909 User Manual Rev H.pdf

Model 909 Single-Gas Analyzer

User Manual

PN 903-8601, Rev. H

Canada LPA DIVISION OF AMETEK PROCESS & ANALYTICAL INSTRUMENTS

Western Research

ii | Model 909 Single-Gas Analyzer

20042010 AMETEK Canada LP, A Division of AMETEK Process & Analytical Instruments Printed in CanadaThis manual is a guide for the use of the Model 909 Single-Gas Analyzer. Data herein has been verified and validated and is believed adequate for the intended use of this instrument. If the instrument or procedures are used for purposes over and above the capabilities specified herein, confirmation of their validity and suitability should be obtained; otherwise, AMETEK does not guarantee results and assumes no obligation or liability. This publication is not a license to operate under, or a recommendation to infringe upon, any process patents.

Offices

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Contents | iii

ContentsOffices .................................................................................................................................. iiSafety Notes ....................................................................................................................... xiElectrical Safety .................................................................................................................. xiGrounding .......................................................................................................................... xiPersonnel and Equipment Safety Information ............................................................ xii

Warnings ..................................................................................................................... xiiCautions ..................................................................................................................... xiv

Warning Labels ................................................................................................................. xvEnvironmental Information ........................................................................................... xvElectromagnetic Compatibility (EMC) ......................................................................... xviSpecial Warnings and Information .............................................................................. xvii

Equipment Used in Haza rdous Locations........................................................... xviiEC Declaration of Conformity ....................................................................................xviiiWarranty and Claims ....................................................................................................... xx

ChAPTEr 1 OvErvIEwPrinciples of Operation .................................................................................................. 1-1

The Basis .................................................................................................................... 1-1The Implementation ................................................................................................ 1-2

Microcontroller Board and Host Controller Board .............................................. 1-3Sample Flow ........................................................................................................ 1-3Discrete Wavelengths .......................................................................................... 1-4

Analyzer Features ............................................................................................................ 1-5Sample System and Electronics .............................................................................. 1-5

About the Analyzer Sample System ............................................................................. 1-8Aspiration Components and Functions ................................................................ 1-8Sample Conditioning Unit (SCU) and Sample Line ........................................... 1-9Calibration ................................................................................................................. 1-9

Air Supply ....................................................................................................................... 1-11Electronics Purge Air .............................................................................................. 1-11Aspirator Drive Air ................................................................................................. 1-11Velocimeter Purge Air ............................................................................................ 1-12

Status Relays .................................................................................................................. 1-12

ChAPTEr 2 SPECIfICATIOnSMethodology .................................................................................................................... 2-1

Standard Ranges ...................................................................................................... 2-1Analyzer Specifications .................................................................................................. 2-2

Response Time .......................................................................................................... 2-2Measurement Accuracy ........................................................................................... 2-2Repeatability .............................................................................................................. 2-2Calibration ................................................................................................................. 2-2

iv | Model 909 Single-Gas Analyzer

Linearity ..................................................................................................................... 2-2Zero Stability ............................................................................................................. 2-2Temperature Drift ..................................................................................................... 2-224-Hour Zero Drift ................................................................................................... 2-3Analog Outputs ........................................................................................................ 2-3Digital Outputs (Communication Ports) ............................................................... 2-3Power Consumption ................................................................................................ 2-3Electrical Requirements ........................................................................................... 2-3Typical Sample Gas Flow Rate ................................................................................ 2-3Ambient Limits .......................................................................................................... 2-4

Temperature ......................................................................................................... 2-4Humidity ............................................................................................................. 2-4Maximum Altitude.............................................................................................. 2-4

Sample Transport ...................................................................................................... 2-4Instrument Air Requirements ................................................................................. 2-4Physical Dimensions (on backpan) ....................................................................... 2-4Status Relays .............................................................................................................. 2-5Temperature Control ................................................................................................ 2-5Output Parameter Ranges ....................................................................................... 2-5Measuring Cell Construction ................................................................................. 2-5Measuring Cell Operating Temperature ............................................................... 2-5Pressure Compensation ........................................................................................... 2-5Approvals and Certifications .................................................................................. 2-6O2 Concentration Signal (Optional) ...................................................................... 2-6

Speed of Response ................................................................................................ 2-6Accuracy .............................................................................................................. 2-6Repeatability ........................................................................................................ 2-624-Hour Zero Drift ............................................................................................. 2-6Temperature Drift ................................................................................................ 2-6Electrical Classification ....................................................................................... 2-6

Velocimeter ................................................................................................................ 2-7Standard Range .................................................................................................. 2-7Accuracy .............................................................................................................. 2-7Repeatability ........................................................................................................ 2-7Stability ............................................................................................................... 2-7Hysteresis ............................................................................................................ 2-7

ATEX (KEMA) Certificates and Analyzer Markings .................................................. 2-8Purged Analyzers ATEX Certificate ....................................................................... 2-8Purged Analyzer Markings ................................................................................... 2-13

No Release ......................................................................................................... 2-13Limited Release .................................................................................................. 2-13

Heater Plate ATEX Certificate ............................................................................... 2-14Heater Plate Marking ............................................................................................. 2-16Disconnect Enclosure Type 200 ATEX Certificate .............................................. 2-17Type 200 Disconnect Enclosure Marking ............................................................ 2-19

Contents | v

ChAPTEr 3 InSTALLATIOn & STArT-UPSafety Considerations ..................................................................................................... 3-2Pre-Installation Requirements....................................................................................... 3-3

Storage Prior to Installation .................................................................................... 3-3Uncrating and Inspecting the Analyzer ................................................................ 3-3General Installation Information ........................................................................... 3-4Tools, Equipment and Supplies Required for Installation ................................. 3-4

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

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

Installing the Sample Conditioning Unit ......................................................... 3-14Installing and Connecting the Sample and Vent Lines ..................................... 3-15Installing and Connecting Instrument Air ....................................................... 3-17Installing the Calibration (Span/Zero) Gas Lines ............................................. 3-18

Connecting I/O Signals, Alarm Relay Contacts, and AC Power ............................ 3-19Electrical Connections ............................................................................................ 3-20

Start-Up and Verification ............................................................................................. 3-25Purged Analyzer (Hazardous Location) Applications ...................................... 3-26Powering Up the Analyzer .................................................................................... 3-28Start-Up Diagnostic Checklist .............................................................................. 3-33Sample System Leak Check .................................................................................. 3-36Manually Zeroing the Analyzer ........................................................................... 3-38Adjusting the Zero Gas Flow Rate ....................................................................... 3-40Adjusting the Sample Gas Flow Rate .................................................................. 3-41

Setting Sample Response Time .......................................................................... 3-41Normal Operation ......................................................................................................... 3-42

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

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

ChAPTEr 4 COnTrOLLEr / USEr InTErfACEIntroduction to the User Interface Panel ..................................................................... 4-2

User Interface Components .................................................................................... 4-2Flow Control Mode Indicators on the User Interface Panel .............................. 4-4Entering Data Using Base Ten (10) Exponents ..................................................... 4-4Entering / Returning to RUN Mode Quick Reference .................................... 4-5

RUN / CFG Mode Quick Reference Sheet Keystroke Combinations ..................... 4-6Entering CFG Mode Quick Reference ............................................................... 4-7Entering CAL Mode Quick Reference ............................................................... 4-8

CAL Mode Quick Reference Sheet Keystroke Combinations ............................ 4-9About CFG / CAL Mode Passwords ..................................................................... 4-10

Changing the Password for CAL Mode ............................................................. 4-10Changing the Password for CFG Mode ............................................................. 4-11

vi | Model 909 Single-Gas Analyzer

Working in the RUN / CFG Operating Modes ......................................................... 4-12While Working in RUN Mode ....................................................................... 4-12While Working in ConFiGuration (CFG) Mode ......................................... 4-13

Returning to RUN Mode From CFG Mode ...................................................... 4-14Defining RUN / CFG Mode Keystroke Terms .................................................... 4-15

RUN / CFG Mode F1 Keystrokes ................................................................... 4-16RUN / CFG Mode F2 Keystrokes ................................................................... 4-18RUN / CFG Mode F3 Keystrokes ................................................................... 4-20RUN / CFG Mode F4 Keystrokes ................................................................... 4-21RUN / CFG Mode F5 Keystrokes ................................................................... 4-23RUN / CFG Mode F6 Keystrokes ................................................................... 4-25

Configuring the Analyzer Control Functions ........................................................... 4-27Output Signal Assignment (OSA) ........................................................................ 4-27

Analog Input Channels ..................................................................................... 4-28Display I/O Board Analog Input Signals ....................................................4-29Micro-Interface Board Analog Input (MAI) Signals ...................................4-30Host Controller Board Analog Input (HAI) Signals ...................................4-31Calculated Results .......................................................................................4-31

Active Temperature and Pressure Compensation ............................................. 4-32Measuring Cell Temperature Compensation ..................................................... 4-32Measuring Cell Pressure Compensation ........................................................... 4-32

Mass Flow Rate ....................................................................................................... 4-33Entering Differential Pressure Transducer Range ............................................ 4-33Entering Temperature Transmitter Coefficients ................................................ 4-34Calculation Constants ....................................................................................... 4-35

Entering KQ .................................................................................................4-35Entering KE .................................................................................................4-35

Stream Temperature and Differential Pressure ................................................. 4-36Stream Temperature (Voltage Input HAI) ...................................................... 4-36Entering Stream Temperature AuxTAvg (T90) ................................................ 4-36Differential Pressure .......................................................................................... 4-37

Entering Differential Pressure AuxTAvg (T90 Average) ............................4-37Stream Temperature (Current Input MAI) .................................................... 4-37

Velocimeter and Emissions Calibration............................................................... 4-38DP Cell Initial Set-up ....................................................................................... 4-39

Default Configuration .................................................................................4-39DP Zero and Span .......................................................................................4-40

Temperature Transmitter ................................................................................... 4-41Flow & Emission Output Calibration ............................................................... 4-43Customizing Velocimeter Backpurge and AuxTAvg (T90) Settings ................. 4-45

Backpurge Interval .......................................................................................4-45Backpurge Duration .....................................................................................4-45AuxTAvg (T90) Averaging Time for the Differential Pressure Signal ........4-45

Contents | vii

Working in the CAL Operating Mode ....................................................................... 4-47Defining CAL Mode Keystroke Terms ................................................................ 4-48

CAL Mode F1 Keystrokes ............................................................................... 4-49CAL Mode F2 Keystrokes ............................................................................... 4-50CAL Mode F3 Keystrokes ............................................................................... 4-51CAL Mode F4 Keystrokes ............................................................................... 4-52CAL Mode F5 Keystrokes ............................................................................... 4-53CAL Mode F6 Keystrokes ............................................................................... 4-55

Setting Up Analyzer Calibration Functions ....................................................... 4-56Flow Control (Sample) Modes ........................................................................... 4-56

Analyzer Control Mode (Automatic Control by the Analyzer) ...................4-57Continuous Backpurge Mode (Manual Control by the User) .....................4-57Continuous Sample Mode (Manual Control by the User) ..........................4-58Continuous Zero Gas Flow Mode (Manual Control by the User)...............4-58Continuous Calibration Gas Flow Mode (Manual Control by the User) ....4-59

Velocimeter Flow Control .................................................................................. 4-60Entering Calibration Gas Concentration .......................................................... 4-60Setting Calibration Gas Timers ......................................................................... 4-61Integration Timer (IntTime) .............................................................................. 4-62Auto-Calibration Interval Timer (ACal) ........................................................... 4-62

Time to Next Auto-Calibration ....................................................................4-62Auto-Zero Interval Timer (AZInt) .................................................................... 4-63

Time to Next Auto-Zero ..............................................................................4-63Setting the Sample Delay Timer (SDelay) ........................................................ 4-64Manual Zero/Span ............................................................................................ 4-65

Manual Zero ................................................................................................4-65Manual Span ...............................................................................................4-65

Spanning Dual Range ....................................................................................... 4-67Solenoid Valve Control ...................................................................................... 4-70

Solenoid Assignments ..................................................................................4-70Auto-Zero/Auto-Span ....................................................................................... 4-71

Manual Start of Auto-Zero ..........................................................................4-72Manual Start of Auto-Span .........................................................................4-73

Auto-Calibration ............................................................................................... 4-74Timed Start of Auto-Calibration ..................................................................4-74Manual Start of Auto-Calibration ...............................................................4-75Remote Start of Auto-Calibration ................................................................4-76

Remote Start of Backpurge (Optional) .............................................................. 4-76Analog Output Channels .................................................................................. 4-78

Setting Output Channel Full-Scale .............................................................4-78Analog Output Calibration ............................................................................... 4-79Measuring Cell Temperature and Pressure ....................................................... 4-81

Default Measuring Cell Temperature ..........................................................4-81Entering Default Cell Pressure ....................................................................4-81

Probe Blow-Back Control (Optional) ................................................................ 4-82

viii | Model 909 Single-Gas Analyzer

ChAPTEr 5 MAInTEnAnCE & TrOUbLEShOOTInGSafety Considerations ..................................................................................................... 5-1Maintenance ..................................................................................................................... 5-2

Preventive Maintenance .......................................................................................... 5-2Analyzer Preventive Maintenance Schedule ....................................................... 5-3Expo-Telektron Safety Systems MiniPurge (Optional) Preventive Maintenance Schedule ......................................................................................... 5-5

Before Performing Maintenance ............................................................................ 5-5Locating a Plug in the Sample System ................................................................ 5-6Detecting a Plug in the Sample System .............................................................. 5-6Preventing a Plug in the Sample System ............................................................ 5-7

Changing Out Replaceable Parts ........................................................................... 5-9Measuring Cell Preventive Maintenance .......................................................... 5-10Source Lamp Replacement ................................................................................. 5-20

When Do the Source Lamps Need to be Replaced? ......................................5-20About the Source Lamps ..............................................................................5-20Replacing the Source Lamps ........................................................................5-21

Auto-Setup ........................................................................................................ 5-27Auto-Setup Completion Number .................................................................5-27PMT Level and PMT Balance .....................................................................5-28Auto-Setup Fault Messages and Corrective Action .....................................5-29

Initiating an Auto-Setup ................................................................................... 5-30Manipulating the Completion Number, PMT Level, and PMT Balance ....5-31

Heater Plate Heater Cartridge and RTD Replacement ..................................... 5-33Examining and Caring For the Flamepaths ....................................................... 5-48

Disconnect Enclosure Flamepath (Joining Surfaces) ......................................... 5-49Troubleshooting and Diagnostics ............................................................................... 5-50

Viewing Errors on the User Interface Panel ....................................................... 5-50Types of Errors (Alarms) ................................................................................... 5-50Viewing Current Error Messages ..................................................................... 5-51Viewing Historical Error Messages ................................................................... 5-52

Host Controller Board Alarm Conditions and Corrective Action .................. 5-53Microcontroller Board Alarm Conditions and Corrective Action .................. 5-61Analyzer Reset ........................................................................................................ 5-65

ChAPTEr 6 ChAPTEr SErvICE & PArTSTechnical Support ............................................................................................................ 6-1Returning Equipment ..................................................................................................... 6-2Recommended Spare Parts ............................................................................................ 6-4

Optical Bench/Measuring Cell Spare Parts ........................................................... 6-5Sample Conditioning Unit (SCU) Spare Parts ..................................................... 6-6Spare Analyzer Fuses ............................................................................................... 6-7Replacement Boards................................................................................................. 6-9

ChAPTEr 7 SOfTwArE GLOSSAryUser Interface Panel Abbreviations .............................................................................. 7-1Abbreviations Used in This Manual ............................................................................. 7-2

Contents | ix

APPEnDIx A OPTIOnSO2 Concentration Measurement .................................................................................. A-1

SSR Outputs ............................................................................................................. A-2Entering Calibration Gas O2 Concentration ........................................................ A-3O2 Span Timer .......................................................................................................... A-3Auto-Calibration ...................................................................................................... A-4Manual O2 Sensor Zero/Span ................................................................................ A-6

Manual O2 Sensor Zero (Air)..............................................................................A-6Manual O2 Sensor Zero (Nitrogen/Air) ..............................................................A-8

Dilution Air Correction ............................................................................................... A-10Correction Equation .............................................................................................. A-10Entering [O2 ] ..................................................................................................... A-11

APPEnDIx b SErIAL COMMUnICATIOn InTErfACE (MODbUS)Overview ......................................................................................................................... B-1Analyzer Modbus Interface Parameters ..................................................................... B-6

Modbus Address ...................................................................................................... B-6Communications Parameters ................................................................................. B-6

Modbus Functions .......................................................................................................... B-7Exception Code ............................................................................................................... B-7Holding Registers ........................................................................................................... B-8Units and Display Bit Image (Register 9) ................................................................. B-22Analyzer Status Bytes (Register 154) ......................................................................... B-22Solenoid Output Bit Image (Register 156) ................................................................ B-23Digital Input Bit Image (Register 157) ....................................................................... B-24Digital Output Bit Image (Registers 158, 159) .......................................................... B-24Gas Flow Control (Registers 189, 190) ....................................................................... B-26

APPEnDIx C COnvErSIOn fACTOrS & CALCULATIOnSConversion Factors......................................................................................................... C-1SI Prefixes......................................................................................................................... C-4Gas Mixtures ................................................................................................................... C-5

Average Molecular Weight ..................................................................................... C-5Specific Gravity ........................................................................................................ C-5Air Composition ....................................................................................................... C-6

Gas Flow Rate Measurement ....................................................................................... C-7Mass Flow Rate ............................................................................................................. C-12References ..................................................................................................................... C-13

APPEnDIx D DrAwInGSAnalyzer Schematic (WX-14716) ..................................................................................D-2Analyzer (GP) Piping & Instrumentation Diagram ..................................................D-3Backpan Mounting Details, GP Analyzers .................................................................D-4Overall Component Layout, GP Analyzers ...............................................................D-5Electronics Enclosure Layout, GP Analyzers .............................................................D-6User Interface Panel (WX-14151) .................................................................................D-7AC Wiring, GP/Div 2/CE/Zone 1 Analyzers (WX-102853) ........................................D-8

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Ribbon Cable Interconnect (WX-102836) ....................................................................D-9Sample/Vent Line Wiring, GP/Div 2 Analyzers (100-1254-5) .................................D-10GP Lower Enclosure to Electronics Wiring, CE Analyzers (WX-102810) ............D-11Heater and Sensor Wiring, GP/Div 2 Analyzers (WX-102851) ..............................D-12Heater and Sensor Wiring, CE/Zone 1 Analyzers (WX-102852) ...........................D-13Disconnect Enclosure Wiring, 120V, Zone 1 Analyzers (100-1343-5) ...................D-14Disconnect Enclosure Wiring, 240V, Zone 1 Analyzers (100-1344-5) ...................D-15Lower Cabinet Wiring, CE/GP Analyzers, 120V (100-1341-3) ...............................D-16Lower Cabinet Wiring, CE/GP Analyzers, 240V (100-1342-3) ...............................D-17Customer Signal Connections, GP/Div 2 Analyzers (WX-102822) .......................D-18Customer Signal Connections, CE/Zone 1 Analyzers (WX-102816) .....................D-19Signal Wiring, GP/Div 2/CE/Zone 1 Analyzers (WX-102815) ................................D-20 15V and 5V Power Supply DC Wiring, GP/Div 2/CE/Zone 1 Analyzers (WX-102811) ..................................................................................................................D-2124V Power Supply DC Wiring, CE/Zone 1 Analyzers (WX-102812).....................D-22RS-232 Communications Cable Wiring (300-9480) ..................................................D-23RS-232/RS-485 Module Wiring, CE/Zone 1 & GP/Div 2 Analyzers (100-2185) ...D-24Wiring Diagram, All Seals, 120V, Zone 1 Analyzers (100-1343-9) .........................D-25Wiring Diagram, All Seals, 240V, Zone 1 Analyzers (100-1344-9) .........................D-26Optical Bench Board (100-1662) .................................................................................D-27Micro-Interface Board (100-0116) ..............................................................................D-28Host Controller Board (Display Interface) (100-0138) ............................................D-29Microcontroller Board (100-0117) ..............................................................................D-30Termination Board (100-1534).....................................................................................D-31Display I/O Board (100-0939) ......................................................................................D-32Measuring Cell/Lamp Assembly (WX-14856) ..........................................................D-33Optional Velocimeter Solenoid Block, 120 V (100-1933-1) .....................................D-34Optional Velocimeter Zeroing Layout, 120 V, 909/910 GP Analyzers (100-1933-2) ....................................................................................................................D-35Optional Velocimeter Solenoid Block, 240 V (100-1934-1) .....................................D-36Optional Velocimeter Zeroing Layout, 240 V, 909/910 GP Analyzers (100-1934-2) ....................................................................................................................D-37Zirconia Oxide O2 Sensor (Optional), Electronics Panel Layout (100-1160-1) ....D-38Zirconia Oxide O2 Sensor (Optional), Wiring Connections (100-1160-2) ............D-39Calibration Manifold Block, Flow Diagram (100-2141-1) .......................................D-40Calibration Manifold Block, Assembly Diagram (100-2141-2)...............................D-41

SUPPLEMEnTAL InfOrMATIOn

Contents | xi

Safety notes

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

An operating procedure which, if not strictly observed, may result in personal injury or envi-ronmental contamination.

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

Important information that should not be overlooked.

Electrical Safety

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

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

Grounding

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

Verify ground continuity of all equipment before applying power.

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xii | Model 909 Single-Gas Analyzer

Personnel and Equipment Safety Information

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

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

warnings

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

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

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

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

Before working on the analyzer, test the area for flammable gases. If an explosive gas atmo-sphere is present, do not open any covers or doors without first disconnecting power and/or alternate power sources to the analyzer.

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Contents | xiii

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

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

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

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

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

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xiv | Model 909 Single-Gas Analyzer

Cautions

Review and follow these Cautions to avoid damaging the equipment.

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

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

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

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

Purged Analyzer (Hazardous Location) Applications: For Zone 1 Installations, all cable entry glands (one power cable entry and two signal cable entries) into the flameproof Disconnect Enclosure must be Ex d certified. As per EN 60079-14:1997, 10.3.2 The cable entry system shall comply with e) flameproof cable entry devices incorporating compound filled seals around the individual cores or other equivalent sealing arrangements. For Zone 2 Installations, use a suitable flameproof cable entry device with a sealing ring, as per EN 60079-14:1997, 10.3.2, item b); or, comply with local wiring regulations and electri-cal codes. In all cases, all unused cable entry ports must be plugged with a certified Ex d plug.

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Contents | xv

warning Labels

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

Protective Conductor Terminal (BORNIER DE LECRAN DE PROTECTION) Schutzerde

Caution Risk of electric shock (ATTENTION RISQUE DE DCHARgE LECTRIQUE) Achtung Hochspannung Lebensgefahr

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

CAUTION Hot Surface (ATTENTION SURFACE CHAUDE) Achtung Heie Oberflche

Environmental Information

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

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

Whentheequipmentisreadytobedisposedof,takeittoyourlocalorregion-al waste collection administration for recycling.

Insomecases,yourendoflifeproductmaybetradedinforcredittowardsthe purchase of new AMETEK instruments. Contact your dealer to see if this program is available in your area.

IfyouneedfurtherassistanceinrecyclingyourAMETEKproduct,contactouroffice listed in the analyzer User Manual.

xvi | Model 909 Single-Gas Analyzer

Electromagnetic Compatibility (EMC)

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

The various configurations of the Model 909 Single-Gas Analyzers should not produce, or fall victim to, electromagnetic disturbances as specified in the European Unions EMC Directive (if applicable to your application). [The NEC/CEC certification is Class I, Division 2, Groups C & D. The KEMA (ATEX) certification for Zone 1 hazardous locations is Ex pd IIB T3.] Strict compliance to the EMC Directive requires that certain installation techniques and wiring practices are used to prevent or minimize erratic behavior of the Analyzer or its electronic neighbors. Below are examples of the techniques and wiring practices to be followed.

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

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

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

!CAUTIOn

Contents | xvii

Special warnings and Information

Equipment Used in haza rdous Locations

Refer to Chapter 2 Specifications for details about the suitability of this equipment in hazard-ous locations.

Explosion Hazard Do Not Disconnect Equipment Unless Power Has Been Switched Off or the Area is Known to be Non-Hazardous. Risque dexplosion Avant de dconnecter lquipement, coupez le courant o vous assurez que lemplacement est design non dangereux.

All input and output wiring must be in accordance with Class I, Division 2 wiring methods (CEC 18-152) and in accordance with the authority having jurisdiction.

!wArnInG

!Avertissement

xviii | Model 909 Single-Gas Analyzer

EC Declaration of Conformity

Contents | xix

xx | Model 909 Single-Gas Analyzer

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

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

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

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

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

Overview | 1-1

OvErvIEw

This chapter discusses the principles of operation and features of the Model 909 Single-Gas Analyzer, and a summary of how the entire system operates. This chapter also provides an overview of the AMETEK sample system and electronics and the various sub-systems that make up the entire analyzer system.

Principles of Operation

The basis

The Model 909 Single-Gas Analyzer measures, at two discrete wave-lengths, the absorbances of ultraviolet radiation (light) by a gas sample. The concentration of the component absorbing the light (absorber) is then determined from relationships developed through application of the ideal gas law in concert with the laws of Bouguer, Beer, and Lambert.

Thus, the absorbance, A, due to a single absorber is,

RTlPkxA ][=

where l is the path length of the light in the gas sample, [x] is the concen-tration (mole percent [see Note]) of absorber x, k is the molar absorptivity of absorber x at the measuring wavelength, , T, and P are the tempera-ture and pressure of the gas sample, respectively, and R is the universal gas constant.

For an ideal gas, mole percent is equal to volume percent. At the nor-mal operating conditions of the analyzer, the real gas mixture deviates from ideal behavior by less than 0.5 percent.

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1-2 | Model 909 Single-Gas Analyzer

For any given system at constant temperature and pressure, the equation can be simplified to:

][ xkCA =

where C lP/RT is a constant depending only upon the system of units employed. The concentration of the absorbing component may be deter-mined from the absorption at the two measuring wavelengths.

The Implementation

The analyzer is comprised of two ultraviolet light sources, a Filter Block containing two wavelength-selective filters, a Beam Splitter, front-sur-faced mirrors, a gas Measuring Cell, and two matched photo detectors (see Figure 1-1).

The Measuring Cell is contained within the analyzers oven. A pressure transducer monitors the pressure at the outlet of the Measuring Cell.

figure 1-1. Analytical schematic.

Overview | 1-3

Microcontroller board and host Controller board

The operation of the analyzer is controlled by two microprocessors. The Microcontroller board is assigned to the Optical Bench board interface, data conversion, data preprocessing functions, temperature control, and handling input/output. The Host Controller board is assigned to the User Interface Panel and keypad control, auxiliary data input signal conver-sion, and final processing of the data from the Microcontroller board.

The Microcontroller board controls the temperature of the temperature-controlled zones. The sample temperature, from the stack duct to inside the Analyzer Oven and Measuring Cell, must be maintained above the water and acid dewpoint temperatures of the sample. The Analyzer Oven, and thereby the Measuring Cell, are controlled (by an electric heater) at a constant temperature in the range from 120 C (248 F) to 150 C (302 F). The temperature sensor a resistance temperature device (RTD) used in the Analyzer Oven is embedded in the Heater Plate. The temperature sensor used in the Sample Line can be a thermistor or an RTD while the Sample Conditioning Unit (SCU) must use an RTD.

Sample flow

The sample gas is drawn from the stack duct through the Sample Conditioning Unit (or stack sample probe, if used) and Sample Line to the dual-chambered Measuring Cell. The gas sample enters the first chamber, flows the length of the Measuring Cell, crosses to the second chamber, flows the length of the Measuring Cell in the opposite direction and exits from the Measuring Cell. When the sample gas reaches the aspirator, it merges with the Aspirator Drive Air (Instrument Air or N2) and then is dispersed to atmosphere via a Sample Vent Pipe.


Discrete wavelengths

To achieve measurements at discrete wavelengths, the placement of the source lamps is such that, at any given time, the photodetectors are ex-posed to light from only one lamp and filter combination (i.e., a discrete wavelength).

As each pulse of light arrives, the Beam Splitter directs half the light to the Reference detector and half through the gas sample to the Measure detector. Because of the longer optical path length, light losses at the mir-rors, and light losses through the Measuring Cell windows, the amount of light received by the Measure detector is less than that received by the Reference detector, even when there is no absorber in the gas sample.

To balance this effect, a screen that filters 30 % of the light is added to the Reference path. At each wavelength, these optical-path factors produce a constant difference between the amounts of light received by the two detectors.

When an absorber is present in the gas sample, the amount of light re-ceived by the Measure detector is reduced further, the magnitude of the reduction being dependent upon the concentration of the absorber. Thus, for each wavelength, the difference in the amounts of light received by the two detectors (corrected for the optical-path factors) is used to deter-mine the absorbance of the gas sample. Then, using the aforementioned equations, the concentration of the absorber (for which the analyzer is configured) is calculated.

Overview | 1-5

Analyzer features

The analyzer has been designed to comply with electrical classification requirements for general purpose and hazardous areas specific to this analyzers intended application. Depending on the application, some of these features may not be available for your analyzer.

Sample System and Electronics

Key features include:

Safe transport of the sample gas May contain toxic percentage levels of either SO2, NO, or NO2, H2S, NH3, or Cl2 from the stack duct, through the analyzers sample sys-tem, and to a vent to atmosphere or back to the stack duct.

Gas calibration system Allows the introduction of calibration gases directly into the analyzers sample system.

Auto-Calibration function Automatically updates the calibration of the analyzer using Calibration Gas mixtures. The Auto-Calibration function can be initiated on com-mand by the user, at user-specified time intervals, or by the closure of a remote dry (potential free) contact.

Auto-Zero function Automatically updates the analyzer zero. The Auto-Zero function can be initiated on command by the user or at user-specified time intervals.

Remote Backpurge (Optional) If configured, allows the user to initiate a backpurge of the analyzer sample system from a remote location. This is done to remove any re-sidual contaminants in the sample system, such as in the case of a gas alarm, for example. This function is initiated by a remote dry (poten-tial free) contact opening.

Calibration Gas Solenoid valve control Up to three solenoid valves can be controlled by the analyzer. One of the control outputs is reserved for the Zero Gas. The length of time that each solenoid valve is on is determined by a separate, user-ad-justable timer. Each of the solenoid-control outputs can be turned off by the user if it is not being used. The timer controlling each solenoid valve can be started manually by the user or automatically by the ana-lyzer during Auto-Calibration.


Auto-Calibration and Calibration Gas solenoid valve control functions Support the use of a single-species calibration gas mixture. The ana-lyzer is configured for a particular calibration gas mixture by the user.

Four independent analog output signal channels The full-scale concentration for each output channel can be set by the user to any value within the measurement range of the analyzer.

Easy Analog Output Calibration The analog output channels are calibrated by entering the zero and full-scale offsets for each output via the User Interface Panel keypad there are no potentiometers to adjust.

Sample control system that detects the state of up to five temperature-controlled zones within the sample system Temperature-controlled zones include the Sample Line, Analyzer

Oven, and Sample Conditioning Unit. There is also a spare temper-ature-controlled zone. Additionally, there is a zone reserved for ap-plications using a heated external probe with a dedicated temperature controller.

The temperature-controlled zones are protected by independent over-temperature circuits. If any of these zones are found to be out of range, the analyzer automatically forces the sample system into Backpurge mode to avoid contaminating the system.

User Interface Panel Provides access to a readout of system signals and parameters, alarm set points, local diagnostics, and user input. The calibration and con-figuration functions are protected by separate passwords.

Three status relays Indicate faults, non-critical conditions, and operational status of the analyzer.

Reliable electronics control system Controls the overall operation of the analyzer.

Continuous purge of the Optical Bench Assembly, Measuring Cell Seal, and the Electronics Enclosure with Instrument Air Prevents contamination of the optical system and the electronics.

No pumps are used Sample gas is transported throughout the sample system by means of an Aspirator within the Analyzer Oven. This provides flow vacuum.

Overview | 1-7

Parts are electrically heated Wetted parts are maintained above the dewpoint temperature of the sample gas stack duct. No steam or other heating media is required.

Mass Flow Calculation (optional) Calculations of the volumetric flow rate of the stack duct (stream) or mass flow rate of the measured component in the stack duct.

Signals representative of the temperature and linear gas velocity of the stack duct or a separate external volumetric flow measuring device supplying flow signal to the Model 909 Analyzer are required for the calculations. The analyzer includes the necessary hardware for mea-suring the stack duct temperature and flow rate.

DCS Communication Interface (optional) A RS-422 (or optional RS-485) port that can be used for remote com-munication with a Distributed Control System (DCS), using Modicon Modbus protocol. The Modbus protocol can be used with the analyzer operating as a slave device, responding to Modbus que-ries within one second. (The Modbus communication interface is optional.)

Dilution Air Correction (optional, for use in General Purpose applications/analyz-ers only) Adjusts the concentration measured by the analyzer to a reference

excess-air condition based on the concentration of oxygen (O2) in the sample. The O2 concentration of the sample can be measured by an optional Zirconium Oxide sensor installed within the analyzer Electronics Enclosure or by a separate, independent, external O2 Sensor.

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About the Analyzer Sample System

The sample gas is transported to and from the analyzer by an aspirator housed within the heated Analyzer Oven.

Figure 1-2 illustrates an example of a piping and instrumentation configuration your application may differ. To view the Piping & Instrumentation diagram for your application, refer to the Final As-Built drawings in the Supplemental Information section of this manual or the Documentation Package shipped with the analyzer.

The major components of the sample system and their functions are de-tailed below. These components are for a variety of analyzer configuration possibilities. Depending on your application, only some of these compo-nents will be used.

Component function

Sample Conditioning Unit (SCU) The SCU which mounts on the stack is used to filter out particulates, prevent liquid carry-over, or otherwise condition the gas sample prior to transporting it through the Sample Line.

Sample Line Transports the sample gas to the analyzer at a temperature above its dewpoint.

Aspirator (if used) Located within the Analyzer Oven, the Aspirator provides suction to transport the sample gas through the sample path. The aspirator uses Instrument Air to extract and drive the sample gas from the stack duct, through the sample system, and vent it to atmosphere (or return it to the stack duct).

Vent Pipe Vents the sample gas to atmosphere. Typically used in stack gas sampling.

Vent Line (if used) Returns the sample gas to the stack duct.

Aspiration Components and functions

The following components make up the Aspirator system. See Figure 1-2 for a typical layout of the Aspirator system (actual drawing may differ for your application refer to Final As-Built drawings shipped with the analyzer).

Component function

Aspirator/Backpurge Air Pressure Regulator Used to adjust drive air flow rate.

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

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Overview | 1-9

Aspirator Isolation Valve Used to manually shut off drive (aspirator) air to the sample system. Used for pressure checking the analyzer sample system.

Aspirator/Backpurge Rotameter Used to adjust the flow rate of the aspirator air.

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

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

Aspirator Provides suction to circulate the sample gas.

Trickle Purge Provides a small flow of air to keep the backpurge connection tubing free of condensate. If an optional O2 Sensor is used, this trickle purge will also cause its output to go high if aspiration is lost.

Sample Conditioning Unit (SCU) and Sample Line

To ensure the temperature of the SCU and Sample Line do not fall below the dewpoint of the sample gas, these temperature-controlled zones are controlled by the analyzer electronics at a user-defined set point. If the temperature of these zones fall below 5 % of the set point temperature, the analyzer will automatically switch from Continuous Sample mode to Continuous Backpurge mode to avoid plugging in the SCU or Sample Line. These zones are also protected from overheating by a separate circuitry that trips the power to these zones if the temperature reaches 181.4 C.

Calibration

Calibration on the analyzer consists of zeroing and spanning the analyzer.

For diagnostic purposes, the calibration gas flow is introduced automati-cally by the analyzer at user-specified time intervals.


Example drawing only. Refer to the Final As-Built drawings for your application in the Supplemental Information section of this manual or the Documentation Package shipped with the analyzer.

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figure 1-2. Piping & Instrumentation diagram (GP Analyzers).

Overview | 1-11

Air Supply

Clean dry instrument air is normally used to drive the aspirator, to purge the analyzer electronics, and to backpurge the sample system. The inlet air pressure must be minimum 210 KPAG (30 PSIG) for General Purpose ap-plications, or in the range of 420840 KPAG (60120 PSIG) for Hazardous Locations. The air is split into three paths as it enters the analyzer: Electronics Purge, Aspirator Drive, and Velocimeter Purge, each with its own controlling regulator.

Electronics Purge Air

The Optical Bench Assembly, Measuring Cell Extension, and the Electronics Enclosure are continuously purged with Instrument Air to prevent contamination of the optical system and the electronics. The purge air is normally obtained from the Instrument Air supply air via a separate regulator and flow restrictor mounted on the left-hand side of the Electronics Enclosure. The required purge air pressure is indicated by a label on the analyzer backpan. The Electronics Enclosure air pressure can be verified by connecting a pressure gauge (e.g., Magnahelix) to the fitting (gauge port) located on the lower right side of the Electronics Enclosure. The Electronics Enclosure air pressure should typically be be-tween 0.1 and 0.2 inches of water with respect to the air pressure outside the cabinet.

Aspirator Drive Air

The Aspirator Drive Air provides suction to circulate the sample gas at a controlled flow rate through the analyzer sample system. The Aspirator Drive Air is fed through the analyzer manifold, where it is routed to the aspirator inside the Analyzer Oven.

When the sample gas reaches the aspirator, it merges with the Aspirator Drive Air (Instrument Air or N2) and then continues on through the gas Vent Pipe which disperses the used sample gas to atmosphere (or Vent Line back to the stack gas, if used).


velocimeter Purge Air

The Velocimeter Purge Air provides instrument air to backpurge (clear) the pitot tubes or to perform a Zero/Span calibration on the Velocimeter.

The purge air is normally obtained from the Instrument Air supply air via a separate regulator and flow restrictor mounted on the left side of the Electronics Enclosure. The required purge air pressure is indicated by a label on the analyzer backpan. The Electronics Enclosure air pressure can be verified by connecting a pressure gauge (e.g., Magnahelix) to the fitting (gauge port) located on the lower right side of the Electronics Enclosure. The Electronics Enclosure air pressure should typically be be-tween 0.1 and 0.2 inches of water with respect to the air pressure outside the cabinet.

Status relays

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

The three sets of status relays used are:

Normal/Fault Status Relay When the analyzer is operating in its normal Run state, this relay is energized. This relay is de-energized if a Fault alarm condition exists within the analyzers built-in diagnostic system (the analyzer requires

service). In RUN mode, S is displayed on the upper-right line of the User Interface Panel to indicate this relay has become de-energized.

With the exception of an Over-Temperature fault (f Temp High) detected by the Over-Temperature RTD Daughter boards on the Sample Line, Vent Line (if used; or SCU), or Analyzer Oven, this relays contacts reset automatically upon correction of the Fault alarm. The Over-Temperature fault, however, must be reset manually. To reset this relay, you must press SW300 on the Termination board, located in the Electronics Enclosure.

When a Fault alarm condition exists (relay is de-energized), the sample system will automatically switch to Backpurge mode if the analyzers Flow Control Mode is set to Analyzer (automatic) Control mode. A lower case b will be displayed in the top-left corner of the RUN mode screen to indicate the analyzer has automatically forced its Flow Control Mode to Backpurge.

Overview | 1-13

Run/Calibration Status Relay When the analyzer is operating in its normal Run state, this relay is energized. This relay switches to de-energized to indicate that calibra-tion of the analyzer is in progress (as detected by the built-in diag-nostic system), that a parameter has been changed in the CALibration mode or ConFiGuration mode (also switches upon exiting CFG mode), or the analyzers Flow Control (Sample) Mode is in Continuous Zero Gas Flow mode or Continuous Sample mode.

Resetting of the contacts is delayed by the Sample Delay Timer (SDelay) duration.

Run/Attention Status Relay When the analyzer is operating in its normal Run state, this relay is energized. This relay is de-energized if a Warning alarm condition exists within the analyzers built-in diagnostic system (the analyzer requires attention), or when the analyzer is operating in CFG or CAL mode. This indicates to the control room that the analyzer is not oper-ating in its normal Run state. The Run/Attention contacts will also be-come de-energized if you manually force the analyzers Flow Control mode to any mode other than Analyzer (automatic) Control mode.

When this relay changes state to de-energized, a lower case m will be displayed in the top-left corner of the RUN mode screen.

Resetting of the contacts is delayed by the Sample Delay Timer (SDelay) duration; otherwise, this relays contacts reset automati-cally upon correction of the Warning alarm, upon switching back to Analyzer (automatic) Control mode, and/or upon exiting CFG or CAL mode.


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Specifications | 2-1

SPECIfICATIOnS

These performance characteristics are based on operation with factory-set filtering time constants, a specified Measuring Cell path length of 40 cm, and the sample gas in the Measuring Cell at predetermined temperatures and pressures.

For applications measuring other species not mentioned in this manu-al, refer to the Documentation Package for a manual supplement.

Purged Analyzer (Hazardous Location) Applications: Additional specifications for ATEX (KEMA) analyzers can be found in the ATEX certificates and analyzer labels under ATEX (KEMA) Certificates and Analyzer Markings, later in this chapter.

Methodology

Dual beam, high resolution, non-dispersive UV. (Optional Zirconia Oxygen Sensor.)

Standard ranges

Maximum ranges are based on sample length (expressed in cm). Minimum ranges are 1/50 of maximum ranges.

SO2 SO2 Range = 20 % SO2 / (Cell length), to a minimum of 250 PPM NO NO Range = 20 % NO / (Cell length), to a minimum of 300 PPM NO2 NO2 Range = 40 % NO2 / (Cell length), to a minimum of 300 PPM H2S H2S Range @ 228 nm = 40 % H2S / (Cell length), to a minimum of 500 PPM H2S Range @ 214 nm = 10 % H2S / (Cell length), to a minimum of 125 PPM NH3 NH3 Range = 10 % NH3 / (Cell length), to a minimum of 125 PPM Cl2 Cl2 Range = 40 % Cl2 / (Cell length), to a minimum of 500 PPM

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Analyzer Specifications

response Time

Dependent on sample gas flow rate and user-adjustable filtering time con-stants. Typically less than 30 seconds to T90 (excluding sample system).

Measurement Accuracy

1.0 % of full-scale of standard ranges, typical (excluding drift and tem-perature effects).

repeatability

< 0.5 % full-scale of standard ranges.

Calibration

Calibration gases in nitrogen.

Linearity

< 1.0 % of reading

Zero Stability

Noise: < 0.2 % of full-scale of standard ranges.

Temperature Drift

SO2 = (40 PPM/Cell length)/C H2S @ 228 nm = (80 PPM/Cell length)/C H2S @ 214 nm = (30 PPM/Cell length)/C NO & NO2 = (120 PPM/Cell length)/C NH3 = (40 PPM/Cell length)/C Cl2 = (120 PPM/Cell length)/C

Use above specifications OR 3*(Customer full-scale/Maximum full-scale), whichever is greater.

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24-hour Zero Drift

SO2: 1.0 % of full-scale of standard rangesNO, NO2, Cl2: 2.0 % of full-scale of standard rangesNH3, H2S: 1.5 % of full-scale of standard ranges

Use above specifications OR the equivalent of 10 C Temperature Drift (whichever is the lesser; with Auto-Zero disabled).

Analog Outputs

Four isolated 420 mADC outputs, each capable of operating a 01000 ohm load. Can be self-powered or loop-powered (loop power sup-plied by customer).

Digital Outputs (Communication Ports)

One RS-232 (or optional RS-485 for Modicon Modbus protocol) port used for service diagnostics.

One RS-422 port with Modicon Modbus protocol (used for interface to customers equipment).

Optional System 200 Configurator Software.

Power Consumption

600 W for analyzer only (excludes Sample Line, SCU, and Vent Line power requirements).

Electrical requirements

Nominal Frequency Range 120 VAC, 10 % 4763 Hz 240 VAC, 10 % 4763 Hz

Typical Sample Gas flow rate

3.05.0 litres/minute (0.10.2 SCFM)

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Ambient Limits

Temperature

550 C (41122 F)

humidity

095 % RH

Temperature drift is approximately 1 PPM/ C for the species listed. To achieve maximum accuracy and stability, install the analyzer in a temperature-controlled environment or zero the analyzer more frequently.

Maximum Altitude

2000 m

Sample Transport

Air aspiration as the drive medium.

Instrument Air requirements

Pressure: 413.6 KPAG (60 PSIG) minimum

Flow: 120 L/min (4.24 SCFM) minimum may vary, depending on application

Air Quality: As per ANSI/ISA S7.0.01 (1996) Quality Standard for Instrument Air.

Physical Dimensions (on backpan)

Height: 1553.6 mm (61.17")Width: 1117.6 mm (44")Depth: 306 mm (12")Weight: Approximately 160 kg (350 lb), entire system and

backpan only (may vary, depending on system).

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Status relays

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

Temperature Control

Independent control of up to five temperature-controlled zones:

AnalyzerOven SampleLine SampleConditioningUnit(SCU) TZone3(sparetemperature-controlledzone) External,heatedprobe(optional)

Output Parameter ranges

Any full-scale within the measuring ranges of the analyzer. Set at the fac-tory, but can be changed by the user.

Measuring Cell Construction

Stainless steel body with quartz windows. Other materials available to suit applications.

Measuring Cell Operating Temperature

Typically 140 C (284 F).

Measuring Cell temperature is measured and controlled to within 1 C (1.8 F) of the set point.

Pressure Compensation

Compensation for Measuring Cell pressure provided for SO2 only. Range: 0210 KPA (030 PSIA) Pressure Transducer accuracy 0.25 % of full-scale.


Approvals and Certifications

NEC/CSA: NEC/CSA Class I, Zone 2 (Division 2), Groups C&D, NFPA 496 Z-Purge

KEMA: 02ATEX2341 X; Ex pd IIB T3GOST: 1ExpydIIBT3

GOST Pattern ApprovalCE Compliance:

Complies with all relevant European DirectivesEMC: Electromagnetic Compatibility Directive:

EN61326 IndustrialLVD: Low Voltage Directive:

EN61010-1

O2 Concentration Signal (Optional)

An optional Zirconia Oxide Oxygen Sensor used on a wet basis and linearized using Nernsts equation. For technical data on this sensor, refer to the Zirconia (Zr743) Oxygen Sensor Instruction Manual that is shipped with the analyzer.

Speed of response

90 % in 30 seconds or less (excluding sample system).

Accuracy

0.1 % O2 (excluding drift and temperature effects).

repeatability

< 0.5 % full-scale of standard ranges.

24-hour Zero Drift

1.0 % O2 (with Auto-Zero disabled).

Temperature Drift

0.0223 % O2 per C

Electrical Classification

General Purpose applications/analyzers only.


velocimeter

Standard range

00.25 "H2O (minimum) 05 "H2O (maximum)

Accuracy

0.14 % of transducer, full-scale.

repeatability


Stability

200 V RMS (based on 05 VDC output).

hysteresis



ATEX (KEMA) Certificates and Analyzer Markings

For installation sites with potentially explosive atmospheres that require ATEX certification, AMETEKs ATEX certificates for the Model 9xx-Series Analyzers (and their marking) are included in the following pages.

Purged Analyzers ATEX Certificate


Purged Analyzer Markings

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

no release

Limited release


Heater Plate ATEX Certificate


heater Plate Marking

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


Disconnect Enclosure Type 200 ATEX Certificate


Type 200 Disconnect Enclosure Marking

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


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Installation & Start-Up | 3-1

InSTALLATIOn & STArT-UP

The Installation & Start-Up chapter contains information about the fol-lowing topics:

Wheretofindsafetyinformationinthisguidebeforeworkingwiththe analyzer.

Howtostoretheanalyzerbeforeinstallation.

Tools,equipment,andsuppliesrequiredforinstallation.

Howtouncrateandinspecttheanalyzerfordamagebeforeinstalling.

Howtoinstallthemechanicalcomponentsandgaslines,andperforma leak check on all of the fittings and connections before powering up the analyzer.

Howtomakealloftherequiredelectricalconnections.

Howtoapplypowertotheanalyzerandconfigureitforoperation.

Whattoexpectduringnormaloperation.

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

!wArnInG


Safety Considerations

Before beginning the installation of the analyzer and before powering it up, review and follow all safety information under Personnel and Equipment Safety Information following the Table of Contents near the beginning of this manual. This information describes procedures to follow to avoid personal injury and/or damage to the equipment. All regulatory agency and personnel safety procedures for your jurisdiction must be followed.

nOTE

Installation & Start-Up | 3-3

Pre-Installation requirements

Storage Prior to Installation

If the analyzer is stored for any period of time prior to installat

Documents

909 User Manual Rev H.pdf