Professional Documents
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User Manual
TQM
COMMITTED TO TOTAL QUALITY
Canada, Inc.
A DIVISION OF AMETEK PROCESS & ANALYTICAL INSTRUMENTS
Western Research
PN 903-8601, REV F 2876 Sunridge Way N.E.
Calgary, AB, Canada T1Y 7H9
Offices
For other offices not listed here, visit us at www.ametekpi.com.
© 2004–2007 AMETEK Canada, Inc., A Division of Process & Analytical Instruments Printed in Canada
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.
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
Accuracy ....................................................................................................... 2-2
Repeatability ................................................................................................ 2-2
Calibration .................................................................................................... 2-2
Linearity ....................................................................................................... 2-2
Zero Stability ................................................................................................ 2-2
Contents | iii
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
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
Microcontroller Board Analog Input (MAI) Signals .................... 4-30
Host Controller 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
Returning to RUN Mode .............................................................. 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
Viewing Error Messages .......................................................................... 4-47
Contents | vii
CHAPTER 5 MAINTENANCE & TROUBLESHOOTING
Safety Considerations ....................................................................................... 5-1
Maintenance ....................................................................................................... 5-2
Preventive Maintenance ............................................................................ 5-2
Analyzer Preventive Maintenance Schedule.......................................... 5-3
Expo-Telektron Safety Systems MiniPurge (Optional) Preventive
Maintenance Schedule ........................................................................... 5-5
Before Performing Maintenance .............................................................. 5-5
Locating a Plug in the Sample System .................................................. 5-6
Detecting a Plug in the Sample System ................................................. 5-6
Preventing a Plug in the Sample System ............................................... 5-7
Changing Out Replaceable Parts .............................................................. 5-9
Measuring Cell Preventive Maintenance ............................................ 5-10
Source Lamp Replacement ................................................................... 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 .......................................................................................... 5-27
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 ..................................................................... 5-30
Manipulating the Completion Number, PMT Level, and PMT
Balance .......................................................................................... 5-31
Heater Plate Heater Cartridge and RTD Replacement ........................ 5-33
Examining and Caring For the Flamepaths .......................................... 5-48
Disconnect Enclosure Flamepath (Joining Surfaces) ........................... 5-49
Troubleshooting and Diagnostics .................................................................. 5-50
Viewing Errors on the User Interface Panel ......................................... 5-50
Types of Errors (Alarms) ...................................................................... 5-50
Viewing Current Error Messages ........................................................ 5-51
Viewing Historical Error Messages ..................................................... 5-52
Host Controller Board Alarm Conditions and Corrective Action ..... 5-53
Microcontroller Board Alarm Conditions and Corrective Action ..... 5-60
Analyzer Reset ........................................................................................... 5-64
APPENDIX A OPTIONS
O2 Concentration ............................................................................................. A-1
SSR Outputs ................................................................................................ A-2
Entering Calibration Gas O2 Concentration ......................................... A-3
O2 Span Timer ............................................................................................ A-3
Auto-Calibration ......................................................................................... A-4
O2 Manual Zero/Span ............................................................................... A-6
Air Zero Gas ......................................................................................... A-6
Nitrogen (N2) Zero Gas ....................................................................... A-8
Dilution Air Correction .................................................................................. A-10
Correction Equation ................................................................................ A-10
Entering [O2 ]spec ................................................................................... A-11
APPENDIX D DRAWINGS
Analyzer Schematic (WX-14716).....................................................................D-2
Backpan Mounting Details, GP Analyzers ...................................................D-3
Overall Component Layout, GP Analyzers .................................................D-4
Electronics Enclosure Layout..........................................................................D-5
User Interface Panel (WX-14151) ....................................................................D-6
Ribbon Cable Interconnect (WX-102836) ......................................................D-7
Sample/Vent Line Wiring, GP/Div 2 Analyzers (WX-102813) ....................D-8
GP Lower Enclosure to Electronics Wiring, CE Analyzers
(WX-102810) .......................................................................................................D-9
Heater and Sensor Wiring, GP/Div 2 Analyzers (WX-102851) ................D-10
Heater and Sensor Wiring, CE/Zone 1 Analyzers (WX-102852) ..............D-11
Contents | ix
Disconnect Enclosure Wiring, Zone 1 Analyzers (WX-102820) ...............D-12
GP Lower Enclosure Wiring, CE Analyzers (WX-102819) ........................D-13
Customer Signal Connections, GP/Div 2 Analyzers (WX-102822) ..........D-14
Customer Signal Connections, CE/Zone 1 Analyzers (WX-102816) .......D-15
Signal Wiring, GP/Div 2/CE/Zone 1 Analyzers (WX-102815) ...................D-16
AC Wiring, GP/Div 2/CE/Zone 1 Analyzers (WX-102818) ........................D-17
± 15V and 5V Power Supply DC Wiring, GP/Div 2/CE/Zone 1
Analyzers (WX-102811) ..................................................................................D-18
24V Power Supply DC Wiring, CE/Zone 1 Analyzers (WX-102812) .......D-19
RS-232 Communications Cable Wiring (300-9480) ....................................D-20
RS-485 Module Wiring, CE/Zone 1 Analyzers (WX-102817) ....................D-21
Seal 1 & Seal 2 Wiring Diagram, CE/Zone 1 Analyzers (WX-102807) .....D-22
Seal 3 Wiring Diagram, CE/Zone 1 Analyzers (WX-102808) ....................D-23
Optical Bench Service Electronics Board (100-1662) .................................D-24
Micro-Interface Board (100-0116) .................................................................D-25
Host Controller Board (100-0138-1) .............................................................D-26
Microcontroller Board (100-0117) .................................................................D-27
Termination Board (100-1534) .......................................................................D-28
Display I/O Board (100-0939) ........................................................................D-29
Measuring Cell/Lamp Assembly (WX-14856) .............................................D-30
Velocimeter Solenoid Block, 120 V (100-1933) ............................................D-31
Velocimeter Solenoid Block, 240 V (100-1934) ............................................D-32
Zirconia Oxide O2 Sensor (Optional), Electronics Panel Layout
(100-1160-1) ......................................................................................................D-33
Zirconia Oxide O2 Sensor (Optional), Wiring Connections
(100-1160-2) ......................................................................................................D-34
SUPPLEMENTAL INFORMATION
An operating procedure which, if not strictly observed, may result in personal injury or
! environmental contamination.
WARNING
! An operating procedure which, if not strictly observed, may result in damage to the equipment.
CAUTION
Electrical Safety
High voltages are present in the analyzer housings. Always shut down power source(s) before
performing maintenance or troubleshooting. Only a qualified electrician should make electrical
connections and ground checks.
Any use of the equipment in a manner not specified by the manufacturer may impair the safety
protection originally provided by the equipment.
Grounding
Instrument grounding is mandatory. Performance specifications and safety protection are void
if instrument is operated from an improperly grounded power source.
Contents | xi
Personnel and Equipment Safety Information
This section describes important safety information to avoid personal injury and damage to the
equipment while installing, operating, maintaining, or servicing the equipment. All safety
regulations, standards, and procedures at the analyzer location must be followed.
All personnel involved with the installation, start-up, operation, maintenance, service, or
troubleshooting of the Model 909 Single-Gas Analyzer must review and follow these Warnings
and Cautions.
Warnings
Review and follow these Warnings to avoid personal injury or environmental contamination.
Always disconnect main AC power and/or external power sources to the analyzer before
! opening any covers or doors on the analyzer to check or perform maintenance on any compo-
WARNING
nents within the enclosures.
If it is necessary to open the analyzer’s covers or doors while the circuits are alive, first
monitor the area for flammable gases (and proceed only when the area is safe).
When the Electronics Enclosure door is open, take appropriate precautions to avoid electrical
shock. Hazardous voltages are present inside.
All electrical connections, adjustments, or servicing of the analyzer should be performed only
! by properly trained and qualified personnel.
WARNING
All electrical connections, materials, and methods (plus all safety policies and procedures) must
be made in compliance with local wiring regulations and electrical code for the hazardous area,
and be approved by the Owner Company.
Follow appropriate regulatory and/or company procedures to lock out the analyzer while
! working on the analyzer electronics.
WARNING
Before working on the sampling system, confirm that the system is purged with Zero Gas and
! is isolated (blocked in) from the process.
WARNING
Because ultraviolet radiation can harm your eyes, avoid direct viewing of the light emanating
! through the end window of the source lamp. If the source lamp must be viewed while energized,
WARNING wear safety glasses that block ultraviolet radiation.
The Analyzer Oven enclosure and components within the Analyzer Oven are hot; take precau-
! tions to avoid burning yourself.
WARNING
The analyzer enclosure may not be opened when an explosive atmosphere is present.
Contents | xiii
Cautions
The electronic circuit boards and other static-sensitive components should be stored and
! transported in static-shielding carriers or packages.
CAUTION
For electrical-shock protection, the analyzer must be operated from a grounded power source
! that has a securely connected protective-ground contact.
CAUTION
If it becomes necessary to handle any of the electronic circuit boards, do not subject the boards
! to static discharge. The ideal solution is a static-safe work area. Since such areas typically are
CAUTION not available at analyzer installation sites, the use of a wrist strap connected directly to a
ground is recommended. If a wrist strap is not available, you should at the very least touch the
metal chassis (to ground yourself) before handling or touching the boards.
When handling the source lamps, it is very important not to touch the lamp windows because
! residual oils from the fingers will absorb ultraviolet light. The window is the flat surface at the
CAUTION end of the narrow glass tube. The lamp assembly is fragile and should be handled with care.
For Zone 2 Installations, use a suitable flameproof cable entry device with a sealing ring, as
per EN 60079-14:1997, 10.3.2, item “b)”; or, comply with local wiring regulations and electri-
cal codes.
In all cases, all unused cable entry ports must be plugged with a certified EEx d plug.
Environmental Information
This AMETEK product contains materials that can be reclaimed and recycled. In some cases the
product may contain materials known to be hazardous to the environment or human health. In
order to prevent the release of harmful substances into the environment and to conserve our
natural resources, AMETEK recommends that you arrange to recycle this product when it
reaches its “end of life”.
Waste Electrical and Electronic Equipment (WEEE) should never be disposed of in a municipal
waste system (residential trash). The Wheelie Bin marking on this product is a reminder to
dispose of the product properly after it has completed its useful life and been removed from
service. Metals, plastics, and other components are recyclable and you can do your part by
doing one of the following steps:
• When the equipment is ready to be disposed of, take it to your local or re-
gional waste collection administration for recycling.
• In some cases, your “end of life” product may be traded in for credit towards
the purchase of new AMETEK instruments. Contact your dealer to see if this
program is available in your area.
Contents | xv
Electromagnetic Compatibility (EMC)
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 environ-
CAUTION
ments.
The various configurations of the Model 909 Single-Gas Analyzer should not produce, or fall
victim to, electromagnetic disturbances as specified in the European Union’s EMC Directive (if
applicable to your application). [The NEC/CEC certification is Class I, Division 2, Groups C & D.
The KEMA (ATEX) certification for Zone 1 hazardous locations is EEx pd IIB T3.] Strict compli-
ance to the EMC Directive requires that certain installation techniques and wiring practices are
used to prevent or minimize erratic behavior of the Analyzer or its electronic neighbors. Below
are examples of the techniques and wiring practices to be followed.
In meeting the EMC requirements , the various Analyzer configurations described in this
manual rely heavily on the use of metallic shielded cables used to connect to the customer’s
equipment and power. Foil and braid shielded I/O and DC power cables are recommended for
use in otherwise unprotected situations. In addition, hard conduit, flexible conduit, and armor
around non-shielded wiring also provides excellent control of radio frequency disturbances.
However, use of these shielding techniques is effective only when the shielding element is
connected to the equipment chassis/earth ground at both ends of the cable run. This may cause
ground loop problems in some cases. These should be treated on a case-by-case basis. Discon-
necting one shield ground may not provide sufficient protection depending on the electronic
environment. Connecting one shield ground via a 0.1 microfarad ceramic capacitor is a tech-
nique allowing high frequency shield bonding while avoiding the AC-ground metal connection.
In the case of shielded cables the drain wire or braid connection must be kept short. A two-inch
connection distance between the shield’s end and the nearest grounded chassis point, ground
bar or terminal is highly recommended. An even greater degree of shield performance can be
achieved by using metallic glands for shielded cable entry into metal enclosures. Expose enough
of the braid/foil/drain where it passes through the gland so that the shield materials can be
wrapped backwards onto the cable jacket and captured inside the gland, and tightened up
against the metal interior.
Inductive loads connected to the low voltage “Alarm Contacts” are not recommended. However,
if this becomes a necessity, adhere to proper techniques and wiring practices. Install an appro-
priate transient voltage suppression device (low voltage MOV, “Transzorb,” or R/C) as close as
possible to the inductive device to reduce the generation of transients. Do not run this type of
signal wiring along with other I/O or DC in the same shielded cable. Inductive load wiring must
be separated from other circuits in conduit by using an additional cable shield on the offending
cable.
In general, for optimum protection against high frequency transients and other disturbances, do
not allow installation of this Analyzer where its unshielded I/O and DC circuits are physically
mixed with AC mains or any other circuit that could induce transients into the Analyzer or the
overall system. Examples of electrical events and devices known for the generation of harmful
electromagnetic disturbances include motors, capacitor bank switching, storm related transients,
RF welding equipment, static, and walkie-talkies.
Explosion Hazard – Do Not Disconnect Equipment Unless Power Has Been Switched Off or
! the Area is Known to be Non-Hazardous.
WARNING
All input and output wiring must be in accordance with Class I, Division 2 wiring methods (CEC
18-152) and in accordance with the authority having jurisdiction.
Contents | xvii
EC Declaration of Conformity
Process photometric analyzers, process moisture analyzers, and sampling systems are warranted to
perform the intended measurement, only in the event that the customer has supplied, and AMETEK has
accepted, valid sample stream composition data, process conditions, and electrical area classification prior
to order acknowledgment. The photometric light sources are warranted for ninety (90) days from date of
shipment. Resale items warranty is limited to the transferable portion of the original equipment
manufacturer’s warranty to AMETEK. If you are returning equipment from outside the North America, a
statement should appear on the documentation accompanying the equipment being returned declaring
that the goods being returned for repair are North American goods, the name of the firm who purchased
the goods, and the shipment date.
The warranty shall not apply to any equipment (or part thereof) which has been tampered with or altered
after leaving our control or which has been replaced by anyone except us, or which has been subject to
misuse, neglect, abuse or improper use. Misuse or abuse of the equipment, or any part thereof, shall be
construed to include, but shall not be limited to, damage by negligence, accident, fire or force of the
elements. Improper use or misapplications shall be construed to include improper or inadequate protec-
tion against shock, vibration, high or low temperature, overpressure, excess voltage and the like, or
operating the equipment with or in a corrosive, explosive or combustible medium, unless the equipment
is specifically designed for such service, or exposure to any other service or environment of greater
severity than that for which the equipment was designed.
The warranty does not apply to used or secondhand equipment nor extend to anyone other than the
original purchaser from us. Should the Buyer ’s technical staff require the on-site assistance of AMETEK’s
agents or employees for service calls covered by this warranty clause, the Buyer shall pay travel time plus
actual travel and living expenses.
THIS WARRANTY IS GIVEN AND ACCEPTED IN LIEU OF ALL OTHER WARRANTIES, WHETHER
EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION AND WARRANTIES OF FITNESS OR OF
MERCHANTABILITY OTHER THAN AS EXPRESSLY SET FORTH HEREIN, AND OF ALL OTHER
OBLIGATIONS OR LIABILITIES ON OUR PART. IN NO EVENT SHALL WE BE LIABLE UNDER THIS
WARRANTY OR ANY OTHER PROVISION OF THIS AGREEMENT FOR ANY ANTICIPATED OR LOST
PROFITS, INCIDENTAL DAMAGES, CONSEQUENTIAL DAMAGES, TIME CHANGES OR ANY OTHER
LOSSES INCURRED BY THE ORIGINAL PURCHASER OR ANY THIRD PARTY IN CONNECTION
WITH THE PURCHASE, INSTALLATION, REPAIR OR OPERATION OF EQUIPMENT, OR ANY PART
THEREOF COVERED BY THIS WARRANTY OR OTHERWISE. WE MAKE NO WARRANTY, EXPRESS
OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTIES OF FITNESS OR OF MER-
CHANTABILITY, AS TO ANY OTHER MANUFACTURER’S EQUIPMENT, WHETHER SOLD SEPA-
RATELY OR IN CONJUNCTION WITH EQUIPMENT OF OUR MANUFACTURE. WE DO NOT AUTHO-
RIZE ANY REPRESENTATIVE OR OTHER PERSON TO ASSUME FOR US ANY LIABILITY IN CON-
NECTION WITH EQUIPMENT, OR ANY PART THEREOF, COVERED BY THIS WARRANTY.
Principles of Operation
The Model 909 Single-Gas Analyzer measures, at two discrete wave-
lengths, the absorbances of ultraviolet radiation (light) by a gas sample.
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, Beer, and Lambert.
The Basis
Thus, the absorbance, A, due to a single absorber is,
[ x ] kλ l P
A= ,
RT
where l is the path length of the light in the gas sample, [x] is the concen-
tration (mole percent [see Note]) of absorber x, kλ is the molar absorptivity
of absorber x at the measuring wavelength, λ, T and P are the temperature
and pressure of the gas sample, respectively, and R is the universal gas
constant.
Overview | 1-1
For any given system at constant temperature and pressure, the equation
can be simplified to:
A= C kλ [ x ] ,
The Implementation
The analyzer is comprised of two ultraviolet light sources, a Filter Block
containing two wavelength-selective filters, a beam splitter, front-surfaced
mirrors, a gas Measuring Cell, and two matched photo detectors (see Figure
1-1). The Measuring Cell is contained within the analyzer’s oven. A pressure
transducer monitors the pressure at the outlet of the Measuring Cell.
Figure 1-1.
Analyzer schematic.
Sample Flow
The sample gas is drawn from the stack duct through the Sample Condi-
tioning Unit (or stack sample probe, if used) and Sample Line to the dual-
chambered Measuring Cell. The gas sample enters the first chamber, flows
the length of the Measuring Cell, crosses to the second chamber, flows the
length of the Measuring Cell in the opposite direction and exits from the
Measuring Cell. When the sample gas reaches the aspirator, it merges
with the Aspirator Drive Air (Instrument Air or N2) and then is dispersed
to atmosphere via a Sample Vent Pipe.
Overview | 1-3
Discrete Wavelengths
As each pulse of light arrives, the beam splitter directs half the light to the
Reference detector and half through the gas sample to the Measure
detector. Because of the longer optical path length, light losses at the
mirrors, and light losses through the Measuring Cell windows, the
amount of light received by the Measure detector is less than that received
by the Reference detector, even when there is no absorber in the gas
sample.
To balance this effect, a screen that filters 30 % of the light is added to the
Reference path. At each wavelength, these optical-path factors produce a
constant difference between the amounts of light received by the two
detectors.
When an absorber is present in the gas sample, the amount of light re-
ceived by the Measure detector is reduced further, the magnitude of the
reduction being dependent upon the concentration of the absorber. Thus,
for each wavelength, the difference in the amounts of light received by
the two detectors (corrected for the optical-path factors) is used to deter-
mine the absorbance of the gas sample. Then, using the aforementioned
equations, the concentration of the absorber (for which the analyzer is
configured) is calculated.
Auto-Calibration function
Automatically updates the calibration of the analyzer using Calibra-
tion Gas mixtures. The Auto-Calibration function can be initiated on
command by the user, at user-specified time intervals, or by the
closure of a remote dry (potential free) contact.
Auto-Zero function
Automatically updates the analyzer zero. The Auto-Zero function can
be initiated on command by the user or at user-specified time inter-
vals.
Overview | 1-5
Auto-Calibration and Calibration Gas solenoid valve control functions
Support the use of a single-species calibration gas mixture. The ana-
lyzer is configured for a particular calibration gas mixture by the user.
Continuous purge of the Optical Bench Assembly, Measuring Cell Seal, and the
Electronics Enclosure with Instrument Air
Prevents contamination of the optical system and the electronics.
Flow Rate
Calculations of the volumetric flow rate of the stack duct (stream) or
mass flow rate of the measured component in the stack duct.
Overview | 1-7
About the Analyzer Sample System
The sample gas is transported to and from the analyzer by an aspirator
housed within the heated Analyzer Oven.
The major components of the sampling system and their functions are
detailed below. These components are for a variety of analyzer configura-
tion possibilities. Depending on your application, only some of these
components will be used.
Component Function
Sample Conditioning Unit (SCU)
The SCU – which mounts on the stack – is used to filter out
particulates, prevent liquid carry-over, or otherwise condition
the gas sample prior to transporting it through the Sample
Line.
Sample Line Transports the sample gas to the analyzer at a temperature
above its dewpoint.
Aspirator (if used) Located within the Analyzer Oven, the Aspirator provides
suction to transport the sample gas through the sample path.
The aspirator uses Instrument Air to extract and drive the
sample gas from the stack duct, through the sampling system,
and vent it to atmosphere (or return it to the stack duct).
Vent Pipe Vents the sample gas to atmosphere. Typically used in stack gas
sampling.
Vent Line (if used) Returns the sample gas to the stack duct.
Component Function
Aspirator/Backpurge Air Pressure Regulator
Used to adjust drive air flow rate.
Check Valve Stops sample gas from entering the instrument air system if
instrument air pressure is reduced below the stack duct
pressure.
Calibration
Calibration on the Model 909 Analyzer consists of zeroing and spanning
the analyzer.
Overview | 1-9
ELECTRONICS ENCLOSURE
MANIFOLD BLOCK
ANALYZER OVEN
SAMPLE SYSTEM
BY OTHERS
VELOCIMETER BLOCK
Figure 1-2.
Piping &
instrumentation
diagram.
Example drawing only. Refer to customer-specific drawings for your
application in the “Supplemental Information” section of this manual
NOTE or the Documentation Package shipped with the analyzer.
When the sample gas reaches the aspirator, 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, if used).
Overview | 1-11
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 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. The required purge air pressure is indicated by a
label on the analyzer backpan. The Electronics Enclosure air pressure can
be verified by connecting a pressure gauge (e.g., Magnahelix™) to the
fitting (gauge port) located on the lower right side of the Electronics
Enclosure. The Electronics Enclosure air pressure should typically be
between 0.1 and 0.2 inches of water with respect to the air pressure
outside the cabinet.
Status Relays
The Model 909 Analyzer uses three relays to indicate the operational
status of the analyzer. Each relay provides a set of SPDT (Form C) dry
(potential-free) contacts. The relays are configured for fail-safe operation
(i.e., energized for the non-alarm condition).
The three sets of status relays used on the Model 909 Analyzer are:
When this relay changes state to de-energized, a lower case “m” will
be displayed in the top-left corner of the RUN mode screen.
Overview | 1-13
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Except where specified, these characteristics are primarily for SO2. For
applications measuring other species, refer to information in the
NOTE
“Supplemental Information” section of this manual.
Methodology
Dual beam, high resolution, non-dispersive UV.
(Optional O2 Integral zirconium oxide.)
Standard Ranges
Maximum ranges are based on sample length (expressed in cm). Mini-
mum ranges are 1/50 of maximum ranges.
SO2 SO2 Range = 20 % SO2 / (Cell length), to a minimum of 250 PPM
NO NO Range = 20 % NO / (Cell length), to a minimum of 300 PPM
NO2 NO2 Range = 40 % NO2 / (Cell length), to a minimum of 300 PPM
H2S H2S Range @ 228 nm = 40 % H2S / (Cell length), to a minimum of
500 PPM
H2S Range @ 214 nm = 10 % H2S / (Cell length), to a minimum of
125 PPM
NH3 NH3 Range = 10 % NH3 / (Cell length), to a minimum of 125 PPM
Cl2 Cl2 Range = 40 % Cl2 / (Cell length), to a minimum of 500 PPM
Specifications | 2-1
Analyzer Specifications
Response Time
Dependent on sample gas flow rate and user-adjustable filtering time
constants. Typically less than 30 seconds to T90 (excluding sample system).
Accuracy
± 1.0 % of full-scale of standard ranges, typical (excluding drift and
temperature effects).
Repeatability
< ± 0.5 % full-scale of standard ranges.
Calibration
Calibration gases in nitrogen.
Linearity
< ± 1.0 % of reading
Zero Stability
Noise: < 0.2 % of full-scale of standard ranges.
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
Analog Outputs
Four isolated 4–20 mADC outputs, each capable of operating a
0–1000 ohm load. Can be self-powered or loop-powered (loop power
supplied by customer).
One RS-422 port with Modicon Modbus® protocol (used for interface to
customer’s equipment).
Power Consumption
600 W for analyzer only (excludes Sample Line, SCU, and Vent Line
power requirements).
Electrical Requirements
Nominal Frequency Range
120 VAC, ± 10 % 47–63 Hz
240 VAC, ± 10 % 47–63 Hz
Specifications | 2-3
Ambient Limits
Temperature
Humidity
0–95 % RH
Maximum Altitude
2000 m
Sample Transport
Air aspiration as the drive medium.
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, heated probe (optional)
Pressure Compensation
Compensation for Measuring Cell pressure provided for SO2 only.
Range: 0–210 KPA (0–30 PSIA)
Pressure Transducer accuracy 0.25 % of full-scale.
Specifications | 2-5
Approvals and Certifications
NEC/CSA: Class I, Zone 2 (Division 2), Groups C&D, NFPA 496
Z-Purge
KEMA: 02ATEX2341 X; EEx pd IIB T3
GOST: 1ExpydIIBT3
GOST Pattern Approval
CE Compliance:
Complies with all relevant European Directives
EMC: Electromagnetic Compatibility Directive:
EN61326 Industrial
LVD: Low Voltage Directive:
EN61010-1
Speed of Response
Accuracy
Repeatability
Temperature Drift
0.0223 % O2 per °C
Electrical Classification
Standard Range
Accuracy
Repeatability
Stability
Hysteresis
Specifications | 2-7
ATEX (KEMA) Certificates and Analyzer Markings
For installation sites with potentially explosive atmospheres that require
ATEX certification, AMETEK’s ATEX certificates for the Model 9xx-Series
Analyzers (and their marking) are included in the following pages.
No Release
0344
II 2 G
Limited Release
0344
II 2 G
Caution/Attention:
Do not open enclosure while energized.
Do not open while a flammable atmosphere is present.
Specifications | 2-13
Heater Plate ATEX Certificate
0344
II 2 G
Caution
Open Circuit before removing covers.
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.
0344
II 2 G
Specifications | 2-19
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The Installation & Start-Up chapter contains information about the fol-
lowing topics:
• How to uncrate and inspect the analyzer for damage before installing.
• How to install the mechanical components and gas lines, and perform
a leak check on all of the fittings and connections before powering up
the analyzer.
After the inspection, close and secure all covers and doors with at
! least one screw. This will keep the electronics equipment secure and
CAUTION
will prevent damage to the doors, covers, electronic components, and
flamepaths (i.e., Disconnect Enclosure) during installation.
When handling the source lamps, it is very important not to touch the
! lamp windows because residual oils from the fingers will absorb
CAUTION
ultraviolet light. The window is the flat surface at the end of the
narrow glass tube. The lamp assembly is fragile and should be handled
with care.
• A supply of 1/4" 316 stainless steel tubing for the Calibration, Span,
Zero, and Aspirator Drive Air lines. Length will vary, depending on
the distance between the analyzer and the stack duct. Supplied by the
customer/end user. Supplied by the customer/end user.
The entire analyzer system (and its backpan) can be mounted directly on
a wall, in a specially designed cabinet, or in a custom-built shelter. In all
cases, the analyzer system must be installed indoors to ensure it is
shielded from harsh environmental elements.
Non-Shelter Installations:
In a suitable, accessible location as close as possible to the sample gas
extraction point (to minimize the amount of sample lag time), mount the
analyzer on a vibration-free wall or instrument rack.
AMETEK recommends mounting the analyzer 1500 mm (59") from the floor
to the centre of the Sample Line inlet connection on the Analyzer Oven.
PROCESS INSTRUMENTS
CONDUIT ENTRY
PLATE
Figure 3-1.
Analyzer backpan
mounting details.
Figure 3-2.
Shelter installation
details.
If your analyzer uses a Measuring Cell other than the typical cell
illustrated in Figure 3-5, refer to the “Supplemental Information”
NOTE
section of this manual for the appropriate drawing.
Make sure that all power to the analyzer is off before installing the
! Optical Bench Assembly.
WARNING
1. 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). To do this, loosen the set screw securing the
pivot pin.
2. Attach the Optical Bench Assembly to the Support Arm Yoke by fitting
the Optical Bench Support Plate to the Support Arm Yoke and secur-
ing it with the pivot pin. Tighten the set screw. The Optical Bench
Assembly should swing freely.
LIVE LOAD
Figure 3-3.
Electronics enclosure,
GP analyzer backpan
layout.
b. Swing the Optical Bench Assembly toward the Analyzer Oven and
then swing the Measuring Cell Assembly toward the Heater Plate.
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. Adjust the entire Measuring Cell/Optical Bench
Assembly as required to firmly seat the Measuring Cell Assembly
against the Heater Plate.
c. Using a flat hex key, 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. Do
not use a ball driver – the head can break off inside the screw. Do
not tighten the screw at this time.
h. Replace the Flame Arrester (black plug) in the counter bole hole in
the Heat Transfer Block.
7. The installation information for the Sample Line and vent is described
under “Installing the Sampling System,” following this section.
Ensure there is sufficient clearance around the SCU to allow for easy
removal and maintenance.
NOTE
Install and terminate the SCU power, RTD, and thermocouple wiring
from the SCU to the Sample Line/SCU Termination Box on the ana-
lyzer backpan. 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.
Do not lift or support the Sample Line by the tubing fitting. Doing so
! may pull the fitting off the sample transport tube. A wire mesh cable
CAUTION support must be installed on the line before lifting it and when a line
is to be suspended vertically. The Sample Line is custom-built for each
installation; they cannot be cut to length on site.
To avoid damaging the Sample Line, use two wrenches to ensure that
the fitting body does not turn on the Teflon line.
1. Open the Electronics Enclosure door and remove the fuses for the
Sample Line and SCU to ensure there is no power being supplied to
these temperature-controlled zone circuits. Refer to the Fuse Legend
on the inside of the analyzer’s Electronics Enclosure door for the
locations of these fuses.
3. Route the Sample Line from the sample gas extraction point (on the
stack duct) to the analyzer.
Ensure there are no loops, sags, or other traps in the Sample Line.
Provide support where needed.
4. Connect the Sample Line to the SCU (or stack sample probe, if used).
5. Run a Vent Pipe between the analyzer and the disposal location (to
atmosphere).
Non-Shelter Installations:
Route the Sample Line through the upper hole on the left side of the
Analyzer Oven. Connect it to the Sample Inlet Fitting.
Route the Vent Pipe through the lower hole on the left side of the
Analyzer Oven. Connect it to the Sample Outlet Fitting.
Shelter Installations:
Route the Sample Line through the hole marked “Sample Line” on the
side of the shelter and then through the upper hole on the left side of
the Analyzer Oven. Connect it to the Sample Inlet Fitting.
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 Outlet Fitting.
Do not add extra insulation to the Sample Line. This will result in a
local hot spot and cause premature failure of the line.
NOTE
Connect the ground lead from each line to the ground terminals before
! connecting the heater leads.
CAUTION
The Instrument Air line is supplied by the customer. 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.
1. Route the Instrument Air line from the Instrument Air supply to the
analyzer.
2. Blow down (purge) the line to remove any liquids or particulate that
may be present in it line before connecting it to the analyzer.
3. Connect the Instrument Air line to the analyzer. The plumbing for the
purge systems and the aspirator drive air feed through the analyzer
manifold is already made by AMETEK.
Non-Shelter Installations:
Route Connect the Instrument Air line to the Instrument Air inlet
fitting on the analyzer.
Shelter Installations:
Connect the Instrument Air line to the “Inst Air” port on the left side
of the shelter.
The Calibration (Span/Zero) Gas lines are supplied by the customer. The
gas lines must be 1/4" 316 stainless steel tubing.
1. Route the Span/Zero Gas lines from each supply tank to the analyzer.
2. Blow down (purge) the lines to remove any liquids or particulate that
may be present in them before connecting them to the analyzer.
In all cases, all unused cable entry ports must be plugged with a
certified EEx d plug.
For AC electrical supply cable and conduit requirements, refer to, and
! comply with, local wiring regulations and electrical codes for the
WARNING
hazardous area.
For safety reasons during maintenance, this switch allows the main
AC power to be disconnected from the analyzer prior to performing
service on the analyzer.
2. Terminate the input signals, analog output signal(s), and alarm relay
contact conductors (see the Customer Signal Connections and other
related customer-specific drawings).
Route the input/output signals and alarm relay conductors into the
Disconnect Enclosure.
Before making the AC power connections, open (turn off) the flameproof
! switch (breaker, if used) to the analyzer, and open all analyzer fuses.
WARNING
Do not apply power to the system until after all of the wiring has been
installed, connected, and verified, and only if the purging system is ready
for operation.
LIVE LOAD
LIVE LOAD
Figure 3-6.
Model 909 GP
Analyzer overall
component layout.
The purge air supply is normally obtained from the Instrument Air supply
connected directly to the Expo-Telektron MiniPurge system.
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.
AC
SS TIV
PA
Figure 3-7. BY E
To ensure safe operating conditions, 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).
After powering up the analyzer for the first time, certain checks must be
performed with the Electronic Enclosure door open to ensure the ana-
lyzer is operating properly. These checks are discussed in the following
power-up procedure. If problems are encountered during power-up, refer
to the “Start-Up Diagnostic Checklist,” later in this chapter, for help in
diagnosing and correcting problems.
When the analyzer’s covers and doors are open, take appropriate precau-
tions to avoid electrical shock. Hazardous voltages are present inside.
1. Close the fuses for the temperature-control zone circuitry. Refer to the
Fuse Legend on the inside of the analyzer Electronics Enclosure door
for the location of these fuses.
If the “Reset in Progress” message still does not appear, take neces-
! sary precautions and check the AC wiring to ensure it is properly
WARNING connected.
Take all necessary safety precautions and power up the analyzer (as
discussed previously). Check the User Interface Panel again to see if
the message appears. If it does, continue with the next step.
When the analyzer system is first powered up, the alarm warning
“w Oven Heater” may be displayed on the User Interface Panel. This
NOTE
warning will clear when the Analyzer Oven temperature controlled
zone is within its normal operating range.
Check the User Interface Panel for indications of other alarms. Alarms are
indicated by a reverse-video S ( S ) on the upper-right line. To view
alarms that have been detected, press F5 4 (and press each of the keys
numbered 1..8) and/or F5 5 (and press each of the keys numbered 1..7)
from RUN mode to view the current Host Controller board and/or
Microcontroller board status/error code conditions.
Check the LEDs on the Termination board to ensure they are on.
If the lamps are not firing or the LEDs on the Termination board are
not on, this can indicate problems with the wiring.
a. From the User Interface Panel, view the set points for each tem-
perature-control zone by pressing F4 0 (from RUN mode) to view
the TStPt screen.
The TStPt screen defaults to the Sample Line temperature-control
zone. You can also view this parameter by pressing 1.
Press 2 to view the Vent Line (or SCU) temperature-controlled zone.
Press 4 to view the Measuring Cell temperature-controlled zone.
7. After approximately two hours (at which time the system should have
reached its normal operating temperature), and if all of the alarm
conditions have cleared (check the User Interface Panel), recheck the
temperature of each zone.
11. Open the isolation valve on the sample gas extraction equipment (e.g.,
SCU) to allow sample gas from the stack duct into the analyzer’s
sampling system.
For systems using a Sample Conditioning Unit (SCU), the SCU will
! be hot. Take precautions to avoid burning yourself.
WARNING
13. Adjust the Aspirator Drive Air Regulator to achieve normal operating
flow rates as described under “Adjusting the Sample Gas Flow Rate,”
later in this chapter.
Problem Encountered
“Reset in Progress” message does not appear on the User Interface Panel
immediately after applying AC power, or after attempting a manual system
reset.
Corrective Action
Simultaneously press • and Ent. If this message still does not appear, take
necessary precautions and check the AC wiring to ensure it is properly
connected.
Problem Encountered
If a reverse-video S ( S ) is displayed on the User Interface Panel, view the
current Host Controller board and/or Microcontroller board status/error code
conditions for current alarms.
The S character will typically be displayed upon start-up due to low tem-
peratures in the temperature-controlled zones.
Corrective Action
To view current alarms, 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..7).
For detailed information about these alarms, refer to the alarm conditions
and corrective action in the Maintenance & Troubleshooting chapter of this
manual.
Problem Encountered
One or both source lamps are not firing.
Corrective Action
Take appropriate safety precautions and check for proper wiring connections.
If the wiring is okay, check the connections of the lamps in their sockets. Review
the section titled “Replacing the Source Lamps” in the Maintenance & Trouble-
shooting chapter of this manual to make adjustments to the lamps. Perform an
Auto-Setup if necessary to ensure the lamps are operating at peak efficiency.
Corrective Action
Take appropriate safety precautions and check for proper I/O wiring connec-
tions.
Also, press the reset switch (SW300) on the Termination board (inside the
Electronics Enclosure) to re-energize any tripped circuits. See Figure 3-8 for
the location of this switch.
Problem Encountered
Temperature zone values do not increase.
Corrective Action
Take appropriate safety precautions and check for proper wiring connections
for the appropriate temperature zone wiring.
Problem Encountered
Temperature zone value reads “181.4”. This temperature value indicates a
faulty RTD for the related temperature zone.
Corrective Action
Take appropriate safety precautions and check the related RTD for a short. If
necessary, replace the RTD with an AMETEK-approved replacement part.
1. With the analyzer powered up, open the Aspirator Drive Air Regula-
tor to allow instrument air into the sampling system.
2. Cap the Sample Line at the SCU and cap the Vent Line at the Sample
Vent Pipe.
3. Use the Aspirator Drive Air Regulator to increase the instrument air
pressure to 70 KPAG (10 PSIG).
4. While working from the User Interface Panel, view RUN mode, press
F6 8 6 to view the CellP (Measuring Cell Pressure) screen and record
the numeric value displayed. This value is the absolute pressure
reading in mmHg (or "Hg). The reading on the User Interface Panel is
automatically updated every second.
Do not use a leak detection fluid on hot fittings. If the analyzer system
! is at operating temperature, the temperature zones must be cooled
CAUTION down before using a leak detection fluid on the fittings.
If the Measuring Cell is suspect, check all fittings to ensure they are
tight and repeat the procedures of testing/repairing/testing until all
leaks have been eliminated.
7. After the analyzer has passed the pressure leak test, remove the cap
from the Sample Line at the SCU (and reconnect it to the SCU). Re-
move the cap from the Vent Line and reconnect it to the Sample Vent
Pipe.
All temperature zones must be at their operating set points before per-
forming a Manual Zero. If necessary, view the temperature zones to
ensure that all zones are at their operating temperatures.
Pressing Esc at any time during this procedure will abort the proce-
dure and return to CAL mode normal display.
NOTE
2. Set the analyzer Flow Control Mode to Continuous Zero Gas mode by
entering the following keystrokes from the User Interface Panel:
a. From RUN mode, enter F6 • and then enter the CALibration mode
password “• •” (at the “PSWD0” prompt). Press Ent to enter CAL
mode.
Run the manual zero for 10 minutes at a flow rate of 2.5 L/min
(5 SCFH). For more information about setting the Zero Gas flow
rate, refer to “Adjusting the Zero Gas Flow Rate,” later in this
section.
Ent for Yes The analyzer will count down from 15 seconds to
zero (Integration Timer duration) during which
time the readings are averaged. (The timer defaults
to 15 seconds if the Integration Timer is set to zero.)
The zero values will be adjusted automatically and
the screen will revert to CAL mode normal display.
Esc for No The function is aborted and the zero values are not
adjusted.
6. Press Ent again to return to CAL mode normal screen and then Esc to
return to RUN mode.
Sample response time may also be used as a parameter for setting the
Aspirator Air pressure. 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.
To check the sample response time, view the RUN mode normal display
and observe the output concentration changes. If the sample response
time is adequate (first response after a Zero function is approximately
30 seconds), no further adjustment is necessary for a Sample Line of less
than 10 metres.
To help you determine in the future if there are problems with your
analyzer, it is important to observe and record initial readings (when
NOTE
the analyzer sampling system is clean) for the photomultiplier tube
(PMT) signal optical filters and the sample response time.
Keep the log book in a safe location until you need to review it for pat-
terns of diminishing PMT signals or a longer sample response time.
The analyzer’s sample response time can be used for two functions. One
function is to help you set the sample gas flow rate (as discussed earlier in
this chapter, under “Setting Sample Response Time”). The other function
is to help you determine if the typical response time is increasing, which
may indicate a plug in the sampling system.
2. After the zero is complete, view the RUN mode normal display and
observe the output concentration changes. Record the time it takes the
analyzer to display the first reading after the analyzer’s Flow Control
function switches from “zero” to “sample”.
Analyzer Configuration
Completed Analyzer Configuration and EEPROM Data Sheets are
shipped with each analyzer. These configuration sheets list all of the
settings that have been made to the analyzer at the factory (to meet
customer requirements). These sheets are located in the “Supplemental
Information” section of this manual and in the Documentation Package
shipped with the analyzer.
• Functions of keypad keys and accessing them from the User Interface
Panel.
Before working from the User Interface Panel, read the section titled
“Introduction to the User Interface Panel” which discusses keypad key
NOTE
functions.
Figure 4-1
Layout of the analyzer
user interface panel.
• The dot matrix display consists of two lines, each capable of displaying
up to 20 alphanumeric characters. The information displayed depends
on your current mode of operation.
• The 21-key keypad allows you to view and/or input (change) informa-
tion from any of the three main modes of operation. The display is
updated once per second; therefore, the display of the result of a
keystroke sequence may be delayed for up to one second. The keypad
consists of the following keys:
Key Description
• The decimal (‘•’) key can be used to enter a decimal character, as part of a
command (used in conjunction with one of the Function keys), or as part of a
password.
– The minus (‘–’) key can be used as part of a negative number, as part of a command
(used in conjunction with one of the Function keys), or as part of a password.
0–9 Numeric keys 0–9 are used to enter numerical data, as part of a Function key
command to activate a function whose value you wish to view or change, or as part
of a password.
Press one of these keys, in addition to the ‘•’ key, ‘–’ key, or one of the numeric keys
0–9, to activate a function whose value you wish to view or change.
From RUN / CFG mode, the ‘F6 0’ keystroke combination will return
the display to the normal display of the mode you are viewing.
Esc The Escape key allows you to discard any changes you make to operating
parameters, but only before they have been saved. The Esc key also allows you
to answer No to a prompt on the screen (whenever ‘?’ appears following
information), and to back out of certain menus.
Del The Delete key is used to delete an existing value from memory when you are
changing an operating parameter.
Ent The Enter key allows you to save any changes you make to operating parameters.
The Ent key can also be used to answer Yes to a prompt on the screen (whenever
‘?’ appears following information).
-1.3765 F5 4 Ent
Refer to the RUN / CFG Mode Quick Reference Sheet (Figure 4-2) for all of
the commands that make up the RUN mode. For detailed information
about working in RUN mode, refer to “Working in the RUN / CFG Oper-
ating Modes,” later in this chapter.
Function commands with a range [e.g., HS (1..8)] indicate you can view or
change more than one parameter from that menu without having to re-
enter the Function key (for that function) each time. For example, to view
the Host Controller Status (HS) menu (press F5 4) and press any numeric
key (1..8) to view the status of a specific alarm. Then, press another nu-
meric key to view the status of another alarm, etc.
1. From RUN mode, press the Function key and one of the other keys (•,
-, 1–9) for the menu you want to view.
Example:
To view the temperatures for each of the temperature-controlled zones
assigned to the Microcontroller board's analog inputs, press F6 8. The
software will default to the first temperature-controlled zone, “s/lT1”
(Sample Line).
To return to the RUN mode normal display from any menu in RUN
mode, press F6 0. To return to the RUN mode normal display from
anywhere in the software, repeatedly press Esc until RUN mode is
returned.
Figure 4-2 is a Quick Reference Sheet that lists each of the available key-
stroke combinations you can use to perform various tasks from RUN and
CFG modes. The RUN and CFG modes are almost identical. You can only
view information from RUN mode but you can change it from CFG mode
(a password is required to enter CFG mode).
The differences between RUN and CFG mode are denoted by “(RUN)”
and “(CFG)” under the Function key headings (Figure 4-2). The
NOTE
specific function (Term) for each mode is listed under “(RUN)” and
“(CFG)”. If “(RUN)” and “(CFG)” are absent, the function is the
same for both modes.
Key F1 F2 F3 F4 F5 F6
RUN CFG
RUN CFG AI:Msr HCHist
• MBAddr — PSWD0 PSWD0?
— Auto-Setup (1..6) (1..9)
(CAL) (CAL)
RUN CFG
PTPara ComPara AuxTAvg MCHist
– TCold PSWD1 PSWD1?
(1..4) (1..3) (1..3) (1..9)
(CFG) (CFG)
TStPt Normal Display
0 KFtr Cell — SN
(1..4) RUN/CFG
Ftr KVal Kp Sig
1 Temp Zones HC/909 Ver
(1..2) (1..2) (1..4) (1..3)
LmpB Ti TR (Show Trn)
2 Samples — MC Ver
(1..2) (1..4) (1..2)
Td Show Res
3 LmpMax Delay — RTime
(1..4) (1..9)
TType HS e
4 PmtLvl — —
(1..4) (1..8) (Show MEmiss)
Adap TDuty MS o
5 PmtBal —
(1..2) (1..8) (1..7) (Show O2Cor)
Output CPRg
6 SigMax — — —
(1..4) (1..2)
STcf
7 Kq Alc — MDI —
(1..5)
AlcG DPRg LmpP Show MAIn
8 Ke —
(1..2) (1..2) (1..2) (1..8)
SetPt O2Para TCycle Show HAIn
9 Units —
(1..2) (1..3) (1..5) (1..8)
Figure 4-2.
RUN / CFG Mode quick
reference sheet –
keystroke combinations.
The major difference between CFG and RUN mode is that in CFG mode,
you can change (configure) certain information.
Example:
To change an existing temperature set point value for the Analyzer Mea-
suring Cell temperature-controlled zone:
3. Press Ent to enter CFG mode. “CFG” will be displayed on the top line,
while the output results from RUN mode will continue to be dis-
played on the bottom line. This is the CFG mode normal display.
5. Press Del to delete the existing value (default = 155.00 °C), and then
enter the new value (for example, “153.00”) at the “TStPt4?” prompt.
6. To save the change, press Ent and then Esc to back out of this menu.
At the “Save ConFig?” prompt, press Ent again to confirm the change.
To return to CFG mode normal display from any menu in CFG mode,
press F6 0. To return to the RUN mode normal display from anywhere in
the software, repeatedly press Esc until RUN mode is returned.
Function commands with a range [e.g., Scale (1..4)] indicate you can view
or change more than one parameter from that menu, without having to
re-enter the Function key (for that function) each time. For example, view
the Scale menu (press F5 1) and press 4 to view the full-scale range for
Output 4. Then, press any numeric key (1..4) to view the full-scale range
for another output, etc.
Example:
To change the analyzer’s Flow Control Mode to Continuous Backpurge:
3. Press Ent to enter CAL mode. “CAL” will be displayed on the top line,
while the output results from RUN mode will continue to be dis-
played on the bottom line. This is CAL mode normal display.
8. Press Esc to return to RUN mode. The screen will display “B” on the
upper-left line to indicate that the analyzer has been manually forced
to Continuous Backpurge mode.
To return to the RUN mode normal display from anywhere in the soft-
ware, repeatedly press Esc until RUN mode returns.
Figure 4-3 is a Quick Reference Sheet that lists each of the available key-
stroke combinations from CAL mode. While working in CAL mode, the
information can be changed (a password is required to enter and work in
CAL mode).
Key F1 F2 F3 F4 F5 F6
• — — — — — —
– — — — — — —
Izero
0 Auto/Zero? Man/Zero? Timer0 — —
(1..4)
Scale Ispan
1 Auto/Span1? Man/Span1? Timer1 Conc1
(1..4) (1..4)
2 Auto/Span2? — Timer2 — FlowCtrl ZCD
PrbT
3 — — — AdjDisable SCD
(1..3)
VTp O2CD
4 Vel/Zero? — — Sol:O2Z
(1..2) (1..2)
5 Vel/Span? — VTi — Sol:O2S O2ZVolt
To
6 Vel/BkPurge? — IntTime — O2SFactor
(1..2)
7 PrbBlowBk? — SDelay DPSpn SFactor VelCtrl
O2 Conc
8 — Man/SpanO2? AZInt Temp DPZ
(1..2)
9 Auto/Cal? Man/ZeroO2? ACal Bw Pres DPSFactor
Figure 4-3.
CAL Mode quick
reference sheet –
keystroke combinations.
1. From RUN mode, press F6 – • • and press Ent to enter CFG mode.
Press F6 • (this is the command to change the CAL mode password).
The message “PSWD0?” appears.
2. Enter a new password (up to 9 characters). You cannot use the Func-
tion keys as part of a password. Record the new password and store it
in a safe place.
3. Press Ent. The new password is entered and the message “PSWD0?”
appears again.
4. Enter the new password a second time and press Ent. Press Ent again
to return to CFG mode normal display.
If this password does not match the first entry of the new password,
the message “<UNCHANGED>” is displayed.
If Yes, press Ent to accept the new password. The display will exit CFG
mode and return to RUN mode.
If No, press Esc to discard the changes. The display will exit CFG
mode and return to RUN mode.
1. From RUN mode, press F6 – • • and press Ent to enter CFG mode.
Press F6 – (this is the command to change the CFG mode password).
The message “PSWD1?” appears.
3. Press Ent. The new password is entered and the message “PSWD1?”
appears again.
4. Enter the new password a second time and press Ent. Press Ent again
to return to CFG mode normal display. If this password does not
match the first entry of the new password, the message
“<UNCHANGED>” is displayed.
5. Press Esc. The User Interface Panel will prompt you to accept the
changes (“Save Config ?”).
If Yes, press Ent to accept the new password. The display will exit CFG
mode and return to RUN mode.
If No, press Esc to discard the changes. The display will exit CFG
mode and return to RUN mode.
During normal operation in RUN mode, the top line of the User Interface
Panel screen displays the current status of the analyzer. For example, 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, by displaying S on
the upper-right line.
When entering keystrokes in RUN mode, the User Interface Panel will
return to the RUN mode normal display under the following circum-
stances:
• If you press a Function key that is not valid for your system.
• If you press a numeric key that is not valid for your system.
To return to the RUN mode normal display from any menu in RUN mode,
press F6 0.
Press To
F5 0 View the analyzer serial number (SN).
F5 1 View the Host Controller board software version number (HC/909V).
F5 2 View the Microcontroller board software version number (MC900V).
F5 4 View the Host Controller board status error/code conditions (HS).
F5 5 View the Microcontroller board status error/code conditions (MS).
F2 0 View the total axial length (cm) of the gas space in the Measuring Cell,
displayed in cm.
While working in CFG mode, all information associated with this mode is
displayed on the top line of the User Interface Panel screen, including
“CFG” to signify the current mode. The temperature values from the RUN
mode normal display will continue to be displayed on the bottom line.
3. Press Ent to enter CFG mode. “CFG” will be displayed on the top line,
while the output results from RUN mode will continue to be dis-
played on the bottom line. This is the CFG mode normal display.
When entering keystrokes in CFG mode, 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.
• If you press a numeric key that is not valid for your system.
To return to RUN mode, press Esc. If any changes have been made to
CFG mode menu settings, the message “SAVE CONFIG?” appears. Press
Ent to answer Yes and then press Esc again to return to RUN mode. Or,
press Esc to answer No. If no changes have been made, the software will
return immediately to RUN mode.
The differences between RUN and CFG modes are denoted by “(RUN)”
and “(CFG)” under the Keystrokes heading in the following pages. Next
to the “(RUN)” and “(CFG)” identifiers are the specific function (Term) for
each mode, followed by a description of the function.
Only the keystroke combinations that are functional in RUN and CFG
modes are listed in the following pages.
Factory-default values (if applicable) for the analyzer have been indicated
for each keystroke. Please consult with your AMETEK representative or
the factory before changing any factory-default values.
Note the differences for the F1 • keystroke in RUN and CFG modes. The
Auto-Setup function is not available in RUN mode.
F1 • (CFG) Auto-Setup The Auto-Setup function optimizes PMT gains and the source lamp currents. Always
initiate an Auto-Setup after any lamps, optical filters, or PMTs have been installed or
replaced. This function is available in CFG mode only.
F1 – PTParaz This temperature-controlled zone is used only with systems employing a heated external
probe with a dedicated temperature controller (controlled by analyzer). For these
systems, this menu item displays a variety of temperature control parameters, where ‘z’ =
1..4. The parameters and their default values are:
1 = Probe Temperature signal low scale for 0 (zero) V.
2 = Probe Temperature signal high scale for full-scale V.
3 = Probe Temperature low alarm set point.
4 = Probe Temperature high alarm set point.
F1 0 KFtrz ** Position of the key filter which gives the weakest signal for a given source lamp
current, where ‘z’ is the filter being used (1..2).
1 = Measure Filter 1
2 = Reference Filter 2
F1 1 Ftrz ** The default source lamp pulse current-control signal (V) for each filter, where ‘z’ = 1..2.
The normal operating range is between 0.5 V and Lamp Max (6.0 V – may vary, check
EEPROM Data Sheets for actual value), with the control signal for the key filter being
Lamp Max.
1 = Measure Filter 1
2 = Reference Filter 2
F1 2 LmpBz ** The base-current set point (V) for each source lamp, which is the minimum operating
current, where ‘z’ = 1..2.
1 = Lamp 1 (closest to the Measuring Cell)
2 = Lamp 2 (farthest from the Measuring Cell)
Note: If your analyzer is configured to measure H2S, both lamps are Cadmium; if your
analyzer is configured to measure SO2, both lamps are Magnesium.
F1 3 LmpMax ** Voltage to which the lamp pulse current-control signal for the key filter location is set
during the Auto-Setup. The nominal value is 6.0 V (may vary, check EEPROM Data
Sheets for actual value).
F1 4 PmtLvl ** The photomultiplier tube (PMT) gain control signal (V), which is based on the signal
from the PMT when the key filter is in the light path. Normal values after a successful
Auto-Setup are from 4.0–7.0 VDC.
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.
Normal values after a successful Auto-Setup are from 4.0–7.0 VDC.
F1 6 SigMax ** The signal from the PMT with the highest gain is set to SigMax when each filter is in
the light path while the Auto-Setup is in progress. SigMax should be between 8.0 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, stack duct
physical data, and units of measurement.
F1 8 Ke The units conversion constant for calculation of component mass flow (Mass/Amount).
The unit for input and output parameters (Metric or Imperial) is set at the factory, and
should not be changed by the user (i.e., do not change from a Metric unit to an Imperial
unit). If a change is required, consult with your AMETEK representative, or contact the
factory.
The user can, however, change the concentration units freely back and forth between
PPM and mole percent (e.g., from Units = 0 to Units = 2, or from Units = 1 to Units = 3, or
vice versa).
F2 • MBAddr Modicon Modbus® slave address – can be any value between 0–255. 0 (zero) will disable
the Modbus® communication interface. For addresses 1–127, select the RS-232 port; for
addresses 128–255 select the RS-422 port.
F2 – ComParaz n The communication setup parameters for the Baud Rate, Stop Bits, and Parity of the serial
communication port, where ‘z’ = 1..3 and where ‘n’ = 0..3.
Note: Any changes to the parameters must be saved to the EEPROM and the analyzer
must be reset to make the changes take effect.
F2 1 Temp Zones z The Temperature Zone code defines the number of temperature-controlled zones used by
the analyzer, where ‘z’ = the sum of the Temperature Zone code (0, 2, 4, 6, or 32) plus the
Standard Bench Type Code (24 = Motorless Bench). The typical displayed value is ‘28’
((‘4’ = 3 temperature-controlled zones) + (‘24’ = Motorless Bench)). For systems with the
manual Blow-Back function enabled, the displayed value is ‘26’ ((‘2’ = 2 temperature-
controlled zones) + (‘24’ = Motorless Bench)). For more information, refer to “Prob Blow-
Back Control” later in this chapter.
The code is the decimal equivalent of an 8-bit binary number, which defines the bench
type in regard to the temperature control parameters.
F2 2 Samples ** Number of times the PMT signal is measured while a filter is completely within the light
path.
F2 3 Delay ** The time interval from when a filter becomes completely within the light path to the first
PMT-signal measurement. The interval is shown as multiples of 1.6 microseconds (μs).
F2 6 Outputz The Output Signal Assignment (OSA) code for each of the four current outputs, where
‘z’ = 1..4. Allows the customer to define which of the calculated results (parameters) will
be available as output signals. These outputs are application-specific. Refer to “Output
Signal Assignment (OSA),” later in this chapter, for more information. The parameters
are:
1 = Output1
2 = Output2
3 = Output3
4 = Output4
F2 7 Alc The Automatic Lamp Control Enable function displays the operational status of the
Automatic Lamp Control function. This parameter is automatically turned on by Auto-
Setup, and should be on during normal operation. However, this function should be
turned off while replacing PMTs or source lamps.
0 = Off
1 = On
Note: This manual does not describe procedures to replace the PMTs. Contact AMETEK
for instructions before attempting to replace the PMTs.
F2 8 AlcGz ** Automatic Lamp Control gain setting for each filter, where ‘z’ = 1..2.
1 = AlcG1
2 = AlcG2
F2 9 SetPtz ** Signal (V) obtained from the Reference PMT for each filter after the Auto-Setup, where
‘z’ = 1..2. These values are updated automatically by Auto-Setup. The Automatic Lamp
Control function adjusts the lamp pulses to maintain the Reference PMT signals to these
values.
1 = SetPt1
2 = SetPt2
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, providing
each remaining zone is within 5 % of its set point value. Entering ‘0’ results in the
analyzer using 5 % of the Measuring Cell temperature set point as the switch
temperature.
F3 0 Not Used —
F3 1 KValz ** The molar absorptivity of the species of interest at the wavelengths used, where
‘z’ = 1..2.
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 —
F4 • AI:Msrz ** The Microcontroller channel number for the analog input signals, where ‘z’ = 1..6. Refer
to “Active Temperature and Pressure Compensation,” later in this chapter, for more
information about enabling/disabling these functions.
1 = O2 Measurement and Dilution Air Computation (optional)
Internal sensor (Zr733) AI:Msr1 = 24
External sensor (linear) AI:Msr1 = 34
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
F4 – AuxTAvgz ** External signal averaging time (seconds) for the auxiliary inputs, where ‘z’ = 1..3. The
averaging time can be set from 0–255 seconds. Setting this averaging time to zero (0)
turns this function off.
1 = Allows the O2 input signal to be filtered (optional).
2 = Allows the Stream Temperature to be filtered.
3 = Allows the Differential Pressure to be filtered.
F4 0 TStPtz ** The control set point for the four temperature-controlled zones, where ‘z’ = 1..4. If the
set point is zero, that zone is not used. The zones and their default values are:
1 = Sample Line (default = 150.00 °C)
2 = SCU (default = 150.00 °C)
3 = TZone3 – Spare (default = 10.00 °C)
4 = Measuring Cell (default = 155.00 °C)
F4 1 Kpz ** The Proportional term of the PID temperature control algorithm for each temperature-
controlled zone, where ‘z’ = 1..4. The parameters and their default values are:
1 = Sample Line (default = 10.00 %)
2 = SCU (default = 10.00 %)
3 = TZone3 – Spare (default = 10.00 %)
4 = Measuring Cell (default = 10.00 %)
F4 2 Tiz ** The Integral term of the PID temperature control algorithm for each temperature-
controlled zone, where ‘z’ = 1..4. The parameters and their default values are:
1 = Sample Line (default = 1000.00 seconds)
2 = SCU (default = 1000.00 seconds)
3 = TZone3 – Spare (default = 1500.00 seconds)
4 = Measuring Cell (default = 2500.00 seconds)
F4 3 Tdz ** The differential (Derivative) term of the PID temperature control algorithm for each
temperature-controlled zone, where ‘z’ = 1..4. The parameters and their default values
are:
1 = Sample Line (default = 0 seconds)
2 = SCU (default = 0 seconds)
3 = TZone3 – Spare (default = 0 seconds)
4 = Measuring Cell (default = 0 seconds)
F4 6 CPRgz ** The Measuring Cell pressure transducer low and high value (mmHg or "Hg)
corresponding to 0.0 VDC and 5.0 VDC respectively, where ‘z’ = 1..2.
1 = Low value (0.0 VDC)
2 = High value (5.0 VDC)
F4 7 STcfz The coefficients to linearize the reading from the stack duct temperature transducer,
where ‘z’ = 1..5. The values are factory-set and must not be changed.
1 = Low Value (default = 0.0)
2 = High Value (default = 50.00)
3 = Not used
4 = Not used
5 = Not used
F4 8 DPRgz The stack duct differential pressure transducer low and high value (mmH2O or "H2O)
corresponding to 0.0 VDC and 5.0 VDC, where ‘z’ = 1..2.
F4 9 O2Paraz Zirconia Oxygen Sensor (O2 Sensor) parameters, where ‘z’ = 1..3. (For use in General
Purpose applications/analyzers only.)
1 = The specified O2 concentration to which the measured
SO2 concentration is corrected.
2 = The concentration corresponding to zero voltage output
(0.25 percent) of the O2 Sensor.
3 = The concentration corresponding to the full-scale voltage output
(25 percent) of the O2 Sensor.
F5 • HCHistz n History buffer for the last nine non-zero Host Controller board status codes where
‘z’ = 1..9, with ‘1’ being the oldest and ‘9’ being the most recent, and where ‘n’ = the sum
value of status code.
F5 – MCHistz n History buffer for the last nine non-zero Microcontroller board status codes where
‘z’ = 1..9, with ‘1’ being the oldest and ‘9’ being the most recent, and where ‘n’ = the sum
value of status code.
F5 3 RTime Total run time of the analyzer since the last reset or system power-up. The format is:
Days Hours:Minutes (### ##:##)
F5 4 HSz The possible Host Controller board status/error code conditions (HStatus), where ‘z’ = 1..8.
For each ‘z’, the appropriate Error Message is displayed if the error condition exists. If the
error condition does not exist, the message “HSz OK” appears.
Refer to the “Maintenance & Troubleshooting” chapter for descriptions of these error
conditions and corrective action to take.
The possible error conditions include:
1 = w EEPROM Full (Warning)
2 = w Out Of Range (Warning)
3 = f Comm Fault (Fault)
4 = f RxData Fault (Fault)
5 = f Temp Low (Fault)
6 = f Temp High (Fault)
7 = w ZDrift\SpanErr (Warning)
8 = w Tmp3 High (Warning) – optional
F5 5 MSz The possible Microcontroller board status/error code conditions (MStatus), where ‘z’ = 1..7.
For each ‘z’, the appropriate Error Message is displayed if the error condition exists. If the
error condition does not exist, the message “MSz OK” appears.
Refer to the “Maintenance & Troubleshooting” chapter for descriptions of these error
conditions and corrective action to take.
F5 6 Not Used —
or
00 Open Open
01 Open Closed
10 Closed Open
11 Closed Closed
F5 8 LmpPz Current lamp pulse (V) for each filter as generated by the Automatic Lamp Control, where
‘z’ = 1..2.
1 = Lamp 1
2 = Lamp 2
F5 9 TCyclez Current temperature control duty cycle (%) for each temperature-controlled zone, where
‘z’ = 1..5.
F6 • (RUN) PSWD0 (CAL) This is the CAL mode entry password prompt, seen only after you press ‘F6 •’ from
RUN mode. From RUN mode, enter these keystrokes to enter and work in CAL mode.
The factory-default password is • • .
F6 • (CFG) PSWD0? This is the CAL mode change password prompt, seen only after you press ‘F6 •’ from
CFG mode. While working in CFG mode, these keystrokes will call up the “PSWD0?”
prompt, which will allow you to change the CAL mode entry password.
The new password can be up to nine characters. The Function keys cannot be used as
part of the password. The new password must be entered twice before it is accepted.
F6 – (CFG) PSWD1? This is the CFG mode change password prompt, seen only after you press ‘F6 –’ from
CFG mode. While working in CFG mode, these keystrokes will call up the “PSWD1?”
prompt, which will allow you to change the CFG mode entry password.
The new password can be up to nine characters. The Function keys cannot be used as
part of the password. The new password must be entered twice before it is accepted.
F6 1 Sigz Displays the Measure and Reference PMT signal for each filter, where ‘z’ = 1..3. The
signals are displayed on the bottom line of the User Interface Panel (the Measure PMT
signal is on the left; the Reference PMT signal is on the right). Normal values are in the
range of 5.0–9.84 VDC.
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)
F6 2 TR z (Show Trn)
** Displays the transmittance (Show Transmittance) for the filter. The transmittance is
shown on the bottom line of the User Interface Panel, where ‘z’ = 1..2.
1 = Filter1 (Measure filter)
2 = Filter2 (Reference filter)
F6 4 e The Show MEmiss menu displays the mass flow rate for the component.
F6 5 o The Show O2Cor menu continuously displays (on the second line of the User Interface
Panel) the O2 corrected concentrations of SO2 (optional).
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. (Note that the actual MAI description (e.g., ‘s/lT1’) is displayed
on the screen, not “Show MAI”.) To return to the RUN mode normal display, press
‘F6 0’.
To view the operating temperature for each of the temperature-control zones or for the
Heater Plate, press the key associated to that parameter.
To view the Stack Stream Temperature, press ‘6’ while viewing this screen.
To view the status of the Over-Temperature relay (OT, either normal or tripped), press ‘5’
while viewing this screen.
The parameter can be assigned to any of the four output channels. The
assignment is made by displaying the output number and assigning a
numeric code that corresponds to the result. Figure 4-4 defines the calcu-
lated result codes. An undefined result code will default to a primary
code, using the last digit that was entered. For example, a code of 83 will
default to a primary code of 3.
CODE
Instantaneous Track-and-Hold
Primary Mass O2 Primary Mass O2
DEFINITION Results Flow Rate Corrected Results Flow Rate Corrected
Output Not Used 0 0 0 0 0 0
Application-specific
1 11 21 51 61 —
(e.g., SO2)
Not Used 2–7 — — — — —
Flow Rate 8 — — — — —
O2 (Optional) 9 — — 59 — —
Figure 4-4.
Calculated Result
(Parameter) Codes.
The codes in Figure 4-4 assign the result to both the User Interface
Panel and analog outputs. To assign a result to the analog output
NOTE only, add 100 to the codes.
Example 2:
To assign the SO2 concentration to analog Output 1 and the User Interface
Panel and return to CFG mode normal display, key in:
There are eight (8) system analog input channels on the Micro-Interface
board. These analog inputs can be viewed on the User Interface Panel by
pressing F6 8 1..8 from RUN mode. The jumper positions are listed below
(under “Display I/O Board Analog Input Signals” and “Microcontroller
Analog Input (MAI) Signals”) so they can be restored by the user if they
should become dislodged (during transit, for example).
The analog input channels are configured at the factory – the analyzer
! will not operate properly if the jumpers or inputs are changed from the
CAUTION
factory settings.
The Display I/O board inputs are labeled 1 to 4 and each has three
jumper-selectable ranges: 0–1 V, 0–5 V, and 0–10 V.
The range is marked on the board beside each jumper position. The jumper
headers and their positions are described below (see also Figure 4-5).
Figure 4-5.
Display I/O board.
The Microcontroller board inputs are labeled 5 to 8 and each has three
jumper-selectable ranges: 0–1 V, 0–5 V, and 0–10 V.
The ranges are not marked on the board. The jumper headers (on the
Micro-Interface board) and their positions are described below (see also
Figure 4-5).
Figure 4-5.
Micro-Interface board.
Calculated Results
Example 1:
To enter a value of 0 mmH2O for the stack duct low differential pressure
(DPRg1) and return to CFG mode, key in:
Example 2:
To enter a value of 25.4 mmH2O for the high differential pressure (DPRg2)
and return to RUN mode normal display, key in:
The coefficients are supplied for reference only and should be changed
! only upon direct instruction from the factory.
CAUTION
Example:
To set coefficient 2 (STcf2) to -7.2156 and return to CAL mode normal
display, key in:
The volume flow rate calculation constant (KQ) and the mass flow rate
calculation constant (KE) depend on the process stream composition, the
specified component, process stream duct dimensions, and units of
measurement for the various factors. These constants are specific to a
given application.
Pressing Ent will cause the new values for KQ and KE to be saved as
part of the configuration data, in non-volatile memory; the old values
NOTE
will be lost.
If the new values are not saved into the configuration, they will be
used temporarily until they are changed or until the next power up or
manual reset. After a power up or reset, the previous values (stored in
non-volatile memory) will again come into effect.
Entering KQ
Example:
To enter a value of KQ = 1200 and return to CFG mode normal display,
key in:
Entering KE
Example:
To enter a value of KE = KMMw = 0.369 for the component and return
to CFG mode normal display, key in:
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:
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:
To return to RUN mode, press Esc. The message “SAVE CONFIG?” will
appear. Press Esc for No; Ent for Yes.
The Velocimeter has been calibrated at the factory and will be re-
calibrated upon initial installation at the site. This section includes
NOTE procedures to perform a re-calibration as required.
• Thermocouple calibrator.
Default Configuration
If it is correct, proceed to the next step. If not, key in Del 21 Ent Ent
and proceed to the next step.
2. Verify that the AuxTAvg (T90) averaging time for the differential
pressure is 2 seconds by keying in F4 – 3 from CFG mode.
4. Verify that the time interval between pitot tube backpurge (VTi)
sequences is 10 minutes by keying in F3 5 from CAL mode.
If it is correct, press Ent to clear the User Interface Panel display for the
next operation. If not, key in Del ## Ent Ent to complete the setup
(where ‘##’ is the values listed on the Analyzer EEPROM Data Sheets).
The DPSFactor should be between 0.75 and 1.25 if the calibration was
performed correctly. It the DPSFactor is not within this range, correct
any malfunction and then repeat Steps 2–4 until an acceptable calibra-
tion is completed.
3. Set the AuxTAvg (T90) averaging time for the stream temperature to 2
seconds. To do this key in F4 – 2 Del 2 Ent Ent.
b. From CFG mode, enter the numerical value from Step 5-a in STcf1
by keying in F4 7 1 Del nnn Ent, where nnn is the numerical
value from Step 5-a.
Example:
The calibrator temperature is 0.0 °C and the temperature trans-
ducer temperature is 6 °C. STcf1 equals the offset of 6.
calibrator value
STcf2 = temperature transducer readout x 150
Example:
The nominal operating temperature (calibrator value) is 677 and
the temperature transducer readout is 680,
677
STcf2 = 680 x 150
STcf2 = 149.33
The following procedure uses the active SO2, DP, and Temperature signals
as parameters for verifying the calculated outputs of process gas volume
flow and mass emissions. Steps 1–4 assume these results have been
assigned to these analog output channels.
Verify the full-scale range for each of the four outputs. To do this, enter
CAL mode and:
If it is correct, proceed to the next step. If not, key in Del nnn Ent Ent
(where nnn is the new full-scale SO2 concentration) and proceed to
the next step.
If it is correct, proceed to the next step. If not, 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. If not, key in Del nnn Ent Ent
(where nnn is the new full-scale Mass Emission) and proceed to the
next step.
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’. If this
output is used as an application-specific output, the full-scale can be
verified and changed following the procedure stated for the other
three outputs (Steps 1–3).
Press F6 0 and record the values for SO2, Stack Volume Flow, and
Emissions.
6. 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.
Q = KQ DP
T
7. 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), calculate the emission (E) rate.
E = KE SO2 Q
Backpurge Interval
This is the time interval between pitot tube backpurge sequences. This
interval can be set from 0–255 minutes. Setting the interval to zero (0)
turns this function off. The factory default is 10 minutes. This function is
labelled VTi and is accessed from CAL mode by pressing F3 5.
Backpurge Duration
This is the duration of the pitot tube backpurge event. Backpurge air is
supplied to the pitot tubes for this duration. The air supply is then turned
off for 25 % of this time to allow pressure equalization in the pitot tubes
and connecting lines. This duration can be set from 0–255 seconds. Setting
this interval to zero turns this function off. The factory default for the
backpurge duration is 60 seconds. This function is labelled VTp and is
accessed from CAL mode by pressing F3 4.
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. As the AuxTAvg (T90)
time is increased, the sensitivity to changes in DP is decreased since the
DP signal is averaged over a longer time period. The averaging time can
be set from 0–255 seconds. Setting this averaging time to zero (0) turns
this function off. This function is labelled AuxTAvg and is accessed from
CFG mode by pressing F4 – 3.
The solenoids then switch back to connect the DP Cell pressure inputs to
the pitot lines. The Q output signal will be held for an additional period of
two times (multiplied by) the set AuxTAvg (T90) averaging time. This
extra hold time prevents the DP Cell zero output, which is produced
during the backpurge cycle, from influencing the averaged on line DP
output. The Q output is held for a total time per backpurge cycle as
follows:
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.
Example:
Using the factory defaults:
Backpurge interval, 10 minutes (600 seconds)
Backpurge duration, 60 seconds
AuxTAvg, 2 seconds
Out of every 10 minute cycle the Q output will be held for 60 seconds +
(0.25 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 only exceptions to this are the error messages “NoData” and
“CommFault”. These errors are both serious system errors, derived from the
Host Controller board, and are the only two alarm messages that are auto-
matically displayed on the bottom line when they are detected. When
viewed from the Host Controller Status (HStatus) screen (F5 4, from RUN
mode), these errors are displayed as “f RxData” and “f Comm Fault”.
While working in CAL mode, any function or result associated with this
mode is displayed on the top line of the User Interface Panel. The output
values from the normal display of RUN mode continue to be displayed on
the bottom line.
3. Press Ent to enter CAL mode. “CAL” will be displayed on the top line,
while the output results from RUN mode will continue to be dis-
played on the bottom line. This is the CAL mode normal display.
When entering keystrokes in CAL mode, 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.
• If you press a numeric key that is not valid for your system.
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 sampling system. The Zero Gas solenoid is turned on and off
automatically during the sequence.
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’.
F1 y Auto/Spany? The Auto-Span function allows you to initialize the analyzer to automatically introduce
Calibration Gas into the sampling system, where ‘y’ = 1..2:
1 = Auto/Span1? (F1 1)
2 = Auto/Span2? (F1 2) – Used only with O2 Sensor (General Purpose applications)
Only the Span function for ‘y’ is performed. The Calibration Gas solenoid valve connected
to SSR output ‘y’ is turned on and off automatically during the sequence.
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’.
F1 3 Not Used —
F1 4 Vel/Zero? Permits the user to manually zero the differential pressure (DP) cell. The readings are
based on the average reading during the last 5 seconds of the command.
F1 5 Vel/Span? Permits the user to manually span the differential pressure (DP) cell. The readings are
based on the average reading during the last 5 seconds of the command.
F1 7 PrbBlow Bk? The manual Probe Blow-Back function is used on systems using a stack sample probe
with a blow-back function. When you press F1 7 from this menu, the prompt “PrbBlow
Bk?” is displayed. Press Ent to initiate a manual probe blow-back. The manual blow-back
sequence, 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 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. Only the functions with
timers set to non-zero durations are included.
The zero offset and calibration will be automatically adjusted only if AdjDisable is set to ‘0’.
F2 • Not Used —
F2 – Not Used —
F2 0 Man/Zero? Permits the user to manually zero the analyzer. 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 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.
F2 1 Man/Span1? Permits the user to manually span the analyzer. The analyzer calibration is automatically
adjusted based on the average reading during the IntTime duration after a Yes response
only when AdjDisable is set to ‘0’. The Calibration (Span) Gas must be introduced
manually into the analyzer sample system. Refer to “Manual Span,” later in this chapter,
for details about how to perform a manual span on the analyzer.
F2 2 Not Used —
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, for use in General Purpose
applications/analyzers only) at the analyzer. 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’. Man/Span must be used to calibrate the sensor if Nitrogen
is used for the Zero Gas. The Calibration (Span) Gas must be introduced manually into
the analyzer sample system. Refer to “O2 Manual Zero/Span” in Appendix A for details
about how to perform a manual Span O2 on the analyzer.
F2 9 Man/ZeroO2? Permits the user to manually zero (air point calibration) the O2 Sensor (if used, for use in
General Purpose applications/analyzers only) at the analyzer. 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’. Man/Zero must be used to calibrate the
sensor if Nitrogen is used for the Zero Gas. The Zero Gas must be introduced manually
into the analyzer sample system. Refer to “O2 Manual Zero/Span” in Appendix A for
details about how to perform a manual Zero O2 on the analyzer.
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, Auto-Span, and Auto-
Calibration functions, where ‘y’ = 0..2.
0 = Timer0 (F3 0)
1 = Timer1 (F3 1)
2 = Timer2 (F3 2) – Used only with O2 Sensor (General Purpose applications)
Timer0 is the zero solenoid timer, while Timer1 and Timer2 are the Calibration Gas
mixture solenoid timers. The duration can be set from 0–255 minutes in one-minute
increments. Setting the duration to ‘0’ turns the specific timer off.
F3 3 PrbTz 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), where ‘z’ = 1..3. These
settings are used by the automatic and manual Probe Blow-Back function.
1 = PrbT1 = The Probe Blow-Back Interval parameter allows you to enter the interval-
time between blow-backs, in minutes. When an interval-time is entered, it is
displayed along with a countdown timer (time remaining until the next blow-back).
2 = PrbT2 = The Probe Blow-Back Duration parameter allows you to enter the duration
(in seconds) of each blow-back.
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, which blow back debris into the stack).
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, where ‘z’ = 1..2. The duration may be set
from 0–255 in one-second increments. Setting the duration to ‘0’ turns the function off:
F3 5 VTi The time interval between pitot tube backpurge sequences. This parameter can be set
from 0–255 minutes in one-minute intervals. Setting the value to ‘0’ turns the function off.
This function also includes a timer that displays the time remaining until the next
backpurge (mmm:ss).
F3 6 IntTime Sets the time period (seconds) over which the reading for each of the manual Zero/Span
functions is averaged. Setting this interval to ‘0’ turns the function off.
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. The delay can be set from 0–255
minutes in one-minute increments. Setting the delay to ‘0’ turns the function off.
F3 8 AZInt Sets the time interval (hours) between Auto-Zero sequences. This permits Auto-Zero to
be performed more frequently than Auto-Calibration. The interval can be set from 0–999
hours in one-hour increments. Setting this interval to ‘0’ turns the function off.
Also used to view the time remaining until the next Auto-Zero (hours and minutes).
F3 9 ACal The Auto-Calibration Interval setting sets the time interval (hours) between Auto-
Calibrations. The interval can be set from 0–999 hours in one-hour increments. Setting
the interval to ‘0’ turns the function off.
Also used to view the time remaining until the next timed Auto-Calibration (hours and
minutes).
F4 • Not Used —
F4 – Not Used —
F4 0 Not Used —
F4 1 Conc1 The concentration of the component (ppm or %) in the Calibration Gas mixture.
The concentration is entered in decimal notation. The maximum concentration which can
be entered is 999 999. If a Calibration Gas is not used, the concentration must be set to
zero.
F4 2 Not Used —
F4 3 Not Used —
F4 4 Not Used —
F4 5 Not Used —
F4 6 Not Used —
F4 7 DPSpn The differential pressure value (mmH2O or "H2O) to which the differential pressure
transducer is spanned.
F4 8 O2Concz The concentration of O2 (%) in the Calibration Gas mixture. The concentration is entered
in decimal notation. The maximum concentration which can be entered is 999 999, where
‘z’ = 1..2.
F4 9 Bw Used in applications where the emission rate is calculated using a fuel factor. Bw is the
water content in the air used in the combustion process.
F5 • Not Used —
F5 – Not Used —
F5 0 Not Used —
F5 1 Scalez The full-scale range for each of the four outputs. If an output is not used, its full-scale
range should be set to zero, where ‘z’ = 1..4. For example, if Scale 1 = 1000 ppm,
output 1 would read 20 mA at 1000 ppm and 4 mA at 0 ppm. These outputs are
application-specific.
1 = Scale1
2 = Scale2
3 = Scale3
4 = Scale4
F5 2 FlowCtrlz The analyzer system Sample Flow Control Mode, where ‘z’ = 0..2, 10..12, 100..102, or
110..112.
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 AdjDisablez 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).
To allow automatic adjustments of the analyzer Zero offset and calibration, set this
function to ‘0’.
To prevent automatic adjustments of the analyzer Zero offset and calibration, set this
function to ‘1’.
F5 4 Sol:O2Z Assigns a solenoid to the O2 Zero Gas. The software confirms the assignment during an
Auto-Calibration action.
If N2 is used as Zero Gas, then the assigned solenoid value entered must be ‘10’
(pseudo-solenoid) to prevent inadvertent Auto-Calibration.
F5 5 Sol:O2S Assigns a solenoid to the O2 Span Gas. The software confirms the assignment during an
Auto-Calibration action. If the Span Gas is attached to Solenoid 2, for example, the O2
Sensor is span calibrated when Auto-Span is initiated by itself or as part of the Auto-
Calibration sequence. (The O2 Sensor is optional, and is for use in General Purpose
applications/analyzers only.)
1 = Filter 1
2 = Filter 2
F5 7 SFactor The span (calibration) factor for the calculated result (component concentration). Adjusted
automatically whenever the analyzer is Spanned if AdjDisable is set to ‘0’.
F5 8 Temp The default temperature for the Measuring Cell (°C or °F). This value is used in place of
the measured Measuring Cell temperature when active temperature compensation is
disabled. Default = 140 °C.
F5 9 Pres The default absolute pressure for the Measuring Cell (mmHg or "Hg). This value is used
in place of the measured Measuring Cell pressure when active pressure compensation is
disabled. Default = 760.00 mmHg.
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, where ‘z’ = Output Channels 1..4. Refer to the
Output Signal Assignment code for the outputs assigned to these channels (press F2 6
from CFG mode). The actual mA value is displayed next to the corresponding output
channel when 4 mA (Zero function) is activated.
1 = Output Channel 1
2 = Output Channel 2
3 = Output Channel 3
4 = Output Channel 4
F6 1 z ISpanz The measured full-scale current (mA) in the current output loop when output is set to full-scale
during the Span calibration procedure, where ‘z’ = Output Channels 1..4. Refer to the Output
Signal Assignment code for the outputs assigned to these channels (press F2 6 from CFG
mode). The actual mA value is displayed next to the corresponding output channel when
20 mA (Span function) is activated.
1 = Output Channel 1
2 = Output Channel 2
3 = Output Channel 3
4 = Output Channel 4
F6 2 ZCD The Zero Cal Drift is used only when AdjDisable is set to ‘0’. After an Auto-Cal, the zero
drift of the calculated result since the last Auto-Cal is recorded here. The drift result is
displayed in ppm.
F6 3 SCD The Span Cal Drift is used only when AdjDisable is set to ‘0’. After an Auto-Cal, the span
drift of the calculated result since the last Auto-Cal is recorded here. The drift result is
displayed in ppm.
F6 4 O2CDz The O2 Cal Drift is used only when AdjDisable is set to ‘0’, where ‘z’ = 1..2. After an Auto-Cal,
the O2 signal drift of the calculated result since the last Auto-Cal is recorded here. The signal
drift result is displayed in ppm.
F6 5 O2ZVolt The O2 Sensor voltage output offset at zero (air point). It is determined by the software
when zero calibration of the O2 Sensor is performed. (The O2 Sensor is optional, and is
for use in General Purpose applications/analyzers only.)
F6 6 O2SFactor The O2 Sensor span factor. It is determined by the software when span calibration of the
O2 Sensor is performed. (The O2 Sensor is optional, and is for use in General Purpose
applications/analyzers only.)
The Flow Control mode determines the state of the sample gas flow. It can
be controlled automatically by the analyzer (Analyzer Control mode) or
forced to any of the manual modes by the user. Each mode is described in
detail in the following pages.
While viewing the Flow Control mode (CAL mode menu) from the User
Interface Panel, the screen will display a code (e.g., 0 = Analyzer Control
mode) that indicates a the current operating mode:
100 Sample Block Valve Analyzer Control (automatic) blank = Sample (by analyzer)
b = Backpurge (by analyzer)
101 Sample Block Valve Continuous Sample Block-Off (manual) B (* See Note)
110 Sample Block Valve Continuous Zero Gas Flow – local (manual) Z
111 Sample Block Valve Continuous Calibration Gas #1 Flow – local (manual) C
112 Sample Block Valve Continuous Calibration Gas #2 Flow – local (manual) C
When the analyzer’s Flow Control Mode is set to Analyzer Control, the
analyzer automatically determines and sets the mode of operation by
monitoring the state of the Fault alarm relay contacts. If there is no Fault
alarm, the analyzer will operate in automatic Continuous Sample. When
in Continuous Sample mode, there is no indicating character on the User
Interface Panel.
The analyzer will not switch back to Continuous Sample mode until the
Fault alarm has been corrected (cleared).
To set the analyzer’s Flow Control to Analyzer Control and return to CAL
mode normal display, key in from CAL mode:
When you force the analyzer into Continuous Backpurge, 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”, which indicates an analyzer-
controlled – or automatic – backpurge).
To manually force the analyzer to zero the sampling system, use the
keypad on the User Interface Panel to key in from CAL mode:
When the user has forced the analyzer into Continuous Sample, “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.
When the analyzer’s Flow Control Mode is set to Continuous Zero Gas
Flow, the analyzer is zeroed with Zero Gas. It will not automatically
switch to Continuous Backpurge mode.
When you force the analyzer into Continuous Zero Gas Flow, “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 sampling system with
Zero Gas.
To manually force the analyzer to zero the sampling system with Zero
Gas, use the keypad on the User Interface Panel to key in from CAL mode:
When you force the analyzer into Continuous Calibration Gas Flow (Gas 1
or Gas 2), “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
sampling system with calibration gas.
The operating mode for the Velocimeter can be controlled by the analyzer
(automatic) or, forced to backpurge by the user:
Analyzer Control
When operating in the Analyzer Control mode, the Velocimeter is
backpurged at the time interval specified by the Velocimeter timer
(VTi, F3 5 from CAL mode).
Backpurge
When operating in the Backpurge mode, the Velocimeter is purged
with instrument air to clear the pitot tubes or to perform a Zero/Span
calibration.
You must enter the concentration of the component you are using in the
calibration gas mixture before initiating a calibration sequence. The con-
centration can be expressed in ppm (v/v) or percent (%), depending on
the units selected. The maximum value allowed is 999 999; fractional
values are entered using normal decimal notation (e.g., 1.495).
Example:
To enter a value of 1.495 % for the component and return to CAL mode
normal display, key in from CAL mode:
There are three independent timers used for automatic calibration of the
analyzer. Each establishes the time period (duration) for which a solenoid
valve controlling the calibration gas mixture is energized during the Auto-
Zero, Auto-Span, and Auto-Calibration sequences. The timer duration
depends on the time required for the calibration gas mixture to reach the
analyzer and to obtain a stable reading.
Timer0 establishes the length of time the analyzer Zero Gas solenoid
valve is turned on during the Auto-Zero sequence. 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.
The time can be set from 0–255 minutes in one-minute increments. Setting
a timer duration to ‘0’ turns the timer off, disabling the function. The
average reading for Auto-Zero, Auto-Span 1, and Auto-Span 2 will be
taken during the last 25 percent of the timer duration.
The Timer must be assigned a value that allows the signals to be stable
during the last 25 percent of the countdown.
NOTE
Example 1:
To set Timer0 duration to 3 minutes and return to CAL mode normal
display, key in from CAL mode:
F3 0 Del 3 Ent Ent
Example 2:
Timer2 is not required for control of a calibration gas mixture. Its duration
must be set to zero (turned off). To set Timer2 to ‘0’ and return to CAL
mode normal display, key in from CAL mode:
F3 2 Del 0 Ent Ent
The Integration Timer (IntTime) allows you to set the duration over
which readings are averaged during manual calibration functions. The
IntTime can be set to a duration from 0–65535 seconds in one-second
increments. Setting the duration to ‘0’ causes the default averaging time
of 15 seconds to be used.
Example:
To set the IntTime to 25 seconds and return to CAL mode normal display,
key in from CAL mode:
The ACal timer sets the interval (hours) between timed Auto-Calibration
sequences. The ACal timer can be set to an interval from 0–999 hours in
one-hour increments. Setting the interval to ‘0’ turns the ACal timer off,
disabling a timed start of the Auto-Calibration sequence. A timed Auto-
Calibration will start only when the analyzer is operating in RUN mode
without any Faults.
Example:
To set the ACal timer interval to 3 hours and return to CAL mode normal
display, key in from CAL mode:
The time remaining until the next Auto-Calibration can be displayed from
CAL mode at any time by pressing F3 9. The User Interface Panel does not
provide a running count of the time remaining until the next Auto-
Calibration – you must press F3 9 to view the time remaining until the
next Auto-Calibration.
Pressing Ent from this menu function returns the CAL mode normal
display, pressing Esc returns RUN mode normal display.
This timer sets the interval (hours) between timed Auto-Zero sequences,
and allows the Auto-Zero function to be performed more frequently than
the Auto-Calibration. The timer can be set to an interval from 0–999 hours
in one-hour increments. Setting the interval to zero (0) turns the timer off,
disabling a timed start of the Auto-Zero sequence. A timed Auto-Zero will
start only when the analyzer is operating in RUN mode without any
Faults.
Example:
To set the AZInt timer interval to 1 hour and return to CAL mode normal
display, key in from CAL mode:
The time remaining until the next Auto-Zero can be displayed from CAL
mode at any time by pressing F3 8. The User Interface Panel does not
provide a running count of the time remaining until the next Auto-Zero;
you must press F3 8 to view the time remaining until the next Auto-Zero.
Pressing Ent returns the CAL mode normal display, pressing Esc returns
the RUN mode normal display.
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. The time delay will also be in effect if a
calibration sequence is aborted. This allows any external recording devices
to mark the point at which the analyzer is again monitoring a representa-
tive sample, 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.
The User Interface Panel gives no indication that the delay is occurring or
that it has occurred. The time delay depends on the time required for the
sample gas to reach the analyzer and a stable reading to be obtained.
The time delay can be set from 0–255 minutes in one-minute increments.
Setting the delay to ‘0’ turns off the SDelay timer. If the delay is ‘0’, the
CAL status relay will indicate that the calibration is complete immediately
following the end of the calibration sequence.
Example:
To set the SDelay timer to 4 minutes and return to CAL mode normal
display, key in from CAL mode:
The Manual Zero and Manual Span functions do not activate the solenoid
valves. The gases must be introduced manually into the analyzer and
allowed to flow through the sampling system until a stable reading is
displayed. The time required for calibration gas to reach the analyzer and
for a stable reading to be achieved and displayed is dependent upon the
volume of the sampling system and calibration gas flow rate. The gas flow
rate, temperature and pressure should be as close as possible to the
normal operating conditions.
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.
Manual Span
1. Ensure that the calibration gas supply is connected and turned on.
Turn off the Aspirator Air.
3. Force the analyzer to manually span the sample system with Calibration
Gas by keying in F5 2 Del 11 Ent, where ‘11’ = Calibration Gas #1.
4. Press F2 1 to initiate the manual span. The User Interface Panel will
prompt “Man/Span1?”.
Ent for Yes The analyzer will count down to zero (IntTime duration)
during which time the reading is averaged. The calibra-
tion value for the component will be adjusted automati-
cally and the CAL mode normal display returned.
Esc for No The function is aborted and the calibration value for
the component is not adjusted.
There are three solid state relay (SSR) outputs available for switching the
solenoid valves controlling the flows of the calibration gas mixtures. Each
SSR output is controlled by a Calibration Gas Timer. The SSR output, its
function, and the Calibration Gas Timer assigned to each are listed below.
0 Auto-Zero 0
1 Auto-Span 1 1
2 Auto-Span 2 2
If the duration for a calibration gas timer is set to a non-zero value, and
the component concentration is specified as zero, the function will be
performed.
4. 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 transi-
tion from the Zero or calibration gas mixture back to the sample gas.
The User Interface Panel gives no indication that this is occurring.
Pressing Esc at any time during this procedure will abort the function
and return to CAL mode normal display.
NOTE
A manual start of the Auto-Zero sequence resets the AZInt timer to its
initial value. The start of the next Auto-Zero will be timed from the begin-
ning of the manual start.
For example, if the AZInt timer is set at 2 hours, the time remaining until
the next timed Auto-Calibration is 30 minutes, and the Auto-Calibration
sequence is started manually, the AZInt timer will be reset, and the time
remaining until the next timed Auto-Calibration remains 2 hours.
Pressing Esc at any time during this procedure will abort the function
and return to CAL mode normal display.
NOTE
Timer0 will begin to count down to zero time. The analyzer zero offset
is adjusted automatically based on the average of the reading during
the last 25 % of the countdown.
Or, press Esc to abort the Auto-Zero sequence; the zero offset is not
adjusted.
Or, press Esc to abort the Auto-Span sequence; the span value is not
adjusted.
Auto-Span 2 and its associated timer (Timer 2) is used only when the
optional O2 Sensor is used (General Purpose applications/analyzers
NOTE
only).
If the ACal timer is set to an interval other than zero, the first Auto-
Calibration sequence occurs after the ACal interval from the time the
analyzer is powered up or reset as long as no fault conditions are present.
Subsequent Auto-Calibration sequences will be initiated at every Auto-
Calibration time interval.
Example:
If the ACal timer is set to “3” and the analyzer is powered up or reset, the
first Auto-Calibration will occur at 3 hours if all temperatures are reached.
The Auto-Calibration sequence will occur at 3-hour intervals unless this
value is changed.
A manual start of the Auto-Calibration sequence does not reset the ACal
timer to its initial value. The start of the next Auto-Calibration will be
timed from the continuing countdown of the original ACal timer setting.
The Auto-Calibration sequence can be started manually by pressing F1 9
Ent from CAL mode.
Example:
If the ACal timer is set at 2 hours, the time remaining until the next timed
Auto-Calibration is 30 minutes, and the Auto-Calibration sequence is
started manually, the ACal timer will continue to count down, and the
time remaining until the next timed Auto-Calibration remains 30 minutes.
Pressing Esc at any time during this procedure will cause it to abort
and return to CAL mode normal display.
NOTE
or
Press Esc for No. The sequence is aborted and adjustments are not
made. The CAL mode normal display is returned.
Upon completion of the sequence, the User Interface Panel returns the
RUN mode normal display.
Example:
If the ACal timer is set at 2 hours, the time remaining until the next timed
Auto-Calibration is 30 minutes and the Auto-Calibration sequence is
started by a contact closure, the ACal timer will continue to count down
and the time remaining until the next timed Auto-Calibration remains 30
minutes. If a timed Auto-Calibration is in progress, the remote-contact
closure will be ignored.
To enable the Remote Backpurge option, add a value of “16” to the Units
value (F1 9 from CFG mode). Refer to F1 9 under “RUN / CFG Mode – F1
Keystrokes,” earlier in this chapter.
OR
CONTACT TABLE
909/910/919/920 900/930 RELAY
Figure 4-6.
Customer signal
connections,
Termination board.
There are four independent isolated 4–20 mADC outputs which can be
self-powered or loop-powered. The user must provide the loop supply for
the loop-powered output. The default signal assignment is configured to
meet the specifications of the end user. If the output signal assignment
must be changed, refer to “Output Signal Assignment (OSA),” earlier in
this chapter.
The full-scale range for the output parameter assigned to each channel
can be set individually within the measuring range of the analyzer. The
measurement will be entered in either ppm or percent, depending on the
units selected in the software. For example, Output Channel 1 can be
scaled to 500 ppm full-scale, Output Channel 2 can be scaled to 300 PPM
full-scale or, all four outputs can be scaled the same.
Example 1:
To set the full-scale range for Output Channel 1 to 500 PPM, and return to
CAL mode normal display, key in:
Example 2:
To set the full-scale range for Output Channel 3 to 300 PPM, and return to
CAL mode normal display, key in:
Pressing Esc at any time during the procedure will abort the proce-
dure and return to CAL mode normal display. The existing calibra-
NOTE tion values and any new values entered up to the point of pressing
Esc will be retained.
To calibrate the current output signal for Output Channel ‘z’, where ‘z’ is
the output channel number (1..4), connect the current meter to the output
(refer to Figure 4-6 for termination points) and press:
Zero current output F6 0 z Current output zero scale value is displayed, where ‘z’
is the Zero current output (IZero) 1..4.
Del Sets the current analog output channel to zero scale
(4 mA).
“nnn” Key in the Zero scale value (mA) that was measured
by the meter.
Ent Zero scale value is entered and displayed.
Span current output F6 1 z Current output full-scale value displayed, where ‘z’ is
the Span current output (ISpan) 1..4.
Del Sets the current analog output channel to full-scale
(20 mA).
“nnn” Key in the full-scale value (mA) that was measured by
the meter.
Ent Full-scale value is entered and displayed.
Example 2:
To calibrate the current output signal for Output Channel 2 and return to
CAL mode normal display, key in:
The Measuring Cell operating temperature and pressure are two of the
parameters used to calculate the analyzer results. 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.
When the default values are used, the Measuring Cell temperature and
pressure are treated as constants. 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).
The default Measuring Cell temperature is 140 °C (284 °F). Do not change
this value.
Example:
To enter a Measuring Cell pressure (Cell Press) of 700 mmHg (absolute)
and return to CAL mode normal display, key in:
The Probe Blow Back control signal is available at terminals 3 (-) and
4 (+) of J106 on the Termination board (also used as the SSR control
NOTE
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.
Safety Considerations
Preventive Maintenance
To reduce the occurrence of problems with the Model 909 Analyzer,
AMETEK recommends that you follow the Preventive Maintenance
Schedule as outlined in the following pages. Since most analyzer prob-
lems originate within the sample handling system, the primary objective
of the Preventive Maintenance Schedule is proper care of the sampling
system.
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 ( SS) 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 Zero the Analyzer
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 sampling 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
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 sampling system). A response time
that is slower than normal may suggest plugging problems in the
analyzer’s sampling 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.
Monthly 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.
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.
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).
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 sampling 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.
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.
If the sample response time is longer than normal, it is most likely due to
plugging somewhere in the sampling 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.
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.
After confirming that the plug is somewhere in the sample inlet, take
all appropriate safety precautions and dismantle the sample system,
NOTE
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.
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. The SCU and Vent Valve (if used)
assemblies should be insulated using the insulation supplied by AMETEK,
plus additional insulation (by customer) if necessary.
Check current operating temperatures and compare them to the set point
temperatures for each temperature zone.
1. While working from the User Interface Panel, manually force the
analyzer to purge the sampling system with Zero Gas (Continuous
Zero Gas Flow mode) by using the keypad on the User Interface Panel
to enter the following keystrokes:
a. From RUN mode, press F6 • and then enter the CALibration mode
password “• •” (at the “PSWD0” prompt). Press Ent to enter CAL
mode.
d. Press Ent again to return to CAL mode normal screen and then Esc
to return to RUN mode.
3. Cap the Sample Line at the SCU. Observe the flow on the rotameter. If
the flow reduces to a stop, a large plug has occurred somewhere in the
sample system.
Remove the cap from the Sample Line and reconnect it to the SCU.
5. After locating the cause of the restriction or plug (and after cleaning or
replacing the part or line), pressure/leak test the fittings or connections
that were loosened or replaced. To do this, follow the procedures
under “Sample System Leak Check” in Chapter 3.
6. Remove the cap from the Vent Line and reconnect it to the Sample
Vent Pipe.
c. Press Del to delete the current setting and then press 0 (0 = Ana-
lyzer Control mode) at the “FlowCtrl?” prompt. Press Ent to save
the change.
d. Press Ent again to return to CAL mode normal screen and then Esc
to return to RUN mode.
8. Check the sample response time. Record the response time, Aspirator
Air pressure, Cal Gas pressure, and Cal Gas flow rate settings. The
recorded values can be used later as a reference while testing response
time.
The o-rings in the Measuring Cell should be replaced every year to avoid
a leak in the sampling system. If the sampling system operates above
atmospheric pressure, sample gas can leak from the Measuring Cell into
the Analyzer Oven.
While the Measuring Cell is disassembled, clean its chambers and parts.
Refer to Figure 5-1 for assistance in locating and identifying the hardware
components that make up the Measuring Cell.
If your system uses a White Cell Assembly for the Measuring Cell,
refer to the “Supplemental Information” section of this manual or the
NOTE
Documentation Package shipped with the analyzer for a drawing and
information on cleaning the Measuring Cell and replacing its o-rings.
1. While working from the User Interface Panel, check and record the
current Flow Control mode. To do this:
a. From RUN mode, enter F6 • and then enter the CALibration mode
password “• •” (at the “PSWD0” prompt). Press Ent to CAL mode.
3. After the zero process is complete, cap the Sample Line at the SCU
and cap the Vent Line at the Sample Vent Pipe.
Before powering down the analyzer, test the area around the analyzer
! for flammable gases. If an explosive gas atmosphere is present, do not
WARNING power down the analyzer or any alternate power sources that supply
power to the analyzer components. Proceed only when the area is
found to be safe.
7. After the Analyzer Oven has cooled down enough to work on, use
appropriate wrenches to disconnect the Sample Line and Vent Line
tubes from the Measuring Cell.
8. Remove the Measuring Cell Assembly from the Heater Plate. The
3 mm holding screw used to secure the Measuring Cell to the Heater
Plate is located in the counter bore hole in the Heat Transfer Block.
Remove the black plug and then remove this screw using only a flat
hex key. Do not use a ball driver – the head can break off inside the
screw.
To help maintain the temperature inside the Oven, close the Oven
door while working on the Measuring Cell.
11. Use an o-ring removal tool to remove the outer o-ring from the Mea-
suring Cell. Take care not to scratch or damage the o-ring groove or
joining surface of the Heat Transfer Block.
Carefully remove the Cell Window from the Measuring Cell by grasp-
ing it by its outer edge and lifting it out of the Measuring Cell. Avoid
touching the window surfaces.
Use an o-ring removal tool to remove the inner o-ring from the Mea-
suring Cell.
Inspect the Window for any chips, cracks, or scratches. Place the
Window on a soft, non-abrasive cloth – and set it aside in a safe loca-
tion – to avoid damaging it.
Inspect the o-rings for flexibility and for any signs of damage (nicks,
cuts, scratches). Set the o-rings aside with the Window for cleaning.
12. While holding the Measuring Cell vertically so that the Reflector Block
end is up, remove the three M4 x 20 mm screws that secure the Reflec-
tor Block to the Measuring Cell. Remove the Reflector Block.
13. Still with the Reflector Block end up, carefully remove the o-rings and
Cell Window from the Measuring Cell, similar to the other o-rings and
Cell Window.
Inspect the Window and o-rings and set them aside with the other
o-rings and Window.
14. Wash the Measuring Cell windows with a non-abrasive agent (such as
Isopropanol). Rinse the windows with distilled water of at least
pharmaceutical grade. If the windows are chipped or cracked, replace
them with new ones (Part No. 300-0281).
Flush and thoroughly rinse the interior of the Measuring Cell with
distilled water of at least pharmaceutical grade. Allow all components
to dry thoroughly before reassembling them.
16. Install a new o-ring (Part No. 300-1503) in the o-ring groove on the flat
surface of the Reflector Block.
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),
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.
While holding the edge of the window, carefully place it in the Mea-
suring Cell.
Orient the Reflector Block with its “peak-line” at 90° to a line through
the Sample and Vent Line fittings, and place the Reflector Block onto
the Measuring Cell. Ensure the Measuring Cell Window does not slide
out of position when the Reflector Block is placed against the Measur-
ing Cell.
17. Install a new o-ring (Part No. 300-1503) in the o-ring groove in the
Heat Transfer Block.
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.
With the Measuring Cell held vertically, grasp the edge of the window
and carefully place it in the o-ring groove in the Measuring Cell.
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.
(The two larger-diameter holes in the Measuring Cell must align with
the two larger-diameter holes in the Heat Transfer Block.) Ensure the
Measuring Cell Window does not slide out of position when the Heat
Transfer Block is placed against the Measuring Cell.
Secure the Heat Transfer Block to the Measuring Cell using three
M4 x 12 mm screws. Tighten the screws evenly.
a. Orient the Measuring Cell with the Reflector Block to the left, the
sample tube fittings vertical, and the counter bore access hole in
the Heat Transfer Block facing away from the analyzer. Replace the
screws and tighten them evenly.
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. Adjust the entire Measuring Cell/Optical Bench
Assembly as required to firmly seat the Measuring Cell Assembly
against the Heater Plate.
Using a flat hex key, 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. Do not use a ball driver – the
head can break off inside the screw. Do not tighten the screw at
this time.
IMPORTANT
Positioning of the Heat Transfer Block in the Analyzer Oven is
NOTE
critical. Improper positioning of the Heat Transfer Block can result in:
• Poor contact between the Sample (Measuring) Cell RTD tip and
the Heat Transfer Block.
Replace the Flame Arrester (black plug) in the counter bole hole in
the Heat Transfer Block.
21. Perform a leak check on the fittings that you just reconnected by
following the procedures under “Sample System Leak Check,” in
Chapter 3.
After you are sure there are no leaks, return to this procedure and
continue with the remaining steps.
23. Return the analyzer to the original Flow Control Mode by entering
CAL mode and keying in F5 2 Del n Ent, where ‘n’ is the numeric
value of the Flow Control Mode recorded earlier. Press Esc to return to
the normal RUN mode.
25. Adjust the Aspirator Drive Air Regulator to achieve normal operating
flow rates [3.0–5.0 L/min (0.1–0.2 SCFM)] as described under “Adjust-
ing the Sample Gas Flow Rate,” in Chapter 3.
The typical life span of the source lamps is approximately 9–12 months of
continuous operation. However, a source lamp can exhibit signs of degra-
dation after 5 to 6 months.
For more information about lamp maintenance, refer to the Model 9xx-
Series Analyzers “Lamp Maintenance Manual Supplement” included in
NOTE
the Supplemental Information section of this manual. This supplement
focuses specifically on signals related to the transmission of light through
the optical path, and how the long-term change in these signals can be
used to diagnose lamp failure, window fouling, and other degradation of
the analytical response of the analyzer.
• The cathode of each Source Lamp must be centred on the optical axis
of the beam splitter for optimal operation of the analyzer. The cathode
and the outer envelope of the Source Lamp are not necessarily con-
centric or consistent from lamp to lamp.
Refer to Figure 5-2 for assistance in locating and identifying the hardware
components encountered while replacing the source lamps. This proce-
dure assumes that the factory-default password (• •) for entry to CAL or
CFG mode is valid. If a password has been changed, the new password
must be used.
Figure 5-2.
Measuring Cell/lamp
assembly.
Before proceeding, test the area around the analyzer for flammable
! gases. If an explosive gas atmosphere is present, do not power down
WARNING
the analyzer or any alternate power sources that supply power to the
analyzer components. Proceed only when the area is found to be safe.
2. Loosen the Lamp Retaining Screw and rotate the Lamp Retaining
Bracket 90 degrees. Remove the Lamp Socket Assembly.
3. Loosen the Lamp Clamping Screws and remove the faulty lamp(s) by
rotating and sliding it downward.
Do not rotate or pull on the base of the source lamp because this may
! cause it to separate from the glass envelope. Grasp the glass envelope
CAUTION
when rotating or pulling the source lamp.
When the analyzer’s covers and doors are open, take appropriate
precautions to avoid electrical shock. Hazardous voltages are present
inside.
8. While working from the User Interface Panel, check and record the
current sampling system operating mode (Flow Control) and then
change it to Continuous Zero Gas Flow mode. To do this:
a. From RUN mode, press F6 • and then enter the CALibration mode
password “• •” at the “PSWD0” prompt. (If PSWD0 [• •] has been
changed from the factory default, use the new password.) Press
Ent to enter CAL mode.
d. Press Ent again to return to CAL mode normal screen and then Esc
to return to RUN mode.
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.
10. Turn off the Automatic Lamp Control function (Alc Enable) by press-
ing F2 7 Del 0 Ent Ent from CFG mode. 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, as described in the following steps.
The message “SIGz m.mmm r.rrr” is displayed, where “z” is the filter
location, “m.mmm” is the Measure PMT signal, and “r.rrr” is the
Reference PMT signal. The PMT signal values displayed on the User
Interface Panel are updated at one-second intervals.
Example:
If replacing Lamp 1, the PMT signal for Filter 1 is displayed by press-
ing F6 1 1. For Lamp 2, press F6 1 2.
12. Slightly loosen the Lamp Clamping Screw. Loosen the Lamp Retain-
ing Screw and rotate the retaining bar 90 degrees.
13. Slowly rotate the new lamp to obtain the maximum signal from the Mea-
sure PMT. (value on the left side of the User Interface Panel). Since the
User Interface Panel is updated at one-second intervals, use slow, small
movements, pausing each turn to view the new value.
14. Loosen the Locking Screw located between the two source lamps.
16. For the second lamp, repeat Steps 10, 13, and 15.
17. Tighten the Locking Screw located between the two source lamps.
18. Return the Lamp Retaining Bracket to its original position and secure
it using the Lamp Retaining Screw. Tighten the Lamp Clamping Screw
to secure the lamps. Do not overtighten these screws; the springs
should not be collapsed.
19. Allow the analyzer to operate for 15 minutes and then initiate an
Auto-Setup, which automatically turns on the Alc Enable function.
Continue with these procedures only after the completion number is
between 0.75–1.25. A normal completion is 1.00, ±0.25.
20. Press Esc Ent. The message “SAVE CONFIG?” will appear.
Press Ent to save the new configuration, and return to RUN mode
normal display.
22. Remove the cap from the Vent Line and reconnect it to the Sample
Vent Pipe. Remove the cap from the Sample Line and reconnect it to
the SCU to allow sample gas from the stack duct into the analyzer’s
sampling system.
23. Close and secure the Electronics Enclosure with its screws.
24. Return the analyzer Flow Control Mode to Analyzer Control (auto-
matic) by entering CAL mode and keying in F5 2 Del 0 Ent. Press Esc
to return to RUN mode.
25. Zero and Span the analyzer (Span function is optional; depends on
application).
26. Adjust the Aspirator Drive Air Regulator to achieve normal operating
flow rates.
IMPORTANT
Although a good completion number is indicative of a successful
NOTE
Auto-Setup, do not rely on it solely.
Always check the PMT Level and PMT Balance after every Auto-
Setup. Refer to “PMT Level and PMT Balance,” following this
section, for details on acceptable levels of these two signals.
PMT Level and PMT Balance are adjusted only during the Auto-Setup
sequence. The range of operation for both these parameters is 0–10 VDC.
Normal values for both, after a successful Auto-Setup, are from 4.0–7.0
VDC. The analyzer will function with values outside this range, but it is a
sign that a change has likely occurred in the transmission of light within
the Optical Bench Assembly. Severe changes in PMT Level and PMT
Balance are as important to notice as the absolute value.
The PMT Level signal adjusts the gain of both PMTs simultaneously in the
same direction. PMT Balance adjusts the gain of the two PMTs in opposite
directions.
If, after completion of the Auto-Setup, these signals are outside the normal
range of operation, check:
• Was the Auto-Setup done with Zero Gas flowing through the sam-
pling system?
• Are the PMTs in their original sockets? (i.e., is the higher gain PMT in
the Measure path?)
• Do the source lamps need replacement? If not, are the source lamps
aligned?
• Have there been any leaks from the Measuring Cell? If so, check the
condition of:
If during the operation of the Auto-Setup either the PMT Level adjust-
ment or PMT Balance signal goes to minimum or maximum, the corre-
sponding adjust fault message appears on the User Interface Panel.
• Ensure that the Measuring Cell was backpurged with Zero Gas.
• Display the source lamp pulse current-control signal for each filter
location. To display these signals, press F1 1 z from RUN mode, where
“z” = 1..2.
• Ensure the lamps are inserted completely into the detector assembly.
• Make sure the lamp power supply cables are connected and not
damaged.
• Ensure the PMT high-voltage (J101, J102) and ribbon (J103) cables are
connected and not damaged.
• Make sure the Measuring Cell windows are clean and not damaged.
1. Press F6 – • • Ent to enter CFG mode. (If PSWD1 has been changed
from the factory default, the new password must be used.)
P301 has two jumper positions, but only one jumper position is used.
Do not put both jumpers on P301.
6. Press Ent for “Yes” (to save the new configuration), and then press Esc
to return to the RUN mode normal display.
This procedure describes how to remove the Heater Plate, replace its
Heater Cartridges and RTDs, and how to ensure proper positioning and
mounting of the Heater Plate Assembly while replacing it.
To replace the Heater Cartridges and RTDs in the Heater Plate Assembly:
1. While working from the User Interface Panel, check and record the
current Flow Control Mode. To do this:
a. From RUN mode, enter F6 • and then enter the CALibration mode
password • • (at the “PSWD0” prompt). Press Ent to display CAL
mode.
3. After the zero process is complete, cap the Sample Line at the SCU
and cap the Vent Line at the Sample Vent Pipe.
Before powering down the analyzer, test the area around the analyzer
! for flammable gases. If an explosive gas atmosphere is present, do not
WARNING power down the analyzer or any alternate power sources that supply
power to the analyzer components. Proceed only when the area is
found to be safe.
5. Wearing insulated gloves, 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.
7. After the Analyzer Oven has cooled down enough to work on, discon-
nect the Sample and Vent Line tubes from the Sample Inlet and Vent
Outlet tubes on the left side of the Analyzer Oven. Pull the Sample
and Vent Lines out of the Analyzer Oven.
Disconnect the Sample and Vent Line tubes from the Measuring Cell.
Disconnect the Aspirator Air tube from the Aspirator Air fitting inside
the Analyzer Oven.
10. Move the C-clip from its groove in the Thermal Insulating Tube to the
space slightly above the groove (see Figure 5-4). Remove the Seal
Cover from the Seal Body.
11. Record the termination point of each wire on the Seal PWB Assembly,
located within the Seal Body. Also, tag the wire(s) of any RTDs and/or
Heater Cartridges that will be re-used (if any) with their termination
points. This will be useful later when replacing the Heater Cartridges
and RTDs.
Disconnect the RTD, Heater Cartridge, and Ground wires from the
Seal PWB Assembly.
Rotate the Seal Body/Thermal Insulating Tube away from the analyzer
to allow more room to remove the Heater Plate. Take care to avoid
damaging the wires.
NOTE
13. Remove the four M6 x 35 hex socket head cap screws and lock washers
that secure the Heater Plate to the Oven wall.
14. Position the wires in the Seal Assembly in a way to prevent damage to
them when removing the Heater Plate Assembly.
Tilt the top of the Heater Plate toward you and pull the Heater Plate
Assembly up and out of the Analyzer Oven.
15. Disassemble the Heater Plate Assembly and replace the Heater Car-
tridges and RTDs.
Separate the two halves of the Heater Plate and carefully pull all of
the wiring through the Lower Heater Plate.
IMPORTANT
If replacing the external RTD (“Sample Cell RTD”), do not remove
NOTE
the RTD wire at this time.
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).
d. Replace the RTDs. Refer to Figure 5-4 and Figure 5-5 when replac-
ing the RTDs.
Looking from the front of the Heater Plate, label the wire from the
RTD on the right side “Overtemp” and the RTD on the left side
“Heater” (see Note in Figure 5-4).
Cut the RTD head off the faulty RTD. Tape the termination end of
the new RTD wire to the RTD end of the old RTD wire. Use the old
wire to pull the wire on the new RTD through the Upper Heater
Plate as you remove the old wire.
Apply Loctite 271 on the large (upper) threads of the RTD Base.
Turn the RTD Tip clockwise onto the RTD Base and hand-tighten
it.
To protect the RTD Tip, wrap a small piece of rubber around it,
lightly grip it with channel-lock pliers, and tighten it until it is
snug.
Looking from the front of the Heater Plate, label the wire from the
RTD on the right-centre side “Sample Cell” (see Figure 5-4).
The hole for the oven mounted Sulfur Condenser RTD – for Model
900 and Model 930 Analyzers with an oven mounted SKO (Sulfur
NOTE
Knock-out) – is plugged with a Heater Blanking Plug (AMETEK Part
No. 300-5730).
Figure 5-5.
Flameproof Heater/
Seal, assembly layout.
17. With the top of the Heater Plate tilted toward you, place the bottom of
the Heater Plate in the bottom of the Analyzer Oven while taking care
to ensure the wires are not damaged. Tilt the Heater Plate backward
until it is resting 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.
Gently push and pull on the Heater Plate while tightening the screws.
This will ensure it is properly seated against the Oven wall.
18. 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.
Figure 5-6.
RTD assembly
diagram.
Ensure the threads of the Thermal Insulating Tube are clean and then
thread the tube back into the Heater Plate, taking care not to cross-
thread the threads. Tighten the tube until an increase in resistance is
felt. Do not overtighten it.
21. Reconnect the Measuring Cell to the Sample Cell RTD on the Heater
Plate. To do this:
a. Orient the Measuring Cell with the Reflector Block to the left, the
sample tube fittings vertical, and the counter bore access hole in
the Heat Transfer Block facing away from the analyzer. Replace the
screws and tighten them evenly.
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. Adjust the entire Measuring Cell/Optical Bench
Assembly as required to firmly seat the Measuring Cell Assembly
against the Heater Plate.
Using a flat hex key, 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. Do not use a ball driver – the
head can break off inside the screw. Do not tighten the screw at
this time.
IMPORTANT
Positioning of the Heat Transfer Block in the Analyzer Oven is
NOTE critical. Improper positioning of the Heat Transfer Block can result in:
• Poor contact between the Sample (Measuring) Cell RTD tip and
the Heat Transfer Block.
Replace the Flame Arrester (black plug) in the counter bole hole in
the Heat Transfer Block.
f. Route the Sample and Vent Lines through their respective holes
on the left side of the Analyzer Oven. Use appropriate wrenches to
reconnect the Sample Line to the Sample Inlet tube in the Ana-
lyzer Oven and the Vent Line to the Vent Outlet tube.
g. Reconnect the Aspirator Air tube to the Aspirator Air fitting inside
the Analyzer Oven.
22. Terminate the Heater Plate RTD and Heater Cartridge wires (and the
Ground wire, if it is also being replaced) to the Seal PWB Assembly.
Refer to Figure 5-7 for the locations of the termination points.
Figure 5-7.
Oven Heater and
Temperature Sensor wiring.
When the analyzer’s covers and doors are open, take appropriate
precautions to avoid electrical shock. Hazardous voltages are present
inside.
27. Perform a leak check on the fittings that you just reconnected by
following the procedures under “Sample System Leak Check,” in
Chapter 3.
After you are sure there are no leaks, return to this procedure and
continue with the remaining steps.
28. Power up the Analyzer Oven by closing its fuse (refer to the Fuse
Legend). 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). Close and secure all
other doors and covers on the analyzer, if not already done.
29. Return the analyzer to the original Flow Control Mode by entering
CAL mode and keying in F5 2 Del n Ent, where ‘n’ is the numeric
value of the Flow Control Mode recorded earlier. Press Esc to return to
the normal RUN mode.
31. Adjust the Aspirator Drive Air Regulator to achieve normal operating
flow rates [3.0–5.0 L/min (0.1–0.2 SCFM)] as described under “Adjust-
ing the Sample Gas Flow Rate,” in Chapter 3.
• All separable joints in the Heater Plate Assembly and Seal Body. These
parts include the joining surfaces of the Heater Plate, the joining
surfaces of the Seal Body and its cover, the RTD mounting locations
(whether RTDs are installed or their holes are plugged), and both the
threaded and cylindrical end of the Thermal Insulation tube between
the Heater Plate and Seal Body.
Take extreme care to avoid damaging the threads on the cable entry
! glands on the Disconnect Enclosure and all threaded parts on or in
CAUTION
the Heater Plate/Seal Assemblies. Clean, defect-free threads are
essential to ensure a flameproof connection.
If at any time the Disconnect Enclosure door is open but is not being
worked on, close and secure it with at least one screw. This will reduce
the risk of inadvertently scratching or damaging the flamepath.
Before closing the door, gently clean these areas with a soft, nonabra-
sive cloth and make sure they are free of debris.
Alarms that have been reset or corrected are stored in their corresponding
History Buffers (HCHist or MCHist), also in RUN mode. The History
Buffers will store up to a maximum of nine alarms in each. These alarm
conditions can be viewed at any time from the User Interface Panel, which
makes this an excellent diagnostic tool.
Warning Alarms
Warning Alarms indicate that the analyzer requires servicing – the
data may be suspect under this condition. As indicated earlier, the
alarm indicator is displayed on the screen when an warning error
is detected by the system.
Fault Alarms
Fault Alarms indicate that a failure has occurred and the analyzer is
not operating properly – the results are not valid. As indicated earlier,
the alarm indicator S is displayed on the screen when a fault error is
detected by the system. Fault errors also cause the Normal/Fault relay
contacts to switch, and the sampling system will automatically switch
to Backpurge mode if the current Flow Control Mode setting is “0”
(Analyzer Control).
To view the current status of error messages detected by the Host Control-
ler or Microcontroller board, follow the command syntax example below:
2. While viewing the error status of either board, press the appropriate
numeric keys to view the status for the error associated with that keystroke.
For the Host Controller board, press any key in the range of 1..8. Press
other numbers on the keypad within this range to view the status of
other errors.
For the Microcontroller board, press any key in the range of 1..7. Press
other numbers on the keypad within this range to view the status of
other errors.
3. To back out of either of these menus, press Esc or enter a new Func-
tion command.
Except for the High Temperature fault (f Temp High), all errors detected
by the analyzer’s diagnostics function will reset automatically once the
problem is resolved. By using keypad commands F5 • and F5 –, while
working from RUN mode, the analyzer allows you to view past error
status messages.
Example:
The displayed Host Controller board status code is 20. The errors detected
are:
20
- 16 f Temp Low (Fault – Host Controller)
4 f Comm Fault (Fault – Host Controller)
To view a history of the last error messages (up to nine maximum) de-
tected by the Host Controller or Microcontroller board, follow the com-
mand syntax example below:
The possible Host Controller board error conditions are polled individually with
the keypad command F5 4 z, where “z” (z = 1..8) is defined by HStatus. For each
“z”, the corresponding error message description is displayed if the error condi-
tion exists; otherwise the message “HSz OK” appears.
HS Code HStatus Alarm Type Condition / Description & Suggested Corrective Action
0 — — HSz OK
If the HS Code returned is ‘0’ and the message displayed is “HSz
OK”, it indicates that the Warning or Fault (Condition/Description) being
viewed does not exist (where ‘z’ is the HStatus number – 1..8 – assigned
to that alarm). This is not an alarm condition.
Corrective Action:
No action is required.
1 1 Warning w EEPROM Full
This Warning condition indicates the number of times that configuration
data has been rewritten to the EEPROM (nonvolatile memory) has
exceeded the safe number. The EEPROM should be replaced as soon
as possible (99 % of the acceptable 20K writes is used).
Corrective Action:
Take appropriate safety precautions, open the Electronics
Enclosure cover, and:
• Replace the EEPROM as soon as possible. The EEPROM is
located on the Host Controller board, inside the Electronics
Enclosure. If you wish to retain current settings following the
replacement of the EEPROM, record any values that you
have changed BEFORE YOU REMOVE THE EEPROM.
After receiving and installing the new EEPROM, re-enter the
parameters to ensure your analyzer will operate the same as
it did prior to replacing the EEPROM. The factory-set default
values will be used until the new values are entered.
Alternatively, you can send the configuration values and P.O.
number for the EEPROM to AMETEK at the same time. At
the factory AMETEK will program the customer-specific
parameters in the EEPROM. In this case, you will only have
to install the EEPROM; the parameters will take effect
immediately upon power-up.
Figure 5-8.
Host Controller (HS)
alarm status
conditions/diagnostics.
Figure 5-8.
Host Controller (HS)
alarm status
conditions/diagnostics.
Figure 5-8.
Host Controller (HS)
alarm status
conditions/diagnostics.
Figure 5-8.
Host Controller (HS)
alarm status
conditions/diagnostics.
Figure 5-8.
Host Controller (HS)
alarm status
conditions/diagnostics.
Figure 5-9.
Micro-Interface board.
SSR
Figure 5-10.
Sample/Vent Line Wiring.
MS Code MStatus Alarm Type Condition / Description & Suggested Corrective Action
0 — — MSz OK
If the MS Code returned is ‘0’ and the message displayed is “MSz
OK”, it indicates that the Warning or Fault (Condition/Description)
being viewed does not exist (where ‘z’ is the MStatus number – 1..7 –
assigned to that alarm). This is not an alarm condition.
Corrective Action:
No action is required.
1 1 Fault f Pulse Timing
This Fault condition indicates that there is a problem with control
parameter updating and pulse timing. This can be caused by a power
interruption.
Corrective Action:
• Reset the analyzer by simultaneously pressing • and Ent on
the User Interface Panel. The message “Reset In Progress”
should be displayed within one second after these keys have
been pressed.
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.
Corrective Action:
Take appropriate safety precautions, open the Electronics
Enclosure cover, and:
• Replace the Microcontroller board. Contact the factory to
verify operation before removing this board.
Figure 5-12.
Microcontroller (MS)
alarm status conditions/
diagnostics.
Note: A temperature zone can indicate “181.4ºC” but not trigger this
alarm if its set point (TStPt, F4 0, RUN mode) is set to zero,
such as is typically the case for a spare temperature zone.
Corrective Action:
Take appropriate safety precautions, open the Electronics
Enclosure cover, and:
• Replace the Microcontroller board. Contact the factory to
verify operation before removing this board.
and/or
• From RUN mode, press F4 0 and then press 1..4 to check
the set point value for each temperature-controlled zone. If a
heated external probe is used, press F1 – and then press 3
and then 4 to check the Probe Temperature (low/high) alarm
set point values.
From RUN mode, press F6 8 and then press 1..8 to check
the current temperature for each temperature-controlled
zone (including the External Probe, if used).
• Using an Ohm meter, measure the resistance of the
temperature sensor (RTD) for the zone(s) which caused the
alarm and test it for an open circuit. If the RTD is faulty,
contact AMETEK for assistance.
• Replace the Temperature Sensor (RTD) Daughter board.
Contact the factory to verify operation before removing
this board.
• Replace the Termination board. Contact the factory to
verify operation before removing this board.
Figure 5-12.
Microcontroller (MS)
alarm status conditions/
diagnostics.
Figure 5-12.
Microcontroller (MS)
alarm status conditions/
diagnostics.
Figure 5-12.
Microcontroller (MS)
alarm status conditions/
diagnostics.
The Service & Parts chapter discusses what to do if you need technical
support from AMETEK, or if you are returning parts for service. This
chapter also lists the recommended spare parts to have on hand to ensure
all consumable and replaceable parts are replaced according to the “Pre-
ventive Maintenance Schedule” included in Chapter 5.
Technical Support
AMETEK Western Research is committed to providing you the best
technical support in the industry. If you need service or application
assistance, 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.
• AMETEK part number for the specific component you are enquiring
about, if known.
(*) Note the ordering part numbers for the different Source Lamps
and order only the appropriate type and quantity of Source Lamps. To
verify the lamp type, open the analyzer and check the label on the
lamps.
M&C Probe
Preventive Maintenance Parts
Part No. 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, 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. Content is subject to change without notice.
The fuse required will depend on line length, voltage, and power
consumption. If the original factory-installed fuse blows, remove it to
NOTE
determine the fuse type required. Consult the Customer Specific
drawings in the “Supplemental Information” section of this manual,
or the Documentation Package shipped with the analyzer for the
appropriate fuse type.
Replacement Boards
These boards apply to 120 VAC and 240 VAC analyzers, and are
required only in the event of failure or damage to a board.
NOTE
Term/Character Definition
f Precedes an error message, which indicates the error is a ‘f’ault alarm (e.g.,
“f Temp Low”).
w Precedes an error message, which indicates the error is a ‘w’arning alarm (e.g.,
“w PMT Signals”).
Glossary | 7-1
Abbreviations Used in This Manual
A/D analog-to-digital
D/A digital-to-analog
DP differential pressure
O2 Concentration
The O2 concentration can be measured using a Zirconia Oxide O2 Sensor
installed in the Analyzer Oven, and displayed on the User Interface Panel.
(The O2 Sensor is optional, and is for use in General Purpose applications/
analyzers only.) The manual for the O2 Sensor (if used) accompanies the
analyzer when this option is installed at the factory.
Calibration of the O2 Sensor requires the use of two calibration gas mix-
tures. The first gas is air; the second gas is an O2 calibration gas mixture.
The air is used to obtain the air reference point. Since the O2 concentration
is determined relative to air, this air reference point establishes the
O2-sensor zero point. The usual concentration of O2 in dry air is 20.95
mole percent. The calibration gas mixture O2 concentration usually is
chosen to be near the normal O2 concentration of the stack duct.
The Model 909 Analyzer and O2 calibration gases must not contain
any component that may interfere with the correct operation of the O2
NOTE
Sensor. Refer to the O2 Sensor manual.
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 Auto-Calibra-
tion. 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:
Press Ent to return to CAL mode normal display or Esc to return to RUN
mode normal display.
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:
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:
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 Auto-
Span 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 auto-
matically adds calibration of the O2 Sensor to the Auto-CAL sequence
when it is enabled.
Example:
To set Timer2 (O2 Span Timer) to 3 minutes and return to CAL mode
normal display, key in:
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 count-
down. 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.
Pressing Esc at any time during this procedure will cause it to abort
and return to CAL mode normal display.
NOTE
4. The CAL status relay will stay on for an additional delay time (min-
utes) 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 se-
quence. 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.
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.
Zero
O2 Zero (Air)
Span
(e.g. SO2)
O2 Span with
Cal gas
Figure A-1.
Example zero/span
sequence.
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
To manually zero the ultraviolet portion of the analyzer system and Zero
and Span the O2 Sensor:
2. Enter CAL mode and press F5 2 and record the numeric value dis-
played (FlowCtrl).
Ent for Yes Timer0 will begin to count down to zero time. The
analyzer and O2 Sensor values will be adjusted auto-
matically based on the average of the reading during
the countdown if AdjDisable is set to ‘0’.
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 values are not adjusted.
9. Connect the O2 Calibration Gas to the Zero Gas inlet and turn on the
O2 Calibration Gas.
Ent for Yes Timer y will begin to count down to zero time. The O2
span value will be adjusted automatically based on the
average of the reading during the countdown if
AdjDisable is set to ‘0’.
13. Press F5 2 Del z Ent (where ‘z’ is the value recorded in Step 2) to
return the analyzer to the original sampling mode.
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 con-
trolling solenoid valves, a manually operated 3-way valve must be in-
stalled 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 control-
ling 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:
2. Enter CAL mode and press F5 2 and record the numeric value dis-
played (FlowCtrl).
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.
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 values are not adjusted.
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’.
17. Press F5 2 Del z Ent (where ‘z’ is the value recorded in Step 2) to
return the analyzer to the original sampling mode.
Correction Equation
The measured component ‘x’ concentration is corrected to a specified
dilution air condition using the following equation:
20.95 - [O 2]spec
[x]c = [x]m
( 20.95 - [O 2]m )
where: [x]c = the measured concentration of component ‘x’ corrected to
the specified O2 concentration;
[x]m = the measured concentration of component ‘x’;
20.95 = the concentration of O2 in air (mole percent);
[O2]spec = the specified process duct O2 concentration to which the
measured component ‘x’ concentration is corrected (mole
percent); and
[O2]m = the measured concentration of O2 (mole percent).
Overview
This Appendix (Modbus Protocol, Revision 2.0, June, 2006) describes the
Modicon Modbus® communication interface on the following Model 9xx-
Series Analyzers and their derivatives: 900ADA\930, 909\910, 919\920, and
921\922. Use the information as it applies to your analyzer.
The RS-422 port receiver pins, Rx±, must be terminated with a terminat-
ing resistor of 120 W when the port is connected to customer equipment.
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.
For example, you can set the analyzer Modbus address from the
ConFiGuration mode. This software menu item is listed as [CFG :
MBAddr (keystroke is F2 • for Model 909\910, 919\920, 921\922;
F4 • for Model 900\930)]. For information on the keystrokes that
must be entered to view parameters, refer to Chapter 4 of this manual.
OR
CONTACT TABLE
909/910/919/920 900/930 RELAY
Figure B-1.
Customer signal
connections, GP/Div 2
analyzers (Models
900ADA\930, 909\910,
919\920), WX-102822.
J6
P1 - RS232 COMMUNICATIONS
Figure B-3.
Rear panel descriptions
(Model 921\922 Analyzers),
WX-14821.
Modbus Address
The analyzer needs to be assigned a Modbus address [CFG : MBAddr]
(keystroke is F2 • for Model 909\910, 919\920, 921\922; F4 • for Model
900\930)], which can be a number from 0–255 with the following defini-
tions:
Communications Parameters
While the number of data bits is always 8, the Baud Rate, number of Stop
Bits, and Parity [CFG : ComParaz, where ‘z’ = ComPara1, ComPara2, or
ComPara3 (keystroke is F2 – for Model 909\910, 919\920, 921\922; F4 – for
Model 900\930)] of the analyzer Modbus serial communications port are
selectable:
1 4800 1 Odd
3 1200 2 Even
The default communication parameter settings (or Value) are “0”, “1”, and
“0” for ComPara1, ComPara2, and ComPara3, respectively (i.e., 9600 baud,
1 stop bit, and no parity, on both RS-232 and RS-422 ports). When a
change is made to one of these parameters, 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.
Code Description
Exception Code
The Model 9xx-Series Analyzers Modbus protocol implementation sup-
ports these exception codes:
Code Description
01 Illegal Function
02 Illegal Address
03 Illegal Value
Two Registers are needed to hold one 32-bit floating-point value; there-
fore, the order of the Registers holding one floating-point value is imple-
mented in the de facto standard way on the analyzer (i.e., the first Register
holds the lower 16 bits while the second Register holds the upper 16 bits
of a 32-bit floating-point value). When requesting a floating-point value,
the analyzer supports the standard Modicon PLC method (i.e., the two
consecutive 16-bit Registers are requested).
a For PPM values with “finer” Units and display selection, scaling is shown in [ ]. For %
values with “coarser” Units and display selection, scaling is shown in [ ].
b Units of measurement for stream flow rate, mass emission, emission rate, and stream
velocity are application dependent.
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.e., display no digit after the
decimal point).
d Refer to the section “Units and Display Bit Image (Register 9),” later in this appendix.
e Each register holds a pair of status code history values. The upper byte (bits 15-8)
contains the older one while the lower byte (bits 7-0) contains the newer one of the
pair. For example, Register #90 holds HC status code history values [1] and [2]; value
[1] is in the upper byte, and value [2] is in the lower byte.
f Refer to the section “Analyzer Status Bytes (Register 154),” later in this appendix.
g Refer to the section “Solenoid Output Bit Image (Register 156),” later in this appendix.
h Refer to the section “Digital Input Bit Image (Register 157),” later in this appendix.
i Refer to the section “Digital Output Bit Image (Registers 158, 159),” later in this
appendix.
j Refer to the section “Gas Flow Control (Registers 189, 190),” later in this appendix.
Air Demand
(900ADA\930)
7 Stream Flow Rate b
1 c
r
(909\919, 910\920, 922, 921)
SV Compensation Enable
(900ADA\930)
336 NO Linearization Enable – – r,w
(910\920, 922)
Trend type d
(900ADA\930)
341 Analog Input Channel for Measuring Cell Temperature – 1 r,w
(9xx)
342 Analog Input Channel for Measuring Cell Pressure – 1 r,w
(9xx)
343 Analog Input Channel for Measuring Stream Temperature – 1 r,w
(910, 909, 922, 921)
Linearization Coefficients 1 to 6
(910\920, 922: six values only)
Linearization Coefficients 1 to 7
(921: seven values only)
552–559 Cross Interference Compensation Vector 2 Elements 1 to 4 – floating-point value r,w
(900ADA\930)
For low concentration (White Cell) and high concentration (Short Cell)
applications, the analyzer configuration parameter [CFG : Units] (key-
stroke 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. In low concentration applications, PPM con-
centration registers may be scaled with a factor of 10 instead of the normal
scale of 1 to give finer resolution results. In high concentration applica-
tions, % concentration registers may be scaled with a factor of 100 instead
of the normal scale of 1000 to prevent register value overflow.
Digital I/O bit images are duplicated in Registers #157, #158, and #159.
The content of these registers are updated once per second.
0 1 0 = Metric Units
2,4* 1 = Imperial Units
3 8 0 = Display 4 Items
8 = Display 3 Items
4 16 0 = Remote ACAL
16 = Remote Backpurge
* Sum of Bits 1 and 2 decimal value.
Description
Bit Value 0 = Normal; 1 = [F]ault \ [W]arning
0 1 [F] filter wheel speed out of range
(9xx with filter wheel)
Description
Bit Value 0 = Normal; 1 = [F]ault \ [W]arning
0 256 [W] EEPROM full
(9xx)
1 512 [W] analog output out of range
(9xx)
2 1,024 [F] HC-MC communication problem
(9xx)
3 2,048 [F] analytical data not received
(9xx)
4 4,096 [F] temperature zone too low
(909\919, 910\920, 900ADA\930)
5 8,192 [F] temperature zone too high
(909\919, 910\920, 900ADA\930)
6 16,384 [W] excessive zero drift or span error
(9xx)
7 32,768 [W] SKO temperature high
(900ADA\930)
1 2 Auto-Zero (9xx)
5 32 Reserved
6 64 Reserved
7 128 Reserved
15 32,768 Reserved
2 4 Reserved
3 8 Reserved
11–15 — Reserved
Bit Description
0 Analyzer Control
1 Continuous Backpurge
2 Continuous Sample
10 Continuous Zero
If the Modbus master initiates the same action before that action is
complete, the message is acknowledged but the action does not
restart. Since only one calibration action can be active at any given
time, the lowest action bit in the request takes precedence.
• Status bits #8 to #10 (Register 159) are set when the corresponding
relay status is true. The conditions under which these relays operate
are described in Chapter 1 of this manual.
Conversion Factors
LENGTH ft m 0.304 8
in mm 25.4
yd m 0.914 40
This Appendix includes all drawings that are included in the main body
of this manual. Many drawings in this manual are examples only, and do
not include all drawings for all possible applications, nor do they depict
all hazardous locations.
IMPORTANT
Job-specific Final “As-Built” drawings are located in the “Supplemen-
NOTE
tal Information” section of this manual and in the Documentation
Package shipped with the analyzer.
CONDUIT ENTRY
PLATE
PROCESS INSTRUMENTS
LIVE LOAD
LIVE LOAD
LIVE LOAD
LIVE LOAD
KEYPAD DISPLAY
OPTICAL PMT
ASSEMBLY BUFFER
SERVICE
ELECTRONICS
LAMP 1
LAMP 2
MOTOR
HOST CONTROLLER
BACKPAN
Ribbon Cable Interconnect (WX-102836)
I/O
INT
TERM
GP Lower Electronics
Enclosure Enclosure
DIGITAL
OR
OR
CONTACT TABLE
909/910/919/920 900/930 RELAY
OR
*
CONTACT TABLE
909/910/919/920 900/930
*
TB-2
Analyzer
AC-L1
15 V DC PWR
SUPPLY
OVERTEMP PS
OverTemp PS Fuse
Oven Heaters
OVERTEMP
RELAYS
ASR900 Probe
24 V DC PWR SUPPLY
NOTES:
LEGEND
OR OR
SEAL 1
(ZONE 1 ONLY)
B&B Electronics
RS232-RS485
MODULE
485LDRC
OR OR
Disconnect Purged
Enclosure Enclosure
Disconnect Purged
Enclosure Enclosure
Exe Disconnect
Enclosure Enclosure
TRANSFORMER
T.S. MOUNTING
RAIL DETAIL
DETAIL
12 3 4 5 6 7 8
S3
(100-1160-2)
ASSEMBLY PANEL,
TERMINAL BLOCK
CONNECTIONS
TOROIDAL
TRANSFORMER
Zirconia Oxide O2 Sensor (Optional), Wiring Connections
SUPPLEMENTAL INFORMATION