OI_PIR3502 PFO3372-EN (2)

Operating Instructions OI/PIR3502/PFO3372-EN Rev.
F2
Process Photometer
PIR3502 and PFO3372
Measurement made easy

The Company
We are an established world force in the design and manufacture of measurement products for industrial process control,
flow measurement, gas and liquid analysis and environmental applications.
As a part of ABB, a world leader in process automation technology, we offer customers application expertise, service and
support worldwide.
We are committed to teamwork, high quality manufacturing, advanced technology and unrivalled service and support.
The quality, accuracy and performance of the Company’s products result from over 100 years experience, combined with a
continuous program of innovative design and development to incorporate the latest technology.
2 OI/PIR3502/PFO3372-EN Rev. F2
PIR3502
PIR3502 Operating Instructions Contents
Contents
1 Safety and symbols .............................................5 3.9.2 Verify zero and span calibration ............. 23
3.9.3 Manual zero (single component) ............ 23
2 Introduction ........................................................6 3.9.4 Manual span (single component)............ 23
2.1 General................................................................... 6 3.9.5 Multiple components (common) ............ 24
2.2 Drawings ................................................................ 6 3.9.6 Multiple components (different) ............ 24
2.3 System description ................................................. 6 3.10 Standard analyzer settings .................................. 24
2.4 Source enclosure .................................................... 6 3.10.1 Basic analyzer.......................................... 25
2.4.1 Optical filter assembly ............................... 6 3.10.2 Inputs and outputs .................................. 25
2.4.2 Purge regulators and gauges (option) ....... 6 3.10.3 Alarm outputs ......................................... 25
2.5 Sample cell assembly ............................................. 6 3.10.4 Valve drivers table .................................. 26
2.6 Detector enclosure ................................................. 7 3.10.5 Digital inputs ........................................... 26
2.6.1 System electronics ..................................... 7 3.10.6 Alarms ..................................................... 27
2.6.2 Liquid crystal display.................................. 7 3.10.7 Component configuration ....................... 28
2.6.3 Detector assembly ..................................... 7 3.10.8 Alarm output configuration .................... 29
2.6.4 Optional optical span filter ........................ 7 3.11 Changing standard settings ................................. 29
2.7 Enclosure purge systems (option) .......................... 7 3.11.1 Changing analog output to 4 to 20 ma.... 29
2.7.1 Y purge....................................................... 7 3.11.2 Changing the scaling of analog output .... 30
2.7.2 X purge ...................................................... 7 3.11.3 Changing the alarm settings.................... 31
2.8 Extended path length reflective cell (option) ......... 7 3.11.4 Changing alarm limits.............................. 32
2.8.1 General description ................................... 7 3.11.5 Changing alarms and warnings ............... 32
2.8.2 Pressure relief valve .................................. 8 3.12 Installing extended pathlength reflective cell...... 35
2.9 Fiber optic analyzer (option) .................................. 8 3.13 Connecting analyzer to vistanet .......................... 36
2.10 Remote front panel option) ................................... 9 3.13.1 Initial setup ............................................. 37
2.11 Temperature and pressure comp (option) ............. 9 3.13.2 Setting access levels ................................ 38
2.11.1 Temperature compensation ...................... 9 3.13.3 Clock setup .............................................. 38
2.11.2 Pressure compensation ............................. 9 3.13.4 Server list ................................................ 39
2.11.3 Applications ............................................. 10
4 Operation.......................................................... 40
3 Installation and startup ..................................... 11 4.1 Controls and indicators ........................................ 40
3.1 Safety considerations ........................................... 11 4.1.1 Detector enclosure ................................. 40
3.2 Preparing for installation ..................................... 11 4.1.2 Source enclosure ..................................... 44
3.2.1 Recommended tools and equipment ...... 11 4.2 Analyzer turn‐on .................................................. 44
3.2.2 Other recommendations for installation . 12 4.3 Routine operations .............................................. 44
3.2.3 Opening and closing analyzer doors ........ 12 4.4 Display concentration mode ................................ 45
3.3 Equipment mounting ........................................... 12 4.5 Display temperature mode .................................. 45
3.4 PIR3502 standard connections ............................. 13 4.6 Display alarms mode ........................................... 46
3.4.1 Power in without x purge ........................ 13 4.7 Calibrate/benchmark mode................................. 46
3.4.2 Power in with x purge .............................. 14 4.7.1 Automatic benchmark ............................ 47
3.4.3 Watchdog alarm ...................................... 15 4.7.2 Manual benchmark ................................. 47
3.4.4 Solenoid connections .............................. 15 4.7.3 Automatic calibration ............................. 48
3.5 PFO3372 standard connections ........................... 16 4.7.4 Manual calibration .................................. 48
3.6 Sample handling system connections .................. 16 4.8 Execute self tests mode ....................................... 48
3.6.1 Vapor sample systems ............................. 17 4.8.1 Self test ................................................... 48
3.6.2 Liquid sample systems ............................. 18 4.8.2 View system monitors............................. 48
3.7 Analyzer optional connections ............................. 18 4.8.3 Manual i/o operation .............................. 49
3.7.1 Enclosure purge ....................................... 18 4.9 Overview of set‐up tables .................................... 51
3.7.2 Optical purge .......................................... 19 4.9.1 Access levels............................................ 51
3.7.3 Optical span filter .................................... 19 4.9.2 Editing ..................................................... 52
3.7.4 Steam heat supply for sample cell ........... 19 4.9.3 Accept soft key ........................................ 52
3.7.5 4 to 20 ma analog output ........................ 19 4.9.4 Left and right arrow soft keys ................. 52
3.7.6 Purge alarm ............................................. 19 4.9.5 Abort soft key.......................................... 52
3.7.7 Remote front panel option ...................... 19 4.9.6 Up and down arrow keys ........................ 52
3.8 Startup ................................................................. 22 4.10 Component configuration ................................... 52
3.9 Manual calibration procedure.............................. 22 4.10.1 Limits ....................................................... 53
3.9.1 Standard configuration ............................ 23 4.10.2 Calibration ............................................... 54
OI/PUV3502/PFO3372-EN, rev F2 3
PIR3502
PIR3502 Operating Instructions Contents
4.10.3 Identify .................................................... 54 6.2.4 Verify analyzer power (with x purge) ...... 72
4.11 Analyzer configuration ......................................... 55 6.2.5 Testing trend board output..................... 82
4.11.1 Autocalibration ........................................ 57 6.2.6 Testing chopper motor operation ........... 84
4.11.2 Alarms...................................................... 57 6.3 Alarms.................................................................. 84
4.11.3 More ........................................................ 58 6.3.1 Analytical alarms ..................................... 85
4.12 Stop the analyzer ................................................. 59 6.3.2 Power on initialization alarms ................. 87
6.3.3 EEPROM checksum test alarms............... 88
5 Technical description......................................... 60 6.3.4 Power supply alarms ............................... 88
5.1 General description .............................................. 60 6.3.5 Vistanet alarms ....................................... 88
5.2 Functional description.......................................... 60 6.4 Factory configuration .......................................... 88
5.3 Detector enclosure ............................................... 62 6.4.1 Inputs ...................................................... 89
5.3.1 Liquid crystal display................................ 64 6.4.2 Outputs ................................................... 90
5.3.2 Front panel control board ....................... 64 6.4.3 Analyzer .................................................. 91
5.3.3 I/O power board ...................................... 65
5.3.4 Power supply board ................................. 65 7 Repair ............................................................... 93
5.3.5 Calculation/control board ....................... 65 7.1 Sample cell window replacement ........................ 93
5.3.6 Calculation/control board dip switches ... 65 7.2 Source replacement............................................. 94
5.3.7 Backplane board ...................................... 66 7.2.1 Platinum source replacement ................. 94
5.3.8 Relay/solenoid driver board .................... 66 7.2.2 Tungsten source replacement ................ 95
5.3.9 Trend boards ........................................... 66 7.3 Chopper motor replacement ............................... 97
5.3.10 Detector assembly ................................... 66 7.4 Detector replacement ....................................... 100
5.3.11 Optical scan filter option ......................... 66 7.5 Extended path length cell replacement ............. 101
5.3.12 Communications board ........................... 67 7.6 Calculation/control pcb replacement ................ 102
5.4 Watchdog alarm ................................................... 67 7.7 Source control pcb replacement ....................... 102
5.5 Source enclosure .................................................. 68
5.5.1 Source assembly ...................................... 69 8 Replacement parts .......................................... 104
5.5.2 Optical filter assembly ............................. 70 8.1 Ordering information......................................... 104
5.5.3 Source control board ............................... 70 8.1.1 Equipment identification ...................... 104
5.5.4 Transformer ............................................. 70 8.1.2 Hardware configuration identification .. 104
5.6 Sample cell assembly ........................................... 70 8.1.3 Software configuration identification ... 105
5.7 Purge options ....................................................... 70 8.1.4 How to order ......................................... 105
5.7.1 Optical purge ........................................... 71 8.2 Sample cell ......................................................... 106
5.7.2 Enclosure purge ....................................... 72 8.3 Source enclosure ............................................... 107
5.8 Y purge ................................................................. 72 8.3.1 Platinum source .................................... 108
5.9 X purge ................................................................. 72 8.3.2 Tungsten source .................................... 109
5.9.1 Override option ....................................... 73 8.3.3 Chopper motor ..................................... 110
5.9.2 Override before power ............................ 73 8.4 Detector enclosure ............................................ 111
5.9.3 Override after x purge shuts off power ... 73 8.4.1 Front panel assembly ............................ 111
5.9.4 X purge function during override ........... 74 8.4.2 Detector ................................................ 112
5.9.5 Remote control of override ..................... 74 8.4.3 Remote front panel ............................... 112
5.10 Vistanet option..................................................... 74 8.5 Relective cell ...................................................... 112
6 Maintenance and troubleshooting .................... 75

6.1 Routine maintenance ........................................... 75
6.1.1 Recommended tools................................ 75
6.1.2 Verify detector voltage ............................ 75
6.1.3 Cell window cleaning procedure ............. 75
6.1.4 Extended path length cell cleaning .......... 78
6.2 Troubleshooting guidelines .................................. 80
6.2.1 Verify zero and span ................................ 80
6.2.2 Adjust optional optical span filter ........... 80
6.2.3 Verify analyzer power (without x purge) . 81
OI/PUV3502/PFO3372-EN, rev F2 4
PIR3502
PIR3502 Operating Instructions 1 Safety and symbols
1 Safety and symbols

The following symbols are used in this manual to alert
the user to possible hazards and to provide additional
information.
Indicates that referenced items are

Indicates that the referred item can susceptible to Electrostatic
be hot and should not be touched Discharge (ESD) damage and
without care. should not be touched without ESD
safe handling tools.
Indicates that a risk of electrical

shock and/or electrocution exists. Alerts the user to pertinent facts
and conditions.
Indicates a potential hazard which

could cause serious injury and/or
death, or indicates the presence of
a hazard which could result in
corruption of software or damage to
equipment or property.
.
OI/PIR3502/PFO3372‐EN, rev F2 5
PIR3502
PIR3502 Operating Instructions 2 Introduction
2 INTRODUCTION
2.1 General
The PIR3502 Analyzer is an on‐line process photometer that continuously identifies and measures components in gas or liquid
streams. In addition it supports VistaNET connection.
2.2 Drawings
Since analyzer configuration depends on the particular application, this manual does not contain generic engineering drawings
and diagrams. You should utilize the drawings, diagrams and replacement parts lists provided on the Important Documents CD‐
ROM supplied with your analyzer to ensure they are the correct ones for your system.
2.3 System description

By using multiple wavelengths, four to eight filters, and a single source infrared beam, the IR Analyzer performs spectroscopic
analyses on simple or complex process streams with single or multiple components of interest, in the near infrared (NIR) and
fundamental infrared (IR) regions of the electromagnetic spectrum. The basic IR Analyzer has three subassemblies: the Source
Enclosure, the Sample Cell Assembly, and the Detector Enclosure (see Figure 2.1). When area classification requires a purging
system, an optional air purging system may be installed with the analyzer.
DETECTOR SAMPLE CELL SOURCE

ENCLOSURE ASSEMBLY ENCLOSURE
Fig. 2.1. Typical PIR3502 Process Photometer
2.4 Source enclosure

The Source Enclosure contains the Source Assembly, Optical Filter Assembly, the Source Power Supply Board, a power
transformer, and the optional purge regulators and gauges. The IR Analyzer has two standard sources: a platinum source for
infrared (IR) applications and a tungsten source for near infrared (NIR) applications.
2.4.1 Optical filter assembly

The Optical Filter Assembly (which is temperature controlled) contains the chopper motor, filter wheel, one lens, and the motor
control electronics. The chopper motor is in the Optical Filter Assembly directly in front of the source and drives a balanced
filter wheel with four or eight filters.
2.4.2 Purge regulators and gauges (option)

Two pressure gauges can be located on the front of the source enclosure, one for optical purge and the other for enclosure
purge. These gauges are connected to their respective regulators located on the inside of the Source Enclosure door.
2.5 Sample cell assembly

The Sample Cell Assembly is isolated from the analyzer’s electronics. This isolation allows easy access to the sample lines,
simplifies routine maintenance procedures, reduces radiant heat effects from heated sample streams, and allows the sample
PIR3502
cell to be heated to high temperatures (150° C) without harming the electronic components in the source and detector
enclosures. The sample cell length, the material of construction, temperature, and pressure are application‐specific.
2.6 Detector enclosure

The Detector Enclosure contains the system electronics, the Detector Assembly, and the optional Optical Span Filter. On the
front panel are the Liquid Crystal Display (LCD), four function keys, four dedicated keys, and the mode selection panel.
2.6.1 System electronics

The system electronics consists of a Power Supply PCB, I/O Power PCB, Calculation/Control PCB, Communications PCB,
Relay/Solenoid Drive PCB, Backplane PCB, Front Panel PCB, and Trend PCBs.
2.6.2 Liquid crystal display

The Liquid Crystal Display (LCD), located on the front of the Detector Enclosure, displays all analysis results, analyzer status,
alarms and warnings, calibration and benchmark information, self‐test information, and set‐up tables.
2.6.3 Detector assembly

The IR Analyzer contains a solid‐state pyroelectric detector that is insensitive to external vibrations and mechanical shock. It is
useful across a broad range of wavelengths and is thermally stable. The detector generates a signal in proportion to the radiant
energy absorbed by the component of interest in the sample. The Detector Assembly can be purged to prevent the analyzer’s
response to changes in ambient carbon dioxide (CO2) and/or moisture (H2O).
An Indium Gallium Arsenide (InGaAs) photodiode detector is used with the PFO3372 Fiber Optic Analyzer. It has the same
stability characteristics as the pyroelectric detector, but the usable wavelength region is limited to 0.8 to 2.0 microns.
2.6.4 Optical span filter option

The Optical Span Filter option provides the operator with an alternate means of verifying the performance of the analyzer. It is
most often used in analyzers with applications that make it difficult or unsafe to acquire a calibration standard.
2.7 Enclosure purge systems (option)

When an area classification indicates combustible gases or particles are present in the air, and an analyzer enclosure containing
a possible source of ignition (electrical circuitry) is to be located in this environment, an air purging system may be installed in
the analyzer enclosure to reduce the degree of risk. The classification of the environment in which the analyzer can be installed
determines type of air purge used. An air purging system may also be installed to protect the analyzer components from
corrosive gases in the environment. The purge specifications tag is located on the inside edge of the front panel of each
enclosure.
2.7.1 Y purge
The Y Purge provides a constant, clean, dry air flow through the enclosures. Y Purge allows the analyzer to operate in a Division
I area. Loss of Y Purge air pressure causes an alarm display on the LCD, but there is no interruption of analyzer power.
2.7.2 X purge
To comply with the safety standards of governing agencies such as ATEX, or per customer request, the X Purge is installed. X
Purge is required when an instrument containing components that may arc or spark is to operate in a Division I/Zone 1 area.
The inside edges of the enclosure front panels are labeled with correct purge requirements. It is the
customer’s responsibility to provide correct volumes to ensure correct purge function.
2.8 Extended path length reflective cell (option)
2.8.1 General description

The permanently aligned long cell path has the multiple‐pass optical system first described by J. U. White. This system,
available in 3, 5, and 10 meter path lengths, uses a field mirror and two objective mirrors. Multiples of four passes are
obtainable with the Extended Path Length Reflective Cell set for 40 passes. Two rows of images of the radiation source are
arrayed on the field mirror for 36 passes.
The mirrors in the cell are coated with silver and a protective ceramic over coating. These mirrors have about 99% reflectivity
in the visible and infrared regions. This is higher than the reflectivity
PIR3502
of gold coated mirrors. The ceramic protected silver coating is also more abrasion resistant than the gold coating. Figure 2.2
illustrates the analyzer with the optional reflective cell.
Reflective
Cell
Fig. 2.2. IR Analyzer with Reflective Cell
2.8.2 Pressure relief valve

There is a pressure relief valve located on the bottom of the cell. The valve is set to release pressure at 10 psig. The release
point may be changed by turning the hex screw inside the valve. The maximum safe limit for the pressure in the glass cell is 45
psig; if the pressure exceeds 45 psig, the cell may rupture. If a metal cell is used see the data sheets for the recommended safe
operating pressure.
2.9 Fiber optic analyzer (option)

The Fiber Optic Analyzer option, PFO3372, is recommended for applications involving high temperatures or pressures, toxic or
corrosive samples, samples that must remain sanitary, or applications requiring a fast response time (as in Lower Explosion
Limit monitoring). The PFO3372 is only used in the near infrared (NIR) region of the electromagnetic spectrum. A single strand
fiber optic cable, used as a wave guide, transmits the light to the sample, where the light travels through the sample in an
extractive or insertion probe. Another single strand fiber optic cable wave guide carries the sample‐modified light back to the
analyzer. This eliminates the need to transfer the sample to the analyzer.
PIR3502
The fiber optic Analyzer combines the Detector Enclosure and the Source Enclosure into a single cabinet (see Figure 2.3). The
Detector Enclosure components are in the top half of the cabinet and the Source Enclosure components are in the bottom half.
Although the PFO3372 packaging differs from that of the PIR3502, they share the same components and operating
characteristics.
DETECTOR
ENCLOSURE
SAMPLE
LIGHTPATH IN
LIGHTPATH OUT
CONNECTION
SOURCE
ENCLOSURE
Fig. 2.3. PFO3372 Ir Analyzer with Fiber Optic Probe
2.10 Remote front panel (option)

The Remote Front Panel option consists of a Detector Enclosure without a detector. When this option is installed and all
jumpers and switch settings completed as noted in "Remote Front Panel Option" in Section 2, the Remote Front Panel option is
operational.
2.11 Temperature and pressure compensation (option)
2.11.1 Temperature compensation

Temperature compensation, which is optional on analyzers that do not have cell heat, is intended to be used for vapor
applications. There are two types of temperature compensation available:
 Gas Law Compensation—Temperature compensation is based upon the Ideal Gas Law and requires no
calibration or setup. An example of where Gas Law Compensation may be useful is for streams at ambient
temperature.
 Empirical Compensation—Temperature compensation is based on experimental data. It requires calibration in

the factory laboratory.
2.11.2 Pressure Compensation

Pressure compensation is used on vapor applications only. It is recommended on suppressed range applications such as 90 to
100% chlorine. Two types of pressure compensation are available:
 Gas Law Compensation—Pressure compensation is based on the Ideal Gas Law and requires no calibration. It is
used in selected applications where the gas sample does not have a fine line spectrum, such as propane or
butane.
PIR3502
 Empirical Compensation—Pressure compensation is base on experimental data. It requires calibration in factory

laboratory. This type of compensation is recommended on suppressed ranges and on applications susceptible to
pressure broadening effects.
2.11.3 Applications
Figure 2.4 illustrates a PIR3502 installation for non‐corrosive samples, showing the temperature and pressure compensation
location and connections.
TEMPERATURE
ENCLOSURE ELECTRONICS COMPENSATION
TEMPERATURE AND/OR CABLE PRESSURE
PRESSURE COMPENSATION COMPENSATION
CABLE
ABB
WATER 10 PPM
STATUS NORMAL ENCLOSURE PURGE
- CAUTION -
CLEAN DISPLAY WINDOW ONLY WITH DAMP
CLOTH
F1 F2 F3 F4
NEXT
HELP
COMP.
DISPLAY CONCENTRATION
DISPLAY TEMPERATURE
MODE
SELECTION
DISPLAY ALARMS/WARNINGS
CALIBRATE/BENCHMARK
OPTICAL PURGE
EXECUTE SELF TESTS
SET-UP TABLES
PRESSURE COMPENSATION
TRANSDUCER INSTALLED ON
STAINLESS STEEL CELL
Fig 2.4. PIR3502 for Non‐Corrosive Samples
Figure 2.5 illustrates a PIR3502 installation for corrosive samples, showing the temperature and pressure compensation
location and connections.
Enclosure Electronics Temperature

Temperature and/or Compensation
Pressure
Pressure Compensation Cable
Compensation
Cable
ABB WATER 1 0 PPM

STATUS NORMAL E NC LO SU R E PU R GE
- CAUTION-
CLEANDISPL AY WINDOW ONL YWIT HDAMP
CLOTH
F1 F2 F3 F4
NE XT HE LP
CO MP.
DI SPLAY CO NC ENTRA TIO N
DI SPLAY TE MPER ATUR E M ODE

SELE CTI ON
DI SPLAY ALA RMS /WARN ING S
CA LIBR ATE/BEN CHM ARK
EXE CUTE SE LFTES TS

O PT C
I AL P U RG E Pressure
SET -UP TAB LES
Compensation
Transducer
PR ESS. CO MP. N2
TO BE SET AT NO
LESS TH AN PS G I
SA M PLE R ET UR N
Pressure Compensation with Purged PRESS. COMP.

N2 INLET
Transducer Panel Installed on

Hastrlloy C, Monel or PTFE Cell
Fig. 2.5. PIR3502 for Corrosive Samples
PIR3502
PIR3502 Operating Instructions 3 Installation and startupp
3 Installation and startup

3.1 Safety considerations
Before starting to install the analyzer, read this safety information.
Before beginning installation, repair, or maintenance on this analyzer contact the local Safety
Department to ensure that all safety guidelines, regulations, and procedures are followed. This includes
obtaining the proper work permits and consulting the Material Safety Data Sheets for safety
requirements.
Before installing, operating, or working on the analyzer, be prepared to work correctly with lethal
voltages, infrared light sources, hazardous gases, and hot surfaces.
Wear protective clothing and use protective equipment appropriate for the specific job, such as rubber
gloves, and goggles, or safety glasses with side shields.
When working on the Photometer there is the possibility of exposure to hazardous sample (liquid and
vapor) as well as nitrogen. Although nitrogen is an inert gas, it does not support human life. All
appropriate precautions and care should be taken.
Ensure that there is adequate ventilation while work is being done on the analyzer.
Because the actual configuration of the analyzer depends on the application, this manual cannot address
all of the associated safety problems. It is the responsibility of the user to know and comply with all
safety and health guidelines, regulations, and procedures that apply.
Before opening the analyzer enclosure doors, be sure the area is safe from hazardous gases and will
remain so the entire time the analyzer is open.
When removing electronic parts and assemblies, it is necessary that proper electrostatic discharge (ESD)
precautions be taken (i.e., wear an ESD wrist strap with a grounding cable and use an ESD shielded bag to
protect the items removed).
3.2 Preparing for installation

The analyzer is shipped with a package titled “Important Papers.” Included in this package are data sheets, installation
drawings, and flow diagrams needed for the installation and setup of the analyzer; these are referred to as the “Data Package.”
After unpacking the analyzer, inspect it for damage. Also check the packing list provided with the analyzer to make sure all
equipment is included. This packing list is taped on the box or crate. It contains a list showing how many cartons were shipped
and what each box or crate contains.
The analyzer should be located as close as is practical to the sample stream, and the analyzer must be mounted in a shelter for
protection from harsh weather or direct water spray. It is recommended that a clearance of 10 inches minimum be allowed on
each side of the analyzer for door opening clearance.
3.2.1 Recommended tools and equipment

Data Package and the engineering drawings shipped with the analyzer
Tools: standard set of Phillips screwdrivers

standard set of straight blade screwdrivers
standard set of SAE wrenches (ATEX analyzers require hex key wrenches)
wrench for mounting bolts
wrench for SMA 950 connectors, for fiber optic analyzers only;
Supplies: leak detection solution

zero sample, application‐specific
PIR3502
span sample, application‐specific

1/4‐inch tubing of sufficient length to meet application requirements for connecting the process line to
the sample handling system and connecting the sample handling system to the analyzer; application‐
specific
1/4‐inch tubing connections/unions sufficient to meet application requirements
ISA grade air, for optical (0‐15 psig cylinder) and/or enclosure (0‐100 psig cylinder) purges; application‐
specific
nitrogen (or other inert gas), 99.95% purity, for optical (0‐15 psig cylinder) and/or enclosure (0‐100 psig
cylinder) purges; application‐specific
Equipment: electrostatic discharge (ESD) wrist strap and grounding cord

electrostatic discharge (ESD) shielded bag
3.2.2 Other recommendations for installation
1. If necessary, it is recommended that a pressure reduction valve be installed between the customer’s primary block valve
and the sample handling system.
2. With a non‐atmospheric vapor application, changes in cell pressure affect the analytical performance of the Analyzer.
Consult ABB Lewisburg for recommendations on procedures to ensure a constant low pressure return.
3. Cell design is application‐specific. Maximum cell window pressure is also application‐specific. Refer to the Data Package
shipped with the analyzer before making any changes that could affect cell pressure limits.
4. Fiber optic cables and connectors are very fragile components and must be handled with extreme care. The fiber optic
cables are shipped connected to the analyzer. It is recommended that during installation, they be run very carefully
through conduit, from the analyzer to the sample probe, to protect the fiber optic cables. Do not twist, bend, or crimp the
fiber optic cables or connectors.
The minimum long term radius for the fiber optic cables is 7.8 inches (200 mm), so conduit bends must
exceed this radius.
3.2.3 Opening and closing analyzer doors

The enclosure doors provide seals that, when combined with the enclosure purge, prevent hazardous gases from leaking into
the enclosures. Use care when opening and closing the doors to ensure these seals maintain their integrity.
1. To open an enclosure, turn the panel latches on the enclosure door fully counterclockwise with a 5/16‐inch or 8 mm hex
key wrench.
2. Swing the door open to access the components inside the enclosure.
3. To close an enclosure, swing its door shut.
4. To lock and seal the enclosure, turn the panel latches on the enclosure door fully clockwise with a 5/16‐inch or 8 mm hex
key wrench.
3.3 Equipment mounting
The Analyzer should be supported under the Detector and Source Enclosures during mounting.
Regardless of the Analyzer's actual weight, never support the Analyzer by the sample cell or the tie bars.
Installing the analyzer is the responsibility of the customer, unless arrangements have been made for ABB
Lewisburg to install the analyzer. Mounting brackets are attached to each analyzer enclosure, one on the
top and one on the bottom (0.406 inch/10.3 mm diameter). A support structure and bolts are normally
not furnished. The Analyzer weighs a minimum of 80 pounds (36 kg). The weight of the analyzer can
increase significantly depending on the size and material of the cell, and the actual analyzer
configuration. Analyzer weight is listed on the packing slip. The analyzer must be mounted on a load
bearing wall or assembly; it is recommended that the minimum weight tolerance be 50 pounds (23 kg)
more than the actual weight of the analyzer.
PIR3502
The analyzer must be mounted so that it is level. Otherwise it may not operate properly.
For ease of installation it is recommended that two vertical u‐channels (Unistrut®) be mounted to the studs, or the reinforced
section, of the load bearing wall/assembly. Then the Analyzer is mounted on two horizontal u‐channels (Unistrut) that are long
enough to span the distance between the vertical u‐channels (Unistrut). The analyzer horizontal mounting assembly can be
bolted to the vertical u‐channels (Unistrut).
3.4 PIR3502 standard connections

Figure 3.1 shows the connections for a typical PIR3502 analyzer. Refer to the application‐specific information in your Data
Package for details of your system.
POWER IN
(TOP OR BOTTOM) SIGNAL SIGNAL
WITHOUT X PURGE #2 #1
STEAM
HEAT IN SAMPLE
(OPTIONAL) PORT #1
EARTHING
CONNECTION
OPTICAL POWER IN SIGNAL SIGNAL SAMPLE STEAM ENCLOSURE OPTICAL

SPAN FILTER WITH #2 #1 PORT #2 HEAT OUT PURGE PURGE
(OPTIONAL) X PURGE (OPTIONAL) (OPTIONAL) (OPTIONAL)
Fig. 3.1. Typical PIR3502 Connections
Always follow the appropriate ESD procedures when removing the printed circuit boards (PCBs).
Electrostatic discharge can render the PCBs useless.
Disconnect all peripheral devices from their power sources before connecting power to the analyzer.
3.4.1 Power In without x purge
1. Ensure that the power switch is OFF at the control box on the power line.
2. Open the Detector Enclosure and locate the I/O Power Assembly PCB on the bottom of the back wall, at the left side of the
enclosure.
PIR3502
3. Connect the primary power cable to TB101 (see Figure 3.2) at TB101 terminals 1 (hot), 24 (neutral), and 3 (ground). The
Neutral and Ground (Earth) connections must be at earth potential (0 volts). Failure to maintain earth potential at these
connection points constitutes a serious safety hazard. This connection may be made from the top or bottom of the
Detector Enclosure through the 3/4‐inch hubs labeled Power In.
Fig. 3.2. Power Connections (without X Purge)
4. Since there is no On/Off switch on the Analyzer, as soon as the power line is installed and the switch in the control box is
turned ON, the analyzer has power.
5. Reconnect power to peripheral devices.
3.4.2 Power In with x purge
1. Ensure that the power switch is OFF at the control box on the power line.
2. Through the 3/4 inch NPT‐F tapped hole, inside the X Purge explosion proof enclosure (see Figure 3.3), connect the power
cable to TB49 terminals 3 (hot), 5 (neutral), and 1 (ground). The Neutral and Ground (Earth) connections must be at earth
potential (0 volts). Failure to maintain earth potential at these connection points constitutes a serious safety hazard. The
power cable may be an ATEX approved cable gland, or carried in a conduit with an approved potted sealoff.
Fig. 3.3. Power Connections (with X Purge)
3. Since there is no On/Off switch on the Analyzer, as soon as the power line is installed and the switch in the control box is
turned to On, power goes to the X Purge. The analyzer will not receive power until the enclosure pressure reaches the set
limit and the X Purge has completed its timed cycle
4. Reconnect power to peripheral devices.
PIR3502
3.4.3 Watchdog alarm

The Watchdog Alarm is standard in the Analyzer. It monitors processor operation and cannot be disabled. Connections are
made through the top or bottom of the Detector Enclosure through the 3/4‐inch hubs labeled Signal #1 and Signal #2. The
Watchdog Alarm output connects to J29 terminals 1 and 2. Figure 3.4 depicts a typical configuration, in which the watchdog
control circuitry opens the watchdog output on alarm. This illustration is for example only; see the Data Package for the wiring
diagram applicable to your analyzer.
Fig. 3.4. Watchdog Alarm Connections
3.4.4 Solenoid connections

The Relay/Solenoid Driver PCB provides the solenoid connections for the analyzer, at J11A through J11E (see Figure 3.5).
Fig. 3.5. Solenoid Connections
PIR3502
3.5 PFO3372 standard connections

Figure 3.6 shows the connections for a typical PFO3372 Fiber Optic NIR Photometer. The connection information in PIR3502
STANDARD CONNECTIONS applies to the PFO3372 also. Please refer to the application‐specific information in your Data
Package for details of your system.
Fiber optic cables and connectors are very fragile components and must be handled with extreme care. When installing the
fiber optic cables, do not twist, bend, or fold the cables or connectors. Do not handle the cables or connectors roughly. Refer
to the Data Package for more fiber optic information.
POWER IN SIGNAL #2
WITHOUT X-PURGE
(TOP OR BOTTOM) SIGNAL #1
LIGHTPATH IN
(TO DETECTOR)
LIGHTPATH OUT
(FROM SOURCE)
ENCLOSURE PURGE
(OPTIONAL)
OPTICAL PURGE
(OPTIONAL)
EARTHING
CONNECTION
POWER IN
SIGNAL #1 SIGNAL #2
Fig. 3.6. Typical PFO3372 Connections
The minimum long term radius for the fiber optic cables is 7.8 inches (200 mm), so conduit bends must
exceed this radius.
The fiber optic cables are connected to the sample line with an in situ or extractive sample probe; the extractive probe is
preferred for most applications. The SMA probe connections are application‐specific; if required, a special SMA tool is supplied,
otherwise the connections can be made by hand or with a standard set of wrenches.
Insert the end of the fiber optic cable into the probe connection. Holding the fiber optic cable so that it doesn’t twist, tighten
the connection, using a 9/16‐inch wrench if necessary.
If required, connect a heating or cooling supply to the probe; these connections should be typical 1/4‐inch tube stubs. Then
connect the sample probe to the sample line; see the Data Package.
3.6 Sample handling system connections

Normally the sample handling system is part of the customer order package provided by ABB. If the tubing and unions required
for the analyzer are included, they are shipped loose and must be connected on site. If the sample handling system is not
supplied by ABB, the customer must provide all needed materials. The basic inlet and outlet connections are the same. Refer
to the information in the Data Package shipped with the analyzer for application‐specific requirements.
PIR3502
3.6.1 Vapor sample systems

Figure 3.7 illustrates a vapor sample handling system for a single stream application. Refer to the application‐specific sample
handling system data package for details of your system.
Fig. 3.7. Example Vapor Sample System
The span sample connects to the sample system at the Span Inlet Valve. Span sample, tubing, and unions are provided by the
customer. After you connect the span sample, actuate the Span Selection Valve to block span flow; then open the Span Inlet
Valve to start span sample flow. Check for leaks and make all necessary repairs before proceeding. When this is complete,
close the Span Inlet Valve to stop span sample flow.
The zero sample connects to the sample system at the Zero Inlet Valve. Zero sample, tubing, and unions are provided by the
customer. In most applications the zero sample is 99.95% pure nitrogen or other similar grade inert gases. After you connect
the zero sample, actuate the Zero Selection Valve to block zero flow; then open the Zero Inlet Valve to start zero sample flow.
Check for leaks and make all necessary repairs before proceeding. When this is complete, close the Zero Inlet Valve to stop
zero sample flow.
The sample pressure relief valve connection needs to be made before the sample inlet connection is made. This connection is
made at the Relief Valve and is used to relieve and carry excessive inlet sample pressure away from the sample system to a
lower pressure process return or flare line.
If the sample is hazardous to equipment or personnel, you should use an inert gas such as nitrogen when
checking for leaks.
The process sample connects to the sample system at the Sample Inlet Valve. Process sample, transport tubing, and unions are
provided by the customer. It may be necessary to install a pressure reducing regulator between the Sample Inlet Valve and the
primary customer block valve (such as the Field Station valve shown in Figure 2‐6). After you connect the process sample,
actuate the Span Selection Valve to block sample flow and open the Sample Inlet Valve to start process sample flow. Verify the
PIR3502
sample pressure and check the entire flow path for leaks. Make all necessary repairs before proceeding. When this is
complete, close the Sample Inlet Valve to stop sample flow.
The sample bypass connects to the sample system at the Check Valve. It requires a constant low pressure at the return point
that is suitable for sample disposal according to local codes. If pressure variations are expected, a backpressure regulator
should be installed between the sample cell outlet and the sample return.
The sample handling system outlet connects to the SAMPLE IN connection at the top of the analyzer sample cell. The SAMPLE
OUT connection at the bottom of the analyzer sample cell connects to the sample handling system return. Tubing and
connections between the analyzer sample cell and the sample handling system are provided by the customer.
3.6.2 Liquid sample systems

Figure 3.8 illustrates a liquid sample handling system for a single stream application. Refer to the application‐specific sample
handling system data package for details of your system.
Fig. 3.8. Example Liquid Sample System
The vapor and liquid sample systems are the same except for the connections to the analyzer. In the liquid system, the SAMPLE
IN connection is at the bottom of the analyzer sample cell and the SAMPLE OUT connection is at the top of the analyzer sample
cell.
3.7 Analyzer optional connections
3.7.1 Enclosure purge

Purge supplies should be connected first when the Analyzer has enclosure or optical purges.
On the bottom of the Source Enclosure (see Figure 3.1) at the Enclosure Purge connection, is a 1/4‐18 NPT‐F fitting for
connecting an ISA Grade Air, Nitrogen, or other inert gas supply line (purge supply is application‐specific). Set the supply
regulator so the outlet gauge displays 40‐80 psig. Set the Enclosure Purge regulator on the back wall inside the Source
PIR3502
Enclosure so the Enclosure Purge gauge on the front panel displays 35 psig. Start purge flow; leak check all connections along
the purge flow path.
If the enclosures have X Purge, all connections must be made and both enclosures closed, so the set
enclosure pressure can be reached and X Purge can complete its timed cycle. Only then will power be
allowed to the analyzer. For more information, see "X PURGE" in Section 4.
3.7.2 Optical purge
On the bottom of the Source Enclosure (see Figure 3.1), at the Optical Purge connection, there is a 1/4‐18 NPT‐F fitting for
connecting an ISA Grade Air, Nitrogen, or other inert gas supply line (purge supply is application‐specific). Set the supply
regulator so the outlet gauge displays 15‐30 psig. Set the Optical Purge regulator on the floor inside the Source Enclosure so
the Optical Purge gauge on the front panel displays 8 psig. Start purge flow and leak check all connections along the purge flow
path.
3.7.3 Optical span filter

On the bottom of the Detector Enclosure (see Figure 2‐1), at the Optical Span Filter connection, there is a 1/8‐27 NPT‐F fitting
for connecting an ISA Grade Air supply line; the supply regulator should be set so that the output gauge displays 20 psig. Verify
analyzer configuration with the information in the Data Package. If applicable, start the air flow and leak check the
connections.
3.7.4 Steam heat supply for sample cell

Heating the sample cell is application‐dependent; verify analyzer configuration with the information in the Data Package. If the
cell is heated with steam, the 1/4‐inch tube stubs will be labeled “Steam In” at the top stub and “Steam Out” at the bottom
stub (see Figure 2‐1). It is the customer’s responsibility to supply the tubing and connections, the steam source and the steam
pressure regulators.
3.7.5 4 to 20 ma analog output

The Front Panel Control Board in the Detector Enclosure has connections for up to four Trend Boards (4 to 20 mA analog
outputs). For each installed Trend Board there must be connections to a customer device made at J21 on the Backplane Board
in the Detector Enclosure (see Figure 3.9). Also each installed Trend Board must be configured in the Set‐Up Tables for Analyzer
Configuration (see "Analyzer Configuration" in Section 4).
Fig. 3.9. Backplane Connections for Analog Outputs
3.7.6 Purge alarm

If the Analyzer has an Enclosure Purge and/or an Optical Purge, according to NFPA 496 (1993) the user must install an audible
or visual alarm in a constantly monitored location. This alarm connection can be made through the 3/4‐inch hubs (Signal #1
and #2) on the top or bottom of the Detector Enclosure. See the Wiring Diagram in the Data Package.
3.7.7 Remote front panel option

Verifying the Remote Front Panel option setup involves checking the settings in both the standard Detector Enclosure and the
Remote Front Panel.
1. Verify that power is OFF to both the standard Detector Enclosure and the Remote Front Panel.
PIR3502
2. Open both units and locate connector J28 on the Backplane Board in each unit (see Figure 3.10).
Fig. 3.10. Backplane Board Layout
3. Verify the cable between J28 on the Backplane Board in the standard Detector Enclosure and J28 on the Backplane Board
in the Remote Front Panel is connected as shown in Figure 3.11.
Fig. 3.11. Remote Front Panel Interconnect Cable
PIR3502
Standard Detector Enclosure
4. Locate DIP Switch SW1 on the Front Panel Board (see Figure 3.12).
Switch SW1
Fig. 3.12. Front Panel Board Layout
5. On the Front Panel Board, verify that position 5 of SW1 is OFF (OPEN).
6. Remove the Calculation/Control Board and locate jumpers JP7, JP8 and JP9, and DIP switch SW2 (see Figure 3.13).
Fig. 3.13. Standard Calculation/Control Board
7. On the Calculation/Control Board verify all three jumpers are between pins 1 and 2, and verify that position 2 of SW2 is
CLOSED.
8. Reinstall the Calculation/Control Board and close the standard Detector Enclosure.
Remote Front Panel
9. Verify that position 5 of SW1 on the Front Panel Board is ON (CLOSED).
PIR3502
10. Remove the Calculation/Control Board (see Figure 3.14) and verify that jumpers JP7, JP8 and JP9 are between pins 2 and 3,
and verify that position 2 of SW2 is OPEN.
Fig. 3.14. Remote Front Panel Calculation/Control Board
11. On the Calculation/Control Board, verify that the following socketed components are not installed:
U39, U37, U43, U45, U31, U49, U44, U38, and U56.
12. Reinstall the Calculation/Control Board and close the Remote Front Panel.
3.8 Startup
After all supplies have been connected, all connections have been tested and verified, and purge flow continues, turn On the
power switch on the power supply line to the analyzer. If the analyzer has X Purge, the X Purge must complete its timed cycle
before the analyzer will receive power.
Allow at least 30 minutes for the analyzer to heat to operating temperature. During this time, clear alarms and warnings as
they display. When the sample cell and casting reach their specified temperatures, those alarms discontinue automatically.
Verify 4 to 20 mA output connections and devices. Now the Analyzer can be calibrated.
3.9 Manual calibration procedure

The Analyzer is calibrated at the factory, using zero and span samples specified by the application. During installation it is vital
that the customer calibrate the Analyzer with “local” zero and span samples, using the zero and span information in the Data
Package for comparison. Figure 3.15 provides a quick reference procedure for manual calibration.
1. Program zero and span sample concentrations in the factory set‐up tables.
2. Go to CALIBRATE/BENCHMARK mode.
3. Zero analyzer.
4. Span analyzer.
Fig. 3.15. Quick Reference for Manual Calibration
PIR3502
Always calibrate zero first, then calibrate span.
3.9.1 Standard configuration

Standard configuration for the Analyzer is manual calibration, which requires that the operator actuate the valves on the
sample handling system (see Figure 3.7 for vapor system or Figure 3.8 for liquid system).
Automated valves are available as a sales order option, and only require that the commands be entered
at the front panel. Before calibrating the analyzer, verify its configuration with the information in the
Data Package.
3.9.2 Verify zero and span calibration concentration settings

Before calibrating the analyzer, verify the zero and span settings in the analyzer with the Data Package. If the local zero and
span calibration supplies do not match the analyzer or the Data Package, the Set‐up Tables must be modified to match the local
calibration samples.
1. Select SET‐UP TABLES on the front panel of the Detector Enclosure.

2. Press MODIFY SET‐UP (F2), then COMPONENT (F1), then CALIBRATION (F2), then ZERO (F2).
3. To change the zero concentration number press the appropriate soft keys. Soft key F2 moves the cursor to the left, soft
key F3 moves the cursor to the right; the up arrow increases the number above the cursor, and the down arrow decreases
the number above the cursor.
4. After the correct concentration has been set, press ACCEPT (F1) and NEXT COMP. (soft key under F1), or ACCEPT (F1) and
then EXIT (F4) if no other component concentrations need to be changed.
5. For Span changes, follow the same procedure except select SPAN (F3) instead of ZERO (F2).
3.9.3 Manual zero (single component applications)
1. Verify zero and span calibration concentration settings (see "Verify Zero and Span Calibration Concentration Settings").
2. Select DISPLAY CONCENTRATION on the front panel of the Detector Enclosure.
3. Actuate the Zero Selection Valve on the sample handling system to pass the zero sample through the sample cell. Zero
calibration is always performed before span calibration.
4. Allow time for the analyzer to stabilize as indicated by the sample concentration reading on the front panel display.
5. When the analyzer is stabilized, use the MODE SELECTION key to move to CALIBRATE/ BENCHMARK.
6. Select MANUAL CALIBRATION (F4) and then ZERO (F1).
7. When the SAMPLE CONCENTRATION reading remains constant, press ACCEPT (F3) and then EXIT (F4).
8. Return the Zero Selection Valve to its original position.
Zero Calibration readings must be accepted or the analyzer will revert to the previous setting and analysis
results may be inaccurate.
It is good practice always to record zero and span readings before calibration, then record the calibration readings, the date
performed, and any changes that may result. Zero calibration should be performed more often than span. How often zero is
performed depends on the application. Always compare zero calibration readings with the last recorded zero calibration. If
there is a significant difference see the troubleshooting procedures in Section 5.
3.9.4 Manual span (single component applications)
Zero calibration is always performed before span calibration.
PIR3502
2. Actuate the Span Selection Valve on the sample handling system to pass the span gas through the sample cell.
3. Select SPAN (F2).
4. When the SAMPLE CONCENTRATION reading remains constant, press ACCEPT (F3) and then EXIT (F4).
5. Return DISPLAY CONCENTRATION to the front panel of the Detector Enclosure.
6. Return the Span Selection Valve to its original position.
7. Open the Sample Valve to allow sample flow.
Span Calibration readings must be accepted, or the analyzer will revert to the previous setting and
analysis results may be inaccurate.
3.9.5 Multiple components, common zero and span samples

When calibrating an Analyzer with multiple components that have a common zero sample and a common span sample, zero
calibration and span calibration can be performed for all components in sequence, with zero calibration performed first for all
components.
For example, components methane, ethane, and carbon dioxide have nitrogen (99.95% pure) as a common zero sample. The
common span sample would contain methane, ethane, and carbon dioxide in correct concentrations, with a make up gas
(usually nitrogen).
First calibrate all components for zero:
2. Select DISPLAY CONCENTRATION on the front panel of the Detector Enclosure.
3. Actuate the Zero Selection Valve on the sample handling system to pass the zero sample through the sample cell.
4. Allow time for the analyzer to stabilize as indicated by the sample concentration reading on the front panel display.
5. When the analyzer is stabilized, use the MODE SELECTION key to move to CALIBRATE/ BENCHMARK.
6. Select MANUAL CALIBRATION (F4) and then ZERO (F1).
7. When the SAMPLE CONCENTRATION reading remains constant, press ACCEPT (F3) and then NEXT COMPONENT.
8. Repeat steps 6 and 7 for each component.
9. When all components have been calibrated for zero, return the Zero Selection Valve to its original position.
Then calibrate all components for span:
2. Actuate the Span Selection Valve on the sample handling system to pass the span gas through the sample cell.
3. Select SPAN (F2).
4. When the SAMPLE CONCENTRATION reading remains constant, press ACCEPT (F3) and then NEXT COMPONENT.
5. Repeat steps 3 and 4 for each component.
6. Return DISPLAY CONCENTRATION to the front panel of the Detector Enclosure.
7. Return the Span Selection Valve to its original position.
8. Open the Sample Valve to allow sample flow.
3.9.6 Multiple components, different zero and span samples

When the application requires different zero and/or span samples for multiple components, each must be calibrated
individually, as described in "Manual Zero (Single Component Applications)" and "Manual Span (Single Component
Applications." This procedure will probably require changing the zero and span sample cylinders for each calibration, for each
component. After calibrating the Analyzer, return DISPLAY CONCENTRATION to the front panel of the Detector Enclosure and
return the Span Selection Valve to its original position. Open the Sample Valve to allow sample flow.
The Analyzer will continue to run until power is shut off manually at the switch on the power supply line, or until the X Purge
shuts off power due to a pressure drop in the enclosures.
3.10 Standard analyzer settings

The following configuration settings are for reference only. These settings do not reflect sales order specifications or
application requirements, which can vary from analyzer to analyzer. Standard settings are in UPPERCASE BOLD.
PIR3502
Before changing settings, be sure to write down the existing analyzer settings. Also make note of the
changes made, the reason for the changes, and the date.
3.10.1 Basic analyzer
Number of Filters: 4 8
Source Type: IR UV
Benchmark Span Filter: Yes NO
Remote Front Panel: Yes NO
Highway Communications: Yes NO
Cell Heat: Yes NO
Pressure/Temperature: Yes NO
Enable Pressure Display: Yes NO
Auto‐calibration (applies to all components)
Actions:
Auto‐zero: DISABLED Benchmark Calibration
Auto‐span: DISABLED Benchmark Calibration
Remote Start Calibration: Disabled ENABLED
Periodic Auto‐calibration: DISABLED Enabled
Times:
Purge Time: _____ 60 SECONDS (1 to 16000 seconds)
Auto‐cal Period: _____ 24 HOURS (0.1 to 1600.0 hours)
Next Auto‐cal: _____ 24 HOURS (0.1 to 1600.0 hours)
3.10.2 Inputs and outputs
Analog Outputs (see "Front Panel Control Board" in Section 4)
No. Driven By Span Scale Zero Level TRACK Alarm Level

(Comp. Name) (ppm) (4 mA) Or Hold (20 mA)
Digital Outputs
Default States (all failsafe by default):
Reset: OFF
Alarm: ON
Mode Indicators:
Calibration Indicator:
Output No.: _____ 3 (001‐014, 031‐044, 101‐108)
Active Level: ON Off
Offline Indicator:
Output No.: _____ 4 (001‐014, 031‐044, 101‐108)
Active Level: ON Off
3.10.3 Alarm outputs
Alarm outputs available are:

Digital #001‐014 and 031‐044 (logic level), and Digital #101‐108 (valve driver).
Digital Output #1 is normally the Common Alarm. The first output of all alarms is normally mapped to Digital Output #1.
PIR3502
Digital Output #2 is normally the Enclosure Purge Alarm. The third output of Enclosure Purge Alarm is normally mapped to
Digital Output #2.
Digital Output #31 is normally the Remote Common Alarm. The second output of all alarms is normally mapped to Digital
Output #32.
Digital Output #32 is normally the Remote Enclosure Purge Alarm. The third output of Remote Enclosure Purge Alarm is
normally mapped to Digital Output #32.
3.10.4 Valve drivers table

For an example see "Calculation/Control Board DIP Switches" in Section 5. If changes are to be made, write down the existing
settings before making any changes; also note the changes and the date they were made. For each Step and Mode, the Valve
Number and whether the valve is On or Off must be indicated.
Step/Mode 1 2 3 4 5 6 7 8
Sample Valve #
Analysis On/Off
Zero
Bench.
Span
Bench.
Zero
Calib
Span
Calib
3.10.5 Digital inputs
User Alarms
Alarm Name Input Active

Number (40 characters maximum) Number Level
1 LOW/High
2 LOW/High
3 LOW/High
4 LOW/High
5 See NOTE below LOW/High
User Alarm #5 is factory‐set on analyzers with remote front panels.

User Alarms #6 and #7 are factory‐set on analyzers with IR sources.
User Alarm #8 is factory‐set on analyzers with enclosure purges.
PIR3502
Remote Start Autocal

State: ENABLED Disabled
Digital Input No.: _____ 3 (# 1‐8, 25‐32)
Active Level: High LOW
Remote Clear Alarm

Digital Input No.: _____ 4 (# 1‐8, 25‐32)
Active Level: High LOW
3.10.6 Alarms
Attributes:
All alarms and warnings are ENABLED.
Cell and casting “warming” warnings TRACK CONDITION.
All other alarms and warnings HOLD UNTIL CLEARED.
Non‐standard alarms must specify the following:

Remote Clear: ENABLED Disabled
Track/Hold: Track Hold
Class: Warning Alarm
Detector AC and DC Alarms (to be set after applications work):

All alarms are ENABLED.
Warnings are set for ± 40% OF NOMINAL EXCURSION.
Alarms are set for ± 50% OF NOMINAL EXCURSION.
Analog/Digital Converter Inputs
INPUT #1
High Alarm Enabled DISABLED Limit: __________ Vdc
High Warning Enabled DISABLED Limit: __________ Vdc
Low Warning Enabled DISABLED Limit: __________ Vdc
Low Alarm Enabled DISABLED Limit: __________ Vdc
INPUT #2
High Alarm Enabled DISABLED Limit: __________ Vdc
High Warning Enabled DISABLED Limit: __________ Vdc
Low Warning Enabled DISABLED Limit: __________ Vdc
Low Alarm Enabled DISABLED Limit: __________ Vdc
Cell Temperature
High Alarm ENABLED Disabled Limit: __________Celsius

High Warning ENABLED Disabled Limit: __________Celsius
Low Warning ENABLED Disabled Limit: __________Celsius
Low Alarm ENABLED Disabled Limit: __________Celsius
Cell Pressure
High Alarm Enabled DISABLED Limit: __________PSIA

High Warning Enabled DISABLED Limit: __________PSIA
Low Warning Enabled DISABLED Limit: __________PSIA
Low Alarm Enabled DISABLED Limit: __________PSIA
PIR3502
3.10.7 Component configuration
The following information is compiled, according to the application, for each component measured; standard settings are in
UPPERCASE BOLD.
Component # _______
Name Text (24 characters) ________________________
Range Text (33 characters) _________________________________
Attributes
Type: MATRIX Equation
Component Equation (use only when Equation is selected above):
Operand 1 ‐
Operator 2 ‐
Operand 3 ‐
Compensation:
Temperature (N/A): Yes NO
Pressure (N/A): Yes NO
Linearity: Yes NO
Concentration Displayed: YES No
Units: % ppm
Units Displayed: YES No
Calibration and Benchmark
Zero:
Auto‐zero: On OFF
Calibration (Gas) Concentration: ______
Span:
Auto‐span: On OFF
Calibration (Gas) Concentration: ______
Alarm Limits
Concentration:
High Alarm: Enabled DISABLED Limit: ______
High Warning: Enabled DISABLED Limit: ______
Low Alarm: Enabled DISABLED Limit: ______
Low Warning: Enabled DISABLED Limit: ______
Benchmark:
Zero:
Warning: Enabled DISABLED
Tolerance: ± ______ % PPM
Concentration: ______
Alarm: Enabled DISABLED
Span:
Calibration:
Zero:
PIR3502

Span:
3.10.8 Alarm output configuration

The following information is compiled, according to the application, for each alarm requiring outputs; standard settings are in
UPPERCASE BOLD. For more alarm information, see Sections 4 and 6.
Alarm Number: ________ (001 ‐ 283)

First Output:
Output Type: DIGITAL Analog
Output Number: 1 ______
Reset State: ON Off
Alarm State: On OFF
Second Output:
Output Number: 31 ______
Reset State: ON Off
Alarm State: On OFF
Third Output:
Output Number: ______ DEFAULT #0
Reset State: ON Off
Alarm State: On OFF
Fourth Output:
Output Number: ______ DEFAULT #0
Reset State: ON Off
Alarm State: On OFF
3.11 Changing standard settings
3.11.1 Changing the analog output from 0 to 20 ma to 4 to 20 ma
Nitrogen is an inert gas that does not support human life. It may be used to purge the Analyzer. All
appropriate precautions and extreme care should be taken when working with nitrogen or any inert gas.
Always be sure there is adequate ventilation when working on the analyzer.
Refer to the Data Package shipped with each analyzer before making any adjustments. Refer to the Data
Package and the purge information tags on the inside edges of the enclosure front panels; for complete
purge information see "PURGE OPTIONS" in Section 4.
1. Turn power OFF to the analyzer.

2. Open the front panel of the Detector Enclosure.
3. Inside the front panel on the Front Panel PCB, put DIP switches 3 and 4 in the OFF position.
PIR3502
4. On the Calculation/Control PCB, put DIP switch 8 in the ON position.

5. Close the front panel.
6. Turn power ON to the analyzer.
7. Using the MODE SELECTION key on the Detector Enclosure front panel, move to SET‐UP TABLES.
8. Press MODIFY SET‐UP (F2), then FACTORY (F3), select OUTPUTS (F2), and then ANALOG (F1).
9. With the up arrow key, toggle to ANALOG OUTPUT NUMBER 01.
10. Using the right arrow soft key (F3) cursor to ZERO LEVEL.
11. With the up arrow key, toggle to 4 mA and then press ACCEPT (F1).
If you fail to press ACCEPT, the analyzer will revert to the original values after you complete this
procedure.

13. Return the DIP switches on the Front Panel PCB and the Calculation/Control PCB to their original positions.
14. Secure the front panel.
15. Turn power ON to the analyzer and observe applicable purge requirements.
16. Press EXIT (F4).
17. Use the MODE SELECTION key to return to DISPLAY CONCENTRATION.
3.11.2 Changing the scaling of the 4 to 20 ma outputs
Refer to the Data Package shipped with each analyzer before making any adjustments. Refer to the data
package and the purge information tags on the inside edges of the enclosure front panels; for complete
purge information see "PURGE OPTIONS" in Section 4.
Prior to re‐scaling the outputs, you should contact the ABB factory to verify that the new range is feasible
on the analyzer.
As a re‐scaling example, the component of interest is currently scaled for 0‐40% and will be rescaled for 0‐50%.

7. Using the MODE SELECTION key, move to SET‐UP TABLES mode.
8. Select MODIFY SET‐UP (F2), ANALYZER (F2), MORE (F3), ANALOG OUTPUTS (F2), ASSIGNMENT/SCALING (F2), and SCALING
(F2).
9. Press the up arrow key to move to the correct output for the component of interest.
10. Using the right arrow soft key (F3), move the cursor to full scale.
11. Using the up and down arrow keys, adjust the setting to read +500000 PPM.
12. Press ACCEPT (F1).
PIR3502
procedure.

15. Secure the front panel.
16. Turn power ON to the analyzer and observe purge requirements if applicable.
3.11.3 Changing the alarm settings to hold or track
Refer to the Data Package shipped with each analyzer before making any adjustments.
Refer to the data package and the purge information tags on the inside edges of the enclosure front
panels; for complete purge information see "PURGE OPTIONS" in Section 4.

8. Select MODIFY SET‐UP (F2), FACTORY (F3), OUTPUTS (F2), ALARM (F3), and ATTRIBUTES (F1).
9. Press the up arrow key to toggle to the desired alarm.
10. Using the right arrow soft key (F3), move the cursor to ALARM MODE.
11. Using the up arrow key, toggle between TRACKS and HOLD. Leave the desired setting displayed.
procedure.
13. Use the left arrow soft key (F2) to cursor to the alarm name.
14. Repeat steps 9 through 12 to change other alarm settings, if required.
17. Secure the front panel
PIR3502
3.11.4 Changing alarm limits for calibration

7. Select MODIFY SET‐UP (F2), COMPONENT (F1), LIMITS (F1), and CALIBRATION (F3).
8. Under CALIBRATION are ZERO (F1) and SPAN (F2); under each of these are ALARMS (F1) and WARNINGS (F2) selections.
For example, to change the span alarm, press SPAN (F2) and then ALARM (F1).
9. Use the up or down arrow key to toggle between ENABLED and DISABLED.
10. Using the left and right arrow soft keys (F2 and F3), move the cursor to the desired setting.
11. Use the up and down arrow keys to change the number above the cursor, until the desired tolerance is displayed.
If you fail to press ACCEPT, the analyzer to revert to the original values after you complete this procedure.
13. If more components need to have alarm settings changed for calibration, press the NEXT COMP key just under the F1 soft
key and repeat steps 7 through 12.
14. When all Zero and Span alarms and warnings have been changed for calibration, turn power OFF to the analyzer.
15. Return DIP switch 8 on the Calculation/Control Board to its original position.
3.11.5 Changing alarms and warnings
This is an example of how to change Analyzer alarm and warning settings. For this example:
• component of interest is being measured at 0 to 10% concentration
• component concentration high level alarm at 9% will be changed to 8%
• component concentration high level warning at 8% will be changed to 7%.
PIR3502
The command sequence used to perform these changes is shown in Figure 3.16.
SETUP TABLES
MODIFY SET‐UP (F2)
COMPONENT (F1)
LIMITS (F1)
CONCENTRATE (F1)
HIGH LEVEL (F1) ENABLE/DISABLE ALARMS
ALARMS (F1) LOW LEVEL (F2) AND SET LEVELS
EXIT (F4)

WARNINGS (F2) LOW LEVEL (F2) AND SET LEVELS
EXIT (F4)
EXIT (F4)
Fig. 3.16. Component Concentration Alarm & Warning Command Tree
1. Use the MODE SELECTION soft key to move to SET‐UP TABLES

2. Select MODIFY SET‐UP (F2).
3. Select COMPONENT (F1), then LIMITS (F1), and CONCENTRATE (F1), which Component Configuration Limits screen (see
Figure 3.17).
Fig. 3.17. Component Configuration Limits Screen
4. Press ALARMS (F1) to select the alarm limits for component concentration and the Component Configuration Alarms
screen appears (see Figure 3.18).
Fig. 3.18. Component Configuration Alarms Screen
PIR3502
5. On the Component Configuration Alarms screen press HIGH LEVEL (F1) to select the high level component concentration
alarm (see Figure 3.19) or press LOW LEVEL (F2) to select the low level alarm. The high level and low level alarm screens
are identical except for the designations high and low, so the procedure for changing the low level alarm is identical to the
procedure for changing the high level alarm.
Fig. 3.19. High Concentration Alarm Screen
On this screen the concentration alarm can be ENABLED or DISABLED, the alarm limit can be set to a plus
or minus number.
The left (F2) and right (F3) arrow soft keys move the cursor from one choice to another. The up and down
arrow keys change the character above the cursor (they toggle between word or symbol choices such as
ENABLED/DISABLED or +/‐, and move one digit up or down for each digit of a number).
6. Press the left arrow key (F2) to move from ENABLED to the line below, which is the component concentration level that
will activate the alarm.
7. To change 9%, use the right arrow key (F3) to move the cursor to the 9 and then press the down arrow key to change the 9
to 8.
8. Press ACCEPT (F1) to change, ABORT (F4) to EXIT.
9. If you need to change the concentration alarms for more than one component, press NEXT COMP, the soft key under F1,
and the next component name displays on the screen along with its alarm setting.
10. When you have completed your changes to the high level alarms, press EXIT (F4) to return to the previous screen (Figure 2‐
18) to select LOW LEVEL (F2) to change the low level alarm, which is done in the same way as the high level alarm.
11. To leave this procedure, continue pressing EXIT (F4) or press the MODE SELECTION key to change the mode displayed.
Warnings are changed the same way alarms are changed.
1. Press EXIT (F4) to return to the MODIFY SET‐UP TABLES COMPONENT CONFIGURATION LIMITS screen (see Figure 3.17).
2. Press WARNINGS (F2).
3. On the Component Configuration Warnings screen (see Figure 3.20), press HIGH LEVEL (F1) to select the high level
component concentration warning or LOW LEVEL (F2) to select the low level warning. The high level and low level warning
screens are identical, except for the designations high and low, so the procedure for changing the low level warning is
identical to the procedure for changing the high level warning.
Fig. 3.20. Component Configuration Warnings Screen
PIR3502
On this screen the concentration alarm can be ENABLED or DISABLED, the alarm limit can be set to a plus
or minus number.
The left (F2) and right (F3) arrow soft keys move the cursor from one choice to another. The up and down arrow keys change
the character above the cursor (they toggle between word or symbol choices such as ENABLED/DISABLED or +/‐, and move one
digit up or down for each digit of a number).
4. Press the left arrow key (F2) to move from ENABLED to the line below, which is the component concentration level that
will activate the warning.
5. To change 8%, use the right arrow key (F3) to move the cursor to the 8 and then press the down arrow key to change the 8
to 7.
6. Press ACCEPT (F1) to change, ABORT (F4) to EXIT.
7. If you need to change the concentration warnings for more than one component, press NEXT COMP, the soft key under F1,
and the next component name displays on the screen along with its warning setting.
8. When you have completed your changes to the high level warning, press EXIT (F4) to return to the previous screen (Figure
2‐19) to select LOW LEVEL (F2) to change the low level warning, which is done in the same way as the high level warning.
9. To leave this procedure, continue pressing EXIT (F4) or press the MODE SELECTION key to change the mode displayed.
3.12 Installing the extended pathlength reflective cell

The Extended Pathlength Reflective Cell is packed in a separate carton when it is shipped with the analyzer. It must be installed
after the Source and Detector Enclosures have been securely mounted in place.
Installing the Extended Pathlength Reflective Cell requires two people, one person to hold the end of the cell to be attached to
the cell base of the analyzer and the other person to hold the other end of the cell and guide it into proper position.
The Extended Pathlength Reflective Cell is attached to the analyzer in a recessed area in the bottom of the cell base (the metal
block between the Source Enclosure and the Detector Enclosure). Transfer mirrors are mounted in openings in the recessed
area in the cell base.
Transfer mirror adjustment should not be necessary at this time.
1. Attach the Reflective Cell to the cell base. The end of the Reflective Cell that has two one‐inch holes in it and a single
mirror glued inside (see Figure 3.21) must be attached to the cell base.
Fig. 3.21. Mounting the Reflective Cell
PIR3502
2. Position the Reflective Cell in the base so that the single mirror is to the back of the analyzer and the two one‐inch holes in
the end of the cell line up exactly with the transfer mirror openings in the cell base. It may take a few tries to get the cell
inserted and the holes in the cell lined up exactly with the transfer mirror openings in the cell base.
3. Turn the cell counterclockwise until it is stopped by the pin in the cell base.
4. Once the cell is in the correct position, use an Allen wrench to secure the Reflective Cell to the cell base with the four set
screws and retainers.
5. If the reflective cell has electric heat, connect the electric heat wires from the reflective cell to the Detector Enclosure as
shown in Figure 3.22. Then proceed to step 6.
Fig. 3.22. Cell Heat Connections
6. Apply power and compare the detector voltages displayed on the analyzer with the detector voltages in the Data Sheets
shipped with the analyzer.
7. After power is applied, make the necessary adjustments to the sample system to start Zero flow. Allow sufficient time for
the Zero sample to flow completely through the cell. The amount of time required for the sample to flow completely
through the cell depends on the flow rate of the sample.
8. Press Mode Select until EXECUTE SELF TESTS is selected.
9. Select SYSTEM MONITORS, then select SIGNALS AND DETECTOR VOLTAGES. This screen displays the voltages for each
filter.
10. Compare the voltages displayed on the analyzer with the Detector Voltages of Optical Filters with Zero Sample on the Data
Sheets.
11. If the displayed voltages are very close to the voltages on the Data Sheet, continue with the startup procedures in
"STARTUP."
12. If the displayed voltages do not match, or are not very close to, the voltages on the Data Sheet, you may not have allowed
sufficient time for the Zero sample to flow completely through the cell. Wait several minutes and compare the voltages
again (samples with a low flow rate can take as long as 30 minutes to fill and flush the cell completely).
13. If after several attempts the displayed voltages are not very close to the voltages on the Data Sheet, and sufficient time
has been allowed for the Zero sample to flow through and completely flush the cell, call the ABB Lewisburg Service
Department immediately.
3.13 Connecting the analyzer to vistanet

If the analyzer is connected to ABB VistaNET 2.0, you must connect the Analyzer to the VistaNET PC as described in the
VistaNET 2.0 Installation Guide (2300‐IG). After the connections have been completed and verified, you must set up the
Analyzer to work on this network. This setup consists of several sets of front panel display entries.
PIR3502
3.13.1 Initial setup

These steps set up the analyzer to work with VistaNET. The paragraphs that follow explain specific additional information
required for full VistaNET operation.

3. On the Calculation/Control PCB, put switch position 3 of DIP switch SW2 in the ON position to enable the VistaNET feature.
Before changing VistaNET information, verify all data with your Network Administrator to ensure proper
VistaNET connection and operation.
6. Use the MODE SELECTION key to move to SET‐UP TABLES.

7. Press MODIFY (F2), ANALYZER (F2), MORE (F3), COMM BOARDS (F3), and VISTANET (F2).
8. On the VistaNET screen press ESSENTIALS (F1).
9. On the Essentials screen (see Figure 3.23), enter the analyzer name, PV‐tag, and domain addresses.
Fig. 3.23. VistaNET Essentials Screen
10. After you have entered and verified the Essentials information, press ACCEPT (F1).
11. On the VistaNET screen, press PARAMETERS (F2).
12. On the Parameters screen (see Figure 3.24), enter the VNSA address, Vista Router address, timeout period, and report
cycle time.
Fig. 3.24. VistaNET Parameters Screen
PIR3502
13. After you have entered and verified the Parameters information, press ACCEPT (F1).
3.13.2 Setting access levels

Next you must enter the appropriate access level. There are three levels of remote access (that is, via VistaNET) granted by the
analyzer.
1. Net Locked: no remote modification of the analyzer's tables is permitted. It requires a SUPERVISOR VNSA access level to
modify any of the analyzer's tables from the front panel (see VistaNET 2.0 Installation Guide 2300‐IG for more
information).
2. Restricted: remote modification of tables is limited to users that have SUPERVISOR or NORMAL access level.
3. Unrestricted: remote modifications can be performed by any user.
You set the remote access level for an analyzer from the front panel as follows:
1. On the VistaNET screen, press MORE (F3).

2. On the More screen, press SECURITY (F1).
3. On the Security screen (see Figure 3.25), you may enter or change the access level.
Fig. 3.25. VistaNET Security Screen
4. After you have entered and verified your changes, press ACCEPT (F1). If you do not want to make any changes to this
screen, press ABORT (F4).
3.13.3 Clock setup

This screen enables you to set the date, time, whether daylight saving time is acknowledged, timezone in hours from GMT, and
day of the week.

2. On the More screen, press CLOCK SETUP (F2).
3. On the Clock Setup screen (see Figure 3.26), you may enter or change the time settings.
Fig. 3.26. VistaNET Clock Setup Screen
PIR3502
3.13.4 Server list

Since you want the analyzer to automatically send analysis results and analyzer events to the VistaREPORTER and
VistaSTORAGE, you must enter their addresses and associated time‐outs in the Server List. The time‐out determines how long
the analytical device will wait for an appropriate response from the server before trying an alternate domain or different server
altogether.
Unlike the Essential Addresses and Access Level, the Server List can be edited remotely. This installation procedure will only
cover editing the Subscriber List from the device’s front panel.
To edit the Server List:

2. On the More screen, press SERVER LIST (F3).
3. On the Server List screen (see Figure 3.27), you may enter or change the type of server, the timeout period, and the
primary and secondary addresses of the analyzer.
Fig. 3.27. VistaNET Server List Screen
PIR3502
PIR3502 Operating Instructions 4 Operation
4 Operation
4.1 Controls and indicators
The screen display, function keys and mode selection panel are located on the Detector Enclosure front panel. The gauges that
display enclosure purge and optical purge pressures are on the Source Enclosure front panel. Valves that control sample and
calibration/benchmark flow are located on the sample handling system, which is usually part of the sales order package
supplied by ABB (a typical sample system is described in Section 2).
4.1.1 Detector enclosure

Normal operation of the analyzer is controlled from the Detector Enclosure front panel (see Figure 4.1), which has the screen
display, function keys and mode selection panel.
SCREEN DISPLAY
KEYPAD
MODE SELECTION
PANEL
Fig.4.1. Detector Enclosure Controls and Indicators
Interior front panel PCB DIP switch settings that deny access to critical operations are described in Section 4. With denials in
place, I/O and set‐up table entries can still be reviewed even though they cannot be modified.
The liquid crystal screen display is a high contrast screen with four lines, 40 characters per line. A cursor underlines the item of
interest (see Figure 4.2).
Fig. 4.2. Front Panel Screen Display
PIR3502
The ranges of the front panel display parameters are application specific and all adjustments should be referenced to the
information in the Data Package included with your analyzer. Figure 4.3 shows typical ranges for these parameters, to provide
an example of the data available.
Fig. 4.3. Front Panel Display Parameter Ranges
These parameter ranges are for reference only. All parameters are application‐dependent. When making
adjustments use the information included in the Data Package shipped with each analyzer.
The keypad contains the function keys and the dedicated keys (see Figure 4.4).
Fig. 4.4. Function And Dedicated Keys
Function keys F1, F2, F3, and F4 on the top row are soft keys whose functions are defined by the labels shown at the bottom of
the current display screen. These function keys allow you to move through the menu tree to initiate analyzer actions and edit
analyzer Set‐up Tables.
The four dedicated keys under the function keys execute the following commands (from left to right):
Next Component displays information on components when there is more

than one component being measured in the analysis
PIR3502
Up Arrow varies according to the selected function: increases the input

number by one, cycles through fixed selections, toggles between
selections (e.g., On or Off), or increases the contrast of the
display screen (except those screens that allow editing of set‐up
parameters or manual operation of outputs)
Down Arrow varies according to the selected function: decreases the input
number by one, cycles through fixed selections, toggles between
selections (e.g., On or Off), or decreases the contrast of the
display screen (except those screens that allow editing of set‐up
parameters or manual operation of outputs)
Help provides additional online information for set‐up screens that are
not self‐ explanatory, and displays alarm‐specific information
The Mode Selection Panel provides the means for you to perform all the normal operator functions for the analyzer. This panel
controls these functions from six operating mode displays and the Mode Selection key (see Figure 4.5). The Mode Selection key
is used to cycle through each of the six basic operating modes of the analyzer. The light emitting diodes (LEDs), adjacent to
each mode name, indicate which operating mode is activated.
Fig. 4.5. Mode Selection Panel
PIR3502
Figure 4.6 shows the menu tree for the Mode Selection Panel.
ZERO (F1)
NEXT ALARM (F1)
SPAN (F2)
DISPLAY CLEAR ALARMS (F2) AUTO
CONCENTRATION BENCHMK (F1) BOTH (F3)
ALARMS (F1) CLEAR ALL (F3)
EXIT (F4)
DISPLAY EXIT (F4)
TEMPERATURE ZERO (F1)
NEXT ALARM (F1)
SPAN (F2)
CLEAR ALARMS (F2)
MANUAL
DISPLAY WARNINGS (F2) BENCHMK (F2)
CLEAR ALL (F3)
WARNINGS
EXIT (F4)
EXIT (F4) EXIT (F4)
ZERO (F1)
CALIBRATE/ SPAN (F2)
BENCHMARK AUTO
CALIB (F3) BOTH (F3)
EXIT (F4)
ZERO (F1)
SPAN (F2)
MANUAL
ACCEPT (F3)
CALIB (F4)
EXIT (F4)
NEXT REPORT (F1) (NON-FUNCTIONAL)
SELF
TEST (F1)
EXIT (F4)
NEXT FILTER (F1)

FILTERS (F1)
EXIT (F4)
ABSORBANCE (F1) MATRIX (F2)
EXIT (F4)
SUPPLIES (F2)
ADC LEVELS (F1)
VIEW
EXECUTE SYSTEM SIGNALS (F3) DETECTOR NEXT FILTER (F1)
SELF TEST MONITORS (F2)
VOLTAGES (F2)
EXIT (F4)
EXIT (F4) EXIT (F4)
DIGITAL NEXT 3 (F1)

INPUTS (F1) <--- (F2)
ONLINE (F1) EXIT (F4)
---> (F3)
VALVE
OFFLINE (F2) DRIVERS (F1)
EXIT (F4)
MANUAL I/O DIGITAL

OPERATION (F3) CONTINUE (F3) NEXT 3 (F1)
OUTPUTS (F2)
LOGIC
OUTPUTS (F2) <--- (F2)
EXIT (F4)
EXIT (F4)
---> (F3)
NEXT 4 (F1)
EXIT (F4)
ANALOG EXIT (F4)
<--- (F2)
OUTPUTS (F3)
---> (F3)
SET-UP SEE SUBSECTIONS EXIT (F4)
TABLES 3.9 THROUGH 3.11 EXIT (F4)
Fig. 4.6. Mode Selection Menu Tree
Each of these functions is described later in this section of the manual.
PIR3502
4.1.2 Source enclosure

The Source Enclosure front panel features the gauges that display enclosure purge and optical purge pressures (see Figure 4.7).
Fig. 4.7. Source Enclosure Indicators
4.2 Analyzer turn‐on

Before starting the analyzer, verify that all installation checks have been completed and compared to the Data Package.
For Y and Z purged analyzers, note the purge label on the front of the analyzer and allow sufficient air purge time before
turning the power source ON at the circuit breaker.
Verify that the X Purge is not in override.
For X Purged and ATEX certified analyzers, you can turn the power ON at the circuit breaker immediately after the air supply is
turned ON. X Purge automatically controls the purge time and applies power to the analyzer only after the purge cycle is
complete. See the analyzer’s Data Package for specific purge cycle time.
After the analyzer is turned ON you should allow at least 30 minutes for the analyzer to heat to operating temperature. During
this time, clear alarms and warnings as they display. When the sample cell and casting reach their specified temperatures,
those alarms discontinue automatically.
Verify the 4 to 20 mA output connections and devices. If the analyzer has not been calibrated, perform the manual calibration
procedure described in "Manual Calibration Procedure" in Section 3. Once you have verified the calibration data you are ready
to place the analyzer into full analytical operation.
4.3 Routine operations

Routine operations are those on‐line operations that can be changed at the front panel. They include the display of component
concentrations, display of sample cell temperature and pressure, display of the filter housing temperature, display of warnings
and alarms, display of benchmark and calibration, display of system monitors, display of digital input levels, display of digital
and analog outputs, and review of analyzer set‐up tables.
These operations are performed using the analyzer’s menu system, which is based on the six basic modes of operation.
Function keys allow you to move through the menu tree one level at a time. At menu levels other than the operating mode top
level, the F4 (EXIT) function key moves you up one level. You may use the Mode Selection key at any point in the menu tree to
jump to the next operating mode.
PIR3502
4.4 Display concentration modE

From power on, the analyzer enters the DISPLAY CONCENTRATION mode (see Figure 4.8). There are no active function keys in
this mode, but pressing the HELP key displays the software version of the analyzer.
Fig. 4.8. Typical Display Concentration Screen
The first line shows the name and concentration of the first enabled component. (The NEXT COMP key cycles through all
enabled components.) The second line contains measurement range information for the displayed component. The third line
contains the analyzer’s status, which is displayed as one of the following:
OFFLINE indicates that the analyzer has been taken offline in the
manual operation menu of the EXECUTE SELF TEST
mode
CALIB/BENCHMK indicates a calibration or benchmark is underway, either

initiated from the front panel, from a periodic automatic
calibration, or from a remote start automatic calibration
signal
ALARM or WARNING indicates that an alarm or warning condition exists
NORMAL indicates all system parameters and concentrations are

at nominal levels
Analyzer status is displayed throughout the operating modes. If several conditions exist at the same time, the most critical
condition is displayed. OFFLINE is the most critical, then CALIB/BENCHMK, then ALARM or WARNING, and NORMAL. For
Example, if the status ALARM is displayed and an automatic calibration begins, the status line displays CALIB until automatic
calibration is completed, then ALARM is displayed again.
4.5 Display temperature mode

In DISPLAY TEMPERATURE mode (see Figure 4.9), the filter housing and sample cell temperatures display in degrees Celsius.
Analyzer status, as in DISPLAY CONCENTRATION mode, is displayed to the right of the temperatures. There is no soft key
function in this mode.
Fig. 4.9. Typical Display Temperature Screen
With the pressure compensation option, the sample cell pressure displays in psia.
PIR3502
4.6 Display alarms mode

When you select DISPLAY ALARMS, the DISPLAY ALARMS & WARNINGS screen appears (see Figure 3‐10). This screen shows the
analyzer status and allows selection of displaying the ALARMS (F1) or WARNINGS (F2).
Fig. 4.10. Display Alarms & Warnings Screen
From this screen you can select ALARMS (F1) or WARNINGS (F2). When you select F1 or F2, the first alarm or warning screen
will appear (see Figure 4.11).
Fig. 4.11. Typical Alarm Mode Screen
On this screen the NEXT ALARM or NEXT WARNING key (F1) displays the next alarm or warning text. The CLEAR ALARM or
CLEAR WARNING key (F2) clears the currently displayed alarm or warning. The CLEAR ALL key (F3) clears all alarms or warnings.
If the alarm condition no longer exists, the alarm or warning display reports “NO ALARMS/WARNINGS PENDING”.
Initialization alarms are displayed on either power up or reset. If an initialization alarm is cleared and the alarm condition still
exists, the alarm is displayed again only at power up or reset. Initialization alarms are alarm numbers 216‐221 and 227‐229.
The HELP key displays alarm specific information that gives the ALARM NUMBER (see Section 5 for alarm number definitions),
and if needed, possible causes. The troubleshooting section of this manual lists alarms and warnings by the ALARM NUMBER
and gives possible causes. The help screen is displayed until the EXIT soft key (F4) is selected, which returns you to the original
alarm screen.
4.7 Calibrate/benchmark mode

When you select CALIBRATE/BENCHMARK, the CALIBRATE/BENCHMARK ANALYZER screen appears (see Figure 4.12). This
screen shows analyzer status and, if enabled, the time to the next periodic automatic calibration. The periodic automatic
calibration may be enabled or disabled under AUTOCAL ACTIONS in the ANALYZER CONFIGURATION section.
Fig. 4.12. Calibrate/Benchmark Analyzer Screen
The soft keys are AUTO BENCHMARK (F1), MANUAL BENCHMARK (F2), AUTO CALIBRATION (F3), or MANUAL CALIBRATION (F4).
PIR3502
The analyzer can be configured to track and hold (freeze) analog outputs during calibration or benchmark. With this
configuration, after exiting the calibration or benchmark screen, the normal sample gas is turned on and a purge time is
observed. The analog outputs remain frozen and the STATUS continues to display calibration or benchmark until the purge
time is completed.
Selecting OFFLINE in the EXECUTE SELF TESTS mode under manual operation aborts any automatic
calibration or benchmark in progress and inhibits starting a new automatic calibration or benchmark.
Selecting a manual calibration or benchmark aborts any automatic calibration in progress and inhibits any
new automatic calibration or benchmark. Selecting an automatic calibration or benchmark aborts any
periodic or remote start automatic calibration and inhibits any new periodic or remote start automatic
calibration.
Access to the calibration /benchmark mode can be restricted (see "Front Panel Control Board" in Section
5). With this restriction in place, pressing any of the Calibrate/Benchmark Mode soft keys displays a
message, CALIBRATE/ BENCHMARK RESTRICTED, and the analysis will not be interrupted.
4.7.1 Automatic benchmark

The AUTOMATIC BENCHMARK screen (see Figure 4.13) displays the analyzer status and allows you to perform zero benchmark
(F1), span benchmark (F2), or both zero and span benchmarks (F3). Displaying the analyzer status allows you to see the results
of the benchmark. If the status returns to normal, the benchmark was within the alarm or warning limits for all components.
An alarm or warning is displayed if the benchmark was not within limits. View the ALARM mode for the description of the
alarm or warning and possible causes.
Fig. 4.13. Automatic Benchmark Screen
4.7.2 Manual benchmark

When you select the MANUAL BENCHMARK screen (see Figure 4.14), the display shows the first enabled component and its
concentration. The function keys allow you to select a ZERO benchmark (F1), which must be done first, or a SPAN benchmark
(F2).
Fig. 4.14. Manual Benchmark Screen
The top line of the zero or span display shows which benchmark was selected, the second line identifies the component, and
the third line shows the alarm low and high limits for this component. When ZERO (F1) or SPAN (F2) is pressed, the appropriate
PIR3502
benchmark gas is turned on and the concentration approaches the zero or span level. You can then compare the final reading
with the displayed limits as a check on the analyzer calibration. The NEXT COMPONENT key displays the next enabled
component, leaves the gas on, and displays the limits for the new component. The EXIT or MODE SELECTION key shuts the
benchmark gas off.
4.7.3 Automatic calibration

Automatic calibration of the analyzer operates the same as automatic benchmark, except that with automatic calibration, if no
alarm limits are violated, the zero absorbance and response factors of all components are adjusted according to the zero and
span calibration gas. An automatic zero or span calibration, whether initiated from the front panel or by periodic auto‐
calibration actions, is enabled or disabled for individual components using Component Configuration (see "Component
Configuration" in Section 3).
4.7.4 Manual calibration

Manual calibration operates the same as manual benchmark, except with manual calibration, if the final reading is acceptable
when compared to the displayed limits, you may choose to recalibrate the currently displayed component by pressing the
ACCEPT key. The EXIT or MODE SELECTION key aborts the calibration and shuts off calibration gas.
4.8 Execute self tests

When you select EXECUTE SELF TESTS, the EXECUTE SELF TESTS screen appears (see Figure 4.15). On this screen the function
keys allow you to select SELF TEST (F1), VIEW SYSTEM MONITORS (F2), or MANUAL I/O OPERATION (F3).
Fig. 4.15. Execute Self Tests Screen
4.8.1 Self test

When you press the SELF TEST (F1) soft key, the SELF TEST screen appears, displaying the following soft keys: NEXT REPORT (F1)
and EXIT (F4). Nothing is displayed because the REPORTS function has not been implemented.
4.8.2 View system monitors

When you press the VIEW SYSTEM MONITORS (F2) soft key, the VIEW SYSTEM MONITORS screen appears (see Figure 4.16).
Fig. 4.16. View System Monitors Screen
This screen allows you to choose to view ABSORBANCE (F1), power SUPPLIES (F2), or low level analyzer SIGNALS (F3).
Absorbance
Selecting ABSORBANCE (F1) displays a screen that offers the choice of absorbance after the filters or absorbance after the
calculation matrix has been applied. Selecting FILTERS (F1) from the View
PIR3502
System Monitors screen displays a screen with the absorbance (in absorbance units) of the first filter position (see Figure 4.17).
Selecting NEXT FILTER (F1) cycles through the remaining filters.
Fig. 4.17. Absorption After Filters Screen
Selecting MATRIX (F2) from the View System Monitors screen displays a screen with the absorbance from the matrix calculation
for the row of the matrix assigned to the component displayed. Selecting the NEXT COMP key cycles through the absorbances
for the other components being analyzed.
Supplies
Selecting SUPPLIES (F2) displays the values of the analyzer’s +5, +15, and ‐15 VDC voltage power supplies.
Signals
Selecting SIGNALS (F3) displays a menu that allows you to choose to view the analog‐to‐digital (ADC) input voltage levels or the
detector voltage levels. Selecting ADC LEVELS (F1) displays the voltage levels at the two ADC input channels. Selecting
DETECTOR VOLTAGES (F2) displays the average (VDC) and peak‐to‐peak (VOLTS) voltages for the first filter. The NEXT FILTER
key cycles through the filters.
4.8.3 Manual i/o operation

Selecting MANUAL I/O OPERATION displays a screen with the mode field containing ONLINE, which means the analyzer is in its
normal operating mode (see Figure 4.18).
Fig. 4.18. Manual I/O Operation Screen
Online/Continue
Selecting CONTINUE (F3) while ONLINE allows you to view all analyzer input and output levels while normal analysis is
underway.
Offline
The analyzer can be configured to restrict access to OFFLINE operation. With this restriction in place, if
the OFFLINE key is pressed, the message, OFFLINE OPERATIONS RESTRICTED, is displayed and the analyzer
remains ONLINE.
OFFLINE manual operations are considered a maintenance function, not normally performed as normal operation. Selecting
OFFLINE (F2) when the analyzer is ONLINE “freezes” all outputs and sensor levels, effectively disabling normal analysis until
ONLINE (F1) is selected, which then restores the original state of the analyzer.
PIR3502
Offline/Continue
Selecting OFFLINE (F2) followed by CONTINUE (F3) allows you to view DIGITAL INPUTS (F1), exercise DIGITAL OUTPUTS (F2), or
exercise ANALOG OUTPUTS (F3).
Selecting DIGITAL INPUTS (F1) displays the 24 digital inputs located at the analyzer’s local front panel as three bytes. Input #1 is
the leftmost and input #24 is the rightmost. A “1” at a location indicates a digital input sees a high logic level while a “0”
indicates a low logic level. Selecting NEXT THREE (F1) on the Digital Inputs screen displays the next three bytes, which are
inputs #25 through #48 located at the analyzer’s remote front panel. Selecting NEXT THREE again displays the three
reserved bytes numbered #49 through #72. Refer to Figure 4.19 for the origin of each digital input.
DIGITAL INPUT NUMBER DIGITAL I/O CARD NUMBER
1–8 1
9 – 16 1 (AUX)
17 – 24 2 (AUX)
25 – 72 RESERVED
Fig. 4.19. Digital Input Numbers/Cards
Selecting DIGITAL OUTPUTS (F3) allows you to select manual operation of valve driver outputs or logic level outputs.
Manual Operation of Valve Driver Outputs: The VALVE DRIVERS key (F1) displays 24 valve driver outputs as three bytes.
Valve driver #1 is leftmost and #24 is rightmost. A “1” at a location indicates the valve driver is supplying the
actuating voltage to the valve solenoid while a “0” indicates the solenoid is not actuated. There are four valve drivers
on each Digital I/O PCB in the Detector Enclosure. Driver’s #1 through #4 are on card #1 and driver’s #5 through #8
are on card #2. Driver’s #9 through #24 are reserved. Initially the cursor is on driver #1. Pressing the UP ARROW or
DOWN ARROW keys toggles the driver to either 0 or 1 at the cursor location. Pressing the LEFT ARROW (F2) or RIGHT
ARROW (F3) soft keys moves the cursor to adjacent drivers.
Manual Operation of Logic Outputs: The LOGIC OUTPUTS key (F2) displays 24 logic level outputs as three bytes. Logic
output #1 is leftmost and #24 is rightmost. A “1” at a location indicates the output transistor is on (closed) while a “0”
indicates the transistor is off (open). The actual high or low level voltages at the output depend on the jumper
configuration of the associated Digital I/O PCB and user supplied power. Pressing the UP ARROW or DOWN ARROW
keys toggles the output to either 0 or 1 at the cursor position. Pressing the LEFT ARROW (F2) or RIGHT ARROW (F3)
soft keys moves the cursor to adjacent outputs. Pressing the NEXT FOUR soft key (F1) displays outputs #25 through
#48. Pressing the
NEXT FOUR soft key again displays outputs #49 through #72, then again displays outputs #73 through #96. Refer to
Figure 4.20 for the output origin of each logic output.
LOGIC OUTPUT NUMBER DIGITAL I/O CARD NUMBER
1–7 1
8 – 14 2
15 – 22 1 (AUX)
23 – 20 2 (AUX)
31 – 96 RESERVED
Fig. 4.20. Logic Output/Digital I/O Numbers
Logic outputs #1 through #14 and valve drivers #1 through #8 are accessed at the TERMINAL STRIP I\O
PANEL. Other non‐reserved outputs are accessed at the respective DIGITAL I\O CARD auxiliary connector.
PIR3502
Selecting ANALOG OUTPUTS displays four analog outputs at a time in milliamps. Outputs #1‐4 originate at the local front panel,
outputs #5‐8 at the remote front panel, and outputs #9‐12 are reserved for future applications. The LEFT ARROW (F2) and
RIGHT ARROW (F3) keys move the cursor to the outputs to be operated, the NEXT FOUR soft key (F1) displays the next
screen of four outputs. The UP ARROW and DOWN ARROW keys increase and decrease the level of the output at the
cursor in 0.1 milliamp steps from 00.0 to 20.0 milliamps.
4.9 Overview of set‐up tables

Selecting SET‐UP TABLES allows you to view or configure the analyzer through the front panel. Operations include defining and
naming components; enabling and disabling components, alarms, and analysis parameters; entering calibration, analysis, and
linearization parameters; configuring automatic valve controls; mapping I/O to concentrations, alarms, and external controls;
scaling trend outputs; and defining the optics system.
The menu tree in SET‐UP TABLES branches out from general to specific topics, eventually ending at a screen that allows viewing
or editing of the parameters. The soft key selections move the operator down the tree one level at a time and the EXIT (F4) soft
key always backs up one level to the previously displayed screen. The top level SET‐UP TABLES screen (see Figure 4.21) offers
the choice to VIEW SET‐UP (F1) or MODIFY SET‐UP (F2).
Fig. 4.21. Set‐Up Tables Screen
VIEW SET‐UP (F1) allows you to view the analyzer configurations, but you cannot make changes to these configurations.
MODIFY SET‐UP (F2) allows you to view and edit these configurations.
Selecting MODIFY SET‐UP allows you to choose COMPONENT (F1), ANALYZER (F2), and FACTORY (F3) configurations (see Figure
4.22).
Component and Analyzer configurations are operator‐level functions. Factory configurations are normally done only at the
factory. "COMPONENT CONFIGURATION" describes the COMPONENT configuration functions and "ANALYZER
CONFIGURATON" describes the ANALYZER configuration functions. The remaining paragraphs in this subsection present
general information about SET‐UP TABLES.
Fig. 4.22. Modify Set‐Up Screen
4.9.1 Access levels

DIP switch configurations (described in "Front Panel Control Board" in Section 4) offer two levels of security in SET‐UP TABLES
mode. The first denies access to any of the MODIFY SET‐UP menus. The second denies access to any of the FACTORY set‐up
menus. The parameters for edit under FACTORY SET‐UP should not have to be modified after the analyzer leaves the factory.
PIR3502
4.9.2 Editing
At the lowest screen of each branch of MODIFY SET‐UP TABLES, the cursor underlines the item of interest and the soft keys
offer the following editing functions: ACCEPT, LEFT ARROW, RIGHT ARROW, and ABORT. In addition, the Up and Down arrow
keys allow you to change the item at the cursor.
4.9.3 Accept soft key

When the items are edited to the desired settings, press the ACCEPT key to store the values displayed. A successful accept
updates the nonvolatile memory that stores the Set‐up Tables and the ABORT soft key changes to EXIT. If you make additional
edits, the EXIT label reverts to ABORT. An unsuccessful accept leaves the ABORT label in place and momentarily displays the
message: EEPROM NOT UPDATED. (The analyzer uses the entered parameters of an unsuccessful update, but on analyzer reset
or power up the values in non‐volatile memory are restored.) DIP switch rocker #8 on the Calculation/Control Board must be
set ON to enable any changes to the Set‐up Tables nonvolatile memory. Values entered beyond the range of the analyzer are
limited to the minimum or maximum value allowed. The limited value replaces the entered value. Also the Set‐up Tables
nonvolatile memory is updated with the limited value. Figure 4.3 (Front Panel Display Parameter Ranges) shows the minimum
and maximum ranges that may be possible; actual ranges are application‐specific. A special case of a value beyond the range of
the analyzer occurs if the T‐RATING of the analyzer is violated when setting sample cell temperature or filter wheel assembly
temperature. In this case, the value is not used by the analyzer in any way and the message: T‐RATING VIOLATION is displayed.
Hardware jumpers are set at the factory for the T‐Rating of the analyzer.
4.9.4 Left and right arrow soft keys

The left and right arrow soft keys move the cursor between the individual characters of an item, or between the items that can
be edited. The cursor wraps around from the first character of an item to the first character of the previous item when using
the left arrow key. The cursor wraps around from the last character of one item to the first character of the next item when
using the right arrow key.
4.9.5 Abort soft key
The ABORT key terminates the edit with no changes to the Set‐up Tables and returns to the previous screen displayed.
4.9.6 Up and down arrow keys

The UP ARROW and DOWN ARROW keys increase and decrease the item at the cursor. Items either have individual characters
in the field edited or have the entire field wholly edited. In the case of individual characters, the character set order is:
{BLANK}!"#$%&’()*+,‐./
0123456789:;<=>?@ABCDEFGHIJKLMNOPQRSTUVWXYZ
In the case of individual digits, the characters are the digits 0 to 9. In the case of items wholly increased/decreased, the
possible selections are cycled through with the UP ARROW and DOWN ARROW keys.
4.10 Component configuration

The analyzer must be in MODIFY SET‐UP TABLES to edit component configurations. Hereafter, “alarms” refers to alarms or
warnings, and “gas” refers to gas or liquid.
Selecting COMPONENT (F1) from the MODIFY SET‐UP TABLES screen displays the COMPONENT CONFIGURATION screen (see
Figure 4.23).
Fig. 4.23. Component Configuration Screen
PIR3502
From this screen you can select component limits, component calibration, or identify components. Figure 4.24 illustrates the
Component menu tree.
Fig. 4.24. Component Menu Tree
LIMITS accesses concentration, benchmark, and calibration alarm settings. CALIBRATION involves entering linearity points and
zeros, and entering zero and span gas concentrations. IDENTIFY allows entries of component name, range, function, and
compensation. Also under IDENTIFY, equations are defined and component display attributes are configured.
4.10.1 Limits
Selecting LIMITS (F1) displays the COMPONENT LIMITS screen, which has the following soft keys: CONCENTRATE (F1),
BENCHMK (F2), and CALIBRATION (F3).
Selecting CONCENTRATE (F1) from the COMPONENT LIMITS screen displays the COMPONENT CONCENTRATION LIMITS screen.
From this screen high and low level alarms and warnings can be enabled or disabled. The alarm concentration can be
entered for the component displayed. The NEXT COMP key accesses the other components.
PIR3502
Selecting BENCHMK (F2) from the COMPONENT LIMITS screen displays the COMPONENT BENCHMARK LIMITS screen. From this
screen benchmark high and low alarms and warnings can be enabled or disabled, and the alarm levels entered for the
component displayed. Levels are defined with entries for the zero and span benchmark gas concentration and a tolerance.
The NEXT COMP key accesses the other components. This allows the use of separate benchmark and calibration gases.
Selecting CALIBRATION (F3) from the COMPONENT LIMITS screen displays the COMPONENT CALIBRATION LIMITS screen. From
this screen calibration high and low alarms and warnings can be enabled or disabled, and the alarm levels entered for the
component displayed. Levels are defined with entries for the zero and span calibration gas concentration and a tolerance.
The NEXT COMP key accesses the other components. This allows the use of separate benchmark and calibration gases.
4.10.2 Calibration
Selecting CALIBRATION (F2) displays the COMPONENT CALIBRATION screen, which has the following soft keys: LINEARITY (F1),
ZERO (F2), and SPAN (F3).
Selecting LINEARITY (F1) allows you to choose linearity points or zero absorbance as the linearity base.
Selecting POINTS (F1) allows you to enter linearity points as pairs in absorbance units and ascending order beginning at
pair #1. Up to eight pairs may be entered for each component. Unused higher pairs must have zeros entered.
Selecting ZEROS (F2) allows you to enter zero absorbance entry (ABS) is the matrix absorbance for low scale (zero)
calibration gas concentration. The concentration entry (CONC) is the low scale calibration gas concentration.
Selecting ZERO (F2) from the COMPONENT CALIBRATION screen enables or disables the automatic zero calibration of individual
components. This selection has no effect on the actions of the manual zero calibration. The zero concentration entry is
the low scale (zero) calibration gas concentration for the current component. For subsequent zero calibrations, adjust this
entry to match the zero calibration gas used. The zero absorbance factor (offset) is automatically updated on subsequent
calibrations. Changing this offset affects the analyzer calibration. The NEXT COMP key accesses the other components.
Selecting SPAN (F3) from the COMPONENT CALIBRATION screen enables or disables the automatic span calibration of individual
components. This selection has no effect on the actions of the manual span calibration. The span concentration entry is
the high scale (span) calibration gas concentration for the current component. For subsequent span calibrations, adjust
this entry to match the span calibration gas used. The response factor (slope) is automatically updated on subsequent
calibrations. Changing this factor affects the analyzer calibration. The NEXT COMP key accesses the other components.
4.10.3 Identify
Selecting IDENTIFY (F3) displays the IDENTIFY COMPONENTs screen, which has the following soft keys: NAME/RANGE (F1),
COMPONENT ATTRIBUTES (F2), and DISPLAY ATTRIBUTES (F3).
Selecting NAME/RANGE:\ (F1) allows you to enter component names and range values. The component name and range
entries are purely text entries. The name can be up to 24 characters and the range up to 33 characters. The name is
intended for component identification. The range entry is intended to display the calibrated range of the analyzer as a
data validation reference in display concentration mode. The range is not used for calculations. The NEXT COMP key
accesses the other components.
Selecting COMPONENT ATTRIBUTES (F2) allows you to select a function or a method of compensation, or define an equation.
Select Function: The state entry enables or disables the components. Up to eight components may be enabled. The type
entry can be either matrix or equation. Matrix types have concentrations measured from sample absorbance.
Equation types are calculated from other components, and constants are entered on the DEFINE EQUATION screen.
The NEXT COMP key accesses the other components.
Select Compensation: Compensations for individual components are enabled or disabled on this screen. Temperature and
pressure compensation are only applicable to gas components calculated as matrix type components. Temperature
compensation corrects the concentration measurement for temperature changes according to the Ideal Gas law. This
option is available for gas samples only. Pressure compensation corrects the concentration measurement for sample
cell pressure variations from the pressure observed during calibration. Pressure compensation requires a pressure
sensor to be installed and requires the sensor to be enabled at the keypath:
FACTORY/ANALYZER/OPTIONS/PRESSURE. Linearity compensation uses the eight point linearity tables that must be
filled in for each component before compensation is enabled. The NEXT COMP key accesses the other components.
PIR3502
Define Equation: Equation type components are defined by two operands and a math operator. The name of the
component being defined is displayed in the top line of the display. The display of the component being defined as
either of the operands is suppressed. Operand #1 is always a component, either a matrix or equation type. The
operator is either addition, subtraction, multiplication, or division. Operand #2 can be a component or a numeric
constant. Division by zero is trapped by changing operand #2 to +1.000000000 when the accept key is pressed. Refer
to the section on COMPONENT DISPLAY ATTRIBUTES for details on the display of equation type components.
The edit of operand #2 is a special case of the editor. The UP ARROW and DOWN ARROW keys cycle operand #2
through all components and the numeric constant. When operand #2 is a component, the LEFT ARROW (F2) and
RIGHT ARROW (F3) keys move to another item. When operand #2 is a constant, the LEFT ARROW (F2) and RIGHT
ARROW (F3) keys move the cursor through the digits, allowing you to edit the constant. To cycle operand #2 back to
components, you must put the cursor on the first (blank) position of constant operand #2.
Selecting DISPLAY ATTRIBUTES (F3) enables or disables the display of individual component concentrations in DISPLAY
CONCENTRATION mode. Note that this does not enable or disable the calculation of the component’s concentration. For
example, suppose the desired display is of component #3, which is the ratio of components #1 and #2. While all three
components are enabled, the display of #1 and #2 can be suppressed and only component #3 displayed in display
concentration mode.
A component’s units can be enabled or disabled on this screen. This allows you to suppress units for component
measurements that have no units (e.g., a ratio of components).
The display of a component’s units are either percent or parts per million (ppm). The range of display for a component is
always ±200%. The resolution of percent displays is 0.0001% and the resolution of ppm displays is 0.01 ppm. Exercise care
when using the multiply and divide math functions in component equations so as not to over‐range the analyzer. Note
that even though the display of units may be disabled, units of measure are always in place (i.e., two components should
have the same units if their ratio is to be taken). The NEXT COMP key accesses the other components.
4.11 Analyzer configuration

The analyzer must be in the MODIFY SET‐UP TABLES to edit analyzer configurations. Hereafter, “alarms” refers to alarms or
warnings, and “gas” refers to gas or liquid.
Selecting ANALYZER (F2) from the MODIFY SET‐UP TABLES screen displays the ANALYZER CONFIGURATION screen (see Figure
4.25).
Fig. 4.25. Analyzer Configuration Screen
PIR3502
From this screen you can configure autocalibration functions, set alarm limits, set cell temperature setpoint, configure analog
outputs, and set VistaNET specific parameters. Figure 4.26 illustrates the Analyzer menu tree.
ANALYZER (F2)
TIMES (F1) SET PURGE TIME, TIME BETWEEN AUTOCALS & TIME FOR NEXT AUTOCAL
AUTOCAL (F1) ACTIONS (F2) SELECT AUTOZERO/AUTOSPAN ACTIONS, ENABLE/DISABLE REMOTE OPERATION & PERIODIC CAL
EXIT (F4) HIGH LEVEL (F1) ENABLE/DISABLE
ALARMS
EXIT (F4)
HIGH LEVEL (F1) ENABLE/DISABLE WARNINGS

DC VOLTS (F1) WARNINGS (F2) LOW LEVEL (F2) AND SET LEVELS
EXIT (F4)
EXIT (F4) HIGH LEVEL (F1) ENABLE/DISABLE
ALARMS
DETECTOR
SIGNAL (F1) EXIT (F4)

AC VOLTS (F2) WARNINGS (F2) LOW LEVEL (F2) AND SET LEVELS
EXIT (F4)
EXIT (F4) EXIT (F4)
HIGH LEVEL (F1) SELECT INPUT, ENABLE/DISABLE

LOW LEVEL (F2) ALARMS AND SET LEVELS
ALARMS (F1)
EXIT (F4)
HIGH LEVEL (F1) SELECT INPUT, ENABLE/DISABLE

ALARMS (F2) ADC WARNINGS AND SET LEVELS
WARNINGS (F2) LOW LEVEL (F2)
INPUTS (F2)
EXIT (F4)
EXIT (F4)
LOW LEVEL (F2) AND SET LEVELS
ALARMS (F1)
EXIT (F4)

TEMPERATUR
E LOW LEVEL (F2) AND SET LEVELS
WARNINGS (F2)
(F1)
EXIT (F4)
EXIT (F4) HIGH LEVEL (F1) ENABLE/DISABLE ALARMS
LOW LEVEL (F2) AND SET LEVELS
ALARMS (F1)
CELL
SENSOR (F3) EXIT (F4)

PRESSURE (F2) WARNINGS (F2) LOW LEVEL (F2) AND SET LEVELS
EXIT (F4)
EXIT (F4)
EXIT (F4) EXIT (F4)
CELL TEMP
SETPOINT (F1) TRACK/HOLD (F1) SET ANALOG OUTPUTS 1-12
4 ANALOG OUTPUTS,
ANALOG ASSIGNMENT (F1)
MORE (F3) APPLICATION DEPENDENT
OUTPUTS (F2)
ASSIGNMENT/ SET ZERO/FULL SCALE
SCALING (F2) SCALING (F2)
RANGES (4-20 MA OUTPUTS)
EXIT (F4)
EXIT (F4) EXIT (F4)
VWS HIGHWAYS (F1) SET ADDRESS AND CYCLE TIME

ESSENTIALS (F1) NAME, PV-TAG, DOMAIN ADDRESSES
COMM PARAMETERS (F2) VNSA, ROUTER, TIMEOUT, CYCLE TIME

BOARDS (F3)
VISTANET (F2) MORE (F3) SECURITY (F1) SET ACCESS LEVEL
EXIT (F4)
EXIT (F4) CLOCK SETUP (F2) SET DATE/TIME
EXIT (F4) SERVER LIST (F3)

UP TO 10
VISTANET
EXIT (F4) SERVERS
Fig. 4.26. Analyzer Menu Tree
PIR3502
AUTOCAL is where autocalibration Times, Actions, auto‐zero and auto‐span are configured. ALARMS consists of setting
detector signals, analog to digital converter, and cell sensor alarms. Under MORE, the cell temperature is entered, analog
outputs are configured, and VistaNET requirements are set.
4.11.1 Autocalibration
Selecting AUTOCAL (F1) displays the AUTOCAL screen, which has the following soft keys: TIMES (F1) and ACTIONS (F2).
Selecting TIMES (F1) enables you to set the purge time, the time between autocalibrations, and the time for the next
autocalibration.
The PURGE time entry is utilized when calibration or benchmark gas is put on or taken off. Purge time is critical to
automatic benchmark and calibration. It is defined as the time the analyzer should delay making measurements after all
valve actuations to allow a new gas to purge the sample cell thoroughly. Automatic valve control at the sample system is
also a factor in purge time. Selecting up to 8 valve operations at 0.1‐second intervals is possible. If the analyzer response
time (signal averaging time) is significant, the purge time should be extended to allow the measurement to stabilize.
The PERIOD entry is the time in hours between automatic calibration actions. The period range is 0.1 to 1600 hours. A
period of 0.0 hours will be trapped and changed to 0.1 hours. While the period is set in this screen, it is enabled or
disabled under ACTIONS.
The NEXT AUTOCAL time entry is the number of hours from the press of the accept key to the initial autocal actions. From
then on, the autocal actions occur on the autocal period entered. This feature allows autocal actions to occur at a certain
time of day.
Selecting ACTIONS (F2) allows you to select auto‐zero and auto‐span actions, enable or disable remote autocalibration, and
enable or disable periodic autocalibration..
The AUTO‐ZERO action may be a zero calibration or a zero benchmark, or it may be disabled. Likewise, the AUTO‐SPAN
action may be a span calibration or a span benchmark, or it may be disabled. These two actions are initiated by a periodic
autocalibration or a remote start autocalibration.
REMOTE autocalibration is initiated by a remote device driving a digital input to the appropriate level. This feature can be
enabled or disabled on this screen. The configuration of the controlling digital input is a Factory configuration.
The PERIODIC autocalibration may be enabled or disabled on this screen.
4.11.2 Alarms
Selecting ALARMS (F2) displays the ALARM LIMITS screen, whose soft keys allow configuration of detector signal, ADC inputs,
and cell sensors.
Selecting DETECTOR SIGNAL (F1) displays the DETECTOR SIGNAL ALARM LIMITS screen, which has the following soft keys: DC
VOLTS (F1) and AC VOLTS (F2).
Selecting DC VOLTS (F1) allows you to enable or disable high and low level alarms and warnings for the average detector
voltage due to all filters. The alarm level can be set between 0.0 and 10.0 Vdc.
Selecting AC VOLTS (F2) allows you to enable or disable high and low level alarms and warnings for the peak excursion of
the detector voltage due to filter #1. The alarm level can be set between 0.0 and 10.0 volts.
Selecting ADC INPUTS (F2) displays the ADC INPUT ALARM LIMITS screen, which allows you to set alarm and warning levels for
analog to digital converter inputs. There are two analog to digital converter (ADC) inputs available as alarm inputs based
on an analog voltage level. These may be enabled or disabled on this screen and the alarm and warning levels can be set
between 0.0 and 10.0 Vdc.
Selecting CELL SENSORS (F3) displays the CELL SENSOR ALARM LIMITS screen, which has the following soft keys:
TEMPERATURE (F1) and PRESSURE (F2).
PIR3502
Selecting TEMPERATURE (F1) displays the CELL TEMPERATURE SENSOR ALARM LIMITS screen, which allows you to enable
or disable high and low level alarm and warning limits on sample cell temperature level. The alarm and warning levels
are entered as degrees Celsius.
Selecting PRESSURE (F2) displays the CELL PRESSURE SENSOR ALARM LIMITS screen, which allows you to enable or disable
high and low level alarm and warning limits on sample cell pressure. The alarm and warning levels are entered as
psia.
4.11.3 More
Selecting MORE (F3) displays the ANALYZER CONFIGURATION screen, which has the following soft keys: CELL TEMP SETPOINT
(F1), ANALOG OUTPUTS (F2), and COMM BOARDS (F3).
Selecting CELL TEMP SETPOINT (F1) displays the CELL TEMPERATURE SETPOINT screen, which allows you to enter the operating
temperature of the sample cell in degrees Celsius.
Selecting ANALOG OUTPUTS (F2) displays the CONFIGURE ANALOG OUTPUTS screen, which allows you to configure analog
output to track concentrations during calibration or hold the last concentration while calibration is in progress, to assign
individual driving sources, and to scale concentration outputs.
Selecting TRACK/HOLD (F1) from the CONFIGURE ANALOG OUTPUTS screen displays the ANALOG OUTPUT screen. From
this screen analog outputs may be individually configured to continue to track concentrations during calibration or to
hold the last concentration during calibration.
Selecting ASSIGNMENT/SCALING (F2) from the CONFIGURE ANALOG OUTPUTS screen displays the ASSIGN ANALOG
OUTPUTS screen, which allows selection of: ASSIGNMENT (F1) or SCALING (F2).
Selecting ASSIGNMENT (F1) from the ASSIGN ANALOG OUTPUTS screen displays the ANALOG OUTPUT screen.
From this screen analog outputs can have their driving sources individually assigned. The drivers of analog
outputs may be component concentrations, a monitored system signal (a monitor), or nothing.
Selecting SCALING (F2) from the ASSIGN ANALOG OUTPUTS screen displays the SCALING screen. From this
screen analog outputs with a component concentration driver assigned may be scaled. The concentration
(in ppm) for the analog output zero level (either 0 or 4 mA) and 20 mA level are entered on this screen.
Analog outputs that have system monitor drivers may not have the zero scale and full scale values edited.
They remain fixed at 0‐100% of the full scale range of the monitored signal.
Selecting COMM BOARDS (F3) displays the COMMUNICATIONS BOARDS screen, which has the following soft keys: VWS
HIGHWAYS (F1) and VISTANET (F2).
Selecting VWS HIGHWAYS (F1) is not used.
Selecting VISTANET (F2) displays the VistaNET screen, which has the following soft keys: ESSENTIALS (F1), PARAMETERS
(F2) and MORE (F3).
Selecting ESSENTIALS (F1) from the VistaNET screen allows you to enter device type and domain addresses.
Selecting PARAMETERS (F2) from the VistaNET screen allows you to set VNSA and Router addresses, timeout
period, and cycle time.
Selecting MORE (F3) from the VistaNET screen displays the MORE OPTIONS screen, which has the following soft
keys: SECURITY (F1), CLOCK SETUP (F2), and SERVER LIST (F3).
Selecting SECURITY (F1) from the MORE OPTIONS screen allows you to set user access levels.
Selecting CLOCK SETUP (F2) from the MORE OPTIONS screen allows you to set the date and time.
Selecting SERVER LIST (F3) from the MORE OPTIONS screen allows you to set up to 10 VistaNET servers.
PIR3502
4.12 Stop the analyzer

The Analyzer does not have an On/Off button or switch, nor are there start and stop commands. To stop the analyzer, simply
remove power. It is not necessary to stop purge or sample flows before removing analyzer power.
To shut down the analyzer in an orderly fashion:
1. Turn off the sample flow at the Sample Inlet Valve.

2. Depending on the analyzer configuration and the reason for stopping the analysis, it may or may not be necessary to stop
the optical or enclosure purge flows; verify analyzer configuration with the analyzer identification tag on the side of the
Detector Enclosure, or with the Data Package. See Section 4 for information on the X Purge Override operation, if
applicable.
3. Purge the sample cell with zero sample, or a non‐hazardous sample if necessary; turn off the zero flow at the Zero Inlet
Valve.
4. Drain the sample cell.
5. Shut Off the power to the analyzer at the power supply circuit breaker.
6. Depending on the reason for stopping the analysis, shut off the other supplies as appropriate.
PIR3502
PIR3502 Operating Instructions 5 Technical description
5 Technical description
5.1 General description
The IR Analyzer is an optical filter photometer that performs spectroscopic analyses in the infrared and near infrared regions of
the electromagnetic spectrum. It uses a single beam with multiple wavelengths to identify the components of interest by
measuring the radiant energy absorbed by the sample stream components.
The source provides a continuous beam of electromagnetic radiation that follows an optical path (see Figure 5.1) which starts at
the source and passes through filters, lenses, the sample cell and windows, and to the detector.
Fig. 5.1. IR Analyzer Optical Diagram
The beam passes through lenses L1 and L2 and is focused through the optical filters on the filter wheel. The chopper motor
rotates the reference and measure filters through the optical path which converts the beam into reference and measure
signals.
The reference wavelength is the one in which the components have little or no absorption. The measure wavelength is the one
in which the component of interest absorbs energy.
The beam then passes through lens L3 where it is collimated before passing through the sample cell. The beam exits the
sample cell and is focused on the detector by lens L4. The detector assembly converts the beam pulses into voltage signals
which the Calculation/Control Board uses to identify the component and its concentration.
5.2 Functional description

The analyzer uses the 0.8 to 15.0 micrometer region of the electromagnetic spectrum, which includes the near infrared and the
fundamental infrared regions.
The platinum source operates in the fundamental infrared region and the tungsten source in the near infrared region. The
amount of emitted radiation is a function of wavelength (or frequency), depending on the temperature of the source and its
emissivity.
PIR3502
Figure 5.2 shows both source curves, with the electromagnetic radiation intensity plotted vs. wavelength. If a sample is
introduced into the beam of electromagnetic radiation, specific frequencies, or wavelengths of energy, are absorbed.
Fig. 5.2. Source Radiation Curves
Infrared spectroscopy measures the effect of infrared energy on molecular vibrations and rotations. When the frequency of the
infrared energy matches the frequency of the molecular vibrations, the infrared energy is absorbed.
The amount of infrared energy absorbed depends on the number of molecules present in the sample. This principle is known as
the Beer‐Lambert Law, which states that the amount of absorbed infrared energy is in proportion to the concentration of the
sample.
The standard analyzer contains a solid‐state pyroelectric detector, designed to be insensitive to external vibrations and
mechanical shock, is thermally stable, and measures a broad range of wavelengths.
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A typical liquid application is the measurement of 0 to 200 ppm water in chlorinated organic streams. In Figure 5.3, a review of
laboratory spectra of chlorinated solvent spiked with 200 ppm water shows a suitable measure wavelength for water.
A reference wavelength is selected where none of the stream components absorbs infrared energy. The use of a reference
wavelength increases analyzer stability because it compensates for background energy changes. These background energy
changes result from fogged windows or source deterioration. Figure 5.3 shows a suitable reference wavelength.
Fig. 5.3. Typical Laboratory Spectrum
After the laboratory study indicates which measure and reference filters to use, the filters are mounted on the Analyzer’s filter
wheel. In this case, the reference wavelength is 3.00 micrometers and the measure wavelength is 2.71 micrometers.
The electronic circuitry takes the logarithm of the ratio of incident energy (Iref) to transmitted energy (Imeas), linearizing the
output signal. The concentration of water (ppm) displays on the LCD.

The Detector Enclosure contains the Liquid Crystal Display (LCD), the Front Panel Control Board, the I/O Power Board, the
Backplane Board, the Power Supply Board, the Communications Board, the Calculation/Control Board, the Relay/Solenoid Drive
Board, the Trend Boards, the Detector
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Assembly, and the optional Optical Span Filter. Figure 5.4 shows the component locations in the Detector Enclosure.
Fig. 5.4. Detector Enclosure Component Locations
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Figure 5.5 is the Detector Enclosure Component Block Diagram.
KEY: ELECTRICAL/ELECTRONIC FLOWS ARE SOLID LINES.

GAS FLOWS ARE BROKEN LINES.
DETECTOR ENCLOSURE
LIQUID RELAY/
CRYSTAL SOLENOID DIGITAL
DISPLAY DRIVER OUTPUTS
(LCD) PCB
ENCLOSURE
PURGE
FROM SOURCE
ENCLOSURE
FRONT CALCULATION/
PANEL CONTROL PCB
CONTROL
PCB
ENCLOSURE
PURGE
+5 VDC
POWER TREND
+15 VDC
SUPPLY OUTPUTS
-15 VDC
PCB
18 VAC
BACKPLANE TO MOTOR
ENCLOSURE
PCB CONTROL
PURGE
PRESSURE
SWITCH TO OPTICAL
DPS-1 FILTER ASSY
HOUSING
HEATER
115 VAC
I/O
PRIMARY
POWER DETECTOR OPTIONAL BEAM
POWER IN
PCB & PREAMP OPTICAL FROM
PCB SPAN SOURCE
FILTER
POWER TO 115 VAC FROM OPTICAL PURGE OPTICAL PURGE

TRANSFORMER TRANSFORMER TO SOURCE FROM SOURCE
T1 IN SOURCE T1 IN SOURCE ENCLOSURE ENCLOSURE
ENCLOSURE ENCLOSURE
Fig. 5.5. Detector Enclosure Block Diagram
5.3.1 Liquid crystal display

The Liquid Crystal Display (LCD), located on the front of the Detector Enclosure, displays all analysis results, analyzer status,
alarms and warnings, calibration and benchmark information, self test information, and Set‐up Tables.
5.3.2 Front panel control board

The Front Panel Control Board is located on the back of the Detector Enclosure door. It interfaces with the display, the front
panel control switches, and the Backplane Board. The Front Panel Control Board also controls up to four trend outputs. These
outputs are set up for 0 to 20 mA or 4 to 20 mA analog signal ranges, which are compatible for computer integration and
remote signal monitoring.
The Front Panel Control Board has eight DIP switches. The configuration of these switches affects only the front panel on which
the change is made. The table below shows the effect of each DIP switch when set in the position shown. The default settings
are made at the factory. The default setting of DIP switch 5 is not shown because it depends on whether the front panel is local
or a remote. Always note the current switch arrangement before making any changes.
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Switch Default
Position Setting Effect Setting
1 ON Denies initiation of calibration or OFF

benchmark operations from the
front panel
2 ON Denies OFFLINE manual operation ON
3 ON Denies any modification of the setup OFF

tables
4 ON Denies any modification of Factory ON

setup tables
5 OFF Identifies the front panel as LOCAL —

ON Identifies the front panel as REMOTE —
6 OFF Reserved for future use (OFF OFF

position is recommended)


5.3.3 I/O power board

The I/O Power Board accepts 100, 115, 230, or 240 Vac primary power, sends it to Transformer T1 for conversion to 115 Vac,
accepts the 115 Vac back from T1 and sends it to the Power Supply Board. Also on this board are the terminal connections for
cell heat and the optical filter assembly heater, and two fuses; the 2 amp fuse protects the electronics and the 4 amp fuse
protects the heaters.
5.3.4 Power supply board

The Power Supply Board uses the 115 Vac to provide operating voltages of +5 Vdc, +15 Vdc, ‐15 Vdc, and +18 Vac.
5.3.5 Calculation/control board

The Calculation/Control Board manages analyzer communications, performs precise mathematical calculations, responds to
continuous polling from the Front Panel Control Board, delivers updated digital and analog data, converts analysis data for front
panel display and analog output, accepts user input from the front panel, and calculates component concentrations and
pressure and temperature compensations.
The Calculation/Control Board also has analog‐to‐digital interface circuitry that continuously manages and monitors
temperatures, power supply voltages, and pressure sensors; receives data from the Backplane Board and manages all analyzer
inputs and outputs; and continuously monitors and reports the status of all alarms.
5.3.6 Calculation/control board dip switches

The switch configuration affects only the front panel on which the change is made. The following table shows the effect of each
switch position of DIP switch SW2 when set in the position shown. The default settings are made at the factory. The default
settings for DIP switches 1, 2, and 3 are not shown because they depend on whether a local front panel, remote front panel,
and a communications board are present. Always note the current switch arrangement before making any changes.
PIR3502
Switch Default
Position Setting Effect Setting
1 ON LOCAL front panel is present —
2 ON REMOTE front panel is present —
3 ON COMMUNICATIONS board is present —
4 OFF Reserved for future use (OFF position is recommended) OFF
8 ON Write to SET‐UP TABLES EEPROM is Enabled OFF
5.3.7 Backplane board

The Backplane Board has digital input connections and also contains the terminals for the motor control, detector signal, cell
temperature probes, casting temperature probes, dc voltage outputs, analog trend outputs and pressure sensor.
5.3.8 Relay/solenoid driver board

The Relay/Solenoid Driver Board provides nine digital outputs for customer connections. Five of these outputs are relay driven
and the other four are solenoid driven.
5.3.9 Trend boards

The Trend Boards provide analog outputs to customer devices. These outputs are set up for 0 to 20 mA or 4 to 20 mA analog
signal ranges, which are compatible for computer integration and remote signal monitoring.
5.3.10 Detector assembly

The IR Analyzer contains a solid‐state pyroelectric detector that is insensitive to external vibrations and mechanical shock. The
detector generates a signal in proportion to the radiant energy absorbed by the component of interest in the sample. The
Detector Assembly can be purged to prevent the analyzer's response to changes in ambient carbon dioxide (CO2) and/or
moisture (H20).
An Indium Gallium Arsenide (InGaAs) photodiode detector is used with the fiber optic configuration. It has the same stability
characteristics as the pyroelectric detector, but the usable wavelength region is limited to 0.8 to 2.0 microns.
5.3.11 Optical span filter option

The optional Optical Span Filter, located in the Detector Enclosure (see Figure 4‐4), provides an alternate means of verifying the
performance of the analyzer. It is most often used in analyzers with processes that make it difficult, or unsafe, to acquire a
calibration standard. An example of such an application would be water in an ethylene dichloride process stream. To use the
Optical Span Filter to check analyzer operation, actuate the Zero Selection Valve to allow zero sample flow and perform the
following:
1. Review the Data Package supplied with the equipment to determine the original benchmark value of the Optical Span
Filter.
2. On the Analyzer, use the Mode Selector to select CALIBRATE/BENCHMARK.
3. In Calibrate/Benchmark mode, select F2, MANUAL BENCHMARK.
4. From the Manual Benchmark screen select F2, SPAN.
5. Check the Span reading and compare it to the benchmark value in the Data Package.
6. Exit to the operating mode by selecting F1, ZERO, or F4, EXIT; return the Zero Selection Valve to its original position.
PIR3502
If the Span reading is significantly different from the benchmark value, the analyzer should be calibrated
with a calibration sample.
5.3.12 Communications board

The Communications Board provides a two‐channel interface between the analyzer and VistaNET.
5.4 Watchdog alarm

The Watchdog Alarm output is built into all process photometers and cannot be disabled because it monitors processor
function. During normal operation, the watchdog circuit receives an electrical signal. If there is a processor failure, the
electrical signal is not sent to the Watchdog, which activates an alarm. It is highly recommended that the Watchdog Alarm be
used to advise when analyzer data is invalid due to processor failure.
The Watchdog Alarm output is a solid state output that operates in a failsafe manner. Under normal operation, the Watchdog
output is a solid state closure; a failure in processor function activates the Watchdog Alarm which opens the output circuit.
The Watchdog Alarm output is accessed at J29 terminals 1 and 2. Figure 5.6 shows a typical configuration for the Watchdog
Alarm, in which the watchdog circuitry opens the watchdog output on alarm. This illustration is only an example; see the Data
Package for the diagram applicable to your analyzer.
Fig. 5.6. Typical Watchdog Alarm Connections
PIR3502

The Source Enclosure contains the Source Assembly, the Optical Filter Assembly, the Source Board, Transformer T1, the Optical
Purge regulator, and the optional Enclosure Purge regulator. Figure 5.7 shows the component locations in the Source
Enclosure.
Fig. 5.7. Source Enclosure Component Locations
PIR3502
Figure 5.8 is the Source Enclosure Block Diagram.
KEY: ELECTRICAL/ELECTRONIC FLOWS ARE SOLID LINES

GAS FLOWS ARE BROKEN LINES
SOURCE ENCLOSURE
PRESSURE
GAUGE
PI-2 ENCLOSURE
AIR
PURGE ALARM
PRESSURE INDICATOR TO
SENSOR DETECTOR
ENCLOSURE DPS-2 ENCLOSURE
PURGE PURGE
AIR PRESSURE
IN REGULATOR
PR-2
OPTICAL PURGE
FROM
DETECTOR
ENCLOSURE
SOURCE TO OPTICAL
POWER OPTICAL PATH THROUGH
SOURCE
SUPPLY FILTER PHOTOMETER
ASSY
PCB ASSY CELL
PRIMARY
POWER MULTITAP
FROM TRANSFORMER
DETECTOR T1
ENCLOSURE
PRESSUR
115 VAC TO
E
DETECTOR
GAUGE
ENCLOSURE
PI-1
OPTICAL
OPTICAL PURGE PURGE
TO DETECTOR PRESSURE
ENCLOSURE REGULATOR
PR-1
NITROGEN
IN
Fig. 5.8. Source Enclosure Block Diagram
5.5.1 Source assembly

The Source Assembly has two collimating lenses and two sources, platinum is used for infrared applications and tungsten is
used for near infrared (NIR) applications. The sources provide a continuous beam of infrared radiation in the portion of the
electromagnetic spectrum in which the sample’s absorbance can be measured. The platinum source has a screw‐in fitting, the
tungsten source is mounted in the enclosure with four hex screws and must be aligned while mounting; see "SOURCE
REPLACEMENT" in Section 6.
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5.5.2 Optical filter assembly

The Optical Filter Assembly contains the chopper motor, filter wheel, one collimating lens, and the motor control electronics.
The chopper motor, contained in a temperature controlled enclosure (casting) directly in front of the source, drives a balanced
filter wheel with four or eight filters; the number and type of filters is application‐dependent. The two collimating lenses in the
source assembly focus the source beam through the filter wheel, then the collimating lens in the Optical Filter Assembly focuses
the beam from the filter wheel through the sample cell.
5.5.3 Source control board

The Source Control Board is located in the upper right hand corner of the Source Enclosure. It receives a 24 Vac supply from
the transformer and supplies the power for the source. The board has several configurations, depending the specific source
used in the Analyzer.
5.5.4 Transformer
Transformer T1 accepts power inputs of 100, 115, 230, and 240 Vac and supply 24 Vac to the Source Board and 115 Vac to the
Power Supply Board for the remaining analyzer power requirements.
5.6 Sample cell assembly

The Sample Cell Assembly is isolated from the analyzer’s electronics, which allows easy access to the sample lines, simplifies
routine maintenance procedures, reduces radiant heat effects from heated sample streams, and allows the sample cell to be
heated to high temperatures (e.g., 150° C) without harming the electronic components. The Sample Cell Assembly uses
stabilizer (tie) rods to provide optical self‐alignment during maintenance.
The proper selection of sample cell construction materials is vital to a successful application. Cell window materials, cell walls,
and all seals must be compatible with both the chemical and physical properties of the sample. Also, the materials must be
able to withstand the process pressure, temperature and other stream conditions. Figure 5.9 lists possible sample cell
materials and parameters.
Standard Window Materials Wavelength Region (micrometers)

Glass 0.8 to 2.6
Quartz 0.8 to 2.6
Sapphire 0.8 to 4.5
Calcium Fluoride 0.8 to 8.0
Barium Fluoride 0.8 to 11.0
Zinc Selenide 0.8 to 15.0
Standard Cell Material Standard Seal Material

Stainless Steel Viton
Monel Kalrez
Hastelloy C Ethylene‐Propylene Copolymer
PTFE
Standard Optical Benches

Cell: 0.6 mm to 1 meter Transmission Cells
Cell: 3, 5, 10 and 22 meter Multipass Reflectance Cells
Fig. 5.9. Possible Sample Cell Materials And Parameters
5.7 Purge options

Purge requirements and supplies are application‐dependent; always refer to the Data Package for purge information specific to
each analyzer. An enclosure purge is application‐dependent for General Purpose or Division 2 applications, but is required for
ATEX Zone I and Division 1 applications. An optical purge is required when the sample measurement is being made in a region
of the electromagnetic spectrum that is sensitive to H2O or CO2.
PIR3502
5.7.1 Optical purge

The purge supply enters the analyzer at the bottom of the Source Enclosure through a tube connector, into a filter, then into a
pressure regulator set at 8 psig, separating into three capillaries, which purges all the optical enclosures. The Optical Purge is
vented to the inside of the Source Enclosure, and to the atmosphere at the sample cell and the bottom of the Detector
Enclosure (see Figure 5.10).
Fig. 5.10. Optical Purge Flow Diagram
PIR3502
5.7.2 Enclosure purge

The ISA Grade air supply enters the analyzer at the bottom of the Source Enclosure through a tube connector, then into a
pressure regulator set at 35 psig, through a flow restrictor, and into the enclosure. The air vents into the atmosphere at the
bottom of the Detector Enclosure; when the cell is electrically heated, the air vents into the atmosphere at the bottom of the
electric heat module (see Figure 5.11).
Fig. 5.11. Enclosure Purge Flow Diagram
5.8 Y purge
The Y Purge supply flows through the Source Enclosure, the tie rods, and the Detector Enclosure. If purge flow is not
maintained, an alarm signal is activated, but power is not removed from the analyzer. Fault conditions that could activate an
alarm are loss of purge supply or blockage of a purge orifice. According to NFPA 496 (1993), with a Y Purge, it is the customer’s
responsibility to connect the analyzer purge alarm to a visual or audible annunciator located in a constantly monitored area.
5.9 X purge
The X Purge flows through the Analyzer in the same manner as the Y Purge, but the X Purge controls the power to the analyzer.
With power On and purge air flow, the X Purge begins monitoring the purge air pressure in the analyzer enclosures. As soon as
the purge air pressure is correct, the X Purge starts its timed cycle. The timed cycle is factory set. If the purge air pressure drops
before the X Purge timed cycle is completed, the X Purge resets the timer and starts over. It continues to reset the timer until
correct pressure is achieved and the timed cycle is completed.
X Purge allows power to the analyzer after the timed cycle is completed. Power continues to the analyzer as long as purge air
pressure is maintained in the analyzer enclosures. The X Purge removes power from the analyzer when the purge air pressure
in the enclosures drops below specifications; power is locked out of the analyzer and an alarm signal is activated.
According to NFPA 496 (1993), because X Purge removes power from the analyzer on an alarm, it is the customer’s option to
connect the analyzer purge alarm to a visual or audible annunciator located in a constantly monitored area.
To restart the X Purge, correct the cause of the drop in pressure, then turn the power Off for a minimum of 10 seconds, then
turn the power On. The X Purge cycle must be completed before power will be allowed to the analyzer. If the cause of the
drop in pressure is not corrected and pressure cannot be achieved or maintained, the X Purge cycle will not be completed and
power will not be allowed to the analyzer.
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5.9.1 Override option

The Override Option is strictly for use during startup, troubleshooting, and maintenance. It is not to be left on during regular
operation of the analyzer.
Before the choice is made to override X Purge, the analyzer location must be known to be safe and hazard
free, and must remain so for the entire time Override is used.
The only X Purge function that is overridden is the X Purge control over power to the analyzer. Override allows power to the
analyzer. X Purge continues to function during use of Override and retains control of power to the analyzer as soon as Override
is canceled.
The area must be well lit for Override to function. A light sensor inside the X Purge housing cancels Override when the housing
cover is replaced. If there is not enough light, Override cannot be activated.
5.9.2 Override before power to the analyzer

At any time during pressurization or purging of the housing (before power is allowed to the analyzer), if the area is known to be
safe, remove the X Purge housing cover and press the Override button (see
Figure 5.12); power is allowed to the analyzer. ATEX versions have a set screw in the lid that must be removed before the X
Purge housing cover can be removed. Pressurization and/or purge cycle of the housing continues during use of override. If
completed, power will be allowed to the analyzer through X Purge; this does not affect Override in any way.
To safely and properly cancel Override, turn the power supply line off at the circuit breaker outside the analyzer, replace the
housing cover (and the ATEX set screw), then turn the power on at the circuit breaker. This resets X Purge and pressurization
and purge cycle begin in the analyzer housing.
Fig. 5.12. X Purge Enclosure with Cover Removed
5.9.3 Override after x purge shuts off power to the analyzer

When X Purge shuts off power to the analyzer and locks it out after a drop in purge air pressure, Override can be used to
restore power to the analyzer for troubleshooting and/or maintenance purposes.
If the area is known to be safe, remove the X Purge housing cover (and the ATEX set screw) and press the Override button (see
Figure 5.12). The X Purge control of power to the analyzer is overridden and the analyzer is powered up; maintenance and
troubleshooting can be performed. The X Purge power lock out has not been canceled and X Purge must be reset so power can
be allowed to the analyzer after Override.
To safely and properly cancel Override and reset X Purge, turn the power supply line off at the circuit breaker outside the
analyzer, replace the X Purge housing cover (and the ATEX set screw), then turn the power on at the circuit breaker. This resets
X Purge and pressurization and purge cycle begin in the analyzer housing.
PIR3502
5.9.4 X purge function during override

When Override is used during start up, pressurization and purge cycle continue, only the X Purge control of power to the
analyzer has been overridden. If the analyzer housing is pressurized and the timed purge cycle is completed, the analyzer will
have power on from the X Purge. If the X Purge housing cover is replaced before the power is turned off at the circuit breaker,
the analyzer will still have power because of X Purge.
As stated above, when Override is used during start up, pressurization and purge cycle continue. If the analyzer housing is
pressurized and the timed purge cycle is completed, the analyzer will have power on from the X Purge. If the analyzer housing
pressure drops, X Purge will shut off power to the analyzer without affecting Override and go into power lock out. When
Override is canceled, if the X Purge housing cover is replaced before the power is turned off at the circuit breaker, the analyzer
will be without power because of X Purge lock out.
To restart the X Purge, correct the cause of the drop in pressure, then cycle the power Off and On. The X Purge cycle must be
completed before power will be allowed to the analyzer. If the cause is not corrected and pressure cannot be achieved or
maintained, the X Purge cycle will not be completed and power will not be allowed to the analyzer.
5.9.5 Remote control of override (not available on csa certified analyzers)
Before the choice is made to override X Purge, the analyzer location must be known to be safe and hazard
free, and must remain so for the entire time override is used.
Override can be remote controlled; terminals are in the X Purge housing for remote hook up (see Figure 4‐12). The customer is
responsible for providing the cable and switch for remote connection and properly installing them. It is also the customer’s
responsibility to make sure remote controlled Override is removed as soon as start up, maintenance and/or troubleshooting is
completed. Override is not to be left on during regular operation of the analyzer.
5.10 VistaNET option

If the analyzer is connected to VistaNET, you must set up the analyzer to work on this network. This setup is described in
"Connecting The Analyzer To Vistanet" in Section 3. Once the network connection is set up and running, it runs automatically.
PIR3502
PIR3502 Operating Instructions 6 Maintenance and troubleshooting
6 Maintenance and troubleshooting
Always refer to the Data Package, the engineering drawings, and the Recommended Spare Parts List
shipped with the analyzer when you are preparing to perform troubleshooting or maintenance.
6.1 Routine maintenance

The Analyzer design eliminates the need for extensive and complex maintenance. The following cleaning procedures should be
performed often enough to maintain analytical integrity and reduce analyzer failure. Maintenance schedules vary depending
on the application, the quality of the sample and process stream, and the age of the analyzer.
The Analyzer produces reliable analyses with up to approximately 50% clouding of the sample cell windows. Therefore, if the
detector signal decreases by 50% or more, check the cell windows for clouding. The windows should be cleaned with a soft,
lint‐free cloth, dampened with a suitable solvent.
6.1.1 Recommended tools

The tools shipped with the analyzer are:
• a 9/64‐inch balldriver, used to remove the sample cell

• a 3/32‐inch Allen wrench, used to remove the filter wheel from its assembly
• a spanner wrench, used to remove and install the cell windows
Other recommended tools are:
• a standard set of Phillips screwdrivers

• a standard set of straight screwdrivers
• a standard set of SAE wrenches; CENELEC units require a set of Allen wrenches
• a 50‐inch‐pound torque wrench, for window replacement
• a valve grinding tool with suction cups, for window removal
• leak detection solution (e.g., Snoop(®)
• a soft, lint‐free cloth
• a suitable solvent, which is application‐dependent
6.1.2 Verify detector voltage

Verifying the detector voltage is the primary troubleshooting procedure. The Data Package lists Detector Voltages with Zero
Sample. Use the MODE SELECTION key to move to EXECUTE SELF TESTS, and then select the following keypath:
VIEW SYSTEM MONITORS (F2)/SIGNALS (F3)/DETECTOR VOLTS (F2).
Compare the voltage displayed in the upper right of the screen (e.g., 0.43 VOLTS) with the voltage in the Data Package. If
applicable, choose NEXT FILTER (F1) and continue comparing the voltages, or choose EXIT (F4). If the detector signal decreases
by 50% or more than the voltages in the Data Package, the cell windows should be cleaned (see "Cell Window Cleaning
Procedure").
6.1.3 Cell window cleaning procedure
1. Close the associated valves to stop sample flow and open or divert the zero sample through the sample cell, purging the
sample cell for five minutes.
If the sample cell is heated, do not purge it with cold sample, it may cause thermal shock damage to the
cell windows.
If the cell has contained a hazardous substance be sure to purge the cell thoroughly with a non‐hazardous
sample.
2. Stop flow through the cell by shutting off the zero sample. Allow time for the cell to drain.
3. Close the sample return valve.
PIR3502
Allow the cell to cool before working on it.
4. Open the Source Enclosure and reduce the optical and enclosure purges to zero psig as applicable.
5. Remove power from the analyzer, following local lock‐out‐tag‐out procedures.
6. Disconnect Sample Ports 1 and 2 (see Figure 6.1).
Fig. 6.1. Analyzer Sample Cell
7. If the sample cell is electrically heated, perform the following; if the cell is not electrically heated, proceed to step 8.
• Remove the insulation from the cell.
• With a 9/64 inch Allen wrench, remove the Allen screws from the top of the block(s), lift the copper tube and
separate the halves of the block(s).
PIR3502
8. Loosen the set screw in the stabilizer block on each side of the cell, approximately three full turns with a 9/64‐inch Allen
wrench (see Figure 6.2).
Fig. 6.2. Cell Window Components
9. With a 9/64‐inch balldriver wrench (included with the analyzer), remove the two Allen screws on each side of the cell that
hold the cell retainer to the subassemblies.
10. With both hands, grasp the knurled cell retainer and pull it toward the center of the cell until the retainer touches the
optical purge vent. Do this on each side.
11. With hands in the center of the cell, slowly remove the cell as evenly as possible from the flange.
12. After the cell is removed, use a 3/8‐inch socket wrench with a three‐inch extension and the spanner wrench (spanner
shipped with the analyzer) to remove the cell window retainer.
13. Removing the retainer allows the cell body washer, cell window spacer, O‐ring, cell window (use valve tool with suction
cups), and the PTFE washer to be removed in sequence; remove the other window. In some short pathlength cells the
PTFE washer is not used.
O‐rings are to be replaced when the cell windows are removed. Failure to replace the o‐rings can cause
sample leakage at the windows (see "SAMPLE CELL WINDOW REPLACEMENT" in Section 6).
14. Clean the cell windows carefully with a soft, lint‐free cloth, and a solvent suitable for removing sample residue.
Do not leave fingerprints on the cell windows. If necessary, use acetone to remove fingerprints.
15. Replace the windows in this order: PTFE washer, cell window (use valve tool with suction cups), a new O‐ring, cell window
spacer (beveled end first), cell body washer, and the cell retainer.
PIR3502
The threaded retainers of the cell should be secured with a torque wrench set at 50 inch‐pounds, unless
otherwise specified in the Data Sheets.
16. Slide the cell evenly into its original position, with the optical purge vents pointing down.
17. Locate the line on the knurled cell retainer and match this line with the line on the subassembly. Do this for each side of
the sample cell to align the mounting holes of the cell retainer to the holes in the cell.
18. Replace and tighten the two Allen screws on both sides of the cell that secure the cell retainers.
19. To stabilize the cell, tighten set screws in the stabilizer block on each side of the cell.
20. If appropriate, install the heater block halves around the cell and install the four Allen screws to secure the block, bend the
copper tube into place.
21. Install the insulation carefully so that insulation does not get into the Sample Ports.
22. Reconnect Sample Ports 1 and 2.
23. If applicable, adjust the optical purge pressure regulator to read 8 psig on the gauge. If applicable, adjust the enclosure
purge pressure regulator to read 35 psig on the gauge.
24. Close the Source Enclosure (see "Opening and Closing Analyzer Doors" in Section 2).
25. With Y or Z Purge, allow the analyzer to purge for the time indicated on the instrument label or in the analyzer data
package. X Purge controls purge time and power to the analyzer (see "X PURGE" in Section 4).
26. Turn on the power and allow the cell to heat before starting any sample flow.
27. Open the valves for the span sample, zero sample, and process sample.
6.1.4 Extended path length reflective cell cleaning recommendations
Do not flush a heated cell with cold liquid, it may cause thermal shock damage to the cell windows.
Cell and Mirrors
Wash the mirrors and the cell interior with mild detergent and water; the cooled cell should be closed off so the washing
solution can be sloshed back and forth inside the cell. Several clean water rinses and a final distilled water rinse are
recommended. Dry completely with clean, dry air, or nitrogen.
Windows
Some applications will require cell windows and some will not. If the cell has windows, they will be installed at the base of the
cell in the one‐inch diameter openings. To remove them for cleaning:
1. Unscrew the four Allen screws holding the cell in the base and remove the cell.
2. Locate the windows and remove the window retainer rings.
3. Note that the windows are cushioned top and bottom by o‐rings; remove and discard the o‐rings.
4. Clean the windows with an appropriate solvent such as acetone and dry them with a lint‐free cloth.
5. Insert new top and bottom o‐rings when putting the windows and window retainers back in place.
6. Mount the cell back on the cell base and tighten the four Allen screws.
Turn the cell counterclockwise until it is stopped by the pin in the cell base. The two openings in the cell
must line up directly over the transfer mirrors.
Optical Alignment of Transfer Mirrors
In addition to the three mirrors of the “White” cell, there are two transfer mirrors (T1 and T2) that reflect the radiation into and
out of the cell. These mirrors are held by spring washers that should not be compressed completely. The transfer mirror
adjustments may be made with a 1/4‐inch Allen wrench that is shipped with the analyzer. When the wrench is removed the
transfer mirrors will remain in position. Transfer mirror adjustments will be necessary to maximize the infrared signal. After
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that, no further adjustments should be necessary. The transfer mirrors will stay aligned whether or not the cell is in the cell
base.
1. In the Detector Enclosure, connect an oscilloscope to the analyzer at TB1‐21 and common.
2. Introduce Zero Sample into the sample cell.
3. Remove the mirror adjustment caps located on the side of the cell base (see Figure 6.3).
Fig. 6.3. Cell Base With Caps In Place
4. Locate the mirror adjustment set screws inside the openings (see Figure 6.4).
SET SCREWS FOR

TRANSFER MIRROR
TILT ADJUSTMENT
DETECTOR
SOURCE
ENCLOSURE
ENCLOSURE
CELL BASE
EXTENDED
PATH
LENGTH
REFLECTIVE
CELL
Fig. 6.4. Cell Base with Caps Removed
5. Using an Allen wrench, turn the set screw clockwise and counterclockwise until maximum peak height is obtained on the
oscilloscope.
6. Move to the other mirror and adjust it until maximum peak height is obtained.
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7. Repeat steps 5 and 6 until no increase in peak height is noticeable.

8. Remove the mirror adjustment caps located on the top of the cell base (see Figure 6.4).
9. Adjust these mirrors according to the procedure in steps 5 through 7.
10. When the adjustments are completed replace the caps removed in steps 3 and 8.
11. Verify that the test point readings are similar to those recorded on the instrument data sheets shipped with each analyzer.
12. Continue with calibration procedures as described Section 2.
6.2 Troubleshooting guidelines
Replacement of optical filters should never be done without first consulting ABB Lewisburg. No two
filters are alike; even replacement of a filter with the same center wavelength may require changes to the
matrix on some applications.
6.2.1 Verify zero and span

The Data Package lists the Zero Absorbance and the Component Response Factor, compare these with the screen displays. Use
the Mode Select key to move to SET‐UP TABLES and select the following keypath:
VIEW SET‐UP (F1)/COMPONENT (F1)/CALIBRATION (F2)/ZERO (F2)
Compare the displayed ZERO ABS FACTOR with the Data Package. Small variances are normal. If the variance is large, you
should perform a zero calibration followed by another verification. If the variance is still large, the zero sample could be bad.
Perform a zero calibration with a new zero sample and then verify zero again. If the variance is large, call the Service
Department at ABB Lewisburg.
To verify the Component Response Factor, perform the above sequence selecting SPAN (F3) instead of ZERO. Compare the
displayed RESPONSE FACTOR with the Data Package and follow the sequence above, performing a span calibration with the
existing span sample, and then a new span sample if necessary. If the variance is large, call the Service Department at ABB
Lewisburg. Keep a record of all calibrations, dates performed, and the zero absorbance and component response factors.
6.2.2 Adjusting the optional optical span filter

If you need to adjust the span reading on a unit having the optional Optical Span Filter, select the following keypath:
VIEW SET‐UP (F1)/COMPONENT (F1)/CALIBRATION (F2)/SPAN (F3)
To adjust the span reading, perform the following steps while observing the span reading on the display.
Before opening the analyzer enclosure doors, ensure the area is safe from hazardous gases and will
appropriate precautions should be taken when working with nitrogen or any other inert gas. Always be
certain there is adequate ventilation when working on the analyzer.
1. Open the Detector Enclosure door.
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2. Verify that the mark on the Optical Span Filter barrel is aligned with the mark on the Retainer Flange (see Figure 6.5).
Retainer
Flange
Alignment
Marks
Barrel
Fig. 6.5. Optical Span Filter Barrel And Flange
3. Slowly move the barrel in (to increase the reading) or out (to decrease the reading) until you attain an acceptable span
reading.
6.2.3 Verify analyzer power (without x purge)
Disconnect all peripheral devices from their power sources before verifying power to the analyzer.
When there is no power at the analyzer, first verify the circuit breaker position on the power supply line to the analyzer. Then
verify the analyzer power connections at TB4 on the I/O Power Assembly in the Detector Enclosure (see Figure 6.6). This does
not include analyzers with X Purge.
a1c ontents.p65
Fig. 6.6. I/O Power Board
Equipment needed: Multimeter, Fluke Model 862 or equivalent
1. Verify the circuit breaker on the power supply line to the analyzer is turned OFF.
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2. Set the multimeter to read ohms and connect it to TB4 pins 5 (ground) and 1 (hot). A normal reading should be between
1.00 megohms and 3.00 megohms.
3. Connect the ohmmeter to TB4 pins 5 (ground) and 4 (neutral). A normal reading should be between 1.00 megohms and
3.00 megohms.
4. Turn the circuit breaker on the power supply line to the analyzer ON.
5. Set the multimeter to read AC Volts and connect it to TB4, pin 1 (hot) and pin 4 (neutral) on the I/O Power Board. A
normal voltage reading should be the same as the input supply voltage.
6.2.4 Verify analyzer power (with x purge)
Disconnect all peripheral devices from their power sources before verifying power to the analyzer.
If the analyzer has X Purge, you must verify power at the power connections inside the X Purge enclosure (see Figure 6.7), then
verify the connections at TB4 on the I/O Power Board in the Detector Enclosure.
Fig. 6.7. X Purge Power Connections
1. Verify the circuit breaker on the power supply line to the analyzer is turned OFF.
2. Set the multimeter to read ohms and connect it to TB49 pins 1 (ground) and 3 (hot) in the X Purge enclosure. A normal
reading should be between 1.00 megohms and 3.00 megohms.
3. Connect the ohmmeter to TB49 pins 1 (ground) and 5 (neutral) in the X Purge enclosure. A normal reading should be
between 1.00 megohms and 3.00 megohms.
4. Turn the circuit breaker on the power supply line to the analyzer to ON.
5. Set the multimeter to read AC Volts and connect it to TB49 pins 3 (hot) and 5 (neutral) in the X Purge enclosure. A normal
voltage reading should be the same as the input supply voltage.
6.2.5 Testing trend board output

To verify a Trend Board is working properly:
1. Turn power to the analyzer OFF.

2. Remove the connector from J21 on the right side of the Backplane PCB.
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3. Connect one end of a lead wire to pin 1 of JP1 on the desired Trend Board (see Figure 6.8).
Fig. 6.8. Trend Board Test Setup
4. Connect the other end of this lead wire to the ground (low) input of a milliammeter set to measure at least 20 mA.
5. Connect one end of a second lead wire to pin 3 of JP1 on the Trend Board.
6. Connect the other end of this wire to the positive input to the milliammeter.
7. Turn power to the analyzer ON.
8. Repeatedly press the MODE SELECTION button to select EXECUTE SELF TESTS.
9. On the EXECUTE SELF TESTS screen select MANUAL I/O OPERATION (F3).
10. On the MANUAL I/O OPERATION screen select OFFLINE (F2).
11. On the MODE: OFFLINE screen select CONTINUE (F3).
12. On the next OFFLINE screen select ANALOG OUTPUTS (F3).
13. On the OFFLINE OPERATION OF ANALOG OUTPUTS screen, you can select the desired Trend Board and the analog output
values (see Figure 6.9).
Fig. 6.9. Offline Operation Of Analog Outputs Screen
14. To select a particular Trend Board, use the left/right arrow keys until the cursor is in the output value of the desired Trend
Board.
15. To change the Trend Board output value, use the up/down arrow keys to select a particular current output. Wait until the
new value stabilizes on the ammeter and then compare the ammeter reading to the selected value on the display.
With the down arrow key you can wrap around from 0.0 to 20.0; with the up arrow key you can wrap
around from 20.0 to 0.0.
16. To test another Trend Board, turn the power to the analyzer OFF.
17. Repeat steps 3 through 15.
18. When you have completed your analog output testing, turn the power to the analyzer OFF.
19. Reinstall connector J21 on the Backplane PCB.
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6.2.6 Testing chopper motor operation

To verify the Chopper Motor is working properly:
1. On the Backplane PCB in the Detector Enclosure locate connector J1 (see Figure 6.10).
Fig. 6.10. Backplane PCB
2. Connect an oscilloscope to J1 pins 3 (sync) and 4 (0 vdc).

3. If the analyzer has a 4‐position wheel, set the oscilloscope to read a 5 Vdc level square wave that is 26 msec in length (see
Figure 6.11).
Fig. 6.11. Chopper Motor Waveform, 4‐Position Wheel
4. If the analyzer has an 8‐position wheel, set the oscilloscope to read a 5 Vdc level square wave that is 52 msec in length (see
Figure 6.12).
Fig. 6.12. Chopper Motor Waveform, 8‐Position Wheel
5. If the waveform is the correct length and is stable, the Chopper Motor and Chopper Motor Control PCB are operating
properly.
6. If the waveform is too slow, too fast, or not stable, contact ABB Service Department for assistance.
6.3 Alarms
This section groups alarms with the alarm number and primary probable causes called out for each group.
Each alarm has an associated type, either setup or built in. A setup alarm can be configured in the setup tables, whereas a built
in alarm cannot. Alarms 1 through 168 and 175 through 198 are setup alarms; all other alarms are built in alarms. The alarm
number is the number displayed in the Help screen associated with the alarm displayed in DISPLAY ALARMS/WARNINGS mode.
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When multiple alarms sound, the higher numbered alarms should be resolved first.
6.3.1 Analytical alarms

Alarm numbers 1 through 226 are on conditions which are continuously monitored during normal sample analysis and
calibration.
ALARMS 1 to 5: USER INPUT ALARMS (1‐5) are user defined and configured alarms.
ALARM 6: FUSE FAILURE, SOURCE BOARD or may be a USER defined and configured alarm.
ALARM 7: SOURCE FAILURE or may be a USER defined and configured alarm.
ALARM 8: CABINET PURGE PRESSURE ALARM or may be a USER defined and configured alarm.
ALARMS 9 to 40: COMPONENT (1‐8) LOW or HIGH CONCENTRATION ALARM or WARNING is displayed when the concentration
of a component falls out of the range limits.
ALARMS 41 to 104: COMPONENT (1‐8) LOW or HIGH CALIBRATION ALARM or WARNING ZERO or SPAN is displayed when an
automatic calibration finds the new calibration factors would violate concentration limits for calibration alarm levels. The
alarm condition indicates the new calibration factors were not implemented.
Probable causes: set‐up table tolerances are too tight, bad calibration gas concentrations, analyzer drift, too long a period
between calibrations or a failed analyzer control board.
ALARMS 105 to 168: COMPONENT (1‐8) LOW or HIGH BENCHMARK ALARM or WARNING ZERO or SPAN is displayed when an
automatic benchmark finds the zero or span benchmark check falls outside the concentration limits for benchmark alarm
levels.
Probable causes: set‐up table tolerances are too tight, bad benchmark gas concentrations, analyzer drift, or too long a
period between calibrations or a failed analyzer control board.
ALARM 169: WATCHDOG ALARM is displayed when there is a processor failure.
ALARM 170: RESERVED
ALARMS 171 and 172: HIGH DETECTOR VOLTAGE ALARM or WARNING is built in to warn when the detector instantaneous
voltage exceeds 9.5 Volts, and to alarm when the detector instantaneous voltage exceeds 9.9 Volts.
Probable causes: failed detector assembly, missing filter in the filter wheel, detector preamp gain setting too high, no
(liquid) sample in cell, failed source power supply board (high source voltage), or failed analyzer control board. Check first
for ALARMS 213 and 214, IMPROPER CHOPPER SIGNAL.
ALARMS 173 and 174: LOW DETECTOR VOLTAGE ALARM or WARNING is built in to warn when the detector instantaneous
voltage is less than 2.5 Volts, and to alarm when the detector instantaneous voltage is less than 2.0 Volts.
Probable causes: failed detector assembly, missing filter in the filter wheel, detector pre‐amp gain setting too high, no
ALARMS 175 to 178: LOW or HIGH DETECTOR DC VOLTAGE ALARM or WARNING is displayed when the average (DC) voltage
due to filter #1 falls outside the limits.
Probable causes: failed detector assembly, missing filter in the filter wheel, or failed analyzer control board.
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ALARM 179: LOW DETECTOR AC VOLTAGE WARNING is displayed when the detector voltage AC component exceeds the
LOWER limits.
Probable causes: optical path obscured (dirty windows, cell optic path blocked, highly absorbing sample), failed source
power supply board (low source voltage), failed source, failed detector assembly. Check first for ALARMS 213 and 214,
IMPROPER CHOPPER SIGNAL.
ALARM 180: HIGH DETECTOR AC VOLTAGE WARNING is displayed when the detector voltage AC component exceeds the
UPPER limits.
ALARM 181: LOW DETECTOR AC VOLTAGE ALARM is displayed when the detector voltage AC component exceeds the LOWER
limits.
Probable causes: optical path obscured (dirty windows, cell optic path blocked, highly absorbing sample), failed source
power supply board (low source voltage), failed source, failed detector assembly. Check first for ALARMS 213 and 214,
IMPROPER CHOPPER SIGNAL.
ALARM 182: HIGH DETECTOR AC VOLTAGE ALARM is displayed when the detector voltage AC component exceeds the UPPER
limits.
ALARMS 183 to 190: LOW or HIGH EXTERNAL 0‐10 VOLT INPUT (1‐2) ALARM or WARNING is displayed when the input to an
analog‐digital channel falls outside the limits.
Probable causes: the user supplied input indicates an alarm condition, entered tolerances are too tight, or a failed
Calculation/Control board.
ALARMS 191 to 194: LOW or HIGH CELL TEMPERATURE ALARM or WARNING is displayed when the sample cell temperature
falls outside the limits and cell temperature is under analyzer control. Check first for ALARMS 202 to 204, 206, and 208 to
212 concerning temperature control.
ALARMS 195 to 198: LOW or HIGH CELL PRESSURE ALARM or WARNING is displayed when the sample cell pressure falls outside
the limits (available with pressure compensation option).
Probable causes: the sample pressure has violated the limits, entered tolerances are too tight, a failed pressure sensor, or
a failed Calculation/Control board.
ALARMS 199 and 200: CASTING TEMPERATURE CONTROL FAILURE HOT or COLD is displayed when the casting temperature
exceeds the setpoint or falls below the proportional band and is not heating (available with electric heat option).
Probable causes: failed casting temperature sensor, failed heating element, or failed Calculation/Control board. Check first
for ALARMS 199 to 201, 205, and 208 to 212 concerning temperature control.
ALARM 201: CASTING TEMPERATURE CONTROL WARMING UP is displayed when the casting is below the (five degree Celsius)
proportional band and is heating. This alarm normally sounds on power on and should be configured to be TRACKING,
thus the alarm will clear when the casting reaches the setpoint.
Probable causes: failed casting temperature sensor, failed heating element, or failed Calculation/Control board. Check first
ALARMS 202 and 203: CELL TEMPERATURE CONTROL FAILURE HOT or COLD is displayed when the cell temperature exceeds
the setpoint or falls below the proportional band and is not heating.
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Probable causes: Failed cell temperature sensor, failed heater assembly, or failed Calculation/Control board. Check first
ALARM 204: CELL TEMPERATURE CONTROL WARMING UP is displayed when the cell is below the (five degree Celsius)
proportional band and is heating. This alarm normally sounds on power on and should be configured to be TRACKING, so
the alarm will clear when the cell reaches the setpoint.
Probable causes: failed cell temperature sensor, failed heater assembly, or failed Calculation/Control board. Check first for
ALARMS 199 to 201, 205, and 208 to 212 concerning temperature control.
ALARMS 205 to 206: SHORTED CASTING or CELL TEMPERATURE PROBE is displayed when a low voltage on the temperature
probe is sensed.
Probable causes: a failed sensor or sensor lead.
ALARM 207: ILLEGAL T‐RATING JUMPER CONFIGURATION is displayed when there are no T‐rating jumpers or more than one
jumper on the analyzer control board.
Probable causes: An illegal configuration or a failed analyzer control board.
ALARMS 208 to 210: TEMPERATURE CONTROL AC ZERO CROSSING MISSING or SLOW or FAST is displayed when there are
frequency problems with the AC power supplied to the analyzer.
Probable causes: Bad power line condition (interference), failed analyzer control board.
ALARMS 211 and 212: TEMPERATURE CONTROL, HIGH or LOW AC LINE VOLTAGE is displayed when the AC power supplied to
the analyzer is marginally high or low.
Probable causes: Bad power line condition, failed analyzer control board.
ALARMS 213 and 214: IMPROPER CHOPPER SIGNAL SLOW/MISSING or FAST/NOISY is displayed when the speed control sync
pulses are abnormal.
Probable causes: failed chopper motor, motor control board, analyzer control board, or opto‐interrupter.
ALARM 215: DETECTOR A/D CONVERTER OVERRANGE is displayed when the voltage generated by the detector assembly is too
great for the analog to digital converter.
Probable causes: Failed detector assembly, failed analyzer control board.
ALARMS 216 and 217: ANALYZER CONTROL BOARD RAM or ROM FAILURE is displayed when a bad RAM memory location or
ROM checksum are found on the control board.
ALARMS 218 and 219: COMMUNICATIONS MICROPROCESSOR RAM or ROM FAILURE is displayed when a bad RAM memory
location or ROM checksum are found at the communications processor on the Calculation/Control board.
ALARMS 220 and 221: CALCULATIONS MICROPROCESSOR RAM or ROM FAILURE is displayed when a bad RAM memory location
or ROM checksum are found at the calculations processor on the Calculation/Control board.
ALARMS 222 to 226: COMMUNICATIONS BROKEN ALARMS are displayed when communications within the module called out
in the alarm name have broken down.
Probable causes: failure of the board called out in the alarm or a failed Calculation/Control board.
6.3.2 Power on initialization alarms

Alarm numbers 227 through 229 are initialization alarms that are activated when the alarm condition is found during a
reset/power on system initialization, but are not monitored continuously.
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ALARM 227: Power on INITIALIZATION is displayed as a warning that the analyzer has gone through its initialization routines.
ALARM 228: ILLEGAL T‐RATING INITIALIZATION is displayed during initialization routines when the analyzer finds a T‐rating
jumper configuration which is violated by a temperature setpoint as entered in the Set‐up Tables.
ALARM 229: ANALYZER POWER INTERRUPTION is displayed as a warning that the analyzer has been powered down and has
gone through its initialization routines.
6.3.3 EEPROM checksum test alarms

Alarm numbers 230 through 277 are validation checks on nonvolatile memory to guard against corrupted Set‐up Tables.
ALARMS 230 to 277: EEPROM CHECKSUM TEST FAILURES are displayed when any subset of the nonvolatile memory which
stores the Set‐up Tables has been corrupted. The suspect area is called out in the alarm name and should be immediately
addressed through the Set‐up Tables.
6.3.4 Power supply alarms

ALARMS 278 to 283: LOW or HIGH DC POWER SUPPLY is displayed as a warning when any of the power supplies violate the
built‐in limits.
Probable causes: excess loading of the power supply or failed power supply board.
6.3.5 VistaNET alarms

ALARMS 284 through 287: VistaNET CHECKSUM TEST FAILURES are displayed when when a particular VistaNET checksum
function has been corrupted.
ALARM 288: REALTIME CLOCK BATTERY BACKUP LOW is displayed when the clock's backup battery is low.
ALARMS 289 and 290: ACCESS CHECKSUM TEST FAILURES are displayed when the Security Access EEPROM Checksum or the
User Access Table Checksum have been corrupted.
6.4 Factory configuration

Factory configuration involves modifying Set‐up Tables whose entries are critical to the operation of the analyzer and generally
need not be altered after the analyzer leaves the factory.
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To view or edit factory configuration, you must select SET‐UP TABLES from the Mode Selection Panel and then select MODIFY
SET‐UP (F2), followed by FACTORY (F3). This accesses the factory configuration menu structure (see Figure 6.13).
Fig. 6.13. Modify Factory Set‐Up Command Tree

Described below are factory set‐up table screens. Under each title is an example “keypath” used to reach the screen, assuming
the analyzer is at the top level of SET‐UP TABLES mode.
The FACTORY screen allows selection of INPUTS (F1), OUTPUTS (F2), or ANALYZER (F3). INPUTS allows you to set autocal start,
clear alarms, and user alarms. OUTPUTS allows you to set analog, digital, and alarms. ANALYZER allows you to set response
time, matrix coefficients, casting and cell temperatures, optics, and pressure sensor.
6.4.1 Inputs
Selecting INPUTS (F1) displays the INPUTS screen, which has the following soft keys: AUTOCAL START (F1), CLEAR ALARMS (F2),
and USER ALARMS (F3).
Selecting AUTOCAL START (F1) from the INPUTS screen displays the AUTOCAL STARTS screen. One digital input is selected to
start the auto calibration sequence. The active level selects which external logic level (0 or 5 Vdc) starts the sequence.
This remote start of the auto calibration sequence is enabled or disabled at keypath: MODIFY SET‐
UP/ANALYZER/AUTOCAL/ACTIONS (see "Autocalibration in Section 3).
Selecting CLEAR ALARMS (F2) displays the CLEAR ALARMS screen. One digital input is selected to clear all alarms. The active
level selects which external logic level clears the alarms. On this screen at CONDITION: ENABLED, the operator can globally
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enable or disable the capability for all alarms to be cleared from a remote (REMOTE CLEAR ALL ALARMS); also, the effect of
REMOTE CLEAR ALL ALARMS on individual alarms can be blocked on the ALARM ATTRIBUTES screen at keypath:
FACTORY/OUTPUTS/ALARM/ATTRIBUTES (see "Outputs").
Selecting USER ALARMS (F3) displays the USER ALARMS screen, which has the following soft keys: EDIT NAMES (F1) and ASSIGN
INPUTS (F2).
Selecting EDIT NAMES (F1) from the USER ALARMS screen allows you to assign names to up to eight external alarm signals.
These names may be up to 40 characters each.
Selecting ASSIGN INPUTS (F2) from the USER ALARMS screen allows you to configure up to eight digital inputs as remote
user alarms. These alarms may be displayed in DISPLAY ALARMS mode and enabled or disabled in the same manner
as the built‐in alarms. The logic level that indicates an alarm level and the digital input number that corresponds to
the user alarm name displayed may be selected on this screen.
6.4.2 Outputs
Selecting OUTPUTS (F2) displays the OUTPUTS screen, which has the following soft keys: ANALOG (F1), DIGITAL (F2), and
ALARM (F3).
Selecting ANALOG (F1) from the OUTPUTS screen allows you to configure individually the ANALOG outputs entries (1 through
12) for either 0 or 4 mA (ZERO LEVEL entry) as their minimum value during normal tracking of their respective drivers. If an
analog output is configured as an alarm output, the ALARM FORCES entry configures the analog output to have 0, 4, or 20
mA as the level that indicates the assigned alarm condition.
Selecting DIGITAL (F2) displays the DIGITAL OUTPUTS screen, from which you can select DEFAULT STATES (F1), VALVE CONTROL
(F2), or MODE INDICATOR (F3).
Selecting DEFAULT STATES (F1) from the DIGITAL OUTPUTS screen displays the DEFUALT STATES screen. From this screen
you can define the on or off state for the digital output number upon a power‐up or reset. Should a digital output be
configured as an alarm output, the ALARM STATE entry determines the on or off state of the digital output displayed
during the alarm condition.
Selecting VALVE CONTROL (F2) allows you to implement automatic valve control for normal sampling, benchmark gas, and
calibration gas. When the analyzer changes modes, the valves are actuated in eight 0.1 second steps. The step being
configured is indicated in the STEP field. The mode entry cycles through BENCHMARK ZERO, BENCHMARK SPAN,
CALIBRATION ZERO, CALIBRATION SPAN, and SAMPLE ANALYSIS that denotes the gas introduced to the sample cell.
The DIGITAL OUTPUT NUMBER entry indicates which digital output is affected by the step. The ON or OFF entry
indicates which state the digital output is changed to at the time step. Digital output numbers 1 through 96 are logic
level outputs that may be jumpered as active low or active high. Digital output numbers 101 through 124 are 110
VDC outputs which may directly drive rated valve solenoids. An entry of digital output #000 for a step configures no
action at that step.
The ACCEPT key must be pressed to store each valve state displayed before moving to another time step
or analyzer mode.
Selecting MODE INDICATOR (F3) displays the MODE INDICATOR OUTPUTS screen, which has the follwoing soft keys:
CALIBRATION (F1) and OFFLINE (F2).
Selecting CALIBRATION (F1) from the MODE INDICATOR screen displays the CALIBRATION INDICATOR screen.
One digital output indicates a calibration or benchmark underway to a remote device. The state of ON or
OFF is assigned to that output and the actual logic high or low output depends on the jumper configuration
on the associated DIGITAL I/O CARD. The calibration indicator is disabled by entering digital output #000.
Selecting OFFLINE (F2)from the MODE INDICATOR screen displays the OFFLINE INDICATOR screen.
Selecting ALARM (F3) from the OUTPUTS screen displays the ALARM CONFIGURATION screen, which has the following soft
keys: ATTRIBUTES (F1) and OUTPUTS (F2).
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Selecting ATTRIBUTES (F1) from the ALARM CONFIGURATION screen allows you to select global alarm attributes. Initially
the name of alarm #1 is displayed along with its attributes. With the cursor on the alarm name, the UP ARROW and
DOWN ARROW cycle through the other alarm names and associated attributes. The alarms are enabled or disabled
with the STATE field. The MODE of the alarm selects the alarm as tracking or holding. A tracking alarm sounds upon
the associated alarm condition but is automatically cleared when the nominal condition returns. A holding alarm
holds its alarm until cleared.
To configure an alarm or warning effect on the analyzer status display, each alarm has a CLASS entry that can be
either alarm or warning. For example, a built in alarm may be classed as a warning if the user considers it of lesser
importance in the application. From then on, the built in alarm is displayed under the DISPLAY WARNINGS mode and
causes the STATUS to read warning rather than alarm.
Finally, the effect of the REMOTE CLEAR digital input is selected. Each individual alarm may be configured to clear on
the remote input or to ignore the remote clear.
Selecting OUTPUTS (F2) from the ALARM CONFIGURATION screen displays the FIRST OUTPUT screen.
Each alarm can trigger up to four outputs to signal the condition to a remote device. The alarm name for alarm #1 is
initially displayed. With the cursor on the alarm name, the UP ARROW and DOWN ARROW cycle through all alarm
names. Likewise, the identifiers FIRST, SECOND, THIRD and FOURTH are selected. The driven output TYPE can be
digital or analog and the OUTPUT NUMBER supplied completes the identification.
If the output is a digital type, the on or off state on alarm is selected at keypath:
FACTORY/OUTPUTS/DIGITAL/DEFAULT STATES.
If the output is an analog type, the level on alarm is selected at keypath: FACTORY/OUTPUTS/ANALOG. An entry of
output #000 is a null selection, disabling one output associated with the alarm under consideration. To disable all
outputs driven by a given alarm, all four available outputs must be set to output #000.
6.4.3 Analyzer
The BASIC ANALYZER screen allows you to select ANALYSIS (F1), TEMP CONTROL (F2), or OPTIONS (F3).
Selecting ANALYSIS (F1) from the BASIC ANALYZER screen displays the ANALYSIS FACTORS screen, which has the following soft
keys: RESPONSE TIME (F1), MATRIX COEF (F2) and COMPENSATION FACTORS (F3).
Selecting RESPONSE TIME (F1) displays the ANALYSIS RESPONSE TIME screen. The analyzer averages concentration
readings for the RESPONSE TIME entered. Note that longer response times require the purge time at keypath:
ANALYZER/AUTOCAL/TIMES to be increased so that the averaged concentration used for calibration or benchmark
has settled. A response time entry of 0000 seconds results in a response time of 0.5 seconds.
Selecting MATRIX COEFFICIENTS (F2) displays a Matrix Coefficients screen. Component concentrations are calculated using
a P‐matrix whose coefficients are calculated at the factory. The matrix is 8x8 with rows corresponding to components
1 through 8 and columns corresponding to wheel filters 1 through 8. Coefficients are trapped to a maximum value of
±1.0000.
All temperature and pressure compensation entries are determined empirically at the factory and should
not be changed.
Selecting COMPENSATION CONSTANTS (F3) displays the COMPENSATION CONSTANTS screen, which has the following soft
keys: CALIB CONSTANTS (F1) and CORRECTION COEFFICIENTS (F2).
Selecting CALIB CONSTANTS (F1) from the COMPENSATION CONSTANTS screen displays a Calibration Constants
screen, which has entries for the full scale pressure of the pressure transducer, the calibration pressure, and
the calibration temperature.
PIR3502
Selecting CORRECTION COEFFICIENTS (F2) from the COMPENSATION CONSTANTS screen displays the
COMPENSATION CORRECTION COEFFICEINTS screen, which has the following soft keys: PRESSURE COEF
(F1) and TEMP COEF.
Selecting PRESSURE COEF (F1) from the COMPENSATION CORRECTION COEFFICIENTS screen displays the
PRESSURE COEF screen, which has entries for zero and span correction factors.
Selecting TEMP COEF (F1) from the COMPENSATION CORRECTION COEFFICIENTS screen displays the TEMP
COEF screen, which has entries for zero and span correction factors.
Selecting TEMP CONTROL (F2) from the BASIC ANALYZER screen displays the TEMPERATURE CONTROL screen, which has the
following soft keys: CASTING (F1) and CELL (F2).
Selecting CASTING (F1) from the TEMPERATURE CONTROL screen displays a Casting Control screen. Temperature control
for the filter wheel casting is enabled or disabled on this screen. The casting temperature SETPOINT is trapped to be
between 40 and 70 degrees Celsius and the nominal is 55 degrees Celsius.
Selecting CELL (F2) from the TEMPERATURE CONTROL screen displays a Cell Control screen. Cell temperature control is
enabled or disabled on this screen. The control algorithm is proportional‐integral‐derivative (PID). The band of
proportional temperature control extends below the setpoint. The control algorithm observes time constants for the
INTEGRAL and DERIVATIVE temperature corrections.
Selecting OPTIONS (F3) from the BASIC ANALYZER screen displays the OPTIONS screen, which has the following soft keys:
OPTICS (F1), PRESSURE (F2), and MORE (F3).
Selecting OPTICS (F1) from the OPTIONS screen display an Optics screen. The number of WHEEL FILTERS, the master
reference filter REFERENCE POSITION on the filter wheel, and the type of SOURCE are set up at the factory to define
the basic optics bench.
Selecting PRESSURE (F2) from the OPTIONS screen displays a Pressure screen. To display cell pressure with cell
temperature in DISPLAY TEMPERATURE mode or to enable pressure compensation, the cell PRESSURE SENSOR must
be installed and enabled here.
Selecting MORE (F3) from the OPTIONS screen displays the MORE OPTIONS screen, which has the following soft keys:
DIGITS DISPLAYED (F2) and RAM UPDATES (F3).
Selecting DIGITS DISPLAYED (F2) from the MORE OPTIONS screen displays a Digits Displayed screen. The number
of decimal places displayed for components measured in percent can be set to two or four digits.
Selecting RAM UPDATES (F3) from the MORE OPTIONS screen displays a RAM Updates screen. When RAM
Updates are enabled, the analyzer will update the RAM with the new values even when the EEPROM WRITE
DIP switch (#8 on the Calculation/Control Board) is Off. Under this condition, the analyzer will revert to the
old values on power cycling or reset. When RAM updates are disabled, the analyzer updates neither RAM
or EEPROM when the EEPROM WRITE DIP switch is Off. When the EEPROM WRITE DIP switch is On, both
the RAM and EEPROM are updated regardless of the state of the RAM UPDATES entry.
PIR3502
PIR3502 Operating Instructions 7 Repair
7 Repair
7.1 Sample cell window replacement
The window O‐rings must be replaced when the cell window is removed. Failure to replace these O‐rings
can cause sample to leak at the windows. See the Recommended Spare Parts List shipped with the
analyzer for the O‐ring part number.
1. Stop flow through the analyzer by closing valves for all types of sample flow; allow the cell to drain.
If the sample cell is heated, do not purge it with cold sample; it may cause thermal shock damage to the
cell windows.
If the cell has contained a hazardous substance be sure to purge the cell thoroughly with a non‐hazardous
sample.
Allow the cell to cool before working on it.
2. Remove power following local lock‐out tag‐out procedures.

3. Disconnect Sample Ports 1 and 2.
4. If the sample cell is not electrically heated, go to step 5. If the cell is electrically heated, remove the insulation from the
cell and remove the 9/64‐inch Allen screws from the top of the block(s), then lift off the block(s).
5. Loosen the set screw in the stabilizer block (see Figure 7.1) on each side of the cell by turning it approximately three full
turns with a 1/16‐inch Allen wrench.
KNURLED
CELL RETAINER SET
STABILIZER SCREW
SAMPLE
BLOCK
ALLEN PORT #1
SCREW
WASHER
CELL CELL O-RING
WINDOW WINDOW (MUST BE
RETAINER SPACER REPLACED)
WINDOW
CELL PTFE WASHER

BODY ALLEN
WASHER SCREW
WASHER
OUTER SAMPLE
INNER CELL
RETAINER RETAINER
O-RING O-RING OPTICAL PURGE VENT
Fig. 7.1. Cell Window Components
PIR3502
9. After the cell is removed, use a 3/8‐inch socket wrench with a three‐inch extension and the spanner wrench (shipped with
the analyzer) to remove the cell window retainer.
10. Remove the cell window retainer with the spanner wrench. This allows the cell body washer, cell window spacer, O‐ring,
cell window (use the valve tool with suction cups), and the PTFE washer to be removed in sequence. Remove the other
cell window using the same procedure.
Do not leave fingerprints on the cell windows. If necessary, use acetone to remove fingerprints.
11. Install the new windows in the reverse order as removed.
The threaded retainers of the cell should be reassembled with a torque wrench at 50 inch‐pounds, unless
specified otherwise in the Data Sheets.
12. Slide the cell as evenly as possible into its original position; make sure the optical purge vents are pointing down (see
Figure 7.1).
13. Locate the line on the knurled cell retainer and match this line with the line on the subassembly. Do this for each side of
the sample cell. This aligns the mounting holes of the cell retainer to the holes in the cell.
14. Replace and tighten the two Allen screws on both sides of the cell that secure the cell retainers.
15. To stabilize the cell, tighten the set screws in the stabilizer block on each side of the cell.
16. Reconnect Sample Ports 1 and 2, and the cell heater cable, if applicable.
17. Open the valves for the span sample, the zero sample, and the process sample.
18. Turn on the power and let the analyzer warm up for 30 minutes.
7.2 Source replacement

See the Data Package to confirm which source is used in the analyzer (platinum or tungsten) and to obtain the correct part
numbers for the analyzer components from the Recommended Spare Parts List.
7.2.1 Platinum source replacement
1. Remove the power following local lock‐out tag‐out procedures.

2. Open the Source Enclosure.
3. Locate the Source Control Board on the right inside wall of the Source Enclosure.
4. Disconnect the two source lead wires (red and black) from terminals WT3 and WT4 on the Source Control Board, using a
1/4‐inch nut driver.
5. Disconnect the two source lead wires (white/red and white/black) from TB1‐1 and TB1‐2 of the Source Control Board,
using a small straight blade screwdriver.
6. Cut and remove any cable ties securing the source control wiring.
PIR3502
7. Disconnect the chopper motor control cable from the Optical Filter Wheel Housing Cover (see Figure 7.2).
OPTICAL OPTICAL
FILTER FILTER
WHEEL WHEEL
HOUSING HOUSING
COVER
PLATINUM
SOURCE
IR BASE
ASSY
OPTICAL
CONNECTOR
SOURCE SOURCE
BODY BODY
SOURCE
SEALING
WASHER AND
TEFLON TAPE
SOURCE ASSEMBLY WITH SOURCE INSTALLED SOURCE ASSEMBLY WITH SOURCE REMOVED
Fig. 7.2. Platinum Source Replacement
Be careful not to break the source element when removing or installing the source assembly; do not
touch the ceramic coated source filament.
8. Unscrew the Source Assembly with a 7/8‐inch wrench.

9. Remove the washer from the existing source assembly and install it on the new source assembly.
10. Wrap PTFE sealant tape around the threads of the new Source Assembly.
11. Screw in the replacement source with the 7/8‐inch wrench without touching the ceramic coated source filament.
Source wires must be connected correctly. Failure to do so will result in extensive, or permanent,
damage to the Source Control Board.
12. Reconnect the red source lead wire to the terminal WT3 of the Source Control Board.
13. Reconnect the black source lead wire to terminal WT4 of the Source Control Board.
14. Connect attached white/red source lead wire to TB1‐1 of the Source Control Board.
15. Connect attached white/black source lead wire to TB1‐2 of the Source Control Board.
16. Reconnect the chopper motor control cable to the Optical Filter Wheel Housing Cover.
17. If applicable, adjust the optical purge pressure regulator for an indication of 8 psig at the optical purge pressure gauge. If
applicable, adjust the enclosure purge pressure regulator for an indication of 35 psig at the enclosure purge pressure
gauge.
18. Close the Source Enclosure door.
20. Turn on the power and let the analyzer warm up for 30 minutes.
21. Calibrate the analyzer as described in Section 2 and record the detector voltages for future reference.
7.3.2 Tungsten source replacement
1. Remove power following local lock‐out tag‐out procedures.

PIR3502
4. Disconnect the two source lead wires (red and black) from terminals WT3 and WT4 of the Source Board, using a 1/4‐inch
nut driver.
5. Disconnect the two source lead wires (white/red and white/black) from TB1‐1 and TB1‐2 of the Source Board, using a small
straight blade screwdriver.
6. Cut and remove cable ties securing source lead wiring.
7. Disconnect the chopper motor control cable from the Optical Filter Wheel Housing cover (see Figure 7.3).
Fig. 7.3. Tungsten Source Replacement
8. Remove the four Allen screws at the end of source assembly with a 3/32‐inch Allen wrench.
9. Extract the source and washer from the source body.
10. Remove the washer from the old tungsten source assembly and install it on the new tungsten source assembly. Do not
touch the tungsten source lamp; if it is touched, completely remove all fingerprints with a soft, clean, dry cloth.
If the O‐ring appears to be worn, replace it with a new O‐ring; failure to do so may result in a bad purge.
11. Insert the new source and its washer into the source body. Do not touch the tungsten source lamp; if it is touched,
completely remove all fingerprints with a soft, clean, dry cloth.
12. Install the four Allen screws at the end of the Source Assembly, but do not tighten them.
Source wires must be connected correctly. Failure to do so will result in extensive or permanent damage
to the Source Control Board.
13. Reconnect the red source lead wire to terminal WT3 of the Source Control Board.
14. Connect the black source lead wire to terminal WT4 of the Source Control Board.
15. Connect the white/red source lead wire to TB1‐1 of the Source Control Board.
16. Connect the attached white/black source lead wire to TB1‐2 of the Source Control Board.
17. Reinstall the chopper motor control cable.
Make sure all work permits and safety precautions are in effect.
18. If the analyzer has X Purge, see "X PURGE" in Section 4 for information on X Purge Override.
19. Open the Detector Enclosure.
PIR3502
20. Turn on the power.

21. Attach an oscilloscope to the detector signal (TB3‐33 on the I/O Board located in the Detector Enclosure) and to the shield
lead to the chassis.
22. Align the tungsten source until maximum peak‐to‐peak voltage is achieved on the oscilloscope, then tighten the Source
Assembly screws.
23. Remove the power and disconnect the oscilloscope. Close the Detector Enclosure door.
Alternate procedure for maximizing the tungsten source:
While viewing the detector signal (keypath: EXECUTE SELF TEST/VIEW MONITORS/SIGNALS/DETECTOR SIGNALS) align the
source until maximum AC voltage is obtained, then tighten the Source Assembly screws (AC voltage is on the right of the
display).
24. If applicable, inside the Source Enclosure adjust the optical purge regulator to read 8 psig on the gauge; adjust the
enclosure purge regulator to read 35 psig on the gauge.
25. Close the Source Enclosure door.
26. If applicable, properly remove X Purge Override (see "X PURGE" in Section 4).
28. Restore power and allow the analyzer to warm up for 30 minutes.
29. Calibrate the analyzer as described in Section 2 and record the detector voltages for future reference.
7.3 Chopper motor replacement

Depending on the analyzer location and the current weather conditions, it may be more appropriate to remove the chopper
motor assembly from the analyzer and work on it at another location.
1. Remove the power following local lock‐out‐tag out procedures.

3. Disconnect the chopper motor control cable.
4. Disconnect the 1/16‐inch optical purge capillary connection from the 1/16‐inch tee.
If the chopper motor assembly is being removed from the analyzer, go to step 5. If the chopper motor
assembly is worked on at the analyzer, go to step 11.
6. Disconnect the two source lead wires (red and black) from terminals WT3 and WT4 of the Source Control Board, using a
1/4‐inch nut driver.
7. Disconnect the two source lead wires (white/red and white/black) from TB1‐1 and TB1‐2 of the Source Control Board,
using a small straight blade screwdriver.
8. Cut and remove any cable ties securing the source control wiring.
9. Remove the four bolts from the Optical Filter Wheel Housing Cover with a 7/16‐inch deep‐well socket connected to a
three‐inch extension.
10. Gently pull the cover off the Optical Filter Housing and place it in the bottom of the enclosure. The assembly should be
ready to remove from the analyzer. When the assembly is in a suitable work area, proceed with this procedure.
PIR3502
11. Disconnect the Motor Connector and the Optical Connector from the Motor Control PCB (see Figure 7.4).
Fig. 7.4. Chopper Motor Replacement
12. Remove the Chopper Motor Plate along with the PCB by removing the three Allen bolts with a 5/32‐inch Allen wrench.
Do not touch the filter wheel when it is moving because the edges and corners of the metal strip (flag) on
the filter wheel are sharp.
When handling the filter wheel, grasp it by the motor body not the motor shaft, or hold the wheel
carefully by the edges. The metal strip (flag) on the filter wheel is thin; if it is damaged, it may not pass
through the optical interrupters on the chopper motor plate.
13. Loosen the set screw holding the shaft of the motor with a 0.035‐inch Allen wrench (supplied with replacement chopper
motor kit). Grasp the motor body and carefully remove the motor along with the filter wheel.
14. Remove the two screws holding the filter wheel to the motor and remove the filter wheel.
15. Place the filter wheel on the new motor, and secure it with the two screws.
16. Place the motor shaft into the motor mounting bracket and tighten the Allen set screw with a 0.035‐inch Allen wrench to
secure the motor shaft.
17. Insert the motor wires through the hole in the Motor Control PCB.
18. Return the Chopper Motor Plate and PCB assembly to their original positions by replacing the three Allen bolts, using a
5/32‐inch Allen wrench.
19. Insert the Optical Connector into the outside connector of the motor control board, then insert the motor control wiring
through the control wiring loop and plug the Motor Connector into the connector in the center of the board.
PIR3502
If the assembly was removed from the analyzer to be worked on, it must be returned to the analyzer at
this point.
20. Reconnect the chopper motor control cable.

Phasing Motor Procedure
22. Set DIP switches 2 and 4 to the OFF position.

23. Reconnect the two ribbon cables.
24. Close the Detector Enclosure.
25. Restore AC power.
26. On the Display Enclosure front panel, go to the Factory Set‐up Tables and DISABLE the casting temperature at the following
keypath:
MODIFY/FACTORY/ANALYZER/TEMP CONTROL/CASTING
27. Press the arrow key to disable the casting temperature controller and then press ACCEPT.
28. Position casting with the source side down and the filter wheel level.
29. With power on, place a jumper between WT1 and WT2 on the Motor Control PCB. Let the filter wheel come to rest.
30. Look between the filter wheel and the motor plate. SW1 and SW2 on the PCB should be completely covered by the filter
wheel flag and the end of the flag should stop at the center of SW3. If it is aligned correctly, go to step 37. If it is not
aligned correctly, continue with step 32.
31. Loosen the set screw in the motor mounting bracket that holds the motor and filter wheel.
32. Grasp the motor leads at the back of the motor and turn until SW1 and SW2 are completely covered by the filter wheel
flag and the end of the flag is in the middle of SW3.
33. Tighten the set screw in the motor mounting bracket.
34. With power on, check proper alignment by removing the jumper between WT1 and WT2 (this allows the motor to turn for
a few seconds), then place the jumper back between WT1 and WT2. Let the filter wheel come to rest.
35. If the filter wheel is not aligned properly, repeat steps 32 through 35.
36. When the wheel is aligned properly, turn the power off and remove the jumper between WT1 and WT2.
37. Remove power from the analyzer following local lock‐out tag‐out procedures.
38. Disconnect the motor control cable.
39. Insert the chopper motor assembly into the optical filter housing and align the casting cover with the optical filter housing
using the dowels as a guide.
Source wires must be connected correctly. Failure to do so will result in extensive, or permanent,
damage to the Source Control Board.
If the assembly was removed from the analyzer to be worked on, it must be reinstalled according to the
following procedure, starting with step 41. If the assembly was not removed from the analyzer, go to
step 46.
40. Reconnect the red source lead wire to terminal WT3 of the Source Control Board.
41. Reconnect the black source lead wire to terminal WT4 of the Source Control Board.
42. Connect the attached white/red source lead wire to TB1‐1 of the Source Control Board.
43. Connect the attached white/black source lead wire to TB1‐2 of the Source Control Board.
44. Reconnect the chopper motor control cable to the filter wheel housing (casting) cover.
45. Replace the four bolts with the 7/16‐inch deep‐well socket connected to a three‐inch extension, and use a torque wrench
to torque the bolts to 87 in.‐lb.
46. Install the 1/16‐inch optical purge capillary.
PIR3502
47. Reconnect the chopper motor control cable.

48. Restore AC power.
49. Go back to Factory Set‐up Tables and ENABLE the casting temperature at the following keypath:
MODIFY/FACTORY/ANALYZER/TEMP CONTROL/CASTING
50. Press the arrow key to ENABLE the casting temperature controller; press ACCEPT.
51. Remove the power following local lock‐out‐tag‐out procedures.
53. Return DIP switches 2 and 4 to the On position.
54. Reconnect the two ribbon cables.
This completes the phasing motor procedure.
56. If applicable, adjust the optical purge regulator for 8 psig on the optical purge gauge; adjust the enclosure purge regulator
for 35 psig indication on the enclosure purge gauge.
59. Calibrate the analyzer as described in Section 2.
7.4 Detector replacement
The replacement detector module may differ from the one in your system. If the defective detector
module has eight pins, you must replace both the detector module and the Detector PCB Assembly (refer
to the Replacement Parts List on the Important Documents CD‐ROM for the correct part numbers).
1. Remove power following local lock‐out‐tag‐out procedures.

3. Disconnect the signal cable connector.
4. Unscrew the three Allen screws from the detector cap with a 3/32‐inch Allen wrench (see Figure 7.5).
Fig. 7.5. Detector Replacement

PIR3502
5. Remove the detector cap along with the detector assembly from the detector housing.
6. Remove the old detector from the PCB socket.
When installing the new detector, do not touch the window.
7. Line up the tab on the new detector with the tab on the PCB socket and carefully plug the new detector flush into the
socket.
Detector Preamp Board Replacement
8. Without touching the detector window, carefully remove the detector from the PCB socket.
9. Unscrew the nut from the receptacle connector and remove the detector assembly from the cap.
10. Loosen the PCB from the detector cap; remove it and the receptacle connector from the cap.
11. Insert the new detector assembly's connector through the hole in the detector cap.
12. Install the nut on the receptacle connector.
13. Press the PCB into the detector cap.
14. Without touching the detector window, line up the tab on the detector with the tab on the PCB socket and carefully plug
the detector flush into the socket.
Re‐assembling the Detector
15. With the indentation in the detector cap to the front of the housing, insert the cap and assembly into the detector
housing.
16. Align the three holes in the detector cap with the three holes in the housing, install the three Allen screws and secure
them with a 3/32‐Allen wrench.
17. Reconnect the signal cable.
21. Calibrate the analyzer as described in Section 2.
7.5 Extended path length reflective cell window replacement

Some applications will require cell windows and some will not. If the cell has windows, they will be installed at the base of the
cell in the one‐inch diameter openings. To remove them for replacement:
1. Unscrew the four Allen screws holding the cell in the base and remove the cell.
2. Locate the windows and remove the window retainer rings.
3. Note that the windows are cushioned top and bottom by O‐rings; remove and discard these O‐rings.
4. Insert new top and bottom O‐rings when putting the new windows in place.
5. Put the window retainer rings back in place.
6. Mount the cell back on the cell base and tighten the four Allen screws.
The cell must be turned counterclockwise until it stops against the pin positioned in the cell base. The
two one‐inch diameter openings in the cell must line up directly over the transfer mirrors.

PIR3502
7.6 Calculation/control pcb replacement
Before opening the Detector Enclosure door, be sure the area is safe from hazardous gases and will
When handling electronic parts and assemblies, it is necessary that proper electrostatic discharge (ESD)
precautions be taken. Wear an ESD wrist strap with a grounding cable and use an ESD shielded bag to
protect PCBs removed.
1. Remove the defective Calculation/Control PCB from the analyzer.

2. If no programming changes have been made to the Calculation/Control PCB (alarm configurations, alarm levels,
autocalibration times, etc.), go to step 7.
3. If programming changes have been made to the Calculation/Control PCB, remove EEPROM chip U49 from the old
Calculation/Control PCB (see Figure 7.6 for location).
Fig. 7.6. Calculation/Control PCB
4. Remove EEPROM chip U49 from the new Calculation/Control PCB.

5. Install EEPROM chip U49 from the old Calculation/Control PCB into the U49 slot of the new Calculation/Control PCB.
6. If your system uses a low‐noise detector, set the jumper in JP1 to connect pins 1 and 2 (see Figure 6‐6 for location).
7. Install the new Calculation/Control PCB in the analyzer.
8. Apply power and start the analyzer as described in Section 2.
7.7 Source control board replacement

This procedure applies to all versions of the Source Control PCB. Source Control PCB Kit 826K001‐1 contains the replacement
board and instructional bulletin for replacing the PCB.
Before opening the Source Enclosure door, be sure the area is safe from hazardous gases and will remain
so the entire time the analyzer is open.
When handling electronic parts and assemblies, it is necessary to take proper electrostatic discharge
(ESD) precautions. Wear an ESD wrist strap with a grounding cable and use an ESD shielded bag to
protect PCBs removed from the analyzer.
1. Remove the Source Control PCB from the Source Enclosure.

2. Verify the Source Control PCB part number.

PIR3502
3. If the PCB you removed is 3526313‐1, install the source jumper in the JP1V position (see Figure 7.7).
Fig. 7.7. Source Control PCB 826A008B‐1
4. If the PCB you removed is 826A008B‐1, install the source jumper in the same position as the jumper on the PCB you
removed.
5. Install the new Source Control PCB.

PIR3502
PIR3502 Operating Instructions 8 Replacement parts
8 Replacement parts
8.1 Ordering information
Since the component parts specific to any given system are defined by the particular application, you
should refer to the “Recommended Spare Parts Lists” on the Important Documents CD‐ROM supplied
with the analyzer, to obtain the full and correct part number for the desired part or assembly.
8.1.1 Equipment identification

The following information, found in the Data Package and on the analyzer nameplate, should be included in any communication
concerning replacement parts or components:
• ABB Sales Order Number
• Analyzer Model Number
• Analyzer Part Number (P/N) and serial number
• For serial numbered subassemblies such as PC boards, include the serial number and the part number (including dash
number and revision letter) for the subassembly in the request
• Applicable references from the “Recommended Spare Parts List” of the Data Package, included with each analyzer
• Description of part
8.1.2 Hardware configuration identification

The nameplate (see Figure 8.1), which is located on the left side of the Detector Enclosure, lists the hardware configuration
information.
Fig. 8.1. Typical Nameplate
The hardware configuration consists of the model number, sales order number, and T‐Rating.

PIR3502
8.1.3 Software configuration identification

The software configuration appears when you enter the Help screen (see Figure 8.2).
Fig. 8.2. typical software configuration
8.1.4 How to order

Please contact your local ABB sales or service representative for specific instructions on ordering parts. Always include the
information listed in Equipment Identification and Configuration Identification in your request.
The remainder of this section lists the replaceable parts and components by their location in the equipment. Part numbers and
drawing numbers listed here are for identification purposes only. When you order parts for replacement, use the list of parts
included in the Engineering Data Package provided with your equipment to ensure you have the correct version of each part.

PIR3502
8.2 Sample cell
Ref
No. Description Part Number
1 O‐Ring 45051‐4‐23
2 Window 3526399‐_
3 PTFE Washer 3526434‐2
4 Inner Retainer O‐Ring 3616556‐1‐127
5 Outer Retainer O‐Ring 45051‐4‐123
Ball Driver (supplied with analyzer) TL56
Spanner Wrench (supplied with analyzer) 3528304‐1
Fig. 8.3. Cell and Cell Window Replacement Parts

PIR3502
Description Part Number
Source Control PCB Kit 826K001‐1

(need Sales Order number)
Motor Control PCB, 4 filter 759A045B‐1
Motor Control PCB, 8 filter 759A045B‐2
Optical Purge Regulator 3616808‐1
Enclosure Purge Regulator 3616808‐1
Optical Purge Gauge (0‐15 psig/0‐100 kPa) 44726‐1
Enclosure Purge Gauge (0‐100 psig/0‐700 kPa) 44726‐4
Fuse, 2 A 250 V 3615086‐06
Transformer T1 3616559‐1
Chopper Motor (see "Chopper Motor")
Platinum Source Assembly (see "Platinum Source")
Tungsten Source Assembly (see paragraph "Tungsten Source")
Consult the Recommended Spare Parts List on the Important Documents CD‐ROM shipped with the
analyzer to verify the type of source used.
Fig. 8.4. Source Enclosure

PIR3502
9.3.1 Platinum source
Ref
1 O‐Ring 45051‐4‐27
2 Adhesive, Epoxy 007895
3 Washer, Source Sealing 3526462‐1
4 Tape, PTFE,1/2 inch wide 006451‐2
5 Base Assembly, Platinum Source 759A039C‐1
Fig. 8.5. Platinum Source Replacement Parts

PIR3502
8.3.2 Tungsten source
Ref
1 O‐Ring, Fluorocarbon, 1‐1/4 x 1‐1/8 x 1/16 45051‐4‐27

2 Adhesive, Epoxy 007895
3 O‐Ring, Fluorocarbon, 1‐3/16 x 1‐1/16 x 1/16 45051‐4‐26
4 Base Assembly, Tungsten Source 759A040B‐1
5 O‐Ring, Fluorocarbon, 5/8 x 1/2 x 1/16 45051‐4‐17
OPTICAL
OPTICAL FILTER SPLIT LOCK ALLEN BOLT
FILTER WHEEL WASHER
WHEEL HOUSING SOURCE
HOUSING COVER WASHER
LOCK
5 WASHER
4
OPTICAL
1 CONNECTOR
2 SOURCE CAP
BODY SCREW
2
LENS RETAINER LOCK
3 WASHER
SPLIT LOCK ALLEN BOLT

WASHER
Fig. 8.6. Tungsten Source Replacement Parts

PIR3502
8.3.3 Chopper motor
Ref
1 Kit, Motor 759K007‐3

2 PCB Assembly, Motor Control 759A045B‐_
0.035‐inch longarm Allen Wrench (supplied with motor kit) TL156
Fig. 8.7. Chopper Motor Replacement Parts

PIR3502
Power Supply PCB 802A016B‐1

Calculation/Control PCB Kit 826K004B‐1
Communications PCB 826A007B‐1
VistaNET Interconnect PCB 802A015B‐1
I/O Power PCB 759A008C‐1
Backplane PCB 826A005B‐1
Fuse, 2.0 A 250 V 3615087‐05
Fuse, 4.0 A 250 V 3615087‐07
Relay/Solenoid Driver PCB 826A003B‐1
Front Panel PCB (see "Front Panel Assembly")
Trend PCB (see "Front Panel Assembly")
Display PCB (see "Front Panel Assembly")
Detector (see "Detector")
Remote Front Panel (see "Remote Front Panel")
Fig. 8.8. Detector Enclosure
8.4.1 Front panel assembly
Front Panel PCB 826A001B‐1

Trend PCB 826A002B‐1
Display PCB Kit 759A104B‐1

PIR3502
8.4.2 Detector
Ref
1 O‐Ring, 1‐7/16 x 1‐5/16 x 1/16, Fluorocarbon 45051‐4‐30

2 Detector Module, IR 759D035‐1
2 Low‐Noise Detector Module 3617765‐1
3 Detector PCB Assembly 759A109‐1
Fig. 8.9. Detector Replacement Parts
8.4.3 Remote front panel
Calculation/Control PCB 826A004B‐2
8.5 Reflective cell
Mirror 8240214‐1

NOTES
OI/PIR3502/PFO3372-EN, rev F2 113

NOTES
OI/PIR3502/PFO3372-EN, rev F2 114

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Prior to installation, the equipment referred to in this
Valves, Actuators and Positioners manual must be stored in a clean, dry environment, in
— Control Valves
accordance with the Company’s published specification.
— Actuators
— Positioners Periodic checks must be made on the equipment’s
condition. In the event of a failure under warranty, the
Water, Gas & Industrial Analytics Instrumentation following documentation must be provided as
— pH, Conductivity and Dissolved Oxygen Transmitters substantiation:
and Sensors — A listing evidencing process operation and alarm logs
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Process Automation We reserve the right to make technical changes o
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Oldends Lane
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LimitedUK possible lack of information in this document.
ABB Inc. Note
2015
01.2013
Tel:
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We reserve
modify the contents all rights inwithout
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Measurements subject matter and illustrations contained therein
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Rev.F2
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or or in parts – is
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OI/PIR3502/PFO3372-EN
UK 24901
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Tel:
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Warminster
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3KXF211101R1001 wholeororin inparts
parts – is
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Process
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GloucestershireABBGL10
Engineering
3TA (Shanghai) Ltd.
Tel:
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Fax:
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Operating Instructions OI/PIR3502/PFO3372-EN Rev.

Measurement made easy

6 Maintenance and troubleshooting .................... 75

1 Safety and symbols

Indicates that referenced items are

Indicates that a risk of electrical

Indicates a potential hazard which

2.3 System description

DETECTOR SAMPLE CELL SOURCE

Fig. 2.1. Typical PIR3502 Process Photometer

2.4 Source enclosure

2.4.1 Optical filter assembly

2.4.2 Purge regulators and gauges (option)

2.5 Sample cell assembly

2.6 Detector enclosure

2.6.1 System electronics

2.6.2 Liquid crystal display

2.6.3 Detector assembly

2.6.4 Optical span filter option

2.7 Enclosure purge systems (option)

2.8 Extended path length reflective cell (option)

2.8.1 General description

Fig. 2.2. IR Analyzer with Reflective Cell

2.8.2 Pressure relief valve

2.9 Fiber optic analyzer (option)

Fig. 2.3. PFO3372 Ir Analyzer with Fiber Optic Probe

2.10 Remote front panel (option)

2.11 Temperature and pressure compensation (option)

2.11.1 Temperature compensation

 Empirical Compensation—Temperature compensation is based on experimental data. It requires calibration in

2.11.2 Pressure Compensation

 Empirical Compensation—Pressure compensation is base on experimental data. It requires calibration in factory

STATUS NORMAL ENCLOSURE PURGE

Fig 2.4. PIR3502 for Non‐Corrosive Samples

Enclosure Electronics Temperature

ABB WATER 1 0 PPM

DI SPLAY CO NC ENTRA TIO N

DI SPLAY TE MPER ATUR E M ODE

CA LIBR ATE/BEN CHM ARK

EXE CUTE SE LFTES TS

Pressure Compensation with Purged PRESS. COMP.

Transducer Panel Installed on

Fig. 2.5. PIR3502 for Corrosive Samples

3 Installation and startup

3.2 Preparing for installation

3.2.1 Recommended tools and equipment

Tools: standard set of Phillips screwdrivers

Supplies: leak detection solution

span sample, application‐specific

Equipment: electrostatic discharge (ESD) wrist strap and grounding cord

3.2.2 Other recommendations for installation

3.2.3 Opening and closing analyzer doors

3.3 Equipment mounting

3.4 PIR3502 standard connections

OPTICAL POWER IN SIGNAL SIGNAL SAMPLE STEAM ENCLOSURE OPTICAL

Fig. 3.1. Typical PIR3502 Connections

3.4.1 Power In without x purge

Fig. 3.2. Power Connections (without X Purge)

3.4.2 Power In with x purge

Fig. 3.3. Power Connections (with X Purge)

3.4.3 Watchdog alarm

Fig. 3.4. Watchdog Alarm Connections

3.4.4 Solenoid connections

Fig. 3.5. Solenoid Connections