Model 900 Air Demand Analyzer Model 930 Sulfur …...Refer to Chapter 2 – Specifications for...

Model 900 Air Demand Analyzer Model 930 Sulfur Pit Analyzer

Operator’s GuideWith Essential Health and Safety Requirements

PN 903-8745, Rev. G

CanadaA DIVISION OF AMETEK PROCESS & ANALYTICAL INSTRUMENTS

Western Research

ii | Model 900 ADA / Model 930 Sulfur Pit Analyzers

© 2013–2019 AMETEK Canada, A Division of AMETEK Process & Analytical Instruments Printed in CanadaThis manual is a guide for the use of the Model 900 Air Demand Analyzer (ADA) and Model 930 Sulfur Pit Analyzer. Data herein has been verified and validated and is believed adequate for the intended use of this instrument. If the instrument or procedures are used for purposes over and above the capabilities specified herein, confirmation of their validity and suitability should be obtained; otherwise, AMETEK does not guarantee results and assumes no obligation or liability. This publication is not a license to operate under, or a recommendation to infringe upon, any process patents.

Offices

For other offices not listed here, visit us at www.ametekpi.com.

USA – HEADQUARTERS150 Freeport RoadPittsburgh, PA 15238, USATel: 412-828-9040Toll Free: 800-537-6044Fax: 412-826-0399USA – Delaware455 Corporate BoulevardNewark, DE 19702, USATel: 302-456-4400 (Main) 800-537-6044 (Service) 800-222-6789 (Ordering)Fax: 302-456-4444USA – Texas4903 West Sam Houston Parkway NorthSuite A-400Houston, TX 77041, USATel: 713-466-4900Toll Free: 1-800-634-8990Fax: 713-849-1924CANADAAMETEK Canada2876 Sunridge Way N.E.Calgary, AB, T1Y 7H9, CanadaTel: 403-235-8400 Toll Free: 800-661-9198Fax: 403-248-3550INDIAAMETEK Instruments India Pvt. Ltd.1st Floor, Prestige Featherlite Tech ParkPlot 148, EPIP Phase IIWhitefield, Bengaluru – 560066, Karnataka, IndiaTel: 91-80-6782-3200Fax: 91-80-6782-3232GERMANYAMETEK GmbHRudolf-Diesel Strasse 16D-40670 Meerbusch, GermanyTel: 49-2159-9136-0Fax: 49-2159-9136-39

FRANCEAMETEK – APIFRond point de l’epine des champsBuroplus Bat D78990 Elancourt, FranceTel: 33-1-30-68-89-20Fax: 33-1-30-68-89-29CHINAAMETEK Commercial Enterprise (Shanghai) Co. Ltd.Part A First Floor, 460 NorthFute RoadWaigaoqiao Free Trade ZoneShanghai, 200131, ChinaTel: 86-21-5868-5111Fax: 86-28-5866-0969Beijing BranchTel: 86-10-8526-2111Fax: 86-10-8526-2141Chengdu BranchTel: 86-28-8675-8111Fax: 86-28-8675-8141Guangzhou BranchTel: 86-20-8363-4768Fax: 86-20-8363-3701MIDDLE EAST – DubaiP.O. Box 17067Jebel Ali Free ZoneDubai, UAETel: 971-4-881-2052Fax: 971-4-881-2053SINGAPOREAMETEK Singapore Pte. Ltd.No. 43, Changi SouthAvenue 2, #04-01486164 SingaporeTel: 65-6486-2388Fax: 65-6481-6588

Contents | iii

ContentsOffices .................................................................................................................................. iiSafety Notes .....................................................................................................................viiiElectrical Safety ................................................................................................................viiiGrounding ........................................................................................................................viiiPersonnel and Equipment Safety Information ............................................................. ix

Warnings ...................................................................................................................... ixCautions ....................................................................................................................... xi

Warning Labels ................................................................................................................. xiiEnvironmental Information ........................................................................................... xiiUV Source Lamps Disposal ............................................................................................ xiiElectromagnetic Compatibility (EMC) ......................................................................... xiiiSpecial Warnings and Information ............................................................................... xiv

Equipment Used in Haza rdous Locations............................................................ xivEU Declaration of Conformity ....................................................................................... xvWarranty and Claims ..................................................................................................... xvii

CHAPTER 1 OVERVIEW ....................................................................................................... 1-1About the Analyzer ......................................................................................................... 1-2

Sample Flow .............................................................................................................. 1-3About the Analyzer Sample System ............................................................................. 1-3Temperature Control System......................................................................................... 1-8

Sample and Vent Lines ............................................................................................ 1-8ASR900 Sample Probe .............................................................................................. 1-8Measuring Cell .......................................................................................................... 1-8

Working in This Manual ................................................................................................ 1-9Supplemental Information – Where Can I Find It? ................................................. 1-10

CHAPTER 2 SPECIFICATIONS ........................................................................................... 2-1Methodology .................................................................................................................... 2-1Standard Ranges ............................................................................................................. 2-1Response Time ................................................................................................................. 2-2Accuracy ............................................................................................................................ 2-2Repeatability .................................................................................................................... 2-2Calibration ........................................................................................................................ 2-2Linearity ............................................................................................................................ 2-3Measuring Cell Construction ........................................................................................ 2-3Stability ............................................................................................................................. 2-3Cross-Talk .......................................................................................................................... 2-3Temperature Drift ............................................................................................................ 2-324-Hour Zero Drift .......................................................................................................... 2-4Customer Connections ................................................................................................... 2-4

Analog Outputs ........................................................................................................ 2-4Digital Communication ........................................................................................... 2-4

iv | Model 900 ADA / Model 930 Sulfur Pit Analyzers

Maximum Sample Gas Pressure ................................................................................... 2-4Electrical Requirements .................................................................................................. 2-4

Maximum Start-Up Power ..................................................................................... 2-4Supply Voltage .......................................................................................................... 2-4

Status Relays .................................................................................................................... 2-5Sample Gas Flow Rate .................................................................................................... 2-5Ambient Limits ................................................................................................................ 2-5

Temperature............................................................................................................... 2-5Humidity .................................................................................................................... 2-5Maximum Altitude ................................................................................................... 2-5

Sample Transport ............................................................................................................ 2-5Instrument Air Requirements ....................................................................................... 2-5Physical Dimensions (on Backpan) .............................................................................. 2-5Cable Entry Ports, Type 200 Disconnect Enclosure .................................................... 2-6Approvals and Certifications ......................................................................................... 2-6

ATEX and IECEx Certificates and Analyzer Markings ....................................... 2-7Purged Analyzers ATEX and IECEx Certificates and Markings ....................... 2-7

Systems with 30 psia Pressure Transducer (Maximum 63 kPag Sample Gas Pressure) ..................................................................................2-15Systems with 100 psia Pressure Transducer (Maximum 350 kPag Sample Gas Pressure) ..................................................................................2-15

Heater Plate ATEX and IECEx Certificates and Marking ................................ 2-16Disconnect Enclosure Type 200 ATEX and IECEx Certificates and Marking . 2-23

CHAPTER 3 INSTALLATION AND START-UP ................................................................... 3-1Safety Considerations ..................................................................................................... 3-2Pre-Installation Requirements....................................................................................... 3-2

Storage Prior to Installation .................................................................................... 3-2Uncrating and Inspecting the Analyzer ................................................................ 3-3Tools and Equipment Required .............................................................................. 3-4

Installing the Mechanical Components ....................................................................... 3-5Installing the Analyzer ............................................................................................. 3-5

Location and Environment .................................................................................. 3-5Installing the Optical Bench Assembly ................................................................. 3-8Installing the Sample System................................................................................ 3-13

Installing the ASR900 Sample Probe ................................................................ 3-13Installing the Sample and Vent Lines ................................................................ 3-13Installing the Instrument Air Line ................................................................... 3-19Installing the Span Gas Line ............................................................................. 3-20

Connecting I/O Signals, Alarm Relay Contacts, and AC Power ............................ 3-21Start-Up and Verification ............................................................................................. 3-27

Purged Analyzers ................................................................................................... 3-28Powering Up the Analyzer .................................................................................... 3-30

Start-Up Diagnostic Checklist .......................................................................... 3-35Sample System Leak Check .................................................................................. 3-38Manually Zeroing the Analyzer ........................................................................... 3-40

Contents | v

Setting the Zero Gas Flow Rate ............................................................................ 3-41Setting the Sample Gas Flow Rate and Sample Response Time ..................... 3-41

Normal Operation ......................................................................................................... 3-42Recording Initial Readings .................................................................................... 3-42

Recording PMT Signals .................................................................................... 3-42Recording Initial Sample Response Time .......................................................... 3-43

Analyzer Configuration ............................................................................................... 3-44

CHAPTER 4 CONTROLLER / USER INTERFACE ............................................................. 4-1Introduction to the User Interface ................................................................................ 4-2

User Interface Components .................................................................................... 4-2Messages/Information Displayed on the User Interface .................................... 4-4Navigating From the User Interface ...................................................................... 4-5

Working in RUN Mode ....................................................................................... 4-6Working in CFG Mode ........................................................................................ 4-6Working in CAL Mode ........................................................................................ 4-7Navigation Examples .......................................................................................... 4-8Entering Passwords to Change Analyzer Parameter Settings ........................... 4-10

Changing the Password for CFG / CAL Mode .............................................4-10RUN / CFG Mode Quick Reference Sheets – Keystroke Commands ................ 4-11

RUN / CFG Mode – Standard Software Version .........................................4-12RUN / CFG Mode – COS/CS2 Software Version ........................................4-13

CAL Mode Quick Reference Sheets – Keystroke Commands ............................ 4-14CAL Mode – Standard Software Version .....................................................4-14CAL Mode – COS/CS2 Software Version ....................................................4-15

Working in the RUN / CFG Operating Modes ......................................................... 4-16RUN / CFG Mode – F1 Commands ..................................................................... 4-17RUN / CFG Mode – F2 Commands ..................................................................... 4-19RUN / CFG Mode – F3 Commands ..................................................................... 4-22RUN / CFG Mode – F4 Commands ..................................................................... 4-23RUN / CFG Mode – F5 Commands ..................................................................... 4-25RUN / CFG Mode – F6 Commands ..................................................................... 4-27

Configuring the Analyzer Control Functions ................................................... 4-29Output Signal Assignment (OSA) ..............................................................4-29Assigning Output Signals With the Track-and-Hold Function Enabled/Disabled .......................................................................................................4-30

Analog Input Channels – Micro-Interface Board .............................................. 4-32Display Operating Temperature ..................................................................4-32Display Measuring Cell Pressure ................................................................4-32

Working in the CAL Operating Mode ....................................................................... 4-33CAL Mode – F1 Commands .................................................................................. 4-33CAL Mode – F2 Commands .................................................................................. 4-34CAL Mode – F3 Commands .................................................................................. 4-35CAL Mode – F4 Commands .................................................................................. 4-36

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CAL Mode – F5 Commands .................................................................................. 4-37CAL Mode – F6 Commands .................................................................................. 4-38Setting Up Analyzer Calibration Functions ....................................................... 4-39

Flow Control (Sample) Modes ........................................................................... 4-39Analyzer Control Mode ...............................................................................4-40Continuous Backpurge/Zero Flow Mode (Manual Control by Operator) ...4-40Continuous Sample Flow Mode (Manual Control by Operator).................4-41

Setting Calibration Gas Timers ............................................................................. 4-42Integration Timer (IntTime) .............................................................................. 4-42Timer0 ............................................................................................................... 4-42Auto-Zero Interval Timer (AZInt) .................................................................... 4-43

Manual Zero/Span .................................................................................................. 4-44Manual Zero ...................................................................................................... 4-44Manual Span ..................................................................................................... 4-44

Auto-Zero ................................................................................................................. 4-47Manual Start of Auto-Zero ............................................................................... 4-48Timed Start of Auto-Zero .................................................................................. 4-48Remote Start of Auto-Zero ................................................................................ 4-49

Analog Output Calibration ................................................................................... 4-51

CHAPTER 5 MAINTENANCE AND TROUBLESHOOTING............................................... 5-1Safety Considerations ..................................................................................................... 5-1Preventive Maintenance ................................................................................................ 5-2

Analyzer Preventive Maintenance Schedule ....................................................... 5-3Expo Technologies MiniPurge® System With eTimer (Optional) Preventive Maintenance Schedule ......................................................................................... 5-5

Preventing, Detecting, and Locating a Plug in the Sample System ................. 5-6Changing Out Replaceable Parts ........................................................................... 5-8

Measuring Cell Maintenance .............................................................................. 5-8Replacing the Source Lamps .............................................................................. 5-17

When Do Source Lamps Need to be Replaced? ............................................5-17About the Source Lamps ..............................................................................5-17Source Lamp Replacement ...........................................................................5-18When is an Auto-Setup Required / Not Required? ......................................5-25Auto-Setup Completion Number .................................................................5-25PMT Level and PMT Balance .....................................................................5-26Auto-Setup Fault Messages and Corrective Action .....................................5-27The Auto-Setup Sequence ............................................................................5-28Manipulating the Completion Number, PMT Level, and PMT Balance ....5-29

Chopper Assembly Maintenance ....................................................................... 5-31Replacing Parts in the Heater Plate................................................................... 5-40ASR900 Sample Probe Preventive Maintenance .............................................. 5-55

Examining and Caring For the Flamepaths ....................................................... 5-56Disconnect Enclosure Flange Flamepath (Joining Surfaces) ............................. 5-57Heater Plate Flange Flamepath (Joining Surfaces)............................................ 5-58

Contents | vii

Troubleshooting and Diagnostics ............................................................................... 5-59Host Controller Board Alarm Conditions and Corrective Action .................. 5-61Microcontroller Board Alarm Conditions and Corrective Action .................. 5-69Analyzer Reset ...............................................................................................................

CHAPTER 6 SERVICE AND PARTS .................................................................................... 6-1Technical Support ............................................................................................................ 6-1Returning Equipment ..................................................................................................... 6-2?? ANSWERS TO YOUR QUESTIONS ?? ................................................................... 6-3

AMETEK SERVICE and AFTERMARKET SALES SUPPORT ............................ 6-3Recommended Preventive Maintenance Spare Parts ............................................... 6-4

Optical Bench/Measuring Cell Spare Parts ........................................................... 6-4Expo Technologies MiniPurge® System With eTimer Spare Parts .................... 6-5Spare Analyzer Fuses ............................................................................................... 6-6Replacement Boards................................................................................................. 6-7Oven Heater Spare Parts ......................................................................................... 6-8Ordering a Hard Copy of the Analyzer Operator’s Guide ............................... 6-8

CHAPTER 7 GLOSSARY ...................................................................................................... 7-1User Interface Abbreviations ......................................................................................... 7-1Abbreviations and Terms Used in This Manual ......................................................... 7-2

APPENDIX A – DRAWINGS ...................................................................................................A-1Ribbon Cable Interconnect (WX-102836) .................................................................... A-2GP Lower Enclosure to Electronics Wiring, CE Analyzers (WX-102810) .................................................................................................................... A-3Heater and Sensor Wiring, GP/Div 2 Analyzers (WX-102851) ................................ A-4Heater and Sensor Wiring, CE/Zone 1 Analyzers (WX-102852) ............................. A-5Lower Cabinet Wiring, CE/GP Analyzers, 120V (100-1341-3) ................................. A-6Lower Cabinet Wiring, CE/GP Analyzers, 240V (100-1342-3) ................................. A-7Signal Wiring, PD/GP/Div 2/CE/Zone 1 Analyzers (WX-102815) ........................... A-8Wiring Diagram, All Seals, Zone 1 Analyzers (100-1343-12) .................................... A-9± 15V and 5V Power Supply DC Wiring, GP/Div 2/CE/Zone 1 Analyzers (WX-102811) .................................................................................................................. A-1024V Power Supply DC Wiring, CE/Zone 1 Analyzers (WX-102812)..................... A-11RS-232 Communications Cable Wiring (300-9480) .................................................. A-12RS-232/RS-485 Module Wiring, CE/Zone 1, GP/Div 2 Analyzers (100-2185) ...... A-13Microcontroller Board (100-0117) .............................................................................. A-14Host Controller Board (Display Interface) (100-0138) ............................................ A-15Model 9xx-Series Analyzer Type 200 Disconnect Enclosure Details .................... A-16

SUPPLEMENTAL INFORMATION ........................................................................................S-1

viii | Model 900 ADA / Model 930 Sulfur Pit Analyzers

Safety Notes

WARNINGS, CAUTIONS, and NOTES contained in this manual emphasize critical instructions as follows:

An operating procedure which, if not strictly observed, may result in personal injury or envi-ronmental contamination. Essential Health and Safety Requirements are also included in – but are not limited to – Warnings.

An operating procedure which, if not strictly observed, may result in damage to the equipment.

Important information that should not be overlooked.

Electrical Safety

High voltages are present in the analyzer housings. Always shut down power source(s) before performing maintenance or troubleshooting. Only a qualified electrician should make electrical connections and ground checks.

Any use of the equipment in a manner not specified by the manufacturer may impair the safety protection originally provided by the equipment.

Grounding

Instrument grounding is mandatory. Performance specifications and safety protection are void if instrument is operated from an improperly grounded power source.

Verify ground continuity of all equipment before applying power.

!WARNING

!CAUTION

NOTE

!CAUTION

Contents | ix

Personnel and Equipment Safety Information

This section describes important safety information to avoid personal injury and damage to the equipment while installing, operating, maintaining, or servicing the equipment. All safety regu-lations, standards, and procedures at the analyzer location must be followed.

All personnel involved with the installation, start-up, operation, maintenance, service, or trou-bleshooting of the analyzer must review and follow these Warnings and Cautions.

Warnings

Review and follow these Warnings to avoid personal injury or environmental contamination.

Always disconnect main AC power and/or external power sources to the analyzer before open-ing any covers or doors on the analyzer to check or perform maintenance on any components within the enclosures. If it is necessary to open the analyzer’s covers or doors while the circuits are live, test the area for flammable gases (and proceed only when the area is safe). Purged Analyzer (Hazardous Location) Applications To work on the analyzer with it powered up and its Electronics Enclosure door open, the Purge Bypass Switch must be in the “BYPASS” position. When the Electronics Enclosure door is open, take appropriate precautions to avoid electrical shock. Hazardous voltages are present inside.

All electrical connections, adjustments, or servicing of the analyzer should be performed only by properly trained and qualified personnel. All electrical connections, materials, and methods (plus all safety policies and procedures) must be made in compliance with local wiring regulations and electrical code for the hazardous area, and be approved by the Owner Company.

Follow appropriate regulatory and/or company procedures to lock out the analyzer while work-ing on its electronics.

Before working on the sample system, confirm that the system is purged with Zero gas and is isolated (blocked in) from the sample stream.

!WARNING

!WARNING

!WARNING

!WARNING

x | Model 900 ADA / Model 930 Sulfur Pit Analyzers

Because ultraviolet radiation can harm your eyes, avoid direct viewing of the light emanating through the end window of the source lamp. If the source lamp must be viewed while ener-gized, wear safety glasses that block ultraviolet radiation.

The Analyzer Oven enclosure and components within the Analyzer Oven are hot; take precau-tions to avoid burning yourself.

Purged Analyzer (Hazardous Location) Applications [Special Conditions for Safe Use] The analyzer may only be energized by using the Purge Bypass Switch with permission of the works manager or his proxy. The permission may only be given when it is made sure that during the time the system is energized by using this switch an explosive atmosphere is not present or when the necessary protective measures against explosion hazard have been taken (“hot permit”). The analyzer enclosure may not be opened when an explosive atmosphere is present.

Purged Analyzer (Hazardous Location) Applications Do not apply power to the analyzer if there is damage (scratches, indentations, or wear) to any flamepath (on the Oven Heater or Disconnect Enclosure). Applying power to an analyzer with a damaged flamepath is dangerous and could result in serious injury or death, or serious dam-age to equipment. See “Examining and Caring for the Flamepaths” in Chapter 5. Replace parts immediately if damage or wear is apparent. Contact AMETEK if there is any doubt about the integrity of any flamepath.

!WARNING

!WARNING

!WARNING

!WARNING

Contents | xi

Cautions

Review and follow these Cautions to avoid damaging the equipment.

The electronic circuit boards and other static-sensitive components should be stored and trans-ported in static-shielding carriers or packages.

For electrical-shock protection, the analyzer must be operated from a grounded power source that has a securely connected protective-ground contact.

If it becomes necessary to handle any of the electronic circuit boards, do not subject the boards to static discharge. The ideal solution is a static-safe work area. Since such areas typically are not available at analyzer installation sites, the use of a wrist strap connected directly to a ground is recommended. If a wrist strap is not available, you should at the very least touch the metal chassis (to ground yourself) before handling or touching the boards.

When handling the source lamps, it is very important not to touch the lamp windows because residual oils from the fingers will absorb ultraviolet light. The window is the flat surface at the end of the narrow glass tube. The lamp assembly is fragile and should be handled with care.

Purged Analyzer (Hazardous Location) Applications M25 x 1.5, 6H cable entries are provided for Power (1 entry) and Signals (2 entries). See the Model 9xx-Series Analyzer Type 200 Disconnect Enclosure Details drawing in Appendix A for cable entry locations. In all cases, all unused cable entry ports must be plugged with a certi-fied Ex d plug. For Division 1/Zone 1 Installations, all cable entry glands (one power cable entry and two signal cable entries) into the flameproof Disconnect Enclosure must be Ex d certified. Conduit or cable seals that comply with the flameproof enclosure cable entry sealing requirements of the local authority must be installed at the entries to the disconnect enclosure. For Division 2/Zone 2 Installations that do not use the Disconnect Enclosure, use a suitable cable entry device with a sealing ring that meets the local requirements for entries into pres-surized enclosures.

!CAUTION

!CAUTION

!CAUTION

!CAUTION

!CAUTION

xii | Model 900 ADA / Model 930 Sulfur Pit Analyzers

Warning LabelsThese symbols may appear on the instrument in order to alert you of existing conditions.

Protective Conductor Terminal (BORNIER DE L’ECRAN DE PROTECTION) Schutzerde

Caution – Risk of electric shock (ATTENTION – RISQUE DE DÉCHARGE ÉLECTRIQUE) Achtung – Hochspannung Lebensgefahr

Caution – Refer to accompanying documents (ATTENTION – SE RÉFERER AUX DOCUMENTS JOINTS) Achtung – Beachten Sie beiliegende Dokumente

CAUTION – Hot Surface (ATTENTION – SURFACE CHAUDE) Achtung – Heiße Oberfläche

Environmental InformationThis AMETEK product contains materials that can be reclaimed and recycled. In some cases the product may contain materials known to be hazardous to the environment or human health. In order to prevent the release of harmful substances into the environment and to conserve our natural resources, AMETEK recommends that you arrange to recycle this product when it reaches its “end of life”.

Waste Electrical and Electronic Equipment (WEEE) should never be disposed of in a munici-pal waste system (residential trash). The Wheelie Bin marking on this product is a reminder to dispose of the product properly after it has completed its useful life and been removed from service. Metals, plastics, and other components are recyclable and you can do your part by doing one of the following steps:

• When the equipment is ready to be disposed of, take it to your local or regional waste collection administration for recycling.

• In some cases, your “end of life” product may be traded in for credit towards the purchase of new AMETEK instruments. Contact your dealer to see if this pro-gram is available in your area.

• If you need further assistance in recycling your AMETEK product, contact our of-fice listed in this manual.

UV Source Lamps DisposalAMETEK recommends that all UV lamps – whether they are new, used, or damaged in any way – need to be disposed of in an environmentally safe manner.

Most UV lamps do not contain restricted substances listed under the European RoHS 2 direc-tive. However, special handling requirements are required for some lamps if they are broken. Two examples include Cadmium and Beryllium lamps. Refer to a current Material Safety Data Sheet (MSDS) for handling any lamp where the glass envelope has been broken and which has exposed the metal cathode in the centre of the lamp.

Contents | xiii

Electromagnetic Compatibility (EMC)

Read and follow the recommendations in this section to avoid performance variations or dam-age to the internal circuits of this equipment when installed in harsh electrical environments.

The various configurations of the Model 900 and Model 930 Analyzers should not produce, or fall victim to, electromagnetic disturbances as specified in the European Union’s EMC Directive (if applicable to your application). Strict compliance to the EMC Directive requires that certain installation techniques and wiring practices are used to prevent or minimize erratic behavior of the Analyzer or its electronic neighbors. Below are examples of the techniques and wiring prac-tices to be followed.

In meeting the EMC requirements, the various Analyzer configurations described in this manual rely heavily on the use of metallic shielded cables used to connect to the customer’s equipment and power. Foil and braid shielded I/O and DC power cables are recommended for use in other-wise unprotected situations. In addition, hard conduit, flexible conduit, and armor around non-shielded wiring also provides excellent control of radio frequency disturbances. However, use of these shielding techniques is effective only when the shielding element is connected to the equip-ment chassis/earth ground at both ends of the cable run. This may cause ground loop problems in some cases. These should be treated on a case-by-case basis. Disconnecting one shield ground may not provide sufficient protection depending on the electronic environment. Connecting one shield ground via a 0.1 microfarad ceramic capacitor is a technique allowing high frequency shield bond-ing while avoiding the AC-ground metal connection. In the case of shielded cables the drain wire or braid connection must be kept short. A two-inch connection distance between the shield’s end and the nearest grounded chassis point, ground bar or terminal is highly recommended. An even greater degree of shield performance can be achieved by using metallic glands for shielded cable entry into metal enclosures. Expose enough of the braid/foil/drain where it passes through the gland so that the shield materials can be wrapped backwards onto the cable jacket and captured inside the gland, and tightened up against the metal interior.

Inductive loads connected to the low voltage “Alarm Contacts” are not recommended. However, if this becomes a necessity, adhere to proper techniques and wiring practices. Install an appropriate transient voltage suppression device (low voltage MOV, “Transzorb,” or R/C) as close as possible to the inductive device to reduce the generation of transients. Do not run this type of signal wiring along with other I/O or DC in the same shielded cable. Inductive load wiring must be separated from other circuits in conduit by using an additional cable shield on the offending cable.

In general, for optimum protection against high frequency transients and other disturbances, do not allow installation of this Analyzer where its unshielded I/O and DC circuits are physically mixed with AC mains or any other circuit that could induce transients into the Analyzer or the overall system. Examples of electrical events and devices known for the generation of harmful electromagnetic disturbances include motors, capacitor bank switching, storm related transients, RF welding equipment, static, and walkie-talkies.

!CAUTION

xiv | Model 900 ADA / Model 930 Sulfur Pit Analyzers

Special Warnings and Information

Equipment Used in Haza rdous Locations

Refer to Chapter 2 – Specifications for details about the suitability of this equipment in hazard-ous locations. This analyzer must not be commissioned until a person trained in the area of evaluating equipment for use in hazardous classified locations has confirmed that this equip-ment and its installation are in compliance with the requirements for the area.

Explosion Hazard – Do Not Disconnect Equipment Unless Power Has Been Switched Off or the Area is Known to be Non-Hazardous. Risque d’explosion – Avant de déconnecter l’équipement, coupez le courant où vous assurez que l’emplacement est designé non dangereux.

All input and output wiring must be in accordance with wiring methods authorized for the area classification by the authority having jurisdiction. Ex d glands or stopping boxes (seals) must be installed on flameproof enclosures and sealing glands must be used for connections made directly to the pressurized enclosure.

!WARNING

!Avertissement

Contents | xv

EU Declaration of Conformity

PN 903-8594 Rev M

EU Declaration of ConformityManufacturer’s Name: AMETEK Canada A Division of AMETEK Process & Analytical Instruments (ISO 9001:2008 Registered)

Manufacturer’s Address: 2876 Sunridge Way N.E. Calgary, Alberta, Canada T1Y 7H9 Phone: (403) 235-8400 / Fax: (403) 248-3550

EU Representative Address: AMETEK Precision Instruments Europe GmbH Rudolf-Diesel-Str. 16 D-40670 Meerbusch, Germany Phone 49-2159 91 36 0 / Fax: 49-2159 91 36 80

Declare under our sole responsibility that the products: Product Names: Model 9xx-Series Photometric Analyzers Model Numbers: 900/930/909/910/919/920 Markings: II 2 G Ex db eb ia pxb IIB T3 Gb (Model 9XX Purged Analyzers) II 2 G Ex db IIB T3 Gb (900 Series Heater Plate) II 2 G Ex db IIB T6 Gb (Disconnect Enclosure Type 200)

Conform to the following EU Standards and Directives:

Electromagnetic Compatibility Directive 2014/30/EU using the following standards:

IEC/EN 61326-1 Electrical equipment for measurement, control and laboratory use – EMC requirements – Part 1: General requirements.

IEC/EN 55011 (CISPR 55011) Radiated Electromagnetic Emissions, Class A 30 MHz to 1 GHz. IEC/EN 55011 (CISPR 55011) Conducted Electromagnetic Emissions, Class A. IEC/EN61000-3-2 Limitsforharmoniccurrentemissions(equipmentinputcurrent≤16Aperphase). IEC/EN61000-3-3 Limitationofvoltagechanges,voltagefluctuationsandflickerinpubliclow-voltagesupply

systems,forequipmentwithratedcurrent≤16Aperphaseandnotsubjecttoconditionalconnection.

IEC/EN 61000-4-2 Testing and measurement techniques – Electrostatic discharge immunity test. IEC/EN61000-4-3 Testingandmeasurementtechniques–Radiated,radio-frequency,electromagneticfield

immunity test. IEC/EN 61000-4-4 Testing and measurement techniques – Electrical fast transient/burst immunity test. IEC/EN 61000-4-5 Testing and measurement techniques – Surge immunity test. IEC/EN 61000-4-6 Testing and measurement techniques – Immunity to conducted disturbances, induced by

radio-frequencyfields. IEC/EN61000-4-8 Testingandmeasurementtechniques–Powerfrequencymagneticfieldimmunitytest. IEC/EN 61000-4-11 Testing and measurement techniques – Voltage dips, short interruptions and voltage

variations immunity tests.

Restriction of Hazardous Substances Directive 2011/65/EU (RoHS 2).

Low Voltage Directive 2014/35/EU using the following standards: EN 61010-1:2001 Safety Requirements for Electrical Equipment for Measurement, Control, and

Laboratory Use – Part 1. General requirements.

Pressure Equipment Directive 2014/68/EU Article 4, Paragraph 3

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xvi | Model 900 ADA / Model 930 Sulfur Pit Analyzers

EU Declaration of Conformity

The object of the declaration described [herein] is in conformity with the relevant Union harmonization legislation (Directive 2014/34/EU): EN 60079-0:2012+A11:2013 General requirements EN60079-1:2014 Equipmentprotectionbyflameproofenclosures‘d’ EN60079-2:2014 Equipmentprotectionbypressurizedenclosures‘p’ EN60079-7:2015+A1:2018 Equipmentprotectionbyincreasedsafety‘e’ EN60079-11:2012 Equipmentprotectionbyintrinsicsafety‘i’

CertificateNumber: KEMA02ATEX2341X(Model9XXPurgedAnalyzers) KEMA 02ATEX2255 X (900 Series Heater Plate) KEMA 01ATEX2219 X (Disconnect Enclosure Type 200) NotifiedBody: DEKRACertificationB.V.0344 Meander 1051, 6825 MJ Arnhem The Netherlands

____________________________

Randy MeadsQuality Assurance ManagerCalgary, Alberta, CanadaFebruary 12, 2019

Page 2 of 2


Western Research

Contents | xvii

Warranty and ClaimsWe warrant that any equipment of our own manufacture or manufactured for us pursuant to our specifications which shall not be, at the time of shipment thereof by or for us, free from defects in material or workmanship un-der normal use and service will be repaired or replaced (at our option) by us free of charge, provided that written notice of such defect is received by us within twelve (12) months from date of shipment of portable analyzers or within eighteen (18) months from date of shipment or twelve (12) months from date of installation of permanent equipment, whichever period is shorter. All equipment requiring repair or replacement under the warranty shall be returned to us at our factory, or at such other location as we may designate, transportation prepaid. Such returned equipment shall be examined by us and if it is found to be defective as a result of defective materials or workman-ship, it shall be repaired or replaced as aforesaid. Our obligation does not include the cost of furnishing any labor in connection with the installation of such repaired or replaced equipment or parts thereof, nor does it include the responsibility or cost of transportation. In addition, instead of repairing or replacing the equipment returned to us as aforesaid, we may, at our option, take back the defective equipment, and refund in full settlement the purchase price thereof paid by Buyer.

Process photometric analyzers, process moisture analyzers, and sample systems are warranted to perform the in-tended measurement, only in the event that the customer has supplied, and AMETEK has accepted, valid sample stream composition data, process conditions, and electrical area classification prior to order acknowledgment. The photometric light sources are warranted for ninety (90) days from date of shipment. Resale items warranty is limited to the transferable portion of the original equipment manufacturer’s warranty to AMETEK. If you are returning equipment from outside Canada, a statement should appear on the documentation accompanying the equipment being returned declaring that the goods being returned for repair are Canadian goods, the name of the firm who purchased the goods, and the shipment date.

The warranty shall not apply to any equipment (or part thereof) which has been tampered with or altered after leaving our control or which has been replaced by anyone except us, or which has been subject to misuse, neglect, abuse or improper use. Misuse or abuse of the equipment, or any part thereof, shall be construed to include, but shall not be limited to, damage by negligence, accident, fire or force of the elements. Improper use or misapplications shall be construed to include improper or inadequate protection against shock, vibration, high or low temperature, overpressure, excess voltage and the like, or operating the equipment with or in a corrosive, explosive or combustible medium, unless the equipment is specifically designed for such service, or exposure to any other service or environ-ment of greater severity than that for which the equipment was designed.

The warranty does not apply to used or secondhand equipment nor extend to anyone other than the original pur-chaser from us. Should the Buyer’s technical staff require the on-site assistance of AMETEK’s agents or employees for service calls covered by this warranty clause, the Buyer shall pay travel time plus actual travel and living expenses.

THIS WARRANTY IS GIVEN AND ACCEPTED IN LIEU OF ALL OTHER WARRANTIES, WHETHER EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION AND WARRANTIES OF FITNESS OR OF MERCHANTABILITY OTHER THAN AS EXPRESSLY SET FORTH HEREIN, AND OF ALL OTHER OBLIGATIONS OR LIABILITIES ON OUR PART. IN NO EVENT SHALL WE BE LIABLE UNDER THIS WARRANTY OR ANY OTHER PROVISION OF THIS AGREEMENT FOR ANY ANTICIPATED OR LOST PROFITS, INCIDENTAL DAMAGES, CONSEQUENTIAL DAMAGES, TIME CHANGES OR ANY OTHER LOSSES INCURRED BY THE ORIGINAL PURCHASER OR ANY THIRD PARTY IN CONNECTION WITH THE PURCHASE, INSTALLATION, REPAIR OR OPERATION OF EQUIPMENT, OR ANY PART THEREOF COVERED BY THIS WARRANTY OR OTHERWISE. WE MAKE NO WARRANTY, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTIES OF FITNESS OR OF MERCHANTABILITY, AS TO ANY OTHER MANUFACTURER’S EQUIPMENT, WHETHER SOLD SEPARATELY OR IN CONJUNCTION WITH EQUIPMENT OF OUR MANUFACTURE. WE DO NOT AUTHORIZE ANY REPRESENTATIVE OR OTHER PERSON TO ASSUME FOR US ANY LIABILITY IN CONNECTION WITH EQUIPMENT, OR ANY PART THEREOF, COVERED BY THIS WARRANTY.

xviii | Model 900 ADA / Model 930 Sulfur Pit Analyzers

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Overview | 1-1

OVERVIEW

This chapter provides an overview of the various sub-systems that make up the AMETEK analyzer and its sample system, and where to find supplemental information for optional equipment.

1-2 | Model 900 ADA / Model 930 Sulfur Pit Analyzers

About the Analyzer

The analyzer is comprised of (Figure 1-1):

• Two ultraviolet light sources (source lamps)

• Chopper Wheel (Filter Wheel) containing up to six interference filters

• Beam Splitter

• Front-surfaced mirrors

• Gas Measuring Cell (contained within an Oven). A pressure transduc-er monitors the pressure at the outlet of the Measuring Cell.

• Two matched Photodetectors

Figure 1-1. Analytical schematic.

Overview | 1-3

Sample Flow

The sample gas is drawn from the sample stream through the ASR900 Sample Probe and Sample Line to the dual-chambered Measuring Cell. The gas sample enters the first chamber, flows the length of the Measuring Cell, crosses to the second chamber, flows the length of the Measuring Cell in the opposite direction and exits the Measuring Cell. From the Measuring Cell, the sample gas flows through the Vent Line back to the sample stream via the ASR900 Probe. An Aspirator in the sample return portion of the ASR900 Probe provides the means of creating flow through the sample system.

About the Analyzer Sample System

The sample system consists of (Figures 1-2 and 1-3):

Component Function

Sample Path

Sample Line This heated line transports the sample gas to the analyzer at a temperature above its dewpoint.

Aspirator Located within the ASR900 Sample Probe, the Aspirator uses Instrument Air to create a small vacuum that moves the sample gas from the extraction point, through the sample system, and returns it to the sample stream through the Sample Probe.

Inspection Tube Provides a visual indicator of any contamination of the sample path.

Measuring (Sample) Cell This is where the actual measurement takes place.

Calibration Manifold (Solenoid Block) Connection point for the Vent Line, calibration gas, and sample path. Preheats calibration gases.

Vent Line This heated line returns the sample gas to the extraction point via the ASR900 Sample Probe at a temperature above its dewpoint.

ASR900 Sample Probe The Probe end extends into the process/tail gas stream to obtain a representative sample. Its flameproof heater maintains the Sample Probe temperature at 130 °C (266 °F). See also ASR900 Sample Probe Installation and Maintenance Guide.

Pressure Transducer Connection

Trickle Purge Flow Provides a small flow of air to keep the line between the pressure transducer and the Calibration Manifold (Solenoid Block) free of condensation.

Pressure Transducer Measures the pressure of the sample gas in the Measuring Cell.


Component Function

Calibration Gas System Introduce Zero and Span gas into the Measuring Cell.

Flow Control Solenoid Introduces Zero gas into system when analyzer sample system is not up to normal operating temperature. Used to Zero the analyzer.

Flow Control Rotameter Used to adjust the flow of Zero and Span gas.

Calibration Gas Port Normally plugged connection used to introduce Span gas into analyzer sample system.

Aspiration ComponentsAspirator Drive Air Regulator

Adjusts drive air flow rate.

Check Valve Stops sample gas from entering the instrument air system if instrument air pressure is reduced below the sample extraction point pressure.

Drive Air Isolation Valve Manually shuts off drive Aspirator Air to the sample system. Used for pressure checking the analyzer sample system.

Aspirator Pressure Gauge Provides indication of Aspirator Air pressure and sample flow rate. Provides indication of process pressure when Aspirator Air is shut off.

Flow Control Solenoid Allows Aspirator Air to be turned off and on automatically if the analyzer is not ready to obtain a sample. This solenoid must be energized for the analyzer to obtain a sample of gas.

Aspirator Tubing Connection This tube, usually 1/4" stainless steel, runs from the Flow Control Solenoid to the Aspirator in the ASR900 Sample Probe.

Aspirator (ASR900 Sample Probe) Provides suction to move the sample gas through the sample path. The Aspirator sucks sulfur from the Sulfur Collection Reservoir (in the Sample Probe).

Probe Check Valve Provides protection against breakage of Aspirator Air line and release of sour gas. This should be installed, if required, at the inlet to the Aspirator Air pre-heater.

Pre-Heater (Flow Restrictor, in Solenoid Block) Warms Aspirator Air to a temperature that will not cause condensation and freezing of sulfur in the Aspirator. Provides a consistent back-pressure for setting the Aspirator Air, which reduces sample rate fluctuations caused by process pressure fluctuations. The flow rate obtained at a gauge pressure of 210 kPa (30 PSIG) is 30 L/min (1 SCFM). To avoid plugging problems within the probe, do not remove this fitting or replace it with a general purpose fitting.

Overview | 1-5

Component Function

Electronics Purge Components The Optical Bench Assembly, Measuring Cell seal, and the Electronics Enclosure are purged (Instrument Air, typically) to prevent contamination of the optical system and the electronics.

Purge Air Regulator Controls the pressure available for an optics purge.

Aspirator Pressure Gauge Use to set the air pressure to a nominal 105 KPAG (15 PSIG).

Electronics Enclosure Purge Air Flow Restrictor Prevents ingress of corrosive gas in Electronics Enclosure in absence of dedicated purge controller.

Cabinet Pressure Port Use this port (on the Solenoid Block) to test the pressure of the Electronics Enclosure.

Optics Purge Flow Restrictor Provides a dedicated purge for the Optical Bench.


Figure 1-2 is an example drawing only. Refer to Final “As-Built” draw-ings for your system in the analyzer Documentation Package.

Figure 1-2. Model 900 Piping and Instrumentation diagram (Zone 1).

NOTE

Overview | 1-7

Figure 1-3 illustrates a typical Oven/Instrumentation layout for Div 2/Zone 1 analyzers. For your system, refer to Final “As Built” drawings in the analyzer Documentation Package.

NOTE

Figure 1-3. Oven/Instrumentation layout (Div 2/Zone 1).


Temperature Control System

Sample and Vent Lines

To ensure the temperature of these lines do not fall below the dewpoint of the sample gas, the lines are controlled at a Set Point of 150 °C.

ASR900 Sample Probe

The temperature of the ASR900 Sample Probe is maintained at 130 °C by a control loop utilizing a temperature sensor (PT100 RTD) and a flameproof heater. The heater is protected from overheating by a temperature switch, which will disconnect power if the heater exceeds approximately 170 °C.

Measuring Cell

The Measuring Cell temperature is controlled to create a stable condition for the analysis of the sample gas to take place and to ensure that no con-densation forms which can obscure the light path of the analyzer. Control is accomplished using a RTD embedded in the Heater Plate. The RTD makes contact with the Measuring Cell mount.

The default and recommended temperature Set Point for the Measuring Cell is set at 150 °C but can be modified through the keypad.

If Sv is the only condensable in the sample stream, the nominal Set Point (150 °C) should be adequate to prevent condensation. If there is indication of the accumulation of Ammonia salt on the Measuring Cell Windows (e.g., NDR reading increases steadily and does not dissipate during pro-longed Zeroing of the analyzer), increase the Measuring Cell Set Point to 155 °C.

Overview | 1-9

Working in This Manual

While working in this manual, icons in the outside page margins represent various kinds of information that serve as reminders or extra information about the topic, or navigation information when working from the User Interface.

Descriptions of User Interface menus, terms, characters, parameters, and commands can be found in Chapter 4 – User Interface.

Reminder icon: These reminders indicate related information about the topic, certain actions that are necessary before continuing with the current procedure, or information that is recommended by AMETEK.

User Interface Navigation icon: While working from the User Interface, use these navigational aids to quickly access different screens. In this example, the system navigates to the Show Results (Show Res) screen, where you can press additional numerical keys (1 through 8) to access the calculated result of each signal. See “Navigating From the User Interface” in Chapter 4 for more information.

Example: See also “Troubleshooting and Diagnostics” in Chapter 5.

Example: (Show Res) RUNF6 31..8


Supplemental Information – Where Can I Find It?

Some analyzers are configured with optional equipment that may require supplemental information. The analyzer Operator’s Guide and this addi-tional information (not part of the main manual) – collectively known as the analyzer Documentation Package – is included with the manual.

If a CD-ROM of the analyzer Documentation Package is ordered, this information is also included in the “Supplemental Information” folder on the CD.

The Documentation Package shipped with each analyzer includes the following:

• Manual Supplements that describe and illustrate installation, operation, layout, and maintenance procedures for non-standard Measuring Cells* or optional equipment*, non-standard (derivative) analyzer models, or information that is intended to replace similar information in the Operator’s Guide. (*These documents can also include a non-standard Spare Parts List or a separate Custom Spare Parts List.)

• Analyzer Programming Parameters sheet, which lists the critical analyzer operating parameters.

• EEPROM Data Sheets, which list the factory-default configuration set-tings of all programmable analyzer parameters.

• Signed Final QC (Quality Control) Document, which includes AMETEK Testing Quality Control information for the analyzer.

• Final As-Built drawings which are customer-specific drawings for the analyzer system.

• Other customer-specific information may also be included (if appli-cable), such as Product Data Sheets, a Custom Spare Parts list, or analyzer Certificates.

An “Operator Interface Quick Reference Sheet,” which lists all of the Function commands used to access analyzer parameters and other information from the User Interface is shipped on the inside of the analyzer’s Electronics Enclosure door.

NOTE

NOTE

Specifications | 2-1

SPECIFICATIONS

The standard customer range is defined as full-scale ranges that fall within the minimum and maximum allowable for a given Measuring Cell. Calculations of minimum and maximum are based on atmospheric pressure.

The specifications listed in this chapter apply to both Model 900 and Model 930 Analyzers, except where noted.

Methodology

Multiple Wavelength, high resolution, non-dispersive ultraviolet.

Standard Ranges

Standard ranges are based on Measuring Cell length (expressed in cm). Typical cell lengths for Air Demand (Model 900) and Pit Gas (Model 930) Analyzers are 3.75, 5.0, 10.0, and 15.0 cm.

Model 900/930:SO2 Range: 10 % SO2 / (Cell length) H2S Range: 20 % H2S / (Cell length)

Model 900 only:COS Range: 5 % / COS (Cell length), to a minimum of 5000 PPM CS2 Range: 5 % / CS2 (Cell length), to a minimum of 5000 PPM

NOTE


Response Time

Dependent on sample gas flow rate and operator-adjustable filtering time constants. Typically less than 30 seconds to T90 (excludes sample system).

Accuracy

Accuracy is determined by comparing analyzer response to a known stan-dard gas after a calibration has been performed.

SO2, H2S: ± 1 % of full-scale of standard ranges

Model 900 only:Air Demand: ± 0.04F Air DemandCOS, CS2: 10 % of full-scale of standard ranges

F is a constant for a given plant which depends upon the acid gas composition. For acid gas H2S concentrations ranging between 30 % and 100 %, F ranges between 5.25 and 3.0. Specifications are for con-centration ranges and conditions that normally exist in sample gas streams of conventional modified Claus plants.

Repeatability

SO2, H2S: < 0.5 % of full-scale of standard ranges

Model 900 only:Air Demand: ± 0.02F Air DemandCOS, CS2: 1 % of full-scale of standard ranges

See Note (Re: "F is a constant...") under “Accuracy.”

Calibration

Generally not required. Field calibration not recommended, except by fac-tory trained technician.

NOTE

NOTE


Linearity

SO2, H2S: <± 1 % of full-scale

Model 900 only:Air Demand: ± 0.04F of full-scaleCOS, CS2: 10 % of full-scale

Measuring Cell Construction

Standard 316 stainless steel body with quartz windows.

Stability

Noise (at constant ambient temperature):

SO2, H2S: ± 0.2 % of full-scale of standard ranges

Model 900 only:COS, CS2: 1 % of full-scale of standard ranges

Cross-Talk

< 1 % SO2 full-scale on to H2S (Model 900: excluding sulfur vapour)

Cross-talk adjustments should be made by factory-trained service personnel only.

Temperature Drift

SO2: (100 PPM / Cell length) / °CH2S: (200 PPM / Cell length) / °C

Model 900 only:COS, CS2: (500 PPM / Cell length) / °C

Concentration signal is compensated for changes in Measuring Cell pressure and temperature.

!CAUTION

NOTE


24-Hour Zero Drift

SO2: 0.5 % of full-scale of standard rangesH2S: 1 % of full-scale of standard ranges

Model 900 only:COS, CS2: 10 % of full-scale of standard ranges

Customer Connections

Analog Outputs

4 isolated 4–20 mA self-powered (or optional loop-powered; loop power by end user).

Digital Communication

One RS-232 port used for service diagnostics.

One RS-422 port for remote communication with a Data Acquisition System (DAS), using Modicon Modbus® protocol.

Optional RS-485 for Modicon Modbus® protocol (requires RS-232 to RS-485 converter).

Optional System 200 Configurator Software.

Maximum Sample Gas Pressure

Maximum Sample Pressure Transducer Gas Pressure 100 psia 350 kPag 30 psia 63 kPag

Electrical Requirements

Maximum Start-Up Power

<750 W maximum start-up with continuous average, depending on ambient temperature (includes 150 W for ASR900 Sample Probe; excludes Sample and Vent Lines).

Supply Voltage

120 VAC (± 10 %), 47–63 Hz240 VAC (± 10 %), 47–63 Hz


Status Relays

The analyzer uses three relays which indicate the operational status of the analyzer. Each relay provides a set of SPDT (Form C) dry (potential free) contacts. The relays are configured for fail-safe operation (i.e., energized for the non-alarm condition).

Sample Gas Flow Rate

3.0–5.0 L/minute (0.1–0.2 SCFM)

Ambient Limits

Temperature

5 °C–50 °C (41 °F–122 °F)

Humidity

0–95 % RH

Maximum Altitude

2000 m

Sample Transport

By aspiration, using air or N2 as the drive gas.

Instrument Air Requirements

Pressure: 210 KPAG (30 PSIG) – General Purpose applications 420–840 KPAG (60–120 PSIG) – Hazardous Locations

Flow: 60–120 L/min (1–4 SCFM)Air Quality: As per ANSI/ISA-S7.0.01 (1996) Quality Standard for

Instrument Air

Physical Dimensions (on Backpan)

Height: 1553.6 mm (61.17")Width: 1117.6 mm (44")Depth: 310 mm (12")

Requires minimum 706 mm (28") for door swing.Weight: 115–160 kg (250–350 lb), entire system and backpan

only (may vary, depending on system).


Cable Entry Ports, Type 200 Disconnect Enclosure

M25 x 1.5, 6H cable entries are provided for Power (1 entry) and Signals (2 entries). See the Model 9xx-Series Analyzer Type 200 Disconnect Enclosure Details drawing in Appendix A for cable entry locations. In all cases, all unused cable entry ports must be plugged with a certified Ex d plug.

Approvals and Certifications

The Model 900 ADA and Model 930 Analyzers are certified for indoor use only, Installation Category II (local level transients, less than those found at power distribution level), and Pollution Degree 2 (normally noncon-ductive environmental pollution occurs with occasional condensation). Complies with all relevant European Directives.

Approvals and certifications include:

NEC/CEC: Class I, Zone 2 (Div 2), Groups C&D, NFPA 496 Z-PurgeATEX/IECEx: Purged Analyzer:

DEKRA Certificate No.: KEMA 02ATEX2341 X; II 2 G Ex db eb ia pxb IIB T3 Gb IECEx Certificate No.: IECEx DEK 13.0054X; Ex db eb ia pxb IIB T3 Gb Heater Plate: DEKRA Certificate No.: KEMA 02ATEX2255 X; II 2 G Ex db IIB T3 Gb

IECEx Certificate No.: IECEx DEK 11.0073X; Ex db IIB T3 Gb Disconnect Enclosure Type 200: DEKRA Certificate No.: KEMA 01ATEX2219 X; II 2 G Ex db IIB T6 Gb IECEx Certificate No.: IECEx DEK 12.0077X; Ex db IIB T6 Gb

GOST: 1ExpydIIBT3 Complies with all relevant European Directives, GOST Pattern Approval

EMC: Electromagnetic Compatibility Directive: 2014/30/EU, with EN61326 Industrial

LVD: Low Voltage Directive: 2014/35/EU, with EN61010-1RoHS: Restriction of Hazardous Substances Directive:

2011/65/EU (RoHS 2)


ATEX and IECEx Certificates and Analyzer Markings

For installation sites with potentially explosive atmospheres that require ATEX and IECEx certification, AMETEK’s ATEX and IECEx certificates for the Model 900/Model 930 Analyzers (and their markings) are included in the following pages.

Purged Analyzers ATEX and IECEx Certificates and Markings




2019-02-05






ATEX- and IECEx-certified Model 900/Model 930 Purged Analyzers are marked with one of the labels shown below (depends on application).

Systems with 30 psia Pressure Transducer (Maximum 63 kPag Sample Gas Pressure)

Systems with 100 psia Pressure Transducer (Maximum 350 kPag Sample Gas Pressure)

See manual before opening.

Minimum purging flow rate:Minimum purging duration:Internal free volume:Minimum overpressure:Maximum overpressure:Maximum leakage rate:

40 Nl/min15 minutes

124 litres50 Pa

1000 Pa10 Nl/min

WARNING - PRESSURIZED ENCLOSUREDo not open while a flammable atmosphere is present.

Western Research Series 9XX Analyzer

Certificate No: KEMA 02ATEX2341 XYear. _______Serial No. ___________________

Ex db eb ia pxb IIB T3 Gb (T amb. -20°C to +50°C)

108-132V = 6.2A MAXPower Dissipation < 100W

216-264V = 3.1A MAX47-63Hz

Minimum Supply Pressure:Maximum Supply Pressure:

60 psig / 4 barg115 psig / 8 barg

AMETEK CANADA LP

IECEx DEK 13.0054X

Maximum Sample Gas Pressure: 63 kPag

II 2 G

0344

See manual before opening.

Minimum purging flow rate:Minimum purging duration:Internal free volume:Minimum overpressure:Maximum overpressure:Maximum leakage rate:

40 Nl/min15 minutes

124 litres50 Pa

1000 Pa10 Nl/min

WARNING - PRESSURIZED ENCLOSUREDo not open while a flammable atmosphere is present.

Western Research Series 9XX Analyzer

Certificate No: KEMA 02ATEX2341 XYear. _______Serial No. ___________________

Ex db eb ia pxb IIB T3 Gb (T amb. -20°C to +50°C)

108-132V = 6.2A MAXPower Dissipation < 100W

216-264V = 3.1A MAX47-63Hz

Minimum Supply Pressure:Maximum Supply Pressure:

60 psig / 4 barg115 psig / 8 barg

IECEx DEK 13.0054X

Maximum Sample Gas Pressure: 350 kPag

II 2 G

0344

AMETEK CANADA LP


Heater Plate ATEX and IECEx Certificates and Marking







ATEX- and IECEx-certified Model 900/Model 930 Analyzers are marked with this label:


Disconnect Enclosure Type 200 ATEX and IECEx Certificates and Marking







ATEX- and IECEx-certified Model 900/Model 930 Analyzers are marked with this label:



Installation and Start-Up | 3-1

INSTALLATION and START-UP

This chapter describes how to install and start up the analyzer, including:

• Safety considerations before working on the analyzer.

• Uncrating, inspecting, and storing the analyzer prior to installation.

• Installing the mechanical components and making the electrical connections.

• Powering up the analyzer and performing start-up checks and adjustments.

The installation of the analyzer must be in accordance with all of the user and local regulatory standards and procedures. There are no operator-serviceable components inside the analyzer. Refer servicing to qualified personnel.

!WARNING


Safety Considerations

Before installing and powering up the analyzer, review and follow all safety information in this chapter and under “Personnel and Equipment Safety Information” following the Table of Contents. This information describes procedures to follow to avoid personal injury and/or damage to the equipment. All regulatory agency and person-nel safety procedures for your jurisdiction must be followed.

Under normal operating conditions, lethal concentrations of H2S and other toxic gases from the sample stream may be present within the sample system. The sample system is defined as all components in the analyzer system through which sample gas passes. A breathing apparatus must be worn when installing/removing equipment from the sample gas extraction point. The sample stream is under positive pressure, and injury or death from inhaling toxic gases in the sample stream could result from attempting to install/remove equipment without the use of a breathing apparatus.

Pre-Installation Requirements

Storage Prior to Installation

If the analyzer and its Optical Bench Assembly are stored for any period of time prior to installation, store the equipment in an environment where it is not subject to dripping or splashing liquids, corrosive gases, high humidity, or excessive heat or cold. Recommended storage conditions include:

Temperature: 0 °C to 50 °C (32 °F to 122 °F)Relative Humidity: < 70 %

Failure to comply with these storage conditions will void your warranty.

!WARNING

!WARNING


Uncrating and Inspecting the Analyzer

The analyzer and its associated sample system is shipped pre-mounted on a backpan, either alone in a crate or in a crated weatherproof shelter. Upon receiving the analyzer system, remove the shipping crates and check the exterior of the shelter and/or analyzer for damage. Open the shelter and verify its internal components are secure and there is no phys-ical damage. Open the Analyzer Oven, Electronics Enclosure, Sample/Vent Line Termination Box, and Disconnect Enclosure (if used), and verify their internal components and wiring are secure and there is no physical damage.

The Optical Bench Assembly is shipped in a separate box. Check this box for any physical damage. If the box is damaged, open it and check the sealed ESD-safe packaging protecting the Optical Bench. If the ESD-safe packaging is not damaged and there appears to be no damage to the Optical Bench, replace it – in its sealed ESD-safe packaging – in its ship-ping box. Reseal the box and store it as per the storage requirements. If the Optical Bench appears to be damaged open the ESD packaging (follow ESD precautions to prevent ESD damage to the electronics), observe the Optical Bench, and contact AMETEK with details of the damage. Reseal the ESD-safe packaging while awaiting instructions from AMETEK.

Avoid damaging the analyzer’s piping and instrumentation by lifting it out of its shipping crate using only its backpan. DO NOT use any piping or instrument to lift.

The analyzer and its backpan weighs approximately 115–160 kg (250–350 lb) (may vary, depending on system). Use caution when lifting it from its crate.

After the inspection, close and secure all covers and doors with at least one screw. This will keep the electronics equipment secure and will prevent damage to the doors, covers, electronic components, and flamepaths (i.e., Disconnect Enclosure – for this, if used, use a soft nonabrasive cloth to gently clean the joining surfaces (flamepath) of this enclosure and its door) during installation.

!WARNING

!CAUTION

!CAUTION


Tools and Equipment Required

To install the analyzer, you need the following tools, equipment, and supplies:

• Set of open-end wrenches for fittings.

• Set of metric hexagonal wrenches.

• Set of metric ball drivers.

• Torque wrench (for Type 200 Disconnect Enclosure), calibrated and set to measure 9.0 Nm, ±1.0 Nm (80 in-lb, ±9 in-lb).

• Wire cutters, strippers, and crimpers.

• Flat blade instrument screwdriver.

• Electric drill.

• Thread lubricant (must not contain copper).

• Soft, nonabrasive cloth.

• Wrist strap (for grounding).

• Detergent-based leak detector (Snoop® or another suitable leak detec-tion agent is permissible).

• One power-disconnect explosion-proof switch (breaker), rated for at least 250 VAC, 3 A and certified for the hazardous location (to satisfy local electrical codes, the switch must be certified by the local author-ity for the appropriate hazardous location). The power-disconnect switch (breaker) must be connected to and mounted near the analyzer, in an easily accessible area. The switch (breaker) must be clearly la-beled (e.g., “AMETEK Model 900 Analyzer Main AC Power Disconnect Switch”). For safety reasons during maintenance, this switch allows the main AC power to be disconnected from the analyzer prior to performing service on the analyzer. This switch (breaker) is to be sup-plied by the custom er/end user.

• Supply of AC electrical supply cable, which must be approved by the local wiring regulations and electrical codes for the hazardous loca-tion, and which must be rated for minimum 80 °C (176 °F).

• A supply of 1/4" 316 stainless steel tubing (NPT-F connectors are required) for the Instrument Air lines. Supplied by the customer/end user.

• A supply of 1/4" 316 stainless steel tubing for the Span, Zero, and Aspirator Drive Air lines. Length will vary, depending on the distance between the analyzer and the sample stream. Supplied by the cus-tomer/end user.


Installing the Mechanical Components

Install the analyzer in its designated location before installing the Optical Bench in the Electronics Enclosure.

Installing the Analyzer

The analyzer system comes mounted on a backpan. See Figure 3-1 for the backpan and mounting hole locations and dimensions, plus necessary clearances on all sides that are required for service. Final “As-Built” draw-ings for your analyzer are located in the Documentation Package shipped with the analyzer.

Location and Environment

The Model 900/930 Analyzers are designed for indoor operation (Pollution Degree 2). In all cases, the analyzer system must be installed indoors to ensure it is shielded from harsh environmental elements. The entire ana-lyzer system (and its backpan) can be mounted directly on a wall inside a building, in a specially designed cabinet, or in a custom-built shelter.

Regardless of which installation method is used, be sure to install the analyzer in a location that is as free as possible from vibrations.

The surrounding ambient temperature of the analyzer must be between 5–50 °C (41–122 °F). If the analyzer system is mounted within a shelter, these conditions are taken into consideration in the design of shelter.

!CAUTION

NOTE


To install the analyzer:

Install the analyzer at an accessible location as close as possible to the sam-ple extraction point to minimize sample response time and, if the Sample Line must be heated, minimize the heating requirements.

For shelter installations, refer to Final “As-Built” shelter drawings in the analyzer Documentation Package.

Figure 3-1 illustrates a typical Zone 1 analyzer layout. While the backpan mounting hole locations and dimensions generally do not change, the plumbing and external wiring will likely change for each installation. For other analyzer configurations, refer to Final “As-Built” drawings in the analyzer Documentation Package.

NOTE


Figure 3-1. Analyzer backpan mounting details (Zone 1).


Installing the Optical Bench Assembly

The Optical Bench Assembly – shipped in a separate box – must be in-stalled in the analyzer’s Electronics Enclosure after the analyzer has been installed.

All electrical connections to the Optical Bench are made via pre-wired connector plugs. No hard wiring is required.

To install the Optical Bench (Figures 3-2, 3-3, and 3-4):

Ensure there is no power being supplied to the analyzer while install-ing the Optical Bench.

1. The Measuring Cell comes installed in the Analyzer Oven. Before installing the Optical Bench, first remove the Measuring Cell from the Oven and connect it to the Optical Bench. To do this:

a. Open the Oven and disconnect the Sample and Vent Line tubes from their fittings on the Measuring Cell.

b. Remove the Heat Transfer Block Plug from the counter bore hole in the Heat Transfer Block (Figure 3-4). Grasp the Measuring Cell and remove the M4 x 25 screw inside the Heat Transfer Block using only a flat hex key. Do not use a ball driver – the head can break off inside the screw.

Remove the Measuring Cell and set it aside.

c. Remove the Optical Bench from its shipping box and then from its ESD-safe packaging.

Remove the (3) M4 x 12 screws from the Beam Splitter (part of the Optical Bench) – Figure 3-4.

Remove the dust cover and the Installation Tag from the Measuring Cell. Use the (3) M4 x 12 screws to secure the Cell Extension to the Beam Splitter on the Optical Bench.

2. Open the Electronics Enclosure and locate the blue Support Arm Yoke, in the top-left corner of the Electronics Enclosure. Loosen the set screw securing the outermost pivot pin in the Support Arm Yoke and remove the pin.

With the blue Support Arm Yoke fully extended, lift the Optical Bench/Measuring Cell Assembly by its upper portion and carefully move it toward the analyzer. Align its Optical Bench Support Plate with the Support Arm Yoke and replace the pivot pin. Tighten the set screw. The Optical Bench should swing freely.

!WARNING


Figure 3-2 illustrates a typical analyzer layout. For your specific analyzer, refer to Final “As-Built” drawings shipped with the analyzer.

NOTE

Figure 3-2. Electronics Enclosure, typical analyzer backpan layout.


4. Install the Measuring Cell in the Analyzer Oven:

a. Swing the Optical Bench toward the Electronics Enclosure and then swing the Measuring Cell toward the Oven (Figure 3-5).

Align the hole in the Heat Transfer Block with the Cell RTD tip (on Heater Plate) and carefully push the Measuring Cell toward the Heater Plate. Adjust the entire Measuring Cell/Optical Bench Assembly as required to firmly seat the Measuring Cell against the Heater Plate.

Using a flat hex key, insert the M4 x 25 screw into the counter bore hole in the Heat Transfer Block and thread it onto the Cell RTD (until it is snug). Do not use a ball driver. Do not tighten the screw at this time.

IMPORTANT Positioning of the Heat Transfer Block in the Oven is critical. Improper positioning of the Heat Transfer Block can result in:

• Poor contact between the Cell RTD tip and the Heat Transfer Block.

• Poor alignment of the Cell Extension seal in the Oven and Electronics Enclosure cabinets.

NOTE

3. Connect Optical Bench wiring:

a. Ribbon cable from J102 on Micro-Interface board to J100 on Optical Bench board.

b. AC power line (connector plug) to TB100 on Optical Bench board.

c. Using the disconnect terminals, connect the yellow/green ground wire from the Electronics Enclosure to the yellow/green ground wire from the Optical Bench.

Figure 3-3. Optical Bench board layout.


b. Adjust the Measuring Cell/Optical Bench Assembly so that the two ribs of the Cell Extension seal fit firmly into the molded depres-sions in the Oven and Electronics Enclosure walls.

Temporarily close the Electronics Enclosure door and tighten its screws to secure the Optical Bench in place.

While closing the Electronics Enclosure door, verify that proper verti-cal alignment of the Optical Bench is maintained. If necessary, vertically align the Optical Bench by loosening the Optical Bench support bracket from the backpan and moving the Optical Bench up or down as required. After aligning the Optical Bench, retighten the support bracket.

c. After the Electronics Enclosure door is closed and secured, ensure no gap exists between the Heat Transfer Block and the Cell RTD. The Measuring Cell must feel secure against the Heater Plate. Gently push and pull on the Measuring Cell to verify it is not loose.

If there is any movement, tighten the M4 x 25 screw again until the Measuring Cell does not move, being careful not to over tighten it. Do not use a ball driver. Over-tightening this screw will damage the threads on the RTD.

d. Replace the Heat Transfer Block Plug in the Heat Transfer Block.

5. Connect the Sample and Vent Line tubes to their fittings on the Measuring Cell.

6. Optional: If using the Optical Bench Purge, connect the purge line (black tube) to the Purge Fitting on the Optical Bench.

NOTE


Figure 3-4. Optical Bench/Measuring Cell assembly.


Installing the Sample System

Final “As-Built” drawings of the analyzer sample system components are included in the analyzer Documentation Package.

Installing the ASR900 Sample Probe

For information on installing the ASR900 Sample Probe, refer to the ASR900 Sample Probe Installation and Maintenance Guide. Also, refer to Final “As-Built” drawings which include important information to follow during installation.

Installing the Sample and Vent Lines

The Sample and Vent Lines can be supplied by AMETEK or the customer. This section assumes these lines are supplied by AMETEK.

Do not lift or support the Sample or Vent Lines by their tubing fit-tings. Doing so can pull the fitting off the sample transport tube. A wire mesh cable support must be installed on the line before lifting it and when a line is to be suspended vertically. The Sample and Vent Lines are custom-built for each installation; they cannot be cut to length on-site. To avoid damaging the Sample or Vent Lines, use two wrenches to ensure that the fitting body does not turn on the Teflon tube.

To install the Sample and Vent Lines:

1. If an explosion-proof power-disconnect switch has already been installed for the Sample and Vent Lines, open it to ensure there is no power being supplied to these temperature zone circuits.

Keep the power-disconnect switch open until the entire system has been installed, the leak check has been completed, and the analyzer is ready for normal operation.

NOTE

!CAUTION

NOTE


2. Unwrap and lay out the Sample and Vent Lines next to each other, with the electrical leads at the analyzer.

3. Route the Sample and Vent Lines from the analyzer to the ASR900 Sample Probe.

Ensure there are no loops, sags, or other traps in the Sample and Vent Lines. Provide support where needed.

Refer to the Sample/Vent Line Final “As-Built” drawings in the ana-lyzer Documentation Package.

4. Make the Sample/Vent Line connections inside the Analyzer Oven (Figure 3-5):

Non-Shelter Installations: Route the Sample Line through the upper hole on the left side of the Analyzer Oven. Connect it to the Sample Inlet fitting.

Route the Vent Line through the lower hole on the left side of the Analyzer Oven. Connect it to the Sample Outlet fitting.

Shelter Installations: Route the Sample Line through the hole marked “Sample Line” on the side of the shelter and then through the upper hole on the side of the Analyzer Oven. Connect it to the Sample Inlet fitting.

Route the Vent Line through the hole marked “Vent Line” on the side of the shelter and then through the lower hole on the side of the Analyzer Oven. Connect it to the Sample Outlet fitting.

Do not add extra insulation to the Sample Line or Vent Line. This will result in a local hot spot and cause premature failure of the line.

5. Connect the Sample and Vent Lines to the ASR900 Sample Probe.

!CAUTION


6. Terminate the Sample Line and Vent Line wiring as indicated in the Sample/Vent Line Wiring drawing (Figure 3-6.1) for GP/Div 2 analyz-ers or the Disconnect Enclosure Wiring drawing (Figure 3-6.2) for Zone 1 analyzers.

Connect the ground lead from each line to the ground terminals before connecting the heater leads.

When terminating the temperature sensor (RTD) leads, either sen-sor in a line can be used as the Control or Over-Temperature sensor (RTD).

!CAUTION

NOTE


Figure 3-5 illustrates a typical Oven/Instrumentation layout for Div 2/Zone 1 analyzers. Figure 3-6.1 is for Zone 1 analyzers, while Figure 3-6.2 is for GP/Div 2 analyzers. For your system, refer to Final “As Built” drawings in the analyzer Documentation Package.

NOTE

Figure 3-5. Oven/Instrumentation layout (Div 2/Zone 1).


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Installing the Instrument Air Line

The Instrument Air line (by customer) must be 1/4" 316 stainless steel tub-ing with appropriate 1/4" NPT connectors.

The Instrument Air must meet the ANSI/ISA-S7.0.01 (1996) specifications at all times. If it cannot meet these requirements, an inlet filter system must be installed.

The air must be supplied to the analyzer pressure regulator at a pressure in the range of 415–840 KPAG (60–120 PSIG) and a flow rate of 60–120 L/min (1–4 SCFM). These values may vary, depending on the application.

Instrument Air connections between the analyzer and the ASR900 Sample Probe are discussed in the ASR900 Sample Probe “Installation and Maintenance Guide.”

Ducting of Compressor Air The point at which the compressor air enters the supply duct(s) should be situated in a non-hazardous area. The intake ducting to a compressor should not normally pass through a hazardous area. If the compressor intake line passes through a hazardous area, it should be constructed of non-combustible material and protected against mechanical damage and corrosion. Adequate precautions should be taken to ensure that the ducting is free from leaks in case the internal pressure is below that of the exter-nal atmosphere. Additional protective measures (example, combustible gas detectors) should be considered to ensure that the ducting is free of flammable concentrations of gas or vapour.

To install the Instrument Air line:

1. Route the line from the Instrument Air supply to the analyzer.

2. Purge the line to remove any liquids or particulate in it before con-necting it to the analyzer.

NOTE

!WARNING


3. Connect the line to the analyzer. The plumbing for the purge systems and the Aspirator drive air feed through the analyzer Manifold is already made by AMETEK.

Non-Shelter Installations: Connect the line to the Instrument Air inlet fitting on the analyzer.

Shelter Installations: Connect the line to the “Inst Air” port on the side of the shelter.

4. Connect the line to the Instrument Air supply.

Installing the Span Gas Line

The Span gas line (by customer) must be 1/4" 316 stainless steel tubing.

To install the Span gas line:

1. Route the line from the Span gas supply to the analyzer.

2. Purge the line to remove any liquids or particulate that may be pres-ent in it before connecting it to the analyzer.

3. Connect the line to the Span gas fitting on the Manifold block and to the Span gas supply.


Connecting I/O Signals, Alarm Relay Contacts, and AC Power

The analog input/output signals, alarm relay contacts, and AC power requirements are specific to each analyzer installation.

Purged Analyzer (Hazardous Location) Applications M25 x 1.5, 6H cable entries are provided for Power (1 entry) and Signals (2 entries). See the Model 9xx-Series Analyzer Type 200 Disconnect Enclosure Details drawing in Appendix A for cable entry locations. In all cases, all unused cable entry ports must be plugged with a certified Ex d plug. For Division 1/Zone 1 Installations, all cable entry glands (one power cable entry and two signal cable entries) into the flameproof Disconnect Enclosure must be Ex d certified. Conduit or cable seals that comply with the flameproof enclosure cable entry sealing require-ments of the local authority must be installed at the entries to the disconnect enclosure.” For Division 2/Zone 2 Installations that do not use the Disconnect Enclosure, use a suitable cable entry device with a sealing ring that meets the local requirements for entries into pressurized enclosures.

Purged Analyzer (Hazardous Location) Applications Take extreme care to avoid damaging the threads on the cable entry glands on the Disconnect Enclosure. Clean, defect-free threads are es-sential to ensure a flameproof connection.

All electrical connections, materials, and methods (plus all safety poli-cies and procedures) must be made in compliance with local wiring regulations and electrical code for the hazardous area, and be approved by the Owner Company.

Refer to “Electromagnetic Compatibility (EMC)” near the beginning of this manual for information about the EMC Directive regarding techniques and wiring practices to be followed. To maintain EMC compliance in European installations, AMETEK recommends using metallic glands and shielded cable (at least 85 % coverage) for both power and signal cable connections.

!WARNING

!CAUTION

!CAUTION

NOTE


Termination points for the Remote Calibration/Remote Backpurge input signal, analog output signals, alarm relay contacts, and AC power will vary, depending on whether the analyzer is mounted only on a backpan or in a shelter, or if it is for use in a General Purpose or Hazardous Area.

Purged Analyzer (Hazardous Location) Applications Install and connect a power-disconnect switch (breaker), rated for at least 250 VAC, 3 A and certified for the hazardous location (to satisfy local electrical codes, the switch must be certified by the local author-ity for the appropriate hazardous location). The power-disconnect switch (breaker) must be connected to and mounted near the analyzer, in an easily accessible area. The switch (breaker) must be clearly la-beled (e.g., “AMETEK Model 900 Analyzer Main AC Power Discon-nect Switch”). For safety reasons during maintenance, this switch allows the main AC power to be disconnected from the analyzer prior to performing service on the analyzer. This switch (breaker) is to be supplied by the customer/end user.

Purged Analyzer (Hazardous Location) Applications Use a soft, nonabrasive cloth to gently clean the joining surfaces (flamepath) of the Disconnect Enclosure and its door. Close the door and replace at least (1) M10 screw while completing the installation. This will ensure the flamepath is not inadvertently damaged.

All electrical connections must be made according to local wiring regulations and electrical codes. Refer to Figure 3-7 (Customer Signal Connections) and Figure 3-8 (Analyzer AC Wiring) for termination points. For shelter instal-lations, refer to Final “As-Built” shelter drawings in the analyzer Documentation Package.

!CAUTION

!CAUTION

NOTE


To make the signal, relay contact, and power connections:

1. General Purpose (GP) Analyzers: Open the Electronics Enclosure and open all of the fuses.

Purged Analyzers (Hazardous Locations): Open the Electronics Enclosure and open all of the fuses. Open the explosion-proof power-disconnect switch.

Loosen and remove all but one of the (24) M10 screws from the Disconnect Enclosure door. Keep this screw in place until you are ready to terminate connections inside the Disconnect Enclosure.

2. Terminate the input signals, analog output signal(s), and alarm re-lay contact conductors (see Figure 3-7 and related Final “As-Built” drawings).

GP Analyzers: Route the input signals, analog output signal, and alarm relay contact conductors into the Electronics Enclosure and terminate the wires.

Purged Analyzers: Route the input signals, analog output signal, and alarm relay contact conductors to the Disconnect Enclosure.

Install cable glands on the signal/relay cables as per the manufac-turer’s instructions. Connect the cable glands to the signal/relay cable entries on the Disconnect Enclosure. In all cases, all unused cable entry ports must be plugged with a certified Ex d plug.

Route the input/output signals and alarm relay conductors into the Disconnect Enclosure.

Apply sealing compound in the signal/relay cable glands as per the manufacturer’s instructions.

Terminate the signal/relay connections inside the Disconnect Enclosure.


3. Terminate the AC power conductors (see Figure 3-8 and related Final “As-Built” drawings).

Before making the AC power connections, open the explosion-proof power-disconnect switch to the analyzer, and open all analyzer fuses. Do not apply power to the system until after all of the wiring has been installed, connected, and verified, and only if the purging system is ready for operation.

GP Analyzers: Route the AC power conductors to the Electronics Enclosure and ter-minate the wires.

Purged Analyzers:

The AC electrical supply cable must be approved by the local wiring regulations and electrical codes for the hazardous location, and must be rated for minimum 80 °C (176 °F).

Following local wiring regulations and electrical codes, route the AC power conductors to the Disconnect Enclosure.

Install a cable gland on the power cable as per the manufacturer’s instructions. Connect the cable gland to the power cable entry on the Disconnect Enclosure.

Route the AC power conductors into the Disconnect Enclosure.

Apply sealing compound in the cable gland as per the manufacturer’s instructions.

Terminate the AC power connections inside the Disconnect Enclosure.

4. Plug all unused cable entry ports with certified Ex d plugs (typically M25 x 1.5, 6H).

5. Purged Analyzers only: Using a wire connector, connect an external ground wire between the “Enclosure Common Ground Terminal Strip” on the analyzer backpan (see Figure 3-9) and a location close to the analyzer.

!WARNING

!CAUTION


Figure 3-7. Customer signal connections.

6. Before closing the Disconnect Enclosure door, use a soft, nonabrasive cloth to gently clean its joining surfaces (flamepath) and make sure they are free of debris. After cleaning these surfaces, inspect the flame-path for scratches or other damage.

If no damage is evident, apply a suitable thread lubricant (must not contain copper) to the threads of the (24) screws that secure the door to the Disconnect Enclosure. Close the door and tighten all screws to 9.0 Nm, ±1.0 Nm (80 in-lb, ±9 in-lb).


Figure 3-8. AC Wiring, GP/Div 2/ CE/Zone 1 Analyzers.


Start-Up and Verification

This section describes equipment and controls on the analyzer system that require adjustments and settings before, during, and after power-up.

Figure 3-9 illustrates the locations of analyzer equipment and con-trols that require adjustments for a typical Zone 1 analyzer layout. Refer to Final “As Built” drawings for your system in the analyzer Documentation Package.

NOTE

Figure 3-9. Model 900/930 Zone 1 Analyzer overall component layout.


Purged Analyzers

The Electronics Enclosure and its Optical Bench and Measuring Cell Extension are continuously purged with Instrument Air to adequately dilute any flammable gases that may have been released into these areas. This function effectively prevents an internal explosion when the ana-lyzer is powered up and operating under normal sampling conditions. AMETEK analyzers that require purged enclosures in hazardous locations use an Expo Technologies MiniPurge® System With eTimer to perform this function.

The purge air supply is normally obtained from the Instrument Air supply connected directly to the Expo MiniPurge® System. The required purge air supply pressure for your analyzer is indicated on Final “As-Built” drawings in the analyzer Documentation Package.

After the Instrument Air supply has been connected to the MiniPurge® system, the ALARM/PRESSURIZED indicator on the MiniPurge® system (Figure 3-9) turns from RED (Alarm condition) to GREEN (Pressurized). Next, the system’s eTimer begins its purge timing cycle, and the four PURGE TIMING indicator LEDs will flash (YELLOW) sequentially, each for 25 % of the total purge time (minimum 15 minutes). During this stage, the MiniPurge® system will purge any flammable gases that may have entered the Electronics Enclosure while its door was open, and then pres-surize the enclosure. After the timing sequence is completed (LEDs off), the pneumatic switch will send a signal to the analyzer and the analyzer will power up (if the Purge Bypass Switch is in the “ACTIVE” position, if all fuses have been engaged, and if the external explosion-proof power-disconnect switch has been closed).

A minimum of 15 minutes is required to properly purge and pressur-ize the analyzer Electronics Enclosure. The Expo Technologies MiniPurge® System uses a Battery Pack to power its purge timer. AMETEK recommends replacing the Battery Pack every three years to ensure proper and safe operation of the purging system. See “Analyzer Preventive Maintenance Schedule” in Chapter 6 for more information.

Working with the purged enclosure open is typically limited to installa-tion, start-up, and certain troubleshooting and maintenance procedures. In these cases, the Purge Bypass Switch (Figure 3-10) must be in the “BYPASS” position (and appropriate safety conditions must have been met, as per company policy).

For normal analyzer operation, the Purge Bypass Switch must be in the “ACTIVE” position and the key must be removed (follow company policy).

!WARNING


To ensure safe operating conditions, the analyzer will not power up until the MiniPurge® system has been connected to the instrument air sup-ply (ALARM/PRESSURIZED indicator is GREEN) and has successfully completed its purge timing cycle (the PURGE TIMING/STATUS LEDs are now off) and the enclosure is pressurized.

After powering up the analyzer for the first time, certain checks must be performed with the Electronic Enclosure door open to ensure the ana-lyzer is operating properly. These checks are discussed in the following power-up procedure. If problems are encountered during power-up, refer to “Start-Up Diagnostic Checklist” in this chapter, for help in diagnosing and correcting problems.

Always disconnect main AC power and/or external power sources to the analyzer before opening any covers or doors on the analyzer to check or perform maintenance on any components within the enclo-sures. If it is necessary to open the analyzer’s covers or doors while the circuits are live, test the area for flammable gases (and proceed only when the area is safe). Purged Analyzer (Hazardous Location) Applications To work on the analyzer with it powered up and its Electronics Enclosure door open, the Purge Bypass Switch must be in the “BYPASS” position. When the Electronics Enclosure door is open, take appropriate precau-tions to avoid electrical shock. Hazardous voltages are present inside.

Do not apply power to the analyzer if any of its flamepaths appear to be scratched, dented, or worn. Applying power to an analyzer with a damaged flamepath is dangerous and could result in serious injury or death, and/or serious damage to equipment. See “Examining and Caring for the Flamepaths” in Chapter 5. Replace parts immediately if damage or wear is apparent. Contact AMETEK if there is any doubt about the integrity of any flamepath.

!WARNING

!WARNING

Figure 3-10. Purge Bypass Switch label.

B YPASS A C TIVE


Powering Up the Analyzer

Before operating the analyzer for the first time, following a power-up or reset, or after maintenance, you must manually backpurge the analyzer’s sample system and adjust the sample gas flow rate. If start-up problems occur, refer to “Start-Up Diagnostic Checklist” in this chapter.

For verification and troubleshooting purposes during power up, it will be necessary to work with the analyzer’s covers and doors open. Before powering up the analyzer, test the area for flammable gases. If an explosive gas atmosphere is present, do not apply power to the analyzer or any alternate power sources that supply power to the ana-lyzer components. Proceed only when the area is found to be safe. When the analyzer’s covers and doors are open, take appropriate precautions to avoid electrical shock. Hazardous voltages are present inside.

IMPORTANT Performing analyzer start-up and verification procedures requires working from the User Interface. Familiarize yourself with working from the User Interface before working on the analyzer. See Chapter 4 for details on how to navigate from the User Interface.

To power up the analyzer and verify it is operating properly:

1. With the Electronics Enclosure open:

GP Analyzers: Close the Analyzer fuse to apply AC power to the analyzer.

!WARNING

NOTE

See Fuse Legend inside Electronics Enclosure door.


Purged Analyzers (Hazardous Locations): Insert the key into the Purge Bypass Switch and switch it to the “BYPASS” position (follow company policy).

[Special Conditions for Safe Use] The analyzer may only be energized by using the Purge Bypass Switch with permission of the works manager or his proxy. The per-mission may only be given when it is made sure that during the time the system is energized by using this switch an explosive atmosphere is not present or when the necessary protective measures against explosion hazard have been taken (“hot permit”). The analyzer enclosure may not be opened when an explosive atmo-sphere is present.

Close the Analyzer fuse.

Apply main AC power to the analyzer by closing the explosion-proof power-disconnect switch.

2. Immediately following power-up, the Host Controller board software version number will appear on the top line of the User Interface and the message “Reset in Progress” will appear on the bottom line.

If the “Reset in Progress” message does not appear within approxi-mately 2 seconds, simultaneously press • and Ent.

If the “Reset in Progress” message still does not appear, take all neces-sary safety precautions to power down the analyzer, open all of the fuses for the temperature zone circuitry, and check the AC wiring to ensure it is properly connected.

After powering down the analyzer, wait 5 minutes to allow the high-voltage capacitors in the source-lamp power supply to discharge.

Review the Analyzer (AC) Power Connections drawing(s) and check the wiring terminations from the power supply source to the analyzer.

Take all necessary safety precautions and power up the analyzer (Step 1). Check the User Interface again to see if the message appears. If it does, continue with the next step.

!WARNING

!WARNING


3. Close/replace all of the fuses (or GFIs) that supply power to the ana-lyzer temperature zone circuitry. For the Sample and Vent Line, install their fuses (and close the explosion-proof power-disconnect switch) to apply power to this temperature zone circuit.

When the analyzer system is first powered up, the alarm “w Oven heater temp” may be displayed on the User Interface. This warning will clear when the Analyzer Oven temperature zone is within its normal operating range.

Check the User Interface for indications of other alarms. Alarms are in-

dicated by on the top-right line. View the HStatus (HS) and MStatus (MS) screens to view active Host Controller and Microcontroller board alarm conditions.

4. While observing the electronics within the Electronics Enclosure, check the source lamps to ensure they are on (firing).

Check the LEDs on the Termination board to ensure they are on.

If the lamps are not firing or the LEDs on the Termination board are not on, this can indicate wiring problems.

5. Allow the sample system (except Cell/Oven zone) to warm up to nor-mal operating temperature and stabilize – approximately two hours. (The Sample and Vent Line zones typically warm up quicker than the Cell/Oven zone.)

Meanwhile, perform the following checks to ensure the analyzer temperature zone circuitry is operating properly. Record the value for each zone to compare the values later.

a. View the TStPt (Temperature Zone Set Point) screen and record the Set Point for each temperature zone:

Press To view temperature zone 1 Sample Line 2 Vent Line 3 ASR900 Probe 4 Cell/Oven Line

NOTE


(HS) RUNF5 41..8 (MS) RUNF5 51..7

(TStPt) RUNF4 0 1..4


b. Check and record the current temperature readings. This will help you determine if the signal wiring is properly terminated and if all of the circuitry is operating properly.

To do this, view the MAI screen (Microcontroller Board Analog Inputs) and press keys 1..8 to view the inputs. Pay close attention to the Sample Line (1), Vent Line (2), and Oven (4) temperatures. The lowest temperature you will see for any zone is 7 °C (45 °F). If this temperature does not increase, check the wiring for proper connections. If the display reads “181.4”, it may indicate a shorted RTD for that temperature zone.

6. After approximately two hours (the system should have reached its normal operating temperature), and if all of the alarms have cleared, recheck each temperature zone. Record the value for each zone. Compare them to the values recorded earlier to ensure they have increased.

Compare the current temperatures to their respective Set Point values recorded earlier. Normal operating temperatures are values that are within 5 % of their Set Point values.

7. If all of the temperature zones have reached normal operating tem-peratures and there are still no alarm conditions or other problems, perform a leak check to ensure there are no leaks in the system.

After the leak check passes, return to this procedure and complete the remaining steps.

8. Close the Oven fuse to apply power to its Heater.

Close and secure all covers and doors on the Electronics Enclosure, Analyzer Oven, Disconnect Enclosure (if used), and Sample/Vent Line Termination Box.

Hazardous Locations While the Disconnect Enclosure is open, take extreme care to avoid scratching or damaging the joining surfaces (flamepath). Before closing the door, gently clean these areas with a soft, nonabra-sive cloth and make sure they are free of debris.

!CAUTION

(MAI) RUNF6 81..8

See “Sample System Leak Check” in this chapter.


9. Purged Analyzers Only: Return the Purge Bypass Switch to the “ACTIVE” position and re-move the key (follow company policy).

10. Allow the analyzer to warm up to operating temperature and stabilize (approximately two hours). When the analyzer is at operating tem-perature, open the Vent Valve on the ASR900 Sample Probe and then open its Sample Valve to allow sample gas into the analyzer sample system.

The ASR Sample Probe will be hot. Take precautions to avoid burning yourself.

11. Manually Zero the analyzer.

12. Adjust the Aspirator Drive Air Regulator to achieve normal operating flow rates.

!WARNING

See “Manually Zeroing the Analyzer” in this chapter. See “Setting the Sample Gas Flow Rate and Sample Response Time” in this chapter.


Start-Up Diagnostic Checklist

This checklist describes problems that may be encountered while power-ing up the analyzer and preparing it for normal operation. If the analyzer experiences problems during power-up, review this checklist and perform the corresponding corrective action to fix any problems.

Problem Encountered “Reset in Progress” message does not appear on the User Interface immedi-ately after applying AC power, or after attempting a manual system reset.

Corrective Action Simultaneously press • and Ent. If this message still does not appear, take necessary precautions and check the AC wiring to ensure it is properly connected.

Problem Encountered If is displayed on the User Interface, alarms are active. The character will typically be displayed upon start-up due to low temperatures in the tempera-ture zones.

Corrective Action View the HStatus (HS) and MStatus (MS) screens to determine which alarms are active. See “Host Controller/Microcontroller Board Alarm Conditions and Corrective Action” in Chapter 5.

Problem Encountered One or both source lamps are not firing.

Corrective Action Take appropriate safety precautions and check for proper wiring connections.

If the wiring is okay, check the lamp socket connections. Review “Replacing the Source Lamps” in Chapter 5 to make adjustments to the lamps. Perform an Auto-Setup if necessary to ensure the lamps are operating at peak efficiency.

(HS) RUNF5 41..8 (MS) RUNF5 51..7


Problem Encountered The LEDs on the Termination board are not on.

Corrective Action Take appropriate safety precautions and check for proper I/O wiring connec-tions. Also, press the reset switch (SW300) on the Termination board (inside the Electronics Enclosure, Figure 3-11) to re-energize any tripped circuits.

Problem Encountered Temperature zone values do not increase.

Corrective Action Take appropriate safety precautions and check for proper wiring connections for the corresponding temperature zone wiring.

Problem Encountered Temperature zone value reads “181.4”. This temperature value indicates a faulty RTD for the related temperature zone.

Corrective Action Take appropriate safety precautions and check the RTD for a short or an open circuit. If necessary, replace the RTD with an AMETEK-approved replacement part. Contact AMETEK for assistance.


Figure 3-11. Over-Temp alarm reset switch (SW300), Termination board.


Sample System Leak Check

The analyzer has been checked at the factory for pressure leaks. However, fittings can loosen during transport, and the Sample, Vent, Instrument Air, and Calibration Gas lines are installed on-site. Therefore, the entire sample system should be checked for leaks before any sample gas is intro-duced into the system for the first time or following the replacement of any lines/fittings or Measuring Cell parts.

Hazardous Locations Before proceeding, test the area around the analyzer for hazardous gases and proceed only when the area is found to be safe.

Preventing leaks in the sample system is critical to ensure proper analyzer operation. If sample gas migrates into the Optical Bench Assembly or Reflector Block due to a leak in the Measuring Cell, the optics will become damaged and most likely require replacement. Most leaks are preventable with the regular replacement of the Measuring Cell o-rings.

To leak check the sample system:

1. With the analyzer powered up, open the Aspirator Drive Air Regulator to allow instrument air into the sample system.

2. Close the Sample and Vent isolation valves on the ASR900 Sample Probe.

3. Use the Aspirator Drive Air Regulator (Figure 3-5) to increase the in-strument air pressure to 70 KPAG (10 PSIG).

To avoid damaging the pressure transducer, do not set the pressure higher than 105 KPAG (15 PSIG).

4. View the CellP (Measuring Cell Pressure) screen and record the nu-meric value displayed. This value is the absolute pressure reading in mmHg (or "Hg).

!CAUTION

!CAUTION

(CellP) RUNF6 8 6

!WARNING


5. Block in the instrument air by closing the Drive Air Isolation Valve and observe the pressure reading. Allow the pressure within the sample system and Measuring Cell to equilibrate (approximately 5 minutes) before taking the initial reading. Meanwhile, continue to observe the CellP reading. If the reading drops less than 10 mmHg (0.39 "Hg) in 4–5 minutes, the system is sufficiently leak-tight.

However, if the reading steadily decreases, there is a leak somewhere in the system.

6. If there is a leak, use a suitable detergent-based leak detection fluid (e.g. Snoop®) to leak check all of the other fittings except those that are hot, such as those on the Measuring Cell. To test the zones that are hot, observe the CellP reading and check for steady or decreasing values.

Do not use a leak detection fluid on hot fittings. If the analyzer system is at operating temperature, the temperature zone circuitry fuses must be opened to allow the temperature zones to cool down before using a leak detection fluid on the fittings.

If the Measuring Cell is suspect, check all fittings to ensure they are tight and repeat the procedures of testing/repairing/testing until all leaks have been eliminated.

7. After the analyzer has passed the pressure leak test, open the Vent Valve and then the Sample Valve on the ASR900 Sample Probe.

The procedure is complete and the analyzer is ready to analyze sample gas.

!CAUTION


Manually Zeroing the Analyzer

A Manual Zero forces the analyzer to purge the sample system with Zero gas which removes any residual contaminants in the sample system. This mode is also used to set the timers to control the Auto-Zero. While a manual Zero is in progress, the RUN mode screen will display “B” on the top-left line to indicate that the analyzer has been manually forced to Continuous Backpurge/Zero Flow mode.

All temperature zones must be at their operating Set Points before performing a Manual Zero. If necessary, view MAI screen and check the temperature zones to ensure that all zones are at their operating temperatures.

This procedure assumes Instrument Air is used as the Zero gas.

Pressing Esc at any time during this procedure will abort the proce-dure and return to CAL mode to normal display.

To manually Zero the analyzer:

1. Ensure that the Zero gas cylinder is turned on.

2. Before changing the Flow Control mode, record the current numeric value (should be “0” – Analyzer Control mode). Change the Flow Control mode to “1” (Continuous Backpurge/Zero Flow).

3. From CAL mode initiate the Manual Zero. The User Interface will prompt “Man/Zero?”. Observe the readings on the bottom line. When the readings have stabilized at or near zero, press:

Ent for Yes The IntTime duration will count down from 15 seconds (default if IntTime is ‘0’) to zero during which time the readings are averaged if AdjDisable is set to ‘0’. The Zero values will be adjusted automatically and the screen will revert to CAL mode normal display.

Esc for No The function is aborted and the Zero values are not adjusted.

Run the Manual Zero for 10 minutes at a flow rate of 2.5 L/min (0.08 SCFM). See “Setting the Zero Gas Flow Rate” in this chapter.

If the User Interface displays a “w Zero Drift” alarm message, restart the Manual Zero (enter F2 0 Ent).

NOTE

(FlowCtrl) CALF5 0 Del 1 Ent Ent

(Man/Zero?) CALF2 0

(MAI) RUNF6 81..8


4. Record the analyzer’s initial Measure and Reference PMT signal read-ings. See “Recording Initial Readings” in this chapter.

5. Change the Flow Control mode back to “0” (Analyzer Control).

6. Return to RUN mode.

7. Turn off the Zero gas.

The Zero is complete and the analyzer is now on-line.

Setting the Zero Gas Flow Rate

When the flow control solenoid is in a de-energized state, instrument air flows into the sample path via a flow controlling rotameter and a Manifold. The Zero gas flow rate must be high enough to adequately purge the Measuring Cell of sample gas to obtain a “good zero.” A good zero can be defined as a state where the concentration outputs of the ana-lyzer are stable and further increases in Zero gas flow rate do not reduce the concentrations observed on the analyzer User Interface. A nominal flow rate of 5–10 SCFH should be sufficient for this purpose.

Set the response time first to ensure a good zero. Some applications may require a higher flow rate.

Setting the Sample Gas Flow Rate and Sample Response Time

The Aspirator Drive Air Regulator is used to control the sample flow through the system. A typical sample flow rate is in the range of 3.0–5.0 L/minute (0.1–0.2 SCFM) and can be achieved by adjusting the Aspirator Pressure Gauge to approximately 10 PSI above the sample stream pressure.

To avoid damaging the pressure transducer, do not set the pressure higher than 105 KPAG (15 PSIG).

The sample response time may vary, depending on Sample Line length.

!CAUTION

NOTE


NOTE


Normal Operation

After the analyzer has been set up and started, the User Interface defaults to RUN mode. During normal operation in RUN mode, the top line dis-plays the output parameter names, while their corresponding values are displayed on the bottom line.

Before engaging the analyzer into normal sampling operation, it is important to observe and record initial readings of the PMT (pho-tomultiplier tube) signals and the sample response time when the analyzer sample system is new and operating at peak efficiency. It is important to understand what normal operating conditions are, and how to use this information to help you diagnose problems with the analyzer.

Recording Initial Readings

AMETEK recommends that you observe and record this information monthly to obtain a history. From these recordings, you will be able to determine if there are problems with the analyzer, such as diminishing PMT signals, or increasing sample response time. These problems typi-cally indicate maintenance is required.

Keep the log book in a safe location until you need to review it for pat-terns of diminishing PMT signals or a longer sample response time.

Recording PMT Signals

To check and record the initial PMT signal readings:


2. While the Zero is in progress, view the Show Signals screen and record the values for the Measure PMT (left side) and Reference PMT (right side) signals for each filter.

Press ‘1’ to view the signals for Filter 1, ‘2’ for Filter 2, etc.

NOTE

(Show Signals) RUN F6 11..6

See “Manually Zeroing the Analyzer” in this chapter.


3. Record these signals in a log book every month.

It is important to record these values during a Manual Zero to simulate the same conditions as during the original recordings. If the values are recorded using the sample gas, the results may be skewed because the composition of the gas can vary. All signals should return to within 5 % of the values recorded the previous month.

Recording Initial Sample Response Time

The analyzer’s sample response time can be used for two functions:

• To help you set the sample gas flow rate.

• To help you determine if the typical response time is increasing, which can indicate a plug in the sample system.

Typically, a good response time is approximately 30 seconds when the sample system is clean and operating at peak efficiency (may vary due to Sample Line length).

To check and record the initial sample response time:


2. After the Zero is complete, view the RUN mode normal display and observe the output concentration changes. Observe and record the time it takes the analyzer to display the first reading after the analyzer’s Flow Control setting is switched from “1” (Continuous Backpurge/Zero Flow) to “0” (Analyzer Control).

It is important to record the response time only after performing a Manual Zero to simulate the same conditions during the original recordings.

3. If the sample response time is adequate (first reading after a Zero and after changing the Flow Control mode from “1” to “0” is approximate-ly 30 seconds), no further adjustment is necessary.

The sample response time may vary, depending on Sample Line length.

4. Record these signals in a log book every month.

NOTE

NOTE

NOTE

See “Manually Zeroing the Analyzer” in this chapter.


Analyzer Configuration

EEPROM Data Sheets and Analyzer Programming Parameters, which list the factory-default configuration settings of all programmable parameters, are located in the analyzer Documentation Package.

If any changes are made to the original configuration, be sure to record the changes for later reference. If the EEPROM is replaced, this data must be re-entered to override the factory defaults.

If necessary, refer to the original EEPROM Data Sheets when changing the analyzer settings back to their original values.

Controller / User Interface | 4-1

CONTROLLER / USER INTERFACE

This chapter contains information about the following topics:

• An introduction to the User Interface.

• How to work from the User Interface and navigate through the vari-ous screens.

• How to view analyzer data, configure analyzer settings, and perform analyzer functions.

• Descriptions of each keystroke command and the information on the various screens.

IMPORTANT Before working from the User Interface, read the entire section titled “Introduction to the User Interface” to learn how to navigate through the screens to work on the analyzer.

NOTE


Introduction to the User Interface

Figure 4-1 illustrates the layout of the analyzer User Interface.

User Interface Components

The User Interface is made up of two areas:

• Display area Consists of two lines, each capable of displaying up to 20 alphanumer-ic characters. The information displayed depends on the current op-eration mode. Messages and other information displayed is discussed in “Messages/Information Displayed on the User Interface.”

- The top line displays the current mode of operation, or a prompt for further keypad input.

During normal operating conditions in RUN mode, the top line displays the names of the outputs. When operating in CALibration or ConFiGuration mode, the mode of operation (CAL or CFG) is also displayed.

- The bottom line displays the results of the outputs.

During normal operating conditions in RUN mode, the bottom line continually displays the value of each output parameter being monitored/controlled by the analyzer.

Depending on the operation mode or the command entered, other information can also be displayed on the bottom line.

Figure 4-1. User Interface layout.


• Keypad The 21-key keypad allows you to view and/or change information from the three main operation modes. The display is updated once per second; therefore, the display of the result of a command may be delayed for up to one second. The keypad consists of the following keys:

Key Description

• Use the decimal (‘•’) key to enter a decimal character, as part of a command (used with a Function key), or as part of a password.

– Use the minus (‘–’) key to enter a negative number, as part of a command (used with a Function key), or as part of a password.

0–9 Use the numeric keys 0–9 to enter numerical data, as part of a command (used with a Function key), or as part of a password.

F1, F2, F3,F4, F5, F6 Use the Function keys (with ‘•’, ‘–’, and numeric keys 0–9) to access the

various operation modes and screens where you can view or change data and operating parameters.

Esc Press the Escape key to discard any changes you make to operating parameters, but only before they have been saved. Also, press Esc to answer ‘No’ to a prompt on the screen (whenever ‘?’ appears following information), and to back out of certain menus.

Del Press the Delete key to delete an existing value from memory when you are changing an operating parameter.

Ent Press the Enter key to save any changes you make to operating parameters. Also, press Ent to answer ‘Yes’ to a prompt on the screen (whenever ‘?’ appears following information).

Example keystroke commands can be seen in “Navigation Examples” in this section.


Messages/Information Displayed on the User Interface

Character / Message Description

“m” or “M” When the analyzer switches the Auto/Manual relay to Manual mode, a lower case “m” is displayed in the top-left line of the RUN mode screen.

When the operator switches the Auto/Manual relay to Manual mode (by pressing F2 • Ent), an upper case “M” is displayed.

If the analyzer detects an alarm by the built-in diagnostics system, this character is displayed on the top-right line. To determine which alarms are active, view the HStatus (HS) and MStatus (MS) screens. For detailed information about alarms, refer to “Troubleshooting and Diagnostics” in Chapter 5.

“NoData” or “CommFault” These serious system alarms are the only two alarm messages that are automatically displayed on the bottom line when they are detected. When viewed from the HStatus screen, these alarms are displayed as “f Analytical data” and “f Internal communication”.

For additional characters that indicate Flow Control modes (automatic and manual control), see “Flow Control (Sample) Modes” in this chapter.

(HS) RUNF5 41..8

(HS) RUNF5 41..8 (MS) RUNF5 51..7


Navigating From the User Interface

While working from the User Interface, there are three modes of opera-tion that you can access. In RUN mode, parameters or variables can only be viewed (they cannot be changed). In CAL or CFG mode, parameters or variables can be changed (passwords are required to enter these modes).

While working from the User Interface, the following rules apply:

• Navigate to the various screens by pressing the corresponding com-mands (refer to “Quick Reference Sheets – Keystroke Commands” for all commands).

• Function commands with a range [e.g., HS (1..8)] indicate you can view or change more than one parameter from that menu, without having to re-enter the entire command each time.

For example, press F5 4 to view the Host Controller Status (HS) menu and press any numeric key (‘1’ through ‘8’) to view the status of a specific alarm, then press another numeric key to view the status of another alarm, etc.

• When the analyzer is first powered up, the User Interface defaults to RUN mode (also known as “RUN mode normal display”). From this mode, you can view analyzer system data, temperature Set Points, current operating values, or alarms (current or historical).

• To return to “RUN mode normal display” from anywhere in the soft-ware, repeatedly press Esc until the RUN mode is returned.

• From RUN / CFG mode, press F6 0 to return to “normal display” for that mode.

• To view screens in CAL or CFG mode, a password is required. See “Entering Passwords to Change Analyzer Parameter Settings” in this section.

• RUN and CFG modes are almost identical; the major difference is that in CFG mode, you can make changes to certain information.

• Pressing Ent after making any changes (in CFG or CAL mode) will cause the configuration data to be saved in non-volatile memory – the old values will be lost.

If the changes are not saved, the previous configuration data will be used following a system reset or power-up.


Working in RUN Mode

While working in RUN mode, the following rules apply:

• RUN is the default and normal operating mode. No password is re-quired to work from RUN mode.

• Data can only be viewed; it cannot be changed.

• When entering commands, the User Interface will return to RUN mode normal display: - If you press a Function key that is not valid for your system. - If you press a numeric key that is not valid for your system. - If a command is not completed within 10 seconds.

• To return to RUN mode normal display from any menu in RUN mode, press F6 0.

Working in CFG Mode

Access to the CFG mode should be restricted to trained technicians. The settings for your analyzer have been configured at the fac-tory to meet specified customer requirements. Changing the factory-set configuration could cause the analyzer to operate incorrectly. Do not change any functions that are not discussed in this section without express written consent from AMETEK.

While working in CFG mode, the following rules apply:

• A password must be entered (from RUN mode) to enter CFG mode.

• In “CFG mode normal display” “CFG” will be displayed on the top line, along with all information associated with this mode. The output results from RUN mode will continue to be displayed on the bottom line.

• While in CFG mode, the Cal Status Relay is turned On.

• Operation constants and configuration data that can be seen in RUN mode, can be entered or changed in CFG mode.

• The two factory-default passwords (for CAL and CFG modes) can be changed in CFG mode.

!CAUTION


• To return to CFG mode normal display from any menu in CFG mode, press F6 0.

• When entering commands, the User Interface will return to CFG mode normal display: - If you press a Function key that is not valid for your system. - If you press a numeric key that is not valid for your system.

• To return to RUN mode, press Esc. If any changes have been made to the CFG mode settings, the message “SAVE CONFIG?” appears. Press Ent to answer “Yes” and then press Esc again to return to RUN mode. Or, press Esc to answer “No”. If no changes have been made, the software will return immediately to the RUN mode.

Working in CAL Mode

While working in CAL mode, the following rules apply:

• A password must be entered (from RUN mode) to enter CAL mode.

• In “CAL mode normal display” “CAL” will be displayed on the top line, along with all functions or results associated with this mode. The output results from RUN mode will continue to be displayed on the bottom line.

• When entering commands, the User Interface will return to CAL mode normal display: - If you press a Function key that is not valid for your system. - If you press a numeric key that is not valid for your system.

IMPORTANT Pressing Ent after making any changes (while working in the CFG or CAL mode) will cause the configuration data to be saved in non-volatile memory – the old values will be lost. If the configuration data are not saved, the previous configuration data will be used following a system reset or power-up.

NOTE


Navigation Examples

• Navigating in RUN mode (example):

To view one of the menus in RUN mode:

1. From RUN mode, enter the command for the screen you wish to view.

Example: To view the temperatures of each of the analyzer’s temperature zones, press F6 8. The Show MAI screen will be displayed, and will default to the first temperature zone, ‘s/lT1’ (Sample Line).

To view other temperature zones, press the other numerical keys 2..8. You do not have to press F6 8 again.

2. To view a different RUN mode screen, enter the command for that screen. If the new screen has sub-menus, press one of the numeric keys to view other data.

• Navigating in CFG mode (example):

To change the existing temperature Set Point value for the Analyzer Oven temperature zone:

1. From RUN mode, press F6 –. The message “PSWD1” appears.

2. Press • • (factory default password) or enter the new password, if changed. An “*” is displayed for each character entered.

3. Press Ent to view the CFG mode screen. “CFG” will be displayed on the top line, while the output results from RUN mode will con-tinue to be displayed on the bottom line. This is the CFG mode normal display.

4. Press F4 0 to display the TStPt (Temperature Set Point) screen. This menu defaults to parameter ‘1’ (Sample Line Set Point tempera-ture). Press ‘4’ to display the Oven Set Point temperature.

5. Press Del to delete the existing value (default = 155.00 °C), and then enter the new value (for example, ‘153.00’) at the “TStPt4?” prompt.

6. To save the change, press Ent and then Esc to back out of this menu. At the “Save ConFig?” prompt, press Ent again to confirm the change.

To discard the changes, press Esc.


• Navigating in CAL mode (example):

To manually change the analyzer’s Flow Control mode to Continuous Backpurge/Zero Flow:

1. From RUN mode, press F6 •. The message “PSWD0” appears.

2. Press • • (factory default password) or enter the new password, if changed. An “*” is displayed for each character entered.

3. Press Ent to view the CAL mode screen. “CAL” will be displayed on the top line, while the output results from RUN mode will continue to be displayed on the bottom line. This is the CAL mode normal display.

4. Press F5 0 to display the FlowCtrl (Flow Control mode) screen. When you enter this screen, the current setting is displayed (e.g., ‘0’ – Analyzer Control mode).

5. Press Del to delete the current setting.

6. Press ‘1’ to change the setting to Continuous Backpurge/Zero Flow mode.

7. Press Ent to save the setting.

8. Press Esc to return to RUN mode. The screen will display “B” on the top-left line to indicate that the analyzer has been manually forced to Continuous Backpurge/Zero Flow mode.


Entering Passwords to Change Analyzer Parameter Settings

To make changes to parameters in CFG or CAL mode, a password must first be entered. The passwords to enter and work in either mode must be entered from RUN mode only. Access to CFG mode should be limited only to trained technicians.

The factory-default password is • • for both modes, but it can be changed for each mode. If changing a password, it is limited to 9 characters and can only be changed from CFG mode. If you change the password for each mode, be sure to record and keep them in a safe place.

If you enter the password incorrectly, the message “<INVALID>” is dis-played on the User Interface. Carefully re-enter the password.

Changing the Password for CFG / CAL Mode

If changing passwords, pressing Ent will cause the passwords to be saved in non-volatile memory – the old passwords will be lost. If the passwords are not saved, the previous passwords will be used follow-ing a system reset or power-up.

To change the CFG or CAL mode passwords:

1. From RUN mode, press F6 – • • and press Ent to display the CFG mode screen.

If changing the password for CFG mode, press F6 – (the command to change the CFG mode password). The message “PSWD1?” appears.

If changing the password for CAL mode, press F6 • (the command to change the CAL mode password). The message “PSWD0?” appears.

2. Enter a new password (up to 9 characters). The Function keys cannot be used as part of a password.

3. Press Ent. The new password is entered and the message “PSWD1?” (CFG mode) or “PSWD0?” (CAL mode) appears again.

4. Enter the new password a second time and press Ent. Press Ent again to return to CFG mode normal display.

If this password does not match the first entry of the new password, the message “<UNCHANGED>” is displayed.

NOTE


5. Press Esc. The User Interface will prompt you to accept the changes (“Save Config ?”).

If Yes, press Ent to accept the new password. The display will exit the CFG mode and return to RUN mode.

If No, press Esc to discard the changes. The display will exit the CFG mode and return to RUN mode.

RUN / CFG Mode Quick Reference Sheets – Keystroke Commands

The RUN and ConFiGuration (CFG) modes contain nearly identical in-formation, with a few exceptions. The RUN / CFG Mode Quick Reference Sheets – Figure 4-2.1 (Standard Software version) and Figure 4-2.2 (COS/CS2 Software version) – list all available commands that allow you to view screens and perform various tasks from these modes. For detailed descrip-tions of each command and working from each screen, see “Working in the RUN / CFG Operating Modes” in this chapter.

In Figures 4-2.1 and 4-2.2, the differences between RUN and CFG modes are denoted by “(RUN)” and “(CFG)” under the Function key headings. The specific function (Term) for each mode is listed under “(RUN)” and “(CFG)”. If “(RUN)” and “(CFG)” are absent, the func-tion is the same for both modes. “–” indicates the command is not used.

See F5 1 (HC Ver) and F5 2 (MC Ver) descriptions under “RUN / CFG Mode – F5 Commands.”

NOTE


RUN / CFG Mode – Standard Software Version

Key F1 F2 F3 F4 F5 F6

• (RUN) (CFG) — Auto-Setup

auto\man toggle Trend Type MB Addr HCHist

(1..9) (RUN) (CFG) PSWD0 PSWD0? (CAL) (CAL)

– — — — Com Para (1..3)

MSHist (1..9)

(RUN) (CFG) PSWD1 PSWD1? (CFG) (CFG)

0 KFtr Cell Compen (1..4)

TStPt (1..4) SN Normal Display

(RUN/CFG)

1 Ftr (1..6) Bench Matrix Row 1

(1..6)Kp

(1..4) HC Ver Sig (1..6)

2 LmpB (1..2) Samples Matrix Row 2

(1..6)Ti

(1..4) MC Ver TR (Show Trn) (1..6)

3 LmpMax Delay Matrix Row 3 (1..6)

Td (1..4) R Time Show Res

(1..8)

4 PmtLvl RPMAvg Matrix Row 4 (1..6)

TType (1..4)

HS (1..8) —

5 PmtBal T90 Matrix Row 5 (1..6)

TDuty (1..8)

MS (1..7) —

6 SigMax Output (1..4)

Matrix Row 6 (1..6)

AbsOV (1..6) RPM —

7 PrbTPara (1..6) Alc Cvect1

(1..8) TCold MDI —

8 — AlcG (1..6)

Cvect 2 (1..2)

CPRg (1..2)

LmpP (1..6)

Show MAIn (1..8)

9 Units SetPt (1..6) Avg (1..4) AI:MSR

(1..2)TCycle (1..6) —

Figure 4-2.1. RUN / CFG mode quick reference sheet (Standard Software version).


RUN / CFG Mode – COS/CS2 Software Version

Key F1 F2 F3 F4 F5 F6

• (RUN) (CFG) — Auto-Setup

auto\man toggle Trend Type MB Addr HCHist

(1..9) (RUN) (CFG) PSWD0 PSWD0? (CAL) (CAL)

– — — — Com Para (1..3)

MSHist (1..9)

(RUN) (CFG) PSWD1 PSWD1? (CFG) (CFG)

0 KFtr Cell Compen (1..4)

TStPt (1..4) SN Normal Display

(RUN/CFG)

1 Ftr (1..6) Bench Matrix Row 1

(1..6)Kp

(1..4) HC Ver Sig (1..6)

2 LmpB (1..2) Samples Matrix Row 2

(1..6)Ti

(1..4) MC Ver TR (Show Trn) (1..6)

3 LmpMax Delay Matrix Row 3 (1..6)

Td (1..4) R Time Show Res

(1..8)

4 PmtLvl RPMAvg Matrix Row 4 (1..6)

TType (1..4)

HS (1..8) —

5 PmtBal T90 Matrix Row 5 (1..6)

TDuty (1..8)

MS (1..7) —

6 SigMax Output (1..4)

Matrix Row 6 (1..6)

AbsOV (1..6) RPM —

7 PrbTPara (1..6) Alc Cvect1

(1..9) TCold MDI —

8 — AlcG (1..6)

Cvect 2 (1..4)

CPRg (1..2)

LmpP (1..6)

Show MAIn (1..8)

9 Units SetPt (1..6) Avg (1..4) AI:MSR

(1..2)TCycle (1..6) —

Figure 4-2.2. RUN / CFG mode quick reference sheet (COS/CS2 software version).


CAL Mode Quick Reference Sheets – Keystroke Commands

The CALibration (CAL) mode allows you to enter the variables required to tailor the analyzer for a specific application and to calibrate the analyzer. The CAL Mode Quick Reference Sheets – Figure 4-3.1 (Standard Software version) and Figure 4-3.2 (COS/CS2 Software version) – list all available commands that allow you to view screens and perform various tasks from this mode. For information about each command and working from each screen, see “Working in the CAL Operating Mode” in this chapter.

“–” indicates the command is not used.

CAL Mode – Standard Software Version

Key F1 F2 F3 F4 F5 F6• — — — — — —– — — — — — —

0 Auto/Zero? Man/Zero? Timer0 — FlowCtrl Izero (1..4)

1 — Man/Span1? — Conc1 [SO2]

Scale (1..4)

Ispan (1..4)

2 — Man/Span2? — Conc2 [H2S] — —

3 — SO2 Xtalk — — — —4 — — — — CS2 Dynamic [Sv]

5 — — — — CS2 Hist (1..9) [COS]

6 — — IntTime — To (1..6) [CS2]

7 — — SDelay — SFactor (1..2) OpRatio

8 — — AZInt TH [SO2] Temp OpOffSet9 — — — TH [H2S] Pres ADFactor

NOTE

Figure 4-3.1. CAL mode quick reference sheet (Standard Software version).

See F5 1 (HC Ver) and F5 2 (MC Ver) descriptions under “RUN / CFG Mode – F5 Commands” in this chapter.


CAL Mode – COS/CS2 Software Version

Key F1 F2 F3 F4 F5 F6• — — — — — —– — — — — — —

0 Auto/Zero? Man/Zero? Timer0 — FlowCtrl Izero (1..4)

1 — Man/Span1? — Conc1 [SO2]

Scale (1..4)

Ispan (1..4)

2 — Man/Span2? — Conc2 [H2S] — —

3 — — — — — —4 — — — — — [Sv]5 — — — — — [COS]

6 — — IntTime — To (1..6) [CS2]

7 — — SDelay — SFactor (1..2) OpRatio

8 — — AZInt TH [SO2] Temp OpOffSet

9 — — — TH [H2S] Pres ADFactor

Figure 4-3.2. CAL mode quick reference sheet (COS/CS2 Software version).


Working in the RUN / CFG Operating Modes

The RUN and ConFiGuration (CFG) mode parameters listed in the fol-lowing pages are identified by the command (Keystroke) used to view the main screen, the abbreviated name (Term) of the screen, and a Definition of each parameter.

The RUN and CFG modes contain nearly identical information, with a few exceptions. The differences between these modes are denoted by “(RUN)” and “(CFG)” under “Keystroke,” while their specific functions are listed under “Term,” followed by their “Definition”. If “(RUN)” and “(CFG)” are absent, the function is the same for both modes. “–” indicates the command is not used.

Definitions preceded by ‘**’ are used primarily for diagnosing prob-lems with the analyzer; therefore, these functions do not need to be accessed frequently.

The information in the following pages includes descriptions of all pa-rameters for the Standard Software and COS/CS2 Software versions. The information is generally the same for both versions, with differences denoted by “applications with COS/CS2 Software version only” or “ap-plications with Standard Software version only”.

Factory-default values (if applicable) are listed for each parameter. Consult with AMETEK before changing any factory-default values.

NOTE

RUN mode allows you to view information only. To change information (CFG mode), a password is required.

See F5 1 (HC Ver) and F5 2 (MC Ver) descriptions.


RUN / CFG Mode – F1 Commands

Note the differences for the F1 • command in RUN and CFG modes. The Auto-Setup is not used in RUN mode.

Keystroke Term Definition

F1 • (RUN) — —

F1 • (CFG) Auto-Setup The Auto-Setup optimizes PMT gains and the source lamp currents. Always initiate an Auto-Setup after any lamps, optical filters, or PMTs have been installed or replaced. For complete details about Auto-Setup and results, refer to the Auto-Setup information in Chapter 5. This function is available in CFG mode only.

F1 – — —

F1 0 KFtrz ** Position of the key filter which gives the weakest signal for a given source lamp current, where ‘z’ (1..2) is the filter being used. 1 = Measure Filter 1 2 = Reference Filter 2

F1 1 Ftrz ** The default source lamp pulse current-control signal (V) for each filter, where ‘z’ = 1..6. The normal operating range is between 0.5 V and Lamp Max (LampMax typical range is 4.5–7.8 VDC – may vary, check EEPROM Data Sheets for actual value), with the control signal for the key filter being Lamp Max. If the Ftr value is negative, the filter position is not used. 1 = Filter 1 4 = Filter 4 2 = Filter 2 5 = Filter 5 3 = Filter 3 6 = Filter 6

Note: Thefilterpositionsassignedtoeachlampwillchange,dependingonthespeciesbeingmeasured,thelamptypes,andtheapplication.Forthefiltersequencefor your application, view the Bench Type code (press F2 1 in RUN mode) and then refer to the Bench descriptions (see “F2 1” under “RUN/CFG Mode – F2 Commands” in this chapter).

F1 2 LmpBz ** The base-current Set Point (V) for each source lamp, which is the minimum operating current, where ‘z’ = 1..2. 1 = Lamp 1 (closest to the Measuring Cell) 2 = Lamp 2 (farthest from the Measuring Cell)

F1 3 LmpMax ** Voltage to which the lamp pulse current-control signal for the key filter location is set during Auto-Setup. To ensure a PMT Level of 7.2–7.4 VDC after an Auto-Setup, the Lamp Max typical range is 4.5–7.8 VDC.

F1 4 PmtLvl ** The photomultiplier tube (PMT) gain control signal (V), which is based on the signal from the PMT when the key filter is in the light path. Normal values after a successful Auto-Setup are from 7.2–7.4 VDC. If the PMT Level is not in this range, adjust the Lamp Max and start another Auto-Setup.

F1 5 PmtBal ** A secondary PMT control signal (V) which adjusts the PMT gain to equalize the PMT sig-nals when the filters with the lowest and highest transmittances are in the light path. Normal values after a successful Auto-Setup are from 4.0–7.0 VDC.

F1 6 SigMax ** The signal from the PMT with the highest gain is set to SigMax when each filter is in the light path while the Auto-Setup is in progress. SigMax should be 8.0–9.0 V (check EEPROM Data Sheets for actual value).

NOTE


F1 7 PrbTParaz Temperature zone parameters for the ASR900 Sample Probe, where ‘z’ = 1..6. The param-eters and their default values are: 1 = Set Point (default = 130 °C) 2 = Proportional Band (default = 5 %) 3 = Integral time (default = 500 seconds) 4 = Derivative time (default = 0) 5 = Duty cycle default (default = 30 %) 6 = Duty cycle maximum (default = 100 %)

F1 8 — —

F1 9 Units Units of measurement used for displaying concentrations, temperatures, and pressures: The value is the sum of five bits: Bit 0 Value Definition 1 0 = Metric Units 1 = Imperial Units Bits 2,1 Value Definition 2,4* 0 = Normal concentration result (PPM). 2 = Normal concentration result (%). 4 = Finer (Low) concentration result (PPM). 6 = Coarse (High) concentration result (%). *Sum of Bits 1 and 2 decimal value Bit 3 Value Definition 8 0 = Display 4 items. 8 = Display 3 items. Bit 4 Value Definition 16 0 = Remote Auto-CAL 16 = Remote Backpurge/Zero Flow For example, if the analyzer is configured for Metric units, Coarse (High) concentration result in percent (%), Display 3 items, Remote Auto-CAL, the result would be: Bit 0 + Bits 2,1 + Bit 3 + Bit 4 [0 + 6 + 8 + 0 = 14]. The unit for input and output parameters (Metric or Imperial) is set at the factory, and should not be changed (i.e., do not change from a Metric unit to an Imperial unit). If a change is required, consult with AMETEK. You can, however, change the concentration units freely back and forth between PPM and mole percent (e.g., from Units = 0 to Units = 2, or from Units = 1 to Units = 3, or vice versa).




F2 • A/M ** Changes the state of the Auto/Manual relay contacts each time the function is executed unless there is an active Fault alarm. The fault must be cleared before the relay contacts can be switched. Note that only “A” (Auto) or “M” (Manual) is displayed, depending on the current state of the relay.

F2 – — —

F2 0 Cell ** Axial length of the Measuring Cell gas space (cm).

F2 1 Benchn ** The Bench Type code, where ‘n’ = the current Bench Code value, defines which PMT is designated as Measure and Reference, the number of temperature zones, and the filter positions assigned to each source lamp.

Standard Bench Type Code

Code b4 (16) b3 (8) b2 (4) b1 (2) b0 (1)

4 0 0 1 0 0

The value in (brackets) beside each bit number is its decimal weighting.

Note: The Standard Bench Type Code lists the default code for the analyzer. Depending on the species being measured, the lamp types, and the application, this code will change. For the Bench Type Code for your application, view the Bench screen (press F2 1 in RUN mode). Do not change the value without direction from AMETEK.

Bench Orientation (b0)

b0 Measure Reference

0 PMT1 PMT2

1 PMT2 PMT1


Temperature Zones (b2, b1)

b2 b1 Number of zones Zone Number

0 0 None None

0 1 2 1, 4

1 0 3 1, 2, 4

1 1 4 1, 2, 3, 4

The Temperature Zone code defines the number of temperature zones used by the ana-lyzer, where ‘n’ = 0, 2, 4, 6, or 32. The definition for each bit is: 0 = No temperature control 2 = 2 temperature zones (1, 4) 4 = 3 temperature zones (1, 2, 4) 6 = 4 temperature zones (1, 2, 3, 4) 32 = Temperature zone 3 (heating logic, heater plate) The code is the decimal equivalent of an 8-bit binary number, which defines the bench type in regard to the temperature control parameters.

The temperature zones are: Zone 1 = Sample Line Zone 2 = Vent Line (or SCU, if used) Zone 3 = TZone3 – Spare Zone 4 = Oven Temperature

Filter Position Assignment (b4, b3)

b4 b3 Lamp 1 Lamp 2

0 0 1-3-5 4-6-2

0 1 3-5 4-6-1-2

1 0 1-3-4-5 6-2

b7, b6, b5 – reserved for future use.

F2 2 Samples ** Number of times the PMT signal is measured while a filter is completely within the light path.

F2 3 Delay ** The time interval from when a filter becomes completely within the light path to the first PMT-signal measurement. The interval is shown as multiples of 1.6 microseconds (µs).

F2 4 RpmAvg **The number of Chopper Wheel rotations used to calculate its speed of rotation (RPM).

F2 5 T90 The time (seconds) required for the output signal to reach 90 percent of the final value after a step change in the concentration. Larger values reduce the noise level on the output signal but, at the same time, increase the response time.

F2 6 Outputz The Output Signal Assignment (OSA) code for each current output, where ‘z’ = 1..4. Allows you to determine which of the calculated results (parameters) will be available as output signals. These outputs are application-specific. Refer to “Output Signal Assignment (OSA)” in this chapter for more information. 1 = Output1 2 = Output2 3 = Output3 4 = Output4


F2 7 Alc The Automatic Lamp Control Enable function displays the operational status of the Automatic Lamp Control function. This parameter is automatically turned on by Auto-Setup after the Auto-Setup is complete, and should be on during normal operation. However, this function should be turned off while replacing source lamps or PMTs. 0 = Off 1 = On

F2 8 AlcGz ** Automatic Lamp Control gain setting for each filter, where ‘z’ = 1..6. 1 = AlcG1 4 = AlcG4 2 = AlcG2 5 = AlcG5 3 = AlcG3 6 = AlcG6

F2 9 SetPtz ** Signal (V) obtained from the Reference PMT for each filter after the Auto-Setup, where ‘z’ = 1..6. These values are updated automatically by Auto-Setup. The Automatic Lamp Control function adjusts the lamp pulses to maintain the Reference PMT signals to these values. 1 = SetPt1 4 = SetPt4 2 = SetPt2 5 = SetPt5 3 = SetPt3 6 = SetPt6




F3 • TrendType This defines which concentration addition will be displayed on the Trend output (see F6 3 8). TrendType is the sum of two concentrations (for example, 3 = [SO2] + [H2S]): 1 = [SO2] 8 = [CS2] {if measuring} 2 = [H2S] 16 = [Sv] 4 = [COS] {if measuring} 32 = [NDr]

F3 – — —

F3 0 Compenz ** The operational status of each compensation function, where ‘z’ = 1..4. 1 = NDR 0,2 = disabled (Off) 2 = Sv 1 = passive\static 3 = COS {if measuring} 3 = active\dynamic 4 = CS2 {if measuring}

F3 y My\z **The value in each row (’y’ = 1..6) and column (‘z’ = 1..6) in the calculation matrix. y = F3 1..F3 6 (row) z = 1..6 (column) F3 1 = M1 M1\1..6 F3 2 = M2 M2\1..6 F3 3 = M3 M3\1..6 F3 4 = M4 M4\1..6 F3 5 = M5 M5\1..6 F3 6 = M6 M6\1..6

F3 7 CVect1\z **The vectors for the first compensation calculations, where ‘z’ = 1..8 or 1..9. 1 = CVect1\1 2 = CVect1\2 3 = CVect1\3 4 = CVect1\4 5 = CVect1\5 6 = CVect1\6 7 = CVect1\7 8 = CVect1\8 9 = CVect1\9 (applications with COS/CS2 Software version only)

F3 8 CVect2\z **The vectors for the second compensation calculations, where ‘z’ = 1..2(..4) 1 = CVect2\1 2 = CVect2\2 3 = CVect2\3 (applications with COS/CS2 Software version only) 4 = CVect2\4 (applications with COS/CS2 Software version only)

F3 9 AvgTz **The averaging times (seconds) of the compensation functions, where ‘z’ = 1..4. 1 = AvgT1 2 = AvgT2 3 = AvgT3 4 = AvgT4




F4 • MBAddr Modicon Modbus® slave address – can be any value between 0–255. ‘0’ disables the Modbus® communication. Addresses 1–127 select the RS-232 port and addresses 128–255 select the RS-422 port.

F4 – ComPara zn The setup parameters for the Baud Rate, Stop Bits, and Parity of the serial communication port, where ‘z’ = 1..3 and where ‘n’ = 0..3.

n = 0..3 Baud Rate Stop Bits Parity

z = 1 z = 2 z = 3

0 9600 Invalid None

1 4800 1 Odd

2 2400 1.5 None

3 1200 2 Even

Note: Parameter changes must be saved to the EEPROM and the analyzer must be resetforthechangestotakeeffect.

To reset the analyzer, take all necessary safety precautions and then press ‘•’ and ‘Ent’ simultaneously.

F4 0 TStPtz ** The control Set Point for the four temperature zones, where ‘z’ = 1..4. If the Set Point is ‘0’, that zone is not used. The zones are: 1 = Sample Line 2 = Vent (sample return) Line 3 = ASR900 Probe (or SKO) 4 = Oven

F4 1 Kpz ** The Proportional term of the PID temperature control algorithm for each temperature zone, where ‘z’ = 1..4. 1 = Sample Line (default = 10.00 %) 2 = Vent (sample return) Line (default = 10.00 %) 3 = ASR900 Probe, or SKO (default = 10.00 %; 0.00 % if not used) 4 = Oven (default = 10.00 %)

F4 2 Tiz ** The Integral term of the PID temperature control algorithm for each temperature zone, where ‘z’ = 1..4. 1 = Sample Line (default = 1000.00 seconds) 2 = Vent (sample return) Line (optional, default = 1000.00 seconds) 3 = ASR900 Probe, or SKO (default = 1500.00 seconds; 0.00 seconds if not used) 4 = Oven (default = 5000.00 seconds)

F4 3 Tdz ** The differential (Derivative) term of the PID temperature control algorithm for each tem-perature zone, where ‘z’ = 1..4. 1 = Sample Line (default = 0 seconds) 2 = Vent (sample return) Line (optional, default = 0 seconds) 3 = ASR900 Probe, or SKO (default = 0 seconds) 4 = Oven (default = 0 seconds)


F4 4 TTypez n ** The type of temperature sensor used for each temperature zone, where ‘z’ = Temperature Zones 1..4. 1 = Sample Line 2 = Vent Line 3 = TZone3 – Spare 4 = Oven and where ’n’ = 0..5 for each of the temperature measurement devices and their tempera-ture zones: 0 = RTD-A: Not Used 1 = Thermistor-A: Not Used 2 = RTD-B: 45 °C to 181 °C (300-4872-B or 300-5769 daughter board), Part No. 100-1096 – Typical Default 3 = Thermistor-B: 76 °C to 187 °C (300-4872-B or 300-5769 daughter board), Part No. 100-1097 4 = RTD-C: Not Used 5 = RTD-D: 120 °C to 260 °C, Part No. 100-2214

F4 5 TDutyz Temperature duty cycles, where ‘z’ = 1..8. ‘z’ = 1..4 This is the default duty cycle (%) of each temperature zone during steady-state operation at the Set Point. The zones and their starting (default) values are: 1 = Sample Line (default = 30 %) 2 = SCU (default = 30 %) 3 = TZone3 – Spare (default = 30 %) 4 = Oven (default = 30 %) ‘z’ = 5..8 This is the maximum duty cycle allowed for each temperature zone. The zones and their default values are: 5 = Sample Line (default = 85 %) 6 = SCU (default = 85 %) 7 = TZone3 – Spare (default = 85 %) 8 = Oven (default = 85 %)

F4 6 AbsOVz **The absorbance offset vector for each filter location, where ‘z’ = 1..6. 1 = Filter 1 4 = Filter 4 2 = Filter 2 5 = Filter 5 3 = Filter 3 6 = Filter 6

F4 7 TCold The Measuring Cell and/or Sample Probe temperature at which the sample system will switch between Sample and Backpurge mode. Entering ‘0’ results in the analyzer using 5 % of the Measuring Cell temperature Set Point as the switch temperature.

F4 8 CPRgz The pressure transducer low and high value (mmHg) corresponding to 0.0 VDC and 5.0 VDC respectively, where ‘z’ = 1..2. 1 = Low Value 2 = High Value

F4 9 AI:Msrz The Microcontroller board channel number for the analog input signals, where ‘z’ = 1..2. If ‘0’ is assigned to either or both of these variables, the values saved as Temperature and/or Pressure will be used to calculate the output signals instead of the measured values. 1 = Measuring Cell Temperature Compensation AI:Msr = 4 (enabled); 0 = disabled 2 = Measuring Cell Pressure Compensation AI:Msr = 6 (enabled); 0 = disabled




F5 • HCHistz History buffer for the last nine non-zero Host Controller board status codes where ‘z’ = 1..9. ‘1’ = oldest; ‘9’ = most recent.

F5 – MCHistz History buffer for the last nine non-zero Microcontroller board status codes where ‘z’ = 1..9. ‘1’ = oldest; ‘9’ = most recent.

F5 0 SN The analyzer serial number.

F5 1 HC\ADA V The Host Controller board software version number. Examples: HCADA e 3.18 (Standard Software) HCADACe 3.18 (COS/CS2 Software)

F5 2 MC\ADA V The Microcontroller board software version number (Model 900). MC\900 V The Microcontroller board software version number (Model 930). Examples: MC900e 5.50 (Standard Software)

MC900Ce 3.18 (COS/CS2 Software)

F5 3 RTime Total run time of the analyzer since the last reset or system power-up. The format is: Days Hours: Minutes (### ## :##)

F5 4 HSz Host Controller board status/alarm code conditions (HStatus), where ‘z’ = 1..8. For each ‘z’, the appropriate Alarm Message is displayed if the alarm condition exists. If the alarm condition does not exist, the message “HSz OK” appears. Refer to Chapter 5 for descrip-tions of alarm conditions. The possible alarm conditions include: 1 = w EEPROM full (Warning) 2 = w Output range (Warning) 3 = f Internal communication (Fault) 4 = f Analytical data (Fault) 5 = f Temp low (Fault) 6 = f Temp high (Fault) 7 = w Zero drift (Warning) 8 = w SKO temp high (Warning), if applicable

F5 5 MSz Microcontroller board status/alarm code conditions (MStatus), where ‘z’ = 1..7. For each ‘z’, the appropriate Alarm Message is displayed if the alarm condition exists. If the alarm condition does not exist, the message “MSz OK” appears. Refer to Chapter 5 for descrip-tions of alarm conditions. The possible alarm conditions include: 1 = f Wheel speed (Fault) 2 = f On-board ADC (Fault) 3 = f On-chip ADC (Fault) 4 = w PMT signal (Warning) 5 = f Communication (Fault) 6 = w ALC (Warning) 7 = w Oven heater temp (Warning)


F5 6 RPM Average speed of the Chopper Wheel (RPM).

F5 7 MDI ab The Microcontroller Board’s Digital Input status code, where ‘a’ and ‘b’ are the status of the inputs. The analyzer has two external digital inputs that are designed to accept a dry (po-tential free) contact closure. Input 1 is reserved for future use. Input 2 is for Remote Start of the Auto-Zero (Calibration) or Remote Start of the Backpurge (optional). a (Input 1) = Reserved for internal use. b (Input 2) = Remote Start of Auto-Zero (Calibration) 0 (external contact is open – normal analyzer operation) 1 (external contact is closed – Auto-Zero is initiated after 5-second delay) or Remote Start of Backpurge 0 (external contact is open – Backpurge is initiated) 1 (external contact is closed – normal analyzer operation: the Flow Control mode changes to automatic Analyzer Control)

Code Contact Status ab Input 1 Input 2

00 Open Open

01 Open Closed

10 Closed Open

11 Closed Closed

F5 8 LmpPz Existing lamp pulse (V) for each filter as generated by the Automatic Lamp Control, where ‘z’ = 1..6. 1 = Filter 1 4 = Filter 4 2 = Filter 2 5 = Filter 5 3 = Filter 3 6 = Filter 6

F5 9 TCyclez Existing temperature control duty cycle for each temperature zone, where ‘z’ = 1..6. 1 = slCycle – Sample Line (default = 0 %) 2 = vlCycle – Vent Line (default = 0 %) 3 = skoCycle – Sulfur Knock-Out (default = 0 %) 4 = celCycle – Analyzer Measuring Cell (default = 100 %) 5 = htrCycle – Heater Plate, Oven (default = 100 %) 6 = prbCycle – ASR900 Sample Probe (default = 0 %)



Note the differences for the F6 •, F6 –, and F6 0 commands in RUN and CFG modes.


F6 • (RUN) PSWD0 (CAL) This is the CAL mode entry password prompt, seen only after you press ‘F6 ·’ from RUN mode. From RUN mode, enter this command to enter CAL mode. The factory-default pass-word is • • .

F6 • (CFG) PSWD0? This is the CAL mode change password prompt, seen only after you press ‘F6 ·’ from CFG mode. From CFG mode, this command will call up the “PSWD0?” prompt, which al-lows you to change the CAL mode entry password. See “Changing the Password for CFG / CAL Mode” in this chapter for information about passwords.

F6 – (RUN) PSWD1 (CFG) This is the CFG mode entry password prompt, seen only after you press ‘F6 –’ from RUN mode. From RUN mode, enter this command to enter CFG mode. The factory-default password is • • .

F6 – (CFG) PSWD1? This is the CFG mode change password prompt, seen only after you press ‘F6 –’ from CFG mode. From CFG mode, this command will call up the “PSWD1?” prompt, which al-lows you to change the CFG mode entry password. See “Changing the Password for CFG / CAL Mode” in this chapter for information about passwords.

F6 0 (RUN) Normal Display This command returns the RUN mode normal display from anywhere in the software. While in RUN mode, the name of the calculated result or parameter is displayed on the top line; its value is displayed on the bottom line.

F6 0 (CFG) Normal Display This command returns the CFG mode normal display from anywhere in CFG mode. The data associated with this mode are displayed on the top line. The output values from RUN mode continue to be displayed on the bottom line.

F6 1 SIGz Displays the Measure and Reference PMT signal for each filter, where ‘z’ = 1..6. The signals are displayed on the bottom line (Measure PMT voltage on left; Reference PMT voltage on right). Normal values are in the range of 5.0–9.84 VDC. 1 = SIG1 4 = SIG4 2 = SIG2 5 = SIG5 3 = SIG3 6 = SIG6

F6 2 TRz ** Displays the transmittance (Show Transmittance) for each filter. The transmittance sig-nals are displayed on the bottom line, where ‘z’ = 1..6. 1 = TR1 4 = TR4 2 = TR2 5 = TR5 3 = TR3 6 = TR6

NOTE


F6 3 Show Resz The Show Results menu displays the calculated result of each signal used, where ‘z’ (z = 1..8) is the numeric code assigned to the result. The name of the result and its value will be displayed and updated at one-second intervals until another result is selected or a different screen is displayed. 1 = SO2 Concentration 2 = H2S Concentration 3 = * COS Concentration (if measuring) 4 = * CS2 Concentration (if measuring) 5 = * Sv Concentration (if measuring) 6 = NDr (Neutral Drift) 7 = AirDm (Air Demand) 8 = Trend (Type) (see F3 • description)

F6 4 — —

F6 5 — —

F6 6 — —

F6 7 — —

F6 8 Show MAIz The Show Microcontroller Board’s Analog Inputs (MAI) function allows you to view the analog input values, where ‘z’ (z = 1..8) is defined by MAI below. The signal level (volts or scaled parameter units) are also displayed. To view the operating temperature for each temperature zone or for the Heater Plate, press the key for that parameter. To view the Measuring Cell pressure (mmHg or "Hg), press ‘6’ from this screen. To view the status of the Over-Temperature relay (normal or tripped), press ‘5’ from this screen.

MAI (z) Message Zone

1 s/lT1 °C Sample Line

2 v/lT2 °C Vent Line

3 Tmp3 Spare or SKO (if used)

4 CellT °C Oven

5 OT normal/tripped S/L, V/L, Oven

6 CellP mmHg Measuring Cell

7 HtrT °C Oven Heater Plate

8 ProbeT °C ASR900 Probe Heater

F6 9 — —


Configuring the Analyzer Control Functions

Output Signal Assignment (OSA)

Outputs (parameters) calculated by the analyzer can be assigned to any of the four outputs and, optionally, the User Interface. (Only results as-signed to the first three channels can be assigned to the User Interface.) Assigning a parameter to an output can be changed from the default shown in Figure 4-4. The assignment is made by displaying the output number and assigning it a numeric code (Figure 4-5).

Keystroke Term Code Name

F2 6 1 Output1

F2 6 2 Output2

F2 6 3 Output3

F2 6 4 Output4

Code† Signal Name

0 Output not used

1 SO2 Concentration

2 H2S Concentration

3 *COS Concentration (if measuring)

4 *CS2 Concentration (if measuring)

5 *Sv Concentration

6 NDR

7 Air Demand

8 Trend (Trend Type)

† See “Output Signal Assignment/code rules” next page. * Indicators only; accuracy not specified.

Figure 4-4. Output signal assignment.

Figure 4-5. Output signal code and name.


Output Signal Assignment/code rules:

• To assign a calculated result to the analog output and the User Interface with the track-and-hold function disabled during Auto-Zero, enter a single-digit code (1, 2, etc.).

• To assign a calculated result to the analog output only – it will not be displayed – with the track-and-hold function disabled during Auto-Zero, add 100 to the single-digit code (101, 102, etc.).

• To assign a calculated result to the analog output and the User Interface with the track-and-hold function enabled during Auto-Zero, add 10 to the single-digit code (11, 12, etc.).

• To assign a calculated result to the analog output only – it will not be displayed – with the track-and-hold function enabled during Auto-Zero, add 110 to the single-digit code (111, 112, etc.).

• Displayed results are active during an Auto-Zero.

Assigning Output Signals With the Track-and-Hold Function Enabled/Disabled

When enabled, the Track-and-Hold function maintains the output at the value calculated just before an Auto-Zero begins. When disabled, the outputs are forced to use the operator-entered fixed values. The outputs will hold at these values for the duration of the Auto-Zero and the Sample Delay Time (SDelay).

Hold function enabled examples (output uses value calculated just before an Auto-Zero begins):

Example 1: To assign the Air Demand signal to Output 1 and the User Interface and return to CFG mode normal display, press:

F2 6 1 Del 17 Ent Ent

Example 2: To assign the SO2 concentration to Output 2 only and return to CFG mode normal display, press:



Hold function disabled examples (outputs use operator-entered fixed values):

Example 1: To assign the Air Demand signal to Output 1 and the User Interface and return to CFG mode normal display, press:


Example 2: To assign the SO2 concentration to Output 2 only and return to CFG mode normal display, press:



Analog Input Channels – Micro-Interface Board

There are eight (8) system analog input channels on the Micro-Interface board. View these inputs on the Show MAI screen. The parameter as-signed to the input and the signal level (volts or scaled parameter units) are displayed.

Display Operating Temperature

The operating temperature for each temperature zone is assigned to the Microcontroller analog inputs 1–4 and 8. The temperature for each zone is displayed by pressing F6 8z, where ‘z’ (z = 1..4, 8) is defined by the input assigned to each channel.

Display Measuring Cell Pressure

The Measuring Cell operating pressure is assigned to Microcontroller ana-log input 6 and is displayed by pressing F6 8 6. The pressure signal is dis-played in mmHg (or "Hg) when active pressure compensation is enabled. When active pressure compensation is disabled, the signal is displayed in volts.

(Show MAI) RUN F6 81..8

Figure 4-6. Micro-Interface board.


NOTE

Working in the CAL Operating Mode

The CALibration (CAL) mode is used to enter the variables required to tai-lor the analyzer for a specific application and to calibrate the instrument.

The CAL mode parameters listed in the following pages are identified by the command (Keystroke) used to view the main screen, the abbreviated name (Term) of the screen, and a Definition of each parameter. “–” indi-cates the command is not used.

Definitions preceded by ‘**’ are used primarily for diagnosing prob-lems with the analyzer; therefore, these functions do not need to be accessed frequently.

The information in the following pages includes descriptions of all pa-rameters for the Standard Software and COS/CS2 Software versions. The information is generally the same for both versions, with differences denoted by “applications with COS/CS2 Software version only” or “ap-plications with Standard Software version only”.

CAL Mode – F1 Commands


F1 • — —

F1 – — —

F1 0 Auto/Zero? Automatic adjustment of the analyzer Zero. The Zero gas (air) solenoid is turned on and off automatically during the Zero. The Zero Offset is adjusted based on the average reading during the last 25 percent of the Timer0 countdown.

F1 1 — —

F1 2 — —

F1 3 — —

F1 4 — —

F1 5 — —

F1 6 — —

F1 7 — —

F1 8 — —

F1 9 — —

To work in CAL mode a password is required.

See F5 1 (HC Ver) and F5 2 (MC Ver) descriptions under “RUN / CFG Mode – F5 Commands.”




F2 • — —

F2 – — —

F2 0 Man/Zero? Allows you to manually Zero the analyzer. The analyzer Zero is automatically adjusted based on the average readings during either the IntTime duration or the last 15 seconds of the countdown after a Yes response. The Zero gas must be introduced manually into the analyzer sample system. Refer to “Manually Zeroing the Analyzer” in Chapter 3.

F2 1 Man/Span1? Allows you to manually Span the analyzer (<SO2>). The analyzer calibration is automati-cally adjusted based on the average readings during the IntTime duration after a Yes response. The Span gas must be introduced manually into the analyzer sample system. Refer to “Manual Span” in this chapter for details about how to manually Span the analyzer.

F2 2 Man/Span2? Allows you to manually Span the analyzer (<H2S>). The analyzer calibration is automati-cally adjusted based on the average readings during the IntTime duration after a Yes response. The Span gas must be introduced manually into the analyzer sample system. Refer to “Manual Span” in this chapter.

F2 3 SO2 Xtalk? Recalculates the matrix elements for Sv and NDR at specific wavelengths to reduce SO2 Cross-Talk (applications with Standard Software version only).

F2 4 — —

F2 5 — —

F2 6 — —

F2 7 — —

F2 8 — —

F2 9 — —




F3 • — —

F3 – — —

F3 0 Timer0 Sets the duration the solenoid valve controlling the Zero gas (air) is energized during the Auto-Zero. The duration can be set from 0–255 minutes in one-minute increments. Setting this timer to ‘0’ turns the Auto-Zero off.

F3 1 — —

F3 2 — —

F3 3 — —

F3 4 — —

F3 5 — —

F3 6 IntTime Sets the duration (seconds) over which the reading for each Manual Zero or Span is aver-aged. Setting this timer to ‘0’ turns the Auto-Zero off.

F3 7 SDelay Sets the time delay (minutes) for the Auto/Manual relay to continue indicating that zeroing is in progress after completion of the Zero, and that the Normal/Fault relay will wait before indicating the fault alarm has been cleared. This permits a smooth transition from the Zero gas back to the sample gas. The delay can be set from 0–255 minutes in one-minute incre-ments. Setting the delay to ‘0’ turns the function off. The delay also occurs when exiting CAL or CFG mode.

F3 8 AZInt Sets the time interval (hours) between Auto-Zeroes. The interval can be set from 0–999 hours in one-hour increments. Setting this interval to ‘0’ turns the function off. Also displays the time remaining until the next Auto-Zero (hours and minutes).

F3 9 — —




F4 • — —

F4 – — —

F4 0 — —

F4 1 Conc1 [SO2] The concentration of SO2 (% or PPM) in the calibration gas mixture. The concentration is entered in decimal form. The maximum concentration which can be entered is 999 999. If a calibration gas is not used, the concentration must be set to ‘0’.

F4 2 Conc2 [H2S] The concentration of H2S (% or PPM) in the calibration gas mixture. The concentration is entered in decimal form. The maximum concentration which can be entered is 999 999. If a calibration gas is not used, the concentration must be set to ‘0’.

F4 3 — —

F4 4 — —

F4 5 — —

F4 6 — —

F4 7 — —

F4 8 TH [SO2] The SO2 value the Track-and-Hold function will hold to (%). ‘0’ = hold to the analyzer calcu-lated output value.

F4 9 TH [H2S] The H2S value the Track-and-Hold function will hold to (%). ‘0’ = hold to the analyzer calcu-lated output value.




F5 • — —

F5 – — —

F5 0 FlowCtrlz The analyzer system Sample Flow Control mode, where ‘z’ = 0..2. 0 = Analyzer Control mode (automatic control by analyzer) 1 = Continuous Backpurge/Zero Flow mode (manually set by operator) 2 = Continuous Sample Flow mode (manually set by operator)

F5 1 Scalez The full-scale range for each of the four outputs, where ‘z’ = 1..4. If an output is not used, its full-scale range should be set to ‘0’. For example, if Scale 1 = 1000 PPM, Output 1 would read 20 mA at 1000 PPM and 4 mA at 0 PPM. These outputs are application-specific. 1 = Scale1 2 = Scale2 3 = Scale3 4 = Scale4

F5 2 — —

F5 3 — —

F5 4 CS2Dyn The existing CS2 concentration (PPM) used for the dynamic compensation of the H2S and SO2 signals for CS2 (applications with Standard Software version only – if measuring).

F5 5 CS2Histz The history of the last nine CS2 readings, where ‘z’ = 1..9, with ‘1’ being the most recent value (other than the current value) and ‘9’ being the oldest. These values are updated 15 minutes after every Auto-Zero, which makes it possible to look back at the CS2 readings for a period of just over two hours. However, updating only occurs if the analyzer CS2 compensation is dynamic (applications with Standard Software version only – if measuring).

F5 6 T0z ** The measuring wavelength transmittance value with Zero gas for each filter, where ‘z’ = 1..6. Adjusted automatically whenever the analyzer is Zeroed. 1 = T01 4 = T04 2 = T02 5 = T05 3 = T03 6 = T06

F5 7 SFactorz The Span (calibration) factor for the calculated result (component concentration), where ‘z’ = 1..2. Adjusted automatically whenever the analyzer is Spanned. 1 = SFactor1 2 = SFactor2

F5 8 Temp The default temperature for the Measuring Cell (°C or °F). This value is used in place of the measured Measuring Cell temperature when active temperature compensation is disabled.

F5 9 Pres The default absolute pressure for the Measuring Cell (mmHg or "Hg). This value is used in place of the measured Measuring Cell pressure when active pressure compensation is disabled.




F6 • — —

F6 – — —

F6 0 IZeroz The measured current (mA) in the current output loop when the output is set to zero-scale during the analyzer Zero, where ‘z’ = Output Channels 1..4. Refer to the Output Signal Assignment code for the outputs assigned to these channels (press F2 6 from CFG mode). The actual mA value is displayed next to the corresponding output channel when 4 mA (Zero) is activated. 1 = IZero1 2 = IZero2 3 = IZero3 4 = IZero4

F6 1 ISpanz The measured full-scale current (mA) in the current output loop when output is set to full-scale during the analyzer Span, where ‘z’ = Output Channels 1..4. Refer to the Output Signal Assignment code for the outputs assigned to these channels (press F2 6 from CFG mode). The actual mA value is displayed next to the corresponding output channel when 20 mA (Span) is activated. 1 = ISpan1 2 = ISpan2 3 = ISpan3 4 = ISpan4

F6 2 — —

F6 3 — —

F6 4 [Sv] The concentration (PPM) of sulfur vapour at analyzer conditions. This static value is used for compensation purposes only.

F6 5 [COS] The concentration (PPM) of COS in the sample gas stream. If the concentration is not known, enter ‘0’. This static value is used for compensation purposes only. (Applicable only if measuring.)

F6 6 [CS2] The concentration (PPM) of CS2 in the sample gas stream. If the concentration is not known, enter ‘0’. This static value is used for compensation purposes only. (Applicable only if measuring.)

F6 7 OpRatio The sample gas H2S to SO2 ratio at which the plant is to be operated. For the conven-tional operation of the modified-Claus Sulfur Recovery process, this value is 2.00. Do not change the factory-default value without first consulting with AMETEK.

F6 8 OpOffset The analog output mid-scale (%) Air Demand signal. For the conventional operation of the modified-Claus Sulfur Recovery process, this value is ‘0.’ Do not change the factory-default value without first consulting with AMETEK.

F6 9 ADFactor The Air Demand (F) factor as shown in the EEPROM Data Sheets (in the analyzer Documentation Package shipped with the analyzer). This factor is application specific. Do not change the factory-default value without first consulting with AMETEK.


Setting Up Analyzer Calibration Functions

This section describes the commonly used functions and controls available in CAL mode.

Flow Control (Sample) Modes

The Flow Control (FlowCtrl) mode sets the state of the sample gas flow, and can be controlled automatically by the analyzer (Analyzer Control mode) or manually forced by the operator to Continuous Sample or Continuous Backpurge/Zero Flow mode.

The screen will display a character on the top-left line that indicates the current operating mode and either automatic or manual control:

Flow Control Mode FlowCtrl (set automatically by analyzer or Character on Code manually by operator) User Interface

0 Analyzer Control blank = Sample (automatic, by Analyzer) m = Backpurge (see *Note)

1 Continuous Backpurge/Zero Flow B (manual, by operator)

2 Continuous Sample S (manual, by operator)

* The ‘m’ character is also displayed when the Remote Backpurge function (optional) is manually activated via a remote dry (potential free) contact opening.

NOTE

(FlowCtrl) CALF5 0


Analyzer Control Mode

When the analyzer’s Flow Control mode is set to Analyzer Control, the analyzer automatically determines and sets the mode of operation by monitoring the state of the Fault alarm relay contacts.

If there are no active Fault alarms, the analyzer will operate in Analyzer Control mode (automatic Sample). When in automatic Sample mode, there is no indicating character on the User Interface.

If the analyzer detects a Fault alarm while it is operating in Automatic

Sample mode, is displayed on the top-right line of the User Interface. When this occurs, the analyzer will switch to automatic Backpurge, and “m” is displayed on the top-left line. The analyzer will not switch back to automatic Sample mode until the cause of the alarm has been corrected (cleared).

Because a low temperature is defined as a fault, the analyzer will switch to automatic Backpurge mode for the length of time required for all tempera-ture zones to stabilize at their Set Points.

To set the analyzer’s Flow Control mode to Analyzer Control mode and return to CAL mode normal display, press:

CAL>F5 0 Del 0 Ent Ent

Continuous Backpurge/Zero Flow Mode (Manual Control by Operator)

When the analyzer’s Flow Control mode is manually set to Continuous Backpurge/Zero Flow, the analyzer sample system is continuously back-purged with Zero gas; it will not switch back to automatic Sample mode.

When you manually force the analyzer into Continuous Backpurge/Zero Flow, “B” is displayed on the top-left line. To manually force the analyzer to this mode, press:


Continuous Backpurge/Zero Flow can also be initiated by an op-tional remote dry (potential free) contact opening. In this case the ‘m’ character is displayed.

NOTE


Continuous Sample Flow Mode (Manual Control by Operator)

When the analyzer’s Flow Control mode is manually set to Continuous Sample, sample gas will continuously flow through the analyzer’s sample system; it will not switch to automatic Backpurge mode.

When you manually force the analyzer into Continuous Sample, “S” is displayed on the top-left line. To manually force the analyzer to this mode, press:


Do not operate the analyzer in Continuous Sample Flow mode for an extended period of time before all temperature zones have stabilized at their operating temperatures. Doing so can result in the analyzer sample system becoming plugged.

!CAUTION


Setting Calibration Gas Timers

The analyzer uses four independent timers for automatic calibration. Each timer establishes the duration for which a solenoid valve controlling the Calibration Gas mixture is energized during Auto-Zeroes and Auto-Spans. The duration depends on the time required for the Calibration Gas mix-ture to reach the analyzer and to obtain a stable reading.

Integration Timer (IntTime)

The IntTime sets the duration over which the readings are averaged dur-ing manual calibrations. The IntTime duration can be set from 0–65535 seconds in one-second increments. Set the duration to ‘0’ to use the de-fault averaging time of 15 seconds.

Example: To set IntTime to 25 seconds and return to CAL mode normal display, press:

F3 6 Del 25 Ent Ent

Timer0

Timer0 sets the duration the analyzer Zero gas solenoid valve is turned on during the Auto-Zero. Timer0 can be set from 0–255 minutes in one-minute increments. Set the duration to ‘0’ to turn the timer off, and disable the Auto-Zero. The average reading for Auto-Zero will be taken during the last 25 percent of the Timer0 time period.

Timer0 must be assigned a value that allows the signals to be stable during the last 25 percent of the countdown.

Example: To set Timer0 to 2 minutes (allowing a 30-second averaging time) and return to CAL mode normal display, press:

F3 0 Del 2 Ent Ent

If a Calibration Gas is not used, the associated timer must be turned Off.

NOTE

NOTE


Auto-Zero Interval Timer (AZInt)

The AZInt timer sets the interval (hours) between timed Auto-Zeroes. The timer can be set from 0–999 hours. Set the interval to ‘0’ to turn the timer off, and disable a timed start of the Auto-Zero. A timed Auto-Zero will start only when the analyzer is operating in RUN mode without any Faults.

The Auto-Zero is included in the Auto-Calibration if the Auto-Zero is en-abled by setting Timer0 to a non-zero condition. If the Auto-Calibrations and Auto-Zeroes are scheduled to run at the same time, Auto-Calibration takes precedence.

Example: To set the AZInt timer to 4 hours and return to CAL mode normal display, press:

F3 8 Del 4 Ent Ent

When you enter F3 8, the existing interval (hours) and the time re-maining until the next Auto-Zero (hours/minutes) are displayed.

NOTE


Manual Zero/Span

The Manual Zero and Manual Span do not activate the solenoid valves. The gases must be introduced manually into the analyzer and allowed to flow through the sample system until a stable reading is displayed. The time required for Calibration gas to reach the analyzer and for a stable reading to be achieved and displayed is dependent upon the volume of the sample system and Calibration gas flow rate. The gas flow rate, tem-perature, and pressure should be as close as possible to the normal operat-ing conditions.

The Calibration gas mixture component concentrations must be en-tered before performing the Manual Span.

Manual Zero

See “Manually Zeroing the Analyzer” and “Setting the Zero Gas Flow Rate” in Chapter 3 for information about how to perform a Manual Zero on the analyzer.

Manual Span

Although it is unnecessary from an analytical perspective to calibrate the span of the analyzer on a regular basis, since the response factors to the various gases do not change, calibration may be necessary to demonstrate the response of the analyzer to calibration gas. There may also be occa-sions where the SO2 cross-talk needs to be checked after changes to the optical system have been made. For these purposes, a calibration gas port has been provided.

The calibration gas follows the same path that the Zero gas is introduced. The flow rate of these gases can be adjusted using the flow controlling rotameter.

To achieve a good result, the following factors are important when run-ning calibration gases:

• A “good zero” has been performed prior to introducing calibration gas.

• The calibration gas must reach the Measuring Cell without contamina-tion or residual sulfur in the system.

• The gas introduced must be at approximately the same temperature as the sample gas.

NOTE


Calibration gas must be injected into the analyzer at a relatively low flow rate (1–2 L/min or 0.04–0.07 SCFM). The routing of the calibration gas tub-ing provides warming of the calibration gas but the system will not allow excessive flow rates of calibration gas to be warmed. At low flow rates, there is always the possibility of calibration gas becoming contaminated with remnants of the sample gas, which will introduce errors into the calibration results.

To overcome this problem, Zero gas is introduced along the same path-way that the calibration gas follows. If the Zero gas does not show signs of contamination at lower flow rates, it is safe to introduce calibration gas.

To perform a Manual Span:

1. Zero the analyzer to remove sample gas contaminants. Note and re-cord the numeric value displayed for Flow Control. Run the Manual Zero for 10 minutes at a flow rate of 2.5 L/min (0.08 SCFM).

Reduce the Zero flow rate to 1.5 L/min (0.05 SCFM). Check for a change in concentration reading. There should be very little change in baseline. If there is a significant change continue with the 2.5 L/min (0.08 SCFM) flow rate for another 10 minutes.

When the analyzer is in Continuous Backpurge/Zero Flow mode there may be air pressure at the Calibration Gas Port. Do not open the Calibration Gas Port when the analyzer is in this mode.

2. Ensure that the Calibration Gas mixture containing component ‘y’ (y = 1, SO2 or y = 2, H2S) is connected to the analyzer’s Calibration Gas Port (Figure 4-7) and turned on.

Turn off the Aspirator Air.

Adjust the Calibration Gas Regulator to obtain a pressure similar to that on the analyzer Aspirator Pressure Gauge.

3. Press F5 0 and record the numeric value displayed for FlowCtrl.

Change the Flow Control setting to Continuous Sample mode. This will allow the flow of Calibration Gas to manually span the sample system.

!WARNING


See “Manually Zeroing the Analyzer” in Chapter 3.


4. To initiate the Manual Span, press F2 y, where ‘y’ = 1 (SO2) or 2 (H2S). The User Interface will prompt “Man/Spany?”.

Observe the concentration reading for the component on the bottom line of the User Interface. When it has stabilized at or near the concen-tration of component ‘y’ in the Calibration Gas mixture, press:

Ent for Yes The IntTimer duration will count down to ‘0’ during which time the reading is averaged if AdjDisable is set to ‘0’. The calibration value for the component will be adjusted automatically and the screen will revert to the CAL mode normal display.

Esc for No The function is aborted and the calibration value for the component is not adjusted.

5. Turn off the Calibration Gas mixture with component ‘y’. The span process for the component is complete.

If required, repeat this procedure for each component.

6. Return the analyzer to the original Flow Control mode by keying in F5 0 Del n Ent where ‘n’ is the numerical value recorded earlier.

7. Remove the calibration gas line and plug the Calibration Gas Port.

Figure 4-7 Calibration gas setup.

(ManSpany) CAL F2 2Del ‘y’ Ent Ent


Auto-Zero

This feature allows you to initiate an automatic calibration. Enter the Zero gas mixture component concentrations before initiating an Auto-Zero.

When an Auto-Zero is performed, the following events occur automatically:

1. The Zero gas solenoid valve is turned on to let the Zero gas mixture flow through the Measuring Cell. The User Interface gives no indica-tion that the solenoid valve has been turned on.

2. The Timer0 duration is displayed on the top line of the User Interface and begins counting down to ‘0’.

3. The analyzer Zero is adjusted to the proper value based on the aver-age of the readings during the last 25 percent of the Timer0 duration (minutes) of the countdown if AdjDisable is set to ‘0’. Upon comple-tion of the Auto-Zero, the CAL mode normal display is returned. The IntTime does not affect the averaging time for the Auto-Zero.

4. The Auto/Manual relay will stay on longer, determined by the SDelay timer, to allow for a smooth transition from the Zero gas mixture back to the sample gas. The User Interface gives no indication that this is occurring.

Pressing Esc at any time during this procedure will abort the func-tion and return to CAL mode normal display. The Flow Control mode must be controlled by the analyzer (i.e., FlowCtrl must be set to ‘0’).

The Auto-Zero can be started manually, automatically on a timed basis, or by a remote dry (potential-free) contact closure. Upon completion of the sequence, the Auto/Man status relay will continue to indicate that a calibration is in process until the SDelay time has expired.

An Auto-Zero initiated on a timed basis or by a remote contact will not be executed if there is a fault alarm.

NOTE

NOTE


Manual Start of Auto-Zero

A manual start of Auto-Zero resets the AZInt Timer to its initial value. The start of the next Auto-Zero will be timed from the beginning of the manual start.

Example: The AZInt Timer is set at 2 hours, the time remaining until the next timed Auto-Calibration is 30 minutes, and the Auto-Calibration is started manu-ally. In this case, the AZInt Timer will be reset, and the time remaining until the next timed Auto-Zero remains 2 hours.

Pressing Esc at any time during this procedure will abort the func-tion and return to CAL mode normal display.

To manually start the Auto-Zero:

1. Press F1 0 (CAL mode) to display the timer duration.

2. Press Ent. The software prompts “Auto/Zero?”.

3. To enable the Auto-Zero, press Ent.

Timer0 will begin to count down to ‘0’. The analyzer Zero Offset is ad-justed automatically based on the average of the readings during the IntTime duration (or the last 15 seconds of the countdown if IntTime = 0 seconds).

Or, press Esc to abort the Auto-Zero; the Zero Offset is not adjusted.

Upon completion of the sequence, enter another command, or press Esc to return to RUN mode normal display.

Timed Start of Auto-Zero

The analyzer automatically initiates the Auto-Zero on a timed basis. The AZInt timer sets the time interval between Zeroes.

NOTE


Remote Start of Auto-Zero

The Auto-Zero can also be initiated by a remote, dry (potential free) contact closure connected to Digital Input 2, Pins 10 and 11 on J108 of the Termination board (Figure 4-8). The contact must remain closed for at least 2 seconds (up to 5 seconds). A remote start of the Auto-Zero resets the AZInt Timer to its initial value. The start of the next Auto-Zero will be timed from the beginning of the remote start.

Example: The AZInt Timer is set at 2 hours, the time remaining until the next timed Auto-Zero is 30 minutes, and the Auto-Zero is started by a contact closure. This will reset the AZInt Timer and the time remaining until the next timed Auto-Zero remains 2 hours. If a timed Auto-Zero is in progress, the remote-contact closure will be ignored.


Figure 4-8. Customer signal connections.


Analog Output Calibration

Calibration of an analog output is performed by entering the measured zero- and full-scale signals for the current output channel. Enter these val-ues in decimal form. Use a current meter to calibrate the current output signals. These values are used to offset the output to the correct values.

If the measured current output is less than 20 mA when the output is set to full-scale, it cannot be increased above that value. The V/I module must be replaced if this value is unacceptable. The output channels have been calibrated at the factory and will be re-calibrated upon initial installation at the site. Further re-calibration is required only when a V/I module or the Termination board is replaced.

Pressing Esc at any time during the procedure will abort the proce-dure and return to CAL mode normal display. The existing calibra-tion values and any new values entered up to the point of pressing Esc will be retained.

To calibrate the current output signal for Output Channel ‘z’, where ‘z’ is the output channel number (1..4), connect the current meter to the output (see Figure 4-8 for termination points) and press:

Zero current output F6 0z Current output zero-scale value is displayed, where ‘z’ is the Zero current output (IZero) 1..4.

Del Sets the current analog output channel to zero-scale (4 mA).

nnn Enter the zero-scale value (mA) that was measured by the meter.

Ent Zero-scale value is entered and displayed.

Span current output F6 1z Current output full-scale value displayed, where ‘z’ is the Span current output (ISpan) 1..4.

Del Sets the current analog output channel to full-scale (20 mA).

nnn Enter the full-scale value (mA) that was measured by the meter.

Ent Full-scale value is entered and displayed.

Calibration complete Ent To return to CAL mode normal display, or

Esc To return to RUN mode normal display, or

Enter another command to perform another function.

!CAUTION

NOTE


Example 1: To calibrate the current output signal for Output Channel 1 and return to CAL mode normal display, press:

F6 0 1 Del Sets the output to zero-scale.

3.97 Ent The current meter reading is 3.97 mA.

F6 1 1 Del Sets the output to full-scale.


Ent Returns the CAL mode normal display.

Example 2: To calibrate the current output signal for Output Channel 2 and return to CAL mode normal display, press:

F6 0 2 Del Sets the output to zero-scale.


F6 1 2 Del Sets the output to full-scale.


Ent Returns the CAL mode normal display.

Maintenance and Troubleshooting | 5-1

MAINTENANCE and TROUBLESHOOTING

This chapter discusses preventive maintenance to keep the analyzer sample system operating at peak efficiency, how to check for plugging in the analyzer sample system, and how to replace internal parts. This chap-ter also discusses how to view alarms (errors) that can be used to diagnose and troubleshoot problems with the analyzer.

Safety Considerations

Before working on the analyzer, read the entire procedure you will be performing to understand how to safely perform mainte-nance on and troubleshoot the analyzer.

Before performing any maintenance, service, or troubleshooting on the analyzer, review and follow all safety information in this chapter and under “Personnel and Equipment Safety Information” following the Table of Contents. This information describes procedures to follow to avoid personal injury and/or damage to the equipment. All regula-tory agency and personnel safety procedures for your jurisdic-tion must be followed. Personnel should be thoroughly familiar with the operation of the analyzer before performing the maintenance procedures described in this chapter.

To prevent an explosion, test the area around the analyzer for flamma-ble gases and proceed with maintenance only when the area is found to be safe (nonhazardous).

NOTE

!WARNING

!WARNING


Under normal operating conditions, lethal concentrations of H2S and other toxic gases from the sample stream may be present within the sample system. The sample system is defined as all components in the analyzer system through which sample gas passes. Before working on the sample system, manually Zero the analyzer, isolate it (block it in) from the sample stream, and disconnect the power. Follow this procedure prior to changing out any analyzer com-ponents or replacing any parts (as part of regular preventive mainte-nance), or when performing leak checks following the replacement of instrument air or other adjustments to any of the connection points in the analyzer’s sample system. If this is not possible, a breathing apparatus must be worn while servicing the sample system.

If handling the circuit boards, do not subject them to static discharge. The ideal solution is a static-safe work area. Since such areas typically are not available at analyzer installation sites, the use of a wrist strap connected directly to a ground is recommended. If a wrist strap is not available, you should at the very least touch the metal chassis to ground yourself before handling the boards.

Preventive Maintenance

The “Analyzer Preventive Maintenance Schedule” lists general mainte-nance to follow, to ensure continued and proper operation of the analyzer.

Preventing leaks in the sample system is critical to proper analyzer operation. If sample gas migrates into the Reflector Block or Optical Bench (uncommon) due to a leak in the Measuring Cell, the optics will become damaged and most likely require replacement. Most leaks are preventable with regular cleaning and replacement of the Measuring Cell o-rings. Leak check the analyzer’s sample system whenever it has been dis-mantled for maintenance.

!CAUTION

!CAUTION

!WARNING


If the analyzer sets alarms that indicate a faulty component requires replacement (see “Troubleshooting and Diagnostics” in this chapter), follow the corresponding replacement procedure in this chapter. For complex maintenance procedures not discussed in this manual, such as replacing heaters, RTDs, or electronic boards, contact AMETEK. Or, review Chapter 6 and then contact AMETEK for as-sistance with returning the assembly/analyzer to the factory for repair.

Analyzer Preventive Maintenance Schedule

To reduce the occurrence of problems with the analyzer follow this sched-ule, which lists the frequency of maintenance required when caring for the analyzer. Since most analyzer problems originate within the sample system, the primary objective of this schedule is proper care of the sample system.

Frequency Task

Daily Check for Warning or Fault Alarms

Check the top-right corner of the User Interface for the S character. If

S appears, view the HStatus and MStatus screens for current alarms to help isolate the problem. See “Troubleshooting and Diagnostics” in this chapter for alarm messages and corrective action.

Check the history buffers (HCHist and MCHist) for recurring alarms. The history buffers contain alarms that have been reset.

Monthly Check the PMT Signals

Manually Zero the analyzer. (See “Manually Zeroing the Analyzer” in Chapter 3.)

View the Show Signals (SIG) screen and record the analyzer PMT signals. All signals should return to within 5 % of the values recorded the previous month. If the Measure signals show significant loss, the Measuring Cell may be contaminated. Cleaning the Measuring Cell window can be delayed until the signals are less than 50 % of their “clean” measured value. Refer to your log book to examine monthly recordings.

Immediately following this monthly maintenance, continue with the monthly task “Check Analyzer Response Time” below.

!WARNING

(HStatus) RUNF5 41..8 (MStatus) RUNF5 51..7 (HCHist) RUNF5 • 1..9 (MCHist) RUNF5 – 1..9

(SIG) RUNF6 11..6


Frequency Task

Monthly Check Analyzer Response Time

Note: Do this task in conjunction with the monthly task “Check the PMT Signals” above.

Manually Zero the analyzer. After the Zero is complete, determine the sample response time by switching the analyzer from Continuous Backpurge/Zero Flow mode to Continuous Sample Flow mode. Observe the RUN mode normal display and record the time it takes the analyzer to display the first reading after the switch. Typically, a good response time is in the range of 30 seconds. A response time that is slower than normal may suggest plugging problems in the analyzer’s sample system.

Refer to “Manually Zeroing the Analyzer” and “Setting the Sample Gas Flow Rate and Sample Response Time” in Chapter 3. See also “Preventing, Detecting, and Locating a Plug in the Sample System” in this chapter.

Monthly Pressure Gauge

Check the Aspirator Pressure gauge.

Aspirator air pressure should be set approximately 10 PSI above the sample stream pressure. See “Setting the Sample Gas Flow Rate and Sample Response Time” in Chapter 3.

Pressure Transducer Air pressure is set at a nominal 105 KPAG (15 PSIG).

CAUTION: To avoid damaging the pressure transducer, do not set the pressure higher than 105 KPAG (15 PSIG).

Monthly Temperature Zones

Check and record the temperatures of all temperature zones and ensure they are all within 5 % of their Set Point values.

Every 6 Months Sheltered Systems

If the analyzer is installed in a custom shelter, check the air filters for the shelter purge and air conditioning systems, and replace if necessary.

Depending on the environmental conditions of the site, more frequent filter replacement may be necessary.

Every 6 Months Sample/Vent Lines

Inspect the Sample and Vent Lines for sags, sharp bends, or damage to the outer skin. If necessary, take appropriate safety precautions and replace the lines. Perform a leak check on all associated fittings after replacing any lines.

9–12 Months Source Lamps

Replace the source lamps.

The lamps may require replacement sooner if analyzer alarms are set (“w ALC” or “w PMT signal”). See also “Source Lamp Replacement” and “Troubleshooting and Diagnostics” in this chapter.


Frequency Task

Every Year Measuring Cell

Replace the o-rings and Cell Windows and clean the interior surfaces to remove any contaminants.

This schedule is a minimum requirement. If other conditions are found to be present (see “Measuring Cell Maintenance”) more frequent cleaning may be required.

Every 2 Years Chopper Assembly, Optical Bench

Replace the Chopper Motor Drive Belt and Chopper Wheel Bearings. If there are recurring analyzer alarms that suggest problems with the Chopper Wheel or other related parts in the Chopper Assembly, replace these parts sooner (that is, “w ALC”, “w PMT signal”, “f Wheel speed”, or “w Zero Drift”).

See “Chopper Assembly Maintenance” in this chapter.

Other ASR900 Sample Probe

Replace the o-rings and filters.

Refer to the ASR900 Sample Probe Installation and Maintenance Guide for recommended preventive maintenance requirements.

Other Flamepath Gap

During each analyzer maintenance, use a feeler gauge to check the flamepath gap of the following locations. The gap must not exceed the listed gap for each location; if the gap exceeds this value, contact AMETEK for advice. See also “Examining and Caring For the Flamepaths” in this chapter.

• Disconnect Enclosure flange (enclosure door and housing joining surfaces). Maximum Flamepath Gap: 0.15 mm

• Heater Plate Assembly flange (upper/lower Heater Plate joining surfaces, inside the Analyzer Oven). Maximum Flamepath Gap: 0.1 mm

For other flamepaths not mentioned here, contact AMETEK.

Expo Technologies MiniPurge® System With eTimer (Optional) Preventive Maintenance Schedule

Frequency Task

— If your analyzer uses an Expo Technologies MiniPurge® System With eTimer, refer to the system’s manual for maintenance frequency and procedures. This manual is shipped with the analyzer.

— To test the pressure of the Electronics Enclosure, use the Cabinet Pressure Port on the Solenoid Block.

Every 3 Years Battery Pack, Expo MiniPurge® System (if analyzer is equipped)

Replace the Battery Pack and perform the commissioning tests as described in the Expo MiniPurge® Type X / ET Size 1 Manual (ML 422).

See “Expo Technologies MiniPurge® System With eTimer Spare Parts” in Chapter 6 for spare parts ordering information.


Preventing, Detecting, and Locating a Plug in the Sample System

Preventing a plug in the sample system: While various factors can contribute to plugs in the sample system, plugs can be avoided in many cases by:

• Maintaining the ambient temperature around the analyzer, and the operating temperatures for each analyzer temperature zone.

From the MAI screen, check the real-time temperature for each Temperature Zone and compare it to its Set Point temperature (on the TStPt screen).

Also, verify the ambient temperature surrounding the analyzer and the operating temperature of the ASR900 Sample Probe is at least 10 °C (18 °F) above the sample stream temperature. It is extremely important to maintain a relatively stable ambient temperature in the vicinity of the analyzer, with no rapid temperature fluctuations.

• Performing regular maintenance (see “Analyzer Preventive Maintenance Schedule” in this chapter).

• Observing the analyzer response time regularly and taking action im-mediately if longer response times are noticed (perform maintenance on components suspected to be restricted or plugged).

Detecting a plug in the sample system: This is best done by observing the analyzer’s measurement response time immediately following a Zero. A typical response is less than 30 seconds to T90 (excludes sample system). Observe your analyzer regularly to learn what a normal response time is and keep records of response times after a Zero. Use the recorded response times as a reference for detecting the formation of plugs in the sample system (that is, longer response times).

The section of the sample system with the highest risk of plugging is the sample inlet and the section of the sample inlet most prone to plugging is the Sample Probe Valve. One way to confirm that a plug is in the sample inlet is to close the Vent Valve (on the ASR900 Sample Probe) and Zero the analyzer. Plugs in the sample outlet (or vent side) of the sample system are rare.

(MAI) RUNF6 81..8 (TStPt) RUNF4 01..4


Locating a plug in the sample system: If analyzer problems occur, they are most likely related to improper sam-ple system operation, such as a plug or leak. A plug in the sample system can cause problems in analyzer response time, either to changing process conditions or to Zero gas. A leak is potentially dangerous and will eventu-ally lead to corrosion problems.


Changing Out Replaceable Parts

The following sections discuss parts that should be replaced, as per the “Analyzer Preventive Maintenance Schedule.”

Performing preventive maintenance on the analyzer requires working from the User Interface. Familiarize yourself with how to work from the User Interface before working on the analyzer (see Chapter 4).

Measuring Cell Maintenance

This procedure discusses a Standard Range Measuring Cell (40 cm or smaller, Figure 5-1). For other types of Measuring Cells, refer to Manual Supplements in the analyzer Documentation Package.

Replace/clean parts in the Measuring Cell:

• Every year.

• Any time an unscheduled cleaning is performed.

• If the analyzer responds slowly to a Zero when the sample system is free of restrictions.

• If evidence of contamination is present in the sample tubing.

NOTE

See Chapter 6 for spare part ordering numbers.


“P/N” refers to Part Number.

To clean and replace parts in the Measuring Cell (Figures 5-1 and 5-9):

Hazardous Locations Before proceeding, test the area around the analyzer for flammable gases and proceed only when the area is found to be safe. Do not open the Electronics Enclosure or other covers/doors, and do not power up/down the analyzer (or computer) if there is a flammable gas atmosphere present.


After the Zero is complete, close the Sample Valve and then the Vent Valve on the ASR900 Sample Probe to isolate the analyzer from the sample stream.

2. Power down the analyzer:

General Purpose (GP) Analyzers: Open the Electronics Enclosure and disconnect power from the analyzer and its temperature zone circuitry by opening the Analyzer, Oven Heater, and ASR Probe fuses, and by removing the Sample and Vent Line fuses.

Purged Analyzers (Hazardous Locations): Open the explosion-proof power-disconnect switch to disconnect power from the analyzer and its temperature zone circuitry. Open the Electronics Enclosure.

Wait 5 minutes to allow the high-voltage capacitors in the source-lamp power supply to discharge.

3. Open the Oven door and allow the Oven to cool down enough to ensure safe handling of its internal components.

The Oven enclosure and components within the Oven are hot; take precautions to avoid burning yourself.

NOTE

!WARNING

!WARNING

!WARNING




4. GP Analyzers Only: Turn off the Instrument Air supply to the analyzer and then close the Aspirator Air valve.

Purged Analyzers: The Instrument Air supply must always remain on for the Purge Bypass Switch to operate properly.

5. After the Oven has cooled down enough to work on, disconnect the Measuring Cell from the Heater Plate and remove it from the Oven:

The analyzer sample system will be under positive pressure; take precautions to avoid injury.

a. Disconnect the Measuring Cell tubing.

b. Remove the Heat Transfer Block Plug from the Heat Transfer Block and then remove the M4 x 25 screw using only a flat hex key. Do not use a ball driver – the head can break off inside the screw.

c. Wearing insulated gloves, grasp the Measuring Cell and carefully pull it straight out from the Heater Plate and Cell RTD (Figure 5-9). Once the Measuring Cell has cleared the Cell RTD, swing the Optical Bench Assembly outward, away from the analyzer.

d. Remove the (3) M4 x 12 screws that secure the Heat Transfer Block to the Cell Extension and remove the Measuring Cell.

To help maintain the temperature inside the Oven, close the Oven door while working on the Measuring Cell.

6. Disassemble and clean the Measuring Cell:

When disassembling the Cell, note the orientation of the Cell parts. It is critical to reassemble the Cell parts later in the exact orientation as they were assembled at the factory. After removing the Cell parts, set them on a clean, lint-free cloth. If the Measuring Cell has a Mirror or Window/Mirror combina-tion, be careful not to touch the Mirror/Reflective surface with your fingers, scratch or rub the Mirror, or use water on the Mirror.

a. Hold the Measuring Cell vertically with the Heat Transfer Block up-ward and remove the (3) M4 x 12 screws that secure the Heat Transfer Block to the Measuring Cell. Remove the Heat Transfer Block.

Grasp the edge of the Cell Window and carefully remove it, then set it aside on a soft, non-abrasive cloth. Remove the (2) o-rings.

!WARNING

!CAUTION

The Purge Bypass Switch must be in the “BYPASS” position.


Figure 5-1. Measuring Cell Assembly.


b. Hold the Measuring Cell vertically with the Reflector Block up-ward and remove (3) M4 x 20 screws that secure the Reflector Block to the Measuring Cell. Remove the Reflector Block.

Grasp the edge of the Cell Window and carefully remove it, then set it aside on a soft, non-abrasive cloth. Remove (2) o-rings.

c. Inspect the Cell Windows for scratches, chips, and cracks and dis-card if damaged.

If the Windows are not damaged, use Kimwipes® EX-L or an equivalent extra low-lint tissue to clean the front and back sides of the Windows. A high purity solvent such as Isopropanol can also be used. Rinse the Windows with pharmaceutical-grade distilled water and set them aside.

If the Measuring Cell has a Mirror or Window/Mirror combina-tion: Stand the Mirror vertically and apply 2-propanol (ultra pure Isopropyl Alcohol) to its surface. Gently place a Kimwipes® EX-L tissue (or an equivalent extra low-lint tissue) on the Mirror surface and allow it to absorb the alcohol and gently pull the Kimwipes tissue along the surface of the Mirror. Dry the Mirror with fil-tered instrument air or allow to air dry. Do not touch the Mirror/Reflective surface with your fingers, scratch or rub the Mirror, or use water on a Mirror.

d. Inspect the interior of the Measuring Cell for particulate and clean it with a nonabrasive detergent and water solution, Isopropanol, or reagent-grade acetone followed by a rinse with pharmaceutical-grade distilled water.

Allow all components to dry thoroughly before reassembling.

7. Replace parts in the Measuring Cell:

If the Cell Windows are found to be scratched, cracked, or chipped, replace them during reassembly. Do not operate the analyzer with faulty parts. Handle the Window only by its outside edge.

a. Install (1) new o-ring (P/N 100-1911) in the groove on the flat sur-face of the Reflector Block.

Hold the Measuring Cell vertically with the Reflector Block end up and install (1) new o-ring (P/N 100-1911) and Window (P/N 300-0281).

!CAUTION


Orient the Reflector Block with its “peak line” at 90° to a line through the fittings and place it on the Measuring Cell. Ensure the Window does not slide out of position when the Reflector Block is placed against the Measuring Cell.

It is critical to reassemble the Reflector Block in the exact orientation as it was assembled at the factory.

Secure the Reflector Block to the Measuring Cell with (3) M4 x 20 screws. Tighten the screws evenly.

b. Install (1) new o-ring (P/N 100-1911) in the Heat Transfer Block.

Hold the Measuring Cell vertically with the Heat Transfer Block end up and install (1) new o-ring (P/N 100-1911) and Window (P/N 300-0281).

Orient the Heat Transfer Block with the Heat Transfer Block Plug access hole at 90° to a line through the fittings (the two larger-diameter holes in the Measuring Cell must align with the two larger-diameter holes in the Heat Transfer Block). Connect it to the Measuring Cell with (3) M4 x 12 screws. Tighten the screws evenly.

8. Reconnect the Measuring Cell to the Optical Bench and secure it to the Cell RTD on the Oven Heater Plate:

a. Orient the Measuring Cell with the Reflector Block to the left, the sample tube fittings vertical, and the Heat Transfer Block Plug ac-cess hole facing away from the analyzer. Reconnect the Measuring Cell to the Cell Extension (on the Optical Bench) using (3) M4 x 12 screws. Tighten the screws evenly.

b. Swing the Optical Bench/Measuring Cell toward the Oven.

Align the hole in the Heat Transfer Block with the Cell RTD tip on the Heater Plate and carefully push the Measuring Cell toward the RTD. Adjust the entire Measuring Cell/Optical Bench Assembly as required to firmly seat the Measuring Cell against the Heater Plate.

!CAUTION


Using a flat hex key, replace the M4 x 25 screw in the counter bore hole in the Heat Transfer Block and thread it onto the Cell RTD (only until snug). Do not use a ball driver. Do not overtighten this screw, as doing so will damage the threads on the RTD.




c. Adjust the Measuring Cell/Optical Bench Assembly so that the sili-con seal on the Cell Extension fits firmly into the molded depres-sions in the Oven and Electronics Enclosure walls. The two ribs of the seal should fit between the inside and outside edges of the Electronics Enclosure wall.



d. Verify there is no clearance between the Heat Transfer Block and the Cell RTD. The Measuring Cell must feel secure against the Heater Plate. Gently push and pull on the Measuring Cell to verify it is not loose.

If there is any movement, tighten the M4 x 25 screw again until the Measuring Cell does not move, being careful not over tighten it. Do not use a ball driver. Over-tightening this screw will damage the threads on the RTD.

Replace the Heat Transfer Block Plug in the Heat Transfer Block.

9. Connect the sample tubing to the Measuring Cell.

NOTE

NOTE


10. GP Analyzers Only: Turn on the Instrument Air supply to the analyzer and open the Aspirator Air valve.

11. Power up the analyzer:

It is necessary to work with the Electronics Enclosure door open after replacing parts in the Heater Assembly. When the analyzer’s covers and doors are open, take appropriate precau-tions to avoid electrical shock. Hazardous voltages are present inside.

GP Analyzers: Close the ASR Probe fuse and replace the Sample and Vent Line fuses. Do not close the Oven Heater fuse at this time, until after the Leak Check has been performed.

Close the Analyzer fuse to apply AC power to the analyzer.

Purged Analyzers: Insert the key into the Purge Bypass Switch and switch it to the “BYPASS” position (follow company policy).


Close the explosion-proof power-disconnect switch to apply main AC power to the analyzer. Do not close the Oven Heater fuse at this time, until after the Leak Check has been performed.

12. Perform a leak check on the sample system fittings that were disconnected.

!WARNING

!WARNING

See “Sample System Leak Check” in Chapter 3.


13. Close the Oven fuse to apply power to its Heater. Close and secure the Electronics Enclosure door with its (3) M6 screws to secure the Optical Bench in place. Close and latch the Oven door. Close and secure all other analyzer covers and doors, if not already done.

Allow the analyzer to warm up to operating temperature and stabilize (approximately two hours). When the analyzer is at operating tem-perature, open the Vent Valve on the ASR900 Sample Probe and then open its Sample Valve to allow sample gas into the analyzer sample system.



Change the Flow Control setting back to Analyzer Control mode.


The procedure is complete.

(FlowCtrl) CALF5 0 Del 0 Ent See “Setting the Sample Gas Flow Rate and Sample Response Time” in Chapter 3.


Replacing the Source Lamps

The typical life span of the source lamps is approximately 9–12 months of continuous operation. However, a source lamp can exhibit signs of degra-dation after 5–6 months.

For more lamp maintenance information, see the Model 9xx-Series Analyzers “Lamp Maintenance Manual Supplement” included in the analyzer Documentation Package.

When Do Source Lamps Need to be Replaced?

Indications of Source Lamp failures are:

• Unstable lamp voltage (check voltage levels on the SIG screen).

• Unstable analyzer output under Zero gas conditions (“w Zero Drift” alarm is displayed on the HStatus screen).

• The “w ALC” alarm is displayed on the MStatus screen).

About the Source Lamps

• Source Lamp 1 is the one closest to the Measuring Cell (Figure 5-2).

• The cathode of the Source Lamp must be centered on the optical axis of the Beam Splitter for optimal operation of the analyzer. The cathode and glass envelope are not necessarily concentric or consistent on each lamp.

• New source lamps must be aligned to ensure optimal operation of the analyzer.

• This procedure is based on the standard Model 900/Model 930 Analyzer, Bench Type Code “4”.

Do not interchange the source lamps. Note the type of lamp in each socket before removing.

NOTE

!CAUTION

(SIG) RUNF6 11..6 (HStatus) RUNF5 41..8 (MStatus) RUNF5 51..7


See F2 1 under “RUN / CFG Mode – F2 Commands” in Chapter 4 for Bench Type.


Source Lamp Replacement

“P/N “ refers to Part Number.

To replace Source Lamps (Figure 5-2):








!WARNING

!WARNING

NOTE




Figure 5-2. Lamp Assembly.




4. Remove the existing lamps:

a. Loosen the Lamp Retaining Screw on the bottom of the lamp sock-ets and rotate the Lamp Retaining Bracket 90 degrees. Remove the Lamp Socket.

b. Remove each lamp by rotating and sliding it downward. If neces-sary, loosen the Lamp Clamping Screw on the Lamp Compression Bar.

Do not rotate or pull on the base of the source lamp because this may cause it to separate from the glass envelope. Grasp the glass envelope when rotating or pulling the source lamp.

5. Install the new lamps:

a. Be sure to install the Mg lamp (Standard Software) or Mn/Ni lamp (COS/CS2 Software) in the Lamp 1 position and the Cd lamp in the Lamp 2 position. Make sure that the narrow end of each lamp is inserted completely into the Detector Assembly. Do not touch the flat window at the end of the lamp.

b. Lightly tighten each Lamp Clamping Screw to secure each lamp. Do not overtighten; the spring should not be collapsed.

c. Replace each Lamp Socket and secure them by rotating the Lamp Retaining Bracket 90 degrees to its original position and tightening the Lamp Retaining Screw. Do not overtighten; the spring should not be collapsed. The lamp must be allowed to move so it can be adjusted later.


!CAUTION




It is necessary to work with the Electronics Enclosure door open after replacing source lamps so that adjustments can be made to the lamps. When the analyzer’s covers and doors are open, take appropriate precau-tions to avoid electrical shock. Hazardous voltages are present inside.

GP Analyzers: Close the ASR Probe and Oven Heater fuses and replace the Sample and Vent Line fuses.




Close the power-disconnect switch to apply main AC power to the analyzer.


After the Zero is complete, allow the analyzer to stabilize for 5 minutes before continuing.

9. Initiate an Auto-Setup and continue with this procedure only after the completion number is between 0.75–1.25.

!WARNING

!WARNING

(AutoSetup) CFGF1 • See “Auto-Setup Completion Number” in this chapter.


10. For the new lamp, view the Ftr screen to determine the filter location with the highest lamp pulse current-control value.

The last digit in each of the following commands is the filter location. Pressing Ent returns the CFG mode normal display.

If Lamp1 was replaced, display the values using these commands (* see Note):

F1 1 1 F1 1 3 F1 1 5 Ent

If Lamp 2 was replaced, display the values using these commands (* see Note):

F1 1 4 F1 1 6 F1 1 2 Ent

If the lamp pulse current-control value for a filter location is negative, that filter location is not used. * The filter positions assigned to each lamp will change depending on the species being measured, the lamp types, and the application. For the filter sequence for your application, view the Bench Type Code (press F2 1 in RUN mode) and then refer to the Filter Position Assignment descriptions (see “F2 1” under “RUN/CFG Mode – F2 Commands” in Chapter 4).

11. Turn off the Automatic Lamp Control (Alc). The Alc Enable function must be off to ensure the analyzer does not make automatic adjust-ments while you are setting the Measure and Reference signals to oper-ate at optimum ratios to each other, in the following steps.

12. For the filter location with the highest lamp pulse current-control value, view the SIG screen and display its PMT signal by pressing F6 1z, where ‘z’ is the filter location.

The message “SIGz m.mmm r.rrr” is displayed, where ‘z’ is the filter location, m.mmm is the Measure PMT signal, and r.rrr is the Reference PMT signal. The PMT signal values are updated at one-second intervals.

NOTE

(Alc) CFGF2 7 Del 0 Ent


Example: If replacing Lamp 1, and the filter location with the highest lamp pulse current-control value is Filter 3, the PMT signal for Filter 3 is displayed by pressing F6 1 3.

If either the Measure or Reference PMT signal becomes equal to or greater than 10.000 V at any time during lamp alignment, decrease the PMT level (CFGF1 4 to view PmtLvl screen) in one-volt incre-ments until it reaches a stable level. Allow the signals to stabilize and continue.

13. Slightly loosen the Lamp Clamping Screw. Loosen the Lamp Retaining Screw and rotate the Lamp Retaining Bracket 90 degrees.

14. Slowly rotate the new lamp to obtain the maximum signal from the Measure PMT. Since the User Interface is updated at one-second inter-vals, use slow, small movements, pausing each turn to view the new value.

Because the Automatic Lamp Control (Alc Enable function) is turned Off, the displayed signal may not be perfectly steady.

15. Loosen the Locking Screw between the two lamps.

16. To obtain the maximum signal from the Measure PMT, adjust the Lamp Adjusting Screw for the lamp being replaced.

17. To replace the second lamp repeat Steps 9–16.

18. Tighten the Locking Screw located between the two source lamps.

19. Return the Lamp Retaining Bracket to its original position and tighten the Lamp Retaining Screw. Tighten the Lamp Clamping Screw to se-cure the lamps. Do not overtighten these screws; the springs should not be collapsed.

NOTE

!CAUTION


20. Initiate another Auto-Setup and continue with this procedure only af-ter the completion number is between 0.75–1.25. See “The Auto-Setup Sequence” in this chapter.

Press Esc Ent. The message “SAVE CONFIG?” will appear. Press Ent to save the new configuration, and return to RUN mode normal display.

21. Close and secure the Electronics Enclosure door with its (3) M6 screws.

Allow the analyzer to warm up to operating temperature and stabilize (30–45 minutes).

22. Open the Vent Valve on the ASR900 Sample Probe and then open its Sample Valve to allow sample gas into the analyzer sample system.


24. Manually Zero the analyzer and then manually Span the analyzer (Span is optional; depends on application).

25. Change the Flow Control setting back to Analyzer Control mode and return to the RUN mode normal display.





When is an Auto-Setup Required / Not Required?

The Auto-Setup optimizes PMT (photomultiplier tube) gains and the source lamp currents. After the Auto-Setup is complete, the Automatic Lamp Control (Alc On) is automatically turned on. View the current sta-tus of this function on the Alc screen (‘0’ = Alc Off; ‘1’ = Alc On).

Auto-Setup is required when:

• The “Warning PMT Signal” alarm is displayed under Error Condition on the Status tab.

• One or both source lamps are replaced or adjusted.

• The Measuring Cell Windows and/or optics are cleaned.

• Any optical filter is replaced.

• One or both PMTs are replaced.

• The Optical Bench board is replaced.

Auto-Setup Completion Number

At the end of every Auto-Setup the analyzer displays a completion num-ber that is the product of the lowest and highest transmittance. A normal completion number is 1.00, ±0.25.

IMPORTANT Although a good completion number is indicative of a successful Auto-Setup, do not rely on it solely. Always check the PMT Level and PMT Balance after every Auto-Setup. See “PMT Level and PMT Balance,” following this section, for details on acceptable levels of these two parameters.

If the completion number is outside of this range it is an indication that the Measure and Reference signals are not at optimum ratios to each other. The most common cause of an abnormal completion number is initiating Auto-Setup when the Measuring Cell has not been properly purged. This results in completion numbers lower than normal. The most likely cause of a higher than normal completion number is incorrect placement of the PMTs in their respective sockets. Although the sensitivity of each PMT is similar, the Measure path PMT typically has a slightly higher gain than the Reference path PMT. Swapping the PMTs from the factory-set positions can produce higher than normal completion numbers.

NOTE

(Alc) CFGF2 7 Del 0 Ent


PMT Level and PMT Balance

PMT Level (PmtLvl) and PMT Balance (PmtBal) are adjusted only dur-ing the Auto-Setup. The typical range of operation for both parameters is 0–10 VDC. After a successful Auto-Setup, normal values for PMT Level should be 7.2–7.4 VDC while the PMT Balance should be between 4.0–7.0 VDC. The analyzer will function with values outside this range, but it is a sign that a change has likely occurred in the transmission of light within the Optical Bench (for example: dirty Windows, weak lamps, weak PMTs, faulty PMT Buffer board – see “Troubleshooting and Diagnostics” in this chapter for alarm conditions and corrective action.

At the end of every Auto-Setup, always check the PMT Level and PMT Balance. Take note of severe changes in these parameters because they are as important as the absolute value.

The PMT Level signal adjusts the gain of both PMTs simultaneously in the same direction. PMT Balance adjusts the gain of the two PMTs in opposite directions by controlling a virtual ground circuit on the Optical Bench board.

It is possible to achieve an acceptable completion number, yet have an unacceptable PMT Level and/or PMT Balance signal. Always check both of these values after an Auto-Setup.

If the PMT signals are outside their normal range of operation after the Auto-Setup is complete, check for the following:

• Adjust the Lamp Max setting slightly (typical range is 4.5–7.8 VDC) and start another Auto-Setup.

• Was the Auto-Setup done with Zero gas flowing through the sample system?

• Are there any PMT- or lamp-related alarms? If so, see “Troubleshooting and Diagnostics” in this chapter for alarm corrective action.

• Are the Measuring Cell Windows clean?

• Are the PMT signals weak?

• Do the source lamps need replacement (weak lamps)? If not, are the source lamps aligned?

• If the lamps were replaced, is the correct socket connected to the cor-rect lamp? Lamp 1 is the closest to the Optical Bench board.

(PmtLvl) RUNF1 4 (PmtBal) RUNF1 5


• Have there been any leaks from the Measuring Cell? If so, check the condition of the Optical Filters, Beam Splitter, Mirrors, Windows, Lenses, and o-rings in the Optical Bench and in the Measuring Cell (including Reflector Block). Contact AMETEK for procedures not discussed in this manual.

• Are the PMTs in their original sockets? (Is the higher gain PMT in the Measure path?)

• Is the PMT Buffer board faulty?

Auto-Setup Fault Messages and Corrective Action

If during an Auto-Setup either the PMT Level adjustment or PMT Balance signal goes to minimum or maximum, the “LVL adjust fault” or “BAL adjust fault” message can appear on the User Interface.

If one or both of these messages appear, ensure that:

• The Measuring Cell was purged with Zero gas.

• Display the source lamp pulse current-control signal for each filter location (Ftr).

• The source lamps are not burned out.

• Each lamp socket is attached securely to each lamp.

• The lamps are inserted completely into the Detector Assembly.

• The lamp power supply cables are connected and not damaged.

• The PMT high-voltage (J101, J102) and flat (J103) cables are connected and not damaged.

• The Measuring Cell Windows are clean and not damaged.

• The Measuring Cell is clean.

Correct any faults and initiate the Auto-Setup.

(Ftr) RUNF1 11..6


The Auto-Setup Sequence

To perform an Auto-Setup:

1. From CFG mode, press F1 • to start the Auto-Setup.

The Auto-Setup starts immediately upon entering F1 •. Do not press any keys while it is in progress.

The process takes about 5 minutes to complete. Six messages will appear:

1. “Adjusting LVL” 4. “Adjusting LVL”2. “Adjusting LMP” 5. “Adjusting LMP”3. “Adjusting BAL” 6. “Completion= b”

2. Upon completion of the Auto-Setup, if the value of ‘b’ in Message 6 is between 0.75–1.25, continue with Step 3.

If the value of ‘b’ is not between 0.75–1.25 move the jumper on head-ers P300 or P301 of the Optical Bench board to an alternate position, install another jumper on P300, or change the position of the jumper on P301 for a drastic change.

Note that when changing the jumpers:• Increasing the jumper position increases the completion number.• Decreasing the jumper position decreases the completion number.• Adding a jumper decreases the completion number.

Restart Auto-Setup (press F1 •). Repeat this procedure until ‘b’ is be-tween 0.75–1.25, then continue with Step 3.

P300 can have up to four jumpers installed; at least one must be pres-ent at all times. P301 has two jumper positions, but only one jumper position is used. Do not put both jumpers on P301.

If further adjustments are required, refer to “Manipulating the Completion Number, PMT Level, and PMT Balance,” following this section.

3. After the value of ‘b’ is between 0.75–1.25, press Ent Esc. The message “SAVE CONFIG?” will appear. Press Ent for Yes (to save the new con-figuration), and then press Esc to return to RUN mode normal display.

NOTE

NOTE

(AutoSetup) CFGF1 •


Manipulating the Completion Number, PMT Level, and PMT Balance

In certain situations (for example, degradation of PMTs or lamps, or the optics are contaminated), it may be necessary to change the P300 and P301 jumper settings on the Optical Bench board. Changing the jumper posi-tions provides coarse gain adjustment of the Reference PMT and therefore changes the completion number result, PMT Level, and PMT Balance.

There are six jumper positions (four in P300 and two in P301) – at least one jumper must be in one of the six positions at all times. The jumper combinations control the coarse supply voltage ranges of the two PMTs, Reference-path and Measure-path. The Optical Bench Auto-Setup proce-dure performs fine adjustment to the PMT supply voltages at one jumper combination. The jumper combinations affect the Auto-Setup in terms of reducing the completion number, increasing or decreasing the resulting PMT Balance and, to a lesser degree, the PMT Level.

Figure 5-3 describes the effect on the PMT Balance and PMT Gain in rela-tion to different jumper positions.

To achieve an acceptable completion number, PMT Balance, and PMT Level:

1. If jumpers have been reconfigured, perform an Auto-Setup.

If the PMT signals are outside their normal range of operation after the Auto-Setup is complete (typical range is 4.5–7.8 VDC), adjust the Lamp Max setting slightly and start another Auto-Setup.

2. After an acceptable completion number, PMT Balance, and PMT Level has been achieved, perform a Manual Zero.

3. After the Zero is complete, change the Flow Control setting back to Analyzer Control mode.

(AutoSetup) CFGF1 •


NOTE


When changing jumpers, one must be present in one of the six posi-tions at all times.

Figure 5-3. Optical Bench board P300/P301 jumper positions vs PMT Balance.

Jumper Positions

P300 P301 1 2 3 4 5 6

X X X X X X X X X Higher PMT

Balance X X X X

Lower Completion Number

X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

X X X X Lower PMT

Balance X X

Higher Completion Number

NOTE


Chopper Assembly Maintenance

Replace the Chopper Motor Drive Belt and Bearings in the Chopper Assembly every 2 years.

“P/N” refers to Part Number.

To replace the Drive Belt and Bearings in the Chopper Assembly (Figures 5-4 and 5-5):








!WARNING

NOTE




!WARNING






5. Meanwhile, open the Electronics Enclosure and:

a. Disconnect the ribbon cable from J100 on the Optical Bench board (from J102 on the Micro-Interface board).

b. Disconnect the AC power line (connector plug) from TB100 on the Optical Bench board.

c. Disconnect terminals of yellow/green ground wire that runs from the Electronics Enclosure to the Optical Bench.

d. Optional: If using the Optical Bench Purge, disconnect the purge line (black tube) from the Optical Bench Purge Fitting.

6. After the Oven has cooled down enough to work on, disconnect the Measuring Cell from the Heater Plate and remove it from the Oven:




!WARNING

!WARNING



To help maintain the temperature inside the Oven, close the Oven door while working on the Measuring Cell.

7. While holding the Optical Bench by its upper portion or Measuring Cell, remove the outermost pivot pin from the blue Support Arm Yoke and carefully remove it from the analyzer.

While removing the Optical Bench from the Electronics Enclosure, do not support the assembly by its circuit boards or source lamps.

Figure 5-4. Optical Bench board layout.

!CAUTION


8. Replace the Drive Belt (o-ring) and Bearings (Figure 5-5):

a. Remove the (4) M3 x 8 screws that secure the Chopper Housing to the Chopper Cover. Separate the two halves of the Chopper Assembly.

b. Remove the Drive Belt by rolling it outward and away from the groove of the Pulley.

c. Remove the Snap Ring and Spring Washer from the Chopper Shaft.

Remove the Bushings (2), Bearings (2), and Chopper Wheel from the Chopper Shaft.

d. Replace one Bushing on the Chopper Shaft, followed by a new Bearing (P/N 300-9437), the Chopper Wheel, another new Bearing and the other Bushing.

Replace the Spring Washer and the Snap Ring on the Chopper Shaft.

e. Replace the new Drive Belt (o-ring, P/N 300-1528) by first placing it in the Chopper Wheel groove and then rolling it over the Pulley and into the groove. Use care to avoid stretching the Drive Belt.

Rotate the Chopper Wheel to ensure the Belt is properly seated in the Chopper Wheel and Pulley grooves, and to make sure the Bearings and other parts are properly aligned.

f. Align the two halves of the Chopper Assembly and secure them using (4) M3 x 8 screws.


Figure 5-5. Optical Bench Chopper Assembly Maintenance diagram.


9. Replace the Optical Bench/Measuring Cell Assembly in the analyzer:

Ensure there is no power being supplied to the analyzer while install-ing the Optical Bench.

a. With the blue Support Arm Yoke fully extended, lift the Optical Bench/Measuring Cell Assembly by its upper portion and carefully move it toward the analyzer. Align its Optical Bench Support Plate with the Support Arm Yoke and replace the pivot pin. Tighten the set screw. The Optical Bench should swing freely.

b. Connect Optical Bench wiring:

Ribbon cable from J102 on Micro-Interface board to J100 on Optical Bench board.

AC power line (connector plug) to TB100 on Optical Bench board.

Connect the yellow/green ground wire using the disconnect terminals.

c. Optional: If using, connect the purge line (black tube) to the Optical Bench Purge Fitting.


a. Open the Oven door. Swing the Optical Bench toward the Electronics Enclosure and then swing the Measuring Cell toward the Oven (Figure 5-6).


!WARNING


Using a flat hex key, replace the M4 x 25 screw in the counter bore hole in the Heat Transfer Block and thread it onto the Cell RTD (until it is snug). Do not use a ball driver. Do not tighten the screw at this time.




b. Adjust the Measuring Cell/Optical Bench Assembly so that the sili-con seal on the Cell Extension fits firmly into the molded depres-sions in the Oven and Electronics Enclosure walls.



c. Verify there is no clearance between the Heat Transfer Block and the Cell RTD. The Measuring Cell must feel secure against the Heater Plate. Gently push and pull on the Measuring Cell to verify it is not loose.

If there is any movement, tighten the M4 x 25 screw again until the Measuring Cell does not move, being careful not to over tighten it. Over-tightening this screw will damage the threads on the RTD.


e. Connect the sample tubing to the Measuring Cell.

NOTE

NOTE




It is necessary to work with the Electronics Enclosure door open after replacing parts in the Chopper Assembly. When the analyzer’s covers and doors are open, take appropriate precau-tions to avoid electrical shock. Hazardous voltages are present inside.





Close the power-disconnect switch to apply main AC power to the analyzer. Do not close the Oven Heater fuse at this time, until after the Leak Check has been performed.


!WARNING

!WARNING







17. Change the Flow Control setting back to Analyzer Control mode.





To replace the Heater Elements and RTDs (Figures 5-6, 5-7, 5-8, 5-9, and 5-10):






Replacing Parts in the Heater Plate

Maintenance on the Heater Plate is not required unless any of its com-ponents fail. If failure occurs, it will be necessary to replace the Heater Elements and RTDs in the Heater Plate.

RTD Resistance Check

Before removing a RTD, test the problematic RTD using the following table to verify its operation.

!WARNING











5. Open the Electronics Enclosure door.

6. After the Oven has cooled down enough to work on:





!WARNING

!WARNING

!WARNING



d. Disconnect and remove all other tubes from the Oven – including any that run to connection points outside the Oven – that may restrict the movement of the Heater Plate later in this procedure.

e. Remove the Aspirator/Sample Line Bracket (2 screws) from the Heater Plate.

7. Remove the (2) M6 x 16 and (2) M6 x 40 screws that secure the Seal Cover to the Seal Body (Figure 5-7.1).

Move the retaining ring from its groove in the Thermal Insulation Tube to the space slightly above the groove (Figure 5-7.1) and remove the Seal Cover.

Remove the Oven Plug (Figure 5-8).

8. Record the termination point of each wire connected to Terminal Strips J1, J2 on the Heater Termination board (Figure 5-7.2) in the Seal Body. Tag the wire(s) of RTDs and/or Heater Elements that will be re-used with their termination points, to use when replacing them later.

Disconnect the faulty RTD and/or Heater Element wires from the Heater Termination board.

9. Remove the (4) M6 x 35 screws and lock washers that secure the Heater Plate to the Oven wall (Figure 5-8).

10. On the front of the Heater Plate, remove the (4) M6 x 25 screws that secure the Upper Heater Plate to the Lower Heater Plate.

Slightly loosen the Seal Body gland nut (inside the Electronics Enclosure).

Tilt the top of the Heater Plate toward you until you can access the (4) M6 x 25 screws on the back of the Heater Plate. Tighten the Seal Body gland nut to hold the Heater Plate in that position.

Remove the (4) M6 x 25 screws and carefully separate the Upper Heater Plate from the Lower Heater Plate. Lean its top against the Oven wall to expose the internal RTDs and Heater Elements. Take care not to damage the internal wires.


OPTIONAL If working on the Heater Plate with it still in the Oven is not practi-cal, remove it from the Oven. To do this, record all wire termination points at the Terminal Strips (J1, J2) inside the Seal Body and then disconnect the wires. Unscrew the Thermal Insulating Tube from the Lower Heater Plate, and move the tube downward to free it from the Heater Plate. Rotate the Seal Body/Thermal Insulation Tube away from the ana-lyzer to allow more room to remove the Heater Plate, taking care not to damage the wires. Tilt the top of the Heater Plate forward and pull the Heater Plate up and out of the Oven. Move the Heater Plate to a suitable work bench to work on it.

11. Replace the Heater Elements and RTDs (Figures 5-8 and 5-9):

Replacing a faulty Heater Element:a. Remove the faulty Heater Element from its channel in the Upper

Heater Plate and carefully pull its wire out from the Seal Body and through the Lower Heater Plate.

b. Install a new Heater Element (P/N 300-8684) in the channel it was removed from.

c. Label the Heater Element wire “Overtemp Heater” or “Heater” as required.

Replacing internal Overtemp and/or Heater RTDs:

Looking at the front of the Heater Plate, the RTD on the right side is “Overtemp” and the RTD on the left side is “Heater”.

a. Unscrew the faulty RTD from the Upper Heater Plate and care-fully pull its wire out from the Seal Body and through the Lower Heater Plate.

b. Thread the new RTD (P/N 300-4924) into the Upper Heater Plate and tighten it using short needle-nose pliers.

Label the RTD wire “Overtemp RTD” or “Heater RTD” as required.

c. Repeat Steps ‘a’ and ‘b’ if replacing the other RTD.

NOTE

NOTE


Replacing the external Sample Cell RTD:a. Wrap a small piece of rubber around the RTD tip, grip the tip with

channel-lock pliers, and loosen/remove it (counter-clockwise). Use short needle-nose pliers to remove the RTD Base from the Upper Heater Plate. Carefully pull its wire out from the Seal Body and through the Lower Heater Plate only at this time.

IMPORTANT When replacing an external RTD, do not remove the RTD wire from the Upper Heater Plate at this time.

b. Assembly the new RTD (P/N 300-4924) and its Base (P/N 300-4914). The RTD Base (and RTD Tip, P/N 300-4913) may be reused if not damaged.

c. Pull the faulty RTD out of the Upper Heater Plate approximately 1", just enough to expose some of the wiring. Cut off the RTD head, strip off some insulation, and solder the termination end of the new RTD wire to the RTD end of the old RTD wire. Use the old wire to pull the new RTD wire through the Upper Heater Plate as you remove the old wire. Label the new RTD wire “Sample Cell”.

d. Apply Loctite 271 (P/N 300-4478) on the small (lower) threads of the RTD Base. Rotate the Base counter-clockwise 3–4 turns (take care not to over-stress the wire) and then screw (clockwise) the Base into the Upper Heater Plate. Hand-tighten the Base. Using short needle-nose pliers, tighten the Base until it is snug. Pull the RTD wire from the bottom of the Upper Heater Plate, until the RTD is seated inside the Base.

e. Apply Loctite 271 on the large (upper) threads of the Base. Thread the RTD Tip clockwise onto its Base and hand-tighten it.

To protect the Tip, wrap a small piece of rubber around it, lightly grip it with channel-lock pliers, and tighten it until it is snug.

f. Repeat Steps ‘a’ through ‘e’ if replacing the optional Sulfur Condenser RTD (if used).

If the Sulfur Condenser RTD is not used, the hole is plugged with a Heater Blanking Plug.

NOTE

NOTE


NOTE

Figure 5-6 illustrates typical Div 2/Zone 1 analyzer layouts. For your specific analyzer, refer to Final “As-Built” drawings shipped with the analyzer.

Figure 5-6. Oven/Instrumentation layout, Div 2/Zone 1.


12. If the Ground wire is damaged, replace it. (Use only 16 AWG High Temperature wire.) Strip 1/8" insulation from the end of the 30" length of high temperature wire (P/N 300-4182). Use a crimping tool to crimp a #8 ring terminal (P/N 300-4182) on the wire. Secure the ring terminal to the bottom of the Upper Heater Plate with a M4 lock washer (P/N 300-0265) and M4 x 8 screw (P/N 300-0006). Tighten the screw. See “Detail A” in Figure 5-9.

13. Install a 3/4" anti-short (P/N 300-5292) around all of the wires and into the bottom hole in the Lower Heater Plate to protect the wires from damage during handling.

14. Feed the RTD and Heater Element wires (and Ground wire, if re-placed) through the Lower Heater Plate and Thermal Insulation Tube, and into the Seal Body.

With the joining surfaces of the Top and Bottom Heater Plates facing each other, position the wires in the wire channel in the Lower Heater Plate. Reassemble the two halves of the Heater Plate, being careful not to pinch any wires between the two plates, and secure them together with the (8) M6 x 25 screws. Tighten the screws.


Figure 5-7.2. Heater Termination board Terminal Strips J1, J2 wiring layout.

Figure 5-7.1. Flameproof Heater/Seal Assembly, 100-1190-1.


Figure 5-8. Flameproof Heater/Seal Assembly layout, WX-14324-1A.


Figure 5-9. Flameproof Heater/Seal, internal component layout, 100-1622-1A.


15. Reinstall the Heater Plate in the Oven: Slightly loosen the Seal Body gland nut (inside the Electronics

Enclosure) and tilt the top of the Heater Plate toward the back of the Oven.

OPTIONAL If the entire Heater Plate was removed from the Oven to work on it, reassemble Heater Plate (see Step 14 for important information about reassembling the Top and Bottom Heater Plates). With the top of the Heater Plate tilted toward you, place the bottom of the Heater Plate in the bottom of the Over, taking care not to damage the wires. Tilt the Heater Plate toward the Oven Wall. Rotate the Seal Body/Thermal Insulating Tube toward the Oven until the top of the Thermal Insulating Tube is in line with the threaded holes in the bottom of the Oven. Guide the wires from the Heater Plate through the Thermal Insulating Tube and into the Seal Body. Ensure the threads of the Thermal Insulating Tube are clean and then thread the tube back into the Heater Plate, taking care not to cross-thread the threads. Tighten the tube until an increase in resistance is felt. Do not overtighten it.

Replace the (4) lock washers and M6 x 35 screws to secure the Heater Plate to the Oven wall. Gently push and pull on the Heater Plate while tightening the screws, to ensure it is properly seated against the Oven wall.

Tighten the gland nut on the Seal Body.

16. Terminate all wiring to Terminal Strips J1, J2 on the Heater Termination board, as per your notes (see also Figure 5-10).

Slide the Seal Cover over the Seal Body and secure it with (2) M6 x 16 and (2) M6 x 40 screws. Replace the retaining ring in the groove in the Thermal Insulating Tube.

Replace the Oven Plug.

17. If the Aspirator/Sample Line Bracket was removed, replace it on the Heater Plate (2 screws).

NOTE


Figure 5-10. Oven Heater and Temperature Sensor wiring, WX-14161.



a. Open the Oven door. Swing the Optical Bench toward the Electronics Enclosure and then swing the Measuring Cell toward the Oven (Figure 5-6).


Using a flat hex key, replace the M4 x 25 screw in the counter bore hole in the Heat Transfer Block and thread it onto the Cell RTD (until it is snug). Do not use a ball driver. Do not tighten the screw at this time.




b. Adjust the Measuring Cell/Optical Bench Assembly so that the sili-con seal on the Cell Extension fits firmly into the molded depres-sions in the Oven and Electronics Enclosure walls.



NOTE

NOTE


c. Verify there is no clearance between the Heat Transfer Block and the Cell RTD. The Measuring Cell must feel secure against the Heater Plate. Gently push and pull on the Measuring Cell to verify it is not loose.

If there is any movement, tighten the M4 x 25 screw again until the Measuring Cell does not move, being careful not to over tighten it. Over-tightening this screw will damage the threads on the RTD.


19. Replace and connect all tubes to their respective connection points inside the Oven – including any that run to connection points outside the Oven.

Connect the Sample and Vent Lines to their connection points in the Oven.

Ensure the sample tubing is connected to the Measuring Cell.



It is necessary to work with the Electronics Enclosure door open after replacing parts in the Heater Assembly. When the analyzer’s covers and doors are open, take appropriate precau-tions to avoid electrical shock. Hazardous voltages are present inside.



!WARNING




Close the power-disconnect switch to apply main AC power to the analyzer. Do not close the Oven Heater fuse at this time, until after the Leak Check has been performed.






26. Change the Flow Control setting back to Analyzer Control mode.



!WARNING




ASR900 Sample Probe Preventive Maintenance

Preventive maintenance for the ASR900 Sample Probe is not discussed in this guide, but it is important to maintain it at recommended intervals. When possible, perform maintenance on the ASR900 Sample Probe at the same time as the analyzer. For probe maintenance details, refer to the ASR900 Sample Probe Installation and Maintenance Guide.


Examining and Caring For the Flamepaths

The analyzer is designed with flamepaths that will prevent flame propa-gation from within the analyzer and its Ex d Disconnect Enclosure to the outside, should an internal explosion occur.

The flamepaths on the analyzer consist of:

• The Ex d Disconnect Enclosure joining surfaces (enclosure door and hous-ing) and its cable entry ports, seal entries, and pressure switch entries.

During each analyzer maintenance, use a feeler gauge to check the flamepath gap of the Disconnect Enclosure flange (enclosure door and housing joining surfaces). The gap must not exceed 0.15 mm; if the gap exceeds this value, contact AMETEK for advice. See Warning below.

• All separable joints in the Heater Plate Assembly and Seal Body. These parts include the joining surfaces of the Heater Plate, the joining surfaces of the Seal Body and its cover, the RTD mounting locations (whether RTDs are installed or their holes are plugged), and both the threaded and cylindrical end of the Thermal Insulation Tube between the Heater Plate and Seal Body.

During each analyzer maintenance, use a feeler gauge to check the flamepath gap of the Heater Plate Assembly flange (upper/lower Heater Plate joining surfaces, inside the Analyzer Oven). The gap must not exceed 0.1 mm; if the gap exceeds this value, contact AMETEK for advice. See Warning below.

Take extreme care to avoid damaging the threads on the cable entry glands on the Disconnect Enclosure and all threaded parts on or in the Heater Plate/Seal Assemblies. Clean, defect-free threads are essen-tial to ensure a flameproof connection.

When performing equipment maintenance in hazardous areas, all safety standards and procedures must be followed, as specified by the Owner Company, local electrical-inspection authority, and National/EU regulations.

Purged Analyzer (Hazardous Location) Applications Do not apply power to the analyzer if there is damage (scratches, indentations, or wear) to any flamepath (on the Oven Heater or Disconnect Enclosure). Applying power to an analyzer with a dam-aged flamepath is dangerous and could result in serious injury or death, or serious damage to equipment. Review this section for com-plete information about caring for the flamepaths. Replace parts immediately if damage or wear is apparent. Contact AMETEK if there is any doubt about the integrity of any flamepath.

!CAUTION

!WARNING

!WARNING


Disconnect Enclosure Flange Flamepath (Joining Surfaces)

Any time the Ex d Disconnect Enclosure is opened, inspect the flamepath for scratches, indentations, or other damage.

The minimum flamepath length must be at least 38 mm and flat (0.05 mm or better) and a maximum surface roughness of 6.3 µm or less. When the bolts are tightened, the gap must not exceed 0.15 mm. Use A2 stainless steel fasteners with yield stress ≥450 MPa (65,300 psi).

If it is necessary to use a cleaning agent, make sure the power to the analyzer is off. Also, the agent must be nonabrasive and must not at-tack aluminum (example, a suitable agent is Isopropanol). Following any maintenance and/or cleaning – and after the cleaning fluid has evaporated completely – immediately close the Disconnect Enclosure.

While the Disconnect Enclosure is open for maintenance or repair, take extreme care to avoid scratching or damaging the joining surfaces (flamepath). If at any time the Disconnect Enclosure door is open but is not being worked on, close and secure it with at least one screw. This will reduce the risk of inadvertently scratching or damaging the flamepath. Before closing the door, gently clean these areas with a soft, nonabra-sive cloth and make sure they are free of debris.

Before opening the Disconnect Enclosure, follow all necessary safety procedures to ensure the area is nonhazardous (main power to the analyzer is off, explosive gas atmosphere is not present, etc.). Before performing maintenance on the analyzer, shut off the power to the analyzer and all alternate power supplies (if used).

!CAUTION

!WARNING

!CAUTION


Heater Plate Flange Flamepath (Joining Surfaces)

Normally, the parts that make up the Heater Plate and its Seal Assembly are not subject to any movement that would cause damage or wear to any of the parts. However, any time the Heater Plate and its Seal Assembly are opened, inspect the flamepath for scratches, indentations, or other dam-age. For all parts, the maximum surface roughness must be 6.3 µm or less. Use A2 stainless steel fasteners with yield stress ≥450 MPa (65,300 psi).

The minimum flamepath lengths and gaps for the different parts that make up the Heater Plate and its Seal Assembly are:

Heater Top/Heater Bottom The flamepath length must 12.1 mm or greater and the gap must not exceed 0.1 mm.

Thermal Tube/Seal Body The flamepath length must 19.2 mm or greater and the gap must not exceed 0.05 mm.

Seal Body/Seal Cover The flamepath length must 17.4 mm or greater and the gap must not exceed 0.07 mm.


Troubleshooting and Diagnostics

Model 900 and 930 Analyzers have a built-in alarm (error) detection sys-tem that continuously monitors the operation of key analyzer operating parameters. An alarm can be detected by either the Host Controller or the Microcontroller board and can be of two types:

• Warning Alarms indicate that the analyzer requires servicing – the data may be suspect under this condition.

• Fault Alarms indicate that a failure has occurred and the analyzer is not operating properly – the results are not valid. Fault alarms also cause the Normal/Fault contacts to switch, and the sample system will automatically switch to automatic Backpurge mode if the current Flow Control mode setting is ‘0’ (Analyzer Control).

Additional diagnostics screens can be viewed from the User Interface if problems cannot be corrected by performing general diagnostics. For more information about these diagnostics functions, refer to the RUN / CFG and CAL Mode Command descriptions in Chapter 4. These diagnostics are indicated by ** preceding their definitions.

When alarms are detected, the alarm indicator is displayed on the top-right line of the User Interface. Typical diagnostic alarms to watch for include sample- and temperature-related alarms.

Generally, most troubleshooting and diagnostics can be done by work-

ing from the analyzer’s User Interface. When is displayed, view the HStatus (1..8) and MStatus (1..7) screens (RUN mode) to determine which alarms are active. If an alarm is active, its description will be displayed next to its associated number. If the active condition does not exist, the message “HSz OK” (for Host Controller board alarms) or “MSz OK” (for Microcontroller board alarms) appears next to its associated number.

To view alarms that have been corrected or reset, view their correspond-ing History Buffers (HCHist or MCHist), also in RUN mode. Each History Buffer can store up to a maximum of nine alarms, with ‘1’ being the oldest and ‘9’ being the most recent.

NOTE

(HStatus) RUNF5 41..8 (MStatus) RUNF5 51..7 (HCHist) RUNF5 • 1..9 (MCHist) RUNF5 – 1..9


If two or more alarms are detected simultaneously, the displayed alarm status code is a sum of the primary alarm codes. To resolve a non-primary status code into its primary alarm codes, subtract the largest primary alarm code from the displayed number. Continue to subtract the largest primary code from the remainder until a primary alarm code is left.

Example: The displayed Host Controller board status code is 20. The alarms detect-ed are:

20 - 16 f Temp low (Fault – Host Controller) 4 f Internal communication (Fault – Host Controller)


Host Controller Board Alarm Conditions and Corrective Action

This section lists valid alarms (errors) that originate from the Host Controller board, including the Alarm Type (Fault or Warning), name and reason the alarm is set (Condition/Description), and Suggested Corrective Action for each. The Host Controller Status Codes (HS Code) and Host Controller numbers (HStatus) to press on the keypad to view the current status or alarms are also listed.

The possible Host Controller board alarms are polled individually with the keypad command F5 4z, where ‘z’ (z = 1..8) is defined by HStatus. For each ‘z’, the corresponding alarm message description is displayed if the alarm exists; otherwise the message “HSz OK” appears.

On the User Interface, the ‘w’ or ‘f ’ preceding an alarm indicates a ‘w’arning or ‘f ’ault condition.

HS Code HStatus Alarm Type Condition / Description and Suggested Corrective Action0 — — HSz OK

If the HS Code returned is ‘0’ and the message displayed is “HSz OK”, it indicates that the Warning or Fault being viewed does not exist (where ‘z’ is the HStatus number 1..8 assigned to that alarm). This is not an alarm condition.

Corrective Action:

No action is required.1 1 Warning w EEPROM Full

The EEPROM (nonvolatile memory) has exceeded the safe num-ber of times that configuration data has been rewritten to it (95 % used).

Corrective Action:

• Replace the EEPROM as soon as possible. Contact AMETEK to verify operation before removing the EEPROM and for information about installing the new EEPROM to ensure your analyzer will operate the same as it did prior to replacing the EEPROM.

NOTE

(HStatus) RUNF54 1..8


HS Code HStatus Alarm Type Condition / Description and Suggested Corrective Action2 2 Warning w Out of Range

The concentration of the output exceeds its normal operating full-scale range by more than 10 %.

Corrective Action:

• From the Output screen, check that the full-scale range is correct for the current sample. If this Warning persists during normal operation, contact AMETEK. A range change and recali-bration may be required.

4 3 Fault f Internal communication

This serious system Fault condition indicates the Host Controller board cannot establish reliable communications with the Micro-controller board.

When this Fault is detected, “CommFault” is displayed immedi-ately on the lower line of the User Interface to indicate the same serious system alarm as “f Internal communication”.

Corrective Action:

Take appropriate safety precautions, open the Electronics Enclo-sure, and:

• Check the flat cable between the Host Controller board (on door inside Electronics Enclosure) and Micro-Interface board (mounted to Electronics Enclosure backpan) for proper connec-tions and inspect it for damage (cuts, nicks, burn marks, etc.).

• Ensure the actuators on switch S100 on the Micro-Interface board are positioned toward the middle of the board. See 5-11 for the location of this switch.

8 4 Fault f Analytical data

This serious system Fault condition indicates the Host Control-ler board is not receiving analytical data from the Microcontroller board.

When this Fault is detected, “NoData” is displayed immediately on the lower line of the User Interface to indicate the same serious system alarm as “f Analytical data”.

Corrective Action:


• Check the Chopper Wheel Optocoupler cable connection.

• Check the flat cable between the Optical Bench board (J103) and the PMT Buffer for proper connections and inspect it for damage (cuts, nicks, burn marks, etc.).

• Check the PMT high-voltage connections at the Optical Bench board (J101, J102) for proper connections.

• Check the flat cable between the Optical Bench board and the Micro-Interface board for proper connections and inspect it for damage (cuts, nicks, burn marks, etc.).

• Check the Chopper Wheel motor connection.

(Output) RUNF2 61..4

See Ribbon Cable Interconnect drawing in Appendix A.



HS Code HStatus Alarm Type Condition / Description and Suggested Corrective Action16 5 Fault f Temp Low

One or more of the temperature zones is operating below its Set Point value by more than 5 %.

If the TCold parameter is used, the Sample and Vent Lines still use 5 % of the Set Point as an alarm point. However, the ASR900 Sample Probe and Analyzer Oven temperature uses the TCold value as an alarm Set Point.

This alarm will occur during a cold start, but will clear when the op-erating temperature of all controlled zones are within their normal operating ranges.

If this alarm is caused by low temperatures in any of the tempera-ture zones, the analyzer will automatically switch to Backpurge mode to ensure the system does not become plugged due to a low temperature in one of its zones.

This alarm can also be caused by a power interruption or a power spike.

Corrective Action:

• From the User Interface:- Check the current temperature (Show MAI screen) for each

temperature zone and compare it to its Set Point temperature (TStPt screen).

- Check each of the associated configuration parameters for temperature control. These parameters may have been lost as a result of a power interruption or a power spike.

• Take appropriate safety precautions, open the Electronics Enclo-sure, and:- Check the fuse for the zone which caused the alarm.

• Other checks/corrective action:- Check the electrical connections between the heater and the

Sample Line, Vent Line, and Analyzer Oven. Check for proper connections and damage to the wiring.

See Figures 5-12.1 and 5-12.2 for Sample and Vent Line over-temperature wiring details.

- Using an Ohm Meter, measure the resistance of the tempera-ture sensor (RTD) for the zone which caused the alarm (view the TType screen to determine sensor type). Test it for an open circuit. If the RTD is faulty, contact AMETEK for as-sistance.

- Replace the Temperature Sensor (RTD) Daughter board(s). Contact AMETEK to verify operation before removing this board.

- Replace the Termination board. Contact AMETEK to verify operation before removing this board.

(TCold) RUNF4 7

(Show MAI) RUNF6 81..8 (TStPt) RUNF4 01..4


(TType) RUNF4 41..4


HS Code HStatus Alarm Type Condition / Description and Suggested Corrective Action32 6 Fault f Temp High

One or more of the temperature zones has exceeded its over-temperature limit of 177 °C/350 °F.

When the analyzer detects this alarm, it will automatically switch to Backpurge mode and also de-energize the over-temperature relay for the zone that has exceeded its limit. This cuts power to the cor-responding heater.

The alarm must be manually reset by pressing the Over-Temp switch (SW300) on the Termination board (Figure 5-13). This also re-energizes the over-temperature relay, which restores power to the corresponding heater.

Corrective Action:

• From the User Interface:- Check the current temperature (Show MAI screen) for each


- Check each of the associated configuration parameters for temperature control. These parameters may have been lost as a result of a power interruption or a power spike.

• Take appropriate safety precautions, open the Electronics Enclo-sure, and:- Check the green LED for each circuit, located on the Termina-

tion board (S/L = LED302; V/L = LED301; Oven = LED300) to verify which zone is experiencing problems.

- Press SW300 on the Termination board to re-energize the tripped circuits.

- Check the fuse for the Over-Temp circuit.

• Other checks/corrective action:- Check the electrical connections between the heater and the

Sample Line, Vent Line, and Analyzer Oven. Check for proper connections and damage to the wiring.

See Figures 5-12.1 and 5-12.2 for Sample and Vent Line over-temperature wiring details.

- Using an Ohm Meter, measure the resistance of the tempera-ture sensor (RTD) for the zone which caused the alarm (view the TType screen to determine sensor type). Test it for an open circuit. If the RTD is faulty, contact AMETEK for as-sistance.

- Replace the Temperature Sensor (RTD) Daughter board(s). Contact AMETEK to verify operation before removing this board.

- Replace the Termination board. Contact AMETEK to verify operation before removing this board.



(TType) RUNF4 41..4


HS Code HStatus Alarm Type Condition / Description and Suggested Corrective Action64 7 Warning w Zero Drift

This condition indicates excessive Zero Drift or Span Error. Exces-sive Zero Drift is indicated if Zero gas transmission values attained after a Zero differ by more than ±10 % from the previous values. A Span Error occurs if a Span Factor attained after a Span is ≤0.85 or ≥1.15.

Corrective Action:

• Ensure the proper gases are being used for the calibration.

• Check the analyzer to determine if the Measuring Cell, its optics, and/or sample system is contaminated. Refer to “Analyzer Preven-tive Maintenance Schedule” and “Measuring Cell Maintenance” in this chapter to help you determine if these areas need to be cleaned.

128 8 Warning w SKO temp high (used only if system uses a SKO)

The sulfur knock-out (SKO) temperature is above the Set Point by more than 5 % of the Set Point value.

Corrective Action:

• From the User Interface:- Check the current temperature (Show MAI screen) for this


• Replace the Temperature Sensor (SKO) Daughter board. Con-tact AMETEK to verify operation before removing this board.

• Replace the Termination board. Contact AMETEK to verify op-eration before removing this board.


Figure 5-11. Micro-Interface board.


Figure 5-12.1. Sample/Vent Line Wiring (Disconnect Enclosure), Zone 1 Analyzer.

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Figure 5-13. Over-Temp alarm reset switch (SW300), Termination board.


Microcontroller Board Alarm Conditions and Corrective Action

This section lists valid alarms (errors) that originate from the Microcontroller board, including the Alarm Type (Fault or Warning), name and reason the alarm is set (Condition/Description), and Suggested Corrective Action for each. The Microcontroller Status Codes (MS Code) and Microcontroller numbers (MStatus) to press on the keypad to view the current status or alarms are also listed.

The possible Microcontroller board alarms are polled individually with the keypad command F5 5z, where ‘z’ (z = 1..7) is defined by MStatus. For each ‘z’, the corresponding alarm message description is displayed if the alarm exists; otherwise the message “MSz OK” appears.

On the User Interface, the ‘w’ or ‘f ’ preceding an alarm indicates a ‘w’arning or ‘f ’ault condition.

MS Code MStatus Alarm Type Condition / Description and Suggested Corrective Action0 — — MSz OK

If the MS Code returned is ‘0’ and the message displayed is “MSz OK”, it indicates that the Warning or Fault being viewed does not exist (where ‘z’ is the MStatus number 1..7 assigned to that alarm). This is not an alarm condition.

Corrective Action:

No action is required.1 1 Fault f Wheel speed

There is no signal from the Chopper Wheel Optocoupler, or the Chopper Wheel speed is outside its normal operating range (240–600 RPM).

Corrective Action:


• Check the Chopper Wheel Optocoupler cable connection.

• Check the Chopper Wheel motor connection.2 2 Fault f On-board ADC

One or both of the discrete analog-to-digital converters (ADC) is not responding.

Corrective Action:


• Replace the Microcontroller board. Contact AMETEK to verify operation before removing this board.

NOTE



MS Code MStatus Alarm Type Condition / Description and Suggested Corrective Action4 3 Fault f On-Chip ADC

Two possible errors may be occurring, either:

• The Microcontroller board’s internal analog-to-digital (ADC) converter is not responding.

and/or

• One or more of the RTDs has failed, causing its temperature zone to read “181.4 °C”.

Upon detection of this fault, the analyzer will automatically switch to Backpurge mode until the alarm has been corrected.

Note: A temperature zone can indicate “181.4ºC” but not trigger this alarm if its Set Point is set to ‘0’ (typical for a spare temperature zone).

Corrective Action:


• Replace the Microcontroller board.

and/or

• Check the current temperature (Show MAI screen) for each temperature zone and compare it to its Set Point temperature (TStPt screen).

To check the ASR900 Sample Probe Set Point temperature, view the PrbTPara screen.

• Using an Ohm meter, measure the resistance of the RTD for the zone which caused the alarm (view the TType screen to determine sensor type). Test it for an open circuit. If the RTD is faulty, contact AMETEK for assistance.

• Replace the Temperature Daughter board. Contact AMETEK to verify operation before removing this board.

• Replace the Termination board. Contact AMETEK to verify operation before removing this board.

(Show MAI) RUNF6 81..8 (TStPt) RUNF4 01..4 (PrbTPara) RUNF1 71 (TType) RUNF4 41..4


MS Code MStatus Alarm Type Condition / Description and Suggested Corrective Action8 4 Warning w PMT Signals

The highest signal from either the Measure or Reference PMT (photomultiplier tube) is outside its normal range (5.0–9.84 VDC). Check these values on the SIG screen.

Corrective Action:




• Check the flat cable between the Optical Bench board and the Micro-Interface board for proper connections and inspect it for damage (cuts, nicks, burn marks, etc.).

From the User Interface:

• From RUN mode, ensure that Automatic Lamp Control (ALC) is On. < ‘ALC 0’ = ALC Off > < ‘ALC 1’ = ALC On >

If the ALC setting is ‘0’ (Off), change it to ‘1’ (On) from CFG mode.

16 5 Fault f Communication

The Microcontroller board cannot establish reliable communica-tions with the Host Controller board.

Corrective Action:


• Check the flat cable between the Host Controller board (on door inside Electronics Enclosure) and Micro-Interface board for proper connections and inspect it for damage (cuts, nicks, burn marks, etc.).

• Ensure the actuators on switch S100 on the Micro-Interface board are positioned toward the middle of the board. See 5-11 for switch location.

(ALC) RUNF2 7 CFGF2 7Del 1 Ent Ent



(SIG) RUNF6 1


MS Code MStatus Alarm Type Condition / Description and Suggested Corrective Action32 6 Warning w Lamp Control

One or both lamp pulse current-control signals has exceeded 9.5 VDC. The Lamp Maximum range is typically 4.5–7.8 VDC (may vary, check EEPROM Data Sheets for actual value).

This alarm may occur during a cold start, but should clear after the source lamps have stabilized.

Corrective Action:


• Ensure the lamp sockets are attached securely to the lamps and that the Lamp Compression Bar is in place.

• Ensure the lamps are inserted completely into the Detector Assem-bly.



From the User Interface:

• The light levels may be too low as a result of natural aging of the lamps. This is an indication that the lamps should be replaced as soon as possible. As a temporary solution, initiate an Auto-Setup to increase the PMT gain to compensate for the reduced light levels.

The Auto-Setup starts immediately upon pressing F1 •. 64 7 Fault f Oven Heater temp

The Oven Heater Plate temperature is approaching its over-tem-perature limit of 177 °C (350 °F); a soft shutdown of the heater will occur.

A soft shutdown of the heater will also occur when the Oven door is open. A soft shutdown means the system will shut down the heater to ensure the temperature of the heater plate does not con-tinue to increase and exceed its temperature rating.

This alarm will occur during a cold start, but will clear after all tem-perature zones have stabilized within their normal operating range.

Corrective Action:


• Using an Ohm Meter, measure the resistance of the Cell RTD and test it for an open circuit. If the RTD is faulty, contact AMETEK for assistance.

(Auto-Setup) CFGF1 •



Analyzer Reset

If the Host Controller board or Microcontroller board must be reset, take all necessary safety precautions and then simultaneously press • and Ent on the User Interface. The message “Reset In Progress” should be dis-played within one second after pressing these keys.

Do not randomly reset the analyzer during normal operation. Typically, the only resets required are in cases where the Host Controller or Microcontroller boards have been replaced. In this case, it is necessary to shut down the analyzer. The analyzer will reset upon normal power-up.

!CAUTION



Service and Parts | 6-1

SERVICE and PARTS

This chapter discusses what to do if you need technical support from AMETEK, or if you are returning parts for service. This chapter also lists the recommended spare parts to have on hand to ensure preventive maintenance is performed according to the schedule in Chapter 5.

Technical Support

AMETEK Western Research is committed to providing you the best tech-nical support in the industry. If you need service or application assistance, contact your local or nearest AMETEK Service Centre or the AMETEK factory at (403) 235-8400 or 1-800-661-9198) or contact your local AMETEK Western Research representative.

For office locations and contact information, refer to the “Offices” page near the beginning of this manual, or visit us at www.ametekpi.com.

Before contacting AMETEK with questions regarding the installation, operation, or maintenance/troubleshooting of your analyzer system, carefully review the contents of this manual. If you are unable to find an explanation for your problem in this manual, please gather the following information prior to contacting AMETEK:

• Analyzer Model number.

• Analyzer Serial number.

• Purchase order number.

• AMETEK part number for the specific component you are enquiring about.

• Information describing the problem.

• Billing address, shipping address, and telephone number.

NOTE


Returning Equipment

If you need to return parts or equipment for repair, you will need a Return Material Authorization (RMA) number. This will ensure your equipment is serviced and returned to you in a prompt and efficient manner. To obtain a RMA number, contact your local or nearest AMETEK Service Centre and have the following information available:

• Analyzer Model number.

• Analyzer Serial number.

• Purchase order number.

• Billing address, shipping address, and telephone number.


?? ANSWERS TO YOUR QUESTIONS ??

• ASAPAMETEK SERVICE ASSISTANCE PROGRAM. AMETEK’s exclusive ASAP program lets you select a service package from a menu of service options. ASAP options include 24-hour phone support, 24-hour on-site guarantee, rapid parts shipment, and many more service benefits. ASAP plans may be written to provide coverage for a single analyzer, or all of the AMETEK process analyzers at your facility.

• AFTERMARKET SALESOur Aftermarket Sales group will keep you supplied with the parts to maintain your analyzer to factory specifications. This is also the group that will keep your analyzer current with upgrades and retrofits.

• TECHNICAL SUPPORTJust call AMETEK and a factory trained Service Engineer will be there to answer your questions. With over 200 years of combined field service ex-perience, our engineers are available to provide operational support or troubleshooting expertise.

• TRAININGWe will train your service technicians at our Technology Transfer Centres located in Calgary, Newark, or at your facility. Our TTCs have equip-ment similar to yours for hands-on training. A diploma will be presented upon completion of the course.

• PRE-lNSTALLATlON INSPECTIONSTo ensure you order the correct analyzer with the options your operation requires, schedule a factory-trained Service Engineer to inspect the proposed analyzer location. The on-site charge for this visit can be deducted from the start-up charge if you select that option.

• START UPSYour decision to buy an AMETEK analyzer is greatly appreciated. After the time and money spent on your analyzer, wouldn’t you expect a fast and successful start up? We can ensure that will happen! Schedule us to be there before you power up the system. We will guarantee a satisfactory commissioning of your analyzer.

• WARRANTY VALIDATIONUpon start-up, we will validate your 1-year warranty. AMETEK’s warranty policy covers all parts and on-site time. Incurred costs will be the responsibility of the customer.

• WARRANTY EXTENSIONSAMETEK offers a 2- or 3-year warranty extension for your analyzers. The warranty is identical to the original policy supplied with the analyzer. Contact AMETEK Service for more details.

• SPARE PARTSThese parts allow each customer to properly maintain their analyzers according to the Analyzer Preventive Maintenance Schedule (Chapter 5), to ensure optimal operations.

MINUTES OR HOURS,WE’RE THERE FOR YOU

The choice is yours...Whether by phone or in person, we can meet the needs required to keep your analyzer running at peak performance. Our factories are located in Calgary, Alberta and Newark, Delaware with a Sales & Service Centre in Houston, Texas. Depending on the programs you select, we will have a factory-trained representative talking to you within minutes – 24 hours a day, 365 days a year or on-site within 24 hours. We stock parts at all three locations.

ANYTIME / ANYWHERE

AMETEK SERVICE and AFTERMARKET SALES SUPPORT

PROCESS INSTRUMENTSCanada: 1-800-661-9198 U.S.A.: 1-800-537-6044


Recommended Preventive Maintenance Spare Parts

This section lists the recommended spare parts to have readily available for the Model 900 and Model 930 Analyzers to ensure the analyzer and its sample system operate at peak efficiency.

IMPORTANT SPARE PARTS INFORMATION Spare Parts for your analyzer may vary from those included in this section. This can be due to applications using nonstandard Measuring Cells or optional equipment. Before ordering spare parts, refer to the “Supplemental Information” section of this manual for a Custom Spare Parts list. If included, use those Part Numbers; if not, use the Part Numbers listed in this section.

For drawings that illustrate the location of all spare parts in the ana-lyzer, see “Preventive Maintenance” in Chapter 5. Content is subject to change without notice.

Optical Bench/Measuring Cell Spare Parts

The replacement of these parts is required as part of the Analyzer Preventive Maintenance Schedule (Chapter 5). It is also necessary to have these parts on hand in case the parts become damaged or contaminated, and need to be replaced earlier than listed in the recommended schedule.

In the event of natural degeneration, damage, or other failure of a Source Lamp, AMETEK recommends changing out both Source Lamps to ensure optimal operation. (*) Note the ordering part numbers for the different Source Lamps and order only the appropriate type and quantity of Source Lamps. The source lamp configurations vary for Standard or COS/CS2 appli-cations. To verify the lamp type, open the analyzer and check the label on each lamp.

NOTE

!CAUTION

NOTE


Optical Bench Spare Parts, 120 VAC/240 VAC Analyzer

Part No. DescriptionQTY

(1 Year)QTY

(2 Year)

100-0688 300-8844

Magnesium (Mg) Source Lamp (Lamp 1, Optical Bench) (Standard Software) OR Manganese (Mn)/Nickel (Ni) Source Lamp (Lamp 1, Optical Bench) (COS/CS2 Software)

1 1

2 2

300-2070 Cadmium (Cd) Source Lamp (Lamp 2, Optical Bench) (Standard or COS/CS2 Software)

1 2

300-1528 O-Ring PUR (Chopper Motor Drive Belt in Optical Bench)

1 2

300-9437 Bearing, Chopper Wheel (Chopper Assembly in Optical Bench)

0 2

Measuring Cell Spare Parts


(1 Year)QTY

(2 Year)

300-0281 Cell Window, Fused Silica (Measuring Cell)

4 6

100-1911 O-Ring, Size 125, Baked Teflon Coated Aflas (Measuring Cell)

8 16

Expo Technologies MiniPurge® System With eTimer Spare Parts

AMETEK recommends replacing the Battery Pack in the Expo Technologies MiniPurge® System, which provides power to the system’s electro-pneumatic timer, every three years to ensure the MiniPurge® System continues to properly purge the AMETEK analyzer’s electronics enclosure.


(3 Year)

301-4356 Battery Pack, Intrinsically Safe for Expo Technologies MiniPurge® System with eTimer

1


Spare Analyzer Fuses

AMETEK recommends having on-site spare fuses used in the analyzer. These fuses do not need to be changed out at regular intervals, but are necessary in the event that a fuse has blown and a replacement is required.

Analyzer Fuses, 120 VAC/240 VAC 120 V 240 VDescription (Location†) Part No. Fuse Type Part No. Fuse Type

Analyzer 300-5924 1.6 A 300-4189 0.8 A (TB2-1)

Over-Temp Power Supply 300-1519 63 mA 300-5097 32 mA (TB2-2)

Oven Heater 300-4550 4 A 300-4548 2 A (TB2-3)

Termination Solenoids 300-4189 0.8 A 300-5557 0.4 A (TB2-4)

ASR Sample Probe 300-4548 2 A 300-4753 1 A (TB2-6)

(*) 24 VDC Power Supply 300-4189 0.8 A 300-5557 0.4 A (TB2-7)

(*) Note: Purgeable Deluxe (PD) (GP/Div 2 only) analyzers do not use the 24 V Power Supply (or 24 V fuse). These fuses are located at TB2 (see “AC Wiring” drawing in Chapter 3).

Sample and Vent Line FusesPart No. Fuse Type

300-9291 6 A

300-9443 8 A

300-9292 10 A

300-9293 16 A

300-6312 20 A

Sample Line fuse (if used) is located at TB3-30 on GP/Div 2 analyzers; TB5-1 on Zone 1 analyzers.Vent Line fuse (if used) is located at TB3-50 on GP/Div 2 analyzers; TB6-1 on Zone 1 analyzers.See “Sample/Vent Line Wiring, GP/Div 2 Analyzers” or “Sample/Vent Line Wiring (Disconnect Enclosure), Zone 1 Analyzers” in Chapter 3, or “Lower Cabinet Wiring” drawings in Appendix A.

The Sample and Vent Line fuses are typically not used; however, if fuse terminals are retrofitted in the field for these temperature zone circuits, the fuse required will depend on line length, voltage, and power consumption. If the original factory-installed or retrofitted fuse blows, remove it to determine the fuse type required.

NOTE


Optical Bench Board Fuses (100-1662) 120 V 240 VDescription Part No. Fuse Type Part No. Fuse Type

Main Board (F200) 300-8778 125 mA 300-8777 63 mA

Photomultiplier Tube 300-3214 0.2 A 300-3214 0.2 A (F300)

Lamp (F201) 300-9524 32 mA 300-9524 32 mA

These fuses are located on the Optical Bench board (Optical Bench Assembly, Electronics Enclosure). Refer to “Optical Bench board component layout” drawing 100-1662 in Chapter 3 for location of fuses.

Disconnect Enclosure Fuse (Zone 1 and CE Analyzers) Customer Signal Termination Board (100-1215)Part No. Fuse Type

300-5790 125 mA

This fuse is located at F100 on the Customer Signal Termination board in the Disconnect Enclosure.

Replacement Boards

If you require replacement boards for the analyzer, use the following part numbers.

Part No. Description (Location) Qty

100-0116 Micro-Interface board, Type “A” (Electronics Enclosure) 1

100-0117 Microcontroller board (Electronics Enclosure) 1

100-0136 Keypad board (Display Interface, Electronics Enclosure door) 1

100-0138 Host Controller board (Display Interface, Electronics Enclosure door) 1

100-1534 Termination board (Hi-Temp) (Electronics Enclosure) 1

100-1662 Optical Bench board (Optical Bench Assembly, 1 Electronics Enclosure)

100-0140 Dual PMT Buffer board (Detector Block Assembly, part of Optical Bench 1 Assembly, Electronics Enclosure)

100-1096 Temperature Daughter board (4 RTDs) (Electronics Enclosure) 1 OR 100-1097 Temperature Daughter board (2 RTDs, 2 Thermistors) (Electronics Enclosure) 1

100-1215* Customer Termination board (Zone 1) (Disconnect Enclosure) 1

100-1214* Sample/Vent Line RTD Termination board (Zone 1) (Disconnect Enclosure) 1

Refer to the “Overall Component Layout” drawing in Chapter 3 and the “Ribbon Cable Interconnect” drawing in Appendix A for the location of the boards in the analyzer. * Used with Zone 1 analyzers only.


Oven Heater Spare Parts

This list includes all of the possible parts that may be required as part of maintenance on the Oven Heater Plate. These parts are required only in the event of failure, loss, or damage to the part. Quantity of parts is deter-mined by the number of parts required. Contact AMETEK if these parts are required.

Part No. Description

300-4924 RTD †

300-4914 RTD Base * ‡

300-4913 RTD Tip * ‡

300-8684 Heater Element

300-4182 High Temperature Wire, 16 AWG, 30"

300-4182 Ring Terminal, #8

300-0265 Lock Washer, 4 mm

300-0006 M4 x 8 Screw

300-4478 Loctite 271† Used for internal Overtemp and Heater RTDs, and external Sample Cell RTD (or Sulfur Condenser RTD, if used).‡ Used for external Sample Cell RTD (or Sulfur Condenser RTD, if used).* Required only if lost or damaged (re-use if not damaged).Refer to drawings in “Optical Bench Chopper Assembly Maintenance” diagram in Chapter 5.

Ordering a Hard Copy of the Analyzer Operator’s Guide

To order a hard copy of the analyzer Operator’s Guide and the entire Documentation Package, use the Part Number below:

Part No. Description Qty

903-8745 Model 900 / Model 930 Analyzer Operator’s Guide 1

Glossary | 7-1

GLOSSARY

User Interface Abbreviations

This listing describes all of the screen titles and characters displayed on the User Interface.

Complete details of all screen titles, messages, and abbreviations are described under “Working in the RUN / CFG Operating Modes” and “Working in the CAL Operating Mode” in Chapter 4.

Term/Character Definition

b Flow Control mode: Analyzer-selected (automatic) Backpurge Flow mode.

B Flow Control mode: User-selected (manual) Continuous Backpurge/Zero Flow mode.

S Flow Control mode: User-selected (manual) Continuous Sample Flow mode.

CAL CALibration mode

CFG ConFiGuration mode

f Precedes an alarm message, which indicates the alarm is a ‘f’ault alarm (e.g., “f Temp low”).

m State of the Auto/Manual status relay, displayed when the analyzer switches the relay to Manual mode.

F1, F2, F3, F4, F5, F6 Function keys, used in conjunction with other keys to enter the various menus from the User Interface. These menus allow you to view or enter data.

M State of the Auto/Manual status relay, displayed when the operator manually switches the relay to Manual mode (by pressing F2 •).

RUN RUN mode

This character (displayed on the top-right line) indicates an alarm has been detected by the built-in diagnostics system.

w Precedes an alarm message, which indicates the alarm is a ‘w’arning alarm (e.g., “w PMT signal”).

7-2 | Model 900 ADA and Model 930 Sulfur Pit Analyzers

Abbreviations and Terms Used in This Manual

Abbreviation Full Term / Description

ADA Air Demand Analyzer

ADC analog-to-digital converter

A/D analog-to-digital

ASR Advanced Sulfur Reduction

Chopper Wheel Filter Wheel

D/A digital-to-analog

DAS Data Acquisition System

DCS Distributed Control System

Documentation Package Manuals and supplemental information for the system, shipped with the analyzer.

DP differential pressure

EEPROM electrical-erasable-programmable-read-only memory

GP General Purpose analyzers

HAI Host Controller Analog Input

MAI Microcontroller Analog Input

Modbus® Communication protocol

PD Purgeable Deluxe analyzers (General Purpose and Division 2)

PID proportional, integral, differential

PMT photomultiplier tube

RTD resistance temperature device

SPDT single pole double throw

SRAM static random access memory

SSR solid-state relay

SKO sulfur knock out (sulfur condenser)

XP Explosion-proof

Appendix A – Drawings | A-1

APPENDIX A – DRAWINGS

This appendix contains drawings that are not included in the main body of this manual.

If your Documentation Package includes “Final As-Built” (job-specif-ic) drawings, use those for installation and maintenance/diagnostic purposes in place of similar “example” drawings in this manual.

NOTE

A-2 | Model 900 ADA / Model 930 Sulfur Pit Analyzers

Ribbon Cable Interconnect (WX-102836)


GP Lower Enclosure to Electronics Wiring, CE Analyzers (WX-102810)


Heater and Sensor Wiring, GP/Div 2 Analyzers (WX-102851)


Heater and Sensor Wiring, CE/Zone 1 Analyzers (WX-102852)


Lower Cabinet Wiring, CE/GP Analyzers, 120V (100-1341-3)


Lower Cabinet Wiring, CE/GP Analyzers, 240V (100-1342-3)


Signal Wiring, PD/GP/Div 2/CE/Zone 1 Analyzers (WX-102815)


Wiring Diagram, All Seals, Zone 1 Analyzers (100-1343-10)

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± 15V and 5V Power Supply DC Wiring, GP/Div 2/CE/Zone 1 Analyzers (WX-102811)


24V Power Supply DC Wiring, CE/Zone 1 Analyzers (WX-102812)


RS-232 Communications Cable Wiring (300-9480)


RS-232/RS-485 Module Wiring, CE/Zone 1, GP/Div 2 Analyzers (100-2185)


Microcontroller Board (100-0117)


Host Controller Board (Display Interface) (100-0138)


Model 9xx-Series Analyzer Type 200 Disconnect Enclosure Details

Supplemental Information | S-1

SUPPLEMENTAL INFORMATION

This section consists of information and documents that are not part of the main manual, but which describe and illustrate installation, operation, layout, and maintenance procedures for non-standard or optional equip-ment – and derivative analyzer models – that make up your analyzer and its sample system.

If you order the Analyzer Documentation Package CD-ROM (all files in PDF format), this information is included in the Supplemental Information folder on the CD. “Supplemental Information – Where Can I Find It?” in Chapter 1 describes the documents listed below.

This section can include:

• Manual Supplements

• Analyzer Programming Parameters sheet

• EEPROM Data Sheets

• Signed Final QC (Quality Control) Document

• Final As-Built drawings

• Other customer-specific information may also be included (if appli-cable), such as Product Data Sheets, a Custom Spare Parts list, or analyzer Certificates.

S-2 | Model 900 ADA / Model 930 Sulfur Pit Analyzers


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Model 900 Air Demand Analyzer Model 930 Sulfur …...Refer to Chapter 2 – Specifications for...

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