Model 909 Single-Gas Analyzer

User Manual

PN 903-8601, Rev. H

Canada LP
A DIVISION OF AMETEK PROCESS & ANALYTICAL INSTRUMENTS
Western Research

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This manual is a guide for the use of the Model 909 Single-Gas 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.

ii | Model 909 Single-Gas Analyzer

Contents
Offices................................................................................................................................... ii
Safety Notes........................................................................................................................ xi
Electrical Safety................................................................................................................... xi
Grounding........................................................................................................................... xi
Personnel and Equipment Safety Information............................................................. xii
Warnings...................................................................................................................... xii
Cautions...................................................................................................................... xiv
Warning Labels.................................................................................................................. xv
Environmental Information............................................................................................ xv
Electromagnetic Compatibility (EMC).......................................................................... xvi
Special Warnings and Information............................................................................... xvii
Equipment Used in Haza­­rdous Locations........................................................... xvii
EC Declaration of Conformity.....................................................................................xviii
Warranty and Claims........................................................................................................ xx
Chapter 1 Overview
Principles of Operation................................................................................................... 1-1
The Basis..................................................................................................................... 1-1
The Implementation................................................................................................. 1-2
Microcontroller Board and Host Controller Board............................................... 1-3
Sample Flow......................................................................................................... 1-3
Discrete Wavelengths........................................................................................... 1-4
Analyzer Features............................................................................................................. 1-5
Sample System and Electronics............................................................................... 1-5
About the Analyzer Sample System.............................................................................. 1-8
Aspiration Components and Functions................................................................. 1-8
Sample Conditioning Unit (SCU) and Sample Line............................................ 1-9
Calibration.................................................................................................................. 1-9
Air Supply........................................................................................................................ 1-11
Electronics Purge Air............................................................................................... 1-11
Aspirator Drive Air.................................................................................................. 1-11
Velocimeter Purge Air............................................................................................. 1-12
Status Relays................................................................................................................... 1-12
Chapter 2 Specifications
Methodology..................................................................................................................... 2-1
Standard Ranges . ..................................................................................................... 2-1
Analyzer Specifications................................................................................................... 2-2
Response Time........................................................................................................... 2-2
Measurement Accuracy............................................................................................ 2-2
Repeatability............................................................................................................... 2-2
Calibration.................................................................................................................. 2-2

Contents | iii

Linearity...................................................................................................................... 2-2
Zero Stability.............................................................................................................. 2-2
Temperature Drift...................................................................................................... 2-2
24-Hour Zero Drift.................................................................................................... 2-3
Analog Outputs......................................................................................................... 2-3
Digital Outputs (Communication Ports)................................................................ 2-3
Power Consumption................................................................................................. 2-3
Electrical Requirements............................................................................................ 2-3
Typical Sample Gas Flow Rate................................................................................. 2-3
Ambient Limits........................................................................................................... 2-4
Temperature.......................................................................................................... 2-4
Humidity.............................................................................................................. 2-4
Maximum Altitude.............................................................................................. 2-4
Sample Transport....................................................................................................... 2-4
Instrument Air Requirements.................................................................................. 2-4
Physical Dimensions (on backpan) . ...................................................................... 2-4
Status Relays............................................................................................................... 2-5
Temperature Control................................................................................................. 2-5
Output Parameter Ranges........................................................................................ 2-5
Measuring Cell Construction.................................................................................. 2-5
Measuring Cell Operating Temperature................................................................ 2-5
Pressure Compensation............................................................................................ 2-5
Approvals and Certifications................................................................................... 2-6
O2 Concentration Signal (Optional)....................................................................... 2-6
Speed of Response................................................................................................. 2-6
Accuracy............................................................................................................... 2-6
Repeatability......................................................................................................... 2-6
24-Hour Zero Drift.............................................................................................. 2-6
Temperature Drift................................................................................................. 2-6
Electrical Classification........................................................................................ 2-6
Velocimeter................................................................................................................. 2-7
Standard Range ................................................................................................... 2-7
Accuracy............................................................................................................... 2-7
Repeatability......................................................................................................... 2-7
Stability................................................................................................................ 2-7
Hysteresis............................................................................................................. 2-7
ATEX (KEMA) Certificates and Analyzer Markings................................................... 2-8
Purged Analyzers ATEX Certificate........................................................................ 2-8
Purged Analyzer Markings.................................................................................... 2-13
No Release.......................................................................................................... 2-13
Limited Release................................................................................................... 2-13
Heater Plate ATEX Certificate................................................................................ 2-14
Heater Plate Marking.............................................................................................. 2-16
Disconnect Enclosure Type 200 ATEX Certificate............................................... 2-17
Type 200 Disconnect Enclosure Marking............................................................. 2-19

iv | Model 909 Single-Gas Analyzer

Chapter 3 Installation & Start-Up
Safety Considerations...................................................................................................... 3-2
Pre-Installation Requirements....................................................................................... 3-3
Storage Prior to Installation..................................................................................... 3-3
Uncrating and Inspecting the Analyzer................................................................. 3-3
General Installation Information............................................................................ 3-4
Tools, Equipment and Supplies Required for Installation.................................. 3-4
Installing the Mechanical Components........................................................................ 3-5
Mounting the Analyzer............................................................................................ 3-5
Location and Environment................................................................................... 3-5
Installing the Optical Bench Assembly.................................................................. 3-8
Installing the Sampling System............................................................................. 3-13
Installing the Sample Conditioning Unit.......................................................... 3-14
Installing and Connecting the Sample and Vent Lines...................................... 3-15
Installing and Connecting Instrument Air........................................................ 3-17
Installing the Calibration (Span/Zero) Gas Lines.............................................. 3-18
Connecting I/O Signals, Alarm Relay Contacts, and AC Power............................. 3-19
Electrical Connections............................................................................................. 3-20
Start-Up and Verification.............................................................................................. 3-25
Purged Analyzer (Hazardous Location) Applications....................................... 3-26
Powering Up the Analyzer..................................................................................... 3-28
Start-Up Diagnostic Checklist............................................................................... 3-33
Sample System Leak Check................................................................................... 3-36
Manually Zeroing the Analyzer............................................................................ 3-38
Adjusting the Zero Gas Flow Rate........................................................................ 3-40
Adjusting the Sample Gas Flow Rate................................................................... 3-41
Setting Sample Response Time........................................................................... 3-41
Normal Operation.......................................................................................................... 3-42
Recording Initial Readings..................................................................................... 3-42
Recording PMT Signals..................................................................................... 3-42
Recording Initial Sample Response Time........................................................... 3-43
Analyzer Configuration................................................................................................ 3-44
Chapter 4 CONTROLLER / USER INTERFACE
Introduction to the User Interface Panel...................................................................... 4-2
User Interface Components..................................................................................... 4-2
Flow Control Mode Indicators on the User Interface Panel............................... 4-4
Entering Data Using Base Ten (10) Exponents...................................................... 4-4
Entering / Returning to RUN Mode – Quick Reference..................................... 4-5
RUN / CFG Mode Quick Reference Sheet – Keystroke Combinations...................... 4-6
Entering CFG Mode – Quick Reference................................................................ 4-7
Entering CAL Mode – Quick Reference................................................................ 4-8
CAL Mode Quick Reference Sheet – Keystroke Combinations............................. 4-9
About CFG / CAL Mode Passwords...................................................................... 4-10
Changing the Password for CAL Mode.............................................................. 4-10
Changing the Password for CFG Mode.............................................................. 4-11

Contents | v

Working in the RUN / CFG Operating Modes.......................................................... 4-12
While Working in RUN Mode… ........................................................................ 4-12
While Working in ConFiGuration (CFG) Mode… .......................................... 4-13
Returning to RUN Mode From CFG Mode....................................................... 4-14
Defining RUN / CFG Mode Keystroke Terms..................................................... 4-15
RUN / CFG Mode – F1 Keystrokes.................................................................... 4-16
RUN / CFG Mode – F2 Keystrokes.................................................................... 4-18
RUN / CFG Mode – F3 Keystrokes.................................................................... 4-20
RUN / CFG Mode – F4 Keystrokes.................................................................... 4-21
RUN / CFG Mode – F5 Keystrokes.................................................................... 4-23
RUN / CFG Mode – F6 Keystrokes.................................................................... 4-25
Configuring the Analyzer Control Functions............................................................ 4-27
Output Signal Assignment (OSA)......................................................................... 4-27
Analog Input Channels...................................................................................... 4-28
Display I/O Board Analog Input Signals����������������������������������������������������4-29
Micro-Interface Board Analog Input (MAI) Signals�����������������������������������4-30
Host Controller Board Analog Input (HAI) Signals�����������������������������������4-31
Calculated Results���������������������������������������������������������������������������������������4-31
Active Temperature and Pressure Compensation.............................................. 4-32
Measuring Cell Temperature Compensation...................................................... 4-32
Measuring Cell Pressure Compensation............................................................ 4-32
Mass Flow Rate........................................................................................................ 4-33
Entering Differential Pressure Transducer Range............................................. 4-33
Entering Temperature Transmitter Coefficients................................................. 4-34
Calculation Constants........................................................................................ 4-35
Entering KQ ������������������������������������������������������������������������������������������������4-35
Entering KE �������������������������������������������������������������������������������������������������4-35
Stream Temperature and Differential Pressure.................................................. 4-36
Stream Temperature (Voltage Input – HAI)....................................................... 4-36
Entering Stream Temperature AuxTAvg (T90)................................................. 4-36
Differential Pressure........................................................................................... 4-37
Entering Differential Pressure AuxTAvg (T90 Average)����������������������������4-37
Stream Temperature (Current Input – MAI)..................................................... 4-37
Velocimeter and Emissions Calibration............................................................... 4-38
DP Cell Initial Set-up........................................................................................ 4-39
Default Configuration���������������������������������������������������������������������������������4-39
DP Zero and Span���������������������������������������������������������������������������������������4-40
Temperature Transmitter.................................................................................... 4-41
Flow & Emission Output Calibration................................................................ 4-43
Customizing Velocimeter Backpurge and AuxTAvg (T90) Settings.................. 4-45
Backpurge Interval���������������������������������������������������������������������������������������4-45
Backpurge Duration�������������������������������������������������������������������������������������4-45
AuxTAvg (T90) Averaging Time for the Differential Pressure Signal��������4-45

vi | Model 909 Single-Gas Analyzer

Working in the CAL Operating Mode........................................................................ 4-47
Defining CAL Mode Keystroke Terms................................................................. 4-48
CAL Mode – F1 Keystrokes................................................................................ 4-49
CAL Mode – F2 Keystrokes................................................................................ 4-50
CAL Mode – F3 Keystrokes................................................................................ 4-51
CAL Mode – F4 Keystrokes................................................................................ 4-52
CAL Mode – F5 Keystrokes................................................................................ 4-53
CAL Mode – F6 Keystrokes................................................................................ 4-55
Setting Up Analyzer Calibration Functions........................................................ 4-56
Flow Control (Sample) Modes............................................................................ 4-56
Analyzer Control Mode (Automatic Control by the Analyzer)�������������������4-57
Continuous Backpurge Mode (Manual Control by the User)���������������������4-57
Continuous Sample Mode (Manual Control by the User)��������������������������4-58
Continuous Zero Gas Flow Mode (Manual Control by the User)��������������4-58
Continuous Calibration Gas Flow Mode (Manual Control by the User)����4-59
Velocimeter Flow Control................................................................................... 4-60
Entering Calibration Gas Concentration........................................................... 4-60
Setting Calibration Gas Timers.......................................................................... 4-61
Integration Timer (IntTime)............................................................................... 4-62
Auto-Calibration Interval Timer (ACal)............................................................ 4-62
Time to Next Auto-Calibration��������������������������������������������������������������������4-62
Auto-Zero Interval Timer (AZInt)..................................................................... 4-63
Time to Next Auto-Zero������������������������������������������������������������������������������4-63
Setting the Sample Delay Timer (SDelay)......................................................... 4-64
Manual Zero/Span............................................................................................. 4-65
Manual Zero������������������������������������������������������������������������������������������������4-65
Manual Span�����������������������������������������������������������������������������������������������4-65
Spanning Dual Range........................................................................................ 4-67
Solenoid Valve Control....................................................................................... 4-70
Solenoid Assignments����������������������������������������������������������������������������������4-70
Auto-Zero/Auto-Span........................................................................................ 4-71
Manual Start of Auto-Zero��������������������������������������������������������������������������4-72
Manual Start of Auto-Span�������������������������������������������������������������������������4-73
Auto-Calibration................................................................................................ 4-74
Timed Start of Auto-Calibration������������������������������������������������������������������4-74
Manual Start of Auto-Calibration���������������������������������������������������������������4-75
Remote Start of Auto-Calibration����������������������������������������������������������������4-76
Remote Start of Backpurge (Optional)............................................................... 4-76
Analog Output Channels................................................................................... 4-78
Setting Output Channel Full-Scale�������������������������������������������������������������4-78
Analog Output Calibration................................................................................ 4-79
Measuring Cell Temperature and Pressure........................................................ 4-81
Default Measuring Cell Temperature����������������������������������������������������������4-81
Entering Default Cell Pressure��������������������������������������������������������������������4-81
Probe Blow-Back Control (Optional)................................................................. 4-82

Contents | vii

............................... 5-61 Analyzer Reset.............................................................. 5-27 Auto-Setup Completion Number�����������������������������������������������������������������5-27 PMT Level and PMT Balance���������������������������������������������������������������������5-28 Auto-Setup Fault Messages and Corrective Action�������������������������������������5-29 Initiating an Auto-Setup......................................................................................................................................................................................................................................................................................................................................................Chapter 5 Maintenance & Troubleshooting Safety Considerations......................... 5-10 Source Lamp Replacement.............. and PMT Balance����5-31 Heater Plate Heater Cartridge and RTD Replacement................................................................................................................................................................................................................................................................................................................................................................................... 5-48 Disconnect Enclosure Flamepath (Joining Surfaces).. 5-51 Viewing Historical Error Messages..................... 5-50 Viewing Current Error Messages................................................................................... 5-9 Measuring Cell Preventive Maintenance........................ 5-7 Changing Out Replaceable Parts............................................................................................................................................................................................................ 5-53 Microcontroller Board Alarm Conditions and Corrective Action................... 5-5 Locating a Plug in the Sample System....... 5-5 Before Performing Maintenance............... 5-52 Host Controller Board Alarm Conditions and Corrective Action.......................................................................... 6-9 Chapter 7 Software Glossary User Interface Panel Abbreviations............. 5-33 Examining and Caring For the Flamepaths............................................................................................................................. 5-50 Types of Errors (Alarms)........................................................................................................... 5-2 Preventive Maintenance............. 6-4 Optical Bench/Measuring Cell Spare Parts.... 5-30 Manipulating the Completion Number............................ 6-6 Spare Analyzer Fuses................................. 7-2 viii | Model 909 Single-Gas Analyzer ........................ 6-7 Replacement Boards......................... 7-1 Abbreviations Used in This Manual.............................................................................................................................................. 5-6 Detecting a Plug in the Sample System................... 5-20 When Do the Source Lamps Need to be Replaced?��������������������������������������5-20 About the Source Lamps������������������������������������������������������������������������������5-20 Replacing the Source Lamps������������������������������������������������������������������������5-21 Auto-Setup... 5-6 Preventing a Plug in the Sample System........................................................ 5-49 Troubleshooting and Diagnostics................................... 5-50 Viewing Errors on the User Interface Panel......................................................... 5-1 Maintenance.......... 6-2 Recommended Spare Parts....................................................................................................................................................................... 5-65 Chapter 6 Chapter Service & Parts Technical Support......... 5-3 Expo-Telektron Safety Systems MiniPurge (Optional) Preventive Maintenance Schedule.................................................. 6-1 Returning Equipment............................................................................................................................. 5-2 Analyzer Preventive Maintenance Schedule............................ 6-5 Sample Conditioning Unit (SCU) Spare Parts..................................................................................... PMT Level.....................................................................................

....................................................................... C-5 Air Composition.......................................................................D-4 Overall Component Layout............................................................................................................ A-3 Auto-Calibration.......................................................................................................................................................................................................................................................... B-26 Appendix C Conversion Factors & Calculations Conversion Factors......................................................... B-7 Exception Code.......................................................D-2 Analyzer (GP) Piping & Instrumentation Diagram....... GP Analyzers............................................................................ B-22 Solenoid Output Bit Image (Register 156).................................................................... A-3 O2 Span Timer................................................... A-10 Entering [O2 ] ...................................................................... C-1 SI Prefixes................................................................................................................................................... B-24 Digital Output Bit Image (Registers 158....................... 190)......... GP Analyzers........................... B-1 Analyzer Modbus Interface Parameters....... A-11 Appendix B Serial Communication Interface (Modbus®) Overview.......... B-6 Modbus Functions................................................................D-7 AC Wiring................................................................................ C-6 Gas Flow Rate Measurement....A-6 Manual O2 Sensor Zero (Nitrogen/Air).................................................................................................................................A-8 Dilution Air Correction............................................................................................................................... 159)................................................................................................................ C-5 Specific Gravity.............. GP/Div 2/CE/Zone 1 Analyzers (WX-102853)...................................................... C-12 References........................................ A-1 SSR Outputs........... C-5 Average Molecular Weight.............. A-6 Manual O2 Sensor Zero (Air)......................... C-4 Gas Mixtures...............................................................................................................................................................D-3 Backpan Mounting Details...................................................................................................................................Appendix A Options O2 Concentration Measurement.......... GP Analyzers....................................................... C-13 Appendix D Drawings Analyzer Schematic (WX-14716)................D-5 Electronics Enclosure Layout.............................................................................................D-6 User Interface Panel (WX-14151)............................... A-10 Correction Equation......................................... B-23 Digital Input Bit Image (Register 157)................................... B-22 Analyzer Status Bytes (Register 154).. B-6 Communications Parameters....................................................................... B-7 Holding Registers....................... B-6 Modbus Address............................................................................................................ C-7 Mass Flow Rate........................................................................................................................... A-4 Manual O2 Sensor Zero/Span.................................................................................................................................................................................................................................................................................................................. A-2 Entering Calibration Gas O2 Concentration....................................................................................................................................................................... B-24 Gas Flow Control (Registers 189.............................................................................................................. ............................................................................. B-8 Units and Display Bit Image (Register 9)..............................................D-8 Contents | ix ..............................................................................................................

...................D-14 Disconnect Enclosure Wiring........................D-29 Microcontroller Board (100-0117)....................................... CE/GP Analyzers....D-24 Wiring Diagram... Zone 1 Analyzers (100-1344-9).................................................... CE Analyzers (WX-102810)..........D-31 Display I/O Board (100-0939).. Assembly Diagram (100-2141-2)............................................ 120V...............D-37 Zirconia Oxide O2 Sensor (Optional)....................D-38 Zirconia Oxide O2 Sensor (Optional).......................... Flow Diagram (100-2141-1)............................ All Seals.................................... GP/Div 2/CE/Zone 1 Analyzers (WX-102815)....D-9 Sample/Vent Line Wiring................ 120 V (100-1933-1).......................D-13 Disconnect Enclosure Wiring........................D-17 Customer Signal Connections...... GP/Div 2 Analyzers (WX-102851).................................. 120V.....................................................................................Ribbon Cable Interconnect (WX-102836)....................................... CE/Zone 1 Analyzers (WX-102816).....D-23 RS-232/RS-485 Module Wiring........... GP/Div 2 Analyzers (WX-102822).....D-10 GP Lower Enclosure to Electronics Wiring...........................D-33 Optional Velocimeter Solenoid Block.......... 240V....... 120 V..D-25 Wiring Diagram... GP/Div 2/CE/Zone 1 Analyzers (WX-102811)................................ Electronics Panel Layout (100-1160-1).D-20 ± 15V and 5V Power Supply DC Wiring........... 240 V (100-1934-1)................................................... Zone 1 Analyzers (100-1343-9). 120V (100-1341-3)..D-26 Optical Bench Board (100-1662)........ GP/Div 2 Analyzers (100-1254-5)........................................................... 240V.......D-18 Customer Signal Connections....D-22 RS-232 Communications Cable Wiring (300-9480).........................................D-16 Lower Cabinet Wiring..................................................................................D-15 Lower Cabinet Wiring.....D-11 Heater and Sensor Wiring......D-28 Host Controller Board (Display Interface) (100-0138)...................................................D-30 Termination Board (100-1534)....... Zone 1 Analyzers (100-1344-5)..........................D-35 Optional Velocimeter Solenoid Block............ CE/Zone 1 Analyzers (WX-102812)...................................... 909/910 GP Analyzers (100-1934-2)........................................ 240 V.D-36 Optional Velocimeter Zeroing Layout... Zone 1 Analyzers (100-1343-5)..D-19 Signal Wiring................................................................ CE/GP Analyzers............ 240V (100-1342-3)...............................D-27 Micro-Interface Board (100-0116)..........................D-12 Heater and Sensor Wiring............................................ Wiring Connections (100‑1160‑2). CE/Zone 1 & GP/Div 2 Analyzers (100-2185).....................D-34 Optional Velocimeter Zeroing Layout...................................................................................................D-32 Measuring Cell/Lamp Assembly (WX-14856). All Seals..............................D-39 Calibration Manifold Block....................... CE/Zone 1 Analyzers (WX-102852)................................D-21 24V Power Supply DC Wiring........................D-41 Supplemental Information x | Model 909 Single-Gas Analyzer .... 909/910 GP Analyzers (100-1933-2).........................D-40 Calibration Manifold Block.

may result in personal injury or environmental contamination. Any use of the equipment in a manner not specified by the manufacturer may impair the safety protection originally provided by the equipment. CAUTION Contents | xi . ! Verify ground continuity of all equipment before applying power. and notes contained in this manual emphasize critical instructions as follows: ! An operating procedure which.Safety Notes warnings. NOTE Electrical Safety High voltages are present in the analyzer housings. Grounding Instrument grounding is mandatory. Performance specifications and safety protection are void if instrument is operated from an improperly grounded power source. if not strictly observed. if not strictly observed. may result in damage to the equipment. cautions. ! An operating procedure which. Always shut down power source(s) before performing maintenance or troubleshooting. Only a qualified electrician should make electrical connections and ground checks. WARNING CAUTION  Important information that should not be overlooked.

and methods (plus all safety policies and procedures) must be made in compliance with local wiring regulations and electrical code for the hazardous area. ! 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 WARNING within the enclosures. When the Electronics Enclosure door is open. maintaining. materials. xii | Model 909 Single-Gas Analyzer . or troubleshooting of the analyzer must review and follow these Warnings and Cautions. service. the Purge Bypass Switch must be in the BYPASS position. operation. All electrical connections. ! WARNING Follow appropriate regulatory and/or company procedures to lock out the analyzer while working on its electronics. If an explosive gas atmosphere is present. All personnel involved with the installation.Personnel and Equipment Safety Information This section describes important safety information to avoid personal injury and damage to the equipment while installing. ! WARNING All electrical connections. All safety regulations. or servicing of the analyzer should be performed only by properly trained and qualified personnel. Hazardous voltages are present inside. standards. do not open any covers or doors without first disconnecting power and/or WARNING alternate power sources to the analyzer. start-up. If it is necessary to open the analyzer’s covers or doors while the circuits are live. Purged Analyzer (Hazardous Location) Applications: To work on the analyzer with it powered up and its Electronics Enclosure door open. and procedures at the analyzer location must be followed. take appropriate precautions to avoid electrical shock. first monitor the area for flammable gases (and proceed only when the area is safe). Warnings Review and follow these Warnings to avoid personal injury or environmental contamination. adjustments. ! Before working on the analyzer. test the area for flammable gases. and be approved by the Owner Company. operating. or servicing the equipment. maintenance.

! Before working on the sample system. The analyzer enclosure may not be opened when an explosive atmosphere is present. Contact AMETEK if there is any doubt about the integrity of any flamepath. ! WARNING The Analyzer Oven enclosure and components within the Analyzer Oven are hot. take precautions to avoid burning yourself. or wear) to any WARNING flamepath (on the Oven Heater or Disconnect Enclosure). ! Purged Analyzer (Hazardous Location) Applications: Do not apply power to the analyzer if there is damage (scratches. or serious damage to equipment. Applying power to an analyzer with a damaged flamepath is dangerous and could result in serious injury or death. Replace parts immediately if damage or wear is apparent. avoid direct viewing of the light emanating through the end window of the source lamp. wear safety glasses that block ultraviolet radiation. 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”). If the source lamp must be viewed while enerWARNING gized. Contents | xiii . indentations. ! Purged Analyzer (Hazardous Location) Applications: [Special Conditions for Safe Use] WARNING The analyzer may only be energized by using the Purge Bypass Switch with permission of the works manager or his proxy. WARNING ! Because ultraviolet radiation can harm your eyes. confirm that the system is purged with Zero Gas and is isolated (blocked in) from the process.

Cautions Review and follow these Cautions to avoid damaging the equipment. comply with local wiring regulations and electrical codes. xiv | Model 909 Single-Gas Analyzer .3. ! When handling the source lamps. Since such areas typically CAUTION are not available at analyzer installation sites. 10. In all cases. or. As per EN 6007914:1997. The lamp assembly is fragile and should be handled with care. it is very important not to touch the lamp windows because residual oils from the fingers will absorb ultraviolet light. all unused cable entry ports must be plugged with a certified Ex d plug. For Zone 2 Installations. 10. The window is the flat surface at the CAUTION end of the narrow glass tube.2. do not subject the boards to static discharge. ! Purged Analyzer (Hazardous Location) Applications: For Zone 1 Installations. If a wrist strap is not available.3. The ideal solution is a static-safe work area. use a suitable flameproof cable entry device with a sealing ring. as per EN 60079-14:1997. ! The electronic circuit boards and other static-sensitive components should be stored and transported in static-shielding carriers or packages.2 “The cable entry system shall comply with … e) flameproof cable entry devices incorporating compound filled seals around the individual cores or other equivalent sealing arrangements”. all cable entry glands (one power cable entry and two signal cable CAUTION entries) into the flameproof Disconnect Enclosure must be Ex d certified. the analyzer must be operated from a grounded power source that has a securely connected protective-ground contact. you should at the very least touch the metal chassis (to ground yourself) before handling or touching the boards. CAUTION CAUTION ! If it becomes necessary to handle any of the electronic circuit boards. item “b)”. the use of a wrist strap connected directly to a ground is recommended. ! For electrical-shock protection.

take it to your local or regional waste collection administration for recycling. Contact your dealer to see if this program is available in your area. • If you need further assistance in recycling your AMETEK product. Metals. • In some cases. In some cases the product may contain materials known to be hazardous to the environment or human health. contact our office listed in the analyzer User Manual. your “end of life” product may be traded in for credit towards the purchase of new AMETEK instruments. 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. plastics. Contents | xv . In order to prevent the release of harmful substances into the environment and to conserve our natural resources. Waste Electrical and Electronic Equipment (WEEE) should never be disposed of in a municipal waste system (residential trash). 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 Information This AMETEK product contains materials that can be reclaimed and recycled. AMETEK recommends that you arrange to recycle this product when it reaches its “end of life”. 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.Warning Labels These symbols may appear on the instrument in order to alert you of existing conditions.

” or R/C) as close as possible to the inductive device to reduce the generation of transients. Install an appropriate transient voltage suppression device (low voltage MOV. flexible conduit. The KEMA (ATEX) certification for Zone 1 hazardous locations is Ex pd IIB T3. The various configurations of the Model 909 Single-Gas Analyzers should not produce. Examples of electrical events and devices known for the generation of harmful electromagnetic disturbances include motors. if this becomes a necessity. Do not run this type of signal wiring along with other I/O or DC in the same shielded cable. 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. use of these shielding techniques is effective only when the shielding element is connected to the equipment chassis/earth ground at both ends of the cable run. RF welding equipment. This may cause ground loop problems in some cases.Electromagnetic Compatibility (EMC) ! CAUTION Read and follow the recommendations in this section to avoid performance variations or damage to the internal circuits of this equipment when installed in harsh electrical environments. storm related transients. 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. ground bar or terminal is highly recommended. Inductive loads connected to the low voltage “Alarm Contacts” are not recommended. Groups C & D. and tightened up against the metal interior. In addition. In general. Disconnecting one shield ground may not provide sufficient protection depending on the electronic environment. 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. capacitor bank switching. An even greater degree of shield performance can be achieved by using metallic glands for shielded cable entry into metal enclosures. Foil and braid shielded I/O and DC power cables are recommended for use in otherwise unprotected situations. Division 2. These should be treated on a case-by-case basis. hard conduit. [The NEC/CEC certification is Class I. In the case of shielded cables the drain wire or braid connection must be kept short. In meeting the EMC requirements. for optimum protection against high frequency transients and other disturbances. and armor around nonshielded wiring also provides excellent control of radio frequency disturbances. Connecting one shield ground via a 0. or fall victim to. Below are examples of the techniques and wiring practices to be followed. xvi | Model 909 Single-Gas Analyzer . “Transzorb.] 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. and walkie-talkies. Inductive load wiring must be separated from other circuits in conduit by using an additional cable shield on the offending cable. static.1 microfarad ceramic capacitor is a technique allowing high frequency shield bonding while avoiding the AC-ground metal connection. adhere to proper techniques and wiring practices. electromagnetic disturbances as specified in the European Union’s EMC Directive (if applicable to your application). However. A two-inch connection distance between the shield’s end and the nearest grounded chassis point. However.

WARNING Avertissement All input and output wiring must be in accordance with Class I. coupez le courant où vous assurez que l’emplacement est designé non dangereux. ! Risque d’explosion – Avant de déconnecter l’équipement. Contents | xvii . Division 2 wiring methods (CEC 18-152) and in accordance with the authority having jurisdiction.Special Warnings and Information Equipment Used in Haza­­rdous Locations Refer to Chapter 2 – Specifications for details about the suitability of this equipment in hazardous locations. ! Explosion Hazard – Do Not Disconnect Equipment Unless Power Has Been Switched Off or the Area is Known to be Non-Hazardous.

EC Declaration of Conformity xviii | Model 909 Single-Gas Analyzer .

Contents | xix .

or any part thereof. fire or force of the elements. OR ANY PART THEREOF COVERED BY THIS WARRANTY OR OTHERWISE. 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. high or low temperature. overpressure. whichever period is shorter. Such returned equipment shall be examined by us and if it is found to be defective as a result of defective materials or workmanship. at the time of shipment thereof by or for us. INCIDENTAL DAMAGES. abuse or improper use. and electrical area classification prior to order acknowledgment. AS TO ANY OTHER MANUFACTURER’S EQUIPMENT. Process photometric analyzers. and sample systems are warranted to perform the intended measurement. CONSEQUENTIAL DAMAGES. WHETHER EXPRESS OR IMPLIED. WE DO NOT AUTHORIZE ANY REPRESENTATIVE OR OTHER PERSON TO ASSUME FOR US ANY LIABILITY IN CONNECTION WITH EQUIPMENT. explosive or combustible medium. free from defects in material or workmanship under normal use and service will be repaired or replaced (at our option) by us free of charge. accident. nor does it include the responsibility or cost of transportation. and refund in full settlement the purchase price thereof paid by Buyer. INCLUDING WITHOUT LIMITATION AND WARRANTIES OF FITNESS OR OF MERCHANTABILITY OTHER THAN AS EXPRESSLY SET FORTH HEREIN. and AMETEK has accepted. but shall not be limited to. All equipment requiring repair or replacement under the warranty shall be returned to us at our factory. AND OF ALL OTHER OBLIGATIONS OR LIABILITIES ON OUR PART. process moisture analyzers. valid sample stream composition data. it shall be repaired or replaced as aforesaid. INCLUDING WITHOUT LIMITATION ANY WARRANTIES OF FITNESS OR OF MERCHANTABILITY. vibration. INSTALLATION. THIS WARRANTY IS GIVEN AND ACCEPTED IN LIEU OF ALL OTHER WARRANTIES. The warranty does not apply to used or secondhand equipment nor extend to anyone other than the original purchaser from us. excess voltage and the like. or operating the equipment with or in a corrosive. TIME CHANGES OR ANY OTHER LOSSES INCURRED BY THE ORIGINAL PURCHASER OR ANY THIRD PARTY IN CONNECTION WITH THE PURCHASE. xx | Model 909 Single-Gas Analyzer .Warranty and Claims We warrant that any equipment of our own manufacture or manufactured for us pursuant to our specifications which shall not be. WE MAKE NO WARRANTY. instead of repairing or replacing the equipment returned to us as aforesaid. damage by negligence. unless the equipment is specifically designed for such service. Resale items warranty is limited to the transferable portion of the original equipment manufacturer’s warranty to AMETEK. Misuse or abuse of the equipment. WHETHER SOLD SEPARATELY OR IN CONJUNCTION WITH EQUIPMENT OF OUR MANUFACTURE. or at such other location as we may designate. Improper use or misapplications shall be construed to include improper or inadequate protection against shock. a statement should appear on the documentation accompanying the equipment being returned declaring that the goods being returned for repair are Canadian goods. neglect. IN NO EVENT SHALL WE BE LIABLE UNDER THIS WARRANTY OR ANY OTHER PROVISION OF THIS AGREEMENT FOR ANY ANTICIPATED OR LOST PROFITS. shall be construed to include. and the shipment date. 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. 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. 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. the Buyer shall pay travel time plus actual travel and living expenses. process conditions. OR ANY PART THEREOF. or exposure to any other service or environment of greater severity than that for which the equipment was designed. COVERED BY THIS WARRANTY. REPAIR OR OPERATION OF EQUIPMENT. we may. In addition. The photometric light sources are warranted for ninety (90) days from date of shipment. take back the defective equipment. at our option. If you are returning equipment from outside Canada. the name of the firm who purchased the goods. EXPRESS OR IMPLIED. or which has been subject to misuse. transportation prepaid. only in the event that the customer has supplied.

mole percent is equal to volume percent. A= [ x ] kλ lP RT where l is the path length of the light in the gas sample. Principles of Operation The Basis The Model 909 Single-Gas Analyzer measures. [x] is the concentration (mole percent [see Note]) of absorber x.Overview This chapter discusses the principles of operation and features of the Model 909 Single-Gas Analyzer.5 percent.  NOTE For an ideal gas. and Lambert. Overview | 1-1 . due to a single absorber is. the real gas mixture deviates from ideal behavior by less than 0. and P are the temperature and pressure of the gas sample. the absorbance. The concentration of the component absorbing the light (absorber) is then determined from relationships developed through application of the ideal gas law in concert with the laws of Bouguer. A. T. respectively. At the normal operating conditions of the analyzer. the absorbances of ultraviolet radiation (light) by a gas sample. and R is the universal gas constant. at two discrete wavelengths. kλ is the molar absorptivity of absorber x at the measuring wavelength. This chapter also provides an overview of the AMETEK sample system and electronics and the various sub-systems that make up the entire analyzer system. and a summary of how the entire system operates. Thus. λ. Beer.

Figure 1-1. 1-2 | Model 909 Single-Gas Analyzer .For any given system at constant temperature and pressure. the equation can be simplified to: A = C kλ [ x ] where C ≡ lP/RT is a constant depending only upon the system of units employed. The concentration of the absorbing component may be determined from the absorption at the two measuring wavelengths. The Measuring Cell is contained within the analyzer ’s oven. Analytical schematic. a gas Measuring Cell. A pressure transducer monitors the pressure at the outlet of the Measuring Cell. and two matched photo detectors (see Figure 1-1). a Filter Block containing two wavelength-selective filters. front-surfaced mirrors. a Beam Splitter. The Implementation The analyzer is comprised of two ultraviolet light sources.

The gas sample enters the first chamber. are controlled (by an electric heater) at a constant temperature in the range from 120 °C (248 °F) to 150 °C (302 °F). Overview | 1-3 . The Analyzer Oven.Microcontroller Board and Host Controller Board The operation of the analyzer is controlled by two microprocessors. temperature control. The Microcontroller board controls the temperature of the temperaturecontrolled zones. data preprocessing functions. and final processing of the data from the Microcontroller board. Sample Flow The sample gas is drawn from the stack duct through the Sample Conditioning Unit (or stack sample probe. and handling input/output. from the stack duct to inside the Analyzer Oven and Measuring Cell. it merges with the Aspirator Drive Air (Instrument Air or N2) and then is dispersed to atmosphere via a Sample Vent Pipe. The Microcontroller board is assigned to the Optical Bench board interface. data conversion. auxiliary data input signal conversion. and thereby the Measuring Cell. The sample temperature. When the sample gas reaches the aspirator. if used) and Sample Line to the dual-chambered Measuring Cell. The temperature sensor – a resistance temperature device (RTD) – used in the Analyzer Oven is embedded in the Heater Plate. The Host Controller board is assigned to the User Interface Panel and keypad control. flows the length of the Measuring Cell. flows the length of the Measuring Cell in the opposite direction and exits from the Measuring Cell. must be maintained above the water and acid dewpoint temperatures of the sample. crosses to the second chamber. The temperature sensor used in the Sample Line can be a thermistor or an RTD while the Sample Conditioning Unit (SCU) must use an RTD.

Then. light losses at the mirrors. the Beam Splitter directs half the light to the Reference detector and half through the gas sample to the Measure detector. As each pulse of light arrives. At each wavelength.Discrete Wavelengths To achieve measurements at discrete wavelengths. the magnitude of the reduction being dependent upon the concentration of the absorber. and light losses through the Measuring Cell windows. To balance this effect.. Because of the longer optical path length. the placement of the source lamps is such that. the photodetectors are exposed to light from only one lamp and filter combination (i. Thus. these optical-path factors produce a constant difference between the amounts of light received by the two detectors. 1-4 | Model 909 Single-Gas Analyzer . When an absorber is present in the gas sample. using the aforementioned equations.e. for each wavelength. even when there is no absorber in the gas sample. at any given time. a discrete wavelength). the amount of light received by the Measure detector is less than that received by the Reference detector. the difference in the amounts of light received by the two detectors (corrected for the optical-path factors) is used to determine the absorbance of the gas sample. the amount of light received by the Measure detector is reduced further. a screen that filters 30 % of the light is added to the Reference path. the concentration of the absorber (for which the analyzer is configured) is calculated.

for example. or Cl2 – from the stack duct. Calibration Gas Solenoid valve control Up to three solenoid valves can be controlled by the analyzer. This function is initiated by a remote dry (potential free) contact opening. such as in the case of a gas alarm. The Auto-Calibration function can be initiated on command by the user. One of the control outputs is reserved for the Zero Gas. or by the closure of a remote dry (potential free) contact. allows the user to initiate a backpurge of the analyzer sample system from a remote location. through the analyzer’s sample system. some of these features may not be available for your analyzer. at user-specified time intervals. user-adjustable timer.Analyzer Features The analyzer has been designed to comply with electrical classification requirements for general purpose and hazardous areas specific to this analyzer’s intended application. Each of the solenoid-control outputs can be turned off by the user if it is not being used. Remote Backpurge (Optional) If configured. NH3. Auto-Calibration function Automatically updates the calibration of the analyzer using Calibration Gas mixtures. The length of time that each solenoid valve is on is determined by a separate. or NO2. Gas calibration system Allows the introduction of calibration gases directly into the analyzer’s sample system. Overview | 1-5 . The timer controlling each solenoid valve can be started manually by the user or automatically by the analyzer during Auto-Calibration. H2S. Depending on the application. The Auto-Zero function can be initiated on command by the user or at user-specified time intervals. and to a vent to atmosphere or back to the stack duct. NO. Auto-Zero function Automatically updates the analyzer zero. This is done to remove any residual contaminants in the sample system. Sample System and Electronics Key features include: Safe transport of the sample gas May contain toxic percentage levels of either SO2.

alarm set points. The analyzer is configured for a particular calibration gas mixture by the user. and operational status of the analyzer. Reliable electronics control system Controls the overall operation of the analyzer. and the Electronics Enclosure with Instrument Air Prevents contamination of the optical system and the electronics. No pumps are used Sample gas is transported throughout the sample system by means of an Aspirator within the Analyzer Oven. User Interface Panel Provides access to a readout of system signals and parameters. Measuring Cell Seal. This provides flow vacuum. non-critical conditions. there is a zone reserved for applications using a heated external probe with a dedicated temperature controller. 1-6 | Model 909 Single-Gas Analyzer . Continuous purge of the Optical Bench Assembly. and Sample Conditioning Unit. and user input. There is also a spare temperature-controlled zone. Three status relays Indicate faults. If any of these zones are found to be out of range. local diagnostics. The temperature-controlled zones are protected by independent over-temperature circuits. Additionally.Auto-Calibration and Calibration Gas solenoid valve control functions Support the use of a single-species calibration gas mixture. The calibration and configuration functions are protected by separate passwords. Sample control system that detects the state of up to five temperature-controlled zones within the sample system Temperature-controlled zones include the Sample Line. Analyzer Oven. Four independent analog output signal channels The full-scale concentration for each output channel can be set by the user to any value within the measurement range of the analyzer. Easy Analog Output Calibration The analog output channels are calibrated by entering the zero and full-scale offsets for each output via the User Interface Panel keypad – there are no potentiometers to adjust. the analyzer automatically forces the sample system into Backpurge mode to avoid contaminating the system.

The Modbus® protocol can be used with the analyzer operating as a slave device. using Modicon Modbus® protocol. DCS Communication Interface (optional) A RS-422 (or optional RS-485) port that can be used for remote communication with a Distributed Control System (DCS). The analyzer includes the necessary hardware for measuring the stack duct temperature and flow rate. Overview | 1-7 .) Dilution Air Correction (optional. responding to Modbus® queries within one second. (The Modbus® communication interface is optional. independent. Mass Flow Calculation (optional) Calculations of the volumetric flow rate of the stack duct (stream) or mass flow rate of the measured component in the stack duct.Parts are electrically heated Wetted parts are maintained above the dewpoint temperature of the sample gas stack duct. The O2 concentration of the sample can be measured by an optional Zirconium Oxide sensor installed within the analyzer Electronics Enclosure or by a separate. No steam or other heating media is required. external O2 Sensor.  NOTE Signals representative of the temperature and linear gas velocity of the stack duct or a separate external volumetric flow measuring device supplying flow signal to the Model 909 Analyzer are required for the calculations. for use in General Purpose applications/analyzers only) Adjusts the concentration measured by the analyzer to a reference excess-air condition based on the concentration of oxygen (O2) in the sample.

or otherwise condition the gas sample prior to transporting it through the Sample Line. These components are for a variety of analyzer configuration possibilities. Aspiration Components and Functions The following components make up the Aspirator system. Aspirator (if used) Located within the Analyzer Oven. refer to the Final “AsBuilt” drawings in the “Supplemental Information” section of this manual or the Documentation Package shipped with the analyzer. Vent Line (if used) Returns the sample gas to the stack duct. See Figure 1-2 for a typical layout of the Aspirator system (actual drawing may differ for your application – refer to Final “As-Built” drawings shipped with the analyzer). prevent liquid carry-over. Component Function Sample Conditioning Unit (SCU) The SCU – which mounts on the stack – is used to filter out particulates. Component Function Aspirator/Backpurge Air Pressure Regulator Used to adjust drive air flow rate. Vent Pipe Vents the sample gas to atmosphere. . The major components of the sample system and their functions are detailed below. Depending on your application.  NOTE Figure 1-2 illustrates an example of a piping and instrumentation configuration – your application may differ. The aspirator uses Instrument Air to extract and drive the sample gas from the stack duct. Check Valve 1-8 | Model 909 Single-Gas Analyzer Stops sample gas from entering the instrument air system if instrument air pressure is reduced below the stack duct pressure. Typically used in stack gas sampling.About the Analyzer Sample System The sample gas is transported to and from the analyzer by an aspirator housed within the heated Analyzer Oven. To view the Piping & Instrumentation diagram for your application. the Aspirator provides suction to transport the sample gas through the sample path. through the sample system. only some of these components will be used. and vent it to atmosphere (or return it to the stack duct). Sample Line Transports the sample gas to the analyzer at a temperature above its dewpoint.

If an optional O2 Sensor is used. this trickle purge will also cause its output to go high if aspiration is lost. Used for pressure checking the analyzer sample system.Aspirator Isolation Valve Used to manually shut off drive (aspirator) air to the sample system. the calibration gas flow is introduced automatically by the analyzer at user-specified time intervals. Aspirator Provides suction to circulate the sample gas. Sample Conditioning Unit (SCU) and Sample Line To ensure the temperature of the SCU and Sample Line do not fall below the dewpoint of the sample gas. Trickle Purge Provides a small flow of air to keep the backpurge connection tubing free of condensate.4 °C. Overview | 1-9 . Aspirator/Backpurge Rotameter Used to adjust the flow rate of the aspirator air. Calibration Calibration on the analyzer consists of zeroing and spanning the analyzer. Tubing Connection This tube. This solenoid must be energized for the analyzer to obtain a sample of gas. If the temperature of these zones fall below 5 % of the set point temperature. For diagnostic purposes. These zones are also protected from overheating by a separate circuitry that trips the power to these zones if the temperature reaches 181. the analyzer will automatically switch from Continuous Sample mode to Continuous Backpurge mode to avoid plugging in the SCU or Sample Line. runs from the Flow Control Solenoid to the Aspirator in the Analyzer Oven. these temperature-controlled zones are controlled by the analyzer electronics at a user-defined set point. Flow Control Solenoid Allows aspirator air to be turned off and on automatically if the analyzer is not ready to obtain a sample from the stack duct. usually 1/4" stainless steel.

. Piping & Instrumentation diagram (GP Analyzers).  NOTE 1-10 | Model 909 Single-Gas Analyzer Example drawing only.Figure 1-2. Refer to the Final As-Built drawings for your application in the “Supplemental Information” section of this manual or the Documentation Package shipped with the analyzer.

Magnahelix™) to the fitting (gauge port) located on the lower right side of the Electronics Enclosure. When the sample gas reaches the aspirator.g. or in the range of 420–840 KPAG (60–120 PSIG) for Hazardous Locations. The air is split into three paths as it enters the analyzer: Electronics Purge. Electronics Purge Air The Optical Bench Assembly. The Aspirator Drive Air is fed through the analyzer manifold.1 and 0. The required purge air pressure is indicated by a label on the analyzer backpan. Aspirator Drive Air The Aspirator Drive Air provides suction to circulate the sample gas at a controlled flow rate through the analyzer sample system. if used). where it is routed to the aspirator inside the Analyzer Oven. The Electronics Enclosure air pressure should typically be between 0. to purge the analyzer electronics. and the Electronics Enclosure are continuously purged with Instrument Air to prevent contamination of the optical system and the electronics. it merges with the Aspirator Drive Air (Instrument Air or N2) and then continues on through the gas Vent Pipe which disperses the used sample gas to atmosphere (or Vent Line back to the stack gas.. The Electronics Enclosure air pressure can be verified by connecting a pressure gauge (e. Measuring Cell Extension. The purge air is normally obtained from the Instrument Air supply air via a separate regulator and flow restrictor mounted on the left-hand side of the Electronics Enclosure.Air Supply Clean dry instrument air is normally used to drive the aspirator. Overview | 1-11 . The inlet air pressure must be minimum 210 KPAG (30 PSIG) for General Purpose applications.2 inches of water with respect to the air pressure outside the cabinet. and to backpurge the sample system. and Velocimeter Purge. each with its own controlling regulator. Aspirator Drive.

The Over-Temperature fault. this relay’s contacts reset automatically upon correction of the Fault alarm. To reset this relay. however. Vent Line (if used.1 and 0. you must press SW300 on the Termination board. Each relay provides a set of SPDT (Form C) dry (potential-free) contacts. The purge air is normally obtained from the Instrument Air supply air via a separate regulator and flow restrictor mounted on the left side of the Electronics Enclosure. Status Relays The analyzer uses three relays which indicate the operational status of the analyzer.e. The Electronics Enclosure air pressure should typically be between 0. S is displayed on the upper-right line of the User Interface Panel to indicate this relay has become de-energized. With the exception of an Over-Temperature fault (f Temp High) – detected by the Over-Temperature RTD Daughter boards – on the Sample Line. energized for the non-alarm condition). A lower case “b” will be displayed in the top-left corner of the RUN mode screen to indicate the analyzer has automatically forced its Flow Control Mode to Backpurge. When a Fault alarm condition exists (relay is de-energized). The required purge air pressure is indicated by a label on the analyzer backpan. Magnahelix™) to the fitting (gauge port) located on the lower right side of the Electronics Enclosure. or Analyzer Oven. This relay is de-energized if a Fault alarm condition exists within the analyzer’s built-in diagnostic system (the analyzer requires service). the sample system will automatically switch to Backpurge mode if the analyzer ’s Flow Control Mode is set to Analyzer (automatic) Control mode.Velocimeter Purge Air The Velocimeter Purge Air provides instrument air to backpurge (clear) the pitot tubes or to perform a Zero/Span calibration on the Velocimeter. The relays are configured for fail-safe operation (i. located in the Electronics Enclosure. In RUN mode.g. 1-12 | Model 909 Single-Gas Analyzer . this relay is energized..2 inches of water with respect to the air pressure outside the cabinet. must be reset manually. or SCU). The three sets of status relays used are: Normal/Fault Status Relay When the analyzer is operating in its normal Run state.. The Electronics Enclosure air pressure can be verified by connecting a pressure gauge (e.

and/or upon exiting CFG or CAL mode. or when the analyzer is operating in CFG or CAL mode. Resetting of the contacts is delayed by the Sample Delay Timer (SDelay) duration. This relay switches to de-energized to indicate that calibration of the analyzer is in progress (as detected by the built-in diagnostic system).Run/Calibration Status Relay When the analyzer is operating in its normal Run state. Overview | 1-13 . that a parameter has been changed in the CALibration mode or ConFiGuration mode (also switches upon exiting CFG mode). Run/Attention Status Relay When the analyzer is operating in its normal Run state. or the analyzer’s Flow Control (Sample) Mode is in Continuous Zero Gas Flow mode or Continuous Sample mode. Resetting of the contacts is delayed by the Sample Delay Timer (SDelay) duration. a lower case “m” will be displayed in the top-left corner of the RUN mode screen. The Run/Attention contacts will also become de-energized if you manually force the analyzer’s Flow Control mode to any mode other than Analyzer (automatic) Control mode. upon switching back to Analyzer (automatic) Control mode. otherwise. This indicates to the control room that the analyzer is not operating in its normal Run state. When this relay changes state to de-energized. This relay is de-energized if a Warning alarm condition exists within the analyzer’s built-in diagnostic system (the analyzer requires attention). this relay is energized. this relay is energized. this relay’s contacts reset automatically upon correction of the Warning alarm.

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to a minimum of 250 PPM NO Range = 20 % NO / (Cell length). to a minimum of 125 PPM Cl2 Range = 40 % Cl2 / (Cell length). to a minimum of 300 PPM NO2 Range = 40 % NO2 / (Cell length).  NOTE  NOTE For applications measuring other species not mentioned in this manual. Purged Analyzer (Hazardous Location) Applications: Additional specifications for ATEX (KEMA) analyzers can be found in the ATEX certificates and analyzer labels under “ATEX (KEMA) Certificates and Analyzer Markings. high resolution. (Optional Zirconia Oxygen Sensor. a specified Measuring Cell path length of 40 cm.) Standard Ranges Maximum ranges are based on sample length (expressed in cm). SO2 NO NO2 H2S NH3 Cl2 SO2 Range = 20 % SO2 / (Cell length). Minimum ranges are 1/50 of maximum ranges. non-dispersive UV. Methodology Dual beam. to a minimum of 500 PPM Specifications | 2-1 . to a minimum of 500 PPM H2S Range @ 214 nm = 10 % H2S / (Cell length). to a minimum of 300 PPM H2S Range @ 228 nm = 40 % H2S / (Cell length).Specifications These performance characteristics are based on operation with factory-set filtering time constants. refer to the Documentation Package for a manual supplement. and the sample gas in the Measuring Cell at predetermined temperatures and pressures.” later in this chapter. to a minimum of 125 PPM NH3 Range = 10 % NH3 / (Cell length).

Repeatability < ± 0. Measurement Accuracy ± 1.0 % of reading Zero Stability Noise: < 0. Calibration Calibration gases in nitrogen. typical (excluding drift and temperature effects).5 % full-scale of standard ranges.Analyzer Specifications Response Time Dependent on sample gas flow rate and user-adjustable filtering time constants. Linearity < ± 1.0 % of full-scale of standard ranges. . Typically less than 30 seconds to T90 (excluding sample system). Temperature Drift SO2 = (40 PPM/Cell length)/°C H2S @ 228 nm = (80 PPM/Cell length)/°C H2S @ 214 nm = (30 PPM/Cell length)/°C NO & NO2 = (120 PPM/Cell length)/°C NH3 = (40 PPM/Cell length)/°C Cl2 = (120 PPM/Cell length)/°C  NOTE 2-2 | Model 909 Single-Gas Analyzer Use above specifications OR 3*(Customer full-scale/Maximum fullscale).2 % of full-scale of standard ranges. whichever is greater.

each capable of operating a 0–1000 ohm load.0–5. Cl2: NH3.0 litres/minute (0.24-Hour Zero Drift SO2: NO. SCU. Optional System 200 Configurator Software. Power Consumption 600 W for analyzer only (excludes Sample Line. Digital Outputs (Communication Ports) One RS-232 (or optional RS-485 for Modicon Modbus® protocol) port used for service diagnostics. Analog Outputs Four isolated 4–20 mADC outputs.2 SCFM) Specifications | 2-3 .1–0.5 % of full-scale of standard ranges Use above specifications OR the equivalent of 10 °C Temperature Drift (whichever is the lesser. ± 10 % 240 VAC. Electrical Requirements Nominal 120 VAC. and Vent Line power requirements). One RS-422 port with Modicon Modbus® protocol (used for interface to customer’s equipment). NO2.0 % of full-scale of standard ranges 1. Can be self-powered or loop-powered (loop power supplied by customer). ± 10 % Frequency Range 47–63 Hz 47–63 Hz Typical Sample Gas Flow Rate 3. with Auto-Zero disabled). H2S:  NOTE 1.0 % of full-scale of standard ranges 2.

entire system and backpan only (may vary. To achieve maximum accuracy and stability.17") 1117.01 (1996) Quality Standard for Instrument Air. Instrument Air Requirements Pressure: 413.6 mm (61. Maximum Altitude 2000 m Sample Transport Air aspiration as the drive medium.24 SCFM) minimum – may vary. depending on system). .Ambient Limits Temperature 5–50 °C (41–122 °F) Humidity 0–95 % RH  NOTE Temperature drift is approximately 1 PPM/ °C for the species listed. install the analyzer in a temperature-controlled environment or zero the analyzer more frequently.6 KPAG (60 PSIG) minimum Flow: 120 L/min (4. Physical Dimensions (on backpan) Height: Width: Depth: Weight: 2-4 | Model 909 Single-Gas Analyzer 1553. depending on application Air Quality: As per ANSI/ISA S7.0.6 mm (44") 306 mm (12") Approximately 160 kg (350 lb).

25 % of full-scale. Pressure Compensation Compensation for Measuring Cell pressure provided for SO2 only.8 °F) of the set point. heated probe (optional) Output Parameter Ranges Any full-scale within the measuring ranges of the analyzer. Temperature Control Independent control of up to five temperature-controlled zones: • • • • • Analyzer Oven Sample Line Sample Conditioning Unit (SCU) TZone3 (spare temperature-controlled zone) External.e. Other materials available to suit applications. Measuring Cell Construction Stainless steel body with quartz windows. Set at the factory.Status Relays The analyzer uses three relays which indicate the operational status of the analyzer. Measuring Cell temperature is measured and controlled to within ±1 °C (±1. The relays are configured for fail-safe operation (i. energized for the non-alarm condition). Each relay provides a set of SPDT (Form C) dry (potential free) contacts. Measuring Cell Operating Temperature Typically 140 °C (284 °F).. but can be changed by the user. Specifications | 2-5 . Range: 0–210 KPA (0–30 PSIA) Pressure Transducer accuracy 0.

Temperature Drift 0. refer to the Zirconia (Zr743) Oxygen Sensor Instruction Manual that is shipped with the analyzer.0 % O2 (with Auto-Zero disabled).Approvals and Certifications NEC/CSA: KEMA: GOST: NEC/CSA Class I. Accuracy ± 0. 2-6 | Model 909 Single-Gas Analyzer . Groups C&D. 24-Hour Zero Drift 1. Ex pd IIB T3 1ExpydIIBT3 GOST Pattern Approval CE Compliance: EMC: LVD: Complies with all relevant European Directives Electromagnetic Compatibility Directive: EN61326 Industrial Low Voltage Directive: EN61010-1 O2 Concentration Signal (Optional) An optional Zirconia Oxide Oxygen Sensor used on a wet basis and linearized using Nernst’s equation. Repeatability < ± 0. For technical data on this sensor.5 % full-scale of standard ranges. Zone 2 (Division 2). NFPA 496 Z‑Purge 02ATEX2341 X. Speed of Response 90 % in 30 seconds or less (excluding sample system).0223 % O2 per °C Electrical Classification General Purpose applications/analyzers only.1 % O2 (excluding drift and temperature effects).

14 % of transducer. full-scale. Repeatability 0.1 % of transducer. Specifications | 2-7 . full-scale. Stability 200 µV RMS (based on 0–5 VDC output).02 % of transducer. full-scale.25 "H2O (minimum) 0–5 "H2O (maximum) Accuracy ± 0. Hysteresis ± 0.Velocimeter Standard Range  0–0.

Purged Analyzers ATEX Certificate 2-8 | Model 909 Single-Gas Analyzer . AMETEK’s ATEX certificates for the Model 9xx-Series Analyzers (and their marking) are included in the following pages.ATEX (KEMA) Certificates and Analyzer Markings For installation sites with potentially explosive atmospheres that require ATEX certification.

Specifications | 2-9 .

2-10 | Model 909 Single-Gas Analyzer .

Specifications | 2-11 .

2-12 | Model 909 Single-Gas Analyzer

Purged Analyzer Markings
ATEX-certified Model 9xx-Series Purged Analyzers are marked with one of
the labels shown below, depending on the application.

No Release

Limited Release

Specifications | 2-13

Heater Plate ATEX Certificate

2-14 | Model 909 Single-Gas Analyzer

Specifications | 2-15

Heater Plate Marking
ATEX-certified Model 9xx-Series Analyzer are marked with the Heater
Plate label shown below.

2-16 | Model 909 Single-Gas Analyzer

Disconnect Enclosure Type 200 ATEX Certificate

Specifications | 2-17

2-18 | Model 909 Single-Gas Analyzer

Type 200 Disconnect Enclosure Marking
ATEX-certified Model 9xx-Series Analyzer are marked with the Type 200
Disconnect Enclosure label shown below.

Specifications | 2-19

This page intentionally left blank. 2-20 | Model 909 Single-Gas Analyzer .

Refer servicing to qualified personnel. • How to make all of the required electrical connections. and perform a leak check on all of the fittings and connections before powering up the analyzer. There are no WARNING operator-serviceable components inside the analyzer. • How to store the analyzer before installation. Installation & Start-Up | 3-1 .Installation & Start-Up The Installation & Start-Up chapter contains information about the following topics: • Where to find safety information in this guide before working with the analyzer. • How to uncrate and inspect the analyzer for damage before installing. • Tools. • How to install the mechanical components and gas lines. • What to expect during normal operation. equipment. • How to apply power to the analyzer and configure it for operation. ! The installation of the analyzer must be in accordance with all of the user and local regulatory standards and procedures. and supplies required for installation.

This information describes procedures to follow to avoid personal injury and/or damage to the equipment. review and follow all safety information under “Personnel and Equipment Safety Information” following the Table of Contents near the beginning of this manual.Safety Considerations  NOTE 3-2 | Model 909 Single-Gas Analyzer Before beginning the installation of the analyzer and before powering it up. All regulatory agency and personnel safety procedures for your jurisdiction must be followed. .

covers. Electronics Enclosure. electronic components. close and secure all covers and doors with at least one screw. Use caution when lifting it from its crate. and flamepaths (i.. Open the shelter and/or analyzer and check that all of the components within are secure and that there is no physical damage. corrosive gases. Sample/Vent Line Termination Box. is shipped premounted on a backpan either alone in a crate or in a crated weatherproof shelter. or excessive heat or cold. it must be housed in a temperature-controlled environment where it is not subject to dripping or splashing liquids. avoid damaging the analyzer’s piping and instrumentation by lifting it out of its shipping crate using only its CAUTION backpan.e. ! After the inspection. Disconnect Enclosure) during installation. Check that all of the components and wiring within the Analyzer Oven. remove the shipping crate and check the exterior of the shelter and/or analyzer for damage. ! For non-shelter systems. Uncrating and Inspecting the Analyzer The analyzer. DO NOT use any piping or instrument as a handle for lifting. Installation & Start-Up | 3-3 . and Disconnect Enclosure are secure and that there is no physical damage. along with its associated sample system. This will keep the electronics equipment secure and CAUTION will prevent damage to the doors. high humidity. Remove the shipping crate and check it for any physical damage.Pre-Installation Requirements Storage Prior to Installation If the analyzer is stored for any period of time prior to installation. Upon receiving the analyzer system. The Optical Bench Assembly is shipped in a separate box. ! WARNING The analyzer and its backpan weighs approximately 160 kg (350 lb).

and Aspirator Drive Air lines. and supplies: • Set of open-end wrenches. set of metric hexagonal wrenches. strippers. Equipment and Supplies Required for Installation To install the analyzer. and crimpers. 1/4" NPT-F connectors are required. • Flat blade instrument screwdriver. depending on the distance between the analyzer and the stack duct. Supplied by the customer/end user.0 Nm). this switch allows the main AC power to be disconnected from the analyzer. • Detergent-based leak detector (Snoop® or another suitable leak detection agent is permissible). • Thread lubricant (must not contain copper). • One flameproof power-disconnect switch (breaker). • Soft. • Supply of 1/4" or 3/8" 316 stainless steel tubing for the Instrument Air line. and set of metric ball drivers. Zero. Supplied by the customer/end user. it is very important not to touch the lamp windows because residual oils from the fingers will absorb CAUTION ultraviolet light. ! When handling the source lamps. Supplied by the customer/end user. 20 A and certified for the hazardous area. The lamp assembly is fragile and should be handled with care. If using 1/4" line. calibrated and set to measure 80 in-lb (9. equipment. ±1. • Torque wrench (for Type 200 Disconnect Enclosure). • Wrist Strap (for grounding). non-abrasive cloth.General Installation Information ! The electronic circuit boards and other static-sensitive components should be stored and transported in static-shielding carriers or CAUTION packages. 3/8–1/4" NPT-F (reducing) connectors are required.0 Nm. • Wire Cutters. if using 3/8" tubing. Length will vary. For safety reasons during maintenance. Span. • A supply of 1/4" 316 stainless steel tubing for the Calibration. This switch is to be supplied by the customer/end user. 3-4 | Model 909 Single-Gas Analyzer . rated for at least 250 VAC. The window is the flat surface at the end of the narrow glass tube. you need the following tools. Tools.

these conditions are taken into consideration in the design of shelter. refer to the associated illustrations for the dimensions and locations of components.Installing the Mechanical Components While installing the mechanical components. ! Do not mount the Optical Bench in the Electronics Enclosure until CAUTION after the analyzer has been mounted in its designated location. in a specially designed cabinet. accessible location as close as possible to the sample gas extraction point (to minimize the amount of sample lag time).  NOTE Regardless of which installation method is used. Location and Environment The entire analyzer system (and its backpan) can be mounted directly on a wall. To mount the analyzer: Non-Shelter Installations: In a suitable. the analyzer system must be installed indoors to ensure it is shielded from harsh environmental elements. See Figure 3-1 for the backpan and mounting hole locations and dimensions. or in a custom-built shelter. Specific drawings for your analyzer are located in the “Supplemental Information” section of this manual or the Documentation Package shipped with the analyzer. If the analyzer system is mounted within an AMETEK-designed shelter. Installation & Start-Up | 3-5 . In all cases. mount the analyzer on a vibration-free wall or instrument rack. Mounting the Analyzer The analyzer system comes mounted on a backpan. plus necessary clearances on all sides that are required for service. be sure to install the analyzer in a location that is as free as possible from vibrations. The surrounding ambient temperature of the analyzer should be maintained between 5–50 °C (41–122 °F).

If possible. the plumbing and external wiring will likely change for each installation. While the backpan and mounting hole locations and dimensions generally do not change. AMETEK recommends mounting the analyzer 1500 mm (59") from the floor to the centre of the Sample Line inlet connection on the Analyzer Oven.0") at the top of the backpan (see Figure 3-1).  NOTE Figure 3-1. provide extra room to allow sufficient access for servicing the analyzer. . 3-6 | Model 909 Single-Gas Analyzer Figure 3-1 illustrates a basic General Purpose (GP) analyzer layout. Analyzer (GP) backpan mounting details.The minimum allowable door swing clearances are 706 mm (27.8" in the front and at least 254 mm (10.

Shelter Installations: AMETEK recommends placing the analyzer shelter in a vibration-free location. Figure 3-2. Installation & Start-Up | 3-7 . GP analyzer. Actual drawings for your application can be found in the “Supplemental Information” section of this manual or in the Documentation Package shipped with the analyzer. Shelter installation details.  NOTE Figure 3-2 illustrates an example of a GP analyzer shelter installation.

Installing the Optical Bench Assembly After the analyzer has been installed. loosen the set screw securing the pivot pin. To do this. 3. 2. the Optical Bench Assembly can be mounted in the Electronics Enclosure and Analyzer Oven. 3-8 | Model 909 Single-Gas Analyzer . 4. Tighten the set screw. Connect the AC power lines (using the connector plug) to TB100 on the Optical Bench board (see Figure 3-4). The Optical Bench Assembly should swing freely.  NOTE ! WARNING If your analyzer uses a Measuring Cell other than the typical cell illustrated in Figure 3-5. Make sure that all power to the analyzer is off before installing the Optical Bench Assembly. Remove the outermost pivot pin from the blue Support Arm Yoke mounted to the back of the Electronics Enclosure in the upper-left corner (see Figure 3-3). Attach the Optical Bench Assembly to the Support Arm Yoke by fitting the Optical Bench Support Plate to the Support Arm Yoke and securing it with the pivot pin. Connect the ribbon cable from J102 on the Micro-Interface board to J100 on the Optical Bench board (see Figure 3-4). refer to the “Supplemental Information” section of this manual for the appropriate drawing. Connect the ground wire. To mount the Optical Bench Assembly: 1.

 NOTE Figure 3-3 illustrates a typical General Purpose (GP) analyzer layout. Electronics enclosure.Figure 3-3. refer to the “Supplemental Information” section of this manual or the Documentation Package shipped with the analyzer. GP analyzer backpan layout. For other analyzer types. Installation & Start-Up | 3-9 .

Figure 3-4. Remove the 3 mm holding screw from the Sample Cell RTD. 3-10 | Model 909 Single-Gas Analyzer . insert the 3 mm holding screw into the counter bore hole in the Heat Transfer Block and thread it (until it is snug) onto the Sample Cell RTD from which it was removed (see Figure 3‑5). Optical Bench board component layout. Adjust the entire Measuring Cell/Optical Bench Assembly as required to firmly seat the Measuring Cell Assembly against the Heater Plate. Swing the Optical Bench Assembly toward the Analyzer Oven and then swing the Measuring Cell Assembly toward the Heater Plate. Do not tighten the screw at this time. b. Do not use a ball driver – the head can break off inside the screw. c. Remove the Flame Arrester (black plug) from the counter bore hole in the Heat Transfer Block (on the Measuring Cell). 5. Align the hole in the Heat Transfer Block with the Sample Cell RTD tip and carefully push the Measuring Cell Assembly toward the Heater Plate. Using an Allen key. Mounting the Measuring Cell Assembly in the Analyzer Oven: a.

Optical Bench/ Measuring Cell/Lamp assembly. Installation & Start-Up | 3-11 .Figure 3-5.

ensure no gap exists between the Heat Transfer Block and the Sample Cell RTD. e.” following this section. Gently push and pull on the Measuring Cell Assembly to verify it is not loose.  NOTE While closing the Electronics Enclosure door. Verify there is no clearance between the Heat Transfer Block and the Sample Cell RTD. If necessary. Connect 1/8" OD Teflon tubing from the purge connection outlet on the purge controller to the Optical Bench purge fitting (see Figure 3‑5). The installation information for the Sample Line and vent is described under “Installing the Sampling System. use an Allen key to tighten the 3 mm holding screw until the Measuring Cell Assembly does not move when you push and pull on it. 7. 3-12 | Model 909 Single-Gas Analyzer . Replace the Flame Arrester (black plug) in the counter bole hole in the Heat Transfer Block. verify that proper vertical alignment of the Optical Bench Assembly is maintained. If necessary. If there is any movement. g. Verify the Measuring Cell Assembly is properly fitted against the Heater Plate and is firmly seated in the molded depressions in the Analyzer Oven wall and Electronics Enclosure wall. retighten the support bracket. tighten the 3 mm holding screw again until the Measuring Cell Assembly does not move when you push and pull on it. The two ribs of the silicon seal should fit between the inside and outside edges of the Electronics Enclosure wall. After aligning the Optical Bench Assembly. The Measuring Cell Assembly must feel secure against the Heater Plate. Close the Electronics Enclosure door and engage the latches to secure the Optical Bench Assembly in place.d. Adjust the Measuring Cell/Optical Bench Assembly so that the silicon seal on the Measuring Cell Extension fits firmly into the molded depressions in the Analyzer Oven wall and Electronics Enclosure wall. There should be no movement. After the Electronics Enclosure door is closed and secured. vertically align the Optical Bench Assembly by loosening the Optical Bench support bracket from the backpan and moving the Optical Bench Assembly up or down as required. being careful not overtighten it. f. Do not use a ball driver – the head can break off inside the screw. 6. h. Do not overtighten this screw as doing so will damage the threads on the RTD.

Refer to the Fuse Legend on the inside of the analyzer’s Electronics Enclosure for locations of these fuses. A breathing apparatus must be worn when installing/removing equipment from the sample gas extraction point. personnel safety procedures.  NOTE Ensure all appropriate fuses are opened before terminating any wiring. The stack duct may be under positive pressure. and injury or death from inhaling toxic gases in the stack duct could result from attempting to install/remove equipment without the use of a breathing apparatus. ! All regulatory agency. refer to the appropriate instructions and drawings included with those components.Installing the Sampling System  NOTE Drawings of the sample system components that make up your analyzer system are included in the “Supplemental Information” section of this manual or the Documentation Package shipped with the analyzer. If parts of the sample system are not supplied by AMETEK. and installation/removal procedures must be followed during the installation/ WARNING removal of the sample system components. Installation & Start-Up | 3-13 .

and thermocouple wiring from the SCU to the Sample Line/SCU Termination Box on the analyzer backpan.  NOTE Ensure there is sufficient clearance around the SCU to allow for easy removal and maintenance. Install the SCU on the stack duct. Refer to the Sample/Vent Line Wiring drawings and other related drawings for Over-Temp Wiring Details. These drawings are located in the “Supplemental Information” section of this manual or the Documentation Package shipped with the analyzer. To install the SCU: 1. These drawings include important information to follow during the installation of this unit. refer to appropriate drawings in the “Supplemental Information” section of this manual or the Documentation Package shipped with the analyzer. RTD. Install and terminate the Pitot/Static line from the SCU to the Velocimeter on the analyzer. 3-14 | Model 909 Single-Gas Analyzer .Installing the Sample Conditioning Unit If the SCU is supplied by AMETEK. refer to instructions and drawings that accompany the SCU. If the SCU is not supplied by AMETEK. 2. Install and terminate the SCU power.

These installation procedures briefly discuss using a vent pipe. Refer to the Fuse Legend on the inside of the analyzer’s Electronics Enclosure door for the locations of these fuses. Provide support where needed.Installing and Connecting the Sample and Vent Lines The Sample Line can be supplied by AMETEK or by the customer. Installation & Start-Up | 3-15 . the leak check has been completed. 3. To install the Sample and Vent Lines: 1. use two wrenches to ensure that the fitting body does not turn on the Teflon line. sags. or other traps in the Sample Line. Note that the electrical leads at the end of the line must be at the analyzer. In this case. To avoid damaging the Sample Line. Open the Electronics Enclosure door and open the Analyzer fuse to ensure there can be no power supplied to the analyzer or the Sample Line and SCU temperature-controlled zone circuits. The Sample Line is custom-built for each installation. they cannot be cut to length on site. 2. Doing so may pull the fitting off the sample transport tube. An alternate Vent Line installation is also available for applications that return the used gas to the extraction point. Unwrap and lay out the Sample Line. and the analyzer is ready for normal operation. Most applications are configured to disperse the used sample gas to atmosphere. the used sample gas is routed directly from the Sample Outlet Fitting in the Analyzer Oven to the dispersal location (vent pipe to atmosphere). This section assumes that the Sample Line is supplied by AMETEK. A wire mesh cable CAUTION support must be installed on the line before lifting it and when a line is to be suspended vertically. ! Do not lift or support the Sample Line by the tubing fitting. Ensure there are no loops. Route the Sample Line from the sample gas extraction point (on the stack duct) to the analyzer.  NOTE Keep these fuses and/or flameproof power-disconnect switch (breaker) open until the entire system has been installed.

6. Run a Vent Pipe between the analyzer and the disposal location (to atmosphere). Connect it to the Sample Inlet Fitting. Connect the Vent Pipe to the fitting at the disposal location. or related drawings located in the “Supplemental Information” section of this manual or the Documentation Package shipped with the analyzer. If the Sample Line is supplied by AMETEK. Make the connections to the Sample Inlet/Outlet Fittings inside the Analyzer Oven. Route the Vent Pipe through the lower hole on the left side of the Analyzer Oven. Non-Shelter Installations: Route the Sample Line through the upper hole on the left side of the Analyzer Oven. CAUTION NOTE 3-16 | Model 909 Single-Gas Analyzer .4. Connect it to the Sample Outlet Fitting. This will result in a local hot spot and cause premature failure of the line. Connect the Sample Line to the SCU (or stack sample probe. ! CAUTION Do not add extra insulation to the Sample Line. Connect it to the Sample Outlet Fitting. refer to the “Supplemental Information” section of this manual or the Documentation Package shipped with the analyzer. if used). 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 left side of the Analyzer Oven. Route the Vent Pipe through the hole marked “Vent Line” on the side of the shelter and then through the lower hole on the left side of the Analyzer Oven. Connect it to the Sample Inlet Fitting. 5.  When terminating the temperature sensor (RTD) leads. ! Connect the ground lead from each line to the ground terminals before connecting the heater leads. either sensor in a line may be used as the Control or Over-Temperature sensor (RTD). 7. Terminate the Sample Line and SCU wiring as indicated in the Sample/Vent Line Wiring drawing in Appendix D. Refer to appropriate drawings for more information about the Sample Line.

3. These values may vary. Shelter Installations: Connect the Instrument Air line to the “Inst Air” port on the left side of the shelter. To install the Instrument Air line: 1.01 (1996) specifications at all times. The tubing must be 1/4" or 3/8" 316 stainless steel tubing with appropriate 1/4" NPT or 3/8‑to‑1/4" NPT (reducing) connectors. Installation & Start-Up | 3-17 . depending on the application. an inlet filter system must be installed. 2. The air must be supplied to the analyzer pressure regulator at a pressure in the range of 420–840 KPAG (60–120 PSIG) and a flow rate of 60–120 L/ min (1–4 SCFM). The Instrument Air must meet the ANSI/ISA-S7. The plumbing for the purge systems and the aspirator drive air feed through the analyzer manifold is already made by AMETEK. 4. Blow down (purge) the line to remove any liquids or particulate that may be present in it line before connecting it to the analyzer. Non-Shelter Installations: Route Connect the Instrument Air line to the Instrument Air inlet fitting on the analyzer. Connect the Instrument Air line to the analyzer.Installing and Connecting Instrument Air The Instrument Air line is supplied by the customer. Route the Instrument Air line from the Instrument Air supply to the analyzer. Refer to the Plumbing Schematic located in the “Supplemental Information” section of this manual (or in a separate Documentation Package shipped with the analyzer).0. Connect the Instrument Air line to the Instrument Air supply. If the Instrument Air cannot meet these requirements.

Connect the appropriate Calibration Gas tube to the appropriate fitting on the manifold block and to the supply tanks. The gas lines must be 1/4" 316 stainless steel tubing. 3-18 | Model 909 Single-Gas Analyzer . To install the Calibration (Span/Zero) Gas lines: 1. 3. Blow down (purge) the lines to remove any liquids or particulate that may be present in them before connecting them to the analyzer. 2. Route the Span/Zero Gas lines from each supply tank to the analyzer.Installing the Calibration (Span/Zero) Gas Lines The Calibration (Span/Zero) Gas lines are supplied by the customer.

! For AC electrical supply cable and conduit requirements. ! Purged Analyzer (Hazardous Location) Applications: Take extreme care to avoid damaging the threads on the cable entry CAUTION glands on the Disconnect Enclosure. and AC power requirements are specific to each analyzer installation.Connecting I/O Signals. ! CAUTION Purged Analyzer (Hazardous Location) Applications: For Zone 1 Installations.  NOTE Refer to the Electromagnetic Compatibility (EMC) page in the contents section of this manual for information that discusses the EMC Directive regarding techniques and wiring practices to be followed. defect-free threads are essential to ensure a flameproof connection. refer to. use a suitable flameproof cable entry device with a sealing ring.2 “The cable entry system shall comply with … e) flameproof cable entry devices incorporating compound filled seals around the individual cores or other equivalent sealing arrangements”. item “b)”. local wiring regulations and electrical codes for the WARNING hazardous area. Installation & Start-Up | 3-19 . In all cases. all unused cable entry ports must be plugged with a certified Ex d plug. 10. comply with local wiring regulations and electrical codes. As per EN 60079-14:1997. For Zone 2 Installations. 10.2. as per EN 60079-14:1997.3. all cable entry glands (one power cable entry and two signal cable entries) into the flameproof Disconnect Enclosure must be Ex d certified.3. Clean. and comply with. or. alarm relay contacts. and AC Power The analog input/output signals. Alarm Relay Contacts.

CAUTION rated for at least 250 VAC. and AC power will vary. depending on whether the analyzer is mounted only on a backpan or in a shelter. For safety reasons during maintenance. 20 A. refer to the customer-specific drawings. or in the Documentation Package shipped with the analyzer. Close the door and replace at least one of the M10 screws while completing the installation. analog output signals. nonabrasive cloth to gently clean the joining surfaces CAUTION (flamepath) of the Disconnect Enclosure and its door. To satisfy local electrical codes. this switch allows the main AC power to be disconnected from the analyzer prior to performing service on the analyzer. the “Supplemental Information” section of this manual. and other electrical connection drawings) that show the connections for the remote calibration/remote backpurge input signal. alarm relay contacts. the switch must be certified by the local authority for the appropriate hazardous area. Drawings (Customer Signal Connections. Analyzer AC Wiring. If the analyzer is installed in a shelter. ! Purged Analyzer (Hazardous Location) Applications: Use a soft. or if it is for use in a General Purpose or Hazardous Location. also included in these locations. near the analyzer (supplied by the customer). ! Purged Analyzer (Hazardous Location) Applications: Install and connect a flameproof power-disconnect switch (breaker). and alarm relay contact termination points are included in this section and in Appendix D. This will ensure the flamepath is not inadvertently damaged. 3-20 | Model 909 Single-Gas Analyzer . analog output signals.Electrical Connections Termination points for the Remote Calibration/Remote Backpurge input signal.

analog output signal. Apply sealing compound in the signal/relay cable gland(s) as per the manufacturer’s instructions. NOTE All electrical connections should be performed only by properly trained and qualified personnel and must be made in compliance with local wiring regulations and electrical code for the hazardous area. analog output signal. Route the input/output signals and alarm relay conductors into the Disconnect Enclosure. Terminate the input signals. Connect the cable gland(s) to the signal/relay cable entry(ies) on the Disconnect Enclosure. and alarm relay contact conductors into the Electronics Enclosure and terminate the wires. Purged Analyzer (Hazardous Location) Applications: Open the Electronics Enclosure and open all of the fuses (or GFIs). General Purpose (GP) Analyzer Applications: Open the Electronics Enclosure and open all of the fuses. Loosen and remove all but one of the M10 x 40 mm hex socket head cap screws that secure the door to the Disconnect Enclosure. Keep this screw in place until you are ready to terminate connections inside the Disconnect Enclosure. Purged Analyzer (Hazardous Location) Applications: Route the input signals. Install a cable gland(s) on the signal/relay cable(s) as per the manufacturer’s instructions. 2. and alarm relay contact conductors to the Disconnect Enclosure. Terminate the signal/relay connections inside the Disconnect Enclosure. analog output signal(s). and power connections: 1. and be approved by the Owner Company. To make the signal. Installation & Start-Up | 3-21 . relay contact. General Purpose Analyzer Applications: Route the input signals. and alarm relay contact conductors (see Figure 3-6 for GP/Div 2 analyzers).

Apply sealing compound in the cable gland as per the manufacturer’s instructions. Close the door and tighten all screws to 80 in-lb. connected. 4. Route the AC power conductors into the Disconnect Enclosure. Terminate the AC power conductors. and verified. use a soft. route the AC power conductors to the Disconnect Enclosure. Refer to the Analyzer AC Wiring drawing (Figure 3-7) – and other related customer-specific drawings – in Appendix D.0 Nm. After cleaning these surfaces. or in the Documentation Package shipped with the analyzer. ! Before making the AC power connections. the Supplemental Information section of this manual. Connect the cable gland to the power cable entry on the Disconnect Enclosure. and open the Analyzer WARNING and Oven Heater fuses. if used) to the analyzer. Do not apply power to the system until after all of the wiring has been installed.3. open (turn off) the flameproof switch (breaker. Terminate the AC power connections inside the Disconnect Enclosure. Purged Analyzer (Hazardous Location) Applications: According to local wiring regulations and electrical codes. apply a suitable thread lubricant (must not contain copper) to the threads of the 24 screws that secure the door to the Disconnect Enclosure. Plug all unused cable entry ports with certified Ex d plugs. and only if the purging system is ready for operation. General Purpose Analyzer Applications: Route the AC power conductors to the Electronics Enclosure and terminate the wires. If no damage is evident. non-abrasive cloth to gently clean its joining surfaces (flamepath) and make sure they are free of debris. Install a cable gland on the power cable as per the manufacturer ’s instructions. ±1. inspect the flamepath for scratches or other damage. 5.0 Nm). 3-22 | Model 909 Single-Gas Analyzer . ±9 in-lb (9. Purged Analyzer (Hazardous Location) Applications only: Before closing the Disconnect Enclosure door.

refer to the electrical connection drawings included in the “Supplemental Information” section of this manual or the Documentation Package shipped with the analyzer.  NOTE Figure 3-6 is for GP/Div 2 analyzers only.Figure 3-6. For other applications. for CE or Zone 1 refer to Customer Signal Connections. GP/Div 2 analyzers. CE/Zone 1 Analyzers in Appendix C. Customer signal connections. Installation & Start-Up | 3-23 .

Figure 3-7. .  NOTE 3-24 | Model 909 Single-Gas Analyzer PD refers to Purgeable Deluxe analyzers (General Purpose & Division 2). AC Wiring. GP/Div 2/CE/ Zone 1 Analyzers.

and after power-up. during. instrumentation. For the actual layout of your application.Start-Up and Verification This section describes equipment and controls on the analyzer system that require adjustments and settings before. the plumbing.  NOTE Figure 3-8 illustrates a basic General Purpose (GP) analyzer layout. Refer to Figure 3-8 for the locations of analyzer equipment or controls that require adjustments. While the Electronics Enclosure layout generally does not change for different applications. and external wiring may differ. Figure 3-8. overall component layout. Installation & Start-Up | 3-25 . refer to the “Supplemental Information” section of this manual or the Documentation Package shipped with the analyzer. Model 909 Analyzer (GP).

if installed) have been closed. This function effectively prevents an internal explosion when the analyzer is powered up and operating under normal sampling conditions. After this time period has elapsed. Figure 3-9. The required purge air supply pressure is indicated in drawings for your analyzer located in the “Supplemental Information” section of this manual or in the Documentation Package shipped with the analyzer. the Purge Bypass Switch (Figure 3-9) must be in the BYPASS position (and appropriate safety conditions must have been met. the analyzer will power up (providing all fuses have been engaged) and any external flameproof switches (or breakers. the PURGE COMPLETE indicator will turn green. the MiniPurge system will purge any flammable gases that may have entered the Electronics Enclosure while its door was open. its purge timer will begin – after the ALARM/PRESSURIZED indicator on the MiniPurge system turns from red (alarm condition) to green (pressurized). In these cases. AMETEK analyzers that require purged enclosures in hazardous locations use an Expo-Telektron MiniPurge system to perform this function.Purged Analyzer (Hazardous Location) Applications 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. After the MiniPurge system has been connected to the instrument air supply. The purge air supply is normally obtained from the Instrument Air supply connected directly to the Expo-Telektron MiniPurge system. and certain troubleshooting and maintenance procedures. start-up. During this first stage. as per company policy). Purge Bypass Switch label. Working with the purged enclosure open is typically limited to installation. At this point. 3-26 | Model 909 Single-Gas Analyzer BY PA SS AC T IV E .

the analyzer will not power up until the MiniPurge system has been connected to the instrument air supply and has completed its purge stage (the PURGE COMPLETE indicator will be green) and the ALARM/PRESSURIZED indicator is green (enclosure is pressurized). If it is necessary to open the analyzer’s covers or doors while the circuits are live.” later in this chapter. ! Always disconnect power and/or external power sources to the analyzer before opening any covers or doors on the analyzer to check or WARNING perform maintenance on any components within the enclosures.For normal analyzer operation. or serious damage to equipment. or wear) to any flamepath (on the Oven Heater or WARNING Disconnect Enclosure). To work on the analyzer with it powered up and its Electronics Enclosure door open. When the Electronics Enclosure is open. for help in diagnosing and correcting problems. Installation & Start-Up | 3-27 . If problems are encountered during power-up. ! Do not apply power to the analyzer if there is damage (scratches. the Purge Bypass Switch must be in the BYPASS position. indentations. After powering up the analyzer for the first time. Applying power to an analyzer with a damaged flamepath is dangerous and could result in serious injury or death. These checks are discussed in the following power-up procedure. the Purge Bypass Switch must be in the ACTIVE position and the key must be removed (follow company policy). Hazardous voltages are present inside. first monitor the area for flammable gases (and proceed only when the area is safe). refer to the “Start-Up Diagnostic Checklist. certain checks must be performed with the Electronic Enclosure door open to ensure the analyzer is operating properly. take appropriate precautions to avoid electrical shock. To ensure safe operating conditions.

To power up the analyzer and verify it is operating properly: 1. you must manually backpurge the analyzer ’s sample system with Zero Gas and adjust the sample gas flow rate. Proceed only when the area is found to be safe. take appropriate precautions to avoid electrical shock. Hazardous voltages are present inside. refer to “Start-Up Diagnostic Checklist.” later in this chapter. With the Electronics Enclosure open: General Purpose Analyzer Applications: Close the Analyzer fuse to apply main AC power to the analyzer. following a power-up or reset. test the area for flammable gases. When the analyzer’s covers and doors are open. 3-28 | Model 909 Single-Gas Analyzer . do not apply power to the analyzer or any alternate power sources that supply power to the analyzer components. If an explosive gas atmosphere is present. ! [Special Conditions for Safe Use] The analyzer may only be energized by using the Purge Bypass WARNING Switch with permission of the works manager or his proxy. Purged Analyzer (Hazardous Location) Applications: Insert the key into the Purge Bypass Switch and switch it to the BYPASS position (follow company policy). Note that power is applied to the Sample Line and SCU temperaturecontrolled circuits when AC power is applied to the analyzer. If startup problems occur. for problems and corrective action to fix any problems. Refer to the Fuse Legend on the inside of the analyzer’s Electronics Enclosure door for the location of this fuse. or after maintenance. ! For verification and troubleshooting purposes during power up. 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”).Powering Up the Analyzer Before operating the analyzer for the first time. it will be necessary to work with the analyzer’s covers and doors open. The analyzer enclosure may not be opened when an explosive atmosphere is present. WARNING Before powering up the analyzer.

continue with the next step. If the “Reset in Progress” message still does not appear. simultaneously press • and Ent. Installation & Start-Up | 3-29 . To check the AC wiring. take all necessary safety precautions to power down the analyzer and open the Analyzer fuse and the Oven Heater fuse. Close the Analyzer fuse. 2. Review the Analyzer (AC) Power Connections drawing(s) and check the wiring terminations from the power supply source to the analyzer. the Host Controller board software version number will appear on the top line of the User Interface Panel and the message “Reset in Progress” will appear on the bottom line. Check the User Interface Panel again to see if the message appears. ! WARNING Wait 5 minutes to allow the high-voltage capacitors in the sourcelamp power supply to discharge. ! If the “Reset in Progress” message still does not appear. take necessary precautions and check the AC wiring to ensure it is properly WARNING connected. check the AC wiring to ensure it is properly connected.  NOTE If the “Reset in Progress” message does not appear within approximately 2 seconds. If it does. Take all necessary safety precautions and power up the analyzer (as discussed previously). Refer to the Fuse Legend on the inside of the analyzer’s Electronics Enclosure door for the location of this fuse. Apply main AC power to the analyzer by closing the flameproof power-disconnect switch (breaker). Immediately following power-up.

Press 2 to view the Vent Line (or SCU) temperature-controlled zone. The Sample Line and Vent Line (or SCU.3. . this can indicate problems with the wiring. While observing the electronics within the Electronics Enclosure. 5. Press 4 to view the Measuring Cell temperature-controlled zone. This warning will clear when the Analyzer Oven temperature controlled zone is within its normal operating range. if used) zones typically warm up quicker than the Measuring Cell zone. Record the value indicated for each zone to use as a reference later while comparing the temperature value.8) and/or F5 5 (and press each of the keys numbered 1. From the User Interface Panel. The TStPt screen defaults to the Sample Line temperature-control zone. Close the Oven fuse to supply power to this temperature-control zone circuit. NOTE Check the User Interface Panel for indications of other alarms. the alarm warning “w Oven Heater” may be displayed on the User Interface Panel. perform the following checks to ensure the analyzer temperature-control zone circuitry is operating properly. To view alarms that have been detected. press F5 4 (and press each of the keys numbered 1. check the source lamps to ensure they are on (firing). Check the LEDs on the Termination board to ensure they are on.. Alarms are indicated by a reverse-video S ( S ) on the upper-right line. If the lamps are not firing or the LEDs on the Termination board are not on. Allow the entire sample system to warm up to normal operating temperature and stabilize. 4. You can also view this parameter by pressing 1.7) from RUN mode to view the current Host Controller board and/ or Microcontroller board status/error code conditions.  When the analyzer system is first powered up. a.  NOTE 3-30 | Model 909 Single-Gas Analyzer The third temperature-controlled zone (“3” = TZone3) is a spare. view the set points for each temperature-control zone by pressing F4 0 (from RUN mode) to view the TStPt screen. This should take approximately 2 hours. Meanwhile..

b. 8. Close and secure all covers and doors on the Electronics Enclosure. Installation & Start-Up | 3-31 . perform a leak (pressure) check to ensure there are no leaks in the system. check the wiring for proper connections. and if all of the alarm conditions have cleared (check the User Interface Panel). it may indicate a shorted RTD for that temperature zone. 6. take extreme care to avoid CAUTION scratching or damaging the joining surfaces (flamepath). Compare the current temperatures to their respective Set Point values recorded earlier. gently clean these areas with a soft. and Sample/SCU Termination Box. press F6 8 from RUN mode to view the Microcontroller Board Analog Inputs (MAI) and pay particularly close attention to the temperatures of the Sample Line. Next.4”. 7. The lowest temperature you will see for any zone is 7 °C (45 °F). follow the procedures listed under “Sample System Leak Check. press F6 8 to view the Microcontroller Board Analog Inputs (MAI) and then press keypad numbers 1 through 4 and record the value for each zone. and Measuring Cell. return to this procedure and complete the remaining steps.” later in this chapter. ! Purged Analyzer (Hazardous Location) Applications: While the Disconnect Enclosure is open. check and record the current temperature readings. Normal operating temperatures are values that are within 5 % of the Set Point values. Vent Line (or SCU. Analyzer Oven. If all of the temperature zones have reached normal operating temperatures and there are still no alarm conditions or other problems. To do this. To perform this test. Then. Disconnect Enclosure. Compare the values to the values recorded earlier to ensure they have increased. if used). After approximately two hours (at which time the system should have reached its normal operating temperature). If the display reads “181. This will help you determine if the signal wiring is properly terminated and if all of the circuitry is operating properly. To do this. Before closing the door. non-abrasive cloth and make sure they are free of debris. If this temperature does not increase. recheck the temperature of each zone.

g. Open the isolation valve on the sample gas extraction equipment (e. 3-32 | Model 909 Single-Gas Analyzer . Take precautions to avoid burning yourself. 11. Purged Analyzer (Hazardous Location) Applications Only: Return the Purge Bypass Switch to the ACTIVE position and remove the key (follow company policy). ! WARNING For systems using a Sample Conditioning Unit (SCU). Adjust the Aspirator Drive Air Regulator to achieve normal operating flow rates as described under “Adjusting the Sample Gas Flow Rate. Manually Zero the analyzer as described under “Manually Zeroing the Analyzer. the SCU will be hot. 12..” later in this chapter.” later in this chapter.9. 10. SCU) to allow sample gas from the stack duct into the analyzer ’s sample system.

Problem Encountered If a reverse-video S ( S ) is displayed on the User Interface Panel. Corrective Action Simultaneously press • and Ent. check the connections of the lamps in their sockets. refer to the alarm conditions and corrective action in the Maintenance & Troubleshooting chapter of this manual. take necessary precautions and check the AC wiring to ensure it is properly connected. or after attempting a manual system reset. If the analyzer experiences problems during power-up. For detailed information about these alarms. If the wiring is okay. view the current Host Controller board and/or Microcontroller board status/error code conditions for current alarms. Corrective Action To view current alarms. Corrective Action Take appropriate safety precautions and check for proper wiring connections.7). If this message still does not appear. Review the section titled “Replacing the Source Lamps” in Chapter 5 of this manual to make adjustments to the lamps. review this checklist and perform the corresponding corrective action to fix any problems. Problem Encountered One or both source lamps are not firing.. Perform an Auto-Setup if necessary to ensure the lamps are operating at peak efficiency.. Installation & Start-Up | 3-33 .Start-Up Diagnostic Checklist This diagnostic checklist describes problems that may be encountered while powering up the analyzer and/or preparing it for normal operation. Problem Encountered “Reset in Progress” message does not appear on the User Interface Panel immediately after applying AC power. The S character will typically be displayed upon start-up due to low temperatures in the temperature-controlled zones. press F5 4 from RUN mode (and press each of the keys numbered 1.8) and/or F5 5 (and press each of the keys numbered 1.

Problem Encountered Temperature zone value reads “181. Corrective Action Take appropriate safety precautions and check for proper wiring connections for the appropriate temperature zone wiring. See Figure 3-10 for the location of this switch. If necessary. 3-34 | Model 909 Single-Gas Analyzer . Also. replace the RTD with an AMETEK-approved replacement part. Corrective Action Take appropriate safety precautions and check for proper I/O wiring connections.4”. This temperature value indicates a faulty RTD for the related temperature zone.Problem Encountered The LEDs on the Termination board are not on. Corrective Action Take appropriate safety precautions and check the related RTD for a short. press the OverTemp Reset switch (SW300) on the Termination board (inside the Electronics Enclosure) to re-energize any tripped circuits. Problem Encountered Temperature zone values do not increase.

Over Temp alarm reset switch (SW300).Figure 3-10. Termination board. Installation & Start-Up | 3-35 .

While working from the User Interface Panel. With the analyzer powered up. Most leaks are preventable with the regular replacement of the Measuring Cell o-rings. Instrument Air. ! To avoid damaging the pressure transducer. After all piping and electrical connections have been made: 1. view RUN mode. Therefore.Sample System Leak Check The analyzer sample system has been pressure-checked for gas leaks at the factory – with the Optical Bench/Measuring Cell Assembly connected – as part of AMETEK’s quality assurance procedures. ! Preventing leaks in the sample handling system is critical to ensure proper analyzer operation. Also. Use the Aspirator Drive Air Regulator to increase the instrument air pressure to 70 KPAG (10 PSIG). Cap the Sample Line at the SCU and cap the Vent Line at the Sample Vent Pipe. open the Aspirator Drive Air Regulator to allow instrument air into the sample system. The reading on the User Interface Panel is automatically updated every second. the optics will become damaged and most likely require replacement. do not set the pressure higher than 105 KPAG (15 PSIG). or following the replacement of any lines/fittings or Measuring Cell parts. Calibration Gas. CAUTION 4. 2. press F6 8 6 to view the CellP (Measuring Cell Pressure) screen and record the numeric value displayed. 3-36 | Model 909 Single-Gas Analyzer . Vent. However. If sample gas migrates into the Optical CAUTION Bench Assembly or Reflector Block due to a leak in the Measuring Cell Assembly. the Sample Line. This value is the absolute pressure reading in mmHg (or "Hg). the Optical Bench/Measuring Cell Assembly has been removed for shipping (in its own crate) and fittings can loosen during transport. and Zero Gas lines are installed on-site. it is important that you perform a leak check on the entire sample system prior to powering up the analyzer for the first time. 3.

Allow the pressure within the analyzer’s sample system and the Measuring Cell to equilibrate (approximately 5 minutes) before taking the initial reading. perform a leak check on all of the other fittings except the fittings that are hot. remove the cap from the Sample Line at the SCU (and reconnect it to the SCU). Installation & Start-Up | 3-37 . 7. Meanwhile. If the reading drops less than 10 mmHg (0. After the analyzer has passed the pressure leak test. there is a leak somewhere in the system. continue to observe the Measuring Cell Pressure reading on the User Interface Panel.g. Remove the cap from the Vent Line and reconnect it to the Sample Vent Pipe.5. ! Do not use a leak detection fluid on hot fittings.39 "Hg) in 4–5 minutes. If the Measuring Cell is suspect. However. Snoop®). check all fittings to ensure they are tight and repeat the procedures of testing/repairing/testing until all leaks have been eliminated. such as those on the Measuring Cell. 6. the temperature zones must be cooled CAUTION down before using a leak detection fluid on the fittings. the system is sufficiently leak-tight. To test the zones that are hot. if the reading steadily decreases. If the analyzer system is at operating temperature. Using a suitable detergent-based leak detection fluid (e. Block in the instrument air by closing the Drive Air Isolation Valve (green handle) and observe the pressure reading on the User Interface Panel. observe the Measuring Cell Pressure (CellP) reading – press F6 8 6 from CFG mode – and check for steady or decreasing values.

3-38 | Model 909 Single-Gas Analyzer . This procedure assumes Instrument Air is used as the Zero Gas. Force the analyzer to manually zero the sample system with Zero Gas by keying in Del 10 Ent (10 = Continuous Zero). c.” later in this section. view the temperature zones to ensure that all zones are at their operating temperatures. Ensure that the Zero Gas cylinder is turned on. b. NOTE To manually zero the analyzer: 1. For more information about setting the Zero Gas flow rate. refer to “Adjusting the Zero Gas Flow Rate. Enter F5 2 to display the FlowCtrl (Flow Control) mode screen. d. Set the analyzer Flow Control Mode to Continuous Zero Gas mode by entering the following keystrokes from the User Interface Panel: a. If necessary. Press Ent to enter CAL mode. 2. From this screen. you can view the current operating mode.5 L/min (5 SCFH).  Pressing Esc at any time during this procedure will abort the procedure and return to CAL mode normal display. Record the numeric value displayed for FlowCtrl. All temperature zones must be at their operating set points before performing a Manual Zero. Run the manual zero for 10 minutes at a flow rate of 2. Press Ent again to return to CAL mode normal screen. which forces the analyzer to purge the sample system with Zero Gas (Continuous Zero Gas Flow mode). enter F6 • and then enter the CALibration mode password “• •” (at the “PSWD0” prompt). From RUN mode.Manually Zeroing the Analyzer The CALibration mode is used for performing the manual Zero function. The Zero function removes any residual contaminants in the sample system.

Press Ent again to return to CAL mode normal screen and then Esc to return to RUN mode. as described under the section titled “Recording Initial Readings. 7. Esc for No The function is aborted and the zero values are not adjusted. where “0” = Analyzer Control mode.) The zero values will be adjusted automatically and the screen will revert to CAL mode normal display. Installation & Start-Up | 3-39 . manually re-zero the analyzer again by pressing F2 0 Ent. Press F2 0 to initiate the Manual Zero. Return the analyzer to Analyzer Control (automatic control) by entering F5 2 Del 0 Ent. The zero process is complete and the analyzer is now on-line. When the readings have stabilized at or near zero. Observe the readings on the bottom line of the User Interface screen.3. 4. 6.” later in this chapter. press: Ent for Yes The analyzer will count down from 15 seconds to zero (Integration Timer duration) during which time the readings are averaged. Turn off the Zero Gas. If the User Interface Panel displays a “w ZDrift/SpnErr” error message. Record the analyzer’s initial Measure and Reference PMT signal readings. (The timer defaults to 15 seconds if the Integration Timer is set to zero. The User Interface Panel will prompt “Man/Zero?”. 5.

5 L/min (10–15 SCFH). Some applications may require a higher flow rate. To obtain a good zero gas flow rate. instrument air flows into the sample path via a flow controlling rotameter and a manifold located within the Analyzer Oven. All that is important during these conditions is that the sample system is kept free of contamination by the sample gas. adjust the rotameter for a flow rate of 5–7. a lower zero flow rate may be desired to avoid a cooling effect of prolonged introduction of air into the sample system. . During warm-up of the sample system or when the analyzer is in Standby.  NOTE 3-40 | Model 909 Single-Gas Analyzer Set the response time first to ensure a good zero. A good zero can be defined as a state where the concentration outputs of the analyzer are stable and further increases in Zero Gas flow rate do not reduce the concentrations observed on the analyzer User Interface Panel. Since excess air flow into the analyzer’s sample system will cool the Measuring Cell and Analyzer Oven. the optimum Zero Gas flow rate is the lowest consistent with a good zero.Adjusting the Zero Gas Flow Rate When the flow control solenoid is in a de-energized state. The flow rate of Zero Gas must be high enough to adequately backpurge the Measuring Cell of sample gas to obtain a “good zero”.

If the sample response time is adequate (first response after a Zero function is approximately 30 seconds). Installation & Start-Up | 3-41 . no further adjustment is necessary for a Sample Line of less than 10 metres. Response time is determined by switching the analyzer from Continuous Backpurge mode to Continuous Sample mode and recording the time it takes the analyzer to display the first reading after the switch to Continuous Sample mode. do not set the pressure higher than 105 KPAG (15 PSIG). Setting Sample Response Time Sample response time may also be used as a parameter for setting the Aspirator Air pressure. depending on Sample Line length.2 SCFM)) will ensure a measurement response time is approximately 30 seconds. The analyzer pressure – measured by the pressure transducer – may also be used to set the sample flow rate. A good sample gas flow rate (3. adjust the Aspirator Air to the appropriate pressure in the range of 7–35 KPAG (1–5 PSIG).0–5.Adjusting the Sample Gas Flow Rate The Aspirator Drive Air Regulator is used to control the sample gas flow rate through the system.0 L/min (0. view the RUN mode normal display and observe the output concentration changes. To view the Measuring Cell pressure (CellP).1–0. enter CFG mode and press F6 8 6. To obtain a response time within this range.  NOTE The sample response time may vary. To check the sample response time. ! CAUTION To avoid damaging the pressure transducer. This is accomplished by first measuring the stack duct pressure with no aspiration (Drive Air Isolation Valve closed) and then adjusting the Aspirator Drive Air Regulator with the Drive Air Isolation Valve open to obtain a pressure of 5–10 mmHg less than the value obtained with the valve closed.

Recording PMT Signals To check and record the initial PMT signal readings: 1. The User Interface Panel is updated once per second. the top line of the User Interface Panel displays the output parameter names. Keep the log book in a safe location until you need to review it for patterns of diminishing PMT signals or a longer sample response time. and how to use this information to help you determine problems with the analyzer. These problems typically indicate maintenance is required. 2. such as diminishing photomultiplier tube (PMT) signals. while their corresponding values are displays on the bottom line. the analyzer ’s User Interface Panel defaults to RUN mode. observe the PMT signal readings. Recording Initial Readings Before operating the analyzer. or increasing sample response time. parameters or variables can only be viewed. it is important to observe and record initial readings (when the analyzer sample system is clean) for the photomultiplier tube (PMT) signal optical filters and the sample response time. While the zero is in progress.  NOTE To help you determine in the future if there are problems with your analyzer.Normal Operation After the analyzer is set up and started. Record the values for the Measure PMT and Reference PMT signals. This is referred to as the RUN mode normal display. view the Show Signals screen by pressing F6 1 from RUN mode. AMETEK recommends that you observe and record this information every month to obtain a history of the readings. From these recordings. The software defaults to Filter 1 (Measure filter). it is important to observe the analyzer to understand what normal operating conditions are. To do this. In RUN mode. During normal operation in RUN mode. they cannot be changed. 3-42 | Model 909 Single-Gas Analyzer . Passwords are required to enter CAL and CFG modes. you will be able to determine if there are problems with the analyzer. Manually zero the analyzer. Parameters or variables can be changed only under the CAL or CFG modes.

Typically. the results may be skewed because the composition of the gas can vary. Record the time it takes the analyzer to display the first reading after the analyzer’s Flow Control function switches from “zero” to “sample”.  NOTE It is important to record these values during a manual Zero function to simulate the same conditions during the original recordings. Installation & Start-Up | 3-43 . If the values are recorded using the sample gas. To check and record the initial sample response time: 1. Record these signals in a log book every month. 3. view the RUN mode normal display and observe the output concentration changes. The other function is to help you determine if the typical response time is increasing. After the zero is complete. Press 3 to view the Baseline Measurement. which may indicate a plug in the sample system. Recording Initial Sample Response Time The analyzer’s sample response time can be used for two functions. which looks at Measure/ Reference PMT signals in an off-state. Press 2 to view the signals for Filter 2 (Reference filter). Manually zero the analyzer. One function is to help you set the sample gas flow rate (as discussed earlier in this chapter.  NOTE It is important to record the response time only after performing a manual Zero function to simulate the same conditions during the original recordings. All signals should return to within 5 % of the values recorded the previous month. 2. under “Setting Sample Response Time”). a good response time is approximately 30 seconds (excluding sample system) when the sample system is clean and operating at peak efficiency (response time may vary due to Sample Line length). Record the values for the Measure PMT and Reference PMT signals.

These sheets are located in the “Supplemental Information” section of this manual and in the Documentation Package shipped with the analyzer. refer to the original Configuration and EEPROM Data Sheets to revert the analyzer back to its original settings. If the sample response time is adequate (first reading after a Zero function and after the analyzer’s Flow Control function switches from “zero” to “sample” is approximately 3 seconds). depending on Sample Line length. These configuration sheets list all of the settings that have been made to the analyzer at the factory (to meet customer requirements). no further adjustment is necessary. Analyzer Configuration Completed Analyzer Configuration and EEPROM Data Sheets are shipped with each analyzer. this data must be re-entered in order to override the factory defaults.  NOTE The sample response time may vary.3. 3-44 | Model 909 Single-Gas Analyzer . be sure to record the changes for later reference. If necessary. Record these signals in a log book every month. If any changes are made to the original configuration. If the EEPROM is replaced. 4.

Controller / User Interface | 4-1 . • Analyzer operating temperatures. including how to change passwords. • Functions of keypad keys and accessing them from the User Interface Panel.  NOTE Pressing Ent after making changes (while working in CFG or CAL mode) will cause the configuration data to be saved in non-volatile memory – the old values will be lost. entering commands to view screens.  NOTE Before working from the User Interface Panel. password information. read the section titled “Introduction to the User Interface Panel” which discusses keypad key functions. and default parameter settings. This section also discusses how to enter the ConFiGuration (CFG) and CALibration (CAL) mode.CONTROLLER / USER INTERFACE The Controller / User Interface chapter contains information about the following topics: • User Interface Panel. the previous configuration data will be used following a system reset or power-up. If the configuration data are not saved. alarm set points. and how to quickly return to RUN mode from anywhere in the software. • Keystroke combination Quick Reference Sheets listing keystroke commands used to view and/or change information from the three software operation modes.

the top line displays the names of the outputs. - The top line displays the current mode of operation. the User Interface Panel displays a “b” on the upper-left line.Introduction to the User Interface Panel Figure 4-1..7) from RUN mode to view the current Host Controller board and/or Microcontroller board status/error code conditions.8) and/or F5 5 (1. To view the alarm that has been detected. When operating in CALibration or ConFiGuration mode.. User Interface Components The User Interface Panel is made up of two areas: • The dot matrix display consists of two lines. During normal operating conditions in RUN mode. the mode of operation (CAL or CFG) is also displayed. The information displayed depends on your current mode of operation. If the analyzer detects an error by the built-in diagnostics system. User Interface Panel Layout. each capable of displaying up to 20 alphanumeric characters. press F5 4 (1. it displays S (a reverse-video S) on the top-right line. or a prompt for further keypad input. 4-2 | Model 909 Single-Gas Analyzer . If the analyzer switches to Backpurge mode.

F F4. • The 21-key keypad allows you to view and/or input (change) information from any of the three main modes of operation. to activate a function whose value you wish to view or change. but only before they have been saved. or as part of a password. as part of a command (used in conjunction with one of the Function keys). F2. When viewed from the Host Controller Status (HStatus) screen (F5 4. The Esc key also allows you to answer No to a prompt on the screen (whenever ‘?’ appears following information). – The minus (‘–’) key can be used as part of a negative number. or as part of a password. The display is updated once per second. Del The Delete key is used to delete an existing value from memory when you are changing an operating parameter.- The bottom line displays the results of the outputs. derived from the Host Controller board – are the only two alarm messages that are automatically displayed on the bottom line when they are detected. The Function keys are used to access the various modes and functions where you can view or change data or operating parameters. Esc The Escape key allows you to discard any changes you make to operating parameters. as part of a command (used in conjunction with one of the Function keys). The error messages “NoData” and “CommFault” – both serious system errors. Under normal operating conditions in RUN mode. The Ent key can also be used to answer Yes to a prompt on the screen (whenever ‘?’ appears following information). the display of the result of a keystroke sequence may be delayed for up to one second. F6 Numeric keys 0–9 are used to enter numerical data. the ‘F6 0’ keystroke combination will return the display to the normal display of the mode you are viewing. Ent The Enter key allows you to save any changes you make to operating parameters. The keypad consists of the following keys: Key Description • The decimal (‘•’) key can be used to enter a decimal character. and to back out of certain menus. as part of a Function key command to activate a function whose value you wish to view or change. 0–9 1. ‘–’ key. From RUN / CFG mode. F5. or as part of a password. F3. the bottom line continually displays the value of each output parameter being monitored/controlled by the analyzer. therefore. these errors are displayed as “f RxData” and “f Comm Fault”. Controller / User Interface | 4-3 . in addition to the ‘•’ key. from RUN mode). Other information may also be displayed on the bottom line depending on the mode of operation or the keystroke command entered. Press one of these keys. or one of the numeric keys 0–9.

• b = Analyzer-selected (automatic) Backpurge Flow mode. • S = User-selected (manual) Continuous Sample Flow mode.Flow Control Mode Indicators on the User Interface Panel When in RUN mode. it indicates the analyzer is operating in automatic Sample mode (Analyzer Control mode). • C = User-selected (manual) Continuous Calibration Gas Flow mode (Gas #1 or Gas #2). For example. The characters that can be displayed are: • If the character is blank. • B = User-selected (manual) Continuous Backpurge Flow mode.3765 F5 4 Ent 4-4 | Model 909 Single-Gas Analyzer . The F5 key serves as the exponential operator (10n). Entering Data Using Base Ten (10) Exponents Data for certain fields can be entered using base ten (10) exponents. Doing so may result in the analyzer becoming plugged.3765 x 104. • Z = User-selected (manual) Continuous Zero Gas Flow mode. ! Do not operate the analyzer in Continuous Sample mode for an extended period of time before all of the temperature-controlled zones WARNING have stabilized at their set point temperature. enter: -1. to enter the numerical value for -1. the first character of the top row of the User Interface Panel indicates the mode of gas flow (Flow Ctrl).

. press its corresponding numerical key 2.Entering / Returning to RUN Mode – Quick Reference When the analyzer is first powered up. HS (1. “s/lT1” (Sample Line).” later in this chapter. repeatedly press Esc until RUN mode is returned.8. Controller / User Interface | 4-5 . The software will default to the first temperature-controlled zone. you can view analyzer system data. press F6 0. -. or alarms (current or historical). From this mode. temperature set points. 1–9) for the menu you want to view. To view other analog input values. To return to the RUN mode normal display from anywhere in the software. This menu also contains certain data that is used primarily for troubleshooting the analyzer. To view one of the menus in RUN mode: 1. From RUN mode.8) to view the status of a specific alarm.. To view a different RUN mode menu. To return to the RUN mode normal display from any menu in RUN mode.8)] indicate you can view or change more than one parameter from that menu without having to reenter the Function key (for that function) each time.g. For example. press one of the numeric keys to view other related data. Example: To view the temperatures for each of the temperature-controlled zones assigned to the Microcontroller board’s analog inputs. press the Function key and one of the other keys (•. refer to “Working in the RUN / CFG Operating Modes. For detailed information about working in RUN mode. Refer to the RUN / CFG Mode Quick Reference Sheet (Figure 4-2) for all of the commands that make up the RUN mode. Then. to view the Host Controller Status (HS) menu (press F5 4) and press any numeric key (1. the User Interface Panel defaults to RUN mode. etc. 2. Information viewed from RUN mode cannot be changed while working from this menu. press F6 8. press another numeric key to view the status of another alarm. You do not have to press F6 8 again.. A password is required to enter this mode. current operating values. press the corresponding Function key and one of the other keys. If the new menu has submenus.. Function commands with a range [e.

4) HS (1..RUN / CFG Mode Quick Reference Sheet – Keystroke Combinations Figure 4-2 is a Quick Reference Sheet that lists each of the available keystroke combinations you can use to perform various tasks from RUN and CFG modes....7) o (Show O2Cor) 6 SigMax Output (1.... The differences between RUN and CFG mode are denoted by “(RUN)” and “(CFG)” under the Function key headings (Figure 4-2)..” later in this chapter. 4-6 | Model 909 Single-Gas Analyzer .3) MCHist (1. the function is the same for both modes.4) — CPRg (1.. For detailed descriptions of each keystroke combination..5) Show HAIn (1. RUN / CFG mode quick reference sheet – keystroke combinations. You can only view information from RUN mode but you can change it from CFG mode (a password is required to enter CFG mode).2) 3 LmpMax Delay — Td (1.8) 9 Units SetPt (1...9) RUN CFG PSWD0 PSWD0? (CAL) (CAL) – PTPara (1...9) RUN CFG PSWD1 PSWD1? (CFG) (CFG) 0 KFtr Cell — TStPt (1...2) Temp Zones KVal (1.  NOTE “–” indicates the keystroke combination is not used..2) — DPRg (1..9) 4 PmtLvl — — TType (1.. refer to “Defining RUN / CFG Mode Keystroke Terms... If “(RUN)” and “(CFG)” are absent. The RUN and CFG modes are almost identical.2) Kp (1....4) HC Ver Sig (1..4) SN Normal Display RUN/CFG 1 Ftr (1..2) — TDuty (1.6) HCHist (1.2) Show MAIn (1. Key • F1 RUN CFG — Auto-Setup F2 F3 F4 F5 F6 MB Addr — AI:Msr (1.4) MC Ver TR (Show Trn) (1.8) Figure 4-2.5) MDI — 8 Ke AlcG (1.3) TCol AuxTAvg (1.3) 2 LmpB (1.4) Com Para (1.2) — O2Para (1.2) LmpP (1. The specific function (Term) for each mode is listed under “(RUN)” and “(CFG)”..3) TCycle (1.8) MS (1.8) e (Show MEmiss) 5 PmtBal Adap (1....2) — — 7 Kq Alc — STcf (1.2) Samples — Ti (1..4) RTime Show Res (1..

press Ent and then Esc to back out of this menu. To return to CFG mode normal display from any menu in CFG mode.00 °C). “153. For instance. This is the CFG mode normal display. 3. 2. 6. At the “Save ConFig?” prompt. if changed. For detailed information about working in CFG mode. “CFG” will be displayed on the top line.Entering CFG Mode – Quick Reference The ConFiGuration (CFG) mode contains information nearly identical to that in the RUN mode menu but with a few exceptions. The message “PSWD1” appears. Press Ent to enter CFG mode.00”) at the “TStPt4?” prompt. refer to “Working in the RUN / CFG Operating Modes. Press • • (factory default password) or the new password. press F6 0. press Esc. The major difference between CFG and RUN mode is that in CFG mode. press Ent again to confirm the change. An “*” is displayed for each character entered. while the output results from RUN mode will continue to be displayed on the bottom line. Press Del to delete the existing value (default = 155. the CFG mode menu also contains the Auto-Setup function. 5. and allows you to change the passwords required to enter CFG and CAL modes. Controller / User Interface | 4-7 .” later in this chapter. and then enter the new value (for example. repeatedly press Esc until RUN mode is returned. Press F4 0 4 to display the Measuring Cell set point temperature. To discard the changes. To save the change. This menu defaults to parameter “1” (Sample Line). 4. From RUN mode. you can change (configure) certain information. To return to the RUN mode normal display from anywhere in the software. Example: To change an existing temperature set point value for the Analyzer Measuring Cell temperature-controlled zone: 1. press F6 – .

g. Press F5 and then 2 to display the FlowCtrl (Flow Control mode) screen.. 4-8 | Model 909 Single-Gas Analyzer . press F6 •. Press Ent to save the setting. etc. if changed. without having to re-enter the Function key (for that function) each time. This is CAL mode normal display. Then. An “*” is displayed for each character entered. “0”.4) to view the full-scale range for another output. 8.4)] indicate you can view or change more than one parameter from that menu.. The message “PSWD0” appears. Press Del to delete the current setting.g. while the output results from RUN mode will continue to be displayed on the bottom line. For example. repeatedly press Esc until RUN mode returns. Press Ent to enter CAL mode. which indicates the analyzer is in Analyzer Control mode). 7. Press Esc to return to RUN mode. Scale (1. 5. press any numeric key (1.. 3. Example: To change the analyzer’s Flow Control Mode to Continuous Backpurge: 1. “CAL” will be displayed on the top line. Press • • (factory default password) or the enter the new password. Press 1 to change the setting to Continuous Backpurge mode. 2. this function displays the current setting (e. 6. For detailed information about working in CAL mode. view the Scale menu (press F5 1) and press 4 to view the full-scale range for Output 4. Function commands with a range [e. From RUN mode. refer to “Working in the CAL Operating Mode. The screen will display “B” on the upper-left line to indicate that the analyzer has been manually forced to Continuous Backpurge mode. When you enter this menu.Entering CAL Mode – Quick Reference The CALibration (CAL) mode allows you to enter the variables required to tailor the analyzer for a specific application and to calibrate the instrument.” later in this chapter.. To return to the RUN mode normal display from anywhere in the software. 4.

2) 4 Vel/Zero? — VTp (1.4) Ispan (1.2) VelCtrl 8 — Man/SpanO2? AZInt O2 Conc (1...4) 1 Auto/Span1? Man/Span1? Timer1 Conc1 Scale (1.2) 7 PrbBlowBk? — SDelay DPSpn SFactor (1.2) 3 — — PrbT (1.” later in this chapter.  “—” indicates the keystroke combination is not used..4) 2 Auto/Span2? Man/Span2? Timer2 Conc2 FlowCtrl ZCalDrift (1.2) — Sol:O2Z O2CD (1. While working in CAL mode. NOTE Key F1 F2 F3 F4 F5 F6 • — — — — — — – — — — — — — 0 Auto/Zero? Man/Zero? Timer0 — — Izero (1.. the information can be changed (a password is required to enter and work in CAL mode)..CAL Mode Quick Reference Sheet – Keystroke Combinations Figure 4-3 is a Quick Reference Sheet that lists each of the available keystroke combinations from CAL mode.2) Temp DPZ 9 Auto/Cal? Man/ZeroO2? ACal Bw Pres DPSFactor Figure 4-3.2) 5 Vel/Span? — VTi — Sol:O2S O2ZVolt O2SFactor 6 Vel/BkPurge? — IntTime — To (1.3) — AdjDisable SCalDrift (1.. refer to “Defining CAL Mode Keystroke Terms.. Controller / User Interface | 4-9 . CAL mode quick reference sheet – keystroke combinations... For detailed descriptions of each keystroke combination...

Enter the new password a second time and press Ent. 4. can be changed only from CFG mode. If you enter the password incorrectly. If this password does not match the first entry of the new password. the message “<INVALID>” will be displayed on the User Interface Panel. Passwords. Once the passwords have been changed. Record the new password and store it in a safe place. The new password is entered and the message “PSWD0?” appears again. 2. Press Ent again to return to CFG mode normal display. You cannot use the Function keys as part of a password. Press F6 • (this is the command to change the CAL mode password). press F6 – • • and press Ent to enter CFG mode. If the passwords are not saved. 3. Once you change the passwords for each mode. the appropriate new password must be used to access CAL or CFG mode. the previous passwords will be used following a system reset or power-up. be sure to record and keep them in a safe place. The passwords to enter and work in either mode can be entered from RUN mode only. From RUN mode. Press Ent. Carefully re-enter the password. Changing the Password for CAL Mode To change the password for CAL mode: 1. The factory-default password is “• •” for both modes. AMETEK recommends that you change the passwords as soon as you become familiar with the operation of the analyzer.  NOTE Pressing Ent will cause the passwords to be saved in non-volatile memory – the old passwords will be lost. A different password should be used for each mode and access to CFG mode should be limited to only trained technicians or electricians. The message “PSWD0?” appears. Enter a new password (up to 9 characters). This applies to the password for both CAL and CFG modes.About CFG / CAL Mode Passwords Access to the CALibration (CAL) or ConFiGuration (CFG) mode is protected by a password. which are limited to 9 characters. The example below assumes that the factory-default password is valid. but it can be changed. the message “<UNCHANGED>” is displayed. 4-10 | Model 909 Single-Gas Analyzer .

The Function keys cannot be used as part of a password. If this password does not match the first entry of the new password. 5. From RUN mode. The display will exit CFG mode and return to RUN mode. press F6 – • • and press Ent to enter CFG mode. The display will exit CFG mode and return to RUN mode. Press Esc. Controller / User Interface | 4-11 .5. Changing the Password for CFG Mode To change the password for CFG mode: 1. press Esc to discard the changes. 2. If Yes. press Esc to discard the changes. If Yes. The User Interface Panel will prompt you to accept the changes (“Save Config ?”). The display will exit CFG mode and return to RUN mode. Press F6 – (this is the command to change the CFG mode password). Press Ent. If No. press Ent to accept the new password. the message “<UNCHANGED>” is displayed. The message “PSWD1?” appears. If No. Record the new password and store it in a safe place. The new password is entered and the message “PSWD1?” appears again. 4. Press Esc The User Interface Panel will prompt you to accept the changes (“Save Config ?”). 3. The display will exit CFG mode and return to RUN mode. Enter the new password a second time and press Ent. Press Ent again to return to CFG mode normal display. Enter a new password (up to 9 characters). press Ent to accept the new password.

4-12 | Model 909 Single-Gas Analyzer . For example. No password is required to work from RUN mode. • If you press a numeric key that is not valid for your system. the top line of the User Interface Panel screen displays the current status of the analyzer. The selected parameter is displayed and updated once per second until another parameter or the RUN mode normal display is selected. When entering keystrokes in RUN mode. the User Interface Panel will return to the RUN mode normal display under the following circumstances: • If you press a Function key that is not valid for your system.Working in the RUN / CFG Operating Modes The RUN and ConFiGuration (CFG) modes. where you can make changes to factorydefault settings. While Working in RUN Mode… The RUN mode allows you to view the parameters or variables that have been configured for your analyzer. During normal operation in RUN mode. with a few exceptions. they cannot be deleted or modified from this mode. by displaying S on the upper-right line. RUN is the default and normal operating mode. • If a keystroke sequence is not completed within 10 seconds. the screen will display a character that indicates the specific Flow Control Mode the analyzer is currently operating in (see “Flow Control (Sample) Mode” later in this chapter for details). The top line also indicates if a fault or warning alarm has been detected by the analyzer. The 10-second time-out feature does not affect these functions. To return to the RUN mode normal display from any menu in RUN mode. Changes to the parameters or variables that can be seen in RUN mode must be done in CFG mode. The parameters that can be viewed by pressing F6 1 through F6 9 are displayed on the bottom line. contain nearly identical information. A password is required to enter CFG mode. press F6 0.

including “CFG” to signify the current mode.Examples of keystroke combinations that can be initiated in RUN mode are listed below. The factory-default password is “• •”. all information associated with this mode is displayed on the top line of the User Interface Panel screen. F5 4 View the Host Controller board status error/code conditions (HS). The temperature values from the RUN mode normal display will continue to be displayed on the bottom line.  NOTE Access to CFG mode should be restricted to trained technicians or electricians. displayed in cm. Do not change any functions that are not discussed in this section without express written consent from AMETEK. While working in CFG mode. Press To F5 0 View the analyzer serial number (SN). F5 1 View the Host Controller board software version number (HC/909V). Access to CFG mode is protected by a password. F5 5 View the Microcontroller board status error/code conditions (MS). The settings for your analyzer have been configured at the factory to meet specified customer requirements. use the new password to access CFG mode. You can also change the two factory-default passwords (for CAL and CFG modes) while working in CFG mode. The password may be entered while working from RUN mode only. F2 0 View the total axial length (cm) of the gas space in the Measuring Cell. Changing the factory-set configuration could cause the analyzer to operate incorrectly. While Working in ConFiGuration (CFG) Mode… CFG mode is used to enter or change operation constants and configuration data that can be seen in RUN mode. Controller / User Interface | 4-13 . F5 2 View the Microcontroller board software version number (MC900V). If you have changed the password.

the software will return immediately to RUN mode. press F6 –. If the configuration data are not saved. the previous configuration data will be used following a system reset or power-up. Press • • (factory default password) or the enter the new password. while the output results from RUN mode will continue to be displayed on the bottom line. do the following: 1. An “*” is displayed for each character entered. The message “PSWD1” appears. Press Ent to enter CFG mode. • If you press a numeric key that is not valid for your system. the display will return to CFG mode normal display under the following conditions: • If you press a Function key that is not valid for your system.To access CFG mode. Or. 4-14 | Model 909 Single-Gas Analyzer . When entering keystrokes in CFG mode. press Esc to answer No. “CFG” will be displayed on the top line. From RUN mode. 3. Press Ent to answer Yes and then press Esc again to return to RUN mode. If no changes have been made. If any changes have been made to CFG mode menu settings. 2.  NOTE Pressing Ent will cause the configuration data to be saved in nonvolatile memory – the old values will be lost. NOTE Returning to RUN Mode From CFG Mode To return to RUN mode.  While in CFG mode. the Cal Status Relay is turned On. press Esc. This is the CFG mode normal display. if changed. the message “SAVE CONFIG?” appears.

Controller / User Interface | 4-15 . the functions are the same for both modes. Please consult with your AMETEK representative or the factory before changing any factory-default values. If the keystroke commands do not include “(RUN)” and “(CFG)”. followed by a description of the function. The differences between RUN and CFG modes are denoted by “(RUN)” and “(CFG)” under the Keystrokes heading in the following pages. “Term” is defined as screen headings (abbreviated titles) or parameters that are displayed on the User Interface Panel. Factory-default values (if applicable) for the analyzer have been indicated for each keystroke. Next to the “(RUN)” and “(CFG)” identifiers are the specific function (Term) for each mode. remember that the information contained and viewed in RUN mode can only be changed when working in CFG mode (a password is required). The following pages list the various keystroke combinations available in RUN and CFG modes.Defining RUN / CFG Mode Keystroke Terms For the purpose of this guide. however. Only the keystroke combinations that are functional in RUN and CFG modes are listed in the following pages. RUN and CFG modes are almost identical.  NOTE Definitions preceded by ‘**’ in the RUN / CFG mode keystroke descriptions are used primarily for diagnosing problems with the analyzer. along with their terms and definitions of each. As indicated earlier.

.0–7. Normal values after a successful Auto-Setup are from 4. F1 5 PmtBal ** A secondary PMT control signal (V) which adjusts the PMT gain to equalize the PMT signals from the filters with the lowest and highest transmittances are in the light path. Keystroke Term Definition F1 • (RUN) Not Used — F1 • (CFG) Auto-Setup The Auto-Setup function optimizes PMT gains and the source lamp currents. check EEPROM Data Sheets for actual value).5 V and Lamp Max (6. KFtrz = = = = Probe Temperature signal low scale for 0 (zero) V Probe Temperature signal high scale for full-scale V Probe Temperature low alarm set point Probe Temperature high alarm set point 1 = Measure Filter 1 2 = Reference Filter 2 F1 1 ** The default source lamp pulse current-control signal (V) for each filter.0 V – may vary.2. both lamps are Cadmium.2). The normal operating range is between 0.0 V (may vary. where ‘z’ = 1. Normal values after a successful Auto-Setup are from 4.0 VDC.0 VDC. which is the minimum operating current. check EEPROM Data Sheets for actual value). stack duct physical data. F1 8 Ke The units conversion constant for calculation of component mass flow (Mass/Amount). where ‘z’ = 1. optical filters.0 and 9.0 V (check EEPROM Data Sheets for actual value). F1 7 Kq The constant for the volume-flow-rate calculation based on stack duct data. LmpBz 1 = Lamp 1 (closest to the Measuring Cell) 2 = Lamp 2 (farthest from the Measuring Cell) Note: If your analyzer is configured to measure H2S. The Auto-Setup function is not available in RUN mode. Always initiate an Auto-Setup after any lamps.4. This function is available in CFG mode only. and units of measurement. 4-16 | Model 909 Single-Gas Analyzer .. with the control signal for the key filter being Lamp Max. both lamps are Magnesium. where ‘z’ = 1..2. this menu item displays a variety of temperature control parameters. Ftrz 1 = Measure Filter 1 2 = Reference Filter 2 F1 2 ** The base-current set point (V) for each source lamp. or PMTs have been installed or replaced..RUN / CFG Mode – F1 Keystrokes Note the differences for the F1 • keystroke in RUN and CFG modes. For these systems. if your analyzer is configured to measure SO2. SigMax should be between 8. F1 3 LmpMax ** Voltage to which the lamp pulse current-control signal for the key filter location is set during the Auto-Setup.0–7. The parameters and their default values are: 1 2 3 4 F1 0 ** Position of the key filter which gives the weakest signal for a given source lamp current. which is based on the signal from the PMT when the key filter is in the light path. F1 4 PmtLvl ** The photomultiplier tube (PMT) gain control signal (V). The nominal value is 6. where ‘z’ is the filter being used (1. 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. F1 – PTParaz This temperature-controlled zone is used only with systems employing a heated external probe with a dedicated temperature controller (controlled by analyzer).

change the concentration units freely back and forth between PPM and mole percent (e. *Sum of Bits 1 and 2 decimal value Bit 3 Value 8 Definition 0 = Display 4 items.1 Value 2. and should not be changed by the user (i. Controller / User Interface | 4-17 .4* Definition 0 = Normal concentration result (PPM).. 4 = Finer (Low) concentration result (PPM). and pressures. Normal concentration result in PPM.. Remote Auto-CAL. 6 = Coarse (High) concentration result (%). if the analyzer is configured for Metric units. or from Units = 1 to Units = 3.g. do not change from a Metric unit to an Imperial unit). The unit for input and output parameters (Metric or Imperial) is set at the factory. or vice versa). Bit 4 Value 16 Definition 0 = Remote Auto-CAL 16 = Remote Backpurge/Zero Flow For example. If a change is required. 8 = Display 3 items. consult with your AMETEK representative. temperatures. The user can. Display 3 items. 2 = Normal concentration result (%).e. however.F1 9 Units Units of measurement used for displaying concentrations. from Units = 0 to Units = 2. The value is the sum of five bits: Bit 0 Value 1 Definition 0 = Metric Units 1 = Imperial Units Bits 2. or contact the factory.1 + Bit 3 + Bit 4 [0 + 0 + 8 + 0 = 8]. the result would be: Bit 0 + Bits 2.

.. Note: To operate the Model 909 Analyzer with an extra temperature control zone. and Parity of the serial communication port. 2. For addresses 1–127. 4) + (‘24’ = Motorless Bench)). 4) + (‘24’ = Motorless Bench)). where ‘z’ = the sum of the Temperature Zone code (0. filter flood) 4-18 | Model 909 Single-Gas Analyzer .5 None 3 1200 2 Even Note: Any changes to the parameters must be saved to the EEPROM and the analyzer must be reset to make the changes take effect. To reset the analyzer. press the • and Ent keys simultaneously. refer to “Probe Blow-Back Control” later in this chapter. wire the RTD input into the SKO terminals J105 5. where ‘z’ = 1. F2 – ComParaz n The communication setup parameters for the Baud Rate. 4) – also used for Probe Blow-Back function 4 = 3 temperature-controlled zones (1.RUN / CFG Mode – F2 Keystrokes Keystroke Term Definition F2 • MBAddr Modicon Modbus® slave address – can be any value between 0–255. select the RS‑232 port. 2. ** Axial length of the Measuring Cell gas space. displayed in cm. 4. the displayed value is ‘26’ ((‘2’ = 2 temperature-controlled zones: 1.3 Baud Rate z = 1 Stop Bits z = 2 Parity z=3 0 9600 Invalid None 1 4800 1 Odd 2 2400 1. or 32) plus the Standard Bench Type Code (24). 3. For more information.. 2. 4) 6 = 4 temperature-controlled zones (1. 2. 2. The temperature-control zones are: Zone 1 = Sample Line Zone 2 = Sample Conditioning Unit (SCU) Zone 3 = TZone3 – Spare Zone 4 = Oven Temperature Probe Isolation Control (filter flood): b6 Probe Style 0 = Non-EPA style Probe Isolation Control 64 = EPA style Probe Isolation Control (i. 3..3 and where ‘n’ = 0.3. 6. Stop Bits. For these systems. the displayed value is ‘62’ ((‘6’ = 4 temperature-controlled zones: 1.e. n = 0. F2 0 Cell F2 1 Temp Zones z The Temperature Zone code defines the number of temperature-controlled zones used by the analyzer. The definition for each bit is: 0 = No temperature control 2 = 2 temperature-controlled zones (1. 4) 32 = Temperature zone 3 (heating logic. heater plate) The code is the decimal equivalent of an 8-bit binary number. The typical displayed value is ‘28’ ((‘4’ = 3 temperature-controlled zones: 1. 4) + (‘24’ = Motorless Bench) + (‘32’ = Temperature zone 3 [reverse logic])). 6 (AC voltage). For systems with the manual Blow-Back function enabled. 0 (zero) will disable the Modbus® communication interface. The extra temperature zones are not available when the Isolation and Blow-back functions are turned on. for addresses 128–255 select the RS-422 port. which defines the bench type in regard to the temperature control parameters.

” later in this chapter.. ** Automatic Lamp Control gain setting for each filter. The interval is shown as multiples of 1.2.. SetPz 1 = SetPt1 2 = SetPt2 Controller / User Interface | 4-19 . Refer to “Output Signal Assignment (OSA). Contact AMETEK for instructions before attempting to replace the PMTs. F2 2 Samples ** Number of times the PMT signal is measured while a filter is completely within the light path. where ‘z’ = 1. and should be on during normal operation. Standard Bench Type Code: 24 = Motorless Bench Note: The Standard Bench Type Code lists the default Bench Type for the Model 909 Analyzer. These values are updated automatically by Auto-Setup. However. where ‘z’ = 1. 2 = Relates to maximum filter time constant. 1 = Relates to absorbance level. This parameter is automatically turned on by Auto-Setup. Do not change the value without direction from your AMETEK representative or from factory personnel. Alc = = = = Output1 Output2 Output3 Output4 0 = Off 1 = On Note: F2 8 AlcGz This manual does not describe procedures to replace the PMTs.6 microseconds (µs). 1 = AlcG1 2 = AlcG2 F2 9 ** Signal (V) obtained from the Reference PMT for each filter after the Auto-Setup.4. F2 3 Delay ** The time interval from when a filter becomes completely within the light path to the first PMT-signal measurement. F2 4 Not Used — F2 5 Adapz Adaptive filtering parameters. where ‘z’ = 1.2. These outputs are application-specific. where ‘z’ = 1..2. Allows the customer to define which of the calculated results (parameters) will be available as output signals. this function should be turned off while replacing PMTs or source lamps. for more information. The Automatic Lamp Control function adjusts the lamp pulses to maintain the Reference PMT signals to these values.. The parameters are: Outputz 1 2 3 4 F2 7 The Automatic Lamp Control Enable function displays the operational status of the Automatic Lamp Control function. F2 6 The Output Signal Assignment (OSA) code for each of the four current outputs.

F3 0 Not Used — F3 1 KValz ** The molar absorptivity of the species of interest at the wavelengths used.2. 1 = KVal1 (Measure filter) 2 = KVal2 (Reference filter) F3 2 Not Used — F3 3 Not Used — F3 4 Not Used — F3 5 Not Used — F3 6 Not Used — F3 7 Not Used — F3 8 Not Used — F3 9 Not Used — 4-20 | Model 909 Single-Gas Analyzer . Entering ‘0’ results in the analyzer using 5 % of the Measuring Cell temperature set point as the switch temperature.RUN / CFG Mode – F3 Keystrokes Keystroke Term Definition F3 • Not Used — F3 – TCold The Measuring Cell temperature at which the analyzer’s Flow Control (Sample) Mode will switch between Continuous Sample mode and Continuous Backpurge mode.. where ‘z’ = 1. providing each remaining zone is within 5 % of its set point value.

. where ‘z’ = 1. The parameters and their default values are: Tdz 1 2 3 4 = = = = Sample Line (default = 10.00 %) Measuring Cell (default = 10. or Internal sensor (Zr734) AI:Msr1 = 44 2 = Measuring Cell Temperature AI:Msr2 = 4 3 = Measuring Cell Pressure AI:Msr3 = 6 4 = Stream Temperature Current Input (MAI) AI:Msr4 = 7 Voltage Input (HAI) AI:Msr4 = 22 5 = Differential Pressure AI:Msr5 = 21 6 = External Probe Temperature (optional) AI:Msr6 = 8 (RTD Input). AuxTAvgz 1 = Allows the O2 input signal to be filtered (optional).00 seconds) SCU (default = 1000.00 seconds) Sample Line (default = 0 seconds) SCU (default = 0 seconds) TZone3 – Spare (default = 0 seconds) Measuring Cell (default = 0 seconds) Controller / User Interface | 4-21 .00 %) SCU (default = 10. that zone is not used.” later in this chapter.. F4 0 ** The control set point for the four temperature-controlled zones. for more information about enabling/disabling these functions. Setting the analog input signals to zero (‘0’) disables the function. 3 = Allows the Differential Pressure to be filtered. If the set point is zero. 2 = Allows the optional External Flow Rate or optional External Stream Temperature to be filtered.RUN / CFG Mode – F4 Keystrokes Keystroke Term Definition F4 • AI:Msrz ** The Microcontroller or Host Controller channel number for the analog input signals. Setting this averaging time to zero (0) turns this function off.4. Refer to “Active Temperature and Pressure Compensation. The parameters and their default values are: Tiz = = = = Sample Line (default = 150. where ‘z’ = 1... The averaging time can be set from 0–255 seconds.4.00 %) = = = = Sample Line (default = 1000. where ‘z’ = 1. The zones and their default values are: TStPtz 1 2 3 4 F4 1 ** The Proportional term of the PID temperature control algorithm for each temperaturecontrolled zone..00 °C) 1 2 3 4 F4 3 ** The differential (Derivative) term of the PID temperature control algorithm for each temperature-controlled zone.00 °C) TZone3 – Spare (default = 10.00 seconds) Measuring Cell (default = 2500.00 °C) SCU (default = 150. where ‘z’ = 1. where ‘z’ = 1.00 °C) Measuring Cell (default = 155.00 seconds) TZone3 – Spare (default = 1500. The parameters and their default values are: Kpz = = = = 1 2 3 4 F4 2 ** The Integral term of the PID temperature control algorithm for each temperature-controlled zone.4.4.3. or External sensor (linear) AI:Msr1 = 34. or AI:Msr6 = 18 (Voltage Input) F4 – ** External signal averaging time (seconds) for the auxiliary inputs.00 %) TZone3 – Spare (default = 10. where ‘z’ = 1. 1 = O2 Measurement and Dilution Air Computation (optional) Internal sensor (Zr733) AI:Msr1 = 24.6..

0) High Value (default = 50.8 This is the maximum duty cycle allowed for each temperature-controlled zone.3 (default = 2 for each of these temperature-controlled zones): 0 1 2 3 F4 5 Temperature duty cycles. CPRgz = = = = = = = = Sample Line (default = 30 %) SCU (default = 30 %) TZone3 – Spare (default = 30 %) Oven (default = 30 %) Sample Line (default = 85 %) SCU (default = 85 %) TZone3 – Spare (default = 85 %) Oven (default = 85 %) 1 = Low value (0. STcfz 1 2 3 4 5 F4 8 The stack duct differential pressure transducer low and high value (mmH2O or "H2O) corresponding to 0.0 VDC respectively.0 VDC and 5. where ‘z’ = 1.25 percent) of the O2 Sensor. The values are factory-set and must not be changed.0 VDC. TDutyz = = = = = = = = Sample Line SCU TZone3 – Spare Measuring Cell Not Used Not Used RTD for 300-4872 Rev.2..8.0 VDC) F4 7 The coefficients to linearize the reading from the stack duct temperature transducer.0 VDC) 2 = High value (5..) 1 = The specified O2 concentration to which the measured SO2 concentration is corrected..4 This is the default duty cycle (%) of each temperature-controlled zone during steady-state operation at the set point.5.. F4 9 O2Paraz Zirconia Oxygen Sensor (O2 Sensor) parameters.2. 4-22 | Model 909 Single-Gas Analyzer . The zones and their starting (default) values are: 1 2 3 4 ‘z’ = 5.4.. DPRgz = = = = = Low Value (default = 0.F4 4 TTypez n ** The type of temperature sensor used for each temperature-controlled zone. where ‘z’ = 1. B board or 300-5769 board (assembly # 100-1097) ‘z’ = 1.00) Not used Not used Not used 1 = Stack duct low differential pressure.3. B board or 300-5769 board (assembly # 100-1096) Thermistor for 300-4872 Rev. 2 = The concentration corresponding to zero voltage output (0.. 2 = Stack duct full-scale differential pressure. 1 2 3 4 and where ‘n’ = 0. where ‘z’ = Temperature Zones 1. where ‘z’ = 1. where ‘z’ = 1...0 VDC and 5. The zones and their default values are: 5 6 7 8 F4 6 ** The Measuring Cell pressure transducer low and high value (mmHg or "Hg) corresponding to 0. where ‘z’ = 1.. (For use with General Purpose applications/analyzers only. 3 = The concentration corresponding to the full-scale voltage output (25 percent) of the O2 Sensor.

MSz = = = = = = = = w EEPROM Full (Warning) w Out Of Range (Warning) f Comm Fault (Fault) f RxData Fault (Fault) f Temp Low (Fault) f Temp High (Fault) w ZDrift\SpanErr (Warning) w Tmp3 High (Warning) – optional Refer to the “Maintenance & Troubleshooting” chapter for descriptions of these error conditions and corrective action to take. F5 2 MC900e V The Microcontroller board software version number. with ‘1’ being the oldest and ‘9’ being the most recent. If the error condition does not exist. with ‘1’ being the oldest and ‘9’ being the most recent. the message “MSz OK” appears. For each ‘z’. The possible error conditions include: 1 2 3 4 5 6 7 8 F5 5 The possible Microcontroller board status/error code conditions (MStatus).. F5 – MCHistz n History buffer for the last nine non-zero Microcontroller board status codes where ‘z’ = 1. the appropriate Error Message is displayed if the error condition exists. where ‘z’ = 1. where ‘z’ = 1.8. The possible error conditions and their descriptions include: 1 2 3 4 5 6 7 F5 6 — Not Used = = = = = = = f Pulse Timing (Fault) f On-board ADC (Fault) f On-chip ADC (Fault) w PMT Signals (Warning) f Comm Error (Fault) w Lamp Control (Warning) f Oven Heater (Fault) Controller / User Interface | 4-23 .9.7. For each ‘z’. the appropriate Error Message is displayed if the error condition exists. The format is: Days Hours:Minutes (### ##:##) F5 4 HSz The possible Host Controller board status/error code conditions (HStatus).. F5 0 SN The analyzer serial number. If the error condition does not exist. and where ‘n’ = the sum value of status code. the message “HSz OK” appears. Refer to the “Maintenance & Troubleshooting” chapter for descriptions of these error conditions and corrective action to take.. F5 3 RTime Total run time of the analyzer since the last reset or system power-up. F5 1 HC909Ae V The Host Controller board software version number. and where ‘n’ = the sum value of status code.RUN / CFG Mode – F5 Keystrokes Keystroke Term Definition F5 • HCHistz n History buffer for the last nine non-zero Host Controller board status codes where ‘z’ = 1.9..

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). TCyclez 1 2 3 4 5 = = = = = 4-24 | Model 909 Single-Gas Analyzer slCycle – Sample Line (default = 0 %) scuCycle – Sample Conditioning Unit (default = 0 %) tmp3Cycle – Spare (default = 0 %) celCycle – Measuring Cell (default = 100 %) htrCycle – Heater Plate. where ‘a’ and ‘b’ are the status of the inputs. a (Input 1) = Reserved for internal use.2. 1 = Lamp 1 2 = Lamp 2 F5 9 Current temperature control duty cycle (%) for each temperature-controlled zone. where ‘z’ = 1. Input 2 is for remote start of the Auto-Zero (Calibration) or remote start of the Backpurge (optional). Oven (default = 100 %) . 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 F5 8 LmpPz 00 Open Open 01 Open Closed 10 Closed Open 11 Closed Closed Current lamp pulse (V) for each filter as generated by the Automatic Lamp Control. where ‘z’ = 1. The analyzer has two external digital inputs that are designed to accept a dry (potential free) contact closure. Input 1 is reserved for future use.F5 7 MDI ab The Microcontroller Board’s Digital Input status code..5..

While working in CFG mode. Normal values are in the range of 5. SO2)] n/a (Not Used) n/a (Not Used) n/a (Not Used) n/a (Not Used) n/a (Not Used) n/a (Not Used) Flow O2 (optional) Controller / User Interface | 4-25 . F6 –. F6 – (CFG) PSWD1? This is the CFG mode change password prompt. seen only after you press ‘F6 –’ from RUN mode. F6 – (RUN) PSWD1 (CFG) This is the CFG mode entry password prompt. its value is displayed on the bottom line.84 VDC..) F6 0 (CFG) While in RUN mode. where ‘z’ = 1. F6 • (CFG) PSWD0? This is the CAL mode change password prompt. F6 1 Displays the Measure and Reference PMT signal for each filter.  NOTE Keystroke Term Definition F6 • (RUN) PSWD0 (CAL) This is the CAL mode entry password prompt.3.RUN / CFG Mode – F6 Keystrokes Note the differences for the F6 •.. the name of the calculated result or parameter is displayed on the top line. The Function keys cannot be used as part of the password. Show Resz 1 2 3 4 5 6 7 8 9 = = = = = = = = = [Signal displayed here – application-specific (e. The signals are displayed on the bottom line of the User Interface Panel (the Measure PMT signal is on the left. The new password must be entered twice before it is accepted. The new password can be up to nine characters. The transmittance is shown on the bottom line of the User Interface Panel.g.9) is the numeric code assigned to the result. The Function keys cannot be used as part of the password. The new password must be entered twice before it is accepted. which will allow you to change the CAL mode entry password. (Note that ‘Normal Display’ is not displayed on the screen. seen only after you press ‘F6 –’ from CFG mode. the Reference PMT signal is on the right). seen only after you press ‘F6 •’ from CFG mode. Normal Display This keystroke combination returns the CFG mode normal display. these keystrokes will call up the “PSWD0?” prompt.2.0–9. (Note that ‘Show Res’ is not displayed. (Note that ‘Normal Display’ is not displayed on the screen. While working in CFG mode.. From RUN mode. From RUN mode.) The name of the result and its value will be displayed and updated at one-second intervals until either another result is selected or ‘F6 0’ is pressed to return to the RUN mode normal display. Sigz F6 2 1 = Filter1 (Measure filter) – Measure PMT/Reference PMT signals 2 = Filter2 (Reference filter) – Measure PMT/Reference PMT signals 3 = Baseline Measurement (looks at Measure/Reference PMTs in an off-state) TR z (Show Trn) ** Displays the transmittance (Show Transmittance) for the filter. The factory-default password is • •.. enter these keystrokes to enter and work in CAL mode. where ‘z’ = 1. which will allow you to change the CFG mode entry password.) The data associated with this mode are displayed on the top line of the User Interface Panel. F6 0 (RUN) Normal Display This keystroke combination returns the RUN mode normal display from anywhere in the software. seen only after you press ‘F6 •’ from RUN mode. and F6 0 keystrokes in RUN and CFG modes. The new password can be up to nine characters. The factory-default password is • •. where ‘z’ (z = 1. enter these keystrokes to enter and work in CFG mode. 1 = Filter1 (Measure filter) 2 = Filter2 (Reference filter) F6 3 The Show Results menu displays the calculated result of the signal used. these keystrokes will call up the “PSWD1?” prompt. The output values from RUN mode continue to be displayed on the bottom line.

F6 9 z Show HAI z The Show Host Controller Board’s Analog Inputs (HAI) function allows you to view the analog input values (voltages or scaled parameters. To view the status of the Over-Temperature relay (OT. not “Show HAI” but “HAI” is displayed if the input is Reserved.g. press the key associated to that parameter.. concentration of species-A times mass emission factor (Ke) for species-A.F6 4 e The Show MEmiss menu displays the mass emission rate of a species (e. (Note that the actual MAI description (e. MAI (z) Message Zone 1 s/lT °C Sample Line 2 scuT °C SCU 3 Tmp °C Spare 4 CellT °C Measuring Cell 5 OT normal or OT tripped Sample Line. To view the operating temperature for each of the temperature-control zones or for the Heater Plate. (Note that the actual HAI description is displayed on the screen. Oven 6 StrT °C or CellP mmHg Stack Stream Temperature HtrT °C Oven Heater MAI8 °C (optional) Reserved for External Probe Temperature 7 8 Measuring Cell For MAI 6 (CellP). ‘s/lT1’) is displayed on the screen..HAI8 Stack Stream Temperature (voltage option) Reserved Internal O2 Concentration (Zr733) or External O2 Concentration or Internal O2 Concentration (Zr734) Reserved . press ‘F6 0’. not “Show MAI”. either normal or tripped). the signal is displayed in volts.. press ‘F6 0’. press ‘6’ while viewing this screen. F6 6 Not Used — F6 7 Not Used — F6 8 z Show MAIz The Show Microcontroller Board’s Analog Inputs (MAI) function allows you to view the analog input values.) To return to the RUN mode normal display. the pressure signal is displayed in mmHg (or "Hg) when active pressure compensation is enabled.g.8 4-26 | Model 909 Single-Gas Analyzer HAI5.g... SO2 ##). (e. F6 5 o The Show O2Cor menu displays the O2 corrected concentrations of SO2 (optional).) To return to the RUN mode normal display. when active pressure compensation is not enabled.. To view the Stack Stream Temperature. HAI (z) 1 Message Zone DiffP mmHg (or "Hg) (optional) Differential Pressure 2 StrT °C 3 HAI3 4 O2 (optional) 5. where ‘z’ = 1.8). SCU. press ‘5’ while viewing this screen.

Configuring the Analyzer Control Functions Output Signal Assignment (OSA) A number of results (or parameters) are calculated by the analyzer. SO2) is determined by species being measured. CODE Instantaneous Track-and-Hold Primary Results Mass Flow Rate O2 Corrected Primary Results Mass Flow Rate O2 Corrected Output Not Used 0 0 0 0 0 0 Low Range so2 concentration (* see Note) 1 11 21 51 61 — High Range SO2 concentration (* see Note) 2 12 22 52 62 — Not Used 2–7 — — — — — Flow Rate 8 — — — — — O2 (Optional) 9 — — 59 — — Definition * Note: Species displayed (so2. Figure 4-4 defines the calculated result codes. Calculated Result (Parameter) Codes. • Track-and-Hold A track-and-hold output records the concentration value that was calculated just before an Auto-Zero/Auto-Span was initiated. using the last digit that was entered. To assign a result to the analog output only.  NOTE The codes in Figure 4-4 assign the result to both the User Interface Panel and analog outputs. It retains this value for the duration of the Auto-Zero/Auto-Span and the Sample Delay Time. An undefined result code will default to a primary code. add 100 to the codes. Figure 4-4. The parameter can be assigned to any of the four output channels. For example. Each result can assume one of two output types: • Instantaneous An instantaneous output tracks the analyzer response during an AutoZero or Auto-Span sequence. Controller / User Interface | 4-27 . The assignment is made by displaying the output number and assigning a numeric code that corresponds to the result. a code of 83 will default to a primary code of 3.

Example 1: To assign the track-and-hold SO2 signal to analog Output 1 and the User Interface Panel and return to CFG mode normal display. These analog inputs can be viewed on the User Interface Panel by pressing F6 8 1.” “Middle. For example. . key in: F2 6 1 Del 1 Ent Ent Analog Input Channels There are eight (8) system analog input channels on the Micro-Interface board. key in: F2 6 1 Del 51 Ent Ent Example 2: To assign the SO2 concentration to analog Output 1 and the User Interface Panel and return to CFG mode normal display. for example).” “Top” always refers to the position nearest the jumper header label on the board.” and “Bottom.A calculated result (parameter) can be assigned to more than one output.. ! CAUTION  NOTE 4-28 | Model 909 Single-Gas Analyzer The analog input channels are configured at the factory – the analyzer will not operate properly if the jumpers or inputs are changed from the factory settings. the SO2 concentration can be assigned to both Channel 1 and Channel 2. The position of the jumper on the header is referenced by “Top.8 from RUN mode. The jumper positions are listed in the following pages (under “Display I/O Board Analog Input Signals” and “Micro-Interface Analog Input (MAI) Signals”) so they can be restored by the user if they should become dislodged (during transit.

and 0–10 V. Display I/O Board Jumper Positions Input Channel Jumper Header Jumper Position Range (VDC) 1 JP200 Middle 0–5 (pitot tube differential pressure) 2 JP201 Middle 0–5 (stack duct temperature) Purgable version only 3 JP202 Middle 0–5 (Reserved) 4 JP203 Top 0–1 (internal O2 concentration or optional external O2 concentration) Figure 4-5.Display I/O Board Analog Input Signals The Display I/O board inputs are labeled 1 to 4 and each has three jumper-selectable ranges: 0–1 V. The jumper headers and their positions are described below. Display I/O board. 0–5 V. The ranges are marked on the board beside each jumper position (see Figure 4-5). Controller / User Interface | 4-29 .

The ranges are not marked on the board. Figure 4-6. 4-30 | Model 909 Single-Gas Analyzer . When active pressure compensation is not enabled. The pressure signal is displayed in mmHg ("Hg) when active pressure compensation is enabled. the signal is displayed in volts. The jumper headers (on the Micro-Interface board) and their positions are described below (see also Figure 4-6). Display Measuring Cell Pressure: The Measuring Cell operating pressure is assigned to Micro-Interface analog input number 6 and is displayed by pressing F6 8 6. and 0–10 V. 0–5 V.Micro-Interface Board Analog Input (MAI) Signals The Micro-Interface board inputs are labeled 5 to 8 and each has three jumper-selectable ranges: 0–1 V. Micro-Interface Board Jumper Positions Input Channel 5 Jumper Header P100 Jumper Position Range (VDC) Bottom 0–10 6 P101 Middle 0–5 (cell pressure) 7 P102 Middle 0–5 (heater temperature) 8 P103 Middle 0–5 Display Process Operating Temperature: The stack duct temperature is assigned to the Micro-Interface analog input 7. The temperature for this zone is displayed by pressing F6 8 7. Micro-Interface board.

The name of the result and its value will be displayed and updated at one-second intervals until either another result is selected or F6 0 is pressed to return to RUN mode normal display. Calculated Results The results. The pressure signal is displayed in mmH2O ("H2O)..Host Controller Board Analog Input (HAI) Signals The Host Controller analog input voltages can be displayed by pressing F6 9 z. Controller / User Interface | 4-31 . The parameter assigned to the input and the signal level (volts or scaled parameter units) is displayed. Display Differential Pressure: The differential pressure is assigned to Host Controller analog input 1 and is displayed by pressing F6 9 1. The temperature for this zone is displayed by pressing F6 9 2.9).9) is the numeric code assigned to the result. Any result can be displayed by pressing F6 3 z where z (z = 1. Mass flow rate parameters can be viewed by pressing F6 4 z (z = 1.8). Display Process Stream Temperature (Voltage Input): The stream temperature for a voltage input is assigned to the Host Controller analog input 2... calculated by the analyzer depend on the software option installed. or parameters. where z is the analog input number (z = 1.

Because the compensation functions are enabled and disabled individually. the default Measuring Cell pressure signal will be used for calculation of the results.. If only active temperature compensation is enabled. The second is to assign the measured pressure and/ or temperature signals to analog input channels on the Microcontroller board. If only active pressure compensation is enabled. key in: F4 • 3 Del 0 Ent Ent 4-32 | Model 909 Single-Gas Analyzer .Active Temperature and Pressure Compensation There are two ways to compensate for Measuring Cell temperature and pressure variations. This setup is done from CFG mode. one or both of the measured values (temperature/pressure) can be used. key in: F4 • 2 Del 0 Ent Ent Measuring Cell Pressure Compensation To enable active pressure compensation and return to CFG mode normal display. The first is to use default (constant) temperature and pressure values. key in: F4 • 2 Del 4 Ent Ent To disable active temperature compensation and return to CFG mode normal display. Analog Input Channel Numbers To Measure Analog Input Signal AI:Msr 1. the default Measuring Cell temperature signal will be used for calculation of the results. key in: F4 • 3 Del 6 Ent Ent To disable active pressure compensation and return to CFG mode normal display.6 (F4 ·) Must Be Assigned To Analog Input Channel O2 Measurement and dilution air computation (optional) 1 24 Measuring Cell Temperature 2 4 Measuring Cell Pressure 3 6 Measuring Cell Temperature Compensation To enable active temperature compensation and return to CFG mode normal display.

key in: F4 8 1 Del 0 Ent Ent Example 2: To enter a value of 25. volume flow rate. Entering Differential Pressure Transducer Range The software reads a voltage which represents the differential pressure measured in the stack. Example 1: To enter a value of 0 mmH2O for the stack duct low differential pressure (DPRg1) and return to CFG mode. Either mmH2O or "H2O can be used. depending on the units selected during initial setup. and mass flow rate can be shown simultaneously on the User Interface Panel. The component concentration.4 Ent Esc Controller / User Interface | 4-33 . The volume flow rate and mass flow rate can be calculated using any system of units (such as the Imperial system or Système Internationale). The following examples describe keystroke combinations to enter the fullscale range of the stack duct differential pressure transducer.4 mmH2O for the high differential pressure (DPRg2) and return to RUN mode normal display. The high-scale value (5 volts) and the low-scale value (0 volts) of the differential pressure transducer must be entered to provide a reference point so the software can convert the voltage reading to engineering units.Mass Flow Rate The mass flow rate (F6 4) function calculates the volume flow rate of the process stream and the mass flow rate of measured components in the process stream. Refer to Appendix C – Conversion Factors and Calculations for explanation of the equations and calculations. key in: F4 8 2 Del 25.

The coefficients are entered at the factory and are listed in the EEPROM Data Sheets. The current output temperature transducer used to measure the process stream temperature is not linear. CAUTION CAUTION The temperature-transmitter coefficients have been calculated at the factory. Example: To set coefficient 2 (STcf2) to -7. the coefficients can be changed. The voltage temperature transducer is linear and only the first two coefficients are used. located in the “Supplemental Information” section of this manual or in the Documentation Package shipped with the analyzer. the others must be zero. key in: F4 7 2 Del -7.Entering Temperature Transmitter Coefficients One of two temperature transducers can be used: current output or voltage output. ! Access to CFG mode should be restricted to trained technicians.2156 and return to CAL mode normal display. ! The coefficients are supplied for reference only and should be changed only upon direct instruction from the factory.2156 Ent Ent 4-34 | Model 909 Single-Gas Analyzer . Changing the factory-set configuration could cause the analyzer to operate incorrectly. If it becomes necessary. Polynomial coefficients are used in a matrix to linearize the temperature transducer output.

Calculation Constants The volume flow rate calculation constant (KQ) and the mass flow rate calculation constant (KE) depend on the process stream composition. the previous values (stored in non-volatile memory) will again come into effect. ! CAUTION  NOTE Access to CFG mode should be restricted to trained technicians. and units of measurement for the various factors. Changing the factory-set configuration could cause the analyzer to operate incorrectly.369 for the component and return to CFG mode normal display. in non-volatile memory. Entering KQ Example: To enter a value of KQ = 1200 and return to CFG mode normal display. the specified component. they will be used temporarily until they are changed or until the next power up or manual reset. the old values will be lost. If the new values are not saved into the configuration. Pressing Ent will cause the new values for KQ and KE to be saved as part of the configuration data. After a power up or reset. key in: F1 8 Del 0. These constants are specific to a given application.369 Ent Ent Controller / User Interface | 4-35 . key in: F1 7 Del 1200 Ent Ent Entering KE Example: To enter a value of KE = KMMw = 0. process stream duct dimensions.

the Microcontroller analog input (MAI) channel number for the stream temperature (current input) signal must be assigned to the algorithm. key in: F4 • 4 Del 0 Ent Ent Entering Stream Temperature AuxTAvg (T90) Example: To enter an AuxTAvg (T90) averaging time of 2 seconds for the stream temperature signal and return to CFG mode normal display. key in: F4 – 2 Del 2 Ent Ent 4-36 | Model 909 Single-Gas Analyzer . the Host Controller analog input (HAI) channel number for the stream temperature (voltage input) and differential pressure signals must be assigned to the algorithm. Stream Temperature (Voltage Input – HAI) To enable stream temperature measurement and return to CFG mode normal display. To enable the measured stream temperature and differential pressure for calculating the results. key in: F4 • 4 Del 22 Ent Ent To disable the stream temperature measurement and return to CFG mode normal display. To enable the measured stream temperature only for calculating the results.Stream Temperature and Differential Pressure The measured process stream temperature and the measured pitot tube differential pressure (DP) are two of the parameters used to calculate the mass flow results.

key in: F4 • 4 Del 0 Ent Ent Controller / User Interface | 4-37 . key in: F4 – 3 Del 2 Ent Ent Stream Temperature (Current Input – MAI) To enable Stream Temperature measurement and return to CFG mode normal display. key in: F4 • 5 Del 21 Ent Ent To disable Differential Pressure measurement and return to CFG mode normal display.Differential Pressure To enable pitot tube Differential Pressure measurement and return to CFG mode normal display. key in: F4 • 5 Del 0 Ent Ent Entering Differential Pressure AuxTAvg (T90 Average) Example: To enter an AuxTAvg (T90) averaging time of 2 seconds for the Differential Pressure signal and return to CFG mode normal display. key in: F4 • 4 Del 7 Ent Ent To disable Stream Temperature measurement and return to CFG mode normal display.

span. temperature transducer. • Thermocouple calibrator. Calibration of a DP Cell output is performed by entering the measured zero. 4-38 | Model 909 Single-Gas Analyzer . • Properly scaled manometer. This section includes procedures to perform a re-calibration as required.  NOTE The Velocimeter has been calibrated at the factory and will be recalibrated upon initial installation at the site. or located in the Supplemental Information section of this manual).Velocimeter and Emissions Calibration The analyzer’s Velocimeter is located on the inside right panel of the Electronics Enclosure. and fullscale values for the output channel. The differential pressure (DP) Cell requires ±15 VDC excitation voltage and outputs 0–5 VDC. and emissions includes: • Multimeter. • DP Cell instructions and layout. These values are used to scale the output to the correct values. • Analyzer EEPROM Data Sheets (shipped with the analyzer. Testing equipment required to calibrate the Velocimeter.

See “Customizing Velocimeter Backpurge and AuxTAvg (T90) Settings. CAUTION Use the following procedure to verify and/or modify the settings. for guidelines on determining new settings. 5. If not. To set up the DP Cell for calibration: 1. Verify that the duration of the pitot tube backpurge (VTp1) is 60 seconds by keying in F3 4 from CAL mode. 4. Verify that the time interval between pitot tube backpurge (VTi) sequences is 10 minutes by keying in F3 5 from CAL mode. continue by keying in the Del 10 Ent Ent and proceed to the next step. This value is listed in the Analyzer EEPROM Data Sheets shipped with the analyzer. Verify the differential pressure value to which the transducer is spanned (DPSpn). If it is correct. proceed to the next step. ! Application-specific conditions might require non-standard settings. 2. proceed to the next step. some initial settings are required. continue by keying in Del 2 Ent Ent and proceed to the next step. The pitot tube differential pressure analog input 5 (AI:Msr5) must be assigned to analog input channel 21. To check this. If not. 3.DP Cell Initial Set-up Default Configuration Before application-specific calibrations are performed. key in Del 21 Ent Ent and proceed to the next step. If it is correct. Verify that the AuxTAvg (T90) averaging time for the differential pressure is 2 seconds by keying in F4 – 3 from CFG mode. proceed to the next step. If this is the case. If it is correct. The following are the recommended factory defaults. If it is correct. Verify this setting is correct by keying in F4 • 5 from CFG mode. proceed to the next step. If it is correct. If not. key in Del ## Ent Ent to complete the setup (where ‘##’ is the value listed on the Analyzer EEPROM Data Sheets). do not replace these settings with the factory defaults. If not. press Ent to clear the User Interface Panel display for the next operation. Controller / User Interface | 4-39 . If not. key in F4 7 from CAL mode.” later in this chapter. continue by keying in Del 60 Ent Ent and proceed to the next step.

Set the Velocimeter flow control mode (VelCtrl) to Analyzer Control (automatic). 4. 3.) Manually span the differential pressure output. (Use the same pressure as used in Step 5 of “Default Configuration. correct any malfunction and then repeat Steps 2–4 until an acceptable calibration is completed. If the DPSFactor is not within this range. From CAL mode key in F6 9 Del 1 Ent Ent. Disconnect the manometer from the positive calibration port. Set the differential pressure transducer span factor (DPSFactor) to 1. Increase the calibration pressure applied to the positive calibration port until the manometer indicates a pressure equal to the span pressure shown on the Analyzer EEPROM Data Sheets (shipped with the analyzer). Press Esc to return to RUN mode.” earlier in this chapter. From CAL mode press F1 4 (Vel/Zero?) Ent to manually zero the differential pressure output. The DPSFactor should be between 0. From CAL mode key in F6 7 Del 0 Ent Ent.75 and 1. From CAL mode key in F1 5 (Vel/Span?). 7. Connect a manometer to the positive calibration port of the Velocimeter and apply zero calibration pressure (no pressure) to the positive calibration port. 4-40 | Model 909 Single-Gas Analyzer . 2. 6. From CAL mode. 5. press F6 9 to display the differential pressure span factor (DPSFactor).DP Zero and Span To calibrate the DP Cell: 1.25 if the calibration was performed correctly.

Refer to drawing “Signal Wiring. To measure the process stream temperature analog input 4 (AI:Msr4 ) must be assigned to analog input channel 22. It may be necessary to change the temperature-transmitter coefficients for calibration (STcf). the others must be zero. 4. The temperature-transmitter coefficients have been calculated at the factory. Key in F4 7 2 to view coefficient 2 (High Value. Set the AuxTAvg (T90) averaging time for the stream temperature to 2 seconds. Controller / User Interface | 4-41 . GP Analyzers” in Appendix D). 2. The default value should be set to ‘0. To do this key in F4 • 4 Del 22 Ent Ent. change it to ‘50. The default value should be set to ‘50. The coefficients are entered at the factory and are listed in the Analyzer EEPROM Data Sheets (shipped with the analyzer). If it is not.0’ by keying in Del 50 Ent Ent. To do this: 1. To do this key in F4 – 2 Del 2 Ent Ent.Temperature Transmitter The temperature transmitter (Stack Thermocouple Module is located on the terminal rail of the backpan in the lower portion of the Electronics Enclosure (see drawing “Electronics Enclosure Layout.0’. Disconnect the thermocouple leads from terminals 1 and 3 on the Stack Thermocouple Module and connect the voltage output leads from the temperature calibrator to these terminals. 3. check coefficient 2. observing the polarity indicated. GP/Div 2/CE/Zone 1 Analyzers (WX-102815)” in Appendix D.0’ by keying in Del 0 Ent Ent. STcf1). change it to ‘0. Changing the factory-set configuration could cause the analyzer to operate incorrectly. STcf2). If it is not. The voltage temperature transducer is linear and only the first two coefficients are used. If it is correct. From CFG mode key in F4 7 1 to view coefficient 1 (Low Value. Configure the calibrator and adjust the output temperature to the expected stack operating temperature. ! CAUTION Access to CFG mode should be restricted to trained technicians. proceed with the next step.0’. If it is correct.

33 4-42 | Model 909 Single-Gas Analyzer . The following adjustment example is for a 0 °C to 750 °C temperature transmitter. b. STcf1 equals the offset of 6. Set the calibrator to 0 °C and observe the offset in temperature by pressing F6 9 2 from RUN mode. a. STcf 2 = 677 x 150 680 STcf2 = 149. Example: The calibrator temperature is 0. d. where nnn is the numerical value from Step 5-a. Adjust the calibrator to a nominal operating temperature (for example. If the temperature indicated on the temperature calibrator doesn’t quite match the display readout.5. perform an adjustment. From CFG mode. c.0 °C and the temperature transducer temperature is 6 °C. Display the Stream Temperature value by pressing F6 9 2 from RUN mode. Make adjustments to STcf2 with the formula: STcf 2 = calibrator value x 150 temperature transmitter readout Example: The nominal operating temperature (calibrator value) is 677 and the temperature transducer readout is 680. enter the numerical value from Step 5-a in STcf1 by keying in F4 7 1 Del nnn Ent. 677 °C).

Key in F5 1 3 to display the full-scale Mass Emission (Scale3). and Temperature signals as parameters for verifying the calculated outputs of process gas volume flow and mass emissions. Key in F5 1 2 to display the full-scale Process Gas Volume Flow (Scale2). 4. This output is not used in the standard configuration of the Model 909 Analyzer as an SO2 analyzer and the full-scale must be set to ‘0’. proceed to the next step. If it is correct. Compare the results to the analyzer calculated outputs. Key in F5 1 4 to display Output 4 (Scale4). proceed to the next step. If not. Verify the full-scale range for each of the four outputs. Perform the verification calculations using a calculator and the formulas provided in the Analyzer EEPROM Data Sheets (shipped with the analyzer). enter CAL mode and: 1. Controller / User Interface | 4-43 . If not. A variance between the calculated outputs generated by manual calculation and the analyzer outputs indicates a configuration problem or a malfunction. 2.Flow & Emission Output Calibration The following procedure uses the active SO2. If not. To do this. key in Del nnn Ent Ent (where nnn is the new full-scale Mass Emission) and proceed to the next step. key in Del nnn Ent Ent (where nnn is the new full-scale SO2 concentration) and proceed to the next step. Steps 1–4 assume these results have been assigned to these analog output channels. the full-scale can be verified and changed following the procedure stated for the other three outputs (Steps 1–3). 3. If it is correct. Key in F5 1 1 to display the full-scale SO2 concentration (Scale1). DP. If this output is used as an application-specific output. key in Del nnn Ent Ent (where nnn is the new full-scale Process Gas Volume Flow) and proceed to the next step. If it is correct. proceed to the next step.

they will be the result of: • Incorrect configuration of one or more of the variables involved. Using the calculated Process Gas Volume Flow rate Q and the SO2 reading (from Step 5) and the KE factor from the EEPROM Data Sheets (shipped with the analyzer). From RUN mode press F6 9 1 to display the current Differential Pressure value. 6. Q = KQ DP T 7. E = K E SO 2 Q 8.5. • A software or hardware malfunction. Return to RUN mode by pressing Esc. calculate the emission (E) rate. Compare these calculated values to the displayed values recorded in Step 5. and Emissions. Record this value. • KQ and KE factors entered are different than those on the Analyzer EEPROM Data Sheets (shipped with the analyzer). Stack Volume Flow. If large differences occur. Refer to the EEPROM Data Sheets and calculate the Process Gas Volume Flow rate Q using the Differential Pressure and Stream Temperature readings (from Step 5) and the KQ factor from the EEPROM Data Sheets. Press F6 0 and record the values for SO2. Press F6 9 2 and record the current Stream Temperature. small changes may have occurred during the time taken to display and record the values and these small changes can result in minor differences between the analyzer calculated values and the manually calculated values. 4-44 | Model 909 Single-Gas Analyzer . Because active parameters are used.

Setting this averaging time to zero (0) turns this function off. the solenoids switch the DP Cell pressure inputs to the positive and negative calibrate ports (which are normally left open to atmosphere) and the pitot lines are connected to the backpurge air supply 5 seconds later. The averaging time can be set from 0–255 seconds. This function is labelled AuxTAvg and is accessed from CFG mode by pressing F4 – 3. Setting this interval to zero turns this function off. The factory default for the backpurge duration is 60 seconds. backpurge duration. the sensitivity to changes in DP is decreased since the DP signal is averaged over a longer time period. As the AuxTAvg (T90) time is increased. Setting the interval to zero (0) turns this function off. This duration can be set from 0–255 seconds. Backpurge Interval This is the time interval between pitot tube backpurge sequences. The air supply is then turned off for 25 % of this time to allow pressure equalization in the pitot tubes and connecting lines. or AuxTAvg (T90) signal averaging times different from the factory defaults to maximize performance and reliability of the Velocimeter. The factory default is 10 minutes. Backpurge air is supplied to the pitot tubes for this duration. These parameters are interrelated in the following way: When a backpurge cycle is initiated. AuxTAvg (T90) Averaging Time for the Differential Pressure Signal This is the averaging time applied to the Differential Pressure (DP) signal and it is used to filter out the small fluctuations in the measured pressure that result from turbulence in the process gas flow. This interval can be set from 0–255 minutes.Customizing Velocimeter Backpurge and AuxTAvg (T90) Settings Application-specific conditions may require backpurge interval. This function is labelled VTp and is accessed from CAL mode by pressing F3 4. Backpurge Duration This is the duration of the pitot tube backpurge event. This function is labelled VTi and is accessed from CAL mode by pressing F3 5. Controller / User Interface | 4-45 .

This allows any residual backpurge pressure in the pitot lines to vent and allows the pressure in the pitot lines to equilibrate to the actual sensed DP levels. Example: Using the factory defaults: Backpurge interval. This extra hold time prevents the DP Cell zero output. The solenoids then switch back to connect the DP Cell pressure inputs to the pitot lines. The Q output is held for a total time per backpurge cycle as follows: Hold time total = 5 seconds + (Backpurge Duration) + (25 % of Backpurge duration) + (2 x AuxTAvg) The backpurge interval time must be greater than the total hold time for the DP signal to track the actual DP from the pitot tubes.25 x 60) seconds + (2 x 2) seconds + 5 seconds = 84 seconds total In this case the Q signal is held for 84 seconds and then tracks the actual process Q for 516 seconds (8 minutes and 36 seconds) out of each 10‑minute cycle. the backpurge air is turned off and the solenoids remain in the backpurge position for an additional 25 % of the set backpurge duration time. which is produced during the backpurge cycle. 10 minutes (600 seconds) Backpurge duration.The flow rate (Q) output is held at the last value prior to the start of the backpurge cycle. When the backpurge duration time elapses. 60 seconds AuxTAvg. from influencing the averaged on line DP output. The Q output signal will be held for an additional period of two times (multiplied by) the set AuxTAvg (T90) averaging time. 4-46 | Model 909 Single-Gas Analyzer . 2 seconds Out of every 10 minute cycle the Q output will be held for 60 seconds + (0.

Working in the CAL Operating Mode The CALibration (CAL) mode is used to enter the variables required to tailor the analyzer for a specific application and to calibrate the instrument. Access to CAL mode is protected by a password. Press • • (factory default password) or the enter the new password. If you have changed the password. When entering keystrokes in CAL mode. do the following: 1. From RUN mode. use the new password to access CAL mode. • If you press a numeric key that is not valid for your system. The message “PSWD0” appears. while the output results from RUN mode will continue to be displayed on the bottom line. press F6 • . the User Interface Panel will return to CAL mode normal display under these conditions: • If you press a Function key that is not valid for your system. An “*” is displayed for each character entered. if changed. To access CAL mode. The factory-default password is “• •”. 3. While working in CAL mode. Press Ent to enter CAL mode.  NOTE Changes made while in CAL mode are saved in the non-volatile memory only when Esc is pressed to return to RUN mode. This is the CAL mode normal display. Controller / User Interface | 4-47 . “CAL” will be displayed on the top line. The password may be entered only while working from RUN mode. any function or result associated with this mode is displayed on the top line of the User Interface Panel. 2. The output values from the normal display of RUN mode continue to be displayed on the bottom line.

Information contained in CAL mode can be changed only when working in CAL mode (a password is required). The following pages list the various keystroke combinations available in CAL mode. refer to the F5 3 keystroke description under “CAL Mode – F5 Keystrokes” later in this chapter.  NOTE  NOTE 4-48 | Model 909 Single-Gas Analyzer Definitions preceded by “**” in the CAL mode keystroke descriptions are used primarily for diagnosing problems with the analyzer. For more information about this function. The Zero and Span results for automatic or manual calibrations can be affected by the status of the Calibration Adjustment Disable (AdjDisable) function. .Defining CAL Mode Keystroke Terms For the purpose of this guide. “Term” is defined as screen headings (titles) or parameters that are displayed on the User Interface Panel screen. along with their terms and definitions of each.

The zero offset and calibration will be automatically adjusted only if AdjDisable is set to ‘0’. F5 4 (Sol:O2Z) and F5 5 (Sol:O2S) define which AutoSpan to use for O2 Zero and O2 Span. Only the Span function for ‘y’ is performed. the prompt “PrbBlow Bk?” is displayed. The readings are based on the average reading during the last 5 seconds of the command. The Calibration Gas solenoid valve connected to SSR output ‘y’ is turned on and off automatically during the sequence. F1 6 Vel/BkPurge? Permits manual backpurging of the pitot tubes..2: 1 = Auto/Span1? (F1 1) – Used in applications with Low Range SO2 and optional O2 Sensor (General Purpose applications). F1 3 Not Used — F1 4 Vel/Zero? Permits the user to manually zero the differential pressure (DP) cell. The analyzer calibration is automatically adjusted based on the average reading during the last 25 percent of the countdown after a Yes response only when AdjDisable is set to ‘0’. which uses the automatic Probe Blow-Back Timer settings. will be performed once and then revert to the automatic settings (see CAL : F3 3 for descriptions of timers). F1 5 Vel/Span? Permits the user to manually span the differential pressure (DP) cell. Auto/Spany? The Auto-Span function allows you to initialize the analyzer to automatically introduce Calibration Gas into the sample system. The manual blow-back sequence. The readings are based on the average reading during the last 5 seconds of the command. Controller / User Interface | 4-49 .CAL Mode – F1 Keystrokes Keystroke Term Definition F1 • Not Used — F1 – Not Used — F1 0 Auto/Zero? The Auto Zero function allows you to initialize the analyzer to automatically introduce Zero Gas into the sample system. Only the functions with timers set to non-zero durations are included. 2 = Auto/Span2? (F1 2) – Used in applications with High Range SO2 and optional O2 Sensor (General Purpose applications). F1 7 PrbBlow Bk? The manual Probe Blow-Back function is used on systems using a stack sample probe with a blow-back function. Press Ent to initiate a manual backpurge of the pitot tubes. F1 8 Not Used — F1 9 Auto/Cal? The Auto-Calibration function allows you to initialize the analyzer to automatically cycle sequentially through the Auto-Zero and Auto-Span functions. The Zero Gas solenoid is turned on and off automatically during the sequence. When you press F1 7 from this menu. F1 y The zero offset is adjusted based on the average reading during the last 25 percent of the Timer0 countdown only if AdjDisable is set to ‘0’. Press Ent to initiate a manual probe blow-back. where ‘y’ = 1.

Refer to “O2 Manual Zero/Span” in Appendix A for details about how to perform a manual Span O2 on the analyzer.CAL Mode – F2 Keystrokes Keystroke Term Definition F2 • Not Used — F2 – Not Used — F2 0 Man/Zero? Permits the user to manually zero the analyzer. either Low Range (so2) or High Range (SO2). The Zero Gas must be introduced manually into the analyzer sample system. Refer to “Manually Zeroing the Analyzer” in Chapter 3 for details about how to perform a manual zero on the analyzer. Man/Zero must be used to calibrate the sensor if Nitrogen is used for the Zero Gas. for details about how to perform a manual span on the analyzer. Refer to “O2 Manual Zero/Span” in Appendix A for details about how to perform a manual Zero O2 on the analyzer. F2 y Man/Spany? Permits the user to manually span the analyzer. for use in General Purpose applications/analyzers only) at the analyzer. The analyzer calibration is automatically adjusted based on the average reading during the Integration Time (IntTime) duration after a Yes response only if AdjDisable is set to ‘0’. Refer to “Manual Span. where ‘y’ = F2 1 or F2 2 (see below). for use in General Purpose applications/analyzers only) at the analyzer. F2 1 = Man/Span1? (so2) F2 2 = Man/Span2? (SO2) F2 3 Not Used — F2 4 Not Used — F2 5 Not Used — F2 6 Not Used — F2 7 Not Used — F2 8 Man/SpanO2? Permits the user to manually span the O2 Sensor (if used. The analyzer zero is automatically adjusted based on the average reading during the IntTime duration after a Yes response only if AdjDisable is set to ‘0’. The sensor zero is automatically adjusted based on the average reading during the IntTime duration after a Yes response only if AdjDisable is set to ‘0’.” later in this chapter. The Calibration (Span) Gas must be introduced manually into the analyzer sample system using the FlowCtrl function. The Zero Gas must be introduced manually into the analyzer sample system. F2 9 Man/ZeroO2? Permits the user to manually zero (air point calibration) the O2 Sensor (if used. The sensor calibration is automatically adjusted based on the average reading during the IntTime duration after a Yes response only if AdjDisable is set to ‘0’. The Calibration (Span) Gas must be introduced manually into the analyzer sample system. Man/Span must be used to calibrate the sensor if Nitrogen is used for the Zero Gas. 4-50 | Model 909 Single-Gas Analyzer .

The interval can be set from 0–999 hours in one-hour increments. Timer0 is the zero solenoid timer. These settings are used by the automatic and manual Probe Blow-Back function..CAL Mode – F3 Keystrokes Keystroke Term Definition F3 • Not Used — F3 – Not Used — F3 y Timery Sets the length of time the solenoid valve (controlling a Zero or Calibration Gas) connected to SSR output ‘y’ is energized during the Auto-Zero. F3 3 The Probe Blow-Back Timers allow you to set up the blow-back feature for systems using a stack sample probe with a blow-back function (optional).. depending on Sample Line length). Setting the interval to ‘0’ turns the function off. where ‘y’ = 0. 3 = PrbT3 = The Probe Blow-Back Pulse Width parameter allows you to enter the duration (in seconds) the analyzer will allow the blow-back system to build up pressure between pulses (air bursts. 2 = PrbT2 = The Probe Blow-Back Duration parameter allows you to enter the duration (in seconds) of each blow-back. The duration can be set from 0–255 minutes in one-minute increments. F3 7 SDelay Sets the time delay (minutes) for the CAL relay to continue indicating that a calibration is in progress after completion of the calibration function. This permits a smooth transition from the Zero/Span Gas back to the sample gas. in minutes (maximum value = 999). F3 8 AZInt Sets the time interval (hours) between Auto-Zero sequences. Setting this interval to ‘0’ turns the function off. Also used to view the time remaining until the next Auto-Zero (hours and minutes). This permits Auto-Zero to be performed more frequently than Auto-Calibration.. The Auto-Zero function will be included in the Auto-Calibration sequence if Auto-Zero is enabled and Timer0 duration is not zero. The interval can be set from 0–999 hours in one-hour increments. F3 5 VTi The time interval between pitot tube backpurge sequences. 0 = Timer0 (F3 0) 1 = Timer1 (F3 1) – Used in applications with Low Range so2 and optional O2 Sensor (General Purpose applications). F3 4 VTpz The duration of the pitot tube backpurge and the delay following the backpurge in which the system will wait before resuming operation. Auto-Span. F3 6 IntTime Sets the time period (seconds) over which the reading for each of the manual Zero/Span functions is averaged. while Timer1 and Timer2 are the Calibration Gas mixture solenoid timers. it is displayed along with a countdown timer (time remaining until the next blow-back). F3 9 The Auto-Calibration Interval setting sets the time interval (hours) between AutoCalibrations. This function also includes a timer that displays the time remaining until the next backpurge (mmm:ss). 2 = Velocimeter backpurge delay (set between 0–120 seconds. PrbTz 1 = PrbT1 = The Probe Blow-Back Interval parameter allows you to enter the intervaltime between blow-backs.2. Setting the duration to ‘0’ turns the function off: 1 = Velocimeter backpurge duration. Setting the duration to ‘0’ turns the specific timer off. Setting this interval to ‘0’ turns the function off. When an interval-time is entered. Setting the delay to ‘0’ turns the function off. Setting the value to ‘0’ turns the function off.2. ACal Also used to view the time remaining until the next timed Auto-Calibration (hours and minutes).3. The duration may be set from 0–255 in one-second increments. which blow back debris into the stack). The delay can be set from 0–255 minutes in one-minute increments. where ‘z’ = 1. where ‘z’ = 1. 2 = Timer2 (F3 2) – Used in applications with High Range SO2 and optional O2 Sensor (General Purpose applications). This parameter can be set from 0–255 minutes in one-minute intervals. Controller / User Interface | 4-51 . and Auto-Calibration functions.

The concentration is entered in decimal notation. either Low Range (so2) or High Range (SO2). The concentration is entered in decimal notation. Bw 4-52 | Model 909 Single-Gas Analyzer . where ‘z’ = 1. where ‘y’ = F4 1 or F4 2 (see below). the concentration must be set to ‘0’. If a Calibration Gas is not used.95 %). The maximum concentration which can be entered is 999 999. The maximum concentration which can be entered is 999 999.2. F4 1 = CalConc1 (so2) F4 2 = CalConc2 (SO2) F4 3 Not Used — F4 4 Not Used — F4 5 Not Used — F4 6 Not Used — F4 7 DPSpn The differential pressure span value (mmH2O or “H2O) to which the differential pressure transducer is spanned. F4 8 O2Concz The concentration of O2 (%) in the Calibration Gas mixture. Bw is the water content in the air used in the combustion process.. 2 = O2 concentration for air point Calibration Gas (typically 20.CAL Mode – F4 Keystrokes Keystroke Term Definition F4 • Not Used — F4 – Not Used — F4 0 Not Used — F4 y Concy The concentration of the component y (ppm or %) in the Calibration Gas mixture. F4 9 Used in applications where the emission rate is calculated using a fuel factor. 1 = O2 concentration for span point Calibration Gas.

then the assigned solenoid value entered must be ‘11’ (pseudosolenoid) to prevent inadvertent Auto-Calibration.4. for example. 100.) If N2 is used as Span Gas. Controller / User Interface | 4-53 . and is for use in General Purpose applications/analyzers only.2.. or 110. if Scale 1 = 1000 ppm. where ‘z’ = 0. then the assigned solenoid value entered must be ‘10’ (pseudosolenoid) to prevent inadvertent Auto-Calibration.102. To prevent automatic adjustments of the analyzer Zero offset and calibration. For example. F5 5 Assigns a solenoid to the O2 Span Gas. (The O2 Sensor is optional. where ‘z’ = ‘0’ or ‘1’. Sol:O2Z If N2 is used as Zero Gas. If an output is not used. F5 4 Assigns a solenoid to the O2 Zero Gas. The software confirms the assignment during an Auto-Calibration action. These outputs are application-specific. AdjDisablez To allow automatic adjustments of the analyzer Zero offset and calibration. set this function to ‘0’. 10. output 1 would read 20 mA at 1000 ppm and 4 mA at 0 ppm.. FlowCtrlz = = = = Scale1 Scale2 Scale3 Scale4 The following codes apply to sample systems using an Aspirator to transport the sample gas: 0 = Analyzer Control Mode (automatic control by the analyzer) 1 = Continuous Backpurge Mode (manually set by the user) 2 = Continuous Sample Mode (manually set by the user) 10 = Continuous Zero Gas Flow Mode (manually set by the user) – probe tip 11 = Continuous Calibration Gas #1 Flow Mode (manually set by the user) – probe tip 12 = Continuous Calibration Gas #2 Flow Mode (manually set by the user) – probe tip The following codes apply to sample systems using a Sample Block Valve: 100 = Analyzer Control Mode (automatic control by the analyzer) 101 = Continuous Sample Block-Off Mode (manually set by the user) 102 = Continuous Sample Mode (manually set by the user) 110 = Continuous Zero Gas Flow Mode (manually set by the user) – local 111 = Continuous Calibration Gas #1 Flow Mode (manually set by the user) – local 112 = Continuous Calibration Gas #2 Flow Mode (manually set by the user) – local F5 3 The Calibration Adjustment Disable function can be set to allow (or prevent) automatic adjustment of the analyzer Zero offset transmittances and Span factors for all Zero and Span operating modes (automatic or manual calibration). its full-scale range should be set to zero. where ‘z’ = 1.. Sol:O2S If the Span Gas is attached to Solenoid 2. the O2 Sensor is span calibrated when Auto-Span is initiated by itself or as part of the Auto-Calibration sequence. The software confirms the assignment during an Auto-Calibration action.CAL Mode – F5 Keystrokes Keystroke Term Definition F5 • Not Used — F5 – Not Used — F5 0 Not Used — F5 1 Scalez The full-scale range for each of the four outputs. set this function to ‘1’. 1 2 3 4 F5 2 The analyzer system Sample Flow Control Mode.112..12..

4-54 | Model 909 Single-Gas Analyzer . where ‘z’ = 1. Adjusted automatically whenever the analyzer is Zeroed if AdjDisable is set to ‘0’.00 mmHg. This value is used in place of the measured Measuring Cell temperature when active temperature compensation is disabled.F5 6 T0z ** The measuring wavelength transmittance value with Zero Gas for each filter. Default = 760. where ‘z’ = 1. This value is used in place of the measured Measuring Cell pressure when active pressure compensation is disabled. F5 9 Pres The default absolute pressure for the Measuring Cell (mmHg or "Hg). either Low Range (so2) or High Range (SO2).. Adjusted automatically whenever the analyzer is Spanned if AdjDisable is set to ‘0’. SFactorz 1 = SFactor1 (so2) 2 = SFactor2 (SO2) F5 8 Temp The default temperature for the Measuring Cell (°C or °F).2.2 (see below).. Default = 140 °C. 1 = Filter 1 2 = Filter 2 F5 7 The span (calibration) factor for the calculated result (component concentration).

4. F6 9 DPSFactor The differential pressure transducer span factor. After an AutoCal. Auto-Span. The Span Cal Drift is determined only when AdjDisable is set to ‘0’. 1 = O2CD 1 (O2 Zero) 2 = O2CD 2 (O2 Span) F6 5 O2ZVolt The O2 Sensor voltage output offset at zero (air point). (The O2 Sensor is optional. where ‘z’ = 1.CAL Mode – F6 Keystrokes Keystroke Term Definition F6 • Not Used — F6 – Not Used — F6 0 IZeroz The measured current (mA) in the current output loop when the output is set to zero scale during the Zero calibration procedure. The actual mA value is displayed next to the corresponding output channel when 20 mA (Span function) is activated. or Manual Zero the Zero Cal Drift factor of the calculated result since the last Zero Calibration. 1 = SCD1 (so2) 2 = SCD2 (SO2) F6 4 O2CDz The O2 Cal Drift is used only when AdjDisable is set to ‘0’. 0 = Analyzer Control (automatic) 1 = Continuous Backpurge F6 8 DPZ The differential pressure transducer zero offset value. where ‘z’ = 1. It is determined by the software when span calibration of the O2 Sensor is performed. Controller / User Interface | 4-55 . The drift results are displayed in PPM or %.2 (see below). where ‘z’ = Output Channels 1. It is determined by the software when zero calibration of the O2 Sensor is performed. The signal drift result is displayed in ppm. either Low Range (so2) or High Range (SO2). where ‘z’ = Output Channels 1. The actual mA value is displayed next to the corresponding output channel when 4 mA (Zero function) is activated. is recorded here.) F6 6 O2SFactor The O2 Sensor span factor. either Low Range (so2) or High Range (SO2).4. The Zero Cal Drift is determined only when AdjDisable is set to ‘0’. (The O2 Sensor is optional. Auto-Zero. is recorded here. and is for use in General Purpose applications/analyzers only. 1 2 3 4 F6 1 z The measured full-scale current (mA) in the current output loop when output is set to fullscale during the Span calibration procedure. or Manual Span the Span Cal Drift factor of the calculated result since the last Span Calibration.. the O2 signal drift of the calculated result since the last Auto-Cal is recorded here. ZCalDriftz = = = = Output Channel 1 Output Channel 2 Output Channel 3 Output Channel 4 Output Channel 1 Output Channel 2 Output Channel 3 Output Channel 4 1 = ZCD1 (so2) 2 = ZCD2 (SO2) F6 3 SCalDriftz After an Auto-Cal.2. ISpanz = = = = 1 2 3 4 F6 2 After an Auto-Cal.. and is for use in General Purpose applications/analyzers only.) F6 7 VelCtrl Velocimeter flow control mode. Refer to the Output Signal Assignment code for the outputs assigned to these channels (press F2 6 from CFG mode)... Refer to the Output Signal Assignment code for the outputs assigned to these channels (press F2 6 from CFG mode). where ‘z’ = 1.. The drift result is displayed in PPM or %.2 (see below).

. Flow Control (Sample) Modes The Flow Control mode determines the state of the sample gas flow. the screen will display a code (e. While viewing the Flow Control mode (CAL mode menu) from the User Interface Panel. It can be controlled automatically by the analyzer (Analyzer Control mode) or forced to any of the manual modes by the user. 0 = Analyzer Control mode) that indicates a the current operating mode: FlowCtrl Code Gas Transport (CAL F5 2) Method Definition/Flow Control Mode (set automatically by analyzer or manually by user) 0 Aspirator Analyzer Control (automatic) Indicating Character on User Interface Panel blank = Sample (by analyzer) b = Backpurge (by analyzer) 1 Aspirator Continuous Backpurge (manual) B (* See Note) 2 Aspirator Continuous Sample (manual) S 10 Aspirator Continuous Zero Gas Flow – probe tip (manual) Z 11 Aspirator Continuous Calibration Gas #1 Flow – probe tip (manual) C 12 Aspirator Continuous Calibration Gas #2 Flow – probe tip (manual) C 100 Sample Block Valve Analyzer Control (automatic) 101 Sample Block Valve 102 Sample Block Valve 112 Sample Block Valve  NOTE 4-56 | Model 909 Single-Gas Analyzer blank = Sample (by analyzer) b = Backpurge (by analyzer) Continuous Sample Block-Off (manual) B (* See Note) Continuous Calibration Gas #1 Flow – local (manual) C Continuous Calibration Gas #2 Flow – local (manual) C * The ‘B’ character is also displayed when the Remote Backpurge function (optional) is activated by the user via a remote dry (potential free) contact opening.Setting Up Analyzer Calibration Functions This section describes the various functions and controls available while working from CAL mode. Each mode is described in detail in the following pages. the codes will vary.. Depending on the method used to transport the sample gas (Aspirator or Sample Block Valve).g.

the analyzer will switch to Continuous Backpurge for the length of time required for all temperaturecontrolled zones to stabilize at their set points.Analyzer Control Mode (Automatic Control by the Analyzer) 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 the analyzer detects a Fault alarm while it is operating in Analyzer Control mode (automatic sample). the analyzer will operate in automatic Continuous Sample. When you force the analyzer into Continuous Backpurge. a reverse-video S ( S ) is displayed on the upper-right line of the User Interface Panel. When errors are detected. use the keypad on the User Interface Panel to key in from CAL mode: F5 2 Del 1 Ent Ent Controller / User Interface | 4-57 . To manually force the analyzer to zero the sample system. it will automatically switch to Continuous Backpurge. When the analyzer automatically switches its Flow Control mode to Backpurge. When in Continuous Sample mode. Because a low temperature is defined as a fault. which indicates an analyzer-controlled – or automatic – backpurge). To set the analyzer’s Flow Control to Analyzer Control and return to CAL mode normal display. there is no indicating character on the User Interface Panel. a “B” will be displayed on the upper-left line of the User Interface Panel to indicate a manual backpurge (as opposed to a “b”. The analyzer will not switch back to Continuous Sample mode until the Fault alarm has been corrected (cleared). key in from CAL mode: F5 2 Del 0 Ent Ent Continuous Backpurge Mode (Manual Control by the User) When the analyzer’s Flow Control Mode is set to Continuous Backpurge. the analyzer is zeroed with instrument air. If there is no Fault alarm. which indicates a manual Backpurge). It will not automatically switch to Continuous Sample mode. the User Interface Panel displays a “b” on the upper-left line (as opposed to a “B”.

To manually force the analyzer to zero the sample system with Zero Gas. the analyzer is zeroed with Zero Gas. “Z” will be displayed on the upper-left line of the User Interface Panel to indicate the analyzer has been manually set to zero the analyzer sample system with Zero Gas. a sample is continuously extracted from the stack duct and passed through the analyzer sample system. When the user has forced the analyzer into Continuous Sample. it will not automatically switch to Continuous Backpurge mode. “S” will be displayed on the upper-left line of the User Interface Panel to indicate the analyzer has been manually set to sample continuously. could result in plugging of the sample system and/or the analyzer. use the keypad on the User Interface Panel to key in from CAL mode: F5 2 Del 10 Ent Ent 4-58 | Model 909 Single-Gas Analyzer . When you force the analyzer into Continuous Zero Gas Flow. use the keypad on the User Interface Panel to key in from CAL mode: F5 2 Del 2 Ent Ent ! Operating the analyzer in Continuous Sample mode for an extended period of time before all of the temperature-controlled zones have staCAUTION bilized at their set point temperatures.Continuous Sample Mode (Manual Control by the User) When the analyzer’s Flow Control Mode is set to Continuous Sample. Continuous Zero Gas Flow Mode (Manual Control by the User) When the analyzer’s Flow Control Mode is set to Continuous Zero Gas Flow. To manually force the analyzer to continuously sample from the stack duct. It will not automatically switch to Continuous Backpurge mode.

the analyzer sample system is purged with Calibration Gas 1 or Calibration Gas 2. key in: F5 2 Del 11 Ent Ent To manually force the analyzer to Continuous Calibration Gas #2 and return to CAL mode normal display.Continuous Calibration Gas Flow Mode (Manual Control by the User) When the analyzer’s Flow Control Mode is set to Continuous Calibration Gas Flow. When you force the analyzer into Continuous Calibration Gas Flow (Gas 1 or Gas 2). key in from CAL mode: F5 2 Del 12 Ent Ent Controller / User Interface | 4-59 . It will not automatically switch to Continuous Backpurge mode. To manually force the analyzer to Continuous Calibration Gas #1 and return to CAL mode normal display. “C” will be displayed on the upper-left line of the User Interface Panel to indicate the analyzer has been manually set to purge the analyzer sample system with calibration gas.

depending on the units selected. 1. key in from CAL mode: F4 1 Del 1. forced to backpurge by the user: Analyzer Control When operating in the Analyzer Control mode. ! If a calibration gas is not used. key in from CAL mode: F6 7 Del 1 Ent Ent Entering Calibration Gas Concentration You must enter the concentration of the component you are using in the calibration gas mixture before initiating a calibration sequence. the Velocimeter is backpurged at the time interval specified by the Velocimeter timer (VTi.495).495 Ent Ent 4-60 | Model 909 Single-Gas Analyzer .. To set the Velocimeter control mode to Backpurge and return to CAL mode normal display. CAUTION Example: To enter a value of 1. The maximum value allowed is 999 999. F3 5 from CAL mode).Velocimeter Flow Control The operating mode for the Velocimeter can be controlled by the analyzer (automatic) or. fractional values are entered using normal decimal notation (e. key in from CAL mode: F6 7 Del 0 Ent Ent Backpurge When operating in the Backpurge mode. the concentration must be set to zero. the Velocimeter is purged with instrument air to clear the pitot tubes or to perform a Zero/Span calibration. The concentration can be expressed in ppm (v/v) or percent (%).495 % for the component and return to CAL mode normal display. To set the Velocimeter control mode to automatic and return to CAL mode normal display.g.

F5 4 (Sol:O2Z) and F5 5 (Sol:O2S) define which AutoSpan to use for O2 Zero and O2 Span. The timer duration depends on the time required for the calibration gas mixture to reach the analyzer and to obtain a stable reading. Its duration must be set to zero (turned off).  NOTE Timer 1 and its associated span function (Auto-Span 1) are used in applications with low range SO2 and optional O2 Sensor (General Purpose applications). key in from CAL mode: F3 2 Del 0 Ent Ent Controller / User Interface | 4-61 . key in from CAL mode: F3 0 Del 3 Ent Ent Example 2: Timer2 is not required for control of a calibration gas mixture. and Auto-Span 2 will be taken during the last 25 percent of the timer duration. Each establishes the time period (duration) for which a solenoid valve controlling the calibration gas mixture is energized during the AutoZero. The average reading for Auto-Zero. Timer0 establishes the length of time the analyzer Zero Gas solenoid valve is turned on during the Auto-Zero sequence. Timer 2 and its associated span function (Auto-Span 2) are used in applications with high range SO2 and optional O2 Sensor (General Purpose applications). NOTE Setting the timers is done from CAL mode. The time can be set from 0–255 minutes in one-minute increments. Timer1 and Timer2 establish the lengths of time (duration) that calibration gas mixtures are turned on during the Auto-Span 1 and Auto-Span 2 sequence. Example 1: To set Timer0 duration to 3 minutes and return to CAL mode normal display. To set Timer2 to ‘0’ and return to CAL mode normal display. and Auto-Calibration sequences. Setting a timer duration to ‘0’ turns the timer off.Setting Calibration Gas Timers There are three independent timers used for automatic calibration of the analyzer. the associated timer must be turned Off. Auto-Span 1. disabling the function. If a calibration gas is not used.  NOTE  The Timer must be assigned a value that allows the signals to be stable during the last 25 percent of the countdown. Auto-Span.

the Auto-Calibration sequence takes precedence. Setting the interval to ‘0’ turns the ACal timer off. The IntTime can be set to a duration from 0–65535 seconds in one-second increments. If the Auto-Calibration and Auto-Zero sequences are scheduled to run at the same time. A timed AutoCalibration will start only when the analyzer is operating in RUN mode without any Faults.Integration Timer (IntTime) The Integration Timer (IntTime) allows you to set the duration over which readings are averaged during manual calibration functions. Pressing Ent returns the CAL mode normal display. key in from CAL mode: F3 9 Del 3 Ent Ent Time to Next Auto-Calibration The time remaining until the next Auto-Calibration can be displayed from CAL mode at any time by pressing F3 9. disabling a timed start of the Auto-Calibration sequence. The User Interface Panel does not provide a running count of the time remaining until the next AutoCalibration – you must press F3 9 to view the time remaining until the next Auto-Calibration. Setting the duration to ‘0’ causes the default averaging time of 15 seconds to be used. The Auto-Zero sequence is included in the Auto-Calibration sequence if the Auto-Zero function is enabled by setting Timer0 to a non-zero value. Example: To set the ACal timer interval to 3 hours and return to CAL mode normal display. The ACal timer can be set to an interval from 0–999 hours in one-hour increments. Example: To set the IntTime to 25 seconds and return to CAL mode normal display. pressing Esc returns RUN mode normal display. 4-62 | Model 909 Single-Gas Analyzer . key in from CAL mode: F3 6 Del 25 Ent Ent Auto-Calibration Interval Timer (ACal) The ACal timer sets the interval (hours) between timed Auto-Calibration sequences.

pressing Esc returns the RUN mode normal display. Time to Next Auto-Zero The time remaining until the next Auto-Zero can be displayed from CAL mode at any time by pressing F3 8. A timed Auto-Zero will start only when the analyzer is operating in RUN mode without any Faults. Setting the interval to zero (0) turns the timer off. disabling a timed start of the Auto-Zero sequence. The timer can be set to an interval from 0–999 hours in one-hour increments. Controller / User Interface | 4-63 . the existing timer interval is displayed (hours) and the time remaining until the next Auto-Zero is displayed (hours and minutes). If the Auto-Calibration and Auto-Zero sequences are scheduled to run at the same time. Example: To set the AZInt timer interval to 1 hour and return to CAL mode normal display. you must press F3 8 to view the time remaining until the next Auto-Zero. Pressing Ent returns the CAL mode normal display. and allows the Auto-Zero function to be performed more frequently than the Auto-Calibration. the Auto-Calibration sequence takes precedence. The Auto-Zero sequence is included in the Auto-Calibration sequence if the Auto-Zero function is enabled by setting Timer0 to a non-zero duration. key in from CAL mode: F3 8 Del 1 Ent Ent  NOTE When you enter F3 8.Auto-Zero Interval Timer (AZInt) This timer sets the interval (hours) between timed Auto-Zero sequences. The User Interface Panel does not provide a running count of the time remaining until the next Auto-Zero.

The time delay will also be in effect if a calibration sequence is aborted. permitting a smooth transition from calibration gas back to sample gas. The User Interface Panel and analog outputs continue to show the actual concentration at the analyzer unless the track-and-hold result codes are assigned to the display and analog outputs. Setting the delay to ‘0’ turns off the SDelay timer. This allows any external recording devices to mark the point at which the analyzer is again monitoring a representative sample. If the delay is ‘0’. The User Interface Panel gives no indication that the delay is occurring or that it has occurred. Example: To set the SDelay timer to 4 minutes and return to CAL mode normal display. The time delay depends on the time required for the sample gas to reach the analyzer and a stable reading to be obtained. the CAL status relay will indicate that the calibration is complete immediately following the end of the calibration sequence. The time delay can be set from 0–255 minutes in one-minute increments. key in from CAL mode: F3 7 Del 4 Ent Ent 4-64 | Model 909 Single-Gas Analyzer .Setting the Sample Delay Timer (SDelay) The SDelay timer determines the period of time after the completion of a calibration sequence that the CAL Status Relay will wait before indicating that a calibration is complete.

Turn off the Aspirator Air. where ‘11’ = Calibration Gas #1 or where ‘12’ = Calibration Gas #2. Press F5 2 and record the numeric value displayed for FlowCtrl. The gas flow rate. Manual Zero Refer to “Manually Zeroing the Analyzer” and “Adjusting the Zero Gas Flow Rate” in Chapter 3 for information about how to perform a manual zero on the analyzer. 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 gases must be introduced manually into the analyzer and allowed to flow through the sample system until a stable reading is displayed. Manual Span To perform a Manual Span: 1.  NOTE The calibration gas mixture component concentration must be entered before performing the Manual Span function. 3. Ensure that the calibration gas supply is connected and turned on. Force the analyzer to manually span the sample system with Calibration Gas by keying in F5 2 Del 11 Ent. Controller / User Interface | 4-65 . temperature and pressure should be as close as possible to the normal operating conditions.Manual Zero/Span The Manual Zero and Manual Span functions do not activate the solenoid valves. The User Interface Panel will prompt “Man/Span1?”. 4. Press F2 1 to initiate the manual span. 2.

Esc for No The function is aborted and the calibration value for the component is not adjusted. 6. When it has stabilized at or near the concentration of component “1” in the Calibration Gas mixture. press: Ent for Yes The analyzer will count down to zero (IntTime duration) during which time the reading is averaged. Observe the concentration reading for the component on the bottom line of the User Interface Panel. Return the analyzer to the original Flow Control Mode by keying in F5 2 Del n Ent where ‘n’ is the numerical value recorded earlier.5. The calibration value for the component will be adjusted automatically and the CAL mode normal display returned. Turn off the calibration gas mixture with component “1”. The span process for the component is complete. 4-66 | Model 909 Single-Gas Analyzer . 7.

Both span-corrected concentrations can be displayed on the User Interface Panel and assigned to the V/I outputs. For other species. Run zero gas and manually zero the analyzer as described under “Manual Zero” earlier in this chapter. and do a Manual Span: a. The optional Dual Span functionality accommodates this. For example. However. typically one Low Range Span and one High Range Span. For the Low Range Span Factor (SFactor1 – so2). The Model 919 Analyzer has only one analytical result but can be spanned at two different concentrations. some applications require spanning the analyzer with two independent span gases.0 Ent Controller / User Interface | 4-67 . b. Set the span gas concentration for Species 1 and 2. Key in F6 • • • Ent to enter Calibration mode. To perform a dual-range span: 1. the Low Range is displayed as “no2” and the High Range is displayed as “NO2”. key in: F5 7 1 Del 1.0.Spanning Dual Range The Model 919 Single-Gas Analyzer has been designed to be linear over its normal operating range. On the User Interface Panel.  NOTE The following procedure uses SO2 as the measured species. and typically needs to be spanned with only one gas.0 Ent For the High Range Span Factor (SFactor2 – SO2). while the second (High) Range is displayed as “SO2”. the Low Range and High Range is displayed similarly. where the first (Low) Range is displayed as “so2”. key in: F5 7 2 Del 1. the Low Range output is indicated by “so2” while the High Range output is indicated by “SO2”. Manually reset both Span Factors to 1. if NO2 is being measured.

Run calibration (span) gas and do a Manual Span: Run the Low Range so2 calibration gas for 2 minutes or until the reading stabilizes. Key in F6 • • • Ent to enter Calibration mode. key in: F5 7 1 Del 1. For complete details. and then key in F2 2 Ent to do a Manual Span.0 Ent d. refer to “Manual Span” earlier in this chapter.0. as described under “Manual Zero” earlier in this chapter. and do an AutoSpan: a. For the Low Range Span Factor (SFactor1 – so2). turn off the span gas. and then key in F2 1 Ent to do a Manual Span. b.c. Set the Span Concentrations to the corresponding tag concentration listed on the calibration cylinder.0 Ent If the tag concentration listed on the cylinder for the High Range Span Concentration (Conc2 – SO2) is 100 ppm. Run the High Range SO2 calibration gas for 2 minutes or until the reading stabilizes. key in: F4 1 Del 25. Manually reset both Span Factors to 1. 2. key in: F5 7 2 Del 1. For example: If the tag concentration listed on the cylinder for the Low Range Span Concentration (Conc1 – so2) is 25 ppm . Set the span gas concentration for Species 1 and 2. After the Manual Span is complete.0 Ent 4-68 | Model 909 Single-Gas Analyzer . key in: F4 2 Del 100. Run zero gas and manually zero the analyzer.0 Ent For the High Range Span Factor (SFactor2 – SO2).

key in: F4 2 Del 100. Run calibration (span) gas and do an Auto-Span: Run the Low Range so2 calibration gas for 2 minutes or until the reading stabilizes. refer to “Auto-Zero/Auto-Span” later in this chapter. Set the Span Concentrations to the corresponding tag concentration listed on the calibration cylinder. For example: If the tag concentration listed on the cylinder for the Low Range Span Concentration (Conc1 – so2) is 25 ppm . 3. and then key in F1 2 Ent to do an Auto-Span. Controller / User Interface | 4-69 . Return the analyzer Flow Control Mode to its original setting and prepare the analyzer for normal operation.c. key in: F4 1 Del 25. Run the High Range SO2 calibration gas for 2 minutes or until the reading stabilizes. turn off the span gas.0 Ent d.0 Ent If the tag concentration listed on the cylinder for the High Range Span Concentration (Conc2 – SO2) is 100 ppm. After the Auto-Span is complete. For complete details. and then key in F1 1 Ent to do an Auto-Span.

For the Auto-Calibration function to operate correctly. • AutoCal (F1 9) – energize solenoid #0. The SSR output. Timer 2 and its associated span function (Auto-Span 2) are used in applications with high range SO2 and optional O2 Sensor (General Purpose applications). Each SSR output is controlled by a Calibration Gas Timer. #1. SSR Output and Timer Assignments SSR Output Function Timer 0 Auto-Zero 0 1 Auto-Span 1 1 2 Auto-Span 2 2  NOTE Cal Gas SSR Output 0 is reserved for use with the zero gas. Timer 1 and its associated span function (Auto-Span 1) are used in applications with low range SO2 and optional O2 Sensor (General Purpose applications).and span-calibrate the zero. and zero. Solenoid Assignments The existing Auto-Calibration functions will now work as follows: • AutoSpan1 (F1 1) – energize solenoid #1 and span-calibrate to Conc1 by adjusting SFactor1 if Conc1 is positive. SSR output 2 will be assigned to Result 1. if the Solenoid Valve for controlling the Result 1 CAL Gas mixture is switched by SSR output 2. Conc1. • AutoSpan2 (F1 2) – energize solenoid #2 and span-calibrate to Conc2 by adjusting SFactor2 if Conc2 is positive. and #2 in sequence. and the Calibration Gas Timer assigned to each are listed below. For example. F5 4 (Sol:O2Z) and F5 5 (Sol:O2S) define which AutoSpan to use for O2 Zero and O2 Span.Solenoid Valve Control There are three solid state relay (SSR) outputs available for switching the solenoid valves controlling the flows of the calibration gas mixtures. This is accomplished by assigning the SSR output (switching the calibration gas solenoid valve) to the calculated result for which the calibration gas is required. the analyzer must know which component is in which gas cylinder. its function. 4-70 | Model 909 Single-Gas Analyzer . and Conc2 accordingly.

. When an Auto-Zero/Auto-Span function is performed. and the span factor for that component will be reset to 1. If the duration for a calibration gas timer is set to a non-zero value. the calibration gas mixture component concentration and a value for the calibration gas timers must be entered before an AutoZero/Auto-Span function can be initiated. Controller / User Interface | 4-71 . the CAL mode normal display is returned.   The Calibration Gas mixture component concentrations and a value for the Calibration Gas timers must be entered before an Auto-Zero/ Auto-Span function can be performed. The analyzer Zero or Span is adjusted to the proper value based on the average of the readings during the last 25 % of the time period (minutes) of the countdown. FlowCtrl must have a value of zero). The CAL status relay will stay on for an additional period of time as determined by the Sample Delay Timer to allow for a smooth transition from the Zero or calibration gas mixture back to the sample gas. the zero offset and span will not be corrected at the end of a calibration sequence. This allows the analyzer to control the calibration gas flow so an external Data Acquisition System can record the actual analyzer output signals during a calibration sequence and to monitor for “calibration out of range” conditions. The User Interface Panel gives no indication that the solenoid valve has been turned on. The solenoid valve assigned to the function selected is turned on to let the Zero or calibration gas mixture flow through the Measuring Cell.Auto-Zero/Auto-Span This feature allows the operator to initiate an automatic calibration sequence. The Timer duration for the function being performed is displayed on the first line of the User Interface Panel and is counted down to zero.  NOTE There is a global variable called Adjust Disable which.e. the function will be performed. and the component concentration is specified as zero. However. Upon completion of the Auto-Zero/ Auto-Span functions.  NOTE Pressing Esc at any time during this procedure will abort the function and return to CAL mode normal display. if disabled (set to ‘0’). The User Interface Panel gives no indication that this is occurring.0. 2. The Flow Control Mode must be controlled by the analyzer (i. 4. The Integration Timer (IntTime) does not affect the averaging time for the Auto-Zero/Auto-Span functions. the following sequence of events occurs automatically: 1. 3.

if the AZInt timer is set at 2 hours. to display the timer duration. Upon completion of the sequence. the time remaining until the next timed Auto-Calibration is 30 minutes. For example.  NOTE Pressing Esc at any time during this procedure will abort the function and return to CAL mode normal display. 2. and the Auto-Calibration sequence is started manually. The start of the next Auto-Zero will be timed from the beginning of the manual start. Or.Manual Start of Auto-Zero A manual start of the Auto-Zero sequence resets the AZInt timer to its initial value. F1 0. The software prompts “Auto/Zero?”. Timer0 will begin to count down to zero time. To manually start the Auto-Zero sequence. 4-72 | Model 909 Single-Gas Analyzer . the zero offset is not adjusted. The analyzer zero offset is adjusted automatically based on the average of the reading during the last 25 % of the countdown. To enable the Auto-Zero sequence. or press Esc to return to RUN mode normal display. the AZInt timer will be reset. key in from CAL mode: 1. press another Function key combination. 3. press Esc to abort the Auto-Zero sequence. and the time remaining until the next timed Auto-Calibration remains 2 hours. press Ent. Press Ent.

press Ent. or press Esc to return to RUN mode normal display. The analyzer span value is adjusted automatically based on the average of the reading during the last 25 % of the countdown. Timer 2 and its associated span function (Auto-Span 2) are used in applications with high range SO2 and optional O2 Sensor (General Purpose applications). 2. The software prompts “Auto/Span1?” or “Auto/Span2? ”. 3. F5 4 (Sol:O2Z) and F5 5 (Sol:O2S) define which AutoSpan to use for O2 Zero and O2 Span. key in from CAL mode: 1.Manual Start of Auto-Span  NOTE Timer 1 and its associated span function (Auto-Span 1) are used in applications with low range SO2 and optional O2 Sensor (General Purpose applications). Timer1 (Auto/Span1?) or Timer2 (Auto/Span2?) will begin to count down to zero time. F1 1 or F1 2 to display the timer duration. the span value is not adjusted. Press Ent. To enable the Auto-Span sequence. Or. press Esc to abort the Auto-Span sequence. To manually start the Auto-Span sequence. Controller / User Interface | 4-73 . press another Function key combination. Upon completion of the sequence.

The ACal timer sets the time interval between calibration sequences. automatically on a timed basis. the first AutoCalibration sequence occurs after the ACal interval from the time the analyzer is powered up or reset as long as no fault conditions are present.Auto-Calibration The Auto-Calibration function automatically performs first an Auto-Zero. The sequence of events for the component is the same as described for Auto-Zero/AutoSpan. Timer 2 and its associated span function (Auto-Span 2) are used in applications with high range SO2 and optional O2 Sensor (General Purpose applications). followed by Auto-Span 1 and Auto-Span 2. This function can be set up by pressing F3 9 from CAL mode. and then entering a value (hours) for the automatic-timed start of the Auto-Calibration sequence. Upon completion of the calibration sequence. or by a remote dry (potential-free) contact closure. the Cal status relay will continue to indicate that a calibration is in process until the Sample Delay Time has expired. 4-74 | Model 909 Single-Gas Analyzer . the first Auto-Calibration will occur at 3 hours if all temperatures are reached. A function can be eliminated from the sequence by setting its associated timer is ‘0’. This function can be started manually. If the ACal timer is set to an interval other than zero. Timed Start of Auto-Calibration The analyzer automatically initiates the Auto-Calibration sequence on a timed basis. Example: If the ACal timer is set to “3” and the analyzer is powered up or reset.  NOTE Timer 1 and its associated span function (Auto-Span 1) are used in applications with low range SO2 and optional O2 Sensor (General Purpose applications). The Auto-Calibration sequence will occur at 3-hour intervals unless this value is changed. F5 4 (Sol:O2Z) and F5 5 (Sol:O2S) define which AutoSpan to use for O2 Zero and O2 Span. Subsequent Auto-Calibration sequences will be initiated at every AutoCalibration time interval.

Example: If the ACal timer is set at 2 hours.Manual Start of Auto-Calibration A manual start of the Auto-Calibration sequence does not reset the ACal timer to its initial value. The sequence is aborted and adjustments are not made. and the Auto-Calibration sequence is started manually. 2. Press Ent for Yes. Controller / User Interface | 4-75 . The User Interface Panel prompts “Auto/Cal?”. To initiate the Auto-Calibration sequence: 1. The start of the next Auto-Calibration will be timed from the continuing countdown of the original ACal timer setting. the time remaining until the next timed Auto-Calibration is 30 minutes. Upon completion of the sequence. The CAL mode normal display is returned.  NOTE Pressing Esc at any time during this procedure will cause it to abort and return to CAL mode normal display. or Press Esc for No. and the time remaining until the next timed Auto-Calibration remains 30 minutes. the User Interface Panel returns the RUN mode normal display. The sequence is started. the ACal timer will continue to count down. The Auto-Calibration sequence can be started manually by pressing F1 9 Ent from CAL mode. Press F1 9.

If a timed Auto-Calibration is in progress. This is done to remove any residual contaminants in the sample system.” earlier in this section. Remote Start of Backpurge (Optional) If configured. dry (potential-free) contact closure connected to Digital Input 2. add a value of “16” to the Units value (F1 9 from CFG mode). To enable the Remote Backpurge option. The contact must remain closed for at least 2 seconds (up to 5 seconds). Example: If the ACal timer is set at 2 hours. for example. Refer to F1 9 under “RUN / CFG Mode – F1 Keystrokes. A remote start of the Auto-Calibration sequence does not reset the ACal timer to its initial value. This function is initiated by a remote dry (potential free) contact opening. For more information refer to “Timed Start of Auto-Calibration. Pins 10 and 11 on J108 of the Termination board (see Figure 4-7). such as in the case of a gas alarm. this function allows the user to initiate a backpurge of the analyzer sample system from a remote location. 4-76 | Model 909 Single-Gas Analyzer . Pins 10 and 11 on J108 of the Termination board (see Figure 4-7). connected to Digital Input 2.Remote Start of Auto-Calibration The Auto-Calibration sequence can also be initiated by a remote. If a timed internal function such as the Auto-Velocimeter Backpurge is in progress when a remote start is requested (by closing the dry contact connected to Digital Input 2) the request will be registered but will not initiate any activity until the currently active internal function has been completed. Once the currently active function has been completed the remote start request will be accepted and acknowledged by a change in state of the CAL status contact. the time remaining until the next timed Auto-Calibration is 30 minutes and the Auto-Calibration sequence is started by a contact closure.” earlier in this chapter. The ACal timer must be set to ‘0’ for this application. The start of the next Auto-Calibration will be timed from the continuing countdown of the original ACal timer setting. the ACal timer will continue to count down and the time remaining until the next timed Auto-Calibration remains 30 minutes.  NOTE If the remote start is requested by a Distributed Control System (DCS) which is also calculating calibration drift values. the remote-contact closure will be ignored. you must ensure that the DCS is the only source of Auto-Calibration requests.

CE/Zone 1 Analyzers in Appendix C. Customer signal connections. Termination board. GP/Div 2 analyzers. refer to the electrical connection drawings included in the “Supplemental Information” section of this manual or the Documentation Package shipped with the analyzer.Figure 4-7. For other applications. Controller / User Interface | 4-77 .  NOTE Figure 4-7 is for GP/Div 2 analyzers only. for CE or Zone 1 refer to Customer Signal Connections.

For example. The user must provide the loop supply for the loop-powered output.” earlier in this chapter. all four outputs can be scaled the same. depending on the units selected in the software. refer to “Output Signal Assignment (OSA).Analog Output Channels There are four independent isolated 4–20 mADC outputs which can be self-powered or loop-powered. key in: F5 1 1 Del 500 Ent Ent Example 2: To set the full-scale range for Output Channel 3 to 300 PPM. The measurement will be entered in either ppm or percent. Example 1: To set the full-scale range for Output Channel 1 to 500 PPM. key in: F5 1 3 Del 300 Ent Ent 4-78 | Model 909 Single-Gas Analyzer . Output Channel 2 can be scaled to 300 PPM full-scale or. Setting Output Channel Full-Scale The full-scale range for the output parameter assigned to each channel can be set individually within the measuring range of the analyzer. and return to CAL mode normal display. If the output signal assignment must be changed. and return to CAL mode normal display. The default signal assignment is configured to meet the specifications of the end user. Output Channel 1 can be scaled to 500 ppm full-scale.

“nnn” Key in the full-scale value (mA) that was measured by the meter. where ‘z’ is the Span current output (ISpan) 1. Enter these values in decimal form. or Esc To return to the RUN mode normal display. These values are used to offset the output to the correct values. Further re-calibration is required only when a V/I module or the Termination board is replaced. To calibrate the current output signal for Output Channel ‘z’.4.Analog Output Calibration Calibration of an analog output is performed by entering the measured zero and full-scale signals for the current output channel. connect the current meter to the output (refer to Figure 4-7 for termination points) and press: Zero current output F6 0 z Current output zero scale value is displayed.4). The existing calibration values and any new values entered up to the point of pressing Esc will be retained. Del Sets the current analog output channel to full-scale (20 mA). Controller / User Interface | 4-79 . Calibration complete Ent To return to CAL mode normal display. Use a current meter to calibrate the current output signals. Ent Zero scale value is entered and displayed... Ent Full-scale value is entered and displayed. ! If the measured current output is less than 20 mA when the output is set to full-scale. where ‘z’ is the Zero current output (IZero) 1. Del Sets the current analog output channel to zero scale (4 mA). The V/I CAUTION 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. Span current output F6 1 z Current output full-scale value displayed.4. it cannot be increased above that value.  NOTE Pressing Esc at any time during the procedure will abort the procedure and return to CAL mode normal display. “nnn” Key in the Zero scale value (mA) that was measured by the meter. where ‘z’ is the output channel number (1. or Press another Function key to perform another function..

97 Ent The current meter reading is 3.06 Ent The current meter reading is 4. Example 2: To calibrate the current output signal for Output Channel 2 and return to CAL mode normal display. 4-80 | Model 909 Single-Gas Analyzer . F6 1 2 Del Sets the output to full-scale. key in: F6 0 1 Del Sets the output to zero scale.18 mA.97 mA. Ent Returns the CAL mode normal display. 20.06 mA.Example 1: To calibrate the current output signal for Output Channel 1 and return to CAL mode normal display. F6 1 1 Del Sets the output to full-scale.92 mA. 19.18 Ent The current meter reading is 20. Ent Returns the CAL mode normal display. 3.92 Ent The current meter reading is 19. key in: F6 0 2 Del Sets the output to zero scale. 4.

When active temperature and pressure compensation are required.” earlier in this chapter. To convert the pressure from "Hg to mmHg. The default values stored as part of the analyzer configuration can be used. or the measured Measuring Cell temperature and/or pressure can be used. Do not change this value. multiply by 25. key in: F5 9 Del 700 Ent Ent Controller / User Interface | 4-81 . If the measured values are to be used.Measuring Cell Temperature and Pressure The Measuring Cell operating temperature and pressure are two of the parameters used to calculate the analyzer results. Example: To enter a Measuring Cell pressure (Cell Press) of 700 mmHg (absolute) and return to CAL mode normal display. the pressure may have to be converted to "Hg before entering the value. the Measuring Cell temperature and pressure are treated as constants. When the default values are used. The default values are listed under the headings “Cell Temperature” and “Cell Pressure” on the EEPROM Data Sheets (in the Documentation Package shipped with the analyzer). refer to “Active Temperature and Pressure Compensation. Depending on the units selected. Default Measuring Cell Temperature The default Measuring Cell temperature is 140 °C (284 °F). the measured values for each are used.4. Entering Default Cell Pressure The Measuring Cell pressure shown on the Analyzer EEPROM Data Sheet is the absolute pressure of the sample in the Measuring Cell in mmHg.

Probe Blow-Back Control (Optional)

For applications using the Probe Blow-back function, it is enabled at
the factory (by disabling Temperature Zone 2).

NOTE

For more information about enabling this function, refer to the F2 1
description under “RUN / CFG Mode – F2 Keystrokes,” earlier in
this chapter.

The Probe Blow-back control can be set up to be performed automatically,
at timed intervals and for timed durations. This is done by setting the
parameters for three timers (Interval, Duration, Pulse Width) from CAL
mode (F3 3). After these timers have been set to non-zero values, the analyzer will initiate a Probe Blow-back at the preset intervals. For more information about these timers, refer to “CAL Mode – F3 Keystrokes,” earlier in
this chapter. See Figure 4-8 for an example timing chart.
A Probe Blow-back can also be started manually by the user, by keying in
F1 7 Ent from CAL mode. The manual blow-back function will perform
one cycle, determined by the Duration Timer setting (CAL mode, F3 3). To
abort a manual blow-back, press the Esc key.
The Probe Blow-back control signal is available at terminals 3 (-) and 4
Probe Blow-back Timing
(+) of J106
on the Termination board (also used as the SSR control for
a heated Vent Line or Sample Conditioning Unit). The signal switches
from 0 VDC to +15 VDC when the Probe Blow Back feature is activated.


NOTE

Probe Blow-back
Air Solenoid

Probe Isolation
Solenoid

CAL Relay

Probe Blow-back Interval (min)
Sample Delay
(sec)

Probe Blow-back Duration (sec)

Probe Blow-back Pulse Width (sec)

2x Probe Blow-back Pulse Width

Figure 4-8.
Probe Blow-back
Timing Chart, example.

4-82 | Model 909 Single-Gas Analyzer

nOTE: Illustration only. not to scale.

Maintenance & Troubleshooting

The Maintenance & Troubleshooting chapter discusses preventive maintenance to keep the analyzer system operating at peak efficiency, how to
check for plugging in the analyzer’s sample system, and how to replace
internal parts. This chapter also discusses how to view error messages to
diagnose and troubleshoot problems with the analyzer.

Safety Considerations


NOTE

Before performing any maintenance, service, or troubleshooting on
the Model 909 Analyzer, review and follow all personnel and equipment safety information under “Personnel and Equipment Safety
Information” following the Table of Contents near the beginning of
this manual. This information describes procedures to follow to avoid
personal injury and/or damage to the equipment. All regulatory
agency and personnel safety procedures for your jurisdiction
must be followed.
Personnel should be thoroughly familiar with the operation of the
analyzer before performing the maintenance procedures described in
this section.

Maintenance & Troubleshooting | 5-1

Maintenance
Generally, there is limited maintenance required to ensure the analyzer
remains operating at peak efficiency, other than that described in the
Analyzer Preventive Maintenance Schedule. This section discusses preventive maintenance to follow to ensure continued and proper operation
of the analyzer. This section also describes parts that require replacing
and the frequency in which they should be replaced, according to the
Analyzer Preventive Maintenance Schedule.

Preventive Maintenance
To reduce the occurrence of problems with the Model 909 Analyzer,
AMETEK recommends that you follow the Analyzer Preventive
Maintenance Schedule as outlined in the following pages. Since most analyzer problems originate within the sample handling system, the primary
objective of the Analyzer Preventive Maintenance Schedule is proper care
of the sample system.
The risk of developing a collection of liquids in low spots or plugging in
the sample system can be reduced by sloping the Sample Line from the
sample extraction point to the analyzer.

!

CAUTION

Preventing leaks in the sample handling system is critical to proper
analyzer operation. The analyzer’s sample system must be leak
checked whenever it has been dismantled for maintenance or repair.

Refer to the “Analyzer Preventive Maintenance Schedule” for suggested
actions and their frequency when caring for the Model 909 Analyzer.
Details and exploded-view drawings to assist you when changing out
parts can be found in appropriate sections later in this chapter.

5-2 | Model 909 Single-Gas Analyzer

Analyzer Preventive Maintenance Schedule
Frequency

Task

Daily

Check for Warning or Fault Alarms

Check the top right corner of the analyzer’s User Interface Panel for
a reverse-video S ( S ) character. If this character appears, view the
software diagnostics to check for current alarms that will help you
isolate the problem. The keypad commands are F5 4 1..8 (HStatus)
and F5 5 1..7 (MStatus) from RUN mode. Refer to “Troubleshooting &
Diagnostics” in this chapter for information about error messages and
the suggested corrective actions.

Check the history buffers for recurring alarms. The history buffers
contain alarms that have been reset. To view historical alarms, use the
F5 • 1..9 (HCHist) and F5 – 1..9 (MCHist) commands while working
from RUN mode.

Monthly

Check the PMT Signals
Note: The Manual Supplement “Model 9xx-Series Analyzer Lamp
Maintenance” suggests to Zero the analyzer daily to provide
the greatest insight into tracking the status of the lamps, optics,
and detector. If possible, zero the analyzer daily or at least more
frequently than monthly.

Manually force the analyzer to purge the sample system with Zero Gas
(Continuous Zero Gas Flow mode) by using the keypad on the User
Interface Panel to enter F5 2 Del 10 Ent from CAL mode.

View the Show Signals (Sig) command in RUN mode (F6 1 1..3) and
record the analyzer PMT signals. All signals should return to within
5 % of the values recorded the previous month. If the Measure PMT
signals show significant loss, the Measuring Cell may be contaminated.
Cleaning the Measuring Cell window(s) can be delayed until the signals
are less than 50 % of their “clean” measured value. Refer to your log
book to examine the monthly recordings.

Return the analyzer Sample Flow Control mode back to its original
setting by entering F5 2 Del 0 Ent from CAL mode (where ‘0’ = Analyzer
Control mode). Press Esc to return the User Interface Panel back to the
RUN mode normal display.

Monthly

Auto-Setup

Initiate an Auto-Setup to optimize the PMT (photomultiplier tube)
gains and the source lamp currents. After the Auto-Setup is complete,
record the results related to the PMT and lamp configuration in a chart.
Refer to the Manual Supplement “Model 9xx-Series Analyzer Lamp
Maintenance” for more information about Auto-Setups and optimizing
lamps, plus an example of a Lamp & PMT Configuration chart to record
these findings.

Monthly

Check Analyzer Response Time

Perform a Manual or Auto Zero on the analyzer. After the Zero is
complete, determine the sample response time by switching the
analyzer from Continuous Backpurge mode to Continuous Sample
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 approximately 30 seconds (excluding sample
system). 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 “Adjusting the Sample
Gas Flow Rate” in Chapter 3. Also, refer to “Locating a Plug in the
Sampling System,” later in this chapter for more information.

Maintenance & Troubleshooting | 5-3

Frequency

Task

Monthly

Pressure Gauges

Check the Aspirator Pressure and Electronics Enclosure Purge Air
Pressure gauges.

Aspirator air pressure should be set in the range of 7–35 KPAG (1–5
PSIG) to ensure a measurement response time of approximately 30
seconds. Refer to “Adjusting the Sample Gas Flow Rate” in Chapter 3
for more details.

Electronics Enclosure Purge 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-Controlled Zones

Check the operating temperatures of all temperature-controlled zones to
ensure they are all within 5 % of their set points. Record and compare
the current temperatures to the actual settings.

Every Three Months
Sample Conditioning Unit (SCU), Optional

If your analyzer uses an SCU, change the filter elements in the SCU
(Probe). If the gaskets are damaged, replace them at the same time.
Clean the parts that make up the filter assemblies. Replace the gaskets
at 6-month intervals, minimum.

Depending on sample stream contamination levels (i.e., sample response
time is continually decreasing), it may be necessary to replace the filters
and clean the SCU more frequently. This may be evident if response time
is longer than normal, or if a good zero cannot be achieved.

If your system uses an SCU (or another type of sample gas extraction
unit) from a manufacturer other than AMETEK, refer to the accompanying
manual for information on the frequency of regular maintenance.

Every Six Months Sheltered Systems

If your analyzer system is installed in a custom shelter, check the air
filters for the shelter purge and air conditioning systems and replace
them if necessary. Depending on the location of the site and its
environmental conditions, it may be necessary to check and replace
these filters more frequently.

Every Six Months Sample Line

Inspect the Sample Line 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
line(s).

9–12 Months

Source Lamps

Replace the source lamps. The source lamps may need to be replaced
sooner if information from the analyzer’s diagnostics indicates
related alarms (i.e., “w Lamp Control” or “w PMT Signals”). Refer to
“Replacing the Source Lamps,” later in this chapter.

Every Year

Measuring Cell

Clean the Measuring Cell and the rest of the analyzer’s sample system.
This schedule is a minimum requirement. If other conditions are found
to be present, as outlined under the section titled “Measuring Cell
Preventive Maintenance,” cleaning may be required more frequently.

At the same time, replace the o-rings.

5-4 | Model 909 Single-Gas Analyzer

Frequency

Task

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
0.1 mm; if the gap exceeds this value, contact AMETEK for advice. See
“Examining and Caring For the Flamepaths,” later in this chapter, for
more information.
• Disconnect Enclosure flange (enclosure door and housing joining
surfaces).
• Heater Plate Assembly flange (upper/lower Heater Plate joining
surfaces, inside the Analyzer Oven).

Expo-Telektron Safety Systems MiniPurge (Optional)
Preventive Maintenance Schedule
Frequency

Task

If your analyzer uses an Expo-Telektron Safety Systems MiniPurge
System, refer to the Expo-Telektron Safety Systems MiniPurge Manual
for recommended preventive maintenance, and how to change out
replaceable parts. This manual is shipped with the analyzer.

Before Performing Maintenance

!

Under normal operating conditions, lethal concentrations of H2S
and other toxic gases from the stack duct may be present within the
WARNING
analyzer’s sample system.
Before working on the sample system, manually force the analyzer to
purge the sample system with Zero Gas (force its Flow Control Mode
to Continuous Zero Gas Flow from CAL mode), isolate it (block it in)
from the stack duct, and disconnect the power. Follow this procedure
prior to changing out any analyzer components or replacing any
replaceable parts (as part of regular preventive maintenance), or performing leaks checks following the replacement of instrument air or
other adjustments to any of the connections points in the analyzer’s
sample system. If this is not possible, a breathing apparatus must be
worn while servicing the sample system.
The sample system is defined as all components in the analyzer system through which sample gas passes.

Maintenance & Troubleshooting | 5-5

Locating a Plug in the Sample System
If analyzer problems occur, they are most likely related to improper
sample system operation, such as plugs or leaks. Plugs in the sample
system cause problems in analyzer response time, either to changing stack
duct conditions or to Zero Gas. Leaks are potentially dangerous and will
eventually lead to corrosion problems.

Detecting a Plug in the Sample System
This is best done by observing the analyzer’s measurement response time
immediately following a Zero function. A typical response time is approximately 30 seconds (excluding sample system). Observe your analyzer and
learn what a normal response time is. Use the recorded response time as a
reference for detecting the formation of plugs in the sample system.
If the sample response time is longer than normal, it is most likely due to
plugging somewhere in the sample system. The next step is to locate and
remove the plug. The portion of the sample system with the highest risk
of plugging is the sample inlet. One way to confirm that a plug is in the
sample inlet is to cap the Vent Line and Zero the analyzer.


NOTE

If your application disperses the used sample gas to atmosphere via a
stack or low pressure flare header, disconnect the Vent Pipe at the Vent
port in the Analyzer Oven and temporarily install a cap.

Observe the Cell Pressure reading (press F6 8 6 from RUN mode), and if
the reading approaches the Zero Gas supply pressure, a plug is present
somewhere in the sample inlet.

!

CAUTION


NOTE

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

After confirming that the plug is somewhere in the sample inlet, take
all appropriate safety precautions and dismantle the sample system,
starting at the SCU.

Plugs in the sample outlet (or vent side) of the sample system are rare.
Plugs in the vent system cause the aspirator drive air to flow back into the
Measuring Cell and, essentially, simulate a Zero Gas Flow or Backpurge
condition.

5-6 | Model 909 Single-Gas Analyzer

Maintenance & Troubleshooting | 5-7 . manually force the analyzer to purge the sample system with Zero Gas (Continuous Zero Gas Flow mode) by using the keypad on the User Interface Panel to enter the following keystrokes: a. The operating temperature of the SCU and Vent Valve (if used) assemblies should be at least 10 °C (18 °F) above the process temperature to ensure optimum sample system performance. a large plug has occurred somewhere in the sample system. Press Ent to enter CAL mode. c. plus additional insulation (by customer) if necessary. press F6 • and then enter the CALibration mode password “• •” (at the “PSWD0” prompt). While working from the User Interface Panel. Press Del to delete the current setting and then press 10 (10 = Continuous Zero Gas Flow mode) at the “FlowCtrl?” prompt. Press Ent again to return to CAL mode normal screen and then Esc to return to RUN mode. b. The SCU and Vent Valve (if used) assemblies should be insulated using the insulation supplied by AMETEK.Preventing a Plug in the Sample System This is done by supplying and maintaining the necessary heat tracing to the Sample Line. Press Ent to save the change. The rotameter should be active with flow indication. Check current operating temperatures and compare them to the set point temperatures for each temperature zone. 3. “S” will be displayed on the User Interface Panel. Cap the Sample Line at the SCU. d. From RUN mode. 2. Observe the flow on the rotameter. Remove the cap from the Sample Line and reconnect it to the SCU. If the flow reduces to a stop. To check the analyzer’s sample system for possible plugging: 1. Press F5 2 to display the FlowCtrl (Flow Control Mode) screen.

After locating the cause of the restriction or plug (and after cleaning or replacing the part or line). Record the response time. 8. 6. Press Ent to save the change. The recorded values can be used later as a reference while testing response time. Return the analyzer Flow Control setting to Analyzer Control mode by entering the following keystrokes: a. d. Observe the flow on the rotameter. Aspirator Air pressure. a large plug has occurred somewhere in the sample system. Press Ent again to return to CAL mode normal screen and then Esc to return to RUN mode. Remove the cap from the Vent Line and reconnect it to the Sample Vent Pipe.  NOTE If your application disperses of the used sample gas directly to atmosphere or via a stack. Enter F5 2 to display the FlowCtrl (Flow Control Mode) screen. Check the sample response time. 7. To do this. disconnect the Vent Pipe at the Vent port in the Analyzer Oven and temporarily install a cap.4. 5-8 | Model 909 Single-Gas Analyzer . Press Ent to enter CAL mode. Disconnect the Vent Line from the Vent Pipe and temporarily install a cap on the line. pressure/leak test the fittings or connections that were loosened or replaced. enter F6 • and then the CALibration mode password “• •” (at the “PSWD0” prompt). follow the procedures under “Sample System Leak Check” in Chapter 3. b. c. Cal Gas pressure. Press Del to delete the current setting and then press 0 (0 = Analyzer Control mode) at the “FlowCtrl?” prompt. If the flow reduces to a stop. From RUN mode. and Cal Gas flow rate settings. 5.

consult with your AMETEK distributor or representative. according to the schedule listed in the “Analyzer Preventive Maintenance Schedule. ! If the User Interface Panel displays Warning or Fault alarm error messages that indicate a faulty component requires replacement CAUTION [described under “Microcontroller Board Alarm Conditions and Corrective Action” or “Host Controller Board Alarm Conditions and Corrective Action” later in this chapter].Changing Out Replaceable Parts The following sections discuss the parts that should be changed out. refer to the purging system’s manual (shipped with the analyzer) for required maintenance and procedures on how to change out replaceable parts. RTDs.” These descriptions focus on the AMETEK sample system. the optics will become damaged and most likely require replacement. Or. Maintenance & Troubleshooting | 5-9 . If sample gas migrates into the Optical Bench CAUTION Assembly or Reflector Block due to a leak in the Measuring Cell Assembly. ! Preventing leaks in the sample system is critical to ensure proper analyzer operation. As indicated in the “Preventive Maintenance Schedule” for the ExpoTelektron Safety Systems MiniPurge System. contact the factory for assistance and information about returning the assembly/analyzer to the factory for repair. or electronics boards. review this manual for replacement procedures. For complex maintenance procedures not discussed in this manual. such as replacing heaters. Most leaks are preventable with regular cleaning and replacement of the Measuring Cell o-rings.

”  NOTE 5-10 | Model 909 Single-Gas Analyzer If your system uses a White Cell Assembly for the Measuring Cell. Refer to Figure 5-1 for assistance in locating and identifying the hardware components that make up the Measuring Cell. sample gas can leak from the Measuring Cell into the Analyzer Oven. refer to the “Supplemental Information” section of this manual or the Documentation Package shipped with the analyzer for a drawing and information on cleaning the Measuring Cell and replacing its o‑rings. the Measuring Cell Windows are scratched. For example. . during an unscheduled cleaning (see cleaning requirements above). Clean the Measuring Cell and its windows: • If the analyzer responds slowly to zero when the sample system is free of restrictions. or • If evidence of contamination is present in the Sample Line. the parts are found to be damaged. or • Every year as indicated in the “Analyzer Preventive Maintenance Schedule. While the Measuring Cell is disassembled.Measuring Cell Preventive Maintenance The o-rings in the Measuring Cell should be replaced every year to avoid a leak in the sample system.” Replace the o-rings in the Measuring Cell: • If. clean its chambers and parts. cracked. or chipped. or the o-rings are damaged. • Every year as indicated in the “Analyzer Preventive Maintenance Schedule. If the sample system operates above atmospheric pressure.

Figure 5-1. Measuring Cell Assembly. Maintenance & Troubleshooting | 5-11 .

To do this: a. Proceed only when the area is found to be safe. cap the Sample Line at the SCU and cap the Vent Line at the Sample Vent Pipe. After the Zero is complete. do not WARNING power down the analyzer or any alternate power sources that supply power to the analyzer components. General Purpose (GP) Analyzer Applications: Open the Electronics Enclosure and disconnect power from the analyzer and its temperature-controlled zone circuitry by opening the Analyzer and Oven Heater fuses. 2. From RUN mode. Record the numeric value displayed for FlowCtrl. b. 4. Power down the analyzer: ! Before powering down the analyzer. From this screen. While working from the User Interface Panel. Manually Zero the analyzer for 2–3 minutes.To clean the Measuring Cell and replace its o-rings: 1. Information on how to do this is described under “Manually Zeroing the Analyzer” in Chapter 3. Refer to the Fuse Legend on the inside of the analyzer’s Electronics Enclosure door for the locations of these fuses. 3. If an explosive gas atmosphere is present. you can view the current operating mode. test the area around the analyzer for flammable gases. Purged Analyzer (Hazardous Location) Applications: Open the flameproof power-disconnect switch (breaker). check and record the current Flow Control mode. enter F6 • and then enter the CALibration mode password “• •” (at the “PSWD0” prompt). Open the Electronics Enclosure. Press Ent to CAL mode. Enter F5 2 to display the FlowCtrl (Flow Control) mode screen. ! WARNING 5-12 | Model 909 Single-Gas Analyzer Wait 5 minutes to allow the high-voltage capacitors in the sourcelamp power supply to discharge. .

Once the Heat Transfer Block has cleared the Cell RTD. Maintenance & Troubleshooting | 5-13 . 7. Purged Analyzer (Hazardous Location) Applications: The Instrument Air supply must always remain on for the Purge Bypass Switch to operate properly. 6. Wearing insulated gloves. disconnect the Measuring Cell from the Oven: ! WARNING The analyzer sample system will be under positive pressure. Disconnect the Sample and Vent Line tubes from their fittings on the Measuring Cell. swing the Optical Bench Assembly outward. c. grasp the Measuring Cell Assembly and carefully pull it straight out from the Heater Plate (located in the counter bore hole in the Heat Transfer Block).  NOTE Various lengths of screws are encountered during disassembly. After the Oven has cooled down enough to work on. General Purpose Analyzers Only: Turn off the Instrument Air supply to the analyzer and then close the Aspirator Air valve.5. take precautions to avoid injury. using the Support Arm Yoke (hinge mechanism) that mounts it to the Electronics Enclosure backpan. take precautions to avoid burning yourself. The Analyzer Oven enclosure and components within the Analyzer Oven are hot. ! WARNING The analyzer sample system will be under positive pressure. open the Analyzer Oven door and allow the Analyzer Oven to cool down enough to ensure safe handling. Remove the Heat Transfer Block Plug from the counter bore hole in the Heat Transfer Block and then remove the 3 mm holding screw using only an Allen key. Do not use a ball driver – the head can break off inside the screw. b. a. Wearing insulated gloves. Take note of where each length is used and be sure to replace the appropriate screws in their original locations when reassembling the Measuring Cell later. away from the analyzer.

5-14 | Model 909 Single-Gas Analyzer . cuts. close the Oven door while working on the Measuring Cell. 10. Remove the three M4 x 12 mm screws that secure the Measuring Cell Extension to the Heat Transfer Block. Set the o-rings aside with the Window for cleaning. Remove the Reflector Block. carefully remove the o-rings and Cell Window from the Measuring Cell. Inspect the o-rings for flexibility and for any signs of damage (nicks. place the Cell parts on a soft. non-abrasive cloth. Inspect the Window and o-rings and set them aside with the other o‑rings and Window. Inspect the Window for any chips. Use an o-ring removal tool to remove the outer o-ring from the Measuring Cell. cracks. To help maintain the temperature inside the Oven. 11. or scratches. ! CAUTION Replace chipped. Remove the Heat Transfer Block. Avoid touching the window surfaces. Still with the Reflector Block end up.8. cracked. Use an o-ring removal tool to remove the inner o-ring from the Measuring Cell. Take care not to scratch or damage the o-ring groove or joining surface of the Heat Transfer Block. similar to the other o-rings and Cell Window. While holding the Measuring Cell vertically so that the Reflector Block end is up. scratches). 12. NOTE 9. Place the Window on a soft. Carefully remove the Cell Window from the Measuring Cell by grasping it by its outer edge and lifting it out of the Measuring Cell. Remove the Measuring Cell. remove the three M4 x 20 mm screws that secure the Reflector Block to the Measuring Cell.  In the next steps. or scratched windows when reassembling the Measuring Cell. non-abrasive cloth – and set it aside in a safe location – to avoid damaging it. Hold the Measuring Cell vertically so that the Heat Transfer Block is up and remove the three M4 x 12 mm screws that secure the Heat Transfer Block to the Measuring Cell.

Secure the Heat Transfer Block to the Measuring Cell using three M4 x 12 mm screws. While holding the edge of the window. With the Measuring Cell held vertically. carefully place it in the Measuring Cell. 300-1503) in the o-ring groove in the Heat Transfer Block. (The two larger-diameter holes in the Measuring Cell must align with the two larger-diameter holes in the Heat Transfer Block. Wash the Measuring Cell windows with a non-abrasive agent (such as Isopropanol). Tighten the screws evenly. grasp the edge of the window and carefully place it in the o-ring groove in the Measuring Cell. With the Measuring Cell held vertically so that the Reflector Block end of the Measuring Cell is up (the end opposite the sample tube fittings). 300-1503) in the o-ring groove on the flat surface of the Reflector Block. replace them with new ones (Part No. or reagent-grade acetone. 15. 16. Ensure the Measuring Cell Window does not slide out of position when the Reflector Block is placed against the Measuring Cell. Inspect the interior of the Measuring Cell for foreign material and clean its interior using a non-abrasive agent such as Isopropanol and water solution. 300-0281). Rinse the windows with distilled water of at least pharmaceutical grade.13. Install a new o-ring (Part No. and place the Reflector Block onto the Measuring Cell. Orient the Reflector Block with its “peak-line” at 90° to a line through the Sample and Vent Line fittings.) Ensure the Measuring Cell Window does not slide out of position when the Heat Transfer Block is placed against the Measuring Cell. Maintenance & Troubleshooting | 5-15 . If the windows are chipped or cracked. Secure the Reflector Block to the Measuring Cell using three M4 x 20 mm screws. Install a new o-ring (Part No. install a new o-ring by using your thumbs to push it into the o-ring groove until it is completely seated in the groove. Invert the Measuring Cell so the end with the Sample and Vent Line fittings is up and install a new o-ring in the o-ring groove in the Measuring Cell. Allow all components to dry thoroughly before reassembling them. Orient the Heat Transfer Block – with the counter bore access hole at 90° to a line through the fittings – and place it over the Measuring Cell. 14. Flush and thoroughly rinse the interior of the Measuring Cell with distilled water of at least pharmaceutical grade. Tighten the screws evenly.

 NOTE IMPORTANT Positioning of the Heat Transfer Block in the Analyzer Oven is critical. c. 5-16 | Model 909 Single-Gas Analyzer . Orient the Measuring Cell with the Reflector Block to the left. Do not tighten the screw at this time. Align the hole in the Heat Transfer Block with the Sample Cell RTD tip and carefully push the Measuring Cell Assembly toward the Heater Plate. Swing the Measuring Cell toward the Analyzer Oven.17. insert the 3 mm holding screw into the counter bore hole in the Heat Transfer Block and thread it (until it is snug) onto the Sample Cell RTD. Improper positioning of the Heat Transfer Block can result in: • Poor contact between the Sample (Measuring) Cell RTD tip and the Heat Transfer Block. Do not use a ball driver – the head can break off inside the screw. The two ribs of the silicon seal should fit between the inside and outside edges of the Electronics Enclosure wall. and the counter bore access hole in the Heat Transfer Block facing away from the analyzer. To do this: a. Adjust the Measuring Cell/Optical Bench Assembly so that the silicon seal on the Measuring Cell Extension fits firmly into the molded depressions in the Analyzer Oven wall and Electronics Enclosure wall. Using an Allen key. • Poor alignment of the Measuring Cell Extension seal in the Analyzer Oven and Electronics Enclosure cabinets. Reconnect the Measuring Cell to the Sample Cell RTD on the Heater Plate. Adjust the entire Measuring Cell/Optical Bench Assembly as required to firmly seat the Measuring Cell Assembly against the Heater Plate. the sample tube fittings vertical. Replace the screws and tighten them evenly. b.

Remove the Sample and Vent Line caps and reconnect them to their respective locations.  While closing the Electronics Enclosure door. as doing so will damage the threads on the RTD. ! If necessary. 18. use an Allen key to tighten the 3 mm holding screw until the Measuring Cell Assembly does not move when you push and pull on it. NOTE If necessary. verify that proper vertical alignment of the Optical Bench Assembly is maintained. The Measuring Cell Assembly must feel secure against the Heater Plate. Replace the Flame Arrester (black plug) in the counter bole hole in the Heat Transfer Block. Temporarily close the Electronics Enclosure door and tighten its screws to secure the Measuring Cell/Optical Bench Assembly in place. Use appropriate wrenches to reconnect the Sample Line and Vent Line tubing to the Measuring Cell. CAUTION Do not overtighten this screw. Maintenance & Troubleshooting | 5-17 . vertically align the Optical Bench Assembly by loosening the Optical Bench support bracket from the backpan and moving the Optical Bench Assembly up or down as required. General Purpose Analyzers Only: Turn on the Instrument Air supply to the analyzer and open the Aspirator Air valve. d. Gently push and pull on the Measuring Cell Assembly to verify it is not loose. Do not use a ball driver – the head can break off inside the screw. e. After aligning the Optical Bench Assembly. retighten the support bracket. Verify there is no clearance between the Heat Transfer Block and the Sample Cell RTD.

Before WARNING powering up the analyzer. The analyzer enclosure may not be opened when an explosive atmosphere is present. do not apply power to the analyzer or any alternate power sources that supply power to the analyzer components. take appropriate precautions to avoid electrical shock. If an explosive gas atmosphere is present. 20. ! The analyzer may only be energized by using the Purge Bypass Switch with permission of the works manager or his proxy. Perform a leak check on the fittings that you just reconnected by following the procedures under “Sample System Leak Check. General Purpose Analyzer Applications: Open the Electronics Enclosure and close the Analyzer fuse to apply AC power to the analyzer and its Sample Line and SCU temperaturecontrol zone circuits. Do not apply power to the Oven circuitry at this time. Do not apply power to the Oven circuitry at this time. until after the Leak Check has been performed. it will be necessary to work with the analyzer’s covers and doors open. When the analyzer’s covers and doors are open. until after the Leak Check has been performed. Apply main AC power to the analyzer by closing the flameproof power-disconnect switch (breaker). This will apply power to the analyzer and its Sample Line and SCU temperature-control zone circuits. After you are sure there are no leaks. test the area for flammable gases. 5-18 | Model 909 Single-Gas Analyzer . Power up the analyzer: ! For verification and troubleshooting purposes during power up. Hazardous voltages are present inside. return to this procedure and continue with the remaining steps.19. Proceed only when the area is found to be safe.” in Chapter 3. The perWARNING 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”). Purged Analyzer (Hazardous Location) Applications: Insert the key into the Purge Bypass Switch and switch it to the BYPASS position (follow company policy).

” in Chapter 3. Allow the analyzer to warm up to operating temperature and stabilize.0–5. Power up the Analyzer Oven.0 L/min (0. This should take approximately 2 hours. Press Esc to return to the normal RUN mode.1–0. Manually Zero the analyzer as described under “Manually Zeroing the Analyzer.” in Chapter 3. 24. where ‘n’ is the numeric value of the Flow Control Mode recorded earlier. Close and secure all other doors and covers on the analyzer. Maintenance & Troubleshooting | 5-19 . Adjust the Aspirator Drive Air Regulator to achieve normal operating flow rates [3. Open the isolation valve on the Sample Valve (or SCU) to allow sample gas into the analyzer sample system.21. Return the analyzer to the original Flow Control Mode by entering CAL mode and keying in F5 2 Del n Ent. open the isolation valve on the Vent Valve (if applicable).2 SCFM)] as described under “Adjusting the Sample Gas Flow Rate. if not already done. Close the Electronics Enclosure door and tighten the three M6 screws on the door to secure the Optical Bench Assembly in place. Close the Analyzer Oven door (secure its latches). 23. 22. When the analyzer is at operating temperature.

• This procedure assumes that the factory-default password (• •) for entry to CAL or CFG mode is valid.  NOTE For more information about lamp maintenance. About the Source Lamps • Source Lamp 1 is the one closest to the Measuring Cell. window fouling. However. • A new Source Lamp must be aligned to ensure optimal operation of the analyzer. or • The “w Lamp Control” (Automatic Lamp Control) MStatus warning message is displayed on the User Interface Panel. a source lamp can exhibit signs of degradation after 5 to 6 months. • If the analyzer is configured to measure SO2. The cathode and the outer envelope of the Source Lamp are not necessarily concentric or consistent from lamp to lamp. refer to the Model 9xx-Series Analyzers “Lamp Maintenance Manual Supplement” included in the Supplemental Information section of this manual. • If the analyzer is configured to measure H2S.Source Lamp Replacement The typical life span of the source lamps is approximately 9–12 months of continuous operation. the new password must be used. both lamps are Cadmium (Cd). and how the long-term change in these signals can be used to diagnose lamp failure. When Do the Source Lamps Need to be Replaced? Indications of Source Lamp failures are: • Unstable lamp voltage (check voltage levels). and other degradation of the analytical response of the analyzer. This supplement focuses specifically on signals related to the transmission of light through the optical path. If a password has been changed. • Unstable analyzer output under Zero Gas conditions (“w Zero drift” warning error is displayed). 5-20 | Model 909 Single-Gas Analyzer . • The cathode of each Source Lamp must be centred on the optical axis of the Beam Splitter for optimal operation of the analyzer. both lamps are Magnesium (Mg).

Maintenance & Troubleshooting | 5-21 . If a password has been changed.Replacing the Source Lamps Refer to Figure 5-2 for assistance in locating and identifying the hardware components encountered while replacing the source lamps. Lamp Assembly. the new password must be used. Figure 5-2. This procedure assumes that the factory-default password (• •) for entry to CAL or CFG mode is valid.

. test the area around the analyzer for flammable gases.To replace Source Lamps: ! Before proceeding. Open the Electronics Enclosure. 1. Refer to the Fuse Legend on the inside of the analyzer’s Electronics Enclosure door for the locations of these fuses. Proceed only when the area is found to be safe. Power down the analyzer: General Purpose Analyzer Applications: Open the Electronics Enclosure and open the Analyzer and Oven Heater fuses to disconnect power from the analyzer and the Oven circuit. Purged Analyzer (Hazardous Location) Applications: Open the flameproof power-disconnect switch (breaker). Remove the Lamp Socket Assembly. 3. 2. do not power down WARNING the analyzer or any alternate power sources that supply power to the analyzer components. Loosen the Lamp Clamping Screws and remove the faulty lamp(s) by rotating and sliding it downward. ! WARNING Wait 5 minutes to allow the high-voltage capacitors in the sourcelamp power supply to discharge. Grasp the glass envelope when rotating or pulling the source lamp. ! CAUTION 5-22 | Model 909 Single-Gas Analyzer Do not rotate or pull on the base of the source lamp because this may cause it to separate from the glass envelope. If an explosive gas atmosphere is present. Loosen the Lamp Retaining Screw and rotate the Lamp Retaining Bracket 90 degrees.

Close the Analyzer fuse to apply AC power to the analyzer and the Oven Heater circuitry. 7. Do not overtighten. When the analyzer’s covers and doors are open. The lamp assembly is fragile and should be handled with care. Maintenance & Troubleshooting | 5-23 . take appropriate precautions to avoid electrical shock. the spring should not be collapsed. The lamp must be allowed to move so it can be adjusted later in this procedure.4. Install the new lamp(s). General Purpose Analyzer Applications: Open the Electronics Enclosure and close the Oven Heater fuse. Reinstall each Lamp Socket Assembly. Note that power is also applied to the Sample Line and SCU temperature-controlled circuits when AC power is applied to the analyzer. Make sure that the narrow end of each lamp is pushed completely into the holder. it is very important not to touch the lamp window because residual oils from the fingers will absorb ultraCAUTION violet light. ! When handling a source lamp. 5. WARNING Before powering up the analyzer. test the area for flammable gases. Rotate the Lamp Retaining Bracket 90 degrees (to its original position) and tighten the Lamp Retaining Screw to secure the Lamp Socket Assemblies. the spring should not be collapsed. The window is the flat surface at the end of the narrow glass tube. Lightly tighten each Lamp Clamping Screw to secure each lamp. If an explosive gas atmosphere is present. Proceed only when the area is found to be safe. Do not overtighten. do not apply power to the analyzer or any alternate power sources that supply power to the analyzer components. Hazardous voltages are present inside. Power up the analyzer: ! It is necessary to work with the Electronics Enclosure door open after replacing source lamps so that adjustments can be made to the lamps. 6.

8. The analyzer enclosure may not be opened when an explosive atmosphere is present. While working from the User Interface Panel. Enter F5 2 and record the current numeric value displayed for Flow Control Mode. Manually force the analyzer to zero the sample system with Zero Gas (Continuous Zero Gas Flow) by using the keypad on the User Interface Panel to enter F5 2 Del 10 Ent from CAL mode. b. press F6 • and then enter the CALibration mode password “• •” at the “PSWD0” prompt. The perWARNING 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”). d. c.) Press Ent to enter CAL mode. To do this: a. (If PSWD0 [• •] has been changed from the factory default. NOTE Allow the analyzer to stabilize for 5 minutes before continuing. check and record the current sample system operating mode (Flow Control) and then change it to Continuous Zero Gas Flow mode. Press Ent again to return to CAL mode normal screen and then Esc to return to RUN mode. 5-24 | Model 909 Single-Gas Analyzer . Allow the analyzer to purge with Zero Gas for 2–3 minutes and then close the isolation valves on the Sample Probe Valve and Vent Line Valve (if used. or cap the Sample and Vent Lines) to isolate the analyzer from the stack duct. From RUN mode. Apply main AC power to the analyzer by closing the flameproof power-disconnect switch (breaker). ! The analyzer may only be energized by using the Purge Bypass Switch with permission of the works manager or his proxy. disconnect the Vent Pipe at the Vent port in the Analyzer Oven and temporarily install a cap. use the new password.  If your application disperses the used sample gas to atmosphere via a stack or low pressure flare header. Purged Analyzer (Hazardous Location) Applications: Insert the key into the Purge Bypass Switch and switch it to the BYPASS position (follow company policy).

75 and 1. and “r. 11. where “z” is Filter 1 or Filter 2.rrr” is the Reference PMT signal. The Alc Enable function must be off to ensure the analyzer is not making automatic adjustments while you are setting the Measure and Reference signals to operate at optimum ratios to each other. small movements. For detailed information about performing an Auto-Setup and how to make adjustments to obtain a completion number within this range. Slowly rotate the new lamp to obtain the maximum signal from the Measure PMT (value on the left side of the User Interface Panel).rrr” is displayed. Turn off the Automatic Lamp Control function (Alc Enable) by pressing F2 7 Del 0 Ent Ent from CFG mode. use slow.25.mmm r.mmm” is the Measure PMT signal. ! If either the Measure (m. Loosen the Lamp Retaining Screw and rotate the retaining bar 90 degrees. Continue with this procedure only after the completion number is between 0. decrease the PMT level (press F1 4 from CFG mode to view the PMT level). 12. Loosen the Locking Screw located between the two source lamps.  NOTE Because the Automatic Lamp Control (Alc Enable function) is turned Off. as described in the following steps. and then initiate an Auto-Setup by pressing F1 •. refer to “Auto-Setup” later in this chapter.mmm) or Reference (r. the displayed signal may not be perfectly steady. Display the PMT signal by pressing F6 1 z. where “z” is the filter location.9. press F6 1 2. “m. the PMT signal for Filter 1 is displayed by pressing F6 1 1. A normal completion is 0. Since the User Interface Panel is updated at one-second intervals.000 VDC at any time while alignCAUTION ing it.25. Enter CFG mode by entering F6 – • • Ent (or use new password. For Lamp 2. if it was changed).rrr) PMT signal becomes equal to or greater than 10.75. 13. Example: If replacing Lamp 1. Allow the signals to stabilize and continue. ±0. 10. The PMT signal values displayed on the User Interface Panel are updated at one-second intervals. 14. The message “SIGz m. Slightly loosen the Lamp Clamping Screw. pausing each turn to view the new value. Maintenance & Troubleshooting | 5-25 .

Purged Analyzer (Hazardous Location) Applications Only: Return the Purge Bypass Switch to the ACTIVE position and remove the key (follow company policy). 24. Close and secure the Electronics Enclosure with its screws. 25. Return the analyzer Flow Control Mode to Analyzer Control (automatic) by entering CAL mode and keying in F5 2 Del 0 Ent.00. the springs should not be collapsed. The message “SAVE CONFIG?” will appear. Return the Lamp Retaining Bracket to its original position and secure it using the Lamp Retaining Screw. 5-26 | Model 909 Single-Gas Analyzer . For the second lamp. Tighten the Locking Screw located between the two source lamps. 19.25. 20. depends on application). 22.25. Continue with these procedures only after the completion number is between 0. Do not overtighten these screws. Adjust the Aspirator Drive Air Regulator to achieve normal operating flow rates. Remove the cap from the Vent Line and reconnect it to the Sample Vent Pipe. repeat Steps 10.15. 16. For detailed information about performing an Auto-Setup and how to make adjustments to obtain a completion number within this range. Remove the cap from the Sample Line and reconnect it to the SCU to allow sample gas from the stack duct into the analyzer sample system. Press Esc Ent. 26. Tighten the Lamp Clamping Screw to secure the lamps.75–1. and 15. To obtain the maximum signal from the Measure PMT. adjust the Lamp Adjusting Screw for the lamp that is being replaced. Allow the analyzer to operate for 30–45 minutes and then initiate another Auto-Setup. Zero and Span the analyzer (Span function is optional. The procedure is complete. ±0. 18. refer to “Auto-Setup” later in this chapter. 21. 13. A normal completion is 1. Press Esc to return to RUN mode. and return to RUN mode normal display. Return to this procedure after the Auto-Setup is complete. 23. which automatically turns on the Alc Enable function. 17. Press Ent to save the new configuration.

for details on acceptable levels of these two signals. Refer to “PMT Level and PMT Balance. When the Auto-Setup is initialized. the Measure path PMT typically has a slightly higher gain than does the Reference path PMT. optical filters. The most likely cause of a higher-than-normal completion number is misplacement of the PMTs in their respective sockets.  NOTE IMPORTANT Although a good completion number is indicative of a successful Auto-Setup.” following this section. where “n” is “0” (Off) or “1” (On). A normal completion is 1. Always initiate an Auto-Setup after any lamps.00. The most common cause of an abnormal completion number is initiating Auto-Setup when the Measuring Cell has not been properly backpurged. This function is available in CFG mode only. To change the status of this function. press F2 7 from RUN mode. or PMTs have been installed or replaced. do not rely on it solely. Auto-Setup Completion Number At the end of every Auto-Setup the analyzer displays a completion number that is the product of the lowest and highest transmittance.25. If the completion number is outside of this range it is an indication that the Measure and Reference PMT signals are not at optimum ratios to each other. Maintenance & Troubleshooting | 5-27 . Although the sensitivity of each PMT is similar. Swapping the PMTs from the factory-set positions can produce higher-than-normal completion numbers. To view the current status of this function.Auto-Setup The Auto-Setup function optimizes PMT (photomultiplier tube) gains and the source lamp currents after the source lamps have been replaced or adjusted. the Automatic Lamp Control (Alc Enable) function is automatically turned on. enter CFG mode and press F2 7 Del n Ent Ent. Always check the PMT Level and PMT Balance after every AutoSetup. ±0. This results in completion numbers lower than normal.

are the source lamps aligned? • Have there been any leaks from the Measuring Cell? If so.0 VDC. F1 5 from RUN mode) after completion of the AutoSetup. after completion of the Auto-Setup. 5-28 | Model 909 Single-Gas Analyzer . It is possible to achieve an acceptable completion number.. The range of operation for both these parameters is 0–10 VDC. yet have an unacceptable PMT Level and/or PMT Balance signal. If. - The mirrors.0–7. these signals are outside the normal range of operation. Normal values for both. Severe changes in PMT Level and PMT Balance are as important to notice as the absolute value.e. check the condition of: - The Lenses and Optical Filters in the Optical Bench. PMT Balance adjusts the gain of the two PMTs in opposite directions. The PMT Level signal adjusts the gain of both PMTs simultaneously in the same direction. The analyzer will function with values outside this range. Always check both of these values (F1 4. but it is a sign that a change has likely occurred in the transmission of light within the Optical Bench Assembly.PMT Level and PMT Balance PMT Level and PMT Balance are adjusted only during the Auto-Setup sequence. after a successful Auto-Setup. and o-rings in the Measuring Cell (including Reflector Block) and Beam Splitter Assembly. check: • Was the Auto-Setup done with Zero Gas flowing through the sample system? • Are the Measuring Cell windows clean? • Are the PMTs in their original sockets? (i. is the higher gain PMT in the Measure path?) • Do the source lamps need replacement? If not. windows. are from 4.

• Ensure the lamp sockets are attached securely to the lamps. where “z” = 1.2.. • Make sure the source lamps are not burned out. Maintenance & Troubleshooting | 5-29 . • Make sure the lamp power supply cables are connected and not damaged. two error messages can appear: • LVL adjust fault • BAL adjust fault If during the operation of the Auto-Setup either the PMT Level adjustment or PMT Balance signal goes to minimum or maximum. • Display the source lamp pulse current-control signal for each filter location. Correct any faults and initiate the Auto-Setup function. J102) and ribbon (J103) cables are connected and not damaged. • Ensure the Measuring Cell is clean. If either or both of these messages appear: • Ensure that the Measuring Cell was backpurged with Zero Gas. • Ensure the lamps are inserted completely into the detector assembly. To display these signals. • Ensure the PMT high-voltage (J101. the corresponding adjust fault message appears on the User Interface Panel. press F1 1 z from RUN mode. • Make sure the Measuring Cell windows are clean and not damaged.Auto-Setup Fault Messages and Corrective Action While the Auto-Setup function is in progress.

Upon completion of the Auto-Setup. • Adding a jumper decreases the completion number. at least one must be present at all times. the new password must be used. (If PSWD1 has been changed from the factory default.75–1. 4. “Completion= b” 3. Note that when changing the jumpers: • Increasing the jumper position increases the completion number.25.25.  NOTE The Auto-Setup function starts immediately upon entering F1 •. The following six messages appear during the process: 1. if the value of “b” in Message 6 is not between 0. or change the position of the jumper on P301 for a drastic change. P301 has two jumper positions. Do not press any keys while it is in progress.75–1. key in from the User Interface Panel: 1.Initiating an Auto-Setup To initiate an Auto-Setup. • Decreasing the jumper position decreases the completion number. move the jumper on headers P300 or P301 of the Optical Bench board to an alternate position. 5-30 | Model 909 Single-Gas Analyzer . “Adjusting LMP” 6. Press F6 – • • Ent to enter CFG mode. “Adjusting LMP” 3.) 2. but only one jumper position is used. “Adjusting LVL” 2.  NOTE P300 may have up to four jumpers installed. “Adjusting LVL” 5. install another jumper on P300. “Adjusting BAL” 4. Press F1 • to start the Auto-Setup. Repeat this procedure until “b” is between 0. The process takes about 5 minutes to complete. Do not put both jumpers on P301. Restart Auto-Setup (press F1 •).

Press Ent for “Yes” (to save the new configuration). There are six jumper positions that can accommodate one jumper each. and PMT Balance Changing the jumper position provides coarse gain adjustment of the Reference PMT and therefore changes the completion number result. PMT Level. and PMT Balance. decreases the PMT Level.75–1. The message “SAVE CONFIG?” will appear.25. to a small degree. Figure 5-3 lists the effect on completion number in relation to different jumper positions. After the value of “b” is between 0. At least one jumper is required. This reduces the completion number. press Ent Esc. The opposite occurs if jumpers are removed or if a single jumper is moved up from Position 1 to Position 6. PMT Level. Adding jumpers increases the supply voltage available to the Reference path PMT. Manipulating the Completion Number. and then press Esc to return to the RUN mode normal display. Maintenance & Troubleshooting | 5-31 .5. increases the PMT Balance and. 6.

NOTE 5-32 | Model 909 Single-Gas Analyzer Lower Completion number x x x 6 higher Completion number .Jumper Positions P300 higher PMT balance P301 1 2 3 4 x x x x x x x x x x x x 5 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 Figure 5-3. Lower PMT balance  x x x x x x x At least one jumper must be in P300 and P301 at all times. Optical Bench board P300/P301 jumper positions.

Maintenance & Troubleshooting | 5-33 . Information on how to do this is described under “Manually Zeroing the Analyzer” in Chapter 3. and how to ensure proper positioning and mounting of the Heater Plate Assembly while replacing it. 2. Enter F5 2 to display the FlowCtrl (Flow Control) Mode screen. Record the numeric value displayed for FlowCtrl. While working from the User Interface Panel. Generally. there is no maintenance required for the Heater Plate. unless any of these components fail.Heater Plate Heater Cartridge and RTD Replacement Replacement of the Heater Plate Assembly’s Heater Cartridges and RTDs is sometimes required as part of repairs to the analyzer. Power down the analyzer: ! Before powering down the analyzer. test the area around the analyzer for flammable gases. To replace the Heater Cartridges and RTDs in the Heater Plate Assembly: 1. do not WARNING power down the analyzer or any alternate power sources that supply power to the analyzer components. From this screen. This procedure describes how to remove the Heater Plate. replace its Heater Cartridges and RTDs. you can view the current operating mode. 4. To do this: a. If an explosive gas atmosphere is present. check and record the current Flow Control Mode. Press Ent to display CAL mode. 3. Manually zero the analyzer. From RUN mode. enter F6 • and then enter the CALibration mode password • • (at the “PSWD0” prompt). After the zero process is complete. cap the Sample Line at the SCU and cap the Vent Line at the Sample Vent Pipe. b. Proceed only when the area is found to be safe.

! WARNING The analyzer sample system will be under positive pressure. ! WARNING Wait 5 minutes to allow the high-voltage capacitors in the sourcelamp power supply to discharge. Open the Electronics Enclosure. Note that disconnecting AC power from the analyzer also disconnects power from the Sample Line and SCU temperature-control zone circuits. Purged Analyzer (Hazardous Location) Applications: The Instrument Air supply must always remain on for the Purge Bypass Switch to operate properly. 7. Purged Analyzer (Hazardous Location) Applications: Open the flameproof power-disconnect switch (breaker). 6. Wearing insulated gloves. The Analyzer Oven enclosure and components within the Analyzer Oven are hot. 5. Pull the Sample and Vent Lines out of the Analyzer Oven. disconnect the Sample and Vent Line tubes from the Sample Inlet and Vent Outlet tubes on the left side of the Analyzer Oven. open the Analyzer Oven door and allow the Analyzer Oven to cool down enough to ensure safe handling of the Heater Plate and other components inside the Oven. Refer to the Fuse Legend on the inside of the analyzer’s Electronics Enclosure door for the locations of these fuses. General Purpose Analyzer Applications: Open the Electronics Enclosure and open the Analyzer and Oven Heater fuses to disconnect power from the analyzer and the Oven circuit. After the Analyzer Oven has cooled down enough to work on. take precautions to avoid burning yourself. Disconnect the Sample and Vent Line tubes from the Measuring Cell. General Purpose Analyzers Only: Turn off the Instrument Air supply to the analyzer and then close the Aspirator Air valve. Disconnect the Aspirator Air tube from the Aspirator Air fitting inside the Analyzer Oven. 5-34 | Model 909 Single-Gas Analyzer .

8. Remove the Measuring Cell Assembly from the Heater Plate. grasp the Measuring Cell Assembly and carefully pull it straight out from the Heater Plate. Remove the Seal Cover from the Seal Body. Maintenance & Troubleshooting | 5-35 . Remove the two M6 x 16 and two M6 x 40 screws that secure the flameproof Seal Cover to the flameproof Seal Body (see Figure 5-4). and Ground wires from the Seal PWB Assembly. Disconnect the RTD. away from the analyzer. 10. Once the Heat Transfer Block has cleared the Sample (Measuring) Cell RTD. Take note of where each length is used and be sure to replace the appropriate screws in their original locations when reassembling the Measuring Cell later. Also. Wearing insulated gloves. Move the C-clip from its groove in the Thermal Insulating Tube to the space slightly above the groove (see Figure 5-5). The holding screw used to secure the Measuring Cell to the Heater Plate is located in the counter bore hole in the Heat Transfer Block. This will be useful later when replacing the Heater Cartridges and RTDs. located within the Seal Body. Heater Cartridge. 11. 9. Loosen the gland nut on the Seal Body. Record the termination point of each wire on the Seal PWB Assembly. using the hinge mechanism that mounts it to the Electronics Enclosure backpan. Remove the black plug and then remove this screw using only an Allen key. Do not use a ball driver – the head can break off inside the screw.  NOTE Various lengths of screws are encountered during disassembly. swing the Optical Bench Assembly outward. tag the wire(s) of any RTDs and/or Heater Cartridges that will be re-used (if any) with their termination points.

5-36 | Model 909 Single-Gas Analyzer .Figure 5-4. Flameproof Heater/Seal Assembly. 100-1098-1.

overall assembly. Flameproof Heater/Seal. WX-14324-1.Figure 5-5. Maintenance & Troubleshooting | 5-37 .

this will partially remove the wires from the tube. NOTE 13. a. Use a 5 mm ball driver to remove the eight M6 x 25 hex socket head cap screws (four on each side) that secure the two halves of the Heater Plate together. Remove the four M6 x 35 hex socket head cap screws and lock washers that secure the Heater Plate to the Oven wall. Separate the two halves of the Heater Plate and carefully pull all of the wiring through the Lower Heater Plate. The Heater Plate is ready to be removed from the Oven. Position the wires in the Seal Assembly in a way to prevent damage to them when removing the Heater Plate Assembly. Remove the Oven Plug (see Figure 5-5). Rotate the Seal Body/Thermal Insulating Tube away from the analyzer to allow more room to remove the Heater Plate. Disassemble the Heater Plate Assembly and replace the Heater Cartridges and RTDs. Take care to avoid damaging the wires. Unscrew the Thermal Insulating Tube from the Lower Heater Plate and move it downward.12. Move the Heater Plate Assembly to a work bench or another similar area where it can be disassembled to replace the Heater Cartridges and RTDs. 14. 5-38 | Model 909 Single-Gas Analyzer .  The Thermal Insulation Tube can remain in the Seal Body. Tilt the top of the Heater Plate toward you and pull the Heater Plate Assembly up and out of the Analyzer Oven. 15.

grip the tip with channel-lock pliers. d. Use short needle-nose pliers to remove the RTD Base. 5-6. Replace the RTDs. To replace the external Sample Cell RTD: Push the RTD wire through the Upper Heater Plate.  NOTE IMPORTANT If replacing the external RTD (“Sample Cell RTD”). Apply Loctite 271 (AMETEK Part No. c. Cut the RTD head off the faulty RTD. 300-4478) on the small (lower) threads of the RTD Base (see Figure 5-7). Maintenance & Troubleshooting | 5-39 . do not remove the RTD wire at this time. Repeat this procedure for each RTD that is being replaced. Refer to Figures 5-5. Tape the termination end of the new RTD wire to the RTD end of the old RTD wire. unscrew the RTDs from the Upper Heater Plate. Use the old wire to pull the wire on the new RTD through the Upper Heater Plate as you remove the old wire. Note that the “Sulfur Condenser RTD” is an option used only for Model 900 and Model 930 Analyzers with an oven mounted SKO (Sulfur Knock-out). Rotate the RTD Assembly counter-clockwise 3 or 4 turns (carefully twisting the wire in the process – DO NOT over stress the wire) and then screw (clockwise) the RTD Base into the Upper Heater Plate. wrap a small piece of rubber around the RTD tip.b. Hand-tighten the RTD. label the wire from the RTD on the right side “Overtemp” and the RTD on the left side “Heater” (see Note in Figure 5-5). If replacing the internal RTDs (Overtemp and Heater). Remove the faulty RTD(s): To remove a RTD. Looking from the front of the Heater Plate. Remove the two Heater Cartridges from their channels in the Upper Heater Plate. and loosen the RTD tip. and 5-7 when replacing the RTDs. To replace the internal Overtemp and Heater RTDs: Thread each RTD base into the bottom of the Upper Heater Plate and tighten each one using short needle-nose pliers.

Install the Heater Cartridges in the Heater Cartridge channels in the Upper Heater Plate and tape together the two wires from each heater to ensure each heater is wired to the proper termination points. 300-5292) around all of the wires and into the bottom hole in the Lower Heater Plate to protect the wires from getting damaged during handling. Apply Loctite 271 on the large (upper) threads of the RTD Base. Use a crimping tool to crimp an uninsulated ring terminal on the wire. ensure all of the wires are carefully positioned in the wire channel in the Lower Heater Plate. Heater Cartridges. wrap a small piece of rubber around it. Using short needle-nose pliers. f. Reassemble the two halves of the Heater Plate. To protect the RTD Tip. e. Strip 1/8" insulation from the end of the 30-inch length of high temperature wire (AMETEK Part No. Looking from the front of the Heater Plate. and tighten it until it is snug. label the wire from the RTD on the right-centre side “Sample Cell” (see Figure 5-5). Secure the ring terminal to the bottom of the Upper Heater Plate with a M4 x 8 hex socket button head cap screw (AMETEK Part No. 300-5730). With the two halves of the Heater Plate facing each other. Tighten the screws with a 5 mm ball driver. If the Ground wire is damaged. replace it. being careful not to pinch any wires between the two plates. 300-4182). and secure them together with eight M6 x 25 hex socket head cap screws. and Ground through the hole in the Lower Heater Plate (that leads to the Thermal Insulating Tube). h. . tighten the RTD Base until it is snug. prepare the Oven Enclosure for the replacement of the Heater Plate. lightly grip it with channel-lock pliers. g. Next. Tighten it with a 2.  NOTE 5-40 | Model 909 Single-Gas Analyzer The Heater Cartridge and RTD replacement is now complete. Feed all wires from the RTDs.5 mm ball driver. Install a 3/4" anti-short (AMETEK Part No. Turn the RTD Tip clockwise onto the RTD Base and hand-tighten it.  NOTE The hole for the oven mounted Sulfur Condenser RTD – for Model 900 and Model 930 Analyzers with an oven mounted SKO (Sulfur Knock-out) – is plugged with a Heater Blanking Plug (AMETEK Part No. 300‑0265). 300‑0006) and a #8 shake-proof washer (AMETEK Part No.

Gently push and pull on the Heater Plate while tightening the screws. Ensure that the front face of the oven liner is flush with the front face of the outer shell of the Analyzer Oven. This will ensure it is properly seated against the Oven wall. Align the Heater Plate with the mounting holes on the back of the Analyzer Oven and replace the four lock washers and M6 x 35 hex socket head cap screws to secure the Heater Plate to the Oven wall.Figure 5-6. Tilt the Heater Plate backward until it is resting against the Oven wall. With the top of the Heater Plate tilted toward you. Maintenance & Troubleshooting | 5-41 . Flameproof Heater/ Seal. place the bottom of the Heater Plate in the bottom of the Analyzer Oven while taking care to ensure the wires are not damaged. 17. 16. assembly layout. WX-14324-1A.

WX-14280. Rotate the Seal Body/Thermal Insulating Tube toward the Analyzer Oven until the top of the Thermal Insulating Tube is in line with the threaded holes in the bottom of the Oven. Tighten the tube until an increase in resistance is felt. Tighten the gland nut on the Seal Body. Do not overtighten it. taking care not to crossthread the threads. 20. RTD assembly diagram. 19. Replace the Oven Plug.Figure 5-7. Guide the wires from the Heater Plate through the Thermal Insulating Tube. 5-42 | Model 909 Single-Gas Analyzer . Ensure the threads of the Thermal Insulating Tube are clean and then thread the tube back into the Heater Plate. 18.

 NOTE IMPORTANT Positioning of the Heat Transfer Block in the Analyzer Oven is critical. To do this: a. and the counter bore access hole in the Heat Transfer Block facing away from the analyzer. Adjust the Measuring Cell/Optical Bench Assembly so that the silicon seal on the Measuring Cell Extension fits firmly into the molded depressions in the Analyzer Oven wall and Electronics Enclosure wall. Adjust the entire Measuring Cell/Optical Bench Assembly as required to firmly seat the Measuring Cell Assembly against the Heater Plate. Using an Allen key. Do not use a ball driver – the head can break off inside the screw. retighten the support bracket. The two ribs of the silicon seal should fit between the inside and outside edges of the Electronics Enclosure wall. verify that proper vertical alignment of the Optical Bench Assembly is maintained. • Poor alignment of the Measuring Cell Extension seal in the Analyzer Oven and Electronics Enclosure cabinets. Reconnect the Measuring Cell to the Sample Cell RTD on the Heater Plate.21. c. Orient the Measuring Cell with the Reflector Block to the left. the sample tube fittings vertical. b. vertically align the Optical Bench Assembly by loosening the Optical Bench support bracket from the backpan and moving the Optical Bench Assembly up or down as required. If necessary. Swing the Measuring Cell toward the Analyzer Oven. While closing the Electronics Enclosure door. Align the hole in the Heat Transfer Block with the Sample Cell RTD tip and carefully push the Measuring Cell Assembly toward the Heater Plate. Do not tighten the screw at this time. Replace the screws and tighten them evenly.  NOTE Temporarily close the Electronics Enclosure door and tighten its screws to secure the Measuring Cell/Optical Bench Assembly in place. After aligning the Optical Bench Assembly. insert the 3 mm holding screw into the counter bore hole in the Heat Transfer Block and thread it (until it is snug) onto the Sample Cell RTD. Improper positioning of the Heat Transfer Block can result in: • Poor contact between the Sample (Measuring) Cell RTD tip and the Heat Transfer Block. Maintenance & Troubleshooting | 5-43 .

as doing so will damage the threads on the RTD. Replace the Flame Arrester (black plug) in the counter bole hole in the Heat Transfer Block. Replace the Seal Cover over the Seal Body and secure it to the Seal Body by first tightening the two M6 x 16 screws on the left face. Refer to Figure 5-8 for the locations of the termination points. Reconnect the Aspirator Air tube to the Aspirator Air fitting inside the Analyzer Oven. Do not overtighten this screw. Use appropriate wrenches to reconnect the Sample Line to the Sample Inlet tube in the Analyzer Oven and the Vent Line to the Vent Outlet tube. 24. replace the two M6 x 40 screws on the top of the cover. Route the Sample and Vent Lines through their respective holes on the left side of the Analyzer Oven. Do not use a ball driver – the head can break off inside the screw. 23. use an Allen key to tighten the 3 mm holding screw until the Measuring Cell Assembly does not move when you push and pull on it. e. Terminate the Heater Plate RTD and Heater Cartridge wires (and the Ground wire. The Measuring Cell Assembly must feel secure against the Heater Plate. f. Move the C-clip back to its original position in the groove in the Thermal Insulating Tube. General Purpose Analyzers Only: Turn on the Instrument Air supply to the analyzer and open the Aspirator Air valve. 5-44 | Model 909 Single-Gas Analyzer .d. Use appropriate wrenches to reconnect the Sample Line and Vent Line tubes to the fittings on the Measuring Cell. g. If necessary. Next. Gently push and pull on the Measuring Cell Assembly to verify it is not loose. 22. if it is also being replaced) to the Seal PWB Assembly. Verify there is no clearance between the Heat Transfer Block and the Sample Cell RTD.

WX-14161.Figure 5-8. Maintenance & Troubleshooting | 5-45 . Oven Heater and Temperature Sensor wiring.

Do not apply power to the Oven circuitry at this time. until after the Leak Check has been performed. Do not apply power to the Oven circuitry at this time.25. Purged Analyzer (Hazardous Location) Applications: Insert the key into the Purge Bypass Switch and switch it to the BYPASS position (follow company policy). do not apply power to the analyzer or any alternate power sources that supply power to the analyzer components. Power up the analyzer: ! For verification purposes during power up. If an explosive gas atmosphere is present. 5-46 | Model 909 Single-Gas Analyzer . This will apply power to the analyzer and its Sample Line and SCU temperature-control zone circuits. The perWARNING 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 atmosphere is present. Hazardous voltages are present inside. take appropriate precautions to avoid electrical shock. When the analyzer’s covers and doors are open. Before powering up WARNING the analyzer. it will be necessary to work with the analyzer’s covers and doors open. ! The analyzer may only be energized by using the Purge Bypass Switch with permission of the works manager or his proxy. test the area for flammable gases. Apply main AC power to the analyzer by closing the flameproof power-disconnect switch (breaker). General Purpose Analyzer Applications: Open the Electronics Enclosure and close the Analyzer fuse to apply AC power to the analyzer and its Sample Line and SCU temperaturecontrol zone circuits. until after the Leak Check has been performed. Proceed only when the area is found to be safe.

0 L/min (0. Allow the analyzer to warm up to operating temperature and stabilize. Maintenance & Troubleshooting | 5-47 . Power up the Analyzer Oven by closing its fuse (refer to the Fuse Legend). Open the isolation valve on the Sample Valve (or SCU) to allow sample gas into the analyzer sample system.0–5. Close and secure all other doors and covers on the analyzer.26. 29. When the analyzer is at operating temperature. Close the Electronics Enclosure door and tighten the three M6 screws on the door to secure the Optical Bench Assembly in place. where ‘n’ is the numeric value of the Flow Control Mode recorded earlier.” in Chapter 3. if not already done. After you are sure there are no leaks. 30.” in Chapter 3.” in Chapter 3. 28. Return the analyzer to the original Flow Control Mode by entering CAL mode and keying in F5 2 Del n Ent. return to this procedure and continue with the remaining steps. Adjust the Aspirator Drive Air Regulator to achieve normal operating flow rates [3. Close the Analyzer Oven door (secure its latches). 27. Perform a leak check on the fittings that you just reconnected by following the procedures under “Sample System Leak Check. This should take approximately 2 hours. open the isolation valve on the Vent Valve (if applicable).1–0.2 SCFM)] as described under “Adjusting the Sample Gas Flow Rate. Manually Zero the analyzer as described under “Manually Zeroing the Analyzer. Press Esc to return to the normal RUN mode.

the RTD mounting locations (whether RTDs are installed or their holes are plugged). defect-free threads are essential to ensure a flameproof connection. These parts include the joining surfaces of the Heater Plate. During each analyzer maintenance. the joining surfaces of the Seal Body and its cover. if the gap exceeds this value. if the gap exceeds this value. The gap must not exceed 0. seal entries. contact AMETEK for advice.1 mm. should an internal explosion occur. and National/ EU regulations. The gap must not exceed 0. 5-48 | Model 909 Single-Gas Analyzer . as specified by the WARNING Owner Company. use a feeler gauge to check the flamepath gap of the Heater Plate Assembly flange (upper/ lower Heater Plate joining surfaces. or wear) to any flamepath. See Warning below.Examining and Caring For the Flamepaths The analyzer is designed with flamepaths that will prevent flame propagation from within the analyzer and its Ex d Disconnect Enclosure to the outside. • All separable joints in the Heater Plate Assembly and Seal Body. all safety standards and procedures must be followed. ! CAUTION 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. Contact AMETEK immediately if there is any doubt about the integrity of any flamepath.1 mm. contact AMETEK for advice. ! When performing equipment maintenance in hazardous areas. local electrical-inspection authority. The flamepaths on the analyzer consist of: • The Ex d Disconnect Enclosure joining surfaces (enclosure door and housing) and its cable entry ports. Replace the parts immediately if damage or wear is apparent. Clean. See Warning below. Applying power to an analyzer WARNING with a damaged flamepath is dangerous and could result in serious injury or death and/or serious damage to equipment. and both the threaded and cylindrical end of the Thermal Insulation tube between the Heater Plate and Seal Body. ! Do not apply power to the analyzer if there is damage (scratches. indentations. use a feeler gauge to check the flamepath gap of the Disconnect Enclosure flange (enclosure door and housing joining surfaces). inside the Analyzer Oven). During each analyzer maintenance. and pressure switch entries.

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. shut off the power to the analyzer and all alternate power supplies (if used). Before performing maintenance on the analyzer. ! Before opening the Disconnect Enclosure. gently clean these areas with a soft. indentations. Also. or other damage. Maintenance & Troubleshooting | 5-49 . the agent must be nonabrasive and must not atCAUTION tack aluminum (example. Following any maintenance and/or cleaning – and after the cleaning fluid has evaporated completely – immediately close the Disconnect Enclosure. a suitable agent is Isopropanol). Before closing the door.). inspect the flamepath for scratches. ! While the Disconnect Enclosure is opened for maintenance or repair. etc. This will reduce the risk of inadvertently scratching or damaging the flamepath. explosive gas atmosphere is not present. ! If it is necessary to use a cleaning agent. follow all necessary safety procedures to ensure the area is nonhazardous (main power to the WARNING analyzer is off. make sure the power to the analyzer is off. take extreme care to avoid scratching or damaging the joining surfaces CAUTION (flamepath).Disconnect Enclosure Flamepath (Joining Surfaces) Any time the Ex d Disconnect Enclosure is opened. nonabrasive cloth and make sure they are free of debris.

what the errors mean. which makes this an excellent diagnostic tool.  NOTE Additional diagnostics screens can be viewed from the User Interface Panel if problems cannot be corrected by performing general diagnostics. and action to take to correct the errors. most troubleshooting and diagnostics can be done by working from the User Interface Panel on the front of the analyzer’s Electronics Enclosure. refer to the RUN / CFG Mode Keystrokes and CAL Mode Keystrokes descriptions in Chapter 4.g. These alarm conditions can be viewed at any time from the User Interface Panel. Alarms that have been reset or corrected are stored in their corresponding History Buffers (HCHist or MCHist). Descriptions of current alarm conditions can be viewed in the HStatus (F5 4 1. Errors generated by operating parameters that exceed the factory-set parameter set points are displayed on the User Interface Panel screen. a reverse-video S ( S ) is displayed on the upper-right line of the User Interface Panel. also in RUN mode. These diagnostics are indicated by ‘**’ preceding their definitions. The error description is preceded by “w” for a WARNING (e.Troubleshooting and Diagnostics This section describes how the Model 909 Analyzer detects and displays errors associated with its operation.. Types of Errors (Alarms) When errors are detected. 5-50 | Model 909 Single-Gas Analyzer . “f Comm Fault”)..7) sub-menus of RUN mode. These errors are generated by either the Host Controller board (HStatus) or the Microcontroller board (MStatus). For more information about these diagnostics functions.g. Typical diagnostic errors to watch for include sample and temperature-control related errors. This section also discusses how to view the alarms from the User Interface Panel and how to reset the analyzer if a system reset is required.8) and MStatus (F5 5 1. Generally. “w Out of Range”) or “f ” for a FAULT (e.. The History Buffers will store up to a maximum of nine alarms in each.. Viewing Errors on the User Interface Panel The analyzer sample and temperature control system incorporates a built-in diagnostics function that continuously monitors the operation of all analyzer operating parameters.

While viewing the error status of either board. the message “HSz OK” (for Host Controller board errors) or “MSz OK” (for Microcontroller board errors) appears next to its associated number. Maintenance & Troubleshooting | 5-51 . Press other numbers on the keypad within this range to view the status of other errors. Fault errors also cause the Normal/Fault relay contacts to switch. Press other numbers on the keypad within this range to view the status of other errors. the alarm indicator S is displayed on the screen when an warning error is detected by the system. and the sample system will automatically switch to Backpurge mode if the current Flow Control Mode setting is “0” (Analyzer Control).. press any key in the range of 1. As indicated earlier. Viewing Current Error Messages To view the current status of error messages detected by the Host Controller or Microcontroller board. press Esc or enter a new Function command. the alarm indicator S is displayed on the screen when a fault error is detected by the system.. follow the command syntax example below: 1. To view the Microcontroller board error status (MS).7. press any key in the range of 1.8. 3. Fault Alarms Fault Alarms indicate that a failure has occurred and the analyzer is not operating properly – the results are not valid. If an error is current. its description will be displayed next to its associated number. If the error condition does not exist.There are two categories of alarms: Warning Alarms Warning Alarms indicate that the analyzer requires servicing – the data may be suspect under this condition. press the appropriate numeric keys to view the status for the error associated with that keystroke. For the Host Controller board. press F5 4. From RUN mode: To view the Host Controller board error status (HS). To back out of either of these menus. As indicated earlier. press F5 5. 2. For the Microcontroller board.

A history buffer is used for Host Controller board status messages (HCHist z. press F5 •.Viewing Historical Error Messages Except for the High Temperature fault (f Temp High). 2. with “1” being the oldest and “9” being the most recent.. Error messages are numbered “1. the oldest code is deleted.. If two or more errors are detected simultaneously. The codes displayed represent past error conditions. Continue to subtract the largest primary code from the remainder until a primary error code is left.9”.. To view the Microcontroller History (MCHist) menu.9”. To view the error messages. where “z”= 1. 5-52 | Model 909 Single-Gas Analyzer . subtract the largest primary error code from the displayed number. By using keypad commands F5 • and F5 –. all errors detected by the analyzer’s diagnostics function will reset automatically once the problem is resolved. press F5 –. the analyzer allows you to view past error status messages.16 4 f Temp Low (Fault – Host Controller) f Comm Fault (Fault – Host Controller) To view a history of the last error messages (up to nine maximum) detected by the Host Controller or Microcontroller board.. where “z” = 1. Example: The displayed Host Controller board status code is 20. the displayed error status code is a sum of the primary error codes. The errors detected are: 20 . From RUN mode: To view the Host Controller History (HCHist) menu.9). follow the command syntax example below: 1.9) and for Microcontroller board status messages (MCHist z. with “1” being the oldest and “9” being the most recent. while working from RUN mode. To resolve a non-primary status code into its primary error codes. Up to a maximum of nine error messages can be displayed from either history menu. Each history buffer contains a maximum of nine error status codes. press any key in the range of “1. If more than nine error status codes accumulate in a buffer.

inside the Electronics Enclosure.8) is defined by HStatus. Corrective Action: Take appropriate safety precautions.Host Controller Board Alarm Conditions and Corrective Action This section lists valid error messages and descriptions (Condition/ Description). and: • Replace the EEPROM as soon as possible. The EEPROM should be replaced as soon as possible (99 % of the acceptable 20K writes is used).  NOTE The “w” or “f ” preceding a message indicates a ‘w’arning or ‘f ’ault alarm condition. The Host Controller Status Codes (HS Code) and Host Controller numbers (HStatus) to press on the keypad to view the current status or errors are also listed. Corrective Action: No action is required. where “z” (z = 1.8 – assigned to that alarm). In this case. it indicates that the Warning or Fault (Condition/Description) being viewed does not exist (where ‘z’ is the HStatus number – 1. This is not an alarm condition.. re-enter the parameters to ensure your analyzer will operate the same as it did prior to replacing the EEPROM. Alternatively. The factory-set default values will be used until the new values are entered. At the factory AMETEK will program the customer-specific parameters in the EEPROM. Maintenance & Troubleshooting | 5-53 . Alarm Type (Fault or Warning). The possible Host Controller board error conditions are polled individually with the keypad command F5 4 z. For each “z”..O. otherwise the message “HSz OK” appears. If you wish to retain current settings following the replacement of the EEPROM. The EEPROM is located on the Host Controller board. the parameters will take effect immediately upon power-up. you will only have to install the EEPROM. • After receiving and installing the new EEPROM. record any values that you have changed BEFORE YOU REMOVE THE EEPROM. open the Electronics Enclosure cover. 1 1 Warning w EEPROM Full This Warning condition indicates the number of times that configuration data has been rewritten to the EEPROM (non-volatile memory) has exceeded the safe number. the corresponding error message description is displayed if the error condition exists. and Suggested Corrective Action for each. number for the EEPROM to AMETEK at the same time. you can send the configuration values and P. HS Code HStatus Alarm Type 0 — — Condition / Description & Suggested Corrective Action HSz OK If the HS Code returned is ‘0’ and the message displayed is “HSz OK”.

and (refer also to the Ribbon Cable Interconnect drawing in Appendix D. etc. and (refer also to the Ribbon Cable Interconnect drawing in Appendix D. if necessary): • Check the ribbon cable between the Optical Bench board (J103) and the PMT (photomultiplier tube) buffer (J1) for proper connections and inspect it for damage (cuts. “NoData” will be displayed immediately on the lower line of the User Interface Panel. Corrective Action: • The parameters have exceeded the normal operating range. etc. 5-54 | Model 909 Single-Gas Analyzer . enter F5 1 1. open the Electronics Enclosure cover. A range change and recalibration may be required. burn marks.). etc. 4 3 Fault f Comm Fault This Fault condition indicates that the Host Controller board cannot establish reliable communications with the Microcontroller board. 8 4 Fault f RxData Fault This Fault condition indicates that the Host Controller board is not receiving analytical data from the Microcontroller board.). burn marks. open the Electronics Enclosure cover. When this serious system fault is detected. The “NoData” error message indicates the same serious system error as “f RxData Fault” (in the HStatus menu). Corrective Action: Take appropriate safety precautions. “CommFault” will be displayed immediately on the lower line of the User Interface Panel. From the User Interface Panel. burn marks. The “CommFault” error message indicates the same system error condition as “f Comm Fault” (in the HStatus menu).4 from CAL mode. nicks. if necessary): • Check the ribbon cable between P203 on the Host Controller board (on the door inside the Electronics Enclosure) and J104 on the Micro-Interface board (mounted to the Electronics Enclosure backpan) for proper connections and inspect it for damage (cuts. See Figure 5-9 for the location of this switch. When this serious system fault is detected. If this warning persists during normal operation..HS Code HStatus Alarm Type 2 2 Warning Condition / Description & Suggested Corrective Action w Out of Range This Warning condition indicates that the concentration of the output exceeds its full-scale range by more than ± 5 %.). • Check the PMT high-voltage connections at the Optical Bench board (J101. nicks. contact the factory. Corrective Action: Take appropriate safety precautions. J102) for proper connections. To check the outputs. • Check the actuators on switch S100 on the Micro-Interface board and ensure that they are positioned toward the middle of the board. • Check the ribbon cable between the Optical Bench board (J100) and the Micro-Interface board (J102) for proper connections and inspect it for damage (cuts. nicks. check that the full-scale range is correct for the current sample.

the “Supplemental Information” section of this manual. - Check each of the associated configuration parameters for temperature control. • Take appropriate safety precautions. These parameters may have been lost as a result of a power interruption or a power spike. Maintenance & Troubleshooting | 5-55 . This error can also be caused by a power interruption or a power spike. the Analyzer Oven temperature uses the TCold value as an alarm set point. - Replace the Termination board. but will clear when the operating temperature of all controlled zones are within their normal operating ranges. Contact the factory to verify operation before removing this board. and: - Check the fuse(s) for the zone(s) which caused the alarm. If the RTD is faulty. 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. Contact the factory to verify operation before removing this board.4 from RUN mode). or the Documentation Package shipped with the analyzer. Corrective Action: • From the User Interface Panel: - Check current operating temperatures for each temperature zone and compare them to their set point temperatures. Zone 1 analyzers.HS Code HStatus Alarm Type 16 5 Fault Condition / Description & Suggested Corrective Action f Temp Low This Fault condition indicates that one or more of the temperature-controlled zones is operating below its set point value by more than 5 % of the set point value. If this alarm is caused by low temperatures in any of the temperaturecontrolled zones. Zone 1 analyzers and other related drawings. - Using an Ohm Meter. For over-temperature wiring details. open the Electronics Enclosure cover. This error will occur during a cold start. If the TCold parameter is used. Refer to the Fuse Legend on the inside of the analyzer’s Electronics Enclosure door for the locations of these fuses. and Analyzer Oven. measure the resistance of the temperature sensor (RTD) for the zone(s) which caused the alarm (enter F4 4 1. However. SCU. refer to Appendix D. refer to the Sample/Vent Line Wiring drawing (Figure 5-10a) for GP/Div 2 analyzers or the Disconnect Enclosure Wiring drawing (Figure 5-10b) for 120 V. • Other checks/corrective action: - Check the electrical connections between the heater and the Sample Line.. For 240 V. - Replace the Temperature Daughter board(s). Test it for an open circuit. the Sample Line and SCU still use 5 % of the set point as an alarm point. contact AMETEK for assistance. Check for proper connections and damage to the lines and wiring.

refer to Appendix D. and: - Check the green LEDs for each circuit. measure the resistance of the temperature sensor (RTD) for the zone(s) which caused the alarm (enter F4 4 1. - Replace the Temperature Daughter board(s).HS Code HStatus Alarm Type 32 6 Fault Condition / Description & Suggested Corrective Action f Temp High This Fault condition indicates that one or more of the temperature-controlled zones has exceeded its over-temperature limit of 177 °C/350 °F. refer to the Sample/Vent Line Wiring drawing (Figure 5-10a) for GP/Div 2 analyzers or the Disconnect Enclosure Wiring drawing (Figure 5-10b) for 120 V. Corrective Action: • From the User Interface Panel: - Check the current operating temperature for each temperature zone and compare it to its set point temperature. This cuts power to the corresponding heater(s). This will also re-energize the Sample Line and SCU over-temperature relays. If the RTD is faulty. Zone 1 analyzers. or the Documentation Package shipped with the analyzer. which will restore power to the Sample Line and SCU heaters. For 240 V. Contact the factory to verify operation before removing this board. Upon detection of this alarm. - Check each of the associated configuration parameters for temperature control. - Check the fuse for the OverTemp circuit. Refer to the Fuse Legend on the inside of the analyzer’s Electronics Enclosure door for the locations of these fuses. open the Electronics Enclosure cover. • Take appropriate safety precautions. SCU. These parameters may have been lost as a result of a power interruption or a power spike. - Press SW300 on the Termination board to re-energize the tripped circuits. This alarm is generated by the Temperature Daughter board(s). For over-temperature wiring details. Test it for an open circuit. Zone 1 analyzers and other related drawings. and Analyzer Oven. - Using an Ohm Meter. • Other checks/corrective action: - Check the electrical connections between the heater and the Sample Line. the analyzer automatically switches to Backpurge mode and also de-energizes the over-temperature relay for the zone that has exceeded its limit.4 from RUN mode). located within the Electronics Enclosure. V/L = LED301. contact AMETEK for assistance. The alarm must be manually reset by pressing SW300 on the Termination board (Figure 5-11). located on the Termination board (S/L = LED302. 5-56 | Model 909 Single-Gas Analyzer .. Contact the factory to verify operation before removing this board. Oven = LED300) to verify which zone is experiencing problems. the “Supplemental Information” section of this manual. - Replace the Termination board. Check for proper connections and damage to the wiring.

its optics. Corrective Action: • Check that the proper gases are being used for the calibration functions. the alarm is currently not used. Corrective Action: • This temperature zone is currently spare.HS Code HStatus Alarm Type 64 7 Warning Condition / Description & Suggested Corrective Action w ZDrift/SpnErr This Warning condition indicates excessive Zero Drift or Span Error. 128 8 Warning w TZone3 This Warning condition indicates a high temperature condition on Temperature-Controlled Zone 3. Maintenance & Troubleshooting | 5-57 . Procedures to clean these parts are listed earlier in this chapter. Excessive Zero Drift is indicated if Zero Gas transmission values attained after a Zero function differ by more than ±10 % from the previous values. and/ or sample system are contaminated. Figure 5-9. A Span Error occurs if a span factor attained after a Span function is ≤ 0. Refer to the “Analyzer Preventive Maintenance Schedule” and “Measuring Cell Preventive Maintenance” in this chapter for more information to help you determine if any of these areas need to be cleaned. Micro-Interface board. • Check the analyzer to determine if the Measuring Cell.85 or ≥ 1.15.

Figure 5-10a. 5-58 | Model 909 Single-Gas Analyzer . GP/Div 2 Analyzers. Sample/Vent Line Wiring.

Figure 5-10b. Maintenance & Troubleshooting | 5-59 . Sample/Vent Line Wiring. 120V (Disconnect Enclosure). Zone 1 Analyzers.

Over Temp alarm reset switch (SW300). Termination board. 5-60 | Model 909 Single-Gas Analyzer .Figure 5-11.

 NOTE The ‘w’ or ‘f ’ preceding a message indicates a ‘w’arning or ‘f ’ault alarm condition. Maintenance & Troubleshooting | 5-61 . where ‘z’ (z = 1. This can be caused by a power interruption.. and: • Replace the Microcontroller board. open the Electronics Enclosure cover. Alarm Type (Fault or Warning). 2 2 Fault f On-board ADC This Fault condition indicates one or both of the discrete analog-to-digital converters (ADC) is not responding. 1 1 Fault f Pulse Timing This Fault condition indicates that there is a problem with control parameter updating and pulse timing. For each ‘z’. The Microcontroller Status Codes (MS Code) and Microcontroller numbers (MStatus) to press on the keypad to view the current status or errors are also listed. The possible Microcontroller board error conditions are polled individually with the keypad command F5 5z. MS Code MStatus Alarm Type 0 — — Condition / Description & Suggested Corrective Action MSz OK If the MS Code returned is ‘0’ and the message displayed is “MSz OK”.Microcontroller Board Alarm Conditions and Corrective Action This section lists valid error messages and descriptions (Condition/ Description). Corrective Action: No action is required. otherwise the message “MSz OK” appears. Corrective Action: Take appropriate safety precautions.7 – assigned to that alarm). Corrective Action: • Reset the analyzer by simultaneously pressing • and Ent on the User Interface Panel. and Suggested Corrective Action for each.7) is defined by MStatus. The message “Reset In Progress” should be displayed within one second after these keys have been pressed. This is not an alarm condition. Contact the factory to verify operation before removing this board. it indicates that no Warning or Fault (Condition/Description) exists (where ‘z’ is the MStatus number – 1. the corresponding error message description is displayed if the error condition exists..

Corrective Action: Take appropriate safety precautions. 5-62 | Model 909 Single-Gas Analyzer . such as is typically the case for a spare temperature zone. causing its temperature zone to read “181. open the Electronics Enclosure cover. and/or • From RUN mode.8 to check the current temperature for each temperature-controlled zone (including the External Probe. • Using an Ohm meter. Contact the factory to verify operation before removing this board. RUN mode) is set to zero. Contact the factory to verify operation before removing this board. press F1 – and then press 3 and then 4 to check the Probe Temperature (low/high) alarm set point values. From RUN mode. Contact the factory to verify operation before removing this board. F4 0. and/or • One or more of the operating temperature sensing RTDs has failed. If a heated external probe is used. If the RTD is faulty.8)... measure the resistance of the temperature sensor (RTD) for the zone(s) which caused the alarm and test it for an open circuit. and: • Replace the Microcontroller board.MS Code MStatus Alarm Type 4 3 Fault Condition / Description & Suggested Corrective Action f On-Chip ADC Two possible errors may be occurring. contact AMETEK for assistance. either: • The Microcontroller board’s internal analog-to-digital (ADC) converter is not responding. Upon detection of either fault. the analyzer will automatically switch the system into the Backpurge mode until the error has been corrected.4 to check the set point value for each temperature-controlled zone. • Replace the Temperature Daughter board(s). • Replace the Termination board. press F4 0 and then press 1.4ºC” but not trigger this alarm if its set point (TStPt.4 °C” on the User Interface Panel (seen by pressing F6 8 z from CFG mode. Note: A temperature zone can indicate “181. where ‘z’ = Microcontroller Analog Inputs 1. if used).. press F6 8 and then press 1.

etc. press F2 7 to view the ALC Enable function. Maintenance & Troubleshooting | 5-63 . burn marks.).0–9.MS Code MStatus Alarm Type 8 4 Warning Condition / Description & Suggested Corrective Action w PMT Signals This Warning condition indicates the highest signal from either the Measure or Reference PMT (photomultiplier tube) is outside its normal range (5. 16 5 Fault f Comm Error This Fault condition indicates that the Microcontroller board cannot establish reliable communications with the Host Controller board. Then. • Check that the actuators on switch S100 on the Micro-Interface board are positioned toward the middle of the board. nicks. press Del 1 Ent Ent to turn it On.).). If the ALC setting is ‘0’. • Check the ribbon cable between the Optical Bench board (J100) and the Micro-Interface board (J102) for proper connections and inspect it for damage (cuts. press F6 1 from RUN mode. From the User Interface Panel: • Check to make sure that the Automatic Lamp Control (ALC) is On. and (refer also to the Ribbon Cable Interconnect drawing in Appendix D. - ALC is Off if ‘ALC 0’ is displayed. nicks. burn marks. and (refer also to the Ribbon Cable Interconnect drawing in Appendix D. To do this: From the RUN mode. - ALC is On if ‘ALC 1’ is displayed. burn marks. enter CFG mode and press F2 7 to view the ALC Enable function. Corrective Action: Take appropriate safety precautions. if necessary): • Check the ribbon cable between the Optical Bench board (J103) and the PMT buffer (J1) for proper connections and inspect it for damage (cuts.84 VDC). etc. To check these values. open the Electronics Enclosure cover. Corrective Action: Take appropriate safety precautions. J102) for proper connections. nicks. open the Electronics Enclosure cover. • Check the PMT high-voltage connections at the Optical Bench board (J101. etc. if necessary): • Check the ribbon cable between P203 on the Host Controller board (on the door inside the Electronics Enclosure) and J104 on the Micro-Interface board (mounted to the Electronics Enclosure backpan) for proper connections and inspect it for damage (cuts. See Figure 5-9 for the location of this switch.

A soft shutdown of the heater will also occur when the Oven door is open. Nominal value is 6. etc. As a temporary solution. J102) for proper connections. initiate an Auto-Setup to increase the PMT gain to compensate for the reduced light levels. but should clear after the source lamps have stabilized. open the Electronics Enclosure cover. contact AMETEK for assistance. Corrective Action: Take appropriate safety precautions. If the RTD is faulty.0 V (may vary. A soft shutdown means the system will shut down the heater to ensure the temperature of the heater plate does not continue to increase and exceed its temperature rating. Corrective Action: Take appropriate safety precautions.MS Code MStatus 32 6 Alarm Type Condition / Description & Suggested Corrective Action Warning w Lamp Control This Warning condition indicates that one or both lamp pulse currentcontrol signals has exceeded its Lamp Maximum signal set point. • Check the ribbon cable between the Optical Bench board (J103) and the PMT buffer (J1) for proper connections and inspect it for damage (cuts. To initiate an Auto-Setup. nicks. • Check the PMT high-voltage connections at the Optical Bench board (J101. The AutoSetup starts immediately. open the Electronics Enclosure cover. enter CFG mode and press F1 •. From the User Interface Panel: • The light levels may be too low as a result of natural aging of the lamps. check EEPROM Data Sheets for actual value). • Check that the lamps are inserted completely into the detector assembly. This is an indication that the lamps should be replaced as soon as possible. This error will occur during a cold start. and (refer also to the Ribbon Cable Interconnect drawing in Appendix D. burn marks. and: • Using an Ohm Meter. if necessary): • Check that the lamp sockets are attached securely to the lamps and that the Lamp Retaining Bar is in place.). a soft shutdown of the heater will occur. measure the resistance of the Measuring Cell RTD and test it for an open circuit. 5-64 | Model 909 Single-Gas Analyzer . but will clear after all of the temperature-control zones have stabilized within their normal operating range. This error may occur during a cold start. 64 7 Fault f Oven Heater This Fault condition indicates the Oven Heater Plate temperature is approaching its over-temperature limit of 177 °C (350 °F).

The analyzer will reset upon normal power-up. simultaneously press • and Ent on the User Interface Panel. the only resets required are in cases where the Host CAUTION Controller or Microcontroller boards have been replaced. Maintenance & Troubleshooting | 5-65 . ! Do not randomly reset the analyzer during normal operation. In this case. The message “Reset In Progress” should be displayed within one second after these keys have been pressed.Analyzer Reset Should a situation arise where the Host Controller board or the Microcontroller board must be reset. Typically. it is necessary to shut down the analyzer.

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This chapter also lists the recommended spare parts to have on hand to ensure all consumable and replaceable parts are available for service according to the “Analyzer Preventive Maintenance Schedule” in Chapter 5. • Billing address.  NOTE For office locations and contact information. carefully review the contents of this manual. refer to the Offices page near the beginning of this manual.Service & Parts This chapter discusses what to do if you need technical support from AMETEK.ametekpi. shipping address. and telephone number. If you need service or application assistance. • Information describing the problem.com. operation. Technical Support AMETEK Western Research is committed to providing you the best technical support in the industry. or visit us at www. if known. Service & Parts | 6-1 . Before contacting AMETEK with questions regarding the installation. • Purchase order number. If you are unable to find an explanation for your problem in this manual. contact your local or nearest AMETEK Service Centre or the AMETEK factory AMETEK at (403) 235-8400 or 1-800-661-9198) or contact your local AMETEK Western Research representative. • Serial number of the analyzer. or if you are returning parts for service. or maintenance/troubleshooting of your analyzer system. • AMETEK part number for the specific component you are enquiring about. please gather the following information prior to contacting AMETEK: • Model number of the analyzer.

This will ensure your equipment is serviced and returned to you in a prompt and efficient manner. • Purchase order number. 6-2 | Model 909 Single-Gas Analyzer . and telephone number. • Serial number of the analyzer. • Billing address. shipping address.Returning Equipment If you need to return parts or equipment for repair. contact your local or nearest AMETEK Service Centre and have the following information available: • Model number of the analyzer. To obtain an RMA number. you will need a Return Material Authorization (RMA) number.

24 hour on-site guarantee. Newark. MINUTES OR HOURS. Texas. We will guarantee a satisfactory commissioning of your analyzer. • SPARE PARTS These parts allow each customer to properly maintain their analyzers according to the recommended Preventive Maintenance Schedule (listed in the manual). • WARRANTY EXTENSIONS AMETEK offers a 2 or 3 year warranty extension for your analyzers.S.. The warranty is identical to the original policy supplied with the analyzer. • ASAP AMETEK SERVICE ASSISTANCE PROGRAM.: 1-800-537-6044 Service & Parts | 6-3 . ANYTIME / ANYWHERE AMETEK SERVICE & AFTERMARKET SALES SUPPORT • PRE-lNSTALLATlON INSPECTIONS To ensure you order the correct analyzer with the options your operation requires.?? ANSWERS TO YOUR QUESTIONS ?? The choice is yours. or at your facility. 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. A diploma will be presented upon completion of the course. This is also the group that will keep your analyzer current with upgrades and retrofits. • AFTERMARKET SALES Our Aftermarket Sales group will keep you supplied with the parts to maintain your analyzer to factory specifications. Our TTCs have equipment similar to yours for hands-on training. After the time and money spent on your analyzer. • TRAINING We will train your service technicians at our Technology Transfer Centres located in Calgary. WE’RE THERE FOR YOU Whether by phone or in person. With over 200 years of combined field service experience.A. AMETEK’s warranty policy covers all parts and onsite time. 365 days a year or on-site within 24 hours. our engineers are available to provide operational support or troubleshooting expertise. we can meet the needs required to keep your analyzer running at peak performance. The on-site charge for this visit can be deducted from the start-up charge if you select that option. to ensure optimal operations. • WARRANTY VALIDATION Upon start-up.. Alberta and Newark. Delaware with a Sales & Service Centre in Houston. We stock parts at all three locations. Contact AMETEK Service for more details. AMETEK’s exclusive ASAP program lets you select a service package from a menu of service options. ASAP options include 24 hour phone support. we will validate your 1 year warranty. rapid parts shipment. Our factories are located in Calgary. Incurred costs will be the responsibility of the customer. • TECHNICAL SUPPORT Just call AMETEK and a factory trained Service Engineer will be there to answer your questions. or all of the AMETEK process analyzers at your facility. schedule a factorytrained Service Engineer to inspect the proposed analyzer location. • START UPS Your decision to buy an AMETEK analyzer is greatly appreciated. we will have a factory-trained representative talking to you within minutes – 24 hours a day. Depending on the programs you select. PROCESS INSTRUMENTS Canada: 1-800-661-9198 U. and many more service benefits. ASAP plans may be written to provide coverage for a single analyzer.

If the analyzer uses a Sample Conditioning Unit (SCU) or “Probe.Recommended Spare Parts This section lists the recommended spare parts to have readily available for the Model 909 Analyzer. This can be due to applications using non-standard Measuring Cells or optional equipment. Before ordering spare parts (for applications measuring gas species other than SO2 or H2S).” refer to either the “AMETEK SCU (Probe) Preventive Maintenance Parts” list or the “M&C Probe Preventive Maintenance Parts” list. if not. refer to the “Supplemental Information” section of this manual or the Documentation Package shipped with the analyzer for a Custom Recommended Spare Parts list. use the Part Numbers listed in this section. 6-4 | Model 909 Single-Gas Analyzer . If included. use those Part Numbers. depending on the probe type used for the application.  NOTE IMPORTANT SPARE PARTS INFORMATION Spare Parts for your analyzer may vary from those included in this section.

Service & Parts | 6-5 .” in parentheses below the Part No. or other failure of a Source Lamp. and need to be replaced. 120 VAC/240 VAC Analyzer Preventive Maintenance Parts Part No. (Drawing No. To verify the lamp type. The replacement of these parts is required as part of the Analyzer Preventive Maintenance Schedule. in the “Preventive Maintenance Parts” list indicates the drawing to refer to in Appendix D for the location of the part in the analyzer. 100-0688 (WX-14856) 300-2070 (WX-14856) SO2 applications Magnesium (Mg) Source Lamp (Optical Bench – Lamp1. open the analyzer and check the label on the lamps. Lamp 2) 300-0281 (WX-14856) 100-1911 (WX-14856) Qty (1 Year) Qty (2 Year) 2 [See (*) Note] 4 [See (*) Note] 2 [See (*) Note] 4 [See (*) Note] Cell Window.Optical Bench/Measuring Cell Spare Parts AMETEK recommends having the following spare parts available to ensure your analyzer will operate at peak efficiency. Lamp 2) OR H2S applications Cadmium (Cd) Source Lamp (Optical Bench – Lamp1. (*) Note the ordering part numbers for the different Source Lamps and order only the appropriate type and quantity of Source Lamps. It is also necessary to have these parts on hand in case the parts become damaged or contaminated. Baled Teflon Coated AFLAS (Measuring Cell) 8 16 Content is subject to change without notice.  NOTE In the event of natural degeneration. damage. AMETEK recommends changing out both Source Lamps to ensure optimal operation.) Description Note: Lamp type is dependent on species being measured. refer to the Note following certain lists for drawing numbers. Fused Silica (Measuring Cell) 4 6 O-Ring size 125. Or. The “Drawing No.

Content is subject to change without notice. Description Qty (1 Year) Qty (2 Year) 300-9266 Ceramic Filter Element 1 2 300-9267 Filter Element Gasket 1 2 300-9268 Lid Seal O-Ring.Sample Conditioning Unit (SCU) Spare Parts AMETEK recommends having the following spare parts available (for either the AMETEK SCU or M&C Probe) to ensure the SCU (Probe) will operate at peak efficiency. 39 mm 1 2 300-9269 Lid Seal O-Ring. 55 mm 1 2 These parts are required only if an M&C Probe is used. Description 300-0962 Filter Element 300-9256 Gasket Set. Viton Qty (1 Year) Qty (2 Year) 10 20 4 8 These parts are required only if an AMETEK SCU (Probe) is used. M&C Probe Preventive Maintenance Parts Part No. AMETEK SCU (Probe). 6-6 | Model 909 Single-Gas Analyzer . The replacement of these parts is required as part of the Preventive Maintenance Schedule. It is also necessary to have these parts on hand in case the parts become damaged or contaminated. by AMETEK Preventive Maintenance Parts Part No. and need to be replaced. Content is subject to change without notice.

 NOTE The Sample and Vent Line (or SCU) fuses are typically no longer used.6 A (*) 24 VDC Power Supply (TB2-7) 300-4189 0. If the original factory-installed or retrofitted fuse blows. Service & Parts | 6-7 .Spare Analyzer Fuses AMETEK recommends having on-site the spare fuses used in the analyzer. See Sample/Vent Line wiring drawings for your application. Fuse Type 240 V Part No. Vent Line fuse is located at TB3-50 on GP/Div 2 analyzers or at TB6-1 on Zone 1 analyzers. in Appendix D.6 A 300-4189 0. 120 VAC/240 VAC Analyzer Fuses Description 120 V Part No. or at TB5-1 on Zone 1 analyzers.75 A O2 Sensor (TB2-6) 300-5465 3. Fuse Type 300-9291 6A 300-9443 8A 300-9292 10 A 300-9293 16 A 300-6312 20 A Sample Line fuse is located at TB3-30 on GP/Div 2 analyzers. Sample and Vent Line (or SCU) Fuses Part No.75 A 300-5557 400 mA All analyzer fuses located at TB2 in the Electronics Enclosure (see the Electronics Enclosure Layout drawing and Analyzer AC Wiring WX-102853 drawing in Appendix D) for locations of these fuses. the fuse required will depend on line length. remove it to determine the fuse type required. These fuses do not need to be changed out at regular intervals.75 A 300-4189 0.75 A Over-Temp Power Supply (TB2-2) 300-1519 63 mA 300-5097 32 mA Oven Heater (TB2-3) 300-4550 4 A 300-4548 2A Termination Solenoids (TB2-4) 300-4189 0. and power consumption. but are necessary in the event that a replacement is required. if fuse terminals are retrofitted for these temperature zone circuits. voltage.75 A 300-5557 400 mA Calibration Solenoids (TB2-5) 300-4189 0.15 A 300-5924 1. Fuse Type Analyzer (TB2-1) 300-8572 1. (*) Note: Purgable Deluxe (PD = GP or Div 2 only) Analyzers do not use the 24V fuse or the 24V Power Supply. however.

6-8 | Model 909 Single-Gas Analyzer . in the Disconnect Enclosure. Fuse Type Main Board (F200) 300-8778 125 mA 300-8777 63 mA Photomultiplier Tube (F300) 300-3214 0.2 A 300-3214 0. Fuse Type 300-5790 125 mA This fuse is located at F100 on the Customer Signal Termination board.AMETEK Sample Conditioning Unit (SCU) Fuse (Probe). Disconnect Enclosure Fuse (Zone 1 and CE analyzers) Customer Signal Termination Board (100-1215-2) Part No. Fuse Type 240 V Part No. Fuse Type 240 V Part No.2 A Lamp (F201) 300-9524 32 mA 300-9524 32 mA See Optical Bench board layout (100-1662) in Appendix D. Optional Description 120 V Part No. Fuse Type Sample Conditioning Unit 300-9443 300-9291 8 A 6A This fuse is located in the AMETEK SCU and is only required if an SCU is used. Optical Bench Board Fuses (100-1662) Description 120 V Part No.

and are required only in the event of failure or damage to a board. Board Replacement Part Numbers Part No. Type “A” 1 100-0117 Microcontroller Board 1 100-0136 Keypad Board 1 100-0138 Host Controller Board (Display Interface) 1 100-1534 Termination Board (Hi-Temp) 1 100-1662 Optical Bench Board 1 100-0140 Dual PMT Buffer Board 1 100-0939 Display I/O Expansion Board 1 100-1096 100-1097 Temperature Daughter Board (4 RTDs) OR Temperature Daughter Board (2 RTDs. 2 Thermistors) 1 100-1215* Customer Termination Board (Zone 1) (Disconnect Enclosure) 1 100-1214* Sample/Vent Line RTD Termination Board (Zone 1) (Disconnect Enclosure) 1 1 Refer to the Overall Component Layout drawing and the Ribbon Cable Interconnect drawing (WX-102836) for the location of the boards in the analyzer. Service & Parts | 6-9 . * Used with Zone 1 analyzers only.Replacement Boards  NOTE These boards apply to 120 VAC and 240 VAC analyzers. Description Qty 100-0116 Micro-Interface Board.

This page intentionally left blank. 6-10 | Model 909 Single-Gas Analyzer .

CAL CALibration mode CFG ConFiGuration mode f Precedes an error message. which indicates the error is a ‘f’ault alarm (e.. and abbreviations are described under “Defining RUN / CFG Mode Keystroke Terms” and “Defining CAL Mode Keystroke Terms” in Chapter 4. displayed on the upper-left line when the user manually changes the Sample Control function to Continuous Sample Flow mode. displayed on the upper-left line when the user manually changes the Sample Control function to Continuous Backpurge Flow mode. displayed on the upper-left line when the user manually changes the Sample Control function to Continuous Zero Gas Flow mode. B User-selected (manual) Continuous Backpurge Flow mode. Complete details of all screen titles. C User-selected (manual) Continuous Calibration Gas Flow mode (Gas #1 or Gas #2). displayed on the upper-left line when the user manually changes the Sample Control function to Continuous Calibration Gas Flow mode.Software Glossary User Interface Panel Abbreviations This listing describes all of the screen titles and characters displayed on the User Interface Panel. messages. w Precedes an error message. S Reverse-video S – The detection of an on error by the built-in error detection system is indicated by this character at the right end of the top line. displayed on the upper-left line while the analyzer is operating in Analyzer Control mode. “f Temp Low”). Term/Character Definition b Analyzer-selected (automatic) Backpurge Flow mode.g. Z User-selected (manual) Continuous Zero Gas Flow mode. which indicates the error is a ‘w’arning alarm (e. “w PMT Signals”). This character is also displayed when the Remote Backpurge function is activated by the user via a remote dry (potential free) contact opening. Software Glossary | 7-1 .g. RUN RUN mode S User-selected (manual) Continuous Sample Flow mode..

Abbreviations Used in This Manual Abbreviation Full Term ADC analog-to-digital converter A/D analog-to-digital BRAM battery backed random access memory D/A digital-to-analog DCS Distributed Control System Div 2 (Analyzer) Division 2 DP differential pressure EEPROM electrical-erasable-programmable-read-only memory GP (Analyzer) General Purpose HAI Host Controller Board Analog Inputs MAI Microcontroller Board Analog Inputs Modbus® Modbus is a registered trademark of Modicon. differential PMT photomultiplier tube RTD resistance temperature device SCU Sample Conditioning Unit SPDT single pole double throw SRAM static random access memory SSR solid-state relay SKO sulfur knock out (sulfur condenser) 7-2 | Model 909 Single-Gas Analyzer . integral. PD (Analyzer) Purgeable Deluxe (General Purpose and/or Division 2) PID proportional. an AEG company.

) The manual for the O2 Sensor (if used) accompanies the analyzer when this option is installed at the factory.  NOTE The Model 909 Analyzer and O2 calibration gases must not contain any component that may interfere with the correct operation of the O2 Sensor.  NOTE Drawings of the Zirconia Oxide O2 Sensor (Electronics Panel Layout and Wiring Connections) are located in Appendix D.Appendix A – Options O2 Concentration Measurement The O2 concentration can be measured using a Zirconia Oxide O2 Sensor installed in the Analyzer Oven. (The O2 Sensor is optional. and is for use in General Purpose applications/ analyzers only. this air reference point establishes the O2 Sensor zero point. The first gas is air. and displayed on the User Interface Panel. Since the O2 concentration is determined relative to air.95 mole percent. The calibration gas mixture O2 concentration usually is chosen to be near the normal O2 concentration of the stack duct. the second gas is an O2 calibration gas mixture. Refer to the Zirconia O2 Sensor Instruction Manual. Appendix A – Options | A-1 . Calibration of the O2 Sensor requires the use of two calibration gas mixtures. The air is used to obtain the air reference point. The usual concentration of O2 in dry air is 20.

SSR Outputs
The analyzer must be configured for which solenoid valve controls which
calibration gas mixture. The solenoid valves are controlled by the analyzer
solid state relay (SSR) outputs. If instrument air is used as the zero gas,
then the O2 zero gas solenoid is assigned to SSR output ‘0’. Nitrogen (N2)
or another inert gas may be used to zero the ultraviolet portion of the
analyzer system.
When nitrogen is used as the zero gas the O2 Sensor cannot be calibrated during an Auto-Cal sequence. SSR output ‘10’ (pseudo SSR) must
be assigned to the O2 zero gas solenoid to prevent inadvertent AutoCalibration. The solenoids controlling the calibration gas mixtures are
assigned to SSR outputs 1 or 2 are preset at the factory.
To determine SSR output assignments, enter CAL mode and key in:
F5 4

The message “Sol:O2Z b” will be displayed, where ‘b’ = ‘0’ or
‘10’, and is the O2 zero gas solenoid valve SSR output assignment. SSR output ‘0’ will always be assigned when the ultraviolet portion of the analyzer is zeroed with air. SSR output ‘10’
(pseudo SSR) will always be assigned when the ultraviolet
portion of the analyzer is zeroed with nitrogen.

F5 5

The message “Sol:O2S b” will be displayed, where ‘b’ = ‘1’ or
‘2’, and is the span gas solenoid valve SSR output assignment.
Record this value.

Press Ent to return to CAL mode normal display or Esc to return to RUN
mode normal display.

A-2 | Model 909 Single-Gas Analyzer

Entering Calibration Gas O2 Concentration
The concentration of O2 in the two-Calibration Gas mixture (O2Conc)
used with the analyzer must be entered before initiating a calibration
sequence. The O2 concentration unit of measurement is mole percent and
the maximum value allowed is 25 mole percent. Fractional values are entered using the normal decimal notation (i.e., 10.45 mole percent).


NOTE

If a Calibration Gas is not used, the O2 concentration must be set to
zero.

Example 1:
To enter a value of 20.95 O2 concentration (mole percent) in the zero air
and return to CAL mode normal display, key in:
F4 8 2 Del 20.95 Ent Esc
Example 2:
To enter a value of 3.22 O2 concentration in the O2 calibration gas mixture
(mole percent) and return to CAL mode normal display, key in:
F4 8 1 Del 3.22 Ent Esc

O2 Span Timer
The O2 Span Timer establishes the time period for which the Solenoid
Valve controlling the O2 Calibration gas is energized during the AutoSpan and Auto-CAL sequences. The O2 Span Timer duration depends
on the time required for the CAL Gas to reach the analyzer and to obtain
a stable reading. Setting the O2 Span Timer to a non-zero duration automatically adds calibration of the O2 Sensor to the Auto-CAL sequence
when it is enabled.
The duration may be set from 0–255 minutes in one-minute increments.
Setting the duration to zero turns the O2 Span Timer Off.
Example:
To set Timer2 (O2 Span Timer) to 3 minutes and return to CAL mode normal display, key in:
F3 2 Del 3 Ent Ent

Appendix A – Options | A-3

Auto-Calibration
The Auto-Calibration function turns on, in sequence, each of the solenoid
valves controlling the calibration gas mixtures. The concentration of the
component in the calibration gas mixtures and the timers must be set to
proper values before initiating an Auto-Calibration.
When an Auto-Calibration is performed the following sequence of events
occurs automatically:
1. The corresponding solenoid is turned on to let the Zero/Span gas flow
through the analyzer system.
2. The corresponding timer duration is displayed on the first line of the
display and is counted down to zero.
3. The zero or span is adjusted to the proper value based on the average
of the readings during the last 25 % of the time period of the countdown. Upon completion of the Auto-Zero/Auto-Span functions, CAL
mode normal display is returned. The Integration Timer (IntTime)
does not affect the averaging time for the Auto-Zero/Auto-Span
functions.


NOTE

Pressing Esc at any time during this procedure will cause it to abort
and return to CAL mode normal display.

4. The CAL status relay will stay on for an additional delay time (minutes) as determined by the Sample Delay Timer (SDelay) to allow for
a smooth transition from the Zero/Span gas back to the sample gas.
The analyzer display gives no indication that this is occurring. Only
those timers that are set to a non-zero value will be included in the
sequence. When air is used as the zero gas for the ultraviolet portion
of the analyzer system, it is also used to calibrate the air point for the
O2 Sensor. Then, calibration gases are used to determine the span factors for the component for which the analyzer is configured, namely
O2. A sample Zero and Span sequence where air is used as the zero
gas is illustrated in Figure A-1.


NOTE

The Model 909 Analyzer and O2 Sensor are zeroed simultaneously
but spanned individually.
When nitrogen is used as the zero gas for the ultraviolet portion of the
Model 909 Analyzer, calibration of the O2 Sensor air point (zero) cannot be included in any of the Auto-Calibration sequences. A manual
Zero/Span must be performed to calibrate the O2 Sensor.

A-4 | Model 909 Single-Gas Analyzer

Sample

Sample

Auto Zero and Span Sequence

Mode

Mode
SSR Output 0

SSR Output 1

SSR Output 2

Timer0

Timer1

Timer2

Sol Valve 0

Sol Valve 1

Sol Valve 2

UV Zero
O2 Zero (Air)

UV Span
(e.g. SO2)

O2 Span with
O2 Cal gas

Figure A-1.
Example zero/span
sequence.

Appendix A – Options | A-5

Manual O2 Sensor Zero/Span
The Manual Zero and Span functions for the O2 Sensor do not activate
the Solenoid Valves. The gases must be introduced manually into the
analyzer – using the FlowCtrl function – and allowed to flow through the
sample system until a stable reading is displayed. The time required for
gas to reach the analyzer and a stable reading to be displayed, is dependent upon the volume of the sample system and the gas flow rate. The
Calibration Gas concentration must be entered before performing the
Zero/Span function.

IMPORTANT
The Zero function must be performed before the Span function.

NOTE

Pressing Esc at any time during this procedure will cause it to abort
and return to CAL mode normal display.

NOTE

Manual O2 Sensor Zero (Air)
To manually Zero the ultraviolet portion of the analyzer system and Zero
and Span the O2 Sensor:
1. Zero the ultraviolet portion of the analyzer:
a. Turn on the Zero Gas (air).
b. Enter CAL mode and press F5 2 and record the numeric value
displayed (FlowCtrl).
c. Force the analyzer sampling mode to Continuous Zero Gas Flow
mode by keying in Del 10 Ent.
d. Press F2 0. The display will prompt “Man/Zero?”.
e. Observe the concentration reading(s) on the bottom line of the
display. When the reading(s) have stabilized at or near air point
(20.95 %), press:
Ent for Yes

Timer0 will begin to count down to zero time. The
analyzer and O2 Sensor values will be adjusted
automatically based on the average of the reading
during the countdown if AdjDisable is set to ‘0’.

Esc for No

The function is aborted; the analyzer value is not
adjusted.

A-6 | Model 909 Single-Gas Analyzer

2. Zero the O2 Sensor:
a. Press F2 9. The display will prompt “Man/ZeroO2?”.
b. Observe the O2 concentration reading on the bottom line of the
display. When the O2 reading has stabilized at or near air point
(20.95 %), press:
Ent for Yes

The timer will count down to zero during which
time the readings are averaged. The air point values
will be adjusted automatically if AdjDisable is set to
‘0’.

Esc for No

The function is aborted; the O2 Sensor value is not
adjusted.

c. Turn off the Zero Gas (air).
3. Span the O2 Sensor:
a. Connect the O2 Calibration Gas to the Zero Gas inlet and turn on
the O2 Calibration Gas.
b. Press F2 8. The display will prompt “Man/SpanO2?”.
c. Observe the O2 concentration reading on the bottom line of the
display. When the O2 reading has stabilized at or near the O2 concentration in the calibration gas mixture press:
Ent for Yes

Timer y will begin to count down to zero. The O2
span value will be adjusted automatically based on
the average of the reading during the countdown if
AdjDisable is set to ‘0’.

Esc for No

The function is aborted; the O2 Sensor value is not
adjusted.

d. Turn off and disconnect the O2 Calibration Gas.
4. Reconnect the zero gas (air) and turn it on.
5. Press F5 2 Del z Ent (where ‘z’ is the value recorded in Step 2) to return the analyzer to the original sampling mode.
6. Press Esc to return to RUN mode normal display.
The Analyzer Zero, O2 Zero, and O2 Span are complete.

Appendix A – Options | A-7

Manual O2 Sensor Zero (Nitrogen/Air)

Sol:O2Z must be assigned the pseudo-solenoid number ‘10’ before
proceeding with the Zero function.

NOTE

Nitrogen (N2) or another inert gas can be used to zero the UV portion of
the analyzer. Because there are only four SSR outputs available for controlling solenoid valves, a manually operated 3-way valve must be installed at the Zero Gas inlet of the solenoid manifold block.
When nitrogen is used as the zero gas the O2 Sensor cannot be calibrated
during an Auto-Cal sequence. SSR output ‘10’ (pseudo SSR) must be assigned to the O2 zero gas solenoid before proceeding with the zero function to prevent inadvertent Auto-Calibration. The solenoids controlling
the calibration gas mixtures are assigned to SSR outputs 1 or 2 are preset
at the factory.
To assign SSR Output ‘10’ to the O2 zero gas solenoid valve and return to
RUN mode, enter CAL mode and key in:
F5 4 Del 10 Ent
To manually Zero the ultraviolet portion of the analyzer system and Zero
and Span the O2 Sensor:
1. Zero the ultraviolet portion of the analyzer:
a. Turn on the Zero Gas (N2).
b. Enter CAL mode and press F5 2 and record the numeric value
displayed (FlowCtrl).
c. Force the analyzer sampling mode to Continuous Zero Gas Flow
mode by keying in Del 10 Ent.
d. Press F2 0. The display will prompt “Man/Zero?”.
e. Observe the concentration reading(s) on the bottom line of the
display. When the reading(s) have stabilized at or near air point
(20.95 %), press:
Ent for Yes

The timer will count down to zero during which
time the readings are averaged. The zero values will
be adjusted automatically if AdjDisable is set to ‘0’.

Esc for No

The function is aborted; the values are not adjusted.

f. Turn off the Zero Gas (N2).
A-8 | Model 909 Single-Gas Analyzer

Force the analyzer sampling mode to Continuous Calibration Gas Flow by keying in F5 2 Del nn Ent (where ‘nn’ is ‘11’ or ‘12’ depending on which calibration gas cylinder contains the O2 calibration gas). b. Span the O2 Sensor a. the value is not adjusted. 3. 4. 5. 6. press: Ent for Yes The timer will count down to zero during which time the readings are averaged. the values are not adjusted. The air point values will be adjusted automatically if AdjDisable is set to ‘0’. Press Esc to return to RUN mode normal display. d. Turn on the Zero Gas (N2). and O2 Span are complete. When the O2 reading has stabilized at or near the O2 concentration in the calibration gas mixture press: Ent for Yes The timer will count down to zero during which time the readings are averaged. The O2 span value will be adjusted automatically if AdjDisable is set to ‘0’. Turn on the air. c. Zero the O2 Sensor: a. Press F2 8. c. Turn off the air. Press F5 2 Del z Ent (where ‘z’ is the value recorded in Step 2) to return the analyzer to the original sampling mode. Appendix A – Options | A-9 . Turn off the O2 Calibration Gas. Esc for No The function is aborted.95 %). When the O2 reading has stabilized at or near air point (20. Esc for No The function is aborted. Press F2 9.2. The Analyzer Zero. O2 Zero. Observe the O2 concentration reading on the bottom line of the display. d. b. The display will prompt “Man/ZeroO2?”. Observe the O2 concentration reading on the bottom line of the display. The display will prompt “Man/Span O2?”. e. Turn on the O2 Calibration Gas.

The O2 concentration is measured by a sensor installed in the Analyzer Oven. [x]m = the measured concentration of component ‘x’. An “o” (lower case “O”) appearing immediately before a calculated result name indicates a dilution-air-corrected result.Dilution Air Correction The Dilution Air Correction function corrects the component concentrations measured by the analyzer to a specific dilution air condition based on the measured O2 concentration and a specified O2 concentration in the stack duct.95 − [O2 ]spec ⎞ ⎟⎟ [ x]c = [ x]m ⎜⎜ ⎝ 20. and the concentration of O2 in the stack duct may be displayed simultaneously on the User Interface Panel. It is not air used to dilute the sample before analysis by the analyzer.95 − [O2 ]m ⎠ where: [x]c = the measured concentration of component ‘x’ corrected to the specified O2 concentration. The measured component concentration. (20. ! CAUTION Access to CFG mode should be restricted to trained technicians. The specified O2 concentration corresponds to a specific amount of Dilution Air.95. [O2]spec = the specified process duct O2 concentration to which the measured component ‘x’ concentration is corrected (mole percent). A-10 | Model 909 Single-Gas Analyzer . independent O2 analyzer.  NOTE For a given application. Dilution Air is excess (combustion) air or air added to the stack duct after the (combustion) process. 20. the correction will not be applied and [x]c = [x]m. and [O2]m = the measured concentration of O2 (mole percent). If [O2]m > 20. or by a separate. Changing the factory-set configuration may cause the analyzer to operate incorrectly.95 = the concentration of O2 in air (mole percent). Correction Equation The measured component ‘x’ concentration is corrected to a specified dilution air condition using the following equation: ⎛ 20.95 – [O2]spec) is a constant. dilution-air-corrected component concentration.

Entering [O2 ] To enter [O2]spec to which the measured concentrations are corrected (example. enter CFG mode and key in: F4 9 1 Del 0 Ent Ent Esc Ent Appendix A – Options | A-11 . [O2]spec = 0 (percent)).

. A-12 | Model 909 Single-Gas Analyzer This page intentionally left blank.

This information applies only to analyzers with this function added. refer to Figure B-3 (WX-14821). For Model 900ADA\930. The converter must be able to: • Provide a logic high signal to the RS-232 CD pin. 909\910. The communication protocol implemented is Modicon Modbus® as defined in “Modicon Modbus Protocol Reference Guide” (PIMBUS-300). An optional RS-232/RS-485 converter can be connected to the RS-232 port for an RS-485 multi-drop system with a 4-wire installation being the preferred choice. The standard connection type between a customer DCS\SCADA\DAS\PLC and a Model 9xx-Series Analyzer can be either a 9 pin RS-232 or a 4-wire RS-422. • Be selected as the line terminating node. For Model 921CE\921CE WM\922CE Analyzers. 909\910. The Modbus protocol transmission mode implemented is Remote Terminal Unit (RTU) with the analyzer operating as a slave device. Use the information as it applies to your analyzer. • Use RS-232 RTS pin to control its transceiver. Overview This Appendix describes the Modicon Modbus® communication interface on the following Model 9xx-Series Analyzers and their derivatives: 900ADA\930. The RS-422 port receiver pins. Rx±. must be terminated with a terminating resistor of 120 W when the port is connected to customer equipment. 919\920. and 919\920 Analyzers. Appendix B – Serial Communication Interface (Modbus®) | B-1 .Appendix B – Serial Communication Interface (Modbus®)  NOTE The Modicon Modbus® communication interface is optional. refer to Figure B-1 (WX-102822) and Figure B-2 (300-9480) for customer connection pin-outs and cabling requirements. 921CE\921CE WM (Wall Mount)\922CE.

followed by the parameter. F4 • for Model 900\930)]. 919\920. For information on the keystrokes that must be entered to view parameters. certain functions used by the 921CE WM are not used by the 921CE Rack Mount version. The main menu (mode) is listed first. however. This software menu item is listed as [CFG : MBAddr (keystroke is F2 • for Model 909\910. you can set the analyzer Modbus address from the ConFiGuration mode.  NOTE B-2 | Model 909 Single-Gas Analyzer References to “9xx” in this appendix indicate that the function is used by all 900-Series Analyzers. . 921CE\921CE WM\922CE. NOTE References to software menus that you can use to configure serial communication parameters use the same abbreviations as the User Interface Panel. References to 921CE (Rack Mount style analyzers) indicate the functions are also used by 921CE WM (Wall Mount style analyzers). refer to Chapter 4 of this manual. For example.

WX-102822. refer to the electrical connection drawings included in Appendix D. or the Documentation Package shipped with the analyzer. the “Supplemental Information” section of this manual. GP/Div 2 analyzers (Models 900ADA\930. 909\910.  NOTE The customer connections shown in Figure B-1 apply to GP/Div 2 analyzers only. for all other applications. 919\920).Figure B-1. Customer signal connections. Appendix B – Serial Communication Interface (Modbus®) | B-3 .

RS-232 service cable to analyzer wiring. 300-9480.Figure B-2. B-4 | Model 909 Single-Gas Analyzer .

WX-14821. Rear panel descriptions (Model 921CE\921CE WM\922CE Analyzers). Appendix B – Serial Communication Interface (Modbus®) | B-5 .Figure B-3.

ComPara2. 921CE\921CE WM (Wall Mount)\922CE. F4 – for Model 900\930)] of the analyzer Modbus serial communications port are selectable: Baud Rate Value (ComPara1) Stop Bits (ComPara2) Parity (ComPara3) 0 9600 Invalid None 1 4800 1 Odd 2 2400 1.5 None 3 1200 2 Even The default communication parameter settings (or Value) are “0”. and Parity [CFG : ComParaz. where ‘z’ = ComPara1. “1”. respectively (i. number of Stop Bits. 919\920. on both RS-232 and RS-422 ports). ComPara2. 921CE\921CE WM (Wall Mount)\922CE. When a change is made to one of these parameters. the Baud Rate.. which can be a number from 0–255 with the following definitions: Modbus Address Definition 0 Disable Modbus interface 1–127 Enable Modbus interface on RS-232 port 128–255 Enable Modbus interface on RS-422 port Communications Parameters While the number of Data Bits is always 8. and “0” for ComPara1.e. 9600 Baud.Analyzer Modbus Interface Parameters A number of analyzer Modbus interface parameters needs to be set up in order to establish communication with the Modbus master. and no Parity. 1 Stop Bit. B-6 | Model 909 Single-Gas Analyzer . the change must first be saved to the analyzer’s EEPROM and then the analyzer must be reset before the new settings will take effect. 919\920. Modbus Address The analyzer needs to be assigned a Modbus address [CFG : MBAddr] (keystroke is F2 • for Model 909\910. or ComPara3 (keystroke is F2 – for Model 909\910. F4 • for Model 900\930)]. and ComPara3.

rejected message Unsupported function requests from the Modbus master result in exception code “01” (Illegal Function) being returned. Only the following relevant function codes are implemented.e. not all Modbus function codes supported by a slave PLC are applicable to the Model 9xx-Series Analyzers. For example. Exception code “06” (Busy.. all address references in Modbus messages are numbered relative to zero. Exception code “02” (Illegal Address) is returned when the requested address is outside the allowed range or writing to a read-only location. rejected message) is returned if the analyzer is unable to proceed with the calibration action requested by the Modbus master.Modbus Functions Because the Modbus protocol is designed for communication among Programmable Logic Controllers (PLCs). the first holding register in a Modbus slave being referenced as “40001” would be addressed as “0”. When the values to be written to holding registers are outside the appropriate ranges. as requested by “Class 0” functions from Modbus serial protocol for Open Modbus/TCP systems (i. multiple-register read/write functions): Code Definition 03 Read multiple holding registers (4x references) 06 Write one holding register (4x references) 16 Write multiple holding registers (4x references) Accordant to Modbus protocol specification. Exception Code The Model 9xx-Series Analyzers Modbus protocol implementation supports these exception codes: Code Definition 01 Illegal Function 02 Illegal Address 03 Illegal Value 06 Busy. Appendix B – Serial Communication Interface (Modbus®) | B-7 . exception code “03” (Illegal Value) is returned.

The register values must be scaled back at the receiving end to yield the actual values. • Registers 160–228 and 450–457 are used for analyzer calibration (CAL) parameters. Second. the first Register holds the lower 16 bits while the second Register holds the upper 16 bits of a 32-bit floating-point value). the boundary is vendor dependent. 288–289. it is translated back to a location within the first 1000 locations. The registers are used for specific analyzer functions. Modbus protocol does not natively support the transfer of floating point values. 290–428. the two consecutive 16-bit Registers are requested). When requesting a floating-point value.Holding Registers Because RAM space on the analyzer is limited and not all DCS\SCADA\ DAS\PLC systems support Modbus floating point value transfer some floating point values. the analyzer supports the standard Modicon PLC method (i.e. Register #7888 is translated back to Register #888. For example. • Registers 9. B-8 | Model 909 Single-Gas Analyzer . which can assume a value from -32768 to +32767 in two’s complement. • Registers 46–159 and 232–287 are used for analyzer diagnostic measurements/information.. all analyzer Modbus Registers holding floating point values are grouped and located at the higher Register locations. and scaling factors are listed in the following pages along with the applicable analyzer model number. units of measurement. Modbus addresses for all Registers wrap round 1000. and 429–449 are used for analyzer results. as follows: • Registers 0–8. However. when a Modbus master requests a Register above 1000. most Modbus master systems divide the Registers into integer section and floating point section. To make the analyzer Modbus register layout work with all such Modbus master systems. 10–45.e. two steps are taken. First. therefore. generated and used by the analyzer. regardless whether they are CAL or CFG parameters. The holding register definitions. are scaled up and converted into integer values to load into Modbus Registers for transmission. That is. therefore.. and 458–659 are used for analyzer configuration (CFG) parameters. Two Registers are needed to hold one 32-bit floating-point value. 229–231. the order of the Registers holding one floating-point value is implemented in the de facto standard way on the analyzer (i. That is. The size of a Modbus holding register is 16-bit. those systems require that all Registers holding floating point values be located above certain register locations.

‘b’. f Refer to the section “Analyzer Status Bytes (Register 154).” later in this appendix. ‘j’. 190). and value [2] is in the lower byte.. ‘e’. e Each register holds a pair of status code history values.” later in this appendix. and ‘k’ in the Holding Register Definitions (in the following pages) are: a For PPM values with “finer” Units and display selection. h Refer to the section “Digital Input Bit Image (Register 157). 159). value [1] is in the upper byte. d Refer to the section “Units and Display Bit Image (Register 9). display no digit after the decimal point). each register contains 2 characters. ‘i’. i Refer to the section “Digital Output Bit Image (Registers 158. scaling is shown in [ ]. ‘h’. j Refer to the section “Gas Flow Control (Registers 189. To conform to the Modicon Modbus® PLC convention (16-bit wide). For example. ‘c’. b Units of measurement for stream flow rate. k An ASCII character string must be read as a block of registers.The references to footnotes ‘a’. ‘f ’.” later in this appendix. c Kq’s and Ke’s must be adjusted in such a way that the analyzer display shows ‘nnnn’ for stream flow rate and mass emission rate at full-scale (i. ‘d’. mass emission.” later in this appendix. The Modbus registers containing a species or sensor name are NUL terminated ASCII character text strings.” later in this appendix. emission rate. The number of characters indicated for each parameter includes the NUL-terminated ASCII character string.” later in this appendix. Register #90 holds HC status code history values [1] and [2]. The upper byte (bits 15–8) is the first character to be displayed while the lower byte (bits 7–0) is the second character to be displayed.e. scaling is shown in [ ]. For % values with “coarser” Units and display selection. The upper byte (bits 15-8) contains the older one while the lower byte (bits 7-0) contains the newer one of the pair. ‘g’. Appendix B – Serial Communication Interface (Modbus®) | B-9 . and stream velocity are application dependent. g Refer to the section “Solenoid Output Bit Image (Register 156).

% 1 [10]. % 1 [10]. % 1 [10]. 922CE: standard range SO2) (900ADA\930: SO2) (921CE\921CE WM. 921CE) Trend (900ADA\930) 8 1 c r ppm. 1000 [100] r Oxygen Concentration (909\919. 922CE. 909\919: Mass Emission of high span range SO2 in Reg11) 1 c r 17–19 Reserved – – – 20–26 O2 Correction of Results 1–7 (910\920. % 1 [10]. 1000 [100] a r 1 Concentration Result 2 (910\920. 921CE\921CE WM) % 1000 r 9 Units and Display Selection (9xx) – d – r 10–16 Mass Emission of Results 1–7 from Flow Rate (910\920. 910\920. 909\919: High span range SO2) ppm. 1000 [100] r 6 Concentration Result 7 (910\920. 922CE: NO2) (900ADA\930: H2S) (921CE\921CE WM. 909\919: High span range of O2 Corrected SO2 in Reg21) ppm. % 1 [10]. 922CE. 910\920. 922CE) (921CE\921CE WM. % 1 [10]. 922CE: NOx) ppm. 1000 [100] r 4 Concentration Result 5 (910\920. 909\919: Low span range SO2) ppm. Reg Definition Units Scaling Access 0 Concentration Result 1 (910\920. 909\919: Low span range of O2 Corrected SO2 in Reg20) (921CE. % 1 [10]. 922CE: application dependent) (900ADA\930: Sv) ppm. 1000 [100] r 5 Concentration Result 6 (9xx: NDr) ppm. 909\919: Mass Emission of low span range SO2 in Reg10) (921CE\921CE WM. 1000 [100] r 2 Concentration Result 3 (910\920. % 1 [10]. 1000 [100] r Air Demand (900ADA\930) 7 Stream Flow Rate (909\919. 1000 [100] r 3 Concentration Result 4 (910\920. 922CE: NO) (900ADA\930: COS) ppm. 922CE) (921CE. % 1 [10]. 1000 [100] r 27–29 Reserved – – – 30–36 Emission Rate of Results 1–7 from F-factors (920) (919: Emission Rate of low span range O2 Corrected SO2 using Kf in Reg30) (919: Emission Rate of high span range O2 Corrected SO2 using Kf in Reg31) 1 c r 37–45 Reserved – – B-10 | Model 909 Single-Gas Analyzer b b b – . 922CE: extended range SO2) (900ADA\930: CS2) ppm.

921CE: pulses 1 & 2 only) mV 1 r b Appendix B – Serial Communication Interface (Modbus®) | B-11 . 909\919: Low span range of Track & Hold O2 Corrected SO2 in Reg70) (921CE\921CE WM.9 (9xx) Coded Status Value e – r 100 S/L Temperature (900ADA\930.°F 10 r 104 Cell Pressure (9xx) mmHg. 910\920. 922CE) RPM 1 r 111–116 Lamp pulse for Optical Filters 1 to 6 (900ADA\930. 910. 910. 909\919. 910\920) °C. "Hg 10 r 105 Stream Temperature (909\919. 909\919: High span range of Track & Hold Mass Emission of SO2 in Reg61) (921CE\921CE WM.. 1000 r 107 Probe Temperature (900ADA\930. 910\920) °C. 910\920) °C. 909\919. 910\920) °C.°F 10 r 101 V/L or SCU Temperature (900ADA\930. 922CE) (909\919.9 (9xx) Coded Status Value e – r 95–99 MC Status Code History Values 1. #48=lower 16-bit. 909\919: Low span range of Track & Hold Mass Emission of SO2 in Reg60) (921CE\921CE WM. "H2O 100. #47=upper 16-bit) sec – r 48–49 Analyzer MC Run Time (9xx: Reg. 909\919. 910\920. #46=lower 16-bit.°F 10 r 108 Oven Heater Temperature (900ADA\930. Reg. 922CE. 909\919: Low span range of Track & Hold SO2 in Reg50) (921CE\921CE WM. 921CE) mmH2O. 909\919.°F 10 r 103 Cell Temperature (9xx) °C. 909\919. 920) 100 r 110 Filter Wheel Speed (900ADA\930.. 910\920) °C. 921CE) °C.°F 10 r 102 Temperature Control Zone 3 Temperature (900ADA\930. #49=upper 16-bit) sec – r 50–89 Track & Hold Results of Registers 0–39 (921CE\921CE WM.°F 10 r 109 Stream Velocity (919.°F 10 r 106 Differential Pressure (909. Reg Definition Units Scaling Access 46–47 Analyzer HC Run Time (9xx: Reg. 909\919: High span range of Track & Hold O2 Corrected SO2 in Reg71) (919: Low span range of Track & Hold Emission Rate of O2 Corrected SO2 using Kf in Reg80) (919: High span range of Track & Hold Emission Rate of O2 Corrected SO2 using Kf in Reg81) 90–94 HC Status Code History Values 1. 909\919: High span range of Track & Hold SO2 in Reg51) Reg 0–39 Reg 0–39 Reg 0–39 (921CE\921CE WM. Reg. 922CE.

% 1 [10]. 909\919: Zero Calibration Drift of high span range SO2 in Reg138) ppm. 910\920) % 1 r 121–126 Reference PMT Signal of Optical Filters 1 to 6 (900ADA\930. % 1 [10]. Low Byte = MC status – 1 r Reserved – – r 156 Solenoid Output Bit Image g (9xx) – – r 157 Digital Input Bit Image h (9xx) – – r 158 Digital Output Bit Image: lower 16-bit i (9xx) – – r. 910\920) % 1 r 118 V/L or SCU Heater Duty Cycle (900ADA\930. 922CE) (921CE\921CE WM. 1=CAL. 922CE) (909\919. 921CE: Signals 1 to 3 only) mV 1 r 127–132 Measurement PMT Signal of Optical Filters 1 to 6 (900ADA\930. 909\919. 909\919: Low span range of Span Calibration Drift of SO2 in Reg144) (921CE\921CE WM. 909\919. 1000 [100] r 144–150 Span Calibration Drift Concentration of Results 1 to 7 (910\920. Reg Definition Units Scaling Access 117 S/L Heater Duty Cycle (900ADA\930. 910\920.w 159 Digital Output Bit Image: upper 16-bit i (9xx) – – r. 910\920.922CE. 910\920. 909\919. 922CE) (909\919. 922CE. 919) % 1 r 137–143 Zero Calibration Drift Concentration of Results 1 to 7 (910\920. 910\920. 1000 [100] r 151 O2 Zero Calibration Drift (909\919. 921CE: Signals 1 to 3 only) mV 1 r 133–134 Reserved – – r 135 Oven Plate Heater Duty Cycle (900ADA\930. 921CE) % 1000 r 152 O2 Span Calibration Drift (909\919. 910\920) % 1 r 119 TZone3 Heater Duty Cycle (900ADA\930. 910\920) % 1 r 136 ASR Probe Heater Duty Cycle (900ADA\930. 909\919. 909\919: High span range of Span Calibration Drift of SO2 in Reg145) ppm. 909\919: Zero Calibration Drift of low span range SO2 in Reg137) (921CE\921CE WM.w 155 B-12 | Model 909 Single-Gas Analyzer . 910\920) % 1 r 120 Oven/Sample Cell Heater Duty Cycle (900ADA\930. 922CE) (921CE\921CE WM. 909\919. 921CE) % 1000 r 153 Operating Mode: 0=RUN. 2=CFG (9xx) – 1 r 154 Analyzer Status Bytes f (9xx) High Byte = HC status.

1000 [100] r.w OpRatio (900ADA\930) – 1000 r. 1000 [100] r.w 166 Span Gas Concentration of Result 7 (910\920.w OpOffset (900ADA\930) ppm. % 1 [10].w Default SO2 Track & Hold Concentration (900ADA\930) ppm. 909\919: Span Gas Concentration of low span range SO2) ppm. 1000 [100] r. 921CE) % 1000 r. 921CE) % 1000 r.w 168 O2 Air Point Concentration (909\919. 922CE: NO2) (900ADA\930: H2S) (921CE\921CE WM. 1000 [100] r.w Appendix B – Serial Communication Interface (Modbus®) | B-13 .w 163 Span Gas Concentration of Result 4 (910\920. % 1 [10]. 922CE: extended range SO2) ppm.w Air Demand Factor (900ADA\930) – 1000 r.w Static CS2 Concentration (900ADA\930) ppm 1 r. 922CE: standard range SO2) (900ADA\930: SO2) (921CE\921CE WM. see Reg. % 1 [10]. 909\919: Span Gas Concentration of high span range SO2) ppm. 922CE: application dependent) ppm.w Static COS Concentration (900ADA\930) ppm 1 r.w 165 Span Gas Concentration of Result 6 (910\920. 1000 [100] r.w 164 Span Gas Concentration of Result 5 (910\920. 1000 [100] r. 910\920. 922CE. % 1 [10]. % 1 [10]. Reg Definition Units Scaling Access 160 Span Gas Concentration of Result 1 (910\920.w 167 Differential Pressure Signal Span Value (909. 922CE: NOx) ppm. 1000 [100] r. 922CE: NO) ppm. 922CE: application dependent) ppm.w Default H2S Track & Hold Concentration (900ADA\930) ppm. 910) (Reserved.w 161 Span Gas Concentration of Result 2 (910\920.w Static Sv Concentration (900ADA\930) ppm 1 r. "H2O 100 r. % 1 [10]. 444–445) mmH2O. 910\920.w 169 O2 Span Gas Concentration (909\919.w 162 Span Gas Concentration of Result 3 (910\920. 1000 [100] r. % 1 [10]. 1000 [100] r. 922CE. % 1 [10]. 1000 [100] r. % 1 [10]. % 1 [10].

°F 10 r.w 191 Ambient Air Moisture Content or Stack Gas Moisture Content (909\919.w 192 Probe Blow-Back Interval (909\919. 910\920) min 1 r.w 195 Default Cell Temperature (9xx) °C. 921CE WM) – j 1 r. 922CE. 921CE WM) sec 1 r.w 173 Timer3 (922CE) min 1 r. 910\920.w 188 Calibration Adjustment Disable (909\919.w 177 Integration Timer (9xx) sec 1 r. 921CE) min 1 r. 921CE WM) sec 1 r. 921CE) – 1 r. 921CE) – 1 r.w 194 Probe Blow-Back Pulse Width (909\919. 921CE) hr 1 r.w 190 Velocimeter Flow Control (909. 910\920. 922CE. 922CE. 910\920. 910\920) sec 1 r. 922CE.w 196 Default Cell Pressure (9xx) (Reserved.w 180–185 Calibration Solenoid # for Results 1–6 (910\920. "Hg 10 "H2O r.w 171 Timer1 (909\919. see Reg.w 176 Auto-Calibration Interval (909\919. 922CE) – 1 r.w Velocimeter Backpurge Delay (909. 448–449) mmHg.w 186 Calibration Solenoid # for O2 Zero (909\919.w 172 Timer2 (909\919. 910. 922CE.w 174 Sample Delay (9xx) min 1 r.w 178 Velocimeter Backpurge Duration (909. 910. 922CE.w 179 Velocimeter Backpurge Interval (909.w B-14 | Model 909 Single-Gas Analyzer . 921CE) % 1000 r. 922CE.w 193 Probe Blow-Back Duration (909\919.w 175 Auto-Zero Interval (9xx) hr 1 r. 921CE) – 1 r. 910\920. 921CE WM) min 1 r. 910\920. 910.w 187 Calibration Solenoid # for O2 Span (909\919. 910\920) sec 1 r. 921CE) min 1 r. 910\920. 910\920. 910. Reg Definition Units Scaling Access 170 Timer0 (9xx) min 1 r.w 189 Gas Flow Control (9xx) – j 1 r.

w 209 Differential Pressure Signal Zero Offset (909. 909\919) – 1 r 240–245 Transmittance of Optical Filters 1 to 6 (900ADA\930. 921CE) mV 1 r. 922CE. 922CE) (900ADA\930: Span Factor 1 & 2 only) (921CE\921CE WM. 910\920. 922CE) (909\919. 910\920. 910\920) mV 1 r. 922CE) (909\919. 921CE) mV 1 r. 921CE: pulse 1 to 3 only) – 10000 r 252–261 Front Panel Display Line 1 (9xx: 20 characters) ASCII character k – r 262–271 Front Panel Display Line 2 (9xx: 20 characters) ASCII character k – r 272–279 Host-Controller Software Version (9xx: 16 characters) ASCII character k – r 280–287 Micro-Controller Software Version (9xx: 16 characters) ASCII character k – r 288–289 Reserved – – r Appendix B – Serial Communication Interface (Modbus®) | B-15 . 909\919: Span Factor of low span range SO2) (921CE\921CE WM. “H2O 100. 922CE) (909\919.w O2 Zero Calibration Offset (922CE. 909\919: Span Factor of high span range SO2) – 1000 r. 910\920.w 213–216 Zero Calibration of Current (I) Output Channels 1 to 4 (9xx) mA 1000 r. 446–447) mmH2O. 921CE WM) (Reserved.w 225–228 Zero Calibration of Voltage (V) Output Channels 1 to 4 (922CE. 921CE) – 1000 r. 910. 910. 921CE WM) – 1000 r.w 211 O2 Signal Zero Offset (909\919. 921CE: pulse 1 to 3 only) – 10000 r 246–251 Absorbance of Optical Filters 1 to 6 (900ADA\930. 910\920. see Reg. 921CE: Zero Transmittance 1 & 2 only) – 1000 r.w 221–224 Zero Calibration of Voltage (V) Output Channels 1 to 4 (922CE. 1000 r.w 229–231 Reserved – – – 232–235 Analyzer MC Analog Inputs 1 to 4 (9xx) – 1 r 236–239 Analyzer HC Analog Inputs 1 to 4 (910\920.w 210 Differential Pressure Signal Span Factor (909. 921CE) % 1000 212 O2 Calibration Span Factor (909\919. Reg Definition Units Scaling Access 197–202 Zero Transmittance of Optical Filters 1 to 6 (900ADA\930.w 217–220 Span Calibration of Current (I) Output Channels 1 to 4 (9xx) mA 1000 r.w 203–208 Span Factor of Concentration Results 1 to 6 (910\920.

" 100 r.w 311 PMT Level Control (9xx) mV 1 r. 922CE) (909\919.5 stop bits 3=2 stop bits – – r 293 Serial Communication Parity (9xx) 0=none 1=odd 3=even – – r 294–298 Reserved – – r 299 EEPROM Write Counter (9xx) – – r 300 Analyzer Action request (9xx) b0=save to EEPROM b1=auto-setup of optical bench b2=return to RUN mode b3=reset analyzer b4-b15=reserved – – r.w 313 Maximum PMT Signal (9xx) mV 1 r. 921CE: pulse 1 & 2 only) mV 1 r.w 301 302–307 Lamp Control Pulse for Optical Filters 1 to 6 (900ADA\930.w 314 Units and Display Selection (9xx) – d – – 315 Cell Length (9xx) cm. 910\920.w 317 PMT Signal Acquisition Samples (9xx) – 1 r. 429–430) 316 Bench Type Selection (9xx) – d – r.w 312 PMT Balance Control (9xx) mV 1 r. Reg Definition Units Scaling Access 290 Analyzer Modbus Device Address (9xx) – – r 291 Serial Communication Baud Rate (9xx) 0=9600 baud 1=4800 baud 2=2400 baud 3=1200 baud – – r 292 Serial Communication Stop Bits (9xx) 1=1 stop bit 2=1.w B-16 | Model 909 Single-Gas Analyzer .w (Reserved.w 308–309 Lamp Pulse Base Control for lamps 1 to 2 (9xx) mV 1 r.w Key filter (9xx) – 1 r.w 310 Maximum Lamp Pulse (9xx) mV 1 r. see Reg.

922CE) sec 1 r.w 334 NDr Compensation Enable (900ADA\930.w Trend type d (900ADA\930) 341 Analog Input Channel for Measuring Cell Temperature (9xx) – 1 r.w 339 NDr Timer2 [Update] (910\920. 922CE) – 1 r. 910\920. 922CE) – – r. Reg Definition Units Scaling Access 318 PMT Signal Acquisition Delay (9xx) – 1 r. 922CE) (909\919. 922CE.w 328–333 ALC Set Point for Optical Filters 1 to 6 (900ADA\930. 921CE) – 1 r. 910\920.w 340 Analog Input Channel for Measuring O2 (910\920. 921CE) – 1 r. 910\920.w 320 T90 Time Constant (900ADA\930. 910\920. 922CE) – – r.w CS2 Compensation Enable (900ADA\930) 338 NDr Timer1 [Tavg] (900ADA\930.w Analog Input Channel for Measuring Stream Velocity (920.w 343 Analog Input Channel for Measuring Stream Temperature (910.w 322–327 ALC Gain for Optical Filters 1 to 6 (900ADA\930. 922CE) sec 1 r.w Interferent Compensation Enable1 (921CE) Sv Compensation Enable (900ADA\930) 336 NO Linearization Enable (910\920.w Interferent Compensation Enable2 (921CE) COS Compensation Enable (900ADA\930) 337 SO2 Crosstalk Compensation Enable (910\920. 910\920. 922CE) – – r. 921CE: Set Point 1 & 2 only) mV 1 r.w 321 ALC Enable (9xx) – – r. 919) Appendix B – Serial Communication Interface (Modbus®) | B-17 . 922CE) – – r.w 335 SO2 Linearization Enable (910\920.w 319 Filter Wheel Averaging Time Constant (900ADA\930. 922CE. 910\920. 921CE: Gain 1 & 2 only) – 1 r. 909.w 342 Analog Input Channel for Measuring Cell Pressure (9xx) – 1 r. 909\919. 922CE) (909\919. 922CE) sec 1 r.

w 359–360 Probe Temperature Lower and Upper Limits (910\920. 922CE. 922CE. "Hg 10 r. 910\920.w B-18 | Model 909 Single-Gas Analyzer . 910\920. 909\919) % 1 r. 909\919.w 366–369 Temperature Control Set Points for Zones 1 to 4 (900ADA\930. 922CE. 922CE. 922CE.w Averaging Time Constant for Stream Velocity (920. 922CE. 921CE) – 1 r. 919.°F 10 r. 435–438) 357–358 Probe Temperature Measurement Range [Low/High] (910\920. see Reg.w 351–352 O2 Measurement Range [Low/High] (910\920. 909\919) % 1 r. 919) Averaging Time Constant for COS (900ADA\930) 349 Averaging Time for Differential Pressure (910. 909\919. 909\919) °C. 910\920. 921CE) mmH2O. 922CE. 909\919) °C.w (Reserved.w Averaging Time Constant for CS2 (900ADA\930) 350 O2 Concentration for Correction Calculation (910\920.w Averaging Time Constant for Sv (900ADA\930) 348 Averaging Time Constant for Stream Temperature (910. 909\919. "H2O 100. 431–434) 355–356 Differential Pressure Measurement Range [Low/High] (910\920.w (Reserved. 909\919.w 353–354 Cell Pressure Measurement Range [Low/High] (9xx) mmHg.°F 10 r.°F 10 r. 921CE) sec 1 r. 909. 909) °C. 922CE. Reg Definition Units Scaling Access 344 Analog Input Channel for Measuring Differential Pressure (910. 909) °C. 921CE) sec 1 r.°F 10 r. 921CE) % 1000 r. 921CE) sec 1 r.w 374–377 Temperature Control Maximum Duty Cycle for Zones 1 to 4 (900ADA\930. 909. 910\920. see Reg. 910\920.w 362–365 Temperature Measurement Type for Zones 1 to 4 (900ADA\930. 921CE) % 1000 r.w 345 Analog Input Channel for Measuring Volumetric Flow Rate (920. 909. 909\919) – 1 r.w 346 Analog Input Channel for Measuring Probe Temperature (910\920. 909\919) – 1 r.w Analog Input Channel for Measuring Interferent (921CE) 347 Averaging Time Constant for O2 Measurement (910\920.1000 r. 921CE) – 1 r.w 370–373 Temperature Control Start-Up Duty Cycle for Zones 1 to 4 (900ADA\930.w 361 Cell Temperature Lower Limit [Tcold] (900ADA\930.

w 390–393 Species Name for Gas 3 (900ADA\930.w 419–423 CFG Mode Password (9xx: 10 characters) ASCII character k – r.w 431–432 Cell Pressure Measurement Range [Low] (9xx) mmHg. 910. "Hg floating-point value r.w 414–418 CAL Mode Password (9xx: 10 characters) ASCII character k – r.w 435–436 Differential Pressure Measurement Range [Low] (910\920. 922CE: 7 characters) ASCII character k – r.w 450–457 Scale for Analog (I and V) Output Channels 1 to 4 (9xx) – floating-point value r. 922CE: 7 characters) ASCII character k – r.w 439–443 Reserved – – – 444–445 Differential Pressure Signal Span Value (909.w 402–405 Species Name for Gas 6 (900ADA\930. 921CE WM) mmH2O. 919. "H2O floating-point value r. 922CE. 910.w 448–449 Default Cell Pressure (9xx) mmHg.w 378–381 Result Assignment of Analog Output Channels 1 to 4 (9xx) 382–385 Species Name for Gas 1 (9xx: 7 characters) ASCII character k – r. "Hg floating-point value r.w 386–389 Species Name for Gas 2 (900ADA\930. "H2O floating-point value r.w 427–428 Cell Temperature Measurement Range [Low/High] (922CE. 909\919.w 446–447 Differential Pressure Signal Zero Offset (909.w 398–401 Species Name for Gas 5 (900ADA\930. "Hg floating-point value r. 921CE WM) mmH2O. 910\920. 921CE) °C.w 437–438 Differential Pressure Measurement Range [High] (910\920.w 433–434 Cell Pressure Measurement Range [High] (9xx) mmHg.w 394–397 Species Name for Gas 4 (900ADA\930.w 429–430 Cell Length (9xx) cm. 910\920. "H2O floating-point value r. "H2O floating-point value r.°F 10 r. 921CE) sec 1 r.w 406–413 Analyzer Serial Number (9xx: 16 characters) ASCII character k – r. 922CE. 921CE) mmH2O.w 426 Averaging Time for Cell Pressure Measurement (922CE. 909\919. 922CE: 7 characters) ASCII character k – r. 922CE. 921CE) sec 1 r. 921CE) sec 1 r. 910\920. Reg Definition Units Scaling Access – 1 r." floating-point value r.w 424 Averaging Time for Volumetric Flow Rate (920. 922CE: 7 characters) ASCII character k – r. 910\920. 922CE: 7 characters) ASCII character k – r.w Appendix B – Serial Communication Interface (Modbus®) | B-19 . 910\920. 921CE) mmH2O.w 425 Averaging Time for Cell Temperature Measurement (922CE.

922CE) (909\919. 922CE.w 530–533 Temperature Compensation Coefficients 1 to 2 (910\920) – floating-point value r.w Interferent Input Measurement Range [Low/High] (921CE) 560–571 Absorbance Offset Vector Elements 1 to 6 (900ADA\930) – floating-point value r.w 610–623 Kf for Concentration Results 1 to 7 (920) (919: one value only) – floating-point value r.w 596–609 Ke for Concentration Results 1 to 7 (910\920.w 518–529 Matrix Row 6 Elements 1 to 6 (900ADA\930. 922CE) – floating-point value r.w B-20 | Model 909 Single-Gas Analyzer .w Adaptive Filtering Coefficients 1 to 2 (909\919.w 590–593 Volumetric Flow Rate Measurement Range [Low/High] (920.w 482–493 Matrix Row 3 Elements 1 to 6 (900ADA\930. 921CE) 534–551 Cross Interference Compensation Vector 1 Elements 1 to 9 (900ADA\930) – floating-point value r. Kv) – floating-point value r. 910\920. 910\920. Cross-section area. 922CE) – floating-point value r. 921CE: k-value 1 & 2 only) – floating-point value r. 910\920. 921CE) – floating-point value r. 919. 919: Low/High range values) – floating-point value r. 921CE. 910\920.w 582–589 Stream Velocity Measurement Parameters 1 to 4 (920.w 594–595 Kq (910.w 494–505 Matrix Row 4 Elements 1 to 6 (900ADA\930. 922CE: six values only) Linearization Coefficients 1 to 7 (921CE: seven values only) 552–559 Cross Interference Compensation Vector 2 Elements 1 to 4 (900ADA\930) – floating-point value r. 919: Low/High range values. Reg Definition Units Scaling Access 458–469 Matrix Row 1 Elements 1 to 6 (900ADA\930. 909) (922CE.w 506–517 Matrix Row 5 Elements 1 to 6 (900ADA\930. 910\920. 909.w Linearization Coefficients 1 to 6 (910\920. 910\920.w 470–481 Matrix Row 2 Elements 1 to 6 (900ADA\930.w Static N2O Concentration (910\920: one value only) 572–581 Stream Temperature Measurement Coefficients 1 to 5 (910. 921CE: one value only) – floating-point value r. 922CE. 922CE) – floating-point value r. 922CE) – floating-point value r. 922CE) (909\919. 922CE) – floating-point value r. 921CE) – floating-point value r.

#158. 910\920. Appendix B – Serial Communication Interface (Modbus®) | B-21 .w 632–639 Temperature Control Ti Values for Zones 1 to 4 (900ADA\930. 919) – floating-point value r. The content of these registers are updated once per second. 910\920.  NOTE The gas species assigned to concentration results listed in the above Holding Registers table assume default configuration for that analyzer model. Their values are updated once per second. In high concentration applications. Kp. Td. % concentration registers may be scaled with a factor of 100 instead of the normal scale of 1000 to prevent register value overflow.w Registers #0 to #89 are results calculated by the analyzer and Registers #100 to #109 are analog inputs measured by the analyzer. PPM concentration registers may be scaled with a factor of 10 instead of the normal scale of 1 to give finer resolution results.w 648–659 ASR Probe Temperature Control Parameters [Set Point. the analyzer configuration parameter [CFG : Units] (keystroke is F1 9) can be set up to provide finer or coarser resolution on the concentration results shown on the User Interface Panel and stored in Modbus holding registers. Registers #160 to #194 are variables the Modbus master can alter either to customize the analyzer calibration process or to alert the analyzer of changing process operating conditions. 909\919) – floating-point value r. 909\919) – floating-point value r. and #159. Digital I/O bit images are duplicated in Registers #157. 910\920. Ti. Registers #121 to #152 are calibration related variables and they are modified only after a calibration action has been performed by the analyzer.w 640–647 Temperature Control Td Values for Zones 1 to 4 (900ADA\930. 909\919) – floating-point value r. Start-Up Duty Cycle & Maximum Duty Cycle] (900ADA\930. For low concentration (White Cell) and high concentration (Short Cell) applications. They are subject to reassignment to customize the analyzer to an application. Reg Definition Units Scaling Access 624–631 Temperature Control Kp Values for Zones 1 to 4 (900ADA\930. Registers #110 to #120 are diagnostic variables and are updated once every four seconds. In low concentration applications.

910\920. Analyzer Status Bytes (Register 154) Analyzer Microcontroller board status (low) byte: Bit Value Definition 0 = Normal.Units and Display Bit Image (Register 9) Bit Value Definition 0 1 0 = Metric Units 1 = Imperial Units 1. 921CE) 1 2 [F] on-board ADC not responding (9xx) 2 4 [F] on-chip A/D not responding (9xx) 3 8 [W] PMT signals out of range (9xx) 4 16 [F] MC-HC communication problem (9xx) 5 32 [W] automatic lamp control out of range (9xx) 6 64 [F] oven heater too hot (909\919. 1 = [F]ault \ [W]arning 0 1 [F] filter wheel speed out of range (9xx with filter wheel) [F] pulse timing (909\919. 2 2.4* 0 = Normal Concentration Result in PPM 2 = Normal Concentration Result in % 4 = Finer (Low) Concentration Result in PPM 6 = Coarse (High) Concentration Result in % 3 8 0 = Display 4 Items 8 = Display 3 Items 4 16 0 = Remote ACAL 16 = Remote Backpurge/Zero Flow * Sum of Bits 1 and 2 decimal value. 900ADA\930) 7 128 reserved for internal use (9xx) B-22 | Model 909 Single-Gas Analyzer .

921CE.384 Reserved 15 32. 909\919) 3 8 Span3 (922CE. 909\919) 2 4 Span2 (922CE.192 Velocimeter Solenoid 2 (910. 909\919) 4 16 Reserved 5 32 Reserved 6 64 Reserved 7 128 Reserved 8 256 Reserved 9 512 M&C Probe Isolation (910\920.096 Velocimeter Solenoid 1 (910\909. Sample (900ADA\930) 14 16. the analyzer is in backpurge.024 [F] HC-MC communication problem (9xx) 3 2.768 Reserved Note: If all solenoids (bits) are off.048 [F] analytical data not received (9xx) 4 4. 900ADA\930) 5 8. Appendix B – Serial Communication Interface (Modbus®) | B-23 .384 [W] excessive zero drift or span error (9xx) 7 32.192 [F] temperature zone too high (909\919. 910\920.Analyzer Host Controller board status (high) byte: Bit Value Definition 0 = Normal.768 [W] SKO temperature high (900ADA\930) [W] TZone3 temperature high (909\919) Solenoid Output Bit Image (Register 156) Bit Value Definition 0 1 Zero (922CE. 921CE. 900ADA\930) 6 16. Sample (910\920.024 M&C Probe Blow-Back (910\920. 1 = [F]ault \ [W]arning 0 256 [W] EEPROM full (9xx) 1 512 [W] analog output out of range (9xx) 2 1. 921CE WM). 921CE WM) 13 8. 910\920. 909\919) 10 1. 921CE). 909\919) 1 2 Span1 (922CE. 909.096 [F] temperature zone too low (909\919. 910\920.048 Reserved 12 4. 910\920. 910\920. 921CE. 909\919) 11 2.

910\920. 920 if Units Bit 4 is Set) 1 = normal (closed) 0 = backpurge (open) Digital Output Bit Image (Registers 158. 159) Register 158 (Digital Output Bit Image: lower 16-bit) Bit Value Definition 0 1 Auto-Calibration (909\919. 919. 922CE. 910. 909. 922CE. 921CE) 4 16 Auto-Span 3 (922CE. 921CE) 5 32 Reserved 6 64 Reserved 7 128 Reserved 8 256 Man-Zero (9xx) 9 512 Man-Span 1 (9xx) 10 1. 921CE) 1 2 Auto-Zero (9xx) 2 4 Auto-Span 1 (909\919. 922CE) SO2 XTalk Reduction (900ADA\930) 12 4. 909\919.Digital Input Bit Image (Register 157) There are two digital inputs on the Model 9xx-Series Analyzers: Bit Value Definition 0 1 Over-Temperature Trip Signal (900ADA\930. 919. 910. 922CE) (900ADA.768 Reserved B-24 | Model 909 Single-Gas Analyzer . 921CE) 3 8 Auto-Span 2 (909\919. 910\920. 922CE) 15 32.096 Man-Span 4 (910\920.384 Man-Span 6 (910\920.024 Man-Span 2 (9xx) 11 2. 910\920. 910\920) 1 = normal 0 = tripped 1 2 Remote Auto-Calibration Contact (921CE. 922CE) 13 8.192 Man-Span 5 (910\920.048 Man-Span 3 (910\920. 922CE) 14 16. 922CE. 920 if Units Bit 4 is Cleared) 1 = start (closed) 0 = normal (open) Remote Backpurge Contact (900ADA. 909.

The bit stays set for as long as the calibration action is in progress so that the Modbus master can read the bit to determine if the action has been completed. 922CE. Appendix B – Serial Communication Interface (Modbus®) | B-25 . 910\920. 921CE WM) 5 32 Velocimeter Span (909. the lowest action bit in the request takes precedence. A calibration action started at the analyzer using a keypad command. 909\919. - One (1) indicates the associated action is in progress. • Writing a “0” while the addressed calibration action is in progress cancels the action. 910. However. 910. the message is acknowledged but the action does not restart. 922CE. 921CE) 1 2 Man-Zero O2 (909\919. 910\920) CAL Relay (922CE. 921CE) 2 4 Reserved 3 8 Reserved 4 16 Velocimeter Zero (909.Register 159 (Digital Output Bit Image: upper 16-bit) Bit Value Definition 0 1 Man-Span O2 (909\919. Since only one calibration action can be active at any given time. 910\920. 921CE WM) 6 64 Velocimeter Backpurge (909. - Zero (0) indicates that the action is inactive. If the Modbus master initiates the same action before that action is complete. 910\920) 8 256 CAL Relay (909\919. cannot be cancelled using Modbus. on a timed basis or by remote digital input. only a calibration action initiated from the Modbus interface can be cancelled from the Modbus interface. 921CE) FAULT Relay (9xx) 10 11–15 1024 — Reserved • Bits #0 to #15 (Register 158) and #0 to #7 (Register 159) indicate the current analyzer calibration action status. Writing a “1” to one of these bits starts the addressed calibration action. 910. 910\920) AUTO\MAN Relay (900ADA\930) 9 512 ATTEN Relay (900ADA\930. 921CE WM) 7 128 Probe Blow-Back (909\919.

FAULT Relay). a calibration action cannot be started by the Modbus master and a busy message is also returned. 190) Value Definition 0 Analyzer Control 1 Continuous Backpurge 2 Continuous Sample 10 Continuous Zero 11 Continuous Span Gas 1 12 Continuous Span Gas 2 B-26 | Model 909 Single-Gas Analyzer . The conditions under which these relays operate are described in Chapter 1 of this manual. Gas Flow Control (Registers 189. When the analyzer encounters a fault condition as indicated by bit #10 (Register 159. • Status bits #8 to #10 (Register 159) are set when the corresponding relay status is true.• Before initiating a calibration action. If a calibration action is already in progress. a busy message is returned. the Modbus master must read bits #0 to #15 (Register 158) and #0 to #7 (Register 159) to ensure that no action is in progress at that time.

101.16 3 3 22.546 092 gal (US) m3 0.042 493 2 ft of gas (60 °F.325 kPa) kmol 0.01 3 Appendix C – Conversion Factors & Calculations | C-1 .001 195 30 ft2 m 2 in2 mm2 in2 cm2 6.453 592 4 g mol kmol 0.573 53 gal (UK) m 0.883 51 3 ppm by volume 3 cm /m 1.785 412 grains/100 ft3 mg/m3 lb mol/ft kmol/m 16.Appendix C – Conversion Factors & Calculations Conversion Factors PARAMETER AMOUNT of SUBSTANCE TO CONVERT FROM: TO: MULTIPLY BY: lb mol kmol 0.325 kPa) kmol 0.044 615 8 m3 of gas (15 °C.0 atm) kmol 0.836 172 4 bbl (42 gal US) m3 0.018 46 ppm percent 0.413 05 fl oz (US) cm3 29.092 903 04 645.158 987 3 fl oz (UK) cm 28.0 weight percent kg/kg 0.003 785 412 gal (US) L 3. 101. 1.000 1 3 3 AREA CAPACITY CONCENTRATION 3 0.0 ppm by weight mg/kg 1.004 546 092 gal (UK) L 4.451 6 yd2 m2 0.001 (for Ideal gas) m of gas (0 °C.

119 826 4 lb/ft3 kg/L 0.471 947 5 ft3/min L/s 0.799 366 7 ft m in mm yd m 0.798 91 lb kg oz (avoirdupois) g 28.746 million BTU/h MW 0.016 047 ton (2000 lb) t 0.016 018 46 g/cm kg/L 1.0 lb/ft3 kg/L 3 DENSITY (Solids) ENERGY MULTIPLY BY: 16.055 056 cal kJ 0.907 184 7 3 LENGTH MASS POWER 3 0.227 124 7 ft3/h m3h 0.018 46 0.004 184 kcal kJ kWh kJ bbl/d t/a FLOW RATE 4.028 316 85 ft /h L/min 0.099 776 44 lb/gal (US) kg/L 0.0 58.272 765 5 gal (US)/min m h 0.103 48 ton (2240 lb) t 1.471 947 5 lb/h t/d 0.453 592 4 ton (2240 lb)/d kg/h 42.453 592 4 BTU/min kW 0.349 52 oz (troy) g 31.304 8 25.030 36 bbl/h 3 m h 0.335 290 7 ton (2000 lb)/d kg/h 37.293 071 1 C-2 | Model 909 Single-Gas Analyzer .4 0.184 3600.914 40 grain mg 64.016 018 46 BTU kJ 1.158 987 3 gal (UK)/min m3h 0.055 056 hp kW 0.017 584 27 BTU/s kW 1.PARAMETER TO CONVERT FROM: TO: DENSITY (Gases) lb/ft3 kg/m3 DENSITY (Liquids) lb/gal (UK) kg/L 0.010 886 22 lb mole/h kmol/h 0.

133 322 4 psi kPa 6.186 8 kcal/kg * °C kJ/kg * °C kW * h/kg * °C kJ/kg * °C BTU/lb mol * °F kJ/kmol * °C 4.PARAMETER TO CONVERT FROM: TO: ATM kPa 101.249 082 in of H2O (60 °F) kPa 0.248 84 mm of Hg = torr (0 °C) kPa 0.764 554 9 Appendix C – Conversion Factors & Calculations | C-3 .2 °F) kPa 0.184 ft/s m/s 0.984 757 BTU/lb * °F kJ/kg * °C 4.02831685 in cm yd3 m3 PRESSURE SPECIFIC HEAT CAPACITY SPEED TEMPERATURE VOLUME 3 3 MULTIPLY BY: 4.304 8 in/s mm/s 2.555 555 555 °F-32 °C 0.0 cm of H2O (4 °C) kPa 0.376 85 in of H2O (39.325 bar kPa 100.555 555 555 ft3 m 3 0.387 06 0.186 8 cal/g mol * °C kJ/kmol * °C 4.609 344 °R K 0.54 mile/h km/h 1.098 063 8 in of Hg (32 °F) kPa 3.555 555 555 Fahrenheit degree Celsius degree 0.184 3 600.386 388 157 in of Hg (60 °F) kPa 3.0 16.

SI Prefixes FACTOR (by which unit is multiplied) PREFIX SYMBOL T EXAMPLE One million million (billion) 1012 tera One thousand million 10 giga G One million 10 mega M megawatt (MW) One thousand 10 kilo k kilometre (km) One hundred 10 hecto* h Ten 10 deca* da UNITY 9 6 3 2 1 gigahertz (GHz) decagram (dag) 1 One tenth 10-1 deci* d decimetre (dm) One hundredth 10 centi* c centimetre (cm) One thousandth 10 milli m milligram (mg) One millionth 10-6 micro µ microsecond (µs) One thousand millionth 10-9 nano n nanosecond (ns) One million millionth 10-12 pico p picofarad (pF) One thousand million millionth 10-15 femto f One million million millionth 10-18 atto a * To be avoided wherever possible. C-4 | Model 909 Single-Gas Analyzer -2 -3 .

At 0 °C and 101. is defined by: Gs = where: s = r = ρs . Mm.” later in this Appendix). 28. the density of dry air2 is 1. it is convenient to use dry air as a reference. Appendix C – Conversion Factors & Calculations | C-5 . s.293 1 kg/cm3. Mair. under “Air Composition. Under these conditions the H2O is at maximum density2.Gas Mixtures Average Molecular Weight The weighted average molecular weight. ρr (Equation 2) density of substance s. and molecular (formula) weight of component i (kg/kmol).965 M air (Equation 3) The weighted average molecular weight of air. For liquids.325 kPa. Gs.325 kPa. was calculated from the composition of air4 in the “Components of Atmospheric Air” list (under “Air Composition”) using Equation 1.000 00 g/mL (or equivalently. and density of a reference material r at a specified temperature and pressure. Specific Gravity The specific gravity. of a substance. If it is assumed that the gases are ideal. it can be shown that the specific gravity of gas j relative to air is defined by: Gj = Mj Mj = . although this does present some problems occasionally because air is a mixture (see “Components of Atmospheric Air” list. For gases.999 973 g/cm3). 100 (Equation 1) concentration of component i in the mixture (mole percent). 0. 1. of a mixture of n components is defined by: Mm = where: [xi] = Mi = n ∑ i=1 [ xi ] M i . the reference material is usually H2O at 3.98 °C and 101.

004 Kr 1.001 H2 0.001 (ppm) Ne 18.002 CO2 0.084 ± 0.946 ± 0.004 O2 20.04 He 5.18 ± 0.5 ± 0.24 ± 0.01 Xe 0.5 CH4 2 N 20 0.033 ± 0.934 ± 0.087 ± 0.001 Ar 0.14 ± 0.Air Composition Components of Atmosphere Air Constituent Content (Percent) N2 78.1 (Exclusive of water vapor)4 C-6 | Model 909 Single-Gas Analyzer .

Gas Flow Rate Measurement The flow rate of a sample stream frequently is determined by using a pitot tube. duct shape and speed-profile shape. Unlike orifice or venturi meters. and two duct diameters ahead of. which effectively measure average gas speeds through constrictions in ducts. the measurement plane should be eight duct diameters downstream from. To obtain an average gas speed requires that a number of measurements be made at different points on a given cross-sectional plane. measurements are made at the centroids of the sub-areas. In general. The number of measurements required to define the gas speed profile adequately depends upon the distance of the measurement plane from upstream or downstream obstructions. Cross Sectional view of rectangular and round ducts. For rectangular ducts. the measurements are made where the centroid arcs of the annular sub-areas intersect two mutually perpendicular lines which both pass through the centre of the measurement plane. Appendix C – Conversion Factors & Calculations | C-7 . the pitot tube measures the gas speed at a single point within a flowing gas stream.6. duct size. any flow obstructions. Figure B-1. The cross-sectional area is then subdivided into equal-area segments (see Figure B-1). Criteria for selecting the number of measurements usually are specified by local regulatory agencies5. The dashed lines in the sketches delineate the sub-areas and the ‘+’ signs indicate the points for the measurements. For round ducts.

i (m/s) [ft/s].907 04] The pitot tube calibration factor (F) is determined empirically.00 but. Pf M (Equation 4) where: vi = linear gas speed at pitot tube tip location. F usually is between 0. Equation 4 is useful3 in the gas speed range of 40 to 60 m/s (15 to 200 ft/s). for the Stausscheibe (S-type) pitot tubes routinely used for source emission tests. U = 59. C-8 | Model 909 Single-Gas Analyzer . Tfa = average temperature of sample stream (see Equation 6) (K) [°R]. and U = a constant that depends upon the system of units employed. F = Pitot tube calibration factor (dimensionless). special methods are required to account for shock wave interferences. Pf = static pressure of the gas stream (KPA) [PSIA].85. (For the above metre-kilogram-second (SI) units. Equation 4 requires modification to account for compression of the gas. Below this range. For standard pitot tubes. F generally is between 0. In the 60 to 230 m/s (200 to 750 ft/s) range. M = molecular weight of gas stream (kg/kmol) [lb/lb mol]. another method of measurement is required. U = 128.The working equation for the pitot tube is: vi = U F Z f T f i ∆ Pi .75 and 0. Zf = compressibility of gas at Tfa and Pf (dimensionless). Pi = differential pressure between the impact pressure head and the local static pressure of the stream at point i (KPA) ["H2O].952 1) [For the above foot-pound-second (imperial) units. Above 230 m/s (750 ft/s). often in a wind tunnel.98 and 1. Tfi = local temperature of flowing gas stream at point i (K) [°R].

(Equation 5) Since the Pitot tube and temperature readings are obtained at the centroids of the equal areas. Appendix C – Conversion Factors & Calculations | C-9 . Thus: Q = va A Tr Pf Zr . where: Qf = volume flow rate of sample stream at Tfa and Pf (m3/s) [ft3/s]. the average temperature and average gas speed are defined by: n T fa = ∑T i .The volumetric flow rate of the sample stream at stream conditions. (Equation 7) the number of measurements. is computed from: Q f = va A . Qf . and A = cross-sectional area of duct at plane of measurement (m2) [ft2]. Pr = reference pressure (KPA) [PSIA]. i=1 n (Equation 6) and n va = where: n = ∑v i=1 n i . Tr = reference temperature (K) [°R]. and Zr = compressibility factor at Tr and Pr (dimensionless). T fa P r Z f (Equation 8) where: Q = volume flow rate of sample stream at Tr and Pr (m3/s) [ft3/s]. va = average linear gas speed through measurement plane (m/s) [ft/s]. It is standard practice to express the volumetric flow rate at specified reference conditions rather than at the sample stream conditions.

va. (Pia)1/2 is computed: n 1/2 ( ∆ Pi a ) = ∑ i=1 ∆ Pi n . Fp. In these cases. The second alternative is used for continuous monitoring systems. the temperature is equal to or greater than 0 °C (32 °F) and the pressure is near atmospheric pressure.The molar flow rate of the sample stream is then obtained from: Q Qm = . (Equation 10) Then (Pia)1/2 is used once in Equation 10 with the results of Equation 6 to calculate the average gas speed. In this approach. C-10 | Model 909 Single-Gas Analyzer . In this approach. the usual output desired is the volumetric flow rate at the specified reference conditions. the Pitot tube is positioned at a fixed point and an additional factor. This position factor corrects the gas speed measured at the fixed point to the average gas speed as determined by measurements from full traverses of the sample stream using another pitot tube. an average square root of the differential pressures. Z rV I (Equation 9) where: Qm = molar flow rate of sample stream (kmol/s) [lb mol/s]. for continuous monitoring systems. Usually the reference conditions and the sample stream conditions are such that the sample fluids can be assumed to behave ideally. the compressibility factors (Zf and Zr) are assumed to be unity. One alternative is used to reduce the number of calculations when manual measurements are carried out. That is. Moreover. is incorporated into the equation. and VI = ideal gas molar volume at Tr and Pr (m3/kmol) [ft3/lb mol]. There are two common alternatives to Equation 7 for obtaining the average gas speed.

Zf M (Equation 13) Appendix C – Conversion Factors & Calculations | C-11 . Tfa (Equation 12) where: KQ = ∆ P pt A F p UF Z r T r Pr Pf . Ppt = Pitot tube differential pressure at the fixed point (KPA) ["H2O]. the continuous monitoring working equation becomes: Q = A F p UF Z r T r Pr Pf Zf M ∆ P pt . Tfa (Equation 11) where: Q = volume flow rate of sample stream at Tr and Pr (m3/s) [ft3/s]. and 8 and incorporating the position factor.By combining Equations 4. Fp = Pitot tube position factor (dimensionless). the sample stream molecular weight and static pressure usually are assumed to be constant so that Equation 11 reduces to: Q = KQ . 6. For a given system.

and Qp is expressed in ft3/s at 70 °F and 1. Ex. then KU = 0. which depends upon the desired units for Ex and the units in which [x] and Qp are expressed.031 974 9. KU = 1. where: Qp = flow rate of sample stream. KU = units conversion factor.0 atm. NOTE For use in Equation 14. [x] must be corrected to the wet basis by multiplying by Cw:  [ H 2 O]  .)  (*) LTD = long ton per day.Mass Flow Rate The mass flow rate of any given component. both the concentration and the stream flow rate must be on the same basis.1 °C and 101. [SO2] is expressed in mole percent.325 KPA. [SO2] expressed in mole percent. and [x] is measured on a wet basis. long ton = 2 240 lb. If Qp is the total flow rate including H2O vapor. ES (the sulfur equivalent of SO2) to be expressed in t/d of S1. and [x] is measured on a dry basis. and [x] = concentration of component x in the sample stream.14737. [x] must be corrected to the same dry basis by dividing by Cw (Equation 15). ES (the sulfur equivalent of SO2) is to be expressed in LTD (* see Note) of S1. and Qp expressed in m3/s at 21. Cw = 1 100   (Equation 15) where: [H2O] = the H2O concentration in the sample stream (mole percent). C-12 | Model 909 Single-Gas Analyzer . If Qp is just the dry flow rate excluding H2O vapor. (Equation 14) For the special case of x = SO2. for x = SO2. (If. in the sample stream is obtained from: E x = K U [x] Q p .

Cecil H. “Protection of Environment”. N.) 2. 6. Ohio: Chemical Rubber Publishing Co.). Kirkpatrick (eds. 1974. Inc. 4. Forker (eds. Selby (eds. (Curve fit to data on pp.: McGraw-Hill. Edmonton.1). p. Shankland and Samuel M. H. 1976.References 1. New York. Alberta. Code of Federal Regulations. Chilton and Sidney D. 3505. 1981. Standards and Approvals Division. Cleveland. Source Sampling Code. 5. New York. N. Hodgman. Handbook of Chemistry & Physics (44th edition). Robert C. Chemical Engineers’ Handbook (4th edition). Alberta Environment.: McGraw-Hill. Chapter 1..). 1963. Norbert Adolph Lange and Gordon M.. ­­ Appendix C – Conversion Factors & Calculations | C-13 . 1962. Industrial Waste Management Branch. Robert S. Perry. Title 40.Y. Paskall. Publication SSC-1/76. Inc..1470-3 of reference 2. 1967 3.Y. Charles D. Weast. Environmental Protection Agency (40 CFR 50. Robert H. Revised as of July 1.). Handbook of Chemistry (Tenth edition).

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Appendix D – Drawings This Appendix includes many drawings that are included in the main body of this manual.  NOTE IMPORTANT Drawings that are job-specific (called “Final As-Built”) are located in the “Supplemental Information” section of this manual and in the Documentation Package shipped with the analyzer. Use these drawings in place of similar “example” drawings used in this manual. Appendix D – Drawings | D-1 . and do not illustrate all possible applications or depict all hazardous locations. Certain drawings in this manual are examples only.

Analyzer Schematic (WX-14716) D-2 | Model 909 Single-Gas Analyzer .

Analyzer (GP) Piping & Instrumentation Diagram  NOTE Example drawing only. Refer to customer-specific Final “As-Built” drawing for your application. shipped with the analyzer. Appendix D – Drawings | D-3 .

.Backpan Mounting Details. shipped with the analyzer. GP Analyzers  NOTE D-4 | Model 909 Single-Gas Analyzer Example drawing only. Refer to customer-specific Final “As-Built” drawing for your application.

Refer to customer-specific Final “As-Built” drawing for your application. GP Analyzers  NOTE Example drawing only. Appendix D – Drawings | D-5 . shipped with the analyzer.Overall Component Layout.

instrumentation. the plumbing. optional components. . While the Electronics Enclosure layout generally does not change for different applications.Electronics Enclosure Layout. and external wiring may differ. GP Analyzers  NOTE D-6 | Model 909 Single-Gas Analyzer Example drawing only. Refer to customer-specific Final “As-Built” drawing for your application. shipped with the analyzer.

User Interface Panel (WX-14151) Appendix D – Drawings | D-7 .

AC Wiring. GP/Div 2/CE/Zone 1 Analyzers (WX-102853) D-8 | Model 909 Single-Gas Analyzer .

Ribbon Cable Interconnect (WX-102836) Appendix D – Drawings | D-9 .

GP/Div 2 Analyzers (100-1254-5) D-10 | Model 909 Single-Gas Analyzer .Sample/Vent Line Wiring.

CE Analyzers (WX-102810) Appendix D – Drawings | D-11 .GP Lower Enclosure to Electronics Wiring.

Heater and Sensor Wiring. GP/Div 2 Analyzers (WX-102851) D-12 | Model 909 Single-Gas Analyzer .

CE/Zone 1 Analyzers (WX-102852) Appendix D – Drawings | D-13 .Heater and Sensor Wiring.

Disconnect Enclosure Wiring. Zone 1 Analyzers (100-1343-5) D-14 | Model 909 Single-Gas Analyzer . 120V.

240V. Zone 1 Analyzers (100-1344-5) Appendix D – Drawings | D-15 .Disconnect Enclosure Wiring.

Lower Cabinet Wiring. 120V (100-1341-3) D-16 | Model 909 Single-Gas Analyzer . CE/GP Analyzers.

Lower Cabinet Wiring. 240V (100-1342-3) Appendix D – Drawings | D-17 . CE/GP Analyzers.

Customer Signal Connections. GP/Div 2 Analyzers (WX-102822) D-18 | Model 909 Single-Gas Analyzer .

Customer Signal Connections. CE/Zone 1 Analyzers (WX-102816) Appendix D – Drawings | D-19 .

GP/Div 2/CE/Zone 1 Analyzers (WX-102815) D-20 | Model 909 Single-Gas Analyzer .Signal Wiring.

GP/Div 2/CE/Zone 1 Analyzers (WX-102811) Appendix D – Drawings | D-21 .± 15V and 5V Power Supply DC Wiring.

24V Power Supply DC Wiring. CE/Zone 1 Analyzers (WX-102812) D-22 | Model 909 Single-Gas Analyzer .

RS-232 Communications Cable Wiring (300-9480) Appendix D – Drawings | D-23 .

RS-232/RS-485 Module Wiring. CE/Zone 1 & GP/Div 2 Analyzers (100-2185) D-24 | Model 909 Single-Gas Analyzer .

Zone 1 Analyzers (100-1343-9) Appendix D – Drawings | D-25 .Wiring Diagram. All Seals. 120V.

Wiring Diagram. Zone 1 Analyzers (100-1344-9) D-26 | Model 909 Single-Gas Analyzer . 240V. All Seals.

Optical Bench Board (100-1662) Appendix D – Drawings | D-27 .

Micro-Interface Board (100-0116) D-28 | Model 909 Single-Gas Analyzer .

Host Controller Board (Display Interface) (100-0138) Appendix D – Drawings | D-29 .

Microcontroller Board (100-0117) D-30 | Model 909 Single-Gas Analyzer .

Termination Board (100-1534) Appendix D – Drawings | D-31 .

Display I/O Board (100-0939) D-32 | Model 909 Single-Gas Analyzer .

Measuring Cell/Lamp Assembly (WX-14856) Appendix D – Drawings | D-33 .

120 V (100-1933-1) D-34 | Model 909 Single-Gas Analyzer .Optional Velocimeter Solenoid Block.

Optional Velocimeter Zeroing Layout. 120 V. 909/910 GP Analyzers (100-1933-2) Appendix D – Drawings | D-35 .

Optional Velocimeter Solenoid Block. 240 V (100-1934-1) D-36 | Model 909 Single-Gas Analyzer .

240 V.Optional Velocimeter Zeroing Layout. 909/910 GP Analyzers (100-1934-2) Appendix D – Drawings | D-37 .

Electronics Panel Layout (100-1160-1) D-38 | Model 909 Single-Gas Analyzer .Zirconia Oxide O2 Sensor (Optional).

Zirconia Oxide O2 Sensor (Optional). Wiring Connections (100‑1160‑2) Appendix D – Drawings | D-39 .

Flow Diagram (100-2141-1) D-40 | Model 909 Single-Gas Analyzer .Calibration Manifold Block.

Assembly Diagram (100-2141-2) Appendix D – Drawings | D-41 .Calibration Manifold Block.

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and various other analyzer information. Information typically included in this section includes: • Manual Supplements – that describe and illustrate installation. which list the Analyzer Information (Serial Number. • Customer-specific Final “As-Built” drawings for the entire system. Programmable Device and Gas Run Data Sheets). Supplements are typically used for Measuring Cells. operation. Testing. typically included in the Documentation Package shipped with the analyzer. Software version). Material Traceability. if required. • Configuration Data Sheet. can include: • Quality Control Documentation (Configuration. Species (Matrix). and communication (Modbus®) information. • EEPROM Data Sheets. Temperature Control.Supplemental Information This section consists of information that supports the operation of this analyzer. Analog Inputs. and maintenance procedures for specific components or optional equipment that make up your sample system. which list the factory-default configuration settings of all programmable parameters. All information in this chapter comprises the Documentation Package. Compensations. nonstandard or optional equipment. or information that is intended to replace similar information – or add to existing information – in the User Manual. Testing. Additional information. which lists all of the Function keystrokes to access analyzer parameters from the User Interface Panel. • Other customer-specific information may also be included (application-specific). Supplemental Information | S-1 . • Operator Interface Quick Reference Sheet. Gas Calibration. configuration of the Optical Bench. Analytical Parameters.

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