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SS500/SS2000

SS3000 H2O/H2O

SS3000 H2O/CO2

SS500/SS2000/SS3000
Gas Analyzer
Hardware Installation
and Maintenance Manual
P/N 4900002215 rev B

Hardware Installation and


Maintenance Manual

SS500/SS2000/SS3000
Gas Analyzer
Hardware Installation and
Maintenance Manual
Use this manual with the
Firmware Operators Manual

Products of

4333 W Sam Houston Pkwy N, Suite 100


Houston, TX 77043-1223
Tel: 800.619.2861
Fax: 713.856.6623
www.spectrasensors.com

Copyright 2015 SpectraSensors, Inc. No part of this manual may be reproduced in


whole or in part without the express written permission of SpectraSensors, Inc.
SpectraSensors reserves the right to change product design and specifications at any
time without prior notice.

Revision History
Revision

Engineering Order

Date

EO15547

4/8/14

ECR16086

3/10/15

TABLE

OF

CONTENTS

List of Figures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii


List of Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .v
1:

Introduction

Who Should Read This Manual . . . . . . . . . . . . . . . . . . . . . . . . .


How to Use This Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . .
Conventions Used in this Manual . . . . . . . . . . . . . . . . . . . . .
SpectraSensors Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About the Gas Analyzers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Differences between the SS500, SS2000, and SS3000 . . . . . .
How the Analyzers Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wavelength Modulation Spectroscopy (WMS) Signal Detection
Getting Familiar with the Analyzer . . . . . . . . . . . . . . . . . . . . . .

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1-1
1-1
1-1
1-3
1-3
1-3
1-3
1-5
1-7
1-8

2: Installation
What Should be Included in the Shipping Box . . . . . . . .
Inspecting the Analyzer . . . . . . . . . . . . . . . . . . . . . . . .
Lifting/carrying the analyzer . . . . . . . . . . . . . . . . . .
Installing the Analyzer. . . . . . . . . . . . . . . . . . . . . . . . .
Hardware and Tools for Installation . . . . . . . . . . . . .
Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting the Analyzer . . . . . . . . . . . . . . . . . . . . . .
To mount the analyzer . . . . . . . . . . . . . . . . . . . . . .
Connecting Electrical Power to the Analyzer . . . . . . . . . .
Protective chassis and ground connections . . . . . . . .
To connect electrical power to the analyzer . . . . . . . .
Connecting the Output Signals . . . . . . . . . . . . . . . . . . .
To connect the output signals . . . . . . . . . . . . . . . . .
Changing the 4-20 mA Current Loop Mode. . . . . . . . . . .
To change the 4-20 mA board from source to sink . . .
Calibrating the analog output . . . . . . . . . . . . . . .
Testing and adjusting the 4-20 mA zero and span
Connecting the Gas Lines. . . . . . . . . . . . . . . . . . . . . . .
To connect the sample supply line . . . . . . . . . . . . . .
To connect the sample return . . . . . . . . . . . . . . . . .
Conditioning the SCS Tubing . . . . . . . . . . . . . . . . . . . .

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. 2-1
. 2-1
. 2-1
. 2-2
. 2-2
. 2-2
. 2-2
. 2-2
. 2-3
. 2-3
. 2-4
. 2-4
. 2-6
. 2-6
. 2-8
. 2-8
. 2-9
2-10
2-10
2-10
2-12
2-13

About the SCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .


Checking the SCS Installation. . . . . . . . . . . . . . . . . . . . . . .
To perform SCS installation checks . . . . . . . . . . . . . . . .
Starting up the SCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To prepare for SCS startup . . . . . . . . . . . . . . . . . . . . . .
To start up the field pressure reducing station. . . . . . . . .
To start up the sample bypass stream on process sample.
To start up the analyzer on process sample . . . . . . . . . .
Shutting Down the SCS . . . . . . . . . . . . . . . . . . . . . . . . . .
To isolate the analyzer for short-term shutdown . . . . . . .
To isolate the analyzer for long-term shutdown . . . . . . . .

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3: Sample Conditioning System (SCS)

Hardware Installation and Maintenance Manual

3-2
3-3
3-3
3-3
3-3
3-4
3-4
3-5
3-5
3-6
3-7

SS500/SS2000/SS3000 Analyzer

Appendix A: Specifications
Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-19

Appendix B: Maintaining & Troubleshooting


Gas Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To keep the sampling lines clean . . . . . . . . . . . . . .
Excessive Sampling Gas Temperatures and Pressures . .
Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Peak Tracking Reset Procedure . . . . . . . . . . . . . . . . . .
Potential Risks Affecting Personnel . . . . . . . . . . . . . . .
Mitigating risks . . . . . . . . . . . . . . . . . . . . . . . . . .
Exposure to process gases . . . . . . . . . . . . . . . .
Electrocution hazard . . . . . . . . . . . . . . . . . . . .
Explosion hazard. . . . . . . . . . . . . . . . . . . . . . .
Cleaning the Mirrors . . . . . . . . . . . . . . . . . . . . . . . . .
Determining the type of cell mirror . . . . . . . . . . . .
Tools and Supplies . . . . . . . . . . . . . . . . . . . . . . . .
To clean the mirrors . . . . . . . . . . . . . . . . . . . . . . .
To replace the stainless steel mirror: . . . . . . . . . . .
Pressure Transducer Replacement. . . . . . . . . . . . . . . .
Periodic SCS Maintenance . . . . . . . . . . . . . . . . . . . . .
Regular SCS Status Check . . . . . . . . . . . . . . . . . .
To check filters . . . . . . . . . . . . . . . . . . . . . . . . . .
Instrument Problems. . . . . . . . . . . . . . . . . . . . . . . . .
Service Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Customer Service . . . . . . . . . . . . . . . . . . . . . . . .
Return Material Authorization . . . . . . . . . . . . . . . .
Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To purge the analyzer for shipment/relocation. . . . .
To prepare the analyzer for shipment or storage . . .
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disclaimers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . B-1
. . . . . . . . . . . . . . B-1
. . . . . . . . . . . . . . B-1
. . . . . . . . . . . . . . B-2
. . . . . . . . . . . . . . B-2
. . . . . . . . . . . . . . B-2
. . . . . . . . . . . . . . B-2
. . . . . . . . . . . . . . B-3
. . . . . . . . . . . . . . B-3
. . . . . . . . . . . . . . B-3
. . . . . . . . . . . . . . B-3
. . . . . . . . . . . . . . B-4
. . . . . . . . . . . . . . B-4
. . . . . . . . . . . . . . B-5
. . . . . . . . . . . . . . B-6
. . . . . . . . . . . . . . B-7
. . . . . . . . . . . . . . B-8
. . . . . . . . . . . . . B-14
. . . . . . . . . . . . . B-15
. . . . . . . . . . . . . B-15
. . . . . . . . . . . . . B-15
. . . . . . . . . . . . . B-21
. . . . . . . . . . . . . B-21
. . . . . . . . . . . . . B-21
. . . . . . . . . . . . . B-21
. . . . . . . . . . . . . B-22
. . . . . . . . . . . . . B-22
. . . . . . . . . . . . . B-23
. . . . . . . . . . . . . B-23
. . . . . . . . . . . . . B-23

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1

ii

4900002215 rev. B 3-10-15

LIST
Figure
Figure
Figure
Figure

OF

FIGURES

11.
12.
13.
14.

SS500/SS2000 analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SS3000 Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schematic of a typical laser diode absorption spectrometer . . . .
Typical raw signal from a laser diode
absorption spectrometer with and without mirror contamination.
Figure 15. Typical normalized absorption
signal from a laser diode absorption spectrometer . . . . . . . . . .
Figure 16. Typical normalized 2f signal; species concentration is
proportional to the peak height . . . . . . . . . . . . . . . . . . . . . . .
Figure 17. Analyzer Overview (SS3000 pictured) . . . . . . . . . . . . . . . . . . .
Figure 18. Electronics control board (AC) for single-channel systems
(SS500/SS2000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 19. Electronics control board (DC) for single-channel systems
(SS500/SS2000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 110. Electronics control board (AC) for dual-channel systems
(SS3000). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 111. Electronics control board (DC) for dual-channel systems
(SS3000). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 21.
Figure 22.
Figure 23.
Figure 24.
Figure 31.

Figure A1.
Figure A2.
Figure A3.
Figure A4.
Figure A5.
Figure A6.
Figure A7.
Figure A8.
Figure A9.

Internal view of electronics enclosure (SS500) . . . . . . . . . . . .


AC and DC connection terminal blocks in electronics enclosure.
Mating terminal block (TB2) in electronics enclosure for
connecting signal cables . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-20 mA output board . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Typical full-featured, single-channel SCS (SS500/SS2000)
on a panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SS500/SS2000 0.8-m cell (moisture) outline and
mounting dimensions . . . . . . . . . . . . . . . . . . . . . . . .
SS500/SS2000 0.1-m cell (carbon dioxide) outline and
mounting dimensions . . . . . . . . . . . . . . . . . . . . . . . .
Drawing of typical full-featured single-channel SCS
(SS500/SS2000) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drawing of typical full-featured singlechannel SCS (SS500/SS20000) in 24x24 enclosure . . .
Drawing of typical full-featured singlechannel SCS (SS500/SS20000) in 30x30 enclosure . . .
Electrical schematic for SS500/SS2000 . . . . . . . . . . . .
Interconnect diagram for single-channel system
(SS500/SS2000) . . . . . . . . . . . . . . . . . . . . . . . . . . .
SS3000 0.8-m/0.1-m cells (H2O/ CO2) outline and
mounting dimensions . . . . . . . . . . . . . . . . . . . . . . . .
SS3000 0.8-m/0.8-m cells (H2O/H2O) outline and
mounting dimensions . . . . . . . . . . . . . . . . . . . . . . . .

Hardware Installation and Maintenance Manual

. . 1-4
. . 1-4
. . 1-5
. . 1-6
. . 1-7
. . 1-8
. . 1-9
. 1-10
. 1-11
. 1-12
. 1-13

. . . 2-5
. . . 2-6
. . . 2-7
. . . 2-9
. . . 3-2

. . . . . . . . A-6
. . . . . . . . A-7
. . . . . . . . A-8
. . . . . . . . A-9
. . . . . . . A-10
. . . . . . . A-11
. . . . . . . A-12
. . . . . . . A-13
. . . . . . . A-14

iii

SS500/SS2000/SS3000 Analyzer

Figure A10. Drawing of typical full-featured dual-channel, dual-stream


SCS (SS3000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure A11. Drawing of typical full-featured dual-channel, dual-stream
SCS (SS3000) in a 36 X 36 enclosure . . . . . . . . . . . . . . .
Figure A12. Electrical schematic for SS3000 . . . . . . . . . . . . . . . . . . .
Figure A13. Interconnect diagram for dual-channel system (SS3000). .
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure
Figure

iv

B1.
B2.
B3.
B4.
B5.
B6.
B7.
B8.
B9.
B10.

. . . . . A-15
. . . . . A-16
. . . . . A-17
. . . . . A-18

Measurement cell types . . . . . . . . . . . . . . . . . . . . . . . . . . .


Stainless steel mirror marking . . . . . . . . . . . . . . . . . . . . . .
Stainless steel mirror - mirror side up . . . . . . . . . . . . . . . . .
Analyzer component locations . . . . . . . . . . . . . . . . . . . . . .
Removed measurement cell with pressure transducer face up
Removing the old pressure transducer . . . . . . . . . . . . . . . .
Removing excess seal tape from flange . . . . . . . . . . . . . . . .
Replacing seal tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing pressure transducer . . . . . . . . . . . . . . . . . . . . . .
Newly installed pressure transducer positioning . . . . . . . . . .

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. B-4
. B-5
. B-8
B-10
B-10
B-11
B-11
B-12
B-12
B-13

4900002215 rev. B 3-10-15

LIST

OF

TABLES

Table 11.

Fuse specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Table 21.

Output signal connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

Table
Table
Table
Table
Table
Table

SS500 H2O analyzer specifications . . . . . . . . . . . . . . . .


SS2000 single-channel H2O analyzer specifications. . . . .
SS2000 single-channel CO2 analyzer specifications . . . . .
SS3000 dual channel H2O/H2O analyzer specifications . .
SS3000 dual channel H2O/CO2 analyzer specifications . .
Replacement parts for SS500/SS2000/SS3000 analyzers

A1.
A2.
A3.
A4.
A5.
A6.

Table B1.

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. A-1
. A-2
. A-3
. A-4
. A-5
A-19

Potential instrument problems and solutions . . . . . . . . . . . . . . . B-16

Hardware Installation and Maintenance Manual

SS500/SS2000/SS3000 Analyzer

THIS PAGE INTENTIONALLY LEFT BLANK

vi

4900002215 rev. B 3-10-15

1 - INTRODUCTION
SpectraSensors SS500/SS2000/SS3000 products are high-speed, diode-laser
based extractive analyzers designed for extremely reliable monitoring of very
low or trace concentrations of specific components in various background
gases. In order to ensure that the analyzer performs as specified, it is
important to closely review the installation and operation sections of this
manual. This manual contains a comprehensive overview of the
SS500/SS2000/SS3000 analyzer and step-by-step instructions on:

Getting familiar with the analyzer


Installing the analyzer and SCS
Maintaining and troubleshooting the system

For instruction on operating the analyzer through firmware programming,


please consult the Firmware Operations Manual.

Who Should Read This Manual


This manual should be read and referenced by anyone installing, operating or
having direct contact with the analyzer.

How to Use This Manual


Take a moment to familiarize yourself with this manual by reading the Table
of Contents.
There are a number of options and accessories available for the
SS500/SS2000/SS3000 analyzers. This manual has been written to address
the most common options and accessories. Images, tables and charts have
been included to provide a visual understanding of the analyzer and its
functions. Special symbols are also used to provide the user with key
information regarding the system configuration and/or operation. Pay close
attention to this information.

General Warnings and Cautions


Instructional icons are provided in this manual to alert the user of potential
hazards, important information and valuable tips. Following are the symbols
and associated warning and caution types to observe when servicing the
analyzer. Some of these symbols are provided for instructional purposes only
and are not labeled on the system.
Equipment Labels
Warning statement for hazardous voltage. Contact may cause
electric shock or burn. Turn off and lock out system before
servicing.

Hardware Installation and Maintenance Manual

11

SS500/SS2000/SS3000 Analyzer

Failure to follow all directions may result in damage or


malfunction of the analyzer.

CAUTION
CLASS 3B INVISIBLE LASER
RADIATION WHEN OPEN
AVOID EXPOSURE TO THE BEAM

INVISIBLE LASER RADIATION - Avoid


exposure to beam. Class 3b Radiation Product.
Refer servicing to the manufacturer or qualified
personnel.

Removing label from measurement cell optical


head will void analyzer warranty.

Instructional Symbols
General notes and important information concerning the
installation and operation of the analyzer.

Failure to follow all directions may result in fire.

INVISIBLE LASER RADIATION - Avoid exposure to beam.


Class 3b Radiation Product. Refer servicing to the manufacturerqualified personnel.

Failure to follow all directions may result in damage or


malfunction of the analyzer.

Maximum voltage and current specifications for fuses.

!
V

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4900002215 rev. B 3-10-15

Introduction

Conventions Used in this Manual


In addition to the symbols and instructional information, the electronic version
of this manual is created with hot links to enable the user to quickly navigate
between different sections within the manual. These links include table, figure
and section references and are identified by a pointing finger cursor
when rolling over the text. Simply click on the link to navigate to the associated
reference.

SpectraSensors Overview
SpectraSensors, Inc. is a leading manufacturer of technologically advanced
electro-optic gas analyzers for the industrial process, gas distribution and
environmental monitoring markets. Headquartered in Houston, Texas,
SpectraSensors was incorporated in 1999 as a spin-off of the NASA/Caltech Jet
Propulsion Laboratory (JPL) for the purpose of commercializing space-proven
measurement technologies initially developed at JPL.

About the Gas Analyzers


The SS500/SS2000/SS3000 are tunable diode laser (TDL) absorption
spectrometers operating in the near infrared region of the spectrum. Each
compact sensor consists of a TDL light source, sample cell and detector
specifically configured to enable high sensitivity measurement of a particular
component within the presence of other gas phase constituents in the stream.
The sensor is controlled by microprocessor-based electronics with embedded
software that incorporates advanced operational and data processing
algorithms.
The SS500/SS2000/SS3000 analyzer may be integrated with a sample
conditioning system (SCS) that has been specifically designed to meet the
sample condition requirements for the analyzer, while preserving sample
integrity and minimizing sample lag time.
A sample conditioning system may also be included with the system that has
been specifically designed to deliver an optimum sample stream that is
representative of the process systems stream at the time of sampling. Most
SS500/SS2000/SS3000 analyzer systems are configured for use at extractive
natural gas sampling stations.

Differences between the SS500, SS2000, and SS3000


The SS500 and SS2000 are single-channel analyzers designed to continuously
measure the moisture content in natural gas pipelines. The SS2000 offers
higher measurement performance in those applications, and its single
measurement channel can also be configured to monitor CO2 levels in natural
gas pipelines, or to measure the moisture content in CO2 pipelines. For
performance specifications, refer to Table A1 through Table A3 and Figure
11 for an image of a standard SS500/SS2000 with a 0.8-m cell.

Hardware Installation and Maintenance Manual

13

SS500/SS2000/SS3000 Analyzer

Figure 11 SS500/SS2000 analyzer

The SS3000 is a dual-channel version of the SS2000 and is usually configured


to measure H2O and/or CO2 in the same or separate pipeline natural gas
sample streams (for performance specifications, refer to Table A4 and
Table A5). Refer to Figure 12 for an image of the analyzer with two 0.8-m
cells.

Figure 12 SS3000 Analyzer

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Introduction

How the Analyzers Work


The SS500/SS2000/SS3000 analyzers employ tunable diode laser absorption
spectroscopy (TDLAS) to detect the presence of trace substances in process
gases. Absorption spectroscopy is a widely used technique for sensitive trace
species detection. Because the measurement is made in the volume of the gas,
the response is much faster, more accurate and significantly more reliable than
traditional surface-based sensors that are subject to surface contamination.
In its simplest form, a diode laser absorption spectrometer typically consists of
a sample cell with a mirror at one end, and a mirror or window at the opposite
end, through which the laser beam can pass. Refer to Figure 13. The laser
beam enters the cell and reflects off the mirror(s) making one or more trips
through the sample gas and eventually exiting the cell where the remaining
beam intensity is measured by a detector. With the SS500/SS2000/SS3000
analyzers, sample gas flows continuously through the sample cell ensuring that
the sample is always representative of the flow in the main pipe.

OPTICAL HEAD

TEC
LASER

DETECTOR

OUTLET

WINDOW
PRESSURE
SENSOR

INLET
FAR MIRROR
0.8-m Measurement Cell
Figure 13 Schematic of a typical laser diode
absorption spectrometer

Due to their inherent structure, the molecules in the sample gas each have
characteristic natural frequencies (or resonances). When the output of the
laser is tuned to one of those natural frequencies, the molecules with that
particular resonance will absorb energy from the incident beam. That is, as the
beam of incident intensity, I0(), passes through the sample, attenuation occurs
via absorption by the trace gas with absorption cross section (). According
Hardware Installation and Maintenance Manual

15

SS500/SS2000/SS3000 Analyzer

to the Beer-Lambert absorption law, the intensity remaining, I(), as measured


by the detector at the end of the beam path of length I (cell length x number
of passes), is given by

I = I 0 exp lN ,

(1)

where N represents the species concentration. Thus, the ratio of the absorption
measured when the laser is tuned on-resonance versus off-resonance is
directly proportional to the number of molecules of that particular species in
the beam path, or

1
N = -------------- ln
l

I -----------.
I0

(2)

Figure 14 shows the typical raw data from a laser absorption spectrometer
scan including the incident laser intensity, I0(), and the transmitted intensity,
I(), for a clean system and one with contaminated mirrors (shown to illustrate
the systems relative insensitivity to mirror contamination). The positive slope
of raw data results from ramping the current to tune the laser, which not only
increases the wavelength with current, but also causes the corresponding
output power to increase. By normalizing the signal by the incident intensity,
any laser output fluctuations are canceled, and a typical, yet more pronounced,
absorption profile results. Refer to Figure 15.
3.0

Signal [a.u.]

2.5

Incident Energy I0()


Raw Signal, I()
Raw Signal, I()
(Contaminated Mirrors)

2.0

1.5

1.0

0.5

0.0
Wavelength [a.u.]

Figure 14 Typical raw signal from a laser diode


absorption spectrometer with and without mirror
contamination

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Introduction

1.0

Signal [a.u.]

0.99

0.98

0.97

0.96
Normalized Absorption Signal
0.95
Wavelength [a.u.]

Figure 15 Typical normalized absorption


signal from a laser diode absorption spectrometer

Note that contamination of the mirrors results solely in lower overall signal.
However, by tuning the laser off-resonance as well as on-resonance and
normalizing the data, the technique self calibrates every scan resulting in
measurements that are unaffected by mirror contamination.

Wavelength Modulation Spectroscopy (WMS) Signal Detection


SpectraSensors takes the fundamental absorption spectroscopy concept a step
further by using a sophisticated signal detection technique called wavelength
modulation spectroscopy (WMS). When employing WMS, the laser drive
current is modulated with a kHz sine wave as the laser is rapidly tuned. A lockin amplifier is then used to detect the harmonic component of the signal that
is at twice the modulation frequency (2f), as shown in Figure 16. This phasesensitive detection enables the filtering of low-frequency noise caused by
turbulence in the sample gas, temperature and/or pressure fluctuations, lowfrequency noise in the laser beam or thermal noise in the detector.

Hardware Installation and Maintenance Manual

17

SS500/SS2000/SS3000 Analyzer

Signal [a.u.]

Normalized
2f Signal

Wavelength [a.u.]

Figure 16 Typical normalized 2f signal; species


concentration is proportional to the peak height

With the resulting low-noise signal and use of fast post-processing algorithms,
reliable parts per million (ppm) or parts per billion (ppb) detection levels are
possible (depending on target and background species) at real-time response
rates (on the order of 1 second).
All SpectraSensors TDL gas analyzers employ the same design and hardware
platform. Measuring different trace gases in various mixed hydrocarbon
background streams is accomplished by selecting a different optimum diode
laser wavelength between 750-3000nm, which provides the least amount of
sensitivity to background stream variations.

Getting Familiar with the Analyzer


SpectraSensors SS500/SS2000/SS3000 analyzers are typically comprised of a
single electronics enclosure and associated measurement cell(s). Refer to
Appendix A for system drawings. On the front panel of the analyzer, the keypad
and LCD display serve as the user interface to each analyzer. The analyzer
control electronics drive the laser, collect the signal, analyze the spectra and
provide measurement output signals. Refer to Figure 17.

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Introduction

MEASUREMENT
CELL AND LASER
MEASUREMENT
CELL AND LASER

ANALYZER
ELECTRONICS
ENCLOSURE

LCD/KEYPAD

POWER
CONNECTION
Figure 17 Analyzer Overview (SS3000 pictured)

Power is connected to the analyzer from an external power source through the
bottom of the enclosure. Refer to Table A1 through Table A5 for system
specifications. The measurement cell(s) along with flow devices to control flow
and pressure for the measurement cell and the bypass loop are mounted on a
panel alongside the enclosure.
Inside the SS500/SS2000 analyzer electronics enclosure is the electronics
assembly as shown in Figure 18 and Figure 19.
Inside the SS3000 analyzer electronics enclosure is the electronics assembly
as shown in Figure 110 and Figure 111.
Fuses are located on the electronics control board, as shown in Figure 18,
Figure 19, Figure 110 and Figure 111.
If you need to replace a fuse, use only the same type and rating
of fuse as the original as listed in Table 11.
Table 11 Fuse specifications
DWG Ref.
Figure 18
Figure 110

F1

Figure 19
Figure 111

F2

!
V

Voltage

Description

Rating

120 VAC

Miniature Fuse, 5 x 20 mm, Time Delay

250VAC/0.8A

240 VAC

Miniature Fuse, 5 x 20 mm, Time Delay

250VAC/0.5A

12 VDC

Miniature Fuse, 5 x 20 mm, Time Delay

250VAC/3.15A

24 VDC

Miniature Fuse, 5 x 20 mm, Time Delay

250VAC/1.6A

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SS500/SS2000/SS3000 Analyzer

TEMPERATURE
CONTROL BOARD

4-20 mA CURRENT LOOP


BOARD (STACKED)

POWER
SUPPLY
LASER
DRIVER
BOARD

BACKPLANE

FUSE
(F1)

COMPONENT
GROUND
CUSTOMER
GROUND
PROTECTIVE
GROUND
ASSIGNABLE
ALARM RELAY
4-20 mA & SERIAL SIGNAL
CONNECTIONS

NO

GENERAL FAULT
ALARM RELAY

COMMON
NC

Figure 18 Electronics control board (AC) for singlechannel systems (SS500/SS2000)

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Introduction

4-20 mA CURRENT LOOP


BOARD (STACKED)

TEMPERATURE
CONTROL BOARD

LASER
DRIVER
BOARD

POWER
SUPPLY

BACKPLANE
FUSE (F2)

TB2
COMPONENT
GROUND
CUSTOMER
GROUND
PROTECTIVE
GROUND
4-20 mA & SERIAL
SIGNAL CONNECTIONS

ASSIGNABLE
ALARM FAULT
NO
COMMON

GENERAL FAULT
ALARM FAULT

NC

Figure 19 Electronics control board (DC) for


single-channel systems (SS500/SS2000)

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111

SS500/SS2000/SS3000 Analyzer

TEMPERATURE
CONTROL BOARD

4-20 mA CURRENT LOOP


BOARD (STACKED)

LASER
DRIVER
BOARD

POWER
SUPPLY

BACKPLANE

FUSE
(F1)
COMPONENT
GROUND
CUSTOMER
GROUND
PROTECTIVE
GROUND

4-20 mA & SERIAL SIGNAL


CONNECTIONS
NO
COMMON
NC

ASSIGNABLE
ALARM RELAY (Ch. A)
GENERAL FAULT
ALARM RELAY (Ch. A)
ASSIGNABLE ALARM
RELAY (Ch. B)
GENERAL FAULT
ALARM RELAY (Ch. B)

Figure 110 Electronics control board (AC) for dualchannel systems (SS3000)

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Introduction

4-20 mA CURRENT LOOP


BOARD (STACKED)

TEMPERATURE
CONTROL BOARD

LASER
DRIVER
BOARD

POWER
SUPPLY

BACKPLANE

FUSE (F2)

TB2

COMPONENT
GROUND
CUSTOMER
GROUND
PROTECTIVE
GROUND
ASSIGNABLE
ALARM RELAY (Ch. A)
GENERAL FAULT
ALARM RELAY (Ch. A)

4-20 mA & SERIAL SIGNAL


CONNECTIONS

NO
COMMON
NC

ASSIGNABLE ALARM
RELAY (Ch. B)
GENERAL FAULT
ALARM RELAY (Ch. B)

Figure 111 Electronics control board (DC) for dualchannel systems (SS3000)

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THIS PAGE INTENTIONALLY LEFT BLANK

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4900002215 rev. B 3-10-15

2 - INSTALLATION
This section describes the processes used to initially install and configure your
SS500, SS2000, or SS3000 and optional sample conditioning system (SCS).
Once the analyzer arrives, you should take a few minutes to examine the
contents before installing the unit.
The safety of the analyzer is the responsibility of the installer and
the organization he/she represents.

What Should be Included in the Shipping Box


The contents of the crate should include:

The SpectraSensors SS500, SS2000, or SS3000

One (SS500 or SS2000) or two (SS3000) external serial cable(s) to


connect the analyzer to a computer

Additional accessories or options as ordered.

A document CD, which includes this manual and other system


manuals

If any of these contents are missing, consult Customer Service on page


B-21.

Inspecting the Analyzer


Unpack and place the unit on a flat surface. Carefully inspect all enclosures for
dents, dings, or general damage. Inspect the inlet and outlet connections for
damage, such as bent tubing. Report any damage to the carrier.
Avoid jolting the instrument by dropping it or banging it against a
hard surface. Do not attempt to pick up the instrument using the
sample cell. Either action may disturb the optical alignment.

Each analyzer is configured with various accessories and options. If there is any
discrepancy in your order, please contact Customer Service on page B-21.

Lifting/carrying the analyzer


At approximately 25 lbs (11.5 Kg), the SS500/SS2000/SS3000 can easily be
lifted from the packaging and moved to the installation location. Take care not
to lift or carry the analyzer by the measurement cells or the cables connected
at the top of the analyzer, or damage may occur.

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21

SS500/SS2000/SS3000 Analyzer

Installing the Analyzer


Installing the analyzer is relatively easy requiring only a few steps that, when
carefully followed, will ensure proper mounting and connection. This section
includes:

Hardware and Tools for Installation


Mounting the Analyzer
Connecting Electrical Power to the Analyzer
Connecting the Output Signals
Connecting the Gas Lines

Hardware and Tools for Installation


Depending on the particular model, the configuration of accessories and
options ordered, you may need the following hardware and tools to complete
the installation process.

Hardware

1/2 Unistrut (or equivalent) bolts and spring nuts

1/2 conduit hubs

Hand drill and bits

1/4 lag bolts or 1/4 machine screws and nuts


Stainless steel tubing (SpectraSensors recommends using 1/4 O.D.
x0.035 wall thickness, seamless stainless steel tubing)
Conduit

Tools
Tape measure
Level
Pencil
Socket wrench set
Screw driver
Crescent wrench
9/16 open-end wrench

Mounting the Analyzer


The SS500/SS2000/SS3000 analyzer is manufactured for wall or Unistrut (or
equivalent) metal framing installations. Depending on your application and
configuration, the analyzer may come premounted on a SCS panel to be
mounted on a wall or Unistrut framing, or without a panel requiring mounting

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4900002215 rev. B 3-10-15

Installation

via the standard electronics enclosure tabs. Refer to the layout diagrams in
Appendix A for detailed mounting dimensions.
When mounting the analyzer, be sure not to position the
instrument so that it is difficult to operate adjacent devices. Allow
3 feet of room in front of the analyzer and any switches.

It is critical to mount the analyzer so that the inlet and outlet lines
reach the inlet and outlet connections on the chassis while still
maintaining flexibility so that the sample lines are not under
excessive stress.

To mount the analyzer:


1. Select a suitable location to mount the analyzer. Choose a shaded area
or use an optional analyzer hood (or equivalent) to minimize sun
exposure.
SpectraSensors analyzers are designed for operation within the
specified ambient temperature range of 4 F to 122 F (20 C
to 50 C). Intense sun exposure in some areas may cause the
analyzer temperature to exceed the maximum.

2. Locate the mounting holes on your unit. Refer to drawings in Appendix A.


3. For wall installations, mark the centers of the top mounting holes.
4. Drill the appropriate size holes for the screws you are using.
5. Hold the analyzer in place and fasten with the top screws.
6. Repeat for the bottom mounting holes.
Once all four screws are tightened the analyzer should be very secure and ready
for the electrical connections.

Connecting Electrical Power to the Analyzer


The analyzer will be configured for 100-240 VAC @ 50/60 Hz single-phase input or
optionally 916 VDC or 1832 VDC input. Check the manufacturing data label or
the terminal block labels to determine the power input requirements. All work must
be performed by personnel qualified in electrical conduit installation. Conduit seals
should be used where appropriate in compliance with local regulations.
Hazardous voltage and risk of electric shock. Before
attaching the wiring to the analyzer, make sure all power to the
wires is off.

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23

SS500/SS2000/SS3000 Analyzer

Careful consideration should be taken when grounding. Properly


ground the unit by connecting ground leads to the grounding
studs provided throughout the system that are labeled with the
ground symbol .
Interconnection of the analyzer enclosure and cell enclosure shall
be accomplished using wiring methods approved for Class 1,
Division 2 hazardous locations as per the Canadian Electrical Code
(CEC) Appendix J and the National Electric Code (NEC) Article
501. The installer is responsible for complying with all local
installation codes.

Depending on the analyzer configuration, the electrical wiring can typically be


connected to the analyzer through a conduit hub located at the bottom right or
left of the electronics enclosure. Refer to Appendix A for system drawings.

Protective chassis and ground connections


Before connecting any electrical signal or power, the protective and chassis
grounds must be connected. Requirements for the protective and chassis
grounds are as follows:

The protective and chassis grounds must be of equal or greater size


than any other current-carrying conductors, including the heater
located in the sample conditioning system.

The protective and chassis grounds must remain connected until all
other wiring is removed.

If the protective and chassis ground is insulated, it must use the


green/yellow color.

Refer to Figure 18, Figure 19, Figure 110 and Figure 111 for the protective
and chassis ground locations.

To connect electrical power to the analyzer:


1. Open the electronics enclosure door. Take care not to disturb the
electrical assembly inside. Refer to Figure 21.
Hazardous voltage and risk of electric shock. Failure to
properly ground the analyzer may create a high-voltage shock
hazard.

2. Run conduit from the power distribution panel to the conduit hub on
the electronics enclosure labeled for power input.
Conduit seals should be used where appropriate in compliance
with local regulations.

24

4900002215 rev. B 3-10-15

Installation

Figure 21 Internal view of electronics enclosure


(SS500)
Because the breaker in the power distribution panel or switch will
be the primary means of disconnecting the power from the
analyzer, the power distribution panel should be located in close
proximity to the equipment and within easy reach of the operator,
or within 10 feet of the analyzer.

An approved switch or circuit breaker rated for 15 amps should be


used and clearly marked as the disconnecting device for the
analyzer.

3. For AC systems, pull ground, neutral and hot wires (#14 AWG
minimum) into the electronics enclosure.
For DC systems, pull ground, plus and minus wires.
4. Strip back the jacket and/or insulation of the wires just enough to
connect to the power terminal block.
5. For AC systems, attach the neutral and hot wires to the power
terminal block by connecting the neutral wire to the terminal marked
NEU and the hot wire to the terminal marked LINE as shown in
Figure 22.
For DC systems, connect the minus wire to the terminal marked
and the positive wire to the terminal marked + as shown in Figure
22.

Hardware Installation and Maintenance Manual

25

SS500/SS2000/SS3000 Analyzer

NEU LINE

AC TERMINAL BLOCK

DC TERMINAL BLOCK

Figure 22 AC and DC connection terminal blocks in


electronics enclosure

6. Connect the ground wire to the ground terminal marked

7. Close and tighten the electronics enclosure door.

Connecting the Output Signals


The 4-20 mA current loop and serial output(s) are supplied from the mating
terminal block (TB2) located inside the analyzer electronics enclosure as shown
in Figure 18, Figure 19, Figure 110 or Figure 111. By default, the 4-20 mA
current loop output is factory set to source current.
The 4-20 mA current loop output is factory set to source current.
To change the 4-20 mA current loop output from source to sink,
see To change the 4-20 mA board from source to sink on
page 2-8.

Connections can be made with customer-supplied cables for the current loop(s)
and factory-supplied cable for the serial connection(s). Consult the wiring
diagrams in .
Hazardous voltage and risk of electric shock. Be sure power
to the analyzer is turned off before opening the electronics
enclosure and making any connections.Appendix A

To connect the output signals:


1. Disconnect power to the analyzer and open the electronics enclosure
cover. Take care not to disturb the electrical assembly inside.

26

4900002215 rev. B 3-10-15

Installation

2. Run conduit from the signal/alarm receiving station to the conduit


hub on the electronics enclosure labeled for signal connections.
Conduit seals should be used where appropriate in compliance
with local regulations.

3. Pull the customer-supplied cable(s) for the current loop(s), digital


output relays, and the SpectraSensors external serial cable(s)
(included in the shipping box) through the conduit into the
electronics enclosure.
4. Strip back the jacket and insulation of the current loop, digital output
relays and serial cables (shown in Figure 18, Figure 19, Figure
110 or Figure 111) just enough to connect to the mating terminal
block (TB2), shown in Figure 23. The mating terminal block can be
pulled up and removed from its base to make the cable connection
process easier.
TB2
1

9 10 11 12

Figure 23 Mating terminal block (TB2) in


electronics enclosure for connecting signal cables

5. Connect the 4-20 mA current loop signal wires to the appropriate


terminals, as indicated in Table 21.
6. Connect the serial cable wires to the appropriate terminals according
to Table 21. For reference, Table 21 also shows the corresponding
pin numbers for configuring a nine-pin Sub-D connector for
connection to a computer serial port.
7. Connect the digital output relays according to the call-outs shown in
Figure 18, Figure 19, Figure 110 or Figure 111.
8. Reinsert the mating terminal block into its base and verify that each
connection is secure.
9. Close and tighten the electronics enclosure cover.

Hardware Installation and Maintenance Manual

27

SS500/SS2000/SS3000 Analyzer

Table 21 Output signal connections

Terminal

Description

D-Conn

Color

Ch. A Serial RX

Pin-3

Black

Ch. A Serial TX

Pin-2

Red

COM Serial Ground

Pin-5

Shield

Ch. B Serial RX

Pin-3

Black

Ch. B Serial TX

Pin-2

Red

Ch. A Current Loop +

Ch. A Current Loop -

Ch. B Current Loop +

Ch. B Current Loop -

10

N/C

11

N/C

12

N/C

NOTE: The description N/C indicates no connection.

10. To complete the connections, connect the other end of the current
loop wires to a current loop receiver and each external serial cable
to a serial port on your computer.

Changing the 4-20 mA Current Loop Mode


By default, the 4-20 mA current loop output is factory set to source current. In
some instances it may be necessary to change the 4-20 mA current loop output
in the field from source to sink. The work must be performed by personnel
qualified in electronics assembly.

To change the 4-20 mA board from source to sink:


1. Disconnect power to the analyzer and open the electronics enclosure
cover. Take care not to disturb the electrical assembly inside.
2. Locate the 4-20 mA board(s) in the center of the electronics
enclosure, as shown in Figure 18, Figure 19, Figure 110 or Figure
111.
3. Remove the jumper (JMP1), shown in Figure 24, connecting the
center hole to point A.

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4900002215 rev. B 3-10-15

Installation

Potentiometers

JMP1

Figure 24 4-20 mA output board

4. For 4-20 mA sink, carefully replace the jumper to connect the center
hole with point P.

Needle nose pliers may be required to remove the jumper.

5. Repeat steps 2-4 as necessary for any remaining 4-20 mA boards.


6. Reconnect power to the analyzer. Confirm the 4 mA (min.) and
20 mA (max.) points. Close and tighten the electronics enclosure
cover. Follow the programming instructions below.

Calibrating the analog output


1. Connect a calibrator and digital multi-meter into the circuit.
2. On the analyzer keypad, press #2 (Mode 2), the password (3142)
and *.
3. Continue pressing the * key until the 4-20 mA % Test parameter
displays.

<CH A SET PARAMETER>


4-20 mA % Test
101
Enter a % (101=Off)
4. Enter the desired percentage of full scale and press *.
a.

Set 4-20 mA % Test = 0; this displays the 4 mA on the AO circuit


when #1 (Mode 1) is pressed.

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29

SS500/SS2000/SS3000 Analyzer

b. Set 4-20 mA Test = 50; this displays the 12 mA on the AO circuit

when #1 (Mode 1) is pressed.

c. Set 4-20 mA Test = 100; this displays the 20 mA on the AO circuit

when #1 (Mode 1) is pressed.

Testing and adjusting the 4-20 mA zero and span


1. Press #1 (Mode 1) and note the 4-20 mA % Test parameter
setting displayed on the analyzer.

<CH A SET PARAMETER>


4-20 mA % Test
0.0
Enter a % (101=Off)
2. Adjust the potentiometers on the end of the board to change the
zero and span readings. Refer to Figure 24.
3. Press # and 1 to return to Normal Mode.
For more information on the analyzer programming, refer to the Firmware
Operators Manual.

Connecting the Gas Lines


Once you have verified that the analyzer is properly wired, you are ready to
connect the sample supply, sample return, and sample bypass (if applicable).
Consult the layout and flow diagrams in Appendix A for guidance. All work must
be performed by technicians qualified in instrument tubing.
Process samples may contain hazardous material in potentially
flammable and/or toxic concentrations. Personnel should have a
thorough knowledge and understanding of the physical properties
and safety precautions for the sample contents before installing
the SCS.

SpectraSensors recommends using 1/4 O.D x 0.035 wall thickness, seamless


stainless steel tubing.

To connect the sample supply line:


1. First, confirm that the sample probe is correctly installed at the
process supply tap and that the sample probe isolation valve is
closed.
Consult sample probe manufacturer instructions for proper
installation procedures.

210

4900002215 rev. B 3-10-15

Installation

The process sample at the sample tap may be at a high pressure.


Use extreme caution when operating the sample probe isolation
valve and field pressure reducing regulator.

All valves, regulators, switches, etc. should be operated in


accordance with site lock-out/tag-out procedures.

2. Also, confirm that the field pressure reducing station is installed


properly at the sample probe and that the pressure regulator at the
field pressure reducing station is closed (adjustment knob turned
fully counter-clockwise).
3. Determine appropriate tubing route from the field pressure reducing
station to the SCS.
4. If configured with this analyzer, install the heat trace bundle in the
heat trace sample inlet.
a. Remove the white foam supplied with the SCS.
b. Run the entire heat trace bundle into the enclosure.
c.

Once installed, seal the rubber tube around the heat trace by
applying heat until the tube shrinks down around the heat trace
bundle.

Hazardous voltage and risk of electric shock. Follow your


plant safety guidelines or refer to your safety engineer before
attempting to heat the rubber tube.

5. If configured with this analyzer, install the heat trace terminal box
external to the SCS enclosure using the supplied GFI Heat Trace
Power conduit hub.
a. Run the heat trace power back out of the enclosure and into the
heat trace terminal box through the GFI Heat Trace Power
conduit hub.
6. Run stainless steel tubing from the field pressure reducing station
(set for the specified inlet pressure) to the sample supply port of the
SCS. Bend tubing using industrial grade benders, check tubing fit to
ensure proper seating between the tubing and fittings. Fully ream all
tubing ends. Blow out the lines for 1015 seconds with clean, dry
nitrogen or air prior to making the connection.
7. Connect the inlet tube to the SCS using the 1/4 stainless steel
compression-type fitting provided.

Hardware Installation and Maintenance Manual

211

SS500/SS2000/SS3000 Analyzer

8. Tighten all new fittings 1-1/4 turns with a wrench from finger tight.
For connections with previously swaged ferrules, thread the nut to
the previously pulled up position, then tighten slightly with a wrench.
Secure tubing to appropriate structural supports as required.
9. Check all connections for gas leaks. SpectraSensors recommends
using a liquid leak detector.
Do not exceed 10 PSIG (0.7 barg) in sample cell. Damage to cell
may result.

To connect the sample return:


1. Confirm that the atmospheric vent header shut-off valve is closed, if
applicable.
All valves, regulators, switches, etc. should be operated in
accordance with site lock-out/tag-out procedures.

2. Determine appropriate tubing route from the SCS to the


atmospheric vent header.
3. Run stainless steel tubing from the sample return port to the
atmospheric vent header connection.
a. Bend tubing using industrial grade benders, check tubing fit to
ensure proper seating between the tubing and fittings.
b. Fully ream all tubing ends.
c.

Blow out the lines for 1015 seconds with clean, dry nitrogen or
air prior to making the connection.

4. Connect the sample return tube to the SCS using the 1/4 stainless
steel compression-type fitting provided.
5. Tighten all new fittings 1-1/4 turns with a wrench from finger tight.
For connections with previously swaged ferrules, thread the nut to
the previously pulled up position, then tighten slightly with a wrench.
Secure tubing to appropriate structural supports as required.
6. Check all connections for gas leaks. SpectraSensors recommends
using a liquid leak detector.
Do not exceed 10 PSIG (0.7 barg) in sample cell. Damage to cell
may result.

7. Be sure to vent the bypass return port and pressure relief vent port
(if applicable) in a similar fashion when the unit is in use.

212

4900002215 rev. B 3-10-15

Installation

Conditioning the SCS Tubing


Newly installed systems invariably have some trace contaminants and/or are
intended for measuring trace amounts of gas constituents that tend to cling to
system walls, which can result in erroneous readings if the constituents are not
in equilibrium with the system walls. Therefore, once the analyzer and SCS are
completely connected, the entire system (i.e., from the sample source valve to
the vent or return) should be conditioned by flowing sample gas through the
system for up to 12 hours (or until reading stabilizes) after the system is
powered up and before actual readings are taken. Progress of the system
conditioning can be monitored via the gas concentration readings. Once the
gas constituents have reached equilibrium with the system walls, the readings
should stabilize.

Hardware Installation and Maintenance Manual

213

SS500/SS2000/SS3000 Analyzer

THIS PAGE INTENTIONALLY LEFT BLANK

214

4900002215 rev. B 3-10-15

3 - SAMPLE CONDITIONING SYSTEM


(SCS)
Personnel should have a thorough understanding of the operation
of the SS500/SS2000/SS3000 analyzer and the procedures
presented here before operating the sample conditioning system.

The process sample at the sample tap may be at a high pressure.


A field pressure reducing regulator is located at the sample tap to
reduce the sample pressure and enable operation of the sample
conditioning system at a low pressure. Use extreme caution when
operating the sample probe isolation valve and field pressure
reducing regulator.

The process sample at the sample tap may be at a high pressure.


Make sure that the field pressure reducing regulator is equipped
with an appropriate pressure relief valve.

SS500/SS2000/SS3000 systems may be ordered with an optional integrated


Sample Conditioning System (SCS). Each SCS has been specifically designed
to deliver a sample stream to the analyzer that is representative of the process
stream at the time of sampling. To ensure the integrity of the sample stream
and its analysis, care must be taken to install and operate the SCS properly.
Therefore, any personnel intending to operate or service the analyzer and SCS
should have a thorough understanding of the process application and the
design of the analyzer and SCS.
Most problems experienced with sample systems tend to result from operating
the system differently than intended. In some cases, the actual process
conditions may be different than originally specified (e.g., flow rates, presence
of contaminants, particulates, or condensables that may only exist under upset
conditions). By establishing understanding of the application and the design of
the system, most issues can be avoided altogether or easily diagnosed and
corrected ensuring successful normal operation.
If there are any remaining questions concerning the design, operation, or
maintenance of the SCS, contact your factory service representative.
Process samples may contain hazardous material in potentially
flammable and/or toxic concentrations. Personnel should have a
thorough knowledge and understanding of the physical properties
and safety precautions for the sample contents before operating
the SCS.

Hardware Installation and Maintenance Manual

31

SS500/SS2000/SS3000 Analyzer

About the SCS


The system drawings and schematics used in this manual are for
illustration purposes only. Always refer to your particular as-built
drawings for your specific system configuration and
specifications.

For a typical full-featured SCS, as shown in Figure 31, sample gas enters the
sample conditioning unit [at the specified supply pressure set by a customersupplied upstream regulator] via the sample supply port, passes through a
shut-off valve, pressure regulator that maintains constant pressure in the
measurement cell, and membrane separator where any liquid in the stream is
removed. Liquid removed by the membrane separator passes through the
bypass loop and collects in a filter housing. A continuous flow (set to the
specified level by a metering valve with integrated flowmeter) not only flushes
the liquid from the membrane separator but also maintains flow through the
sample lines, which reduces sample variation.

Figure 31 Typical full-featured, single-channel SCS


(SS500/SS2000) on a panel

32

4900002215 rev. B 3-10-15

Sample Conditioning System (SCS)

The flow exiting the bypass loop is combined with the flow exiting the
measurement cell and sent out the sample return port to be vented to a safe
location.

Checking the SCS Installation


Before operating the system for the first time, a careful check of the installation
of the entire SCS from the sample probe to the vent is recommended.

To perform SCS installation checks:


1. Confirm that the sample probe is correctly installed at the process
supply tap and that the sample probe isolation valve is closed.
2. Confirm that the field pressure reducing station is installed properly
at the sample probe.
3. Confirm that the relief valve at the field pressure reducing station
has been set to the specified setpoint.
4. Confirm that all valves are closed.
5. Confirm that the power is available to the analyzer, and if applicable,
that the local switch is off.
6. Confirm that the field analog and alarm signal wiring is connected
properly (see Connecting the Output Signals on page 2-6).
7. Confirm that the atmospheric vent is properly connected.
8. Confirm that the analyzer house atmospheric vent is properly
installed, if applicable.
9. Confirm that all sample system tubing has been thoroughly leak
checked.

Starting up the SCS


After the SCS installation has been thoroughly checked, you are ready to begin
preparing for initial SCS startup.

To prepare for SCS startup:


1. If applicable, apply AC power to the heat-traced sample transport
tubing at the tracer control system.
If applicable, personnel should have a thorough understanding of
the operation of the tracer power supply and control system
before operating the SCS.

Hardware Installation and Maintenance Manual

33

SS500/SS2000/SS3000 Analyzer

2. If applicable, confirm that the sample supply line electric tracer


temperature controller at the tracer control system is set to the
temperature specified.
3. If applicable, confirm proper heating of the sample supply tubing.
4. Confirm that all sample system shut-off valves are closed.
5. Confirm that the sample bypass and analyzer flowmeter control
valves are gently closed (adjustment knob turned clockwise).

Do not overtighten the control valves or damage could occur.

To start up the field pressure reducing station:


The process sample at the sample tap may be at a high pressure.
Use extreme caution when operating the sample probe isolation
valve and field pressure reducing regulator.

1. Confirm that the sample probe isolation valve is closed.


2. Confirm that the pressure regulator at the field pressure reducing
station is closed (adjustment knob turned fully counterclockwise).
3. Slowly open the sample probe process shut-off valve at the sample
supply tap.
4. Slowly open the pressure regulator at the field pressure reducing
station (adjustment knob turned clockwise) and set the pressure
regulator to the specified pressure.
5. Blow sample through the sample transport tubing to flare or safe
vent to ensure that dirt or liquids are in the sample tubing.
6. Reconnect the sample transport tubing and set the pressure or the
regulator to the specified pressure.

To start up the sample bypass stream on process sample:


1. Open the atmospheric vent header shut-off valve for the combined
sample bypass and measurement cell effluent from the SCS, if
applicable.
2. Open the sample supply port shut-off valve and slowly open the
pressure regulator (turning knob clockwise).
3. Set the inlet pressure regulator on the panel to a setting that will
maintain the specified flowmeter settings and provide good control
using the analyzer and bypass flow control valves.

34

4900002215 rev. B 3-10-15

Sample Conditioning System (SCS)

4. Open the bypass flowmeter control valve to establish sample flow


from the sample probe and set the flowmeter to the specified value.
Do not exceed 10 PSIG at any time in the cell. Refer to Appendix A
for analyzer specifications.

To start up the analyzer on process sample:


1. Open the sample flowmeter control valve to approximately the
specified flow.
2. If required, adjust the pressure regulator at the field pressure
reducing station to the specified setpoint.
3. Adjust the sample flowmeter control valve to the specified flow.
The adjustment setpoints of the analyzer flowmeter and pressure
regulator will be interactive and may require multiple adjustments
until the final setpoints are obtained.

The analyzer system has been designed for the sample flow rate
specified. A lower than specified sample flow rate may adversely
affect analyzer performance. If you are unable to attain the
specified sample flow rate, contact your factory sales
representative.

4. Confirm the sample flow and pressure setpoints and readjust the
control valves and pressure regulator to the specified setpoints, if
necessary.
5. Confirm the sample bypass flow and readjust the bypass control
valve to the specified setpoint, if necessary. The SCS is now
operating with the process sample.
6. Power up the analyzer according to the procedure given in To
power up the analyzer in the Firmware Manual.

Shutting Down the SCS


Process samples may contain hazardous material in potentially
flammable and/or toxic concentrations. Personnel should have a
thorough knowledge and understanding of the physical properties
and safety precautions for the sample contents before operating
the SCS.

Hardware Installation and Maintenance Manual

35

SS500/SS2000/SS3000 Analyzer

The process sample at the sample tap is at a high pressure. A


pressure reducing regulator is located at the sample tap to reduce
the sample pressure and enable operation of the SCS at a low
pressure. Use extreme caution when operating the sample probe
isolation valve and field pressure reducing regulator.

To isolate the analyzer for short-term shutdown:


The analyzer can be isolated from the process sample tap for short-term
shutdown or maintenance of the analyzer without requiring the shutdown of
the field pressure reducing station.
Process samples may contain hazardous material in potentially
flammable and/or toxic concentrations. Personnel should have a
thorough knowledge and understanding of the physical properties
and safety precautions for the sample contents before operating
the SCS.
Due to the high pressure of the process sample, it is advisable to
allow the sample bypass flow to continue during short-term
isolation of the analyzer. Continuing sample bypass flow allows
the field pressure regulator to continue normal operation without
possible overpressure and activation of the relief valve in the
event the pressure regulator leaks when the downstream flow is
discontinued.
The sample transport line must be vented to the atmospheric vent
header through the bypass flowmeter to avoid pressure surges.
The procedure given in the following steps can be followed
regardless of whether or not the SCS has been isolated from the
process tap as described in the previous section.

All valves, regulators, switches, etc. should be operated in


accordance with site lock-out/tag-out procedures.

1. Close the sample supply shut-off valve.


2. Allow the sample to flow until all residual gas has dissipated from the
lines as indicated by no flow on the sample and sample bypass
flowmeters.
3. Close the atmospheric vent header shut-off valve for the combined
sample bypass and measurement cell effluent from the SCS.

36

4900002215 rev. B 3-10-15

Sample Conditioning System (SCS)

4. Turn off power to the analyzer.


If the system will not be out of service for an extended period, it
is advised that power remain applied to the sample transport line
electric tracer, if applicable.

To isolate the analyzer for long-term shutdown:


If the analyzer is to be out of service for an extended period, the analyzer must
be isolated at the process sample tap.
Process samples may contain hazardous material in potentially
flammable and/or toxic concentrations. Personnel should have a
thorough knowledge and understanding of the physical properties
and safety precautions for the sample contents before operating
the SCS.
Due to the high pressure of the process sample, it is advisable to
allow the sample bypass flow to continue during long-term
isolation of the analyzer. Continuing sample bypass flow allows
the field pressure regulator to continue normal operation without
possible overpressure and activation of the relief valve in the
event the pressure regulator leaks when the downstream flow is
discontinued.
The sample transport line must be vented to the atmospheric vent
header through the bypass flowmeter to avoid pressure surges.
The procedure given in the following steps can be followed
regardless of whether or not the SCS has been isolated from the
process tap as described in the previous section.

All valves, regulators, switches, etc. should be operated in


accordance with site lock-out/tag-out procedures.

1. Open (or confirm open) the or atmospheric vent header shut-off


valve for the effluent from the SCS.
2. Confirm flow in the sample bypass flowmeter (the actual flow is not
critical).
3. Close the sample probe process shut-off valve at the sample supply
process tap.
4. Allow pressure in the field pressure reducing regulator to dissipate
until only a low residual pressure is indicated on the pressure gauge
at the field station.

Hardware Installation and Maintenance Manual

37

SS500/SS2000/SS3000 Analyzer

5. Close the field pressure reducing regulator (adjustment knob turned


fully counterclockwise).
6. Close the sample supply shut-off valve.
7. Leave the flowmeter control valves open.
8. Close the atmospheric vent header shut-off valve for the sample
bypass and measurement cell effluent from the SCS.
9. Turn off power to the analyzer.
10. Turn off the AC power to the sample tracer, if applicable, at the
power distribution panel.
Although power could be shut off to the sample supply electric
tracer, it is advisable to allow this line to remain heated unless the
SCS is to be out of service for an extended period or maintenance
is required on the line.

38

4900002215 rev. B 3-10-15

Appendix A: Specifications
Table A1 SS500 H2O analyzer specifications

Performance
Typical Measurement Ranges

Repeatability

220 lbs/MMscf (40422 ppmv)


250 lbs/MMscf (401055 ppmv)
2100 lbs/MMscf (402110 ppmv)
0.5 lb/MMscf (10 ppmv) or 2% of reading

Response Time

0.25 2 seconds (dependent on flow rate and sample


system volume)

Application Data
Environmental Temperature Range

-4 to 122 F (-20 to 50 C)

Environmental Relative Humidity

8% for temperatures up to 31C MAX

Altitude

Up to 4000 m

Maximum Cell Pressure

70kPaG (10 PSIG)

Sample Cell Pressure Range

700-1400 mbara

Sample Flow Rate

0.51.0 SLPM (12 SCFH) typical (not flow dependent)

Recommended Validation

Bureau of Mines chilled mirror, portable TDL or binary


gas with methane background

Electrical & Communications


Input Voltages

100240 VAC, 50/60 Hz


916 VDC or 1832 VDC - Optional

Contact Rating
(Inductive Load)

250V, 3A N.O. contact, 1.5A N.C. contact


24V, 1A N.O. and .C. contact

Communication

Analog: (2) 4-20mA Isolated, 1200 ohms @ 24VDC


max load
Serial: RS-232C
Protocol: Modbus Gould RTU, Daniel RTU or ASCII

Digital Output

(2) General Fault and Assignable alarms

Physical Specifications
Class 1, Div 2
System Dimensions

439 mm H x 371 mm W x 146 mm D


(17.27" H x 14.59" W x
5.75" D)

Weight

Approx. 25 lbs (11.5 Kg)

Enclosure Type

NEMA 3R-304 Stainless Steel

Area Classification
Certification

CSA Class 1, Division 2, Groups A, B, C & D; T3C

1. Consult factory for alternative ranges.


2. Software adjustable.
3. Supply voltage not to exceed 10% of nominal. Transient over-voltages according to Overvoltage
Category II.

Hardware Installation and Maintenance Manual

A1

SS500/SS2000/SS3000 Analyzer

Table A2 SS2000 single-channel H2O analyzer specifications

Performance
Typical Measurement Ranges

Repeatability

0.520 lbs/MMscf (0422 ppmv)


0.550 lbs/MMscf (01055 ppmv)
0.5-100 lbs/MMscf (0-2110 ppmv)
0.2 lb/MMscf (4 ppmv) or 2% of reading

Response Time

0.25 - 2 seconds (dependent on flow rate and sample


system volume)

Application Data
Environmental Temperature Range

-4 to 122 F (-20 to 50 C)

Environmental Relative Humidity

80% for temperatures up to 31C MAX

Altitude

Up to 4000 m

Maximum Cell Pressure

70kPaG (10 PSIG)

Sample Cell Pressure Range

700-1400 mbara

Sample Flow Rate

0.51.0 SLPM (12 SCFH) typical (not flow dependent)

Recommended Validation

Bureau of Mines chilled mirror, portable TDL or binary


gas with methane background

Electrical & Communications


Input Voltages

100240 VAC, 50/60 Hz


916 VDC or 1832 VDC - Optional

Contact Rating
(Inductive Load)

250V, 3A N.O. contact, 1.5A N.C. contact


24V, 1A N.O. and N.C. contact

Communication

Analog: (2) 4-20mA Isolated, 1200 ohms @ 24 VDC


max load
Serial: RS-232C
Protocol: Modbus Gould RTU, Daniel RTU or ASCII

Digital Output

(2) General Fault and Assignable alarms

Physical Specifications
Class 1, Div 2
System Dimensions

439 mm H x 371 mm W x 146 mm D


(17.27" H x 14.59" W x 5.75" D)

Weight

Approx. 25 lbs (11.5 Kg)

Enclosure Type

NEMA 3R-304 Stainless Steel

Area Classification
Certification

CSA Class I, Division 2, Groups A, B, C & D; T3C

1. Consult factory for alternative ranges.


2. Software adjustable.
3. Supply voltage not to exceed 10% of nominal. Transient over-voltages according to Overvoltage
Category II.

A2

4900002215 rev. B 3-10-15

Specifications

Table A3 SS2000 single-channel CO2 analyzer specifications

Performance
Typical Measurement Range

Repeatability

05%, 010%, 020%


400 ppmv or 2% of reading

Response Time

0.25 - 2 seconds (dependent on flow rate and sample system


volume)

Application Data
Environmental Temperature Range

-4 to 122 F (-20 to 50 C)

Environmental Relative Humidity

80% for temperatures up to 31C MAX

Altitude

Up to 4000 m

Maximum Cell Pressure

70kPaG (10 PSIG)

Sample Cell Pressure Range

700-1400 mbara

Sample Flow Rate

0.51.0 SLPM (12 SCFH) typical (not flow dependent)

Recommended Validation

Binary cal gas bottle with methane background

Electrical & Communications


Input Voltages

100240 VAC, 50/60 Hz


916 VDC or 1832 VDC - Optional

Contact Rating
(Inductive Load)

250V, 3A N.O. contact, 1.5A N.C. contact


24V, 1A N.O. and N.C. contact

Communication

Analog: (2) 4-20mA Isolated, 1200 ohms @ 24 VDC max


load
Serial: RS-232C
Protocol: Modbus Gould RTU, Daniel RTU or ASCII

Digital Output

(2) General Fault and Assignable alarms

LCD Display

Concentration, cell pressure, temperature & diagnostics

Physical Specifications
Class 1, Div 2
System Dimensions

444 mm H x 376 mm W x 135 mm D


(17.5" H x 14.8" W x 5.8" D)

Weight

Approx. 25 lbs (11.5 Kg)

Enclosure Type

NEMA 3R-304 Stainless Steel

Area Classification
Certification

CSA Class I, Division 2, Groups A, B, C & D; T3C

1. Consult factory for alternative ranges.


2. Software adjustable.
3. Supply voltage not to exceed 10% of nominal. Transient over-voltages according to Overvoltage
Category II.

Hardware Installation and Maintenance Manual

A3

SS500/SS2000/SS3000 Analyzer

Table A4 SS3000 dual channel H2O/H2O analyzer specifications

Performance
Typical Measurement Ranges

Repeatability

0.520 lbs/MMscf (0422 ppmv)


0.550 lbs/MMscf (01055 ppmv)
0.5-100 lbs/MMscf (0-2110 ppmv)
0.2 lb/MMSCF (4 ppmv) or 2% of reading

Response Time

0.25 - 2 seconds (dependent on flow rate and sample system volume)

Application Data
Environmental Temperature Range

-4 to 122 F (-20 to 50 C)
15 to 140 F (-10 to 60 C) - Optional

Environmental Relative Humidity

80% for temperatures up to 31C MAX

Altitude

Up to 4000 m

Maximum Cell Pressure

70kPaG (10 PSIG)

Sample Cell Pressure Range

700-1400 mbara

Sample Flow Rate

0.51.0 SLPM (12 SCFH) typical (not flow dependent)

Recommended Validation

Bureau of Mines chilled mirror, portable TDL or


binary gas with methane background

Electrical & Communications


Input Voltages

100240 VAC, 50/60 Hz


916 VDC or 1832 VDC - Optional

Contact Rating
(Inductive Load)

250V, 3A N.O. contact, 1.5A N.C. contact


24V, 1A N.O. and N.C. contact

Communication

Analog: (2) 4-20mA Isolated, 1200 ohms @ 24 VDC


max load
Serial: RS-232C
Protocol: Modbus Gould RTU, Daniel RTU or ASCII

Digital Output

(4) General Fault and Assignable alarms

LCD Display

Concentration, cell pressure, temperature & diagnostics

Physical Specifications
Size

439 mm H x 475 mm W x 146 mm D


(17.27" H x 18.68" W x 5.75" D)

Weight

Approx. 25 lbs (11.5 Kg)

Sample Cell Construction

316L Series Polished Stainless Steel

Area Classification
Certification

CSA Class I, Division 2, Groups A, B, C & D; T3C

1. Consult factory for alternative ranges.


2. Software adjustable.
3. Supply voltage not to exceed 10% of nominal. Transient over-voltages according to Overvoltage Category II.

A4

4900002215 rev. B 3-10-15

Specifications

Table A5 SS3000 dual channel H2O/CO2 analyzer specifications

Performance
Typical Measurement Ranges (H2O)

Repeatability (H2O)
Concentration (CO2)

0.520 lbs/MMscf (0422 ppmv)


0.550 lbs/MMscf (01055 ppmv)
0.5-100 lbs/MMscf (0-2110 ppmv)
0.2 lb/MMscf (4 ppmv) or 2% of reading

05%, 010%, 020%

Repeatability (CO2)

400 ppmv or 2% of reading, whichever is greater

Response Time

0.25 - 2 seconds (dependent on flow rate and sample


system volume)

Application Data
Environmental Temperature Range

-4 to 122 F (-20 to 50 C)
15 to 140 F (-10 to 60 C) - Optional

Environmental Relative Humidity

80% for temperatures up to 31C MAX

Altitude

Up to 4000 m

Sample Inlet Pressure to Sample System

2550 PSIG (1.73.4 barg)

Cell Operating Pressure

700-1400 mbara

Sample Flow Rate

0.51.0 SLPM (12 SCFH) typical (not flow dependent)

Recommended Validation

H2O: Bureau of Mines chilled mirror, portable TDL or


binary gas with methane background
CO2: Binary cal gas bottle with methane background

Electrical & Communications


Input Voltages

100240 VAC, 50/60 Hz


916 VDC or 1832 VDC - Optional

Contact Rating
(Inductive Load)

250V, 3A N.O. contact, 1.5A N.C. contact


24V, 1A N.O. and N.C. contact

Communication

Analog: (1 or 2) 4-20mA Isolated, 1200 ohms @ 24


VDC max load
Serial: RS-232C
Protocol: Modbus Gould RTU, Daniel RTU or ASCII

Digital Output

(4) General Fault and Assignable alarms

LCD Display

Concentration, cell pressure, temperature & diagnostics

Physical Specifications
Size

439 mm H x 475 mm W x 146 mm D


(17.27" H x 18.58" W x 5.758" D)

Weight

Approx. 25 lbs (11.5 Kg)

Sample Cell Construction

316L Series Polished Stainless Steel

Area Classification
Certification

CSA Class I, Division 2, Groups A, B, C & D; T3C

1. Consult factory for alternative ranges.


2. Software adjustable.
3. Supply voltage not to exceed 10% of nominal. Transient over-voltages according to Overvoltage
Category II.

Hardware Installation and Maintenance Manual

A5

SS500/SS2000/SS3000 Analyzer

Figure A1 SS500/SS2000 0.8-m cell (moisture)


outline and mounting dimensions

A6

4900002215 rev. B 3-10-15

Specifications

Figure A2 SS500/SS2000 0.1-m cell (carbon


dioxide) outline and mounting dimensions

Hardware Installation and Maintenance Manual

A7

SS500/SS2000/SS3000 Analyzer

A8





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Figure A5 Drawing of typical full-featured single-channel SCS (SS500/SS20000) in


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Hardware Installation and Maintenance Manual

120/240
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120/240 VAC
ANALYZER POWER
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A11

Figure A6 Electrical schematic for SS500/SS2000

Specifications

CH. A
4-20 mA/RS232 SIGNAL
OUTPUT

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PROCESSOR
TO
PROCESSOR

SS500/SS2000/SS3000 Analyzer

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Specifications

Figure A8 SS3000 0.8-m/0.1-m cells (H2O/ CO2)


outline and mounting dimensions

Hardware Installation and Maintenance Manual

A13

SS500/SS2000/SS3000 Analyzer

Figure A9 SS3000 0.8-m/0.8-m cells (H2O/H2O)


outline and mounting dimensions

A14

4900002215 rev. B 3-10-15






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A15

Figure A10 Drawing of typical full-featured dual-channel, dual-stream SCS (SS3000)

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SS500/SS2000/SS3000 Analyzer

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TO CH. A & CH. B


PROCESSORS

CH. A

120/240
VAC

R4 R3 R2 R1

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A17

Figure A12 Electrical schematic for SS3000

120/240 VAC
ANALYZER POWER
INPUT

Specifications

4-20 mA/RS-232 SIGNAL


OUTPUT

CHANNEL A CELL

CH. B

CHANNEL B CELL

Hardware Installation and Maintenance Manual

TO CH. A
PROCESSOR

TO CH. B
PROCESSOR

SS500/SS2000/SS3000 Analyzer

A18

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Specifications

Spare Parts
Below is a list of spare parts for the SS500/SS2000/SS3000 analyzers with
recommended quantities for 2 years of operation. Due to a policy of continuous
improvement, parts and part numbers may change without notice. Not all parts
listed are included on every analyzer. When ordering, please specify the system
serial number to ensure that the correct parts are identified.
Table A6 Replacement parts for SS500/SS2000/SS3000 analyzers

Part Number

2 YR
QTY

Description
Electronics

0190217106

Cable, External, Serial (RS-232C)

0190213000

Temperature Control Board

2900000090

4-20 mA Current Loop Board (not for 12VDC analyzer)

2300000030

4-20 mA Current Loop Board (for 12VDC analyzers)

1100002128

Kit, 2nd 4-20 mA Current Loop Board (not for 12VDC or


SS3000) 1

0190216300

Power Supply, 12 VDC

0190216400

Power Supply, 24 VDC

0190216500

Power Supply, 100-240 VAC 50/60 Hz, CSA

0190230011

Keypad Assembly

0190231000

Display Assembly

0190217102

Pressure Transducer Assembly

0190217111

Pressure Transducer Assembly for Dual Channel SS3000

0219900005

Kit, O-rings Viton, 2-Pass Cell

0219900011

Kit, Fuse, AC, DC

0900002146

Stainless steel mirror (0.1-m and 0.8-m cell only)

1
1

Pressure Transducer Options


5500002016

Pressure Sensor, 30 psia, 5V, 1/8 MNPT DIN4365 NACE

6000002244

Cable, Pres/Temp, EXT, 22

6000002245

Cable, Pres/Temp, Dual, EXT, 22

Maintenance
0219900001

Spares Kit, (O-rings, fuses), (Domestic U.S.)

0219900005

Spares Kit, (O-rings, fuses), (International)

0219900007

Cleaning Kit (Domestic U.S./Canada)

0219900017

Cleaning Kit (International)

1. Contact SpectraSensors service department before attempting replacement. Replacing this


component without technical support could cause damage to other components.

Hardware Installation and Maintenance Manual

A19

SS500/SS2000/SS3000 Analyzer

Table A-6 Replacement parts for SS500/SS2000/SS3000 analyzers (Continued)

Part Number

2 YR
QTY

Description
Sample Conditioning Systems

61303042S4

Ball Valve, 1/4 TF (SS)

6100002193

Membrane & O-Ring, Membrane Separator

2800002057

Membrane Separator Cover O-ring, Viton

6101671208

Membrane Separator, 1/4 FNPT (SS)

6134100274

Flowmeter, 0-2 SLPM, Glass, Valve

6132125254

Pressure Regulator, 025 PSIG, 1/4 FNPT (SS)

6101510004

Filter Housing, Mini SS/Glass

Cables
0190217205

Hrns, Ribbon, 10 Cond., 9 in

0190217204

Cable, PWR Supply Output, 14 in

0190217208

Cable, TE Cooler

0190217206

Cable, Signal Output

0190217101

Cable, External, Optical Head

0190217201

Cable, Internal, Optical Head

0190217202

Cable, Int, Temp/Pres

0190217211

Cable, Int, Temp/Pres, Dual

6000002221

Cable, 4X Relay Ctrl, 9.5 in

6000002222

Cable, 2X Relay Ctrl, 10 in

General
4900002215

SS500/SS2000/SS3000 Hardware Installation and


Maintenance Manual, additional copies

4900002225

Firmware v2.51 Operators Manual, additional


copies

For a complete listing of new or updated certificates, please visit


the product page at www.spectrasensors.com.

A20

4900002215 rev. B 3-10-15

Appendix B: Maintaining &


Troubleshooting
This section presents recommendations and solutions to common problems,
such as gas leaks, contamination, excessive sampling gas temperatures and
pressures, and electrical noise. If your analyzer does not appear to be
hampered by one of these related problems, contact your sales representative
for service.

Gas Leaks
Probably the most common cause of erroneous measurements is outside air
leaking into the sample supply line. It is recommended the supply lines be
periodically leak-tested, especially if the analyzer has been relocated or has
been replaced or returned to the factory for service and the sample lines have
been reconnected.
Do not use plastic tubing of any kind for sample lines. Plastic
tubing is permeable to moisture and other substances which can
contaminate the sample stream. SpectraSensors recommends
using 1/4 O.D x0.035 wall thickness, seamless stainless steel
tubing.
Process samples may contain hazardous material in potentially
flammable and/or toxic concentrations. Personnel should have a
thorough knowledge and understanding of the physical properties
and safety precautions for the sample contents before operating
the SCS.

Contamination
Contamination and long exposure to high humidity are valid reasons for
periodically cleaning the gas sampling lines. Contamination in the gas sampling
lines can potentially find its way to the sample cell and deposit on the optics or
interfere with the measurement in some other way. Although the analyzer is
designed to withstand some contamination, it is recommended to always keep
the sampling lines as contamination free as possible. If mirror contamination
is suspected, see Cleaning the Mirrors on page B-4.

To keep the sampling lines clean:


1. Make sure that a membrane separator filter (included with most
systems) is installed ahead of the analyzer and operating normally.
Replace the membrane if necessary. If liquid enters the cell and
accumulates on the internal optics, a Power Fail Error will result.

Hardware Installation and Maintenance Manual

B1

SS500/SS2000/SS3000 Analyzer

2. Turn off the sample valve at the tap in accordance with site lock-out,
tag-out rules.
3. Disconnect the gas sampling line from the supply port of the
analyzer.
4. Wash the sampling line with alcohol or acetone and blow dry with
mild pressure from a dry air or nitrogen source.
5. Once the sampling line is completely free of solvent, reconnect the
gas sampling line to the supply port of the analyzer.
6. Check all connections for gas leaks. SpectraSensors recommends
using a liquid leak detector.

Excessive Sampling Gas Temperatures and


Pressures
The embedded software is designed to produce accurate measurements only
within the allowable cell operating range (see Appendix A). Pressures and
temperatures outside these ranges will trigger a P/T Fail Error fault. Refer to
the Firmware Manual for this analyzer for instruction on system faults.
If the pressure, temperature, or any other readings on the LCD
appear suspect, they should be checked against the specifications
(see Appendix A).

Electrical Noise
High levels of electrical noise can interfere with laser operation and cause it to
become unstable. Always connect the analyzer to a properly grounded power
source. Refer to Protective chassis and ground connections on page
2-4.

Peak Tracking Reset Procedure


The analyzers software is equipped with a peak tracking function that keeps
the laser scan centered on the absorption peak. Under some circumstances,
the peak tracking function can get lost and lock onto the wrong peak. If the
difference between PkDf and PkD1 is more than 4, or Track Fail Error is
displayed, the peak tracking function should be reset. Refer to the Firmware
Manual for this analyzer for instruction.

Potential Risks Affecting Personnel


This section addresses the appropriate actions to undertake when faced with
hazardous situations during or before service of the analyzer. It is not possible
to list all potential hazards within this document. The user is responsible for
identifying and mitigating any potential hazards present when servicing the
analyzer.
B2

4900002215 rev. B 3-10-15

Maintaining & Troubleshooting

Technicians are expected to follow all safety protocols established


by the customer that are necessary for servicing the analyzer.
This may include, but is not limited to, lockout/tagout procedures,
toxic gas monitoring protocols, PPE requirements, hot work
permits and other precautions that address safety concerns
related to performing service on process equipment located in
hazardous areas.

Mitigating risks
Refer to the instructions for each situation listed below to mitigate associated
risks.

Exposure to process gases


1. Shut off the process gas to the analyzer before any service that
would require opening a part of the sample plumbing.
2. Purge the system with nitrogen.
3. Shut off the nitrogen purge before opening any part of the sample
system.

Electrocution hazard
1. Shut off power at the main disconnect external to the analyzer.
Complete this action before performing any service that requires
working near the main input power or disconnecting any wiring or
other electrical components.

2. Open enclosure door.


If service must be performed with power engaged (gain adjustment, etc.):
1. Note any live electrical components and avoid any contact with
them.
2. Only use tools with a safety rating for protection against accidental
contact with voltage up to 1000V (IEC 900, ASTF-F1505-04, VDE
0682/201).

Explosion hazard
Any work in a hazardous area must be carefully controlled to avoid creating any
possible ignition sources (e.g., heat, arching, sparking, etc.). All tools must be
appropriate for the area and hazards present. Electrical connections must not
be made or broken with power on (to avoid arching).

Hardware Installation and Maintenance Manual

B3

SS500/SS2000/SS3000 Analyzer

Cleaning the Mirrors


If contamination makes its way into the cell and accumulates on the internal
optics, a Power Fail Error will result. If mirror contamination is suspected,
please consult with your factory sales representative before attempting to
clean the mirrors. If advised to do so, use the following procedure.
Do not attempt to clean the cell mirror until you have consulted
with your factory service representative and have been advised to
do so.

The sample cell assembly contains a low-power, 10 mW MAX, CW


Class 3b invisible laser with a wavelength between 700-3000 nm.
Never open the sample cell flanges or the optical assembly unless
the power is turned off.

Always handle the optical assembly by the edge of the mount.


Never touch the coated surfaces of the mirror.

Determining the type of cell mirror


Measurement cells will come equipped with either a glass or stainless steel
mirror. Before determining whether to clean or replace the mirror, identify the
type of measurement cell being used in the analyzer. Analyzers will come
equipped with one or more, depending on configuration, of the cell types shown
in Figure B1.

0.1-m CELL

0.8-m CELL
Figure B1

B4

Measurement cell types

4900002215 rev. B 3-10-15

Maintaining & Troubleshooting

The stainless steel mirrors have been identified with either an X engraved on
the external bottom side of the mirror or a groove around the rim of the mirror.
Glass mirrors can be used on any size cell. To determine the type of mirror
being used for the system cell:
1. Feel at the bottom of the cell for the engraved X marking or the
side of the mirror for a groove. Refer to Figure B2 below.

MIRROR MARKED
WITH X

Figure B2

MIRROR GROOVED
RIM - SIDE VIEW

Stainless steel mirror marking

a. If the bottom surface is smooth, a glass mirror is being used.


b. If the bottom surface is rough or engraved, or a groove on the
side of the mirror is detected, a stainless steel mirror is being
used.
Do not attempt to replace a glass mirror with a stainless steel
mirror or system calibration may be adversely affected.

To clean the mirror, refer to the instructions To clean the mirrors on page
B-6. "To replace the stainless steel mirror:" refer to the instructions on
page B7.

Tools and Supplies:

Lens cleaning cloth (Cole Parmer EW-33677-00 TEXWIPE


Alphawipe Low-Particulate Clean Room Wipes or equivalent)

Reagent-grade isopropanol (ColeParmer EW-88361-80 or


equivalent)

Small drop dispenser bottle (Nalgene 2414 FEP Drop Dispenser


Bottle or equivalent)

Acetone-impenetrable gloves (North NOR CE412W Nitrile Chemsoft


CE Cleanroom Gloves or equivalent)

Hardware Installation and Maintenance Manual

B5

SS500/SS2000/SS3000 Analyzer

Hemostat (Fisherbrand 13-812-24 Rochester-Pean Serrated


Forceps)

Bulb blower or dry compressed air/nitrogen


Torque wrench
Permanent marker
Flashlight

To clean the mirrors:


1. Power down the analyzer following the procedure outlined in To
power down the analyzer in the Firmware Manual for this
analyzer.
2. Isolate the analyzer from the sample bypass flow by following the
procedure outlined in To isolate the analyzer for short-term
shutdown on page 3-6.
3. If possible, purge the system with nitrogen for 10 minutes.
4. Carefully mark the orientation of the mirror assembly on the cell
body.
Careful marking of the mirror orientation is critical to restoring
system performance upon reassembly after cleaning.

5. Gently remove the mirror assembly from the cell by removing the
six socket-head cap screws and set on a clean, stable and flat
surface.
6. Look inside the sample cell at the top mirror using a flashlight to
ensure that there is no contamination on the top mirror.
Due to its proximity to the optical head, SpectraSensors does not
recommend cleaning the top mirror. If the top mirror is visibly
contaminated, contact your factory service representative.

7. Remove dust and other large particles of debris using a bulb blower
or dry compressed air/nitrogen. Pressurized gas duster products are
not recommended as the propellant may deposit liquid droplets onto
the optic surface.
8. Put on clean acetone-impenetrable gloves.
9. Double fold a clean sheet of lens cleaning cloth and clamp near and
along the fold with the hemostats or fingers to form a brush.
10. Place a few drops of isopropanol onto the mirror and rotate the
mirror to spread the liquid evenly across the mirror surface.

B6

4900002215 rev. B 3-10-15

Maintaining & Troubleshooting

11. With gentle, uniform pressure, wipe the mirror from one edge to the
other with the cleaning cloth only once and only in one direction to
remove the contamination. Discard the cloth.
Never rub an optical surface, especially with dry tissues, as this
can mar or scratch the coated surface.

12. Repeat with a clean sheet of lens cleaning cloth to remove the streak
left by the first wipe. Repeat, if necessary, until there is no visible
contamination on the mirror.
13. Carefully replace the mirror assembly onto the cell in the same
orientation as previously marked making sure the O-ring is properly
seated.
14. Tighten the 6 socket-head cap screws evenly with a torque wrench
to 13 in-lbs.

To replace the stainless steel mirror:


If your system has been configured with a stainless steel mirror in the 0.1-m
or 0.8-m measurement cell, use the following instructions to replace the mirror,
if necessary.
If stainless steel mirrors are replacing another version of mirror in
the field, such as glass, the analyzer may need to be returned to
the factory for re-calibration to ensure optimal cell function. Refer
to Return Material Authorization on page B-21.

1. Power down the analyzer as instructed in the section called


Powering Down the Analyzer in the Firmware Manual for this
analyzer.
2. Isolate the analyzer from the sample bypass flow by shutting off the
appropriate valve(s) and/or pressure regulator.
All valves, regulators, switches, etc. should be operated in
accordance with site lock-out/tag-out procedures.

3. If possible, purge the measurement cell with nitrogen for 10


minutes.
Process samples may contain hazardous material in potentially
flammable and/or toxic concentrations. Personnel should have a
thorough knowledge and understanding of the physical properties
and safety precautions for the sample contents before operating
the SCS.

Hardware Installation and Maintenance Manual

B7

SS500/SS2000/SS3000 Analyzer

4. Gently remove the mirror assembly from the cell by removing the
socket-head cap screws and set on a clean, stable and flat surface.
The sample cell assembly contains a low-power, 10 mW MAX, CW
Class 3b invisible laser with a wavelength between 750-3000 nm.
Never open the sample cell flanges or the optical assembly unless
the power is turned off.

Always handle the optical assembly by the edge of the mount.


Never touch the optical surfaces of the mirror.

5. Confirm need to replace mirror due to contamination. If yes, set


mirror aside.
6. Put on clean acetone-impenetrable gloves.
7. Obtain the new stainless steel mirror. Refer to Figure B3.

Figure B3 Stainless steel


mirror - mirror side up

8. Check the O-ring.


a. If a new O-ring is needed, apply grease on fingertips and then
to the new O-ring.
b. Place newly greased O-ring into the groove around the outside
of the mirror taking care not to touch the mirror surface.
9. Carefully place the new stainless steel mirror onto the cell making
sure the O-ring is properly seated.
10. Tighten the socket-head cap screws evenly with a torque wrench to
13 in-lbs.

Pressure Transducer Replacement


A pressure transducer may need to be replaced in the field as a result of one
or more of the following conditions:

B8

Loss of pressure reading


Incorrect pressure reading
4900002215 rev. B 3-10-15

Maintaining & Troubleshooting

Pressure transducer not responding to pressure change


Physical damage to the pressure transducer

Use the following information to replace a pressure transducer.

Tools and materials:

9/16 wrench
7/8 wrench
9-64 Allen wrench
Flat-head screwdriver
Phillips-head screwdriver
Metal pick
Military grade stainless steel PFTE tape (or equivalent)
Dry nitrogen
Isoproypl alcohol
Alcohol can be hazardous. Follow all safety precautions when in
use and thoroughly wash hands prior to eating.

To replace the pressure transducer:


1. Close the external flow of gas at the sample inlet.
2. Power off the system. Refer to the Firmware Manual for this analyzer
for Powering down the analyzer.
3. Purge the system by connecting dry nitrogen to the sample inlet.
Allow the SCS to purge for 5-10 minutes.
4. Close the nitrogen flow.
5. Remove the optical cable harness at the circular connector. Refer to
Figure 1-1.

Hardware Installation and Maintenance Manual

B9

SS500/SS2000/SS3000 Analyzer

CIRCULAR
CONNECTORS

CIRCULAR
CONNECTORS

CELL INLET
PRESSURE
TRANSDUCER

CELL
INLET

MOUNTING
BRACKETS

MEASUREMENT
CELL
CELL OUTLET

CELL OUTLET
SS500/SS2000

Figure B4

SS3000

Analyzer component locations

6. Disconnect the cell inlet using a 9/16 wrench.


7. Disconnect the cell outlet using a 9/16 wrench.
8. Disconnect the thermistor cable at the circular connector.
9. Remove the pressure transducer cable from the circular connector.
For new model pressure transducers with quick-disconnects, detach
the pressure transducer cable from the pressure transducer at the
connector using a Phillips-head screwdriver. Do not remove the black
connector from the cable.
10. Remove the foam insulation from around the measurement cell.
11. Dismount the cell from the bracket by removing the four securing
screws (four on top and four on the bottom) using a 9-64 Allen
wrench. Place the measurement cell on a clean, flat surface with the
pressure transducer facing up. Refer to Figure 1-2.

Figure B5 Removed measurement cell with


pressure transducer face up
B10

4900002215 rev. B 3-10-15

Maintaining & Troubleshooting

Orient the measurement cell to avoid any debris from entering the
cell.

12. Using a 9/16 wrench, secure the flange while using a 7/8 wrench
to remove the old pressure transducer. Refer to Figure B6.

Figure B6
transducer

Removing the old pressure

a. Hold the supporting wrench on the flange stable and parallel to


the surface. Do not move.
b. Turn the 7/8 wrench counterclockwise to loosen the pressure
transducer until it is able to be removed.
13. Remove excess seal tape from the flange opening and threads and
check galling. Refer to Figure B7.

Figure B7 Removing excess seal tape from


flange

Hardware Installation and Maintenance Manual

B11

SS500/SS2000/SS3000 Analyzer

Threads showing signs of galling indicate a possible leak. Refer to


Customer Service on page B-21 to arrange for repair.

14. Remove the new pressure transducer from the packaging. Retain the
black connector cap on the transducer - do not remove.
15. Wrap stainless steel PTFE tape around the threads at the top of the
pressure transducer, beginning from the base of the threads to the
top, approximately three times taking care to avoid covering the top
opening. Refer to Figure B8.

Figure B8

Replacing seal tape

16. Insert the new pressure transducer into the threaded flange keeping
the transducer parallel to the surface for proper fitting.
17. Hand tighten pressure transducer clockwise into the flange until no
longer moving freely. Refer to Figure B9.

Figure B9

B12

Replacing pressure transducer

4900002215 rev. B 3-10-15

Maintaining & Troubleshooting

18. Using the 9/16 wrench to hold the flange in place, turn the
transducer clockwise with a 7/8 wrench until tight. Two or three
threads on the pressure transducer should still be visible.
Make sure the black connector at the bottom of the pressure
transducer is facing up from the measurement cell. Refer to
Figure B10.

Figure B10 Newly installed pressure


transducer positioning

19. Remove the black connector from the pressure transducer and
discard.
20. Connect the new harness/cable to the new pressure transducer.
If the new model pressure transducer cable is currently installed
in the SCS, reattach the cable to the pressure transducer after the
cell has been remounted.

21. Conduct a leak test to determine that the new pressure transducer
is not leaking.

Do not allow cell to exceed 10 PSIG or damage could occur.

For any questions related to leak testing the pressure transducer,


refer to Customer Service on page B-21.

22. Remount the cell to the mounting brackets using a 9-64 Allen
wrench with the pressure transducer facing forward.
23. Replace the foam insulation around the measurement cell.
24. Reinstall cell inlet and cell outlet using a 9/16 wrench.
25. Reconnect the thermistor.

Hardware Installation and Maintenance Manual

B13

SS500/SS2000/SS3000 Analyzer

26. Connect the new pressure transducer harness and cable to the
circular connector.
27. Reconnect the optical cable harness.
28. Turn the system power on. Refer to the Firmware Manual for this
analyzer for Powering up the analyzer.
29. Run a validation on the analyzer. Refer to the Firmware Manual for
instructions to Start Validation.
a. If the system passes, the pressure transducer replacement is
successful.
b. If the system does not pass, refer to Customer Service on
page B-21 for instruction.

Periodic SCS Maintenance


Due to the chemical properties of the process samples, care must
be taken to repair or replace components with proper materials of
construction. Maintenance personnel should have a thorough
knowledge and understanding of the chemical characteristics of
the process before performing maintenance on the SCS.

The status of the SCS should be checked regularly to confirm proper operation
(pressures, flows, etc.) and detect potential problems or failures before
damage occurs. If maintenance is required, isolate the part of the system to be
serviced by following the appropriate procedure under Shutting Down the
SCS on page 3-5.
All filter elements should be checked periodically for loading. Obstruction of a
filter element can be observed by a decreasing supply pressure or bypass flow.
If loading of a filter is observed, the filter should be cleaned and the filter
element replaced. After observation for some time, a regular schedule can be
determined for replacement of filter elements.
No other regularly scheduled maintenance should be required for the system.

Preventive and On-Demand SCS Maintenance


Due to the chemical properties of the process samples, care must
be taken to repair or replace components with proper materials of
construction. Maintenance personnel should have a thorough
knowledge and understanding of the chemical characteristics of
the process before performing maintenance on the SCS.

Preventive and on-demand maintenance will be required when components


and parts deteriorate or fail as a result of continuous use. The performance of
the entire SCS and individual components should be monitored regularly so
that maintenance may be performed on a scheduled basis in order to prevent
a failure that could take the system out of operation.
B14

4900002215 rev. B 3-10-15

Maintaining & Troubleshooting

The SCS is designed for convenient removal and replacement of component


parts. Complete spare components should always be available. In general, if a
problem or failure occurs, the complete part should be removed and replaced
to limit system down time. Some components may be repaired (replacement
of seats and seals, etc.) and then reused.
If the sample supply line does not appear to completely clear during normal
operation, it may be necessary to clean the sample transport line to remove
any liquid that may adhere to the wall of the tubing. The sample transport line
should be purged dry with air or nitrogen before the system is placed back in
operation.
The system must be taken out of service during any cleaning of
the sample transport line.

If liquid makes it into the analyzer SCS, a filter element may become
obstructed leading to a decreasing supply pressure or bypass flow. If
obstruction of a filter is observed, the filter should be cleaned and the filter
element replaced.

Regular SCS Status Check


1. Read and record the flowmeter settings while the gas is flowing.
2. Compare the current readings with the past readings to determine
any variations. Reading levels should remain consistent.
3. If reading levels decrease, check the filters.

To check filters:
1. Shut down the system following the procedure in Shutting Down
the SCS on page 3-5.
2. Inspect, repair or replace the filter as required.
For additional information, contact SpectraSensors Technical
Service Group at 800-619-2861.

3. Restart the system following the procedure in Starting up the


SCS on page 3-3.

Instrument Problems
If the instrument does not appear to be hampered by gas leaks, contamination,
excessive sampling gas temperatures and pressures, or electrical noise, refer
to Table B1 before contacting your sales representative for service.

Hardware Installation and Maintenance Manual

B15

SS500/SS2000/SS3000 Analyzer

Table B1 Potential instrument problems and solutions

Symptom

Response

Non-Operation (at start up)

Is the power connected to both the


analyzer and power source? Is the
switch on?

Non-Operation (after start up)

Is the power source good? (100250 VAC @ 50-60 Hz, 9-16 VDC, 1832 VDC).
Check fuse(s). If bad, replace with
equivalent amperage, slow-blow fuse.
Contact a factory sales representative
for service information.

Power Fail Error

Turn off the power to the unit and


check the optical head cables for a
loose connection. Do not disconnect
or reconnect any optical head
cables with the power connected.
Refer to the Firmware Manual for this
analyzer to verify a Power Fail error.
Check the inlet and outlet tubes to see
if they are under any stress. Remove
the connections to the inlet and outlet
tubes and see if the power goes up.
The existing tubing may need to be
replaced with stainless steel flexible
tubing.
Possible mirror contamination issue.
Contact a factory sales representative
for service information. If advised to do
so, clean the mirrors by following the
instructions under To clean the mirrors on page B-6.
Possible alignment problem. Contact a
factory sales representative for service
information.
Capture diagnostic data and send the
file to SpectraSensors (see To read
diagnostic data with HyperTerminal in the Firmware Manual for this
analyzer).

B16

4900002215 rev. B 3-10-15

Maintaining & Troubleshooting

Table B-1 Potential instrument problems and solutions (Continued)

Symptom
Null Fail Error

Response
Refer to the Firmware Manual for this
analyzer for instruction on verifying or
clearing a Null Fail Error fault.
Move the jumper JMP1 on the electronics main board next to the pre-pot.
Capture diagnostic data and send the
file to SpectraSensors (see To read
diagnostic data with HyperTerminal in the Firmware Manual for this
analyzer).

Spectrum Fail Error

Turn off the power to the unit and


check the optical head cables for a
loose connection. Do not disconnect
or reconnect any optical head
cables with the power connected.
Turn the analyzer off for 30 seconds
and then turn it on again.
Reset the peak tracking.
Capture diagnostic data and send the
file to SpectraSensors (see To read
diagnostic data with HyperTerminal in the Firmware Manual for this
analyzer).

P/T Fail Error

Check that the actual pressure in the


measurement cell is within specification
(see Appendix A).
Check that the actual temperature in
the measurement cell is within specification (see Appendix A).
If the temperature reading is incorrect,
check that the pressure/temperature
cable is tight. Check the connector on
the cell temperature sensor. Check the
temperature connector on the backplane board. (Note: A temperature
reading greater than 150 C indicates a
short circuit on the temperature sensor
leads; a reading of less than 40 C
indicates an open circuit).
If the pressure reading is incorrect,
check that the pressure/temperature
cable is tight. Check the connector on
the pressure transducer. Check the
pressure connector on the backplane
board.

Hardware Installation and Maintenance Manual

B17

SS500/SS2000/SS3000 Analyzer

Table B-1 Potential instrument problems and solutions (Continued)

Symptom
Track Fail Error

Response
Refer to the Firmware Manual for
instruction on PkDf and PkD1faults.
Reset the peak tracking. Refer to the
Firmware Manual for this analyzer.

Front panel display is not lit and no characters appear

Check for correct voltage on terminal


block input. Observe polarity on DC
powered units.
Check for correct voltage after fuses.
Check for 5 VDC on red wires, 12 VDC
on yellow wires, and 24 VDC on orange
wires from power supply (black wires
are ground).
Check connections on display communication and power cables.

Strange characters appear on front panel


display

Check connections on display communication cable.

No reading on device connected to


current loop

Make sure that connected device can


accept a 4-20 mA signal. The analyzer
is set to source current.
Make sure the device is connected to
the correct terminals on the green connector (see Figure 23 on page 27).
Check the open circuit voltage (3540 VDC) across the current loops terminals on the green connector (see
Figure 23 on page 27).
Replace the current loop device with a
milliampere meter and look for current
between 4 mA and 20 mA. A voltmeter
connected across a 249-ohm resistor
can be used instead of the milliampere
meter; it should read between 1 and 5
volts.

Reading seems to always be low by a


fixed amount

See Adjusting Analyzer Reading to


Match Specific Standard(s) in the
Firmware Manual for this analyzer.
Capture diagnostic data and send the
file to SpectraSensors (see To read
diagnostic data with HyperTerminal in the Firmware Manual for this
analyzer).

B18

4900002215 rev. B 3-10-15

Maintaining & Troubleshooting

Table B-1 Potential instrument problems and solutions (Continued)

Symptom

Response

Reading seems to always be low by a


fixed percentage

See Adjusting Analyzer Reading to


Match Specific Standard(s) in the
Firmware Manual for this analyzer.

Reading is erratic or seems incorrect

Check for contamination in the sample


system, especially if the readings are
much higher than expected.
Capture diagnostic data and send the
file to SpectraSensors (see To read
diagnostic data with HyperTerminal in the Firmware Manual for this
analyzer).

Serial output is displaying garbled data

Make sure the computer COM port is


set for correct baud, 8 data bits, 1 stop
bit, no parity, and no flow control.
Be sure no other programs are using
the COM port selected.
Make sure the connections are good.
Verify the correct pin connections with
an ohmmeter.
Make sure to select the correct COM
port that the cable is plugged into.

Serial output is providing no data

Make sure the computer COM port is


set for 19200 baud, 8 data bits, 1 stop
bit, no parity, and no flow control.
Be sure no other programs are using
the COM port selected.
Make sure to select the correct COM
port into which the cable is plugged.
Make sure the connections are good.
Verify the correct pin connections with
an ohmmeter.

LCD does not update. Unit is locked up.

Switch off power, wait 30 seconds, and


then switch power back on.
Gas concentration is equal to zero.

Pressing keys on front panel does not


have specified effect

Hardware Installation and Maintenance Manual

Check connections on keypad cable.

B19

SS500/SS2000/SS3000 Analyzer

Table B-1 Potential instrument problems and solutions (Continued)

Symptom
Current loop is stuck at 4 mA or 20 mA

Response
Check display for fault message. If
alarm has been triggered, reset the
alarm.
On the current loop board, check the
voltage between the end of resistor R1
closest to the jumper and ground. If
the concentration reading is high, the
voltage should be near 1 VDC. If the
concentration reading is low, the voltage should be near 4.7 VDC. If not, the
problem is probably on the HC12 main
board. Return to factory for service.

Reading seems to always be high by a


fixed amount

See Adjusting Analyzer Reading to


Match Specific Standard(s) in the
Firmware Manual for this analyzer.
Capture diagnostic data and send the
file to SpectraSensors (see To read
diagnostic data with HyperTerminal in the Firmware Manual for this
analyzer).

Reading seems to always be high by a


fixed percentage

See Adjusting Analyzer Reading to


Match Specific Standard(s) in the
Firmware Manual of this analyzer.
Capture diagnostic data and send the
file to SpectraSensors (see To read
diagnostic data with HyperTerminal in the Firmware Manual for this
analyzer).

Reading goes to 0

If 4-20 mA Alarm Action is set to 0,


look on display for a fault message (see
To change parameters in Mode 2
or Mode 3 in the Firmware Manual for
this analyzer).
Gas concentration is equal to zero.

Reading goes to full scale

If 4-20 mA Alarm Action is set to 1,


look on display for a fault message (see
To change parameters in Mode 2
or Mode 3 in the Firmware Manual for
this analyzer).
Gas concentration is greater than or
equal to full scale value.

B20

4900002215 rev. B 3-10-15

Maintaining & Troubleshooting

Service Contact
If the troubleshooting solutions do not resolve the problem, contact customer
service. To return the unit for service or replacement, refer to "Return
Material Authorization".

Customer Service
4333 W Sam Houston Pkwy N, Suite 100
Houston, TX 77043-1223
United States of America
For SpectraSensors North America Service:
Phone: 1-800-619-2861, and press 2 for Service
Fax: 1-713-856-6623
E-mail: service@spectrasensors.com
For SpectraSensors International Service, please contact the
SpectraSensors distributor in your area, or contact:
Phone: +1-713-466-3172, and press 2 for Service
Fax: +1-713-856-6623
E-mail: techsupport@spectrasensors.com

Return Material Authorization


If returning the unit is required, obtain a Return Materials Authorization
(RMA) Number from Customer Service before returning the analyzer to the
factory. Your service representative can determine whether the analyzer can be
serviced on site or should be returned to the factory. All returns should be
shipped to:
11027 Arrow Rte.
Rancho Cucamonga, CA 91730-4866
United States of America
(909) 948-4100

Packing
SpectraSensors analyzer systems and auxiliary equipment are shipped from
the factory in appropriate packaging. Depending on the size and weight, the
packaging may consist of a cardboard-skinned container or a wooden crate. All
inlets and vents are capped and protected when packaged for shipment.
If the equipment is to be shipped or stored for any length of time, it should be
packed in the original packaging when shipped when shipped from the factory.
If analyzer has been installed and or operated (even for purposes of a
demonstration), the system should first be decontaminated (purged with an
inert gas) before powering down the analyzer.

Hardware Installation and Maintenance Manual

B21

SS500/SS2000/SS3000 Analyzer

Process samples may contain hazardous material in potentially


flammable and/or toxic concentrations. Personnel should have a
thorough knowledge and understanding of the physical properties
of the sample and prescribed safety precautions before installing,
operating or maintaining the analyzer.

To purge the analyzer for shipment/relocation:


If the analyzer is configured for differential measurements, purge
the system with power on to ensure dry and wet portions of SCS
are properly purged.

1. Refer to the procedure To isolate the analyzer for long-term


shutdown on page 3-7.
2. Disconnect the sample tubing at the inlet to the analyzer.
3. Connect clean, dry nitrogen to the sample inlet. Set to 30 PSIG.
4. Open the low pressure flare or atmospheric vent header shut-off
valve for the effluent from the sample bypass.
5. Allow the analyzer to purge for 20 minutes.
6. Shut off the nitrogen purge and disconnect.
7. Close the low pressure flare or atmospheric vent header shut-off
valve for the effluent from the sample bypass.
8. Cap off all connections.

To prepare the analyzer for shipment or storage:


1. Follow all instructions "To purge the analyzer for
shipment/relocation".
2. Cap all inlets, outlets, vents, conduit or gland openings (to prevent
foreign material such as dust or water from entering the system)
using the original fittings supplied as part of the packaging from the
factory.
3. Pack the equipment in the original packaging in which it was
shipped. If the original packaging material is no longer available, the
equipment should be adequately secured (to prevent excessive
shock or vibration) within a weather-proof enclosure. Contact
"Customer Service" for any questions related to packaging.
4. If returning the analyzer to the factory, complete the
Decontamination Form provided by SpectraSensors "Customer
Service" and attach to the outside of the shipping package as
instructed before shipping.

B22

4900002215 rev. B 3-10-15

Maintaining & Troubleshooting

Storage
The packaged analyzer should be stored in a sheltered environment that is
temperature controlled between -20C (-4F) and 50C (122F), and should
not be exposed to direct sun, rain, snow, condensing humidity or corrosive
environments.

Disclaimers
SpectraSensors accepts no responsibility for consequential damages arising
from the use of this equipment. Liability is limited to replacement and/or repair
of defective components.
This manual contains information protected by copyright. No part of this guide
may be photocopied or reproduced in any form without prior written consent
from SpectraSensors.

Warranty
The manufacturer warrants the items delivered shall be free from defects
(latent and patent) in material and workmanship for a period of one year after
delivery to the Buyer. The Buyers sole and exclusive remedy under this
warranty shall be limited to repair or replacement. Defective goods must be
returned to the manufacturer and/or its distributor for valid warranty claims.
This warranty shall become inapplicable in instances where the items have
been misused or otherwise subjected to negligence by the Buyer.
Notwithstanding any other provision of this contract, no other warranties,
whether statutory or arising by operation of law, expressed or implied,
including but not limited to those of merchantability or fitness for particular
purpose, shall apply to the goods or services hereunder, other than the repair
and replacement warranty above. Seller shall in no event be liable to Buyer or
any third party for any damage, injury or loss, including loss of use or any
direct or indirect incidental or consequential damages of any kind.

Hardware Installation and Maintenance Manual

B23

SS500/SS2000/SS3000 Analyzer

THIS PAGE INTENTIONALLY LEFT BLANK

B24

4900002215 rev. B 3-10-15

INDEX
Numerics
4-20 mA current loop 2-6

A
Absorption profile 1-6
Acetone B-2
Acetone-impenetrable gloves B-5, B-6, B8
Analyzer shutdown
Long-term 3-7
Short-term 3-6
Attenuation 1-5

B
Beer-Lambert absorption law 1-6

F
Faults
Null Fail Error B-17
P/T Fail Error B-2, B-17
Power Fail Error B-1, B-4, B-16
Spectrum Fail Error B-17
Track Fail Error B-2, B-18
Field pressure reducing regulator 3-1
Field pressure reducing station 3-3, 3-4,
3-5, 3-6
Flowmeter 3-2, 3-5, 3-6, 3-7
Sample 3-4
Sample Bypass 3-7

G
Gas leaks 2-12, B-1, B-2
Gas lines 2-10
Ground wire 2-6

C
Cautions 1-1
Cleaning
Gas sampling lines B-1
Mirrors B-4
COM port B-19
Contamination B-1
Mirrors 1-7
Control system
Tracer 3-3, 3-4
Current 1-6
Current loop 2-6
Receiver 2-8

D
Detector 1-5

E
Electric tracer 3-4
Electrical noise B-2
Electronics enclosure 2-4, 2-6
Enclosure
Electronics 2-6, 2-8, 2-9
Erroneous readings 2-13
Excessive sampling
Gas pressure B-15
Gas temperature B-15
Excessive sampling gas temperature B-2

Hardware Installation and Maintenance Manual

H
Hardware 2-2

I
Incident intensity 1-5
Installation 2-2
Isopropanol B-5

L
Laser beam 1-5
Laser output fluctuations 1-6
Leak detector 2-12, B-2
Lens tissue B-5
Lock-in amplifier 1-7

M
Mating terminal block 2-7, 2-9
Membrane separator 3-2, B-1
Mirror contamination 1-7, B-1, B-4

N
Natural frequencies 1-5

Index1

SS500/SS2000/SS3000 Analyzer

O
Optional analyzer hood 2-3
Outline schematic A-8, A-9, A-10, A-12, A15, A-16, A-17, A-18
Output Signal
4-20 mA current loop 2-6
Serial output 2-6

P
Parameters
Diagnostic
PkD1 B-18
PkDf B-18
Measurement and control
4-20 mA Alarm Action B-20
Peak tracking reset B-2
Pin numbers 2-7
Port
Bypass return 2-12
Pressure relief vent 2-10, 2-12
Sample inlet 2-11
Sample return 2-12, 3-3
Sample supply 3-2
Pressure regulator 3-2, 3-4, 3-5, 3-6

R
Raw data 1-6
Recommendations and solutions to
common problems B-1
Resonances
Natural frequencies
Return materials authorization (RMA)
number B-21

S
Sample bypass 3-4, 3-6
Start-up 3-4
Sample conditioning system (SCS) 3-1,
3-3, B-7
Periodic maintenance B-14
Preventive and on-demand
maintenance B-14
Shut down 3-5
Start-up 3-3
Sample gas 1-5, 3-2
Sample probe 3-1, 3-3, 3-4, 3-5, 3-6
Serial cable 2-7
Serial connection 2-6
Service contact B-21
Signal wires 2-7
Stainless steel tubing 2-10, 2-11, B-1

Index2

System conditioning 2-13


System models
SS2000 1-3
SS3000 1-4
SS500 1-3

T
Temperature controller
Electric tracer 3-4
Tools 2-2
Trace gas measurement (mixed
background) 1-8
Troubleshooting
Cleaning mirrors B-4
Tools and supplies B-5
Contamination B-1
Electrical noise B-2
Excessive sampling gas pressure B-2
Gas leaks B-1
Tunable diode laser (TDL) 1-3
Tunable diode laser absorption
spectroscopy (TDLAS) 1-5

V
Valve
Control 3-5
Flowmeter control 3-5
Isolation 3-1, 3-3, 3-4, 3-6
Metering 3-2, 3-5
Relief 3-3, 3-6, 3-7
Shut-off 3-2, 3-4, 3-6, 3-7, 3-8

W
Warnings
General 1-1
Wavelength Modulation Spectroscopy
(WMS) signal detection 1-7

4900002215 rev. B 3-10-15