Safety Manual TDLS GPro 500

Tunable Diode Laser Spectrometer

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TABLE OF CONTENT
1 Introduction............................................................................................................................5
1.1 Safety information............................................................................................................5
Laser Spectrometer GPro 500

1.2 Symbols.........................................................................................................................5
1.3 Purpose..........................................................................................................................5
1.4 Qualified personnel..........................................................................................................5
1.4.1 Transport, storage and handling..............................................................................5
1.5 Additional documentation.................................................................................................6
1.6 General...........................................................................................................................6
1.7 Proper use of the product..................................................................................................7
1.7.1 Measuring principle...............................................................................................7
1.7.2 Instrument description............................................................................................8
1.7.3 Software...............................................................................................................8
1.7.4 System overview...................................................................................................8

2 Installation and start-up........................................................................................................ 10

2.1 General considerations................................................................................................... 10
2.1.1 External sensors for pressure and temperature........................................................ 10
2.2 Preparations.................................................................................................................. 10
2.2.1 Cables and electrical connections......................................................................... 10
2.3 Installation and adjustments........................................................................................... 11
2.3.1 Mechanical installation......................................................................................... 11
2.3.2 Orientation of the process adaption....................................................................... 11
2.3.3 Purging.............................................................................................................. 12
2.3.4 Signal optimization.............................................................................................. 15

3 Configuration of the GPro 500 with the MT-TDL Suite.............................................................. 16

3.1 Wiring and connection with the PC.................................................................................. 16
3.2 MT-TDL Suite overview / structure...................................................................................... 17
3.3 Setting the password...................................................................................................... 18
3.4 Configuration of the pressure and temperature compensation............................................. 18
3.5 Setting of optical path length...........................................................................................20
3.6 Configuration of analog outputs......................................................................................20

4 Operation..............................................................................................................................22
4.1 Instrument start-up.........................................................................................................22
4.2 Instrument shut-down....................................................................................................22
4.3 Fault indication..............................................................................................................22

5 Maintenance.........................................................................................................................24
5.1 Routine maintenance...................................................................................................... 24

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6 Calibration and adjustment....................................................................................................25

6.1 Tools required for verification and calibration.................................................................... 25
6.2 Calibration.................................................................................................................... 25
6.2.1 Calibration of oxygen sensors using the calibration tube.......................................... 25
6.2.2 Calibration of all other gases using an additional extractive flow-through cell.............26
6.2.3 Calibration of a Blow-Back Process Adaption.......................................................... 27
6.2.4 Calibration of a GPro 500 with in situ probe in a by-pass installation........................ 28
6.2.5 Calibration of a GPro 500 working in an extractive system....................................... 28
6.3 Adjustment of the GPro 500............................................................................................29
6.3.1 One-point calibration...........................................................................................30
6.3.2 Process calibration.............................................................................................. 31
6.4 Verification of the direct passive analog outputs................................................................ 32

7 Troubleshooting....................................................................................................................33
8.1 SIL Parameters..............................................................................................................33
8.1.1 Covered types of GPro 500...................................................................................33
8.1.2 SIL parameters....................................................................................................33
8.2 Compliance and Standards Information............................................................................33
8.3 Labels..........................................................................................................................34
8.3.1 Type labels.........................................................................................................34
8.3.2 Additional labels..................................................................................................35

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FIGURES
Figure 1. General setup GPro 500.......................................................................................................9

Figure 2. Probe, gasket, and spectrometer of the GPro 500................................................................. 11

Laser Spectrometer GPro 500

Figure 3. Optimizing the process purge gas flow................................................................................ 13

Figure 4. Graph of the raw data from the adjustment window.............................................................. 14

Figure 5. Scaled graph, noise has to be less than 2 × 10−4................................................................. 14

Figure 6. Transmission and NSL for signal optimization...................................................................... 15

Figure 7. Start window of MT-TDL Suite (connected to an O2 laser)....................................................... 17

Figure 8. Menu for configuring the pressure and temperature compensation using external sensors........ 19

Figure 9. Configuring menu of the analog outputs GPro 500............................................................... 21

Figure 10. Screenshot of MT-TDL Suite with active fault indication.........................................................23

Figure 11. Blow-back process adaption ............................................................................................ 27

Figure 12. Calibration menu.............................................................................................................29

Figure 13. Screenshots one-point calibration.....................................................................................30

Figure 14. Screenshots process calibration........................................................................................ 31

Figure 15. External out tab............................................................................................................... 32

Figure 16. Labels for ATEX (left) and FM (right) version.......................................................................34

Figure 17. Note label.......................................................................................................................35

Figure 18. Grounding labels.............................................................................................................35

Disclaimer of Liability
To ensure consistency with the hardware and software described the contents of this publication have been
reviewed carefully. However, since variance cannot be excluded entirely we cannot guarantee full consistency.

GPro is a registered trademark of the METTLER TOLEDO group in Switzerland, USA, Germany and France.
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1 Introduction
1.1 Safety information
Read this manual and ensure that you fully understand its content before you attempt to install, operate
or maintain the GPro 500® used in a safety integrated (SIL) environment.

1.2 Symbols
Pay particular attention to all special information and warnings. This type of information is marked with
the corresponding pictograms. To observe these notices will ensure your personal safety and prevent
damage of property:

WARNING
Warnings highlight specific hazards which, if not taken
into account, may result in personal injury or death.

CAUTION
Cautions highlight hazards which, if not taken into account,
can result in damage to the TDL or to other equipment or property.

This manual incorporates also “be aware” information, which is used as follows:

hhThis highlights information which is useful for you to pay attention, for example specific opera-
tion conditions.

1.3 Purpose
This document contains information and safety instructions required to use the GPro 500 with direct
analog output option (GPro 500 XXXXXXXXXXXXXXXX _ _ / _A in SIL environments.
The manual is intended for personnel responsible for planning, installation, commissioning, service and
maintenance.

1.4 Qualified personnel

The GPro 500 described in this manual may be only operated by personnel which is qualified for the
specific task in accordance with the relevant documentation, in particular its warnings and safety in-
structions.
Qualified personnel are those, who based on their trainings and experience, are able of identifying risks
and avoiding potential hazards when working with the GPro 500.

1.4.1 Transport, storage and handling

Proper transport, storage, installation, assembly, commissioning, operation and maintenance are re-
quired to ensure that the GPro 500 operate safely and without any problems. The permissible ambient
conditions must be complied with. The information in the relevant documentation must be observed.

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1.5 Additional documentation

This manual has to be used together with the following documents:
• GPro 500 Series Pre-Installation Requirements
• Safety Instructions GPro 500 (Art. nr 30 037 965)
Laser Spectrometer GPro 500

• GPro 500 Quick Setup Guide (Art. nr 30 080 928)

• Operating Instructions TDLS GPro 500 (Art. nr 30 029 557)

hhPlease study the entire documentation carefully before installing or using the GPro 500. It is a
sophisticated instrument utilizing state-of-the-art electronic and laser technology. Installation,
operation and maintenance of the instrument require care and preparation and should only be
attempted by competent /qualified personnel. Failure to do so may damage the instrument and
void the warranty.

CAUTION
METTLER TOLEDO strongly recommends having the final installation and commissioning
executed under the full supervision of a METTLER TOLEDO representative.
Do not power up the system before the wiring has been fully checked by trained personal.
It is strongly recommended to have the wiring approved by
a METTLER TOLEDO Service representative.
Wrong wiring can lead to damage of the sensor head and /or the M400 transmitter.

1.6 General
The GPro 500 designed for continuous in situ monitoring of gases in stacks, pipes, ducts, extractive
measurement cells etc. and it is based on tunable diode laser technology. The GPro 500 utilizes a single
side installation (probe-type TDL) without the need for alignment to measure the average gas concentra-
tion along the line-of-sight path in the probe.
The GPro 500 can be considered to be a Type B element acc. to IEC 61508:2010.
The gas concentration is provided to the DCS as linear analog signal (4 – 20 mA, NAMUR). 4 mA indicate
low level, 20 mA indicate high level. The analog values for instrument errors can be parameterized within
the NAMUR settings.

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1.7 Proper use of the product

The GPro 500 covers a wide range of applications. SIL may only be covered for applications within the
following conditions:

Component Process gas temperature (°C) Process gas pressure (mbar abs. ⁄⁄ psia)
O2 0 … 600 0.3 … 8 // 4.35 … 116.03
O2 & spectral temperature 0 … 150 0.8 … 5 // 11.63 … 72.52
CO (ppm) 0.8 … 2 // 11.63 … 29.00
CO (%) 0.8 … 1.5 // 11.63 … 21.75
CO2 (%) 0.8 … 2 // 11.63 … 29.00
CO2 & CO 0.8 … 2 // 11.63 … 29.00
H2O 0 … 600 0.8 … 2 // 11.63 … 29.00
HCl 0.8 … 3 // 11.63 … 43.50
H2S 0.8 … 2 // 11.63 … 29.00
CH4 0.8 … 3 // 11.63 … 43.50
NH3 0.8 … 3 // 11.63 … 43.50

Table 1. GPro 500 application conditions for in situ measurement

WARNING
The GPro 500 may only be used for applications described
in the catalogue and approved by METTLER TOLEDO.

CAUTION
The approval might contain limitations which differ from the conditions
provided in the table above. These limitations have to be followed.

1.7.1 Measuring principle

For detailed information about the measuring principle, the influence of dust load, temperature and
pressure as well as cross interferences please refer to chapter 1.4 of the Operating Instructions TDLS
GPro 500.

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1.7.2 Instrument description

The GPro 500 TDL normally consists of 3 –  4 separate units:
• TDL head /spectrometer
• process adaption / probe
Laser Spectrometer GPro 500

• junction box
• optional M400 transmitter (user interface; see remark below).

hhThe M400 transmitter is NOT included in the safety function.

hhIt is possible to connect the GPro 500 to the M400 transmitter also in a SIL installation to use
the M400 as a local viewer.

CAUTION
When the analog outputs of the M400 are used and /or when the GPro 500
is configured or operated via the M400 the SIL compliance is no longer valid.

External pressure and temperature measurements must be available; depending on the application, am-
bient conditions and process adaption additional purge gas (in general N2, 99.7) might be necessary.

1.7.3 Software
The software of the GPro 500 consists of 2 programs:
• The firmware of the GPro 500 (not visible to the user) which is integrated in the CPU electronics. It
performs all necessary calculations and self-monitoring tasks.
• The MT-TDL Suite which is a Windows based program. It runs on a standard PC connected to the
GPro  500 through the Ethernet connection. It enables communication and parameterization of the
GPro  500 during installation, normal operation, calibration and service. For a detailed description
please refer to chapter 6 of the Operating Instructions TDLS GPro 500.

1.7.4 System overview

A connecting device is required to connect the GPro 500
• to the power supply
• with the external 4… 20 mA analog signals for temperature and pressure compensation
• with the DCS
• with the operating software MT-TDL Software Suite installed on a computer / laptop
• to the optional M400 transmitter
For ATEX applications, an existing junction box can be used, or one can be ordered as an accessory (see
Operating Instructions TDLS GPro 500 Appendix chapter 2.3).
For more information about installation in hazardous areas, please refer to chapter 1.3.2, 1.3.3, 1.5.2
and 8 in the Operating Instructions TDLS GPro 500.
In SIL configurations the GPro 500 passive analog outputs are connected directly to the DCS. To con-
figure the GPro 500 during commissioning and for maintenance operation, it is necessary to use the
MT-TDL Software Suite.
Only the two direct analog outputs of the GPro 500 are considered as safety critical outputs and are
part of the safety function. Please ensure that the control system is able to interpret the according failure
analog values.

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P
5
T

4
6 1 2 3

Figure 1. General setup GPro 500 – process adaption may vary

1 GPro 500 sensor head with insertion probe (here the 390 mm probe)
2 Purging with N2, one inlet for the process side and one inlet and one outlet for the sensor side
3 Process flange
4 Junction box (connecting device)
5 2 × 4 … 20 mA analog input for pressure and temperature compensation
6 Ethernet connection
7 Grounding for the TDL head
8 External power supply (24 VDC; 5 … 60 W) for the sensor power head
9 2 × 4 … 20 mA direct analog outputs

WARNING
When connecting the external power supply to the junction box,
do not exceed the 24 VDC, max. 60 W limit!

WARNING
When connecting the external analog inputs for pressure and temperature
compensation make sure that the complete system is switched off!

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2 Installation and start-up

hhWe recommend to have a pre-installation meeting with your local METTLER TOLEDO representa-
tive / METTLER TOLEDO service to discuss all details of the the installation.

hhFurther details and valuable information are provided in the GPro 500 Series Pre-Installation
Laser Spectrometer GPro 500

Requirements

hhNote: For complete information regarding the installation please refer to GPro 500 Series Pre-
Installation Requirements, the GPro 500 Quick Setup Guide, and to Operating Instructions
TDLS GPro 500.

2.1 General considerations

2.1.1 External sensors for pressure and temperature
It is in the responsibility of the end user to install appropriate pressure and temperature sensors. We
recommend using only external sensors with SIL qualified analog output (4–20 mA).

WARNING
Ensure that neither the GPro 500 nor the external pressure and temperature
sensors are energized when connecting them to the junction box.
Do not open the junction box in an explosive
atmosphere when the GPro 500 is energized.

hhIf the analog outputs of the external sensors are set properly with respect to out-of-range and
failure signals the GPro 500 is able to detect both.
• External analog signals between 3.6 … 3.8 mA and 20.0 … 20.5 mA are considered as out of range
of the external sensors
• External analog signal is considered as failure signal when it is either below 3.8 mA or above 20.5 mA
• In case of failure signal the GPro 500 will also change to the failure state and the reading is set by the
software to 110 %
• Please note: the GPro 500 is not able to detect measurement errors of the external sensors by us-
ing higher diagnosis function. As long as the external analog signal is between 4 and 20 mA the
GPro 500 will assume well working external sensors

2.2 Preparations
• You will find a detailed information in chapters 2.1 to 2.4 of the Operating Instructions TDLS GPro 500

2.2.1 Cables and electrical connections

The laser head /spectrometer is connected to the junction box
• ATEX version: The GPro 500 comes with a pre-installed 16 wire cable and cable gland. The standard
length of the cable is 5 m.
• FM version must be installed using a suitable cabling conduit system in accordance with local codes
and regulations.
For details of the wiring please refer to chapter 5 of the Operating Instructions TDLS GPro 500.

WARNING
Do not forget to ground the GPro 500

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2.3 Installation and adjustments

2.3.1 Mechanical installation
The GPro 500 is designed to be very easy to install. The optical path is aligned in the factory so the
installation procedure is simply to bolt it to the process flange, mount the purging tube (6 mm or optional
¼" tube fitting) and mount the cables.
For details about the flanges, dimensions for the flanges etc. please refer to chapter 4 of the Operating
Instructions TDLS GPro 500.

hhFor efficient installation you must make sure that the pre-installation requirements are met prior
to the visit of the METTLER TOLEDO technician.

hhIf the process is running it is recommended for purged probes to connect and turn on the purging
at maximum flow before inserting the probe into the process. This is to avoid instant contamina-
tion of the optics.

WARNING
Do not use FORCE when you assemble the spectrometer and the process
adaption. The head will slot into the process adaption at the right angle.
The mechanical tolerance of the parts is very small, using force will damage
the interface resulting in alignmen issues and loss in transmission!
Also ensure that the gasket is in place.

Figure 2. Probe, gasket, and spectrometer of the GPro 500

2.3.2 Orientation of the process adaption

• Ensure that the flange gasket is in place.
• When an SP or NP without filter is installed ensure that the holes /slots are facing the process that the
process flow is perpendicular to the probe.
• Prior to installing a probe with filter mark the position /angle of the dust shield on the flange. Ensure
that the dust shield is facing the process in coming flow

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2.3.3 Purging
Depending on the configuration supplied there may be requirement for either one or two optical purges
(instrument and process purge).
Standard purged probe SP Blow-back probe with filter BB
Laser Spectrometer GPro 500

Non-purged probe without filter NP Wafer type probe W

Non-purged probe with filter FP Extractive probe W
Detailed information about the location of the spectrometer and process purge connections is provided
in chapter 3 of the Operating Instructions TDLS GPro 500.
Detailed drawings of all process adaptions are provided in chapter 4 of the Operating Instructions TDLS
GPro 500.

Instrument purge
The GPro 500 TDL head attaches to the process adaption via a precision mechanical interface. Between
the optical window of the TDL and the process window of the process adaption is a cavity. This cavity
is part of the optical path of the analyzer and therefore it is important that there are no traces of the gas
to be measured, i.e. O2 or H2O or other, in this space. Otherwise it will add to the measurement signal
leading to a wrong reading. The instrument purge is to flush this space.
For O2 measurement this is normally nitrogen is used and for other measurements instrument grade air is
recommended.
Typical purge gas flow for instrument purge is < 1 L /min.

hhNote: All current process adaptions require instrument purge.

hhNote: Ensure that the purge is available at all times during operation.
Process purge
For standard purge probes and for in-line wafer cells in addition to the instrument purge a process purge
is necessary to protect the optical surfaces from direct contact with the process gas. The process purge
gas flow is adjusted during commissioning.

hhProcess purge is critical for the protection of the wetted optical components and for correct
operation of the analyzer. Therefore, it must be running all the times! A no-flow alarm switch is
recommended to this purpose.
For oxygen applications nitrogen purge is required or alternatively another clean, non-explosive, non-
corrosive, dry and O2 free gas. For other measurements, instrument grade air is normally recommended.
The GPro 500 SP and W process adaption are designed to consume as little purge gas as possible while
keeping the optical surfaces protected and clean.
Alternatively, gas cylinders may be used to ensure proper purging of the probes.

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WARNING
The process purge gas inlet must have a check valve to avoid
contamination of the purging system from process gas.
Always start process purging at maximum before inserting
the probe or before starting the process.
Process purge gas must always run in order to avoid contamination
of the optical surfaces and ensure protection of the optical surfaces.
Do not remove and / or disassemble the process purge gas
inlet otherwise the PED pressure certificate is void.
Do not connect the instrument and process purge in series, otherwise
when disassembling the sensor head the process purging will stop.

For further details, please refer to chapter 3 of the Operating Instructions TDLS GPro 500.

Adjusting the process purge gas flow

The flow rate of the purging will affect the effective path length and consequently the measurement value.
Therefore one of the following procedures should be used.
Adjusting the process purge gas flow for normal/high readings
Start with a very high flow rate and gradually decrease it. The measurement value will then start at a
low value and increase with decreasing purge flow. At some point it will level out and stay constant for a
while and then again start increasing. Choose a purge flow in the middle of the constant region.

CAUTION
If the process flow rate remains constant this will be a good purge flow but the effective
path length will always be a function of the process flow rate so be observant on this.

2
Inecreased reading

1 4

Decreasing purge flow

Figure 3. Optimizing the process purge gas flow

On the x-axis there is purge flow and on the y-axis there is the instrument concentration reading.
1 Concentration reading with high purge flow. The path length is now shorter than the effective
path length since the purge tubes is completely filled with purging gas and some of the purging
gas is flowing into the measurement path.
2 Concentration reading with optimized purge flow. The path length is now equal to the effective
path length since the purge tubes are completely filled with purge gas. See the illustration below.
3 Concentration reading with no purge flow. The path length is now equal to the nominal path
length since the probe is completely filled with process gas.
4 The optimized purge flow.

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Adjusting the process purge gas flow for low readings

1 Connect the GPro 500 to the MT-TDL Suite
2 Switch to the adjustment tab*
3 If necessary, scale the adjustment graph to 0.005 per scale or lower
4 Start with a high flow rate and gradually decrease it until:
Laser Spectrometer GPro 500

a The NSL ratio is below 50

b The signal-to-noise amplitude is <2 × 10−4 in the graph

* Available with MT-TDL Suite Version 6.17 and higher

Figure 4. Graph of the raw data from the adjustment window

Figure 5. Scaled graph, noise has to be less than 2 × 10−4

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2.3.4 Signal optimization

MT-TDL Suite always shows two diagnostic values which aid in optimizing the signal quality:
• Transmission value
• NSL

Transmission and
NSL for signal
optimization

Figure 6. Transmission and NSL for signal optimization

Signal optimization is achieved by slow rotating the blue TDL head (with loosen security clamp) until
the NSL value is below 50 and the transmission value is at least higher than 50 %, ideally above 70 %.
Subsequently fully tighten the security clamp and confirm that the values are still acceptable.

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3 Configuration of the GPro 500 with the MT-TDL Suite

3.1 Wiring and connection with the PC
The connection between the PC and the GPro 500 is made by connecting the Ethernet port of the PC
Laser Spectrometer GPro 500

to pin 13 … 16 of the junction box with a common available Ethernet cable. Depending on the type of
Ethernet cable (T568A or T568B) the wiring is as below:
• T568A Ethernet cable
-- White /green goes to 13
-- Green solid goes to 14
-- White /orange goes to 15
-- Orange solid goes to 16
• T568B Ethernet cable
-- White /orange goes to 13
-- Orange solid goes to 14
-- White /green goes to 15
-- Green solid goes to 16

After start of the MT-TDL Suite the connection between the GPro 500 and the PC is established automati-
cally.

hhWhen using the software VPN must be turned OFF.

hhWindows XP users need to correct the IP address please refer to chapter 6.2 of the Operating
Instructions TDLS GPro 500.

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3.2 MT-TDL Suite overview / structure

1
11 10
2 3
4

5
6

18
12

13

14
15

16

17
20 21 19

Figure 7. Start window of MT-TDL Suite (connected to an O2 laser)

1 Version of MT-TDL Suite
2 Menu bar
3 Version of the firmware installed on the GPro 500
4 MAC and IP address of the GPro 500
5 Value for the temperature when fixed temperature is activated (see no. 8)
6 Value for the pressure when fixed pressure is activated (see no. 8)
7 Toggle between fixed and measured values for temperature and pressure
8 The effective optical path length
9 Set point for simulated curve
10 Simulated curve (yellow)
11 Measured curve (blue)
12 Actual concentration of the measured gas
13 Transmission value
14 SNR (= signal-to-noise ratio)
15 NSL (= noise-to-signal level)
16 External temperature reading
17 External pressure reading
18 Tab menu
19 Alarm
20 Reset all trends
21 Flash settings

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3.3 Setting the password

Firmware 6.23 for O2 or higher can be password protected.
To activate the password change to the menu “password → change password”, enter a new password
and confirm it.
Laser Spectrometer GPro 500

hhThe TDL is delivered with the standard password 0000

hhAs long as the standard password is not changed the password protection is not active
CAUTION
Reset of the password can only be done by the METTLER TOLEDO service.

3.4 Configuration of the pressure and temperature compensation

The GPro 500 with direct analog output option can be used in SIL installations with the following settings
for the process pressure and temperature:
• Pressure: FIXED VALUE or EXTERNAL INPUT
• Temperature: FIXED VALUE or EXTERNAL INPUT

Configuration for fixed pressure and /or temperature values

hhThe use of fixed values for either process gas temperature and /or pressure is only recommended
if they are stable for example when a heated extractive cell is used.
To activate and configure fixed values for pressure and /or temperature proceed as follows:
1 Activate either fixed pressure or temperature (or both) by clicking on the respective button (no 8)
2 Enter the correct value / values (no 6 and /or 7)
3 Transmit the settings by using the “flash settings button” (no 22)

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Configuration of pressure and /or temperature compensation using external sensors

When external pressure and temperature sensors are used the analog inputs have to be configured
according to the specification of the sensor:

Figure 8. Menu for configuring the pressure and temperature compensation using external sensors
1 Switch to the “external in” tab
2 Enter the start and end value of the pressure / temperature sensor in the respective field
3 Transmit the settings using the “Flash Settings” button

hhIf the settings are correct and the wiring between the analog outputs of the sensors and the junc-
tion box is correct the actual readings for pressure and sensor are shown in 17 and 18

hhThe trend of the external readings is shown in the graph in the “external in” tab

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General note on pressure and temperature compensation

hhWe recommend to use an absolute pressure sensor
hhThe quality /accuracy of the pressure signal has a direct impact onto the reading of the GPro 500.
hhAs a rule of thumb an error in the pressure reading of 5 mbar result in an error of 0.5 % of the
Laser Spectrometer GPro 500

reading of the GPro 500.

hhThe accuracy of the temperature measurement also influences the reading of the GPro 500.
hhAs a rule of thumb an error or 1 °C in the temperature signal will lead to an error of 0.25 % of
reading

hhIn case of failure and /or disconnection of the pressure and /or temperature sensor, the analog
output of the GPro 500 will switch into the alarm / failure state.

hhPlease note the GPro 500 is not able to detect measurement errors of the external sensors by
using higher diagnosis function. As long as the external analog signal is between 4 and 20 mA
the GPro 500 will assume well working external sensors.
The best readings are achieved when the correct process pressure and temperature is provided via
correct working external sensors. However, for processes which run on stable or nearly stable pressure
and /or temperature using fixed pressure and /or temperature may be the better choice. Whether the
measurement will work without pressure and /or temperature sensor has to be discussed during the
evaluation of your application.

3.5 Setting of optical path length

The reading of the GPro 500 depends on the correct optical path length (opl). It depends on the probe
length installed. Detailed information about the opl for all our probes is provided in chapter 4 of the
Operating Instructions TDLS GPro 500 in particular page 63).
The values given in the table are valid when the instrument and the process purge are running. Depend-
ing on the process conditions and the setting of the process purge this value may have to be slightly
adapted.
To change the settings for the optical path length proceed as follows:
1 Click on the respective field in the MT-TDL Suite (no 9)
2 Enter the new value
3 Observe the reading
4 If the reading is correct make the setting permanent by using the “flash settings” button (no 22)
5 If the reading is not correct repeat step 1 … 4.

hhThe optical path length influences directly the reading of the GPro 500. The setting of the ad-
equate OPL has a direct impact on the accuracy of the measurement value.

3.6 Configuration of analog outputs

In SIL configurations the GPro 500 passive analog outputs are connected directly to the DCS. To con-
figure the GPro 500 during commissioning and for maintenance operation, it is necessary to use the
MT-TDL Software Suite.
Only the two direct analog outputs of the GPro 500 are considered as safety critical outputs and are
part of the safety function. Please ensure that the control system is able to interpret the according failure
analog values.
The analog outputs are configured in the “external out” tab of the MT-TDL Suite. If the “external OUT” tab
is not visible, the connected GPro 500 does not have the direct analog output option.
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Figure 9. Configuring menu of the analog outputs GPro 500

1 Assignment of the analog outputs:
Each analog output (AO) can be assigned to the following parameter by choosing from the drop
down menu:
• Concentration (ppm and dewpoint for H2O measurement)
• Concentration (%vol)
• Pressure (mbar and psi)
• Temperature (°C and °F)
• Transmission (%)
• DLI (days)
• TTM (days)
2 When the parameter is selected put in the respective range that has to be linearly mapped to the
4 … 20 mA values. Units must be the same as those of the parameter selected above.
3 Assignment of the error level:
Error signals can be set for each AO for the hardware, software and the system. To do this use
the respective pull-down menu. The following choices can be selected:
• No alarm: no action is taken when an error occurs
• Low alarm: AO signal goes to 3.6 mA in case of an error
• High alarm: AO signal goes to 22 mA in case of an error
4 In addition, the AOs can be set to 3.8 or 21 mA in case of an out-of-range condition. To activate
this, use the check boxes “underrun /overflow”.
5 Assignment of the hold mode:
The behavior of the AOs during operations like calibration, service mode etc. can be set as fol-
lows by using the respective pull-down menu:
• Last value
• Fixed value
The fixed readings can be set using the corresponding fields.
6 Make the settings permanent by using the “Flash Settings” button

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4 Operation
4.1 Instrument start-up
Assumed that the TDL is connected correctly via the junction box to the power supply it will power up
Laser Spectrometer GPro 500

automatically when the power is switched on. The start-up time is approximately 1 min.

4.2 Instrument shut-down

To shut down the instrument simply disconnect it form the power supply. No other measures need to be
taken.

WARNING
To not interrupt the process purge as long as the process
is running and the probe is in the process!

4.3 Fault indication

The GPro 500 will signal a fault situation as analog value to the DCS. Depending on the configuration
the analog value will either fall below 3.6 mA or go to 22 mA.
The reading will stay at 110 % as long as the fault /error message is active.

hhIt is important that the receiving device (in general the DCS) is able to detect and interpret the
fault situation to comply with the safety function.

Fault messages are also indicated at the simulation window (upper half) of the MT-TDL suite.

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Figure 10. Screenshot of MT-TDL Suite with active fault indication

hhMonitoring the transmission of the GPro 500 via the 2 ndanalog output gives always complete
information about the cleanliness of the optical surfaces of the GPro 500. Furthermore, if the
transmission starts to drop a maintenance /service intervention can be planned.

For troubleshooting of all fault situations please refer to chapter 9 of the Operating Instructions TDLS
GPro 500.

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5 Maintenance
The GPro 500 is designed to reduce maintenance to a minimum. Experience has shown that mainte-
nance intervals of more than 12 months are acceptable for most applications. The maintenance opera-
tions described below will secure continuous and safe operation of the instrument.
Laser Spectrometer GPro 500

5.1 Routine maintenance

The GPro 500 has not moving parts and require no consumables. However, for best performance we
recommend to routinely carry out the following steps:
• Monitor the transmission value (see above)
• Clean the process window and corner cube when necessary (for details please refer to chapter 7.3.2,
7.3.3 and 7.3.4 of the Operating Instructions TDLS GPro 500)
• Check the connection between the measurement probe and the process for leakages.
• For applications where the concentration of the measured gas is normally zero: Check the instrument
response by applying some gas at least every 12 months. Do the test only when the GPro 500 is at
least 70 minutes powered on. Apply a sufficiently high concentration of the measurement component
to obtain a strong response for at least 10 minutes. During this test no warnings or errors should be
displayed. If you are in doubt about your analyzer contact your supplier.
• Check the calibration every 12 months (depending on the required accuracy). Recalibrate if necessary,
see next section.

hhEnsure that the DCS is aware of any maintenance work

hhThe GPro 500 is only one part of the safety installation we strongly recommend to test also
the external pressure and temperature sensor acc. to the recommendations of the respective
manufacturers

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6 Calibration and adjustment

The GPro 500 is factory calibrated and – proper installation, operation, and maintenance assumed – it
does not require any calibration during the whole service life. The drift of the spectrometers laser diode
emission frequency is negligible since it does not come into contact with the process and do not decay
drastically over time thus we only recommend a verification check once a year.
Moreover, the unique Spectra-ID™ software of the GPro 500 has a built-in line locking function which
checks the emission frequency of the laser diode independent of the measured target gas concentration.
However, there might be situations were a calibration is desired or necessary.

6.1 Tools required for verification and calibration

• Certified calibration gas or ambient air (set point 20900 ppm) for Oxygen calibration
• Verification /calibration kit (p/n 30 034 139) plus the cross-pipe verification add-on tool (p/n 30 428 120)
if your process adaption is a cross-pipe
• Temperature and pressure sensor or alternatively localized weather services can be used

hhIf your GPro 500 measures CO ppm level please contact your supplier about the correct configu-
ration of the calibration tube.

hhDepending on site regulations and for your personal safety it is recommended to use your per-
sonal protective equipment (PPE)

hhAccess to the analyzer must be granted (“hot-work” permit)

In the following the terms adjust/adjustment and calibrate/calibration are used in the following sense:
Adjust: Calibration values will be overtaken and used for the measurement.
Additionally, the data will be stored in the calibration history
Calibration: The calibration values will be stored in the history for documentation but will
not be used for the measurement. The calibration values from the last valid
adjustment will be further used for the measurement

6.2 Calibration
Depending on the configuration of the GPro 500 (for example with in situ probe installed, with in situ
probe installed in a by-pass, with a blow-back probe or extractive probe) the verification process may
differ slightly

6.2.1 Calibration of oxygen sensors using the calibration tube

• Remove the spectrometer head (blue head) from the process probe and connect it gently to the cali-
bration tube. Do not forget the flat gasket (p/n 30 080 914)
• Connect your computer / laptop to the junction box using the Ethernet port and start MT-TDL Suite
• Rotate the head on the calibration unit gently until the transmission is maximized (in any case above
50 %)
• Fully tighten the safety Tri-Clamp
• Connect the calibration tube to the calibration gas and to the exhaust
• If certified calibration gas is used, flush the calibration tube with calibration gas and wait at least
5 min to allow for thermal stabilization
• During the stabilization time change the optical path length to 20 cm in the MT-TDL Suite
• Configure the gas pressure and temperature to be constant and enter the respective value

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If you are only performing a simple calibration, observe the values of the reading and record it for docu-
mentation and certification purposes.
For documentation in MT-TDL Suite you can also follow the calibration procedure described in section 6.3
Laser Spectrometer GPro 500

but activate “calibrate” instead of “adjust”. The calibration factor is stored in the calibration history but not
used for measurement.
If the reading shows more than 2 % error or when an adjustment is requested follow the calibration
procedure described below.

WARNING
Do not interrupt the process purge as long as the process is
running and the process adaption is in the process!

6.2.2 Calibration of all other gases using an additional extractive flow-through

cell
The optional calibration tube is only suitable for the calibration for oxygen sensors. For all other gases,
there is the possibility to use an extractive cell for the target gas you want to verify/calibrate. Please
consult your local METTLER TOLEDO representative for exact configuration.
Your local METTLER TOLEDO organization will provide you further details about these two possibilities.
This section describes the validation of a GPro 500 using an extractive flow-through cell available from
METTLER TOLEDO.
For the validation of O2 and H2O with an external extractive cell N2 for spectrometer purge and corner-
cube purge (only dual-window) is mandatory.
• If you are using corrosive or toxic gases for the calibration process carry out a leak test following your
site regulations
• Remove the spectrometer head (blue head) from the process probe and connect it gently to the calibra-
tion cell, do not forget to use the flat gasket
• Connect your computer/laptop to the junction box and start MT-TDL Suite
• Rotate the head on the calibration unit gently until the transmission is maximized (in any case above
50 %)
• Fully tighten the safety Tri-Clamp
• Connect the calibration unit to the calibration gas and to the exhaust
• If certified calibration gas is used flush the calibration tube with calibration gas and wait at least 5 min
to allow for thermal stabilization
• During the stabilization time check whether the optical path length of the calibration cell is correct in
MT-TDL Suite, if not change it
• Configure the gas pressure and temperature to be constant and enter the respective values

If you are only performing a simple calibration, observe the values of the reading and record it for docu-
mentation and certification purposes.
For documentation in MT-TDL Suite you can also follow the calibration procedure described in section
6.3 but activate “calibrate” instead of “adjust”. The calibration factor is stored in the calibration history
but not used for measurement.
If the reading shows more than 2 % error or when an adjustment is requested follow the adjustment
procedure described below.

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WARNING
Do not interrupt the process purge as long as the process is
running and the process adaption is in the process!

6.2.3 Calibration of a Blow-Back Process Adaption

Figure 11. Blow-back process adaption

Blow-back filter process adaptions are especially good at coping with process gases that contain par-
ticularly high levels of dust or liquids. It is also possible to fill the protected inner volume of the filter with
a calibration gas:
• Connect the calibration gas bottle via a pressure reducer and a flow regulator to the blow-back inlet of
the process adaption.
• Adjust the pressure to be slightly above the process gas pressure
• Adjust the flow regulator to a flow between 1 and 10 l/h
• If you are using corrosive or toxic gases for the calibration process carry out a leak test following your
site regulations
• Connect your computer/laptop to the junction box and start MT-TDL Suite
• Open the calibration gas bottle and flush the filter with calibration gas.
• Observe the reading of the TDL (ppm-trend tab) and wait until the signal is stable
• If the signal does not stabilize enhance the pressure of the calibration gas.

WARNING
During the calibration/adjustment using the blow-back inlet the calibration
gas flows freely into the process and mixes with the process gas.
If this is not possible choose another suited
calibration method as described above.

If you are only performing a simple calibration, observe the values of the reading and record it for docu-
mentation and certification purposes.
We highly recommend a flow monitoring alarm switch at the process purge inlet to detect blocking of
the filter by dust.
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For documentation in MT-TDL Suite you can also follow the calibration procedure described in section
6.3 but activate “calibrate” instead of “adjust”. The calibration factor is stored in the calibration history
but not used for measurement.
If the reading shows more than 2 % error or when an adjustment is requested follow the adjustment
Laser Spectrometer GPro 500

procedure described in section 6.3.

6.2.4 Calibration of a GPro 500 with in situ probe in a by-pass installation

Special preparation
• The by-pass must be closed for the duration of the verification /calibration
• Temperature and pressure sensors must be installed in the by-pass and wired properly to the GPro
• Purging (spectrometer and process) must kept on during the verification /calibration at the same flow
as under normal process conditions
• In case of a hot process make sure that the system has enough time to reach thermal stability.
Verification
hhConnect your computer / laptop to the junction box and start MT-TDL Suite
• Connect the calibration gas supply to the by-pass and start flushing the by-pass with approx. the
same gas speed as the process gas. This is necessary to ensure the optical path length remains the
same during the verification.
• In case the same process flow conditions cannot be reached the opl will change and must be changed
to calibration flow conditions in MT-TDL Suite for the time of the calibration.

hhThe quality of the calibration depends on the quality of the setting for the new opl!
If you are only performing a simple verification, observe the values of the reading and record it for docu-
mentation and certification purposes.
For documentation in MT-TDL Suite you can also follow the calibration procedure described in section
6.3 but activate “calibrate” instead of “adjust”. The calibration factor is stored in the calibration history
but not used for measurement.
If the reading shows more than 2 % error or when an adjustment is requested follow the adjustment
procedure described in section 6.3.

6.2.5 Calibration of a GPro 500 working in an extractive system

The correct procedure to provide calibration gas depends strongly on the realization of the sampling
system. As a consequence, we can give only some general guidelines.

WARNING
Before you open the sample gas path of the extractive system check
whether there can be back pressure from the exhaust line.
If this is the case the connection between the exhaust line and the sample
gas outlet of the extractive cell need to be closed by a suited valve

• Let the spectrometer purge run

• Switch off the process gas flow
• Connect the extractive cell to the calibration gas or open the calibration gas valves
• Flush the cell with calibration gas
• Allow at least 5 min time for thermal stabilization

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If you are only performing a simple verification, observe the values of the reading and record it for docu-
mentation and certification purposes.
For documentation in MT-TDL Suite you can also follow the calibration procedure described in section
6.3 but activate “calibrate” instead of “adjust”. The calibration factor is stored in the calibration history
but not used for measurement.
If the reading shows more than 2 % error or when an adjustment is requested follow the adjustment
procedure described in section 6.3.

6.3 Adjustment of the GPro 500

If a calibration is requested switch to the “calibration tab” in MT-TDL Suite:

Figure 12. Calibration menu

Calibration modes
One-point-calibration: Calibration with a certified calibration gas
Process calibration: Process gas is used as calibration gas. For this calibration method it is nec-
essary to obtain the concentration of the measurement gas by a 2nd analyzer.
Please note that the quality of the calibration depends strongly on the quality
of the concentration value.
Both are slope calibrations.
“cal type” allows to switch between both modes

Difference between “adjust” and “calibrate”

Adjust: Calibration values will be overtaken and used for the measurement.
Additionally, the data will be stored in the calibration history
Calibration: The calibration values will be stored in the history for documentation but will
not be used for the measurement. The calibration values from the last valid
adjustment will be further used for the measurement

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6.3.1 One-point calibration

• Choose “1-Point” in the “cal-type” field

• Activate “adjust”
Laser Spectrometer GPro 500

• Set the correct values for temperature and pressure

• Set the right opl (typically for the standard calibration tube
20 cm)
• Press “Set ENV”

• Enter the correct calibration gas concentration

• Press “Set PPM”

• Wait until “output on hold” will light up

• Observe the reading of the TDL
• Click “Store”
• Wait until the “output on hold” green light has turned off
• One-point calibration finished

Figure 13. Screenshots one-point calibration

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6.3.2 Process calibration

• Activate “process” in the “cal type” field

• Activate “adjust”
• Enter the correct concentration in ppm
• Click on the “Set PPM” button

• Wait until “output on hold” is activated

• Wait until the reading of the GPro 500 is stable
• Click on the “Store” button
• Wait until the “output on hold” light is switched off
• Process calibration finished

Figure 14. Screenshots process calibration

hhIf the calibration fails please contact your supplier or the METTLER TOLEDO support.
hhRegardless whether the GPro 500 is validated or calibrated we strongly recommend to measure
the analog value of the analyzer by use of a suited multimeter and check whether the expected
value in shown in the DCS.

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6.4 Verification of the direct passive analog outputs

The direct passive analog outputs of the GPro500 can be checked using the hold mode of the analog
outputs.
Laser Spectrometer GPro 500

Figure 15. External out tab

• Check that the passive analog outputs are powered correctly

• Connect the passive analog outputs to a multi meter
• Connect the GPro 500 to the PC and start MT-TDL Suite
• Switch to the “external out” tab
• Choose “fixed value” for the hold mode
• Enter the respective fixed values in the corresponding fields; please note the values must be within the
range defined in the “Linear Mapping” section.
• For example, for the configuration shown in Fig. 15 the fixed value for channel 1 must be set to
– 0  % to get an analog signal of 4 mA
– 12.5 % to get an analog signal of 12 mA
– 25 % to get an analog signal of 20 mA
• Switch the hold button on
• The reading of the multi meter shall now show the analog equivalent of the setting for the fixed value
• To return to normal measurement mode: switch the hold button off

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7 Troubleshooting
All information about the maintenance and error messages are given in chapter 9 of the Operating In-
structions TDLS GPro 500. There you find also some recommendations about the actions to be taken.

8 Failure rate data, certifications, standards, and label-

ling
8.1 SIL Parameters
8.1.1 Covered types of GPro 500
• GPro 500 with direct analog output option (GPro 500 XXXXXXXXXXXXXXXX _ _ / _ A)
• Software version 6.0 and higher
• GPro 500 with 4 … 20 mA current output

8.1.2 SIL parameters

• SIL requirement: SIL 2
• PFDavg (1 year): 1.00 E-03
• Safe failure fraction (SFF): 91 %
The GPro 500 can be considered to be a type B element with a hardware fault tolerance of 0. The failure
rates according to IEC 61508:2010 for the GPro 500 are listed in the Appendix

8.2 Compliance and standards information

• The GPro 500 TDL complies with the European Community “Electromagnetic Compatibility Directive”
and “Low Voltage Directive”
• The TDL is rated in accordance to Over voltage Category II, Pollution Degree.
• The TDL complies with the Class B digital apparatus requirements of ICES-003 of Canada through the
application of EN 55011:2007.
• L’analyseur est conforme aux Conditions B numériques d’appareillage de classe de NMB-003 du
Canada par l’application du EN 55011:2007.
• This TDL complies with Part 15 of the US FCC Rules for Class B equipment. It is suitable for operation
when connected to a public utility power supply that also supplies residential environments.
• The TDL has been assessed to IEC 61010-1:2001 +Corr 1: 2002 + Corr 2:2003 for electrical safety
including any additional requirements for US and Canadian national differences.
• METTLER TOLEDO Ltd is a BS EN ISO 9001 and BS EN ISO 14001 certified organization.

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8.3 Labels
8.3.1 Type labels
The spectrometer of the GPro 500 is marked with a product identification label:
Laser Spectrometer GPro 500

1 4

5
11
6
10
7
9
8

4
1
5

11 6

10
7
9
8

Figure 16. Labels for ATEX (left) and FM (right) version

1 Gas to be measured
2 Manufacturer
3 Country of origin
4 Product name
5 Product key
6 Part number
7 Serial number
8 Ambient temperature limits
9 ATEX (left) / FM (right) marking
10 Power rating
11 Enclosure rating

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8.3.2 Additional labels

Note labels

1/2" NPT
GAS GRP A: SEAL
REQUIRED AT
ENCLOSURE ENTRANCE
WARNING –
WAIT 2 MIN. BEFORE
OPENING AFTER
DE-ENERGIZING
Figure 17. Note label

Grounding labels

M6x12
M4x6

Figure 18. Grounding labels

35
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