMPLE SUPPLIED TO THE
ANALYZER AND ITS VARIATION LIMITS MUST BE APPROVED BY YOKOGAWA to ensure safe operation of the device. Gas stream supplied to
the analyzer gas cell for analysis can be potentially harmful for people and environment. DO NOT DISCONNECT THE ANALYZER GAS TUBES
(INLET OR OUTLET) DURING ITS OPERATION. CHECK FOR LEAKS AFTER INSTALLATION BEFORE SUPPLYING THE GAS SAMPLE.
FLUSH ANALYZER WITH NITROGEN OR INSTRUMENT AIR FOR 15 MINUTES BEFORE DISCONNECTING FROM THE GAS LINES.
The inlets and outlets of the sampled gas are labeled with the warning sign:
5) Other labels used on this analyzer
The areas of potentially hazardous voltage are labeled with this sign:
Caution, refer to the user manual
Alternating current
Direct current
Protective ground terminal
Function ground terminal (do not use this terminal as the protective ground terminal.)
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

Yokogawa products and parts are guaranteed free from defects in workmanship and material under normal use and service for a period of
(typically) 12 months from the date of shipment from the manufacturer. Individual sales organizations can deviate from the typical warranty
period, and the conditions of sale relating to the original purchase order should be consulted. Damage caused by wear and tear, inadequate
maintenance, corrosion, or by the effects of chemical processes are excluded from this warranty coverage.
In the event of warranty claim, the defective goods should be sent (freight paid) to the service department of the relevant sales organization for
repair or replacement (at Yokogawa discretion). The following information must be included in the letter accompanying the returned goods:
• Part number, model code and serial
• Number
• Original purchase order and date
• Length of time in service and a description of the
process
• Description of the fault, and the circumstances of
failure
• Process/environmental conditions that may be
related to the failure of the device.
• A statement whether warranty or nonwarranty
service is requested
• Complete shipping and billing instructions for
return of material, plus the name and phone
number of a contact person who can be reached
for further information.
Returned goods that have been in contact with process uids must be decontaminated/ disinfected before shipment. Goods should carry a
certicate to this effect, for the health and safety of our employees. Material safety data sheets should also be included for all components of
the processes to which the equipment has been exposed.

IM 11Y01B02-01E-A 3rd Edition June 19, 2012-00
Table of Contents
 
 
 
 
2.1 Functional Decription ................................................................................................2-1
2.1.1 Measurement .......................................................................................................2-2
 
 
4.1 Main Electronic Housing ...........................................................................................4-1
4.2 Process Interface ......................................................................................................4-4
4.3 Communications ........................................................................................................4-4
4.4 Software .....................................................................................................................4-7
4.5 Data Reporting, Storage and Retrieval ......................................................................4-7
 
5.1 Mounting the Analyzer ...............................................................................................5-1
5.2 Sample Inlet and Outlet considerations .....................................................................5-2
5.3 Wiring Details .............................................................................................................5-3
5.4 Purge Gas Requirements and Hazardous Area Systems ..........................................5-5
 
6.1 Menu Structure Map ..................................................................................................6-1
6.2 Software Guide ..........................................................................................................6-5
6.3 Non-Process Parameters .........................................................................................6-14
6.4 Stream Switching and Valve Control Outputs ..........................................................6-16
6.5 Controlling the Analyzer Remotely or Locally via External PC/Laptop ....................6-19
6.5.1 Instructions from Connecting an External Computer to the Analyzer ..............6-19
6.5.2 Using Ultra-VNC Software ................................................................................6-20
6.5.3 Remote Interface Unit (RIU) ..............................................................................6-21
6.5.4 Virtual Analyzer Controller (VAC) Operating Software Map ...............................6-21
6.5.6 Virtual Analyzer Controller (VAC) Operating Software Guide ............................6-22
 
7.1 Maintaining Good Transmission .................................................................................7-1
7.1.1 Maintaining Window and Mirror ..........................................................................7-1
7.2 Analog Signal Field Loop Check ..............................................................................7-10
7.3 Data Reporting, Storage and Retrieval ....................................................................7-10
7.4 Validation and Calibration ........................................................................................7-11
7.4.1 Off-Line Manuall/Automatic Checking/ Validation .............................................7-11
7.4.2 Off-Line Manual/Automatic Calibration .............................................................7-14


IM 11Y01B02-01E-A 3rd Edition June 19, 2012-00
 
8.1 Common Troubleshooting Step .................................................................................8-2
8.1.1 On Process Gas or Zero Gas or Span Gas ..........................................................8-2
8.1.2 Trouble Shooting procedure for lost and /or Low Transmission ..........................8-3
8.2 Analyzer Warnings .....................................................................................................8-3
8.3 Analyzer Faults ...........................................................................................................8-4
 
9.1 Conguring Data Capture ..........................................................................................9-5
9.2 downloading the Data ................................................................................................9-8
 



IM 11Y01B02-01E-A 3rd Edition June 19, 2012-00

  
1.0  Carefully un-pack and check equipment for any obvious damage.
1.1 Ensure the appropriate utilities are available and ready for connection. These may include electri-
cal power, nitrogen purge gas, instrument air, validation gas, etc. Make sure the sample handling and
conditioning system meets the sample inlet and outlet requirements for TDLS220. Refer to Section XX
“Installation” for details.
1.2 Ensure you comply with any local and/or site specic safety requirements.
1.3 Read the appropriate sections of the Instruction Manual BEFORE starting any installation work – 

2.0  Ensure there is sufcient physical space to mount the analyzer and allow suitable space for any future
maintenance access. Mount the analyzer/panel to a secure vertical surface using appropriate style
shake-proof fasteners. Avoid areas prone to vibration to ensure long term reliability – the analytical mea-
surement itself is not affected by vibration.
3.0  Ensure that all wiring will meet local codes and site requirements
3.1 Connect protective ground wire to the protective ground terminal of TDLS220. Use minimum 14 AWG
wire or equivalent.
3.2 Connect the appropriate single phase AC electrical power supply.
• 110/240 50/60 Hz to the power/heater control line lter using supplied cable crimp terminal
plugs. A suitable mains disconnect device must be supplied. Refer to the “Installation”
section of this manual for details.
3.3 Check termination details before proceeding to prevent damage to electronics.
Connect any analog I/O signals to the optional analog I/O Board. Outputs land on TB8 and any pressure
inputs land on TB9.
Heated ow cells have the gas temperature signal already terminated at TB9.
A table of wiring terminations is included in this Instruction Manual
3.4 Connect any other equipment such as Ethernet, solenoid valves, digital I/O, etc. Note. Solenoids require
directional diode or ferrite coil on eld wires at terminal block to prevent noise spikes.
3.5 Check terminations and ensure all cable shields are landed per supplied wiring details.
4.0 




Connect the appropriate analyzer purge gas (nitrogen for oxygen analyzers) and make site connections
per the supplied purge gas sequence details (including any Hazardous area purge system). Start the
purge gas ow accordingly.
Some Oxygen analyzers may be capable of operating with Instrument Air purge alone or in conjunction
with Nitrogen purge of the measurement enclosure.
4.1 Connect process gas sample to the inlet port and the process sample return/vent to the ow cell outlet
port.
Ensure all inlet lines are clean and dry before connecting to prevent contamination of the ow cell and
ow cell window/mirror.
1 Quick Start

IM 11Y01B02-01E-A 3rd Edition June 19, 2012-00

4.2 
5.0  Make sure the power module door is closed. Do not open this door when the analyzer is powered. Apply
the AC power to the analyzer.
5.1 Open the Control module door. Inside this module use the internal On-Off switch to power-up the ana-
lyzer (located lower right hand side).
5.2 Observe the various LED clusters on the backplane and FPGA boards.
All blue LEDs located lower right side on the back-plane should be on.
5.3 Observe the Green power indicator on the SBC.
5.4 Observe the LEDs on the optional analog I/O board.
6.0  If there is an installed optional 6.5” Display and Keypad – Observe the Main Menu messages and status
information.
6.1 If there is no installed User Interface, then connect a laptop PC via Ethernet to the SBC mounted on the
backplane. Initiate the supplied UltraVNC software from the laptop to initiate a VNC session with the
‘blind’ analyzer and observe the analyzer Main Menu via the laptop.
6.2 

6.3 If the analyzer displays a Warning “Validation Required” then this indicates that there is no target gas
absorption peak found at start-up. Either, shut down the analyzer, introduce some measured gas into the
ow cell and re-start, or perform a validation. This will ensure that the analyzer is correctly tuned to the
measurement gas absorption peak. If this Warning cannot be cleared by either method, please contact
Yokogawa Laser Analysis Division or your local agent for further assistance.
7.0 

By way of the appropriate user interface, the correct process parameters and other parameters can now
be entered.
7.1 Enter the Basic Menu and go to Congure.
7.2  Enter in the correct process gas pressure (if Active, see Advanced Congure).
7.3  Enter in the correct process gas temperature (if Active, see Advanced Congure).
7.4 If any other parameters are required to be set (such as analog I/O ranges, alarms levels, Auto Validation
sequences) then the Advanced Menu needs to be accessed.



Go to the Data section under Basic and congure the appropriate ‘Record Result Data’ settings. This will
ensure the analyzer stores important information during operation that may be used to verify operation/
status/diagnostics and other trouble shooting.
8.0 

Using the correct password (Default 1234), enter in to the Advanced Menu, then the Congure.
8.1 Select the desired measurement units for path length, pressure and temperature.

IM 11Y01B02-01E-A 3rd Edition June 19, 2012-00

8.2  Select Fixed or Active.
If Fixed, enter in the correct process gas pressure.
If Active, enter in the 4-20mA input signal range proportional to the pressure transmitter output range.
8.3  Select Fixed or Active.
If Fixed, enter in the correct process gas temperature.
If Active, enter in the 4-20mA input signal range proportional to the temperature range.
8.4 Congure the system I/O by entering in to the System I/O sub menu in Congure.
8.5 If the optional Analog I/O board is installed, then select Analog Output and set the appropriate 4mA and
20mA values for Ch1 Concentration and Ch2 Transmission.
8.6 Select what mode (Block, Track or Hold) the 4-20mA outputs are to be when the analyzer is in Warning,
Fault, Export Data and Calibration Modes.
8.7 Congure Digital I/O – Warnings and Faults. Many of these will be factory pre-set so if unsure about any
settings then leave as Factory Default.
Select and set level for Alarm Limit to either the Measured Gas or Transmission.
8.8 Go to the Data screen and set the appropriate parameters for ‘Record Result Data’ and ‘Spectrum Cap-
ture’. These will ensure the analyzer stores important information during operation that may be used to
verify operation/status/diagnostics and other trouble shooting..
8.9 Go to the Trends screen and review/plot several of the listed parameters to check analyzer performance
over a period of time.
8.10 

If the application is to using purge gas containing the target gas (e.g. Oxygen measurement with
Instrument Air Purge) then the Non-Process parameters should be congured as detailed later in this
manual under the Software Section.
9.0  When the site/eld conguration is complete and the analyzer has operated for at least two hours with-
out any functional alarms, then perform an export data routine.
9.1 To Export Data, simply insert an empty USB memory stick in to a USB port on the launch unit back
plane. The data transfer may take several minutes.

9.2 Close out the VNC software and disconnect the service PC – if connected.
9.3 Ensure the doors/lids are closed and tightly sealed.
9.4 The system is now in normal operation mode.
9.5 We RECOMMEND sending all the Exported Data les to Yokogawa Laser Analysis Division along
with any notes and comments. We will then be able to store these les on a master record for
future reference.



Failure to do so may result in damage and can void any warranty!

