Metek 920 Operator'S Manual With Essential Health And Safety Requirements Download Page 85 | Manualshive

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Installation and Start-Up | 3-25

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

1.

General Purpose (GP) Analyzers:

Open the Electronics Enclosure and open all of the fuses.

Purged Analyzers (Hazardous Locations):

Open the Electronics Enclosure and open all of the fuses. Open the
explosion-proof power-disconnect switch.

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

2. Terminate the input signals, analog output signal(s), and alarm re-

lay contact conductors (see Figure 3-7 and related Final “As-Built”
drawings).

GP Analyzers:

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

Purged Analyzers:

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

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

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

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

Terminate the signal/relay connections inside the Disconnect
Enclosure.

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Summary of Contents for 920

Page 1: ...Model 920 Multi Gas Analyzer Operator s Guide With Essential Health and Safety Requirements PN 903 8765 Rev E Canada A DIVISION OF AMETEK PROCESS ANALYTICAL INSTRUMENTS Western Research ...

Page 2: ...Parkway North Suite A 400 Houston TX 77041 USA Tel 713 466 4900 Toll Free 1 800 634 8990 Fax 713 849 1924 CANADA AMETEK Canada 2876 Sunridge Way N E Calgary AB T1Y 7H9 Canada Tel 403 235 8400 Toll Free 800 661 9198 Fax 403 248 3550 INDIA AMETEK Instruments India Pvt Ltd 1st Floor Prestige Featherlite Tech Park Plot 148 EPIP Phase II Whitefield Bengaluru 560066 Karnataka India Tel 91 80 6782 3200 F...

Page 3: ...mity xvi Warranty and Claims xviii CHAPTER 1 OVERVIEW 1 1 About the Analyzer 1 2 Sample Flow 1 3 About the Analyzer Sample System 1 3 Temperature Control System 1 8 Sample Vent Lines 1 8 Measuring Cell 1 8 Working in This Manual 1 9 Supplemental Information Where Can I Find It 1 10 CHAPTER 2 SPECIFICATIONS 2 1 Methodology 2 1 Standard Ranges 2 1 Response Time 2 2 Accuracy 2 2 Repeatability 2 2 Cal...

Page 4: ...inearity 2 7 Reproducibility 2 7 Temperature Coefficient 2 7 Speed of Response 2 7 Zero Stability 2 7 NOx Concentration Signals 2 8 Full Scale Maximum 2 8 Cross Interference 2 8 Linearity 2 8 Ambient Temperature Coefficient 2 8 Reproducibility 2 8 Speed of Response 2 8 Zero Stability 2 8 Cable Entry Ports Type 200 Disconnect Enclosure 2 9 Approvals and Certifications 2 9 ATEX and IECEx Certificate...

Page 5: ...rt Up and Verification 3 29 Purged Analyzers 3 30 Powering Up the Analyzer 3 32 Start Up Diagnostic Checklist 3 37 Sample System Leak Check 3 40 Manually Zeroing the Analyzer 3 42 Setting the Zero Gas Flow Rate 3 43 Setting the Sample Gas Flow Rate and Sample Response Time 3 44 Normal Operation 3 45 Recording Initial Readings 3 45 Recording PMT Signals 3 45 Recording Initial Sample Response Time 3...

Page 6: ...mmands 4 39 Setting Up Analyzer Calibration Functions 4 40 Flow Control Sample Modes 4 40 Analyzer Control Mode Automatic Control by Analyzer 4 41 Continuous Backpurge Flow Mode Manual Control by Operator 4 42 Continuous Sample Flow Mode Manual Control by Operator 4 42 Continuous Zero Gas Flow Mode Manual Control by Operator 4 42 Continuous Calibration Gas Flow Mode Manual Control by Operator 4 43...

Page 7: ... Source Lamps Need to be Replaced 5 17 About the Source Lamps 5 17 Source Lamp Replacement 5 18 When is an Auto Setup Required Not Required 5 25 Auto Setup Completion Number 5 25 PMT Level and PMT Balance 5 26 Auto Setup Fault Messages and Corrective Action 5 27 The Auto Setup Sequence 5 28 Manipulating the Completion Number PMT Level and PMT Balance 5 29 Chopper Assembly Maintenance 5 31 Replacin...

Page 8: ...ect WX 102836 A 2 GP Lower Enclosure to Electronics Wiring CE Analyzers WX 102810 A 3 Heater and Sensor Wiring GP Div 2 Analyzers WX 102851 A 4 Heater and Sensor Wiring CE Zone 1 Analyzers WX 102852 A 5 Lower Cabinet Wiring CE GP Analyzers 120V 100 1341 3 A 6 Lower Cabinet Wiring CE GP Analyzers 240V 100 1342 3 A 7 Signal Wiring PD GP Div 2 CE Zone 1 Analyzers WX 102815 A 8 Wiring Diagram All Seal...

Page 9: ...ld 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 Ground...

Page 10: ...while the circuits are live test the area for flammable gases and proceed only when the area is safe Purged Analyzer Hazardous Location Applications To work on the analyzer with it powered up and its Electronics Enclosure door open the Purge Bypass Switch must be in the BYPASS position When the Electronics Enclosure door is open take appropriate precautions to avoid electrical shock Hazardous volt...

Page 11: ...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 ...

Page 12: ...s because residual oils from the fingers will absorb ultraviolet light The window is the flat surface at the end of the narrow glass tube The lamp assembly is fragile and should be handled with care Purged Analyzer Hazardous Location Applications M25 x 1 5 6H cable entries are provided for Power 1 entry and Signals 2 entries See the Model 9xx Series Analyzer Type 200 Disconnect Enclosure Details d...

Page 13: ...rking on this product is a reminder to dispose of the product properly after it has completed its useful life and been removed from service Metals plastics and other components are recyclable and you can do your part by doing one of the following steps When the equipment is ready to be disposed of take it to your local or region al waste collection administration for recycling In some cases your e...

Page 14: ...0 1 microfarad ceramic capacitor is a technique allowing high frequency shield bond ing while avoiding the AC ground metal connection In the case of shielded cables the drain wire or braid connection must be kept short A two inch connection distance between the shield s end and the nearest grounded chassis point ground bar or terminal is highly recommended An even greater degree of shield performa...

Page 15: ...e requirements for the area Explosion Hazard Do Not Disconnect Equipment Unless Power Has Been Switched Off or the Area is Known to be Non Hazardous Risque d explosion Avant de déconnecter l équipement coupez le courant où vous assurez que l emplacement est designé non dangereux All input and output wiring must be in accordance with wiring methods authorized for the area classification by the auth...

Page 16: ... EN 61000 3 2 Limits for harmonic current emissions equipment input current 16 A per phase IEC EN 61000 3 3 Limitation of voltage changes voltage fluctuations and flicker in public low voltage supply systems for equipment with rated current 16 A per phase and not subject to conditional connection IEC EN 61000 4 2 Testing and measurement techniques Electrostatic discharge immunity test IEC EN 61000...

Page 17: ...0079 7 2015 A1 2018 Equipment protection by increased safety e EN 60079 11 2012 Equipment protection by intrinsic safety i Certificate Number KEMA 02ATEX2341 X Model 9XX Purged Analyzers KEMA 02ATEX2255 X 900 Series Heater Plate KEMA 01ATEX2219 X Disconnect Enclosure Type 200 Notified Body DEKRA Certification B V 0344 Meander 1051 6825 MJ Arnhem The Netherlands ____________________________ Randy M...

Page 18: ...ring 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 equi...

Page 19: ...verview 1 1 OVERVIEW This chapter provides an overview of the various sub systems that make up the AMETEK analyzer and its sample system and where to find supplemental information for optional equipment ...

Page 20: ...ght sources source lamps Chopper Wheel Filter Wheel containing up to six interference filters Beam Splitter Front surfaced mirrors Gas Measuring Cell contained within an Oven A pressure transduc er monitors the pressure at the outlet of the Measuring Cell Two matched Photodetectors Figure 1 1 Analyzer schematic ...

Page 21: ... consists of Isolation Valve Isolates the sample path from the Sample Probe that extends into the process duct Steam Inlet Exhaust Connections for dry saturated steam which is used to heat the sample gas within the Heat Transfer Block inside the probe Heat Transfer Block Circulates the dry saturated steam around the Sample Probe pipe the Sample Probe Assembly to heat the sample gas Steam Jacketed ...

Page 22: ... Calibration Gas System Introduces Zero and Span gas into the Measuring Cell Flow Control Solenoid Introduces Zero gas into system when analyzer sample system is not up to normal operating temperature Used to Zero the analyzer Flow Control Rotameter Used to adjust the flow of Zero and Span gas Calibration Gas Port Normally plugged connection used to introduce calibration gas into the analyzer samp...

Page 23: ... Block Warms Aspirator Air to a temperature that will not cause condensation and freezing of sulfur in the Aspirator Provides a consistent back pressure for setting the Aspirator Air which reduces sample rate fluctuations caused by process pressure fluctuations The flow rate obtained at a gauge pressure of 210 kPa 30 PSIG is 30 L min 1 SCFM To avoid plugging problems within the probe do not remove...

Page 24: ...el 920 Multi Gas Analyzer Figure 1 2 is an example drawing only Refer to Final As Built draw ings for your system in the analyzer Documentation Package NOTE Figure 1 2 Piping Instrumentation diagram CE Zone 1 ...

Page 25: ...e 1 3 illustrates a typical Oven Instrumentation layout for CE Zone 1 analyzers For your system refer to Final As Built drawings in the analyzer Documentation Package Figure 1 3 Oven Instrumentation layout CE Zone 1 NOTE ...

Page 26: ...suring Cell The Measuring Cell temperature is controlled to create a stable condition for the analysis of the sample gas to take place and to ensure that no con densation forms which can obscure the light path of the analyzer Control is accomplished using a RTD embedded in the Heater Plate The RTD makes contact with the Measuring Cell mount The default and recommended temperature Set Point for the...

Page 27: ... information about the topic certain actions that are necessary before continuing with the current procedure or information that is recommended by AMETEK User Interface Navigation icon While working from the User Interface use these navigational aids to quickly access different screens In this example the system navigates to the Show Results Show Res screen where you can press additional numerical...

Page 28: ...ion that is intended to replace similar information in the Operator s Guide These documents can also include a non standard Spare Parts List or a separate Custom Spare Parts List Analyzer Programming Parameters sheet which lists the critical analyzer operating parameters EEPROM Data Sheets which list the factory default configuration set tings of all programmable analyzer parameters Signed Final Q...

Page 29: ...ral Purpose applications analyzers only Standard Ranges Maximum ranges are based on Measuring Cell 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 NOx NOx Range 20 NOx Cell length to a minimum of 300 PPM H2 S H2 S R...

Page 30: ...rmed excluding drift and temperature effects 1 0 of full scale of standard ranges typical 2 0 of full scale of standard ranges H2S NH3 application Repeatability 0 5 full scale of standard ranges Calibration Calibration gases in nitrogen Linearity 1 0 of full scale for SO2 1 5 of full scale for NOx Zero Stability Noise 0 2 of full scale of standard ranges Cross Talk 1 0 NO2 full scale on to SO2 1 0...

Page 31: ...rd ranges NOx NH3 H2 S 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 Customer Connections Analog Outputs 4 isolated 4 20 mA self powered or optional loop powered loop power by end user Digital Communication One RS 232 port used for service diagnostics One RS 422 port for remote communication...

Page 32: ...udes Sample Line and Vent Line SCU power requirements Supply Voltage 120 VAC 10 47 63 Hz 240 VAC 10 47 63 Hz Status Relays The analyzer uses three relays which indicate the operational status of the analyzer Each relay provides a set of SPDT Form C dry potential free contacts The relays are configured for fail safe operation i e energized for the non alarm condition Sample Gas Flow Rate 3 0 5 0 L ...

Page 33: ...ple Transport By aspiration using air or N2 as the drive gas Instrument Air Requirements Pressure 210 KPAG 30 PSIG General Purpose applications 420 840 KPAG 60 120 PSIG Hazardous Locations Flow 60 120 L min 1 4 SCFM Air Quality As per ANSI ISA S7 0 01 1996 Quality Standard for Instrument Air Physical Dimensions on Backpan Height 1553 6 mm 61 17 Width 1117 6 mm 44 Depth 310 mm 12 Requires minimum 7...

Page 34: ...h 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 ...

Page 35: ...ducibility 0 5 of reading excluding noise and drift effects Temperature Coefficient 1 PPM SO2 C Concentration signal is compensated for changes in Measuring Cell pressure and temperature Speed of Response Dependent on sample flow rate and user adjustable filtering time con stants Typically a 30 second response to 90 of change Zero Stability Noise 1 PPM SO2 with recommended 30 second filter ing tim...

Page 36: ...t Temperature Coefficient 2 PPM NOx C Reproducibility 0 5 of reading excluding noise and drift effects Speed of Response Dependent on sample flow rate and user adjustable filtering time con stants Typically a 30 second response to 90 of change Zero Stability Noise 1 PPM NOx with recommended 30 second filter ing time constant Drift 10 PPM NOx day with Auto Zero disabled and excluding ambient temper...

Page 37: ... all relevant European Directives Approvals and certifications include NEC CEC Class I Zone 2 Div 2 Groups C D NFPA 496 Z Purge ATEX IECEx Purged Analyzer DEKRA Certificate No KEMA 02ATEX2341 X II 2 G Ex db eb ia pxb IIB T3 Gb IECEx Certificate No IECEx DEK 13 0054X Ex db eb ia pxb IIB T3 Gb Heater Plate DEKRA Certificate No KEMA 02ATEX2255 X II 2 G Ex db IIB T3 Gb IECEx Certificate No IECEx DEK 1...

Page 38: ...gs For installation sites with potentially explosive atmospheres that require ATEX and IECEx certification AMETEK s ATEX and IECEx certificates for the Model 920 Analyzer and their markings are included in the follow ing pages Purged Analyzer ATEX and IECEx Certificates and Markings ...

Page 39: ...Specifications 2 11 ...

Page 40: ...2 12 Model 920 Multi Gas Analyzer ...

Page 41: ...Specifications 2 13 2019 02 05 ...

Page 42: ...2 14 Model 920 Multi Gas Analyzer ...

Page 43: ...Specifications 2 15 ...

Page 44: ...2 16 Model 920 Multi Gas Analyzer ...

Page 45: ...Specifications 2 17 ...

Page 46: ... T3 Gb T amb 20 C to 50 C 108 132V 6 2A MAX Power Dissipation 100W 216 264V 3 1A MAX 47 63Hz Minimum Supply Pressure Maximum Supply Pressure 60 psig 4 barg 115 psig 8 barg AMETEK CANADA LP IECEx DEK 13 0054X Maximum Sample Gas Pressure 63 kPag II 2 G 0344 See manual before opening Minimum purging flow rate Minimum purging duration Internal free volume Minimum overpressure Maximum overpressure Maxi...

Page 47: ...Specifications 2 19 Heater Plate ATEX and IECEx Certificates and Marking ...

Page 48: ...2 20 Model 920 Multi Gas Analyzer ...

Page 49: ...Specifications 2 21 ...

Page 50: ...2 22 Model 920 Multi Gas Analyzer ...

Page 51: ...Specifications 2 23 ...

Page 52: ...2 24 Model 920 Multi Gas Analyzer ...

Page 53: ...Specifications 2 25 ATEX and IECEx certified Model 920 Analyzers are marked with this label ...

Page 54: ...2 26 Model 920 Multi Gas Analyzer Disconnect Enclosure Type 200 ATEX and IECEx Certificates and Marking ...

Page 55: ...Specifications 2 27 ...

Page 56: ...2 28 Model 920 Multi Gas Analyzer ...

Page 57: ...Specifications 2 29 ...

Page 58: ...2 30 Model 920 Multi Gas Analyzer ...

Page 59: ...Specifications 2 31 ...

Page 60: ...2 32 Model 920 Multi Gas Analyzer ATEX and IECEx certified Model 920 Analyzers are marked with this label ...

Page 61: ... the analyzer prior to installation Installing the mechanical components and making the electrical connections Powering up the analyzer and performing start up checks and adjustments The installation of the analyzer must be in accordance with all of the user and local regulatory standards and procedures There are no operator serviceable components inside the analyzer Refer servicing to qualified p...

Page 62: ...system through which sample gas passes A breathing apparatus must be worn when installing removing equipment from the sample gas extraction point The sample stream is under positive pressure and injury or death from inhaling toxic gases in the sample stream could result from attempting to install remove equipment without the use of a breathing apparatus Pre Installation Requirements Storage Prior ...

Page 63: ...al Bench replace it in its sealed ESD safe packaging in its ship ping box Reseal the box and store it as per the storage requirements If the Optical Bench appears to be damaged open the ESD packaging follow ESD precautions to prevent ESD damage to the electronics observe the Optical Bench and contact AMETEK with details of the damage Reseal the ESD safe packaging while awaiting instructions from A...

Page 64: ...nnect switch breaker must be connected to and mounted near the analyzer in an easily accessible area The switch breaker must be clearly la beled e g AMETEK Model 920 Analyzer Main AC Power Disconnect Switch For safety reasons during maintenance this switch allows the main AC power to be disconnected from the analyzer prior to performing service on the analyzer This switch breaker is to be sup plie...

Page 65: ...n and Environment The analyzer is designed for indoor operation Pollution Degree 2 In all cases the analyzer system must be installed indoors to ensure it is shielded from harsh environmental elements The entire analyzer system and its backpan can be mounted directly on a wall inside a building in a specially designed cabinet or in a custom built shelter Regardless of which installation method is ...

Page 66: ...ter installations refer to Final As Built shelter drawings in the analyzer Documentation Package Figure 3 1 illustrates a typical Zone 1 analyzer layout While the backpan mounting hole locations and dimensions generally do not change the plumbing and external wiring will likely change for each installation For other analyzer configurations refer to Final As Built drawings in the analyzer Documenta...

Page 67: ...Measuring Cell and remove the M4 x 25 screw inside the Heat Transfer Block using only a flat hex key Do not use a ball driver the head can break off inside the screw Remove the Measuring Cell and set it aside c Remove the Optical Bench from its shipping box and then from its ESD safe packaging Remove the 3 M4 x 12 screws from the Beam Splitter part of the Optical Bench Figure 3 4 Remove the dust c...

Page 68: ...i Gas Analyzer Figure 3 2 illustrates a typical analyzer layout For your specific analyzer refer to Final As Built drawings shipped with the analyzer NOTE Figure 3 2 Electronics enclosure typical analyzer backpan layout ...

Page 69: ...k with the Cell RTD tip on Heater Plate and carefully push the Measuring Cell toward the Heater Plate Adjust the entire Measuring Cell Optical Bench Assembly as required to firmly seat the Measuring Cell against the Heater Plate Using a flat hex key insert the M4 x 25 screw into the counter bore hole in the Heat Transfer Block and thread it onto the Cell RTD until it is snug Do not use a ball driv...

Page 70: ...ter aligning the Optical Bench retighten the support bracket c After the Electronics Enclosure door is closed and secured ensure no gap exists between the Heat Transfer Block and the Cell RTD The Measuring Cell must feel secure against the Heater Plate Gently push and pull on the Measuring Cell to verify it is not loose If there is any movement tighten the M4 x 25 screw again until the Measuring C...

Page 71: ...Installation and Start Up 3 11 Figure 3 4 Optical Bench Measuring Cell assembly ...

Page 72: ...ufficient clearance above the Sample Probe and Vent Valve Assemblies for easy removal If using a Sample Conditioning Unit SCU or AMETEK s op tional Heated Acid Gas HAG Sample Probe refer to the analyzer Documentation Package for more installation information Also see the HAG Sample Probe Installation and Maintenance Guide for complete installation information If possible install the Sample Probe V...

Page 73: ... Vent Lines by their tubing fit tings Doing so can pull the fitting off the sample transport tube A wire mesh cable support must be installed on the line before lifting it and when a line is to be suspended vertically The Sample and Vent Lines are custom built for each installation they cannot be cut to length on site To avoid damaging the Sample and Vent Lines use two wrenches to ensure that the ...

Page 74: ... Shelter Installations Route the Sample Line through the upper hole on the left side of the Analyzer Oven Connect it to the Sample Inlet fitting Route the Vent Line through the lower hole on the left side of the Analyzer Oven Connect it to the Sample Outlet fitting Shelter Installations Route the Sample Line through the hole marked Sample Line on the side of the shelter and then through the upper ...

Page 75: ...til after the Steam Inlet Exhaust Lines have been installed and a Leak Check has been performed and there are no leaks 6 Terminate the Sample Line and Vent Line or SCU wiring as indicated in the Sample Line drawings in the analyzer Documentation Package Connect the ground lead from each line to the ground terminals before connecting the heater leads When terminating the temperature sensor RTD lead...

Page 76: ...ut CE Zone 1 Figure 3 5 illustrates a typical Oven Instrumentation layout for CE Zone 1 analyzers Figure 3 6 1 is for Zone 1 analyzers while Figure 3 6 2 is for GP Div 2 analyzers For your system refer to Final As Built drawings in the analyzer Documentation Package NOTE ...

Page 77: ...and Start Up 3 17 Figure 3 6 1 Sample Vent Line Wiring Disconnect Enclosure Zone 1 H G N DISCONNECT ENCLOSURE 900 910 920 930 ZONE 1 ANALYZERS ANALYZER AC G G H N H N G SAMPLE LINE CONNECTIONS VENT LINE CONNECTIONS ...

Page 78: ... BOX SEE NOTE 1 9XX HI TEMP 9XX HI TEMP BK 18 W 18 N O N O N O W 18 BK 12 BK 12 TB3 TB3 TB3 TB3 W 18 8 9 10 12 16 6 7 5 13 11 15 14 19 20 21 3 NOTES ISOLATION SEE NOTE 3 1 2 IF USING A SAMPLE LINE OR VENT LINE w o TS PLACE A JUMPER BETWEEN TERMINALS 19 20 AND 24 25 IN THE SAMPLE VENT LINE TERMINATION BOX ALL WIRES ARE PART OF WIRING HARNESS 301 1636 INDICATES THE IDENTIFICATION TAG THAT IS SUPPLIE...

Page 79: ...Package To install the Steam Inlet Exhaust tubing 1 After the Sample Probe Valve and Vent Valve Assemblies have been installed run the tubing from the steam source to the Sample Probe Valve Using NPT F connectors connect one end of the steam tubing to the steam source and the other end to the Steam Inlet port on the Sample Probe Valve For both the Steam Inlet Exhaust tubes configure the steam plum...

Page 80: ...e installation is complete as described under Powering up the Analyzer later in this chapter After all connections have been made and a Leak Check has been per formed and there are no leaks install the Heat Transfer Block on the Sample Probe Valve Install one Insulating Flex Pack supplied by AMETEK on each valve assembly If necessary install additional insula tion supplied by customer around each ...

Page 81: ...nd Maintenance Guide Ducting of Compressor Air The point at which the compressor air enters the supply duct s should be situated in a non hazardous area The intake ducting to a compressor should not normally pass through a hazardous area If the compressor intake line passes through a hazardous area it should be constructed of non combustible material and protected against mechanical damage and cor...

Page 82: ...e to the Inst Air port on the side of the shelter 4 Connect the line to the Instrument Air supply Installing the Span Zero Gas Lines The Span Zero gas lines by customer must be 1 4 316 stainless steel tubing To install the Span Zero gas lines 1 Route the lines from each supply tank to the analyzer 2 Purge the lines to remove any liquids or particulate that may be pres ent in them before connecting...

Page 83: ...ries to the disconnect enclosure For Division 2 Zone 2 Installations that do not use the Disconnect Enclosure use a suitable cable entry device with a sealing ring that meets the local requirements for entries into pressurized enclosures Purged Analyzer Hazardous Location Applications Take extreme care to avoid damaging the threads on the cable entry glands on the Disconnect Enclosure Clean defect...

Page 84: ...lyzer in an easily accessible area The switch breaker must be clearly la beled e g AMETEK Model 920 Analyzer Main AC Power Discon nect Switch For safety reasons during maintenance this switch allows the main AC power to be disconnected from the analyzer prior to performing service on the analyzer This switch breaker is to be supplied by the customer end user Purged Analyzer Hazardous Location Appl...

Page 85: ...lated Final As Built drawings GP Analyzers Route the input signals analog output signal and alarm relay contact conductors into the Electronics Enclosure and terminate the wires Purged Analyzers Route the input signals analog output signal and alarm relay contact conductors to the Disconnect Enclosure Install cable glands on the signal relay cables as per the manufac turer s instructions Connect t...

Page 86: ...rdous location and must be rated for minimum 80 C 176 F Following local wiring regulations and electrical codes route the AC power conductors to the Disconnect Enclosure Install a cable gland on the power cable as per the manufacturer s instructions Connect the cable gland to the power cable entry on the Disconnect Enclosure Route the AC power conductors into the Disconnect Enclosure Apply sealing...

Page 87: ... surfaces flamepath and make sure they are free of debris After cleaning these surfaces inspect the flame path for scratches or other damage If no damage is evident apply a suitable thread lubricant must not contain copper to the threads of the 24 screws that secure the door to the Disconnect Enclosure Close the door and tighten all screws to 9 0 Nm 1 0 Nm 80 in lb 9 in lb ...

Page 88: ...NG DETAIL REFER TO WX 102810 FOR Relays Overtemp AND 24 V DC Power Supply 24V Power Supply Fuse O2 Electronics TB 2 TB 2 100 1662 PWB Optical Bench Isolation BlowBk Refer to Table 1 OR DP Bracket Vel Solenoids Optional 100 1933 4 Velocimeter Display I O 100 0939 Oven Heaters 100 1622 PWB Customer Termination 100 1534 Cal Solenoids 100 2141 920 Isolation Blow Back S L V L SKO Probe Oven Velocimeter...

Page 89: ...uire adjustments and settings before during and after power up Figure 3 9 illustrates the locations of analyzer equipment and con trols that require adjustments for a typical Zone 1 analyzer layout Refer to Final As Built drawings for your system in the analyzer Documentation Package NOTE Figure 3 9 Overall component layout CE Zone 1 ...

Page 90: ...he total purge time minimum 15 minutes During this stage the MiniPurge system will purge any flammable gases that may have entered the Electronics Enclosure while its door was open and then pres surize the enclosure After the timing sequence is completed LEDs off the pneumatic switch will send a signal to the analyzer and the analyzer will power up if the Purge Bypass Switch is in the ACTIVE posit...

Page 91: ...heck or perform maintenance on any components within the enclo sures If it is necessary to open the analyzer s covers or doors while the circuits are live test the area for flammable gases and proceed only when the area is safe Purged Analyzer Hazardous Location Applications To work on the analyzer with it powered up and its Electronics Enclosure door open the Purge Bypass Switch must be in the BY...

Page 92: ...ly power to the analyzer or any alternate power sources that supply power to the ana lyzer components Proceed only when the area is found to be safe When the analyzer s covers and doors are open take appropriate precautions to avoid electrical shock Hazardous voltages are present inside IMPORTANT Performing analyzer start up and verification procedures requires working from the User Interface Fami...

Page 93: ...tely following power up the Host Controller board software version number will appear on the top line of the User Interface and the message Reset in Progress will appear on the bottom line If the Reset in Progress message does not appear within approxi mately 2 seconds simultaneously press and Ent If the Reset in Progress message still does not appear take all neces sary safety precautions to powe...

Page 94: ...ure they are on firing Check the LEDs on the Termination board to ensure they are on If the lamps are not firing or the LEDs on the Termination board are not on this can indicate wiring problems 5 Allow the sample system except Cell Oven zone to warm up to nor mal operating temperature and stabilize approximately two hours The Sample and Vent Line or SCU zones typically warm up quicker than the Ce...

Page 95: ...perature zone Record the value for each zone Compare them to the values recorded earlier to ensure they have increased Compare the current temperatures to their respective Set Point values recorded earlier Normal operating temperatures are values that are within 5 of their Set Point values 7 If all of the temperature zones have reached normal operating tem peratures and there are still no alarm co...

Page 96: ...nd reconnect the Sample Line to the Sample port in the Analyzer Oven to allow sample gas into the analyzer sample system For systems using Sample Probe and Vent Valves the jacketed valves will be hot Take precautions to avoid burning yourself Optional systems with Heated Acid Gas Sample Probe warning the probe will be hot Open the Vent Valve on the HAG Sample Probe Open the Sample Valve to allow s...

Page 97: ...ring to ensure it is properly connected Problem Encountered If S is displayed on the User Interface alarms are active The S character will typically be displayed upon start up due to low temperatures in the tempera ture zones Corrective Action View the HStatus HS and MStatus MS screens to determine which alarms are active See Host Controller Microcontroller Board Alarm Conditions and Corrective Ac...

Page 98: ...s Problem Encountered Temperature zone values do not increase Corrective Action Take appropriate safety precautions and check for proper wiring connections for the corresponding temperature zone wiring Problem Encountered Temperature zone value reads 181 4 This temperature value indicates a faulty RTD for the related temperature zone Corrective Action Take appropriate safety precautions and check ...

Page 99: ...Installation and Start Up 3 39 Figure 3 11 Over Temp alarm reset switch SW300 Termination board ...

Page 100: ...Reflector Block due to a leak in the Measuring Cell the optics will become damaged and most likely require replacement Most leaks are preventable with the regular replacement of the Measuring Cell o rings To leak check the sample system 1 With the analyzer powered up open the Aspirator Drive Air Regulator to allow instrument air into the sample system 2 Close the isolation valves on the sample gas...

Page 101: ... Cell To test the zones that are hot observe the CellP reading and check for steady or decreasing values Do not use a leak detection fluid on hot fittings If the analyzer system is at operating temperature the temperature zone circuitry fuses must be opened to allow the temperature zones to cool down before using a leak detection fluid on the fittings If the Measuring Cell is suspect check all fit...

Page 102: ...1 Ensure that the Zero gas cylinder is turned on 2 Before changing the Flow Control mode record the current numeric value should be 0 Analyzer Control mode Change the Flow Control mode to Continuous Zero Gas Flow mode either 10 probe tip or 110 manual 3 From CAL mode initiate the Manual Zero The User Interface will prompt Man Zero Observe the readings on the bottom line When the readings have stab...

Page 103: ...he concentration outputs of the ana lyzer are stable and further increases in Zero gas flow rate do not reduce the concentrations observed on the analyzer User Interface A nominal flow rate of 5 10 SCFH should be sufficient for this purpose Set the response time first to ensure a good zero Some applications may require a higher flow rate Since excess air flow into the analyzer sample system will c...

Page 104: ...e system A typical sample flow rate is in the range of 3 0 5 0 L minute 0 1 0 2 SCFM and can be achieved by adjusting the Aspirator Air to the appropriate pressure in the range of 7 35 KPAG 1 5 PSIG To avoid damaging the pressure transducer do not set the pressure higher than 105 KPAG 15 PSIG The sample response time may vary depending on Sample Line length NOTE CAUTION ...

Page 105: ...zer Recording Initial Readings AMETEK recommends that you observe and record this information monthly to obtain a history From these recordings you will be able to determine if there are problems with the analyzer such as diminishing PMT signals or increasing sample response time These problems typi cally indicate maintenance is required Keep the log book in a safe location until you need to revie...

Page 106: ... at peak efficiency may vary due to Sample Line length To check and record the initial sample response time 1 Manually Zero the analyzer 2 After the Zero is complete view the RUN mode normal display and observe the output concentration changes Observe and record the time it takes the analyzer to display the first reading after the analyzer s Flow Control setting is switched from Continuous Zero Ga...

Page 107: ...mable parameters are located in the analyzer Documentation Package If any changes are made to the original configuration be sure to record the changes for later reference If the EEPROM is replaced this data must be re entered to override the factory defaults If necessary refer to the original EEPROM Data Sheets when changing the analyzer settings back to their original values ...

Page 108: ...3 48 Model 920 Multi Gas Analyzer This page intentionally left blank ...

Page 109: ...d navigate through the vari ous screens How to view analyzer data configure analyzer settings and perform analyzer functions Descriptions of each keystroke command and the information on the various screens IMPORTANT Before working from the User Interface read the entire section titled Introduction to the User Interface to learn how to navigate through the screens to work on the analyzer NOTE ...

Page 110: ...ser Interface The top line displays the current mode of operation or a prompt for further keypad input During normal operating conditions in RUN mode the top line displays the names of the outputs When operating in CALibration or ConFiGuration mode the mode of operation CAL or CFG is also displayed The bottom line displays the results of the outputs During normal operating conditions in RUN mode t...

Page 111: ... used with a Function key or as part of a password F1 F2 F3 F4 F5 F6 Use the Function keys with and numeric keys 0 9 to access the various operation modes and screens where you can view or change data and operating parameters Esc Press the Escape key to discard any changes you make to operating parameters but only before they have been saved Also press Esc to answer No to a prompt on the screen wh...

Page 112: ...r will switch to automatic Backpurge and b is displayed on the top left line as opposed to a B which indicates manual Continuous Backpurge initiated by the operator S is also displayed For detailed information about Flow Control mode indicators refer to Flow Control Sample Modes in this chapter NoData or CommFault These serious system alarms are the only two alarm messages that are automatically d...

Page 113: ...ecific alarm then press another numeric key to view the status of another alarm etc When the analyzer is first powered up the User Interface defaults to RUN mode also known as RUN mode normal display From this mode you can view analyzer system data temperature Set Points current operating values or alarms current or historical To return to RUN mode normal display from anywhere in the soft ware rep...

Page 114: ...ttings for your analyzer have been configured at the fac tory to meet specified customer requirements Changing the factory set configuration could cause the analyzer to operate incorrectly Do not change any functions that are not discussed in this section without express written consent from AMETEK While working in CFG mode the following rules apply A password must be entered from RUN mode to ente...

Page 115: ...ile working in CAL mode the following rules apply A password must be entered from RUN mode to enter CAL mode In CAL mode normal display CAL will be displayed on the top line along with all functions or results associated with this mode The output results from RUN mode will continue to be displayed on the bottom line When entering commands the User Interface will return to CAL mode normal display I...

Page 116: ...t Point value for the Analyzer Oven temperature zone 1 From RUN mode press F6 The message PSWD1 appears 2 Press factory default password or enter the new password if changed An is displayed for each character entered 3 Press Ent to view the CFG mode screen CFG will be displayed on the top line while the output results from RUN mode will con tinue to be displayed on the bottom line This is the CFG ...

Page 117: ...hile the output results from RUN mode will continue to be displayed on the bottom line This is the CAL mode normal display 4 Press F5 2 to display the FlowCtrl Flow Control mode screen When you enter this screen the current setting is displayed e g 0 Analyzer Control mode 5 Press Del to delete the current setting 6 Press 1 to change the setting to Continuous Backpurge Flow mode 7 Press Ent to save...

Page 118: ...ds pressing Ent will cause the passwords to be saved in non volatile memory the old passwords will be lost If the passwords are not saved the previous passwords will be used follow ing a system reset or power up To change the CFG or CAL mode passwords 1 From RUN mode press F6 and press Ent to display the CFG mode screen If changing the password for CFG mode press F6 the command to change the CFG m...

Page 119: ...terface will prompt you to accept the changes Save Config If Yes press Ent to accept the new password The display will exit the CFG mode and return to RUN mode If No press Esc to discard the changes The display will exit the CFG mode and return to RUN mode ...

Page 120: ... for both modes indicates the command is not used Figure 4 2 RUN CFG mode Quick Reference Sheet Key F1 F2 F3 F4 F5 F6 RUN CFG Auto Setup MB Addr T 1 2 AI Msr 1 6 HCHist 1 9 RUN CFG PSWD0 PSWD0 CAL CAL PTPara 1 4 Com Para 1 3 TCold AuxTAvg 1 3 MCHist 1 9 RUN CFG PSWD1 PSWD1 CFG CFG 0 KFtr Cell Compen 1 4 TStPt 1 4 SN Normal Display RUN CFG 1 Ftr 1 6 Bench M atrix Row 1 1 6 Kp 1 4 HC920 e Sig 1 6 2 ...

Page 121: ... chapter In Figure 4 3 keystroke command F1 2 has two options See CAL Mode F1 Commands in this chapter for a description of these op tions indicates the command is not used Figure 4 3 CAL mode Quick Reference Sheet Key F1 F2 F3 F4 F5 F6 0 Auto Zero Man Zero Timer0 ConcX Sol R 1 6 Izero 1 4 1 Auto Span1 Man Span1 Timer1 Conc1 Scale 1 4 Ispan 1 4 2 Auto Span2 IsolBlowBk Man Span2 Timer2 Conc2 FlowCt...

Page 122: ...s are denoted by RUN and CFG under Keystroke while their specific functions are listed under Term followed by their Definition If RUN and CFG are absent the function is the same for both modes indicates the command is not used Definitions preceded by are used primarily for diagnosing prob lems with the analyzer therefore these functions do not need to be accessed frequently Factory default values ...

Page 123: ...ulse current control signal V for each filter where z 1 6 The normal operating range is between 0 5 V and Lamp Max LampMax typical range is 4 5 7 8 VDC may vary check EEPROM Data Sheets for actual value with the control signal for the key filter being Lamp Max If the Ftr value is negative the filter position is not used 1 Filter 1 4 Filter 4 2 Filter 2 5 Filter 5 3 Filter 3 6 Filter 6 Note The fil...

Page 124: ...playing concentrations temperatures and pressures The value is the sum of five bits Bit 0 Value Definition 1 0 Metric Units 1 Imperial Units Bits 2 1 Value Definition 2 4 0 Normal concentration result PPM 2 Normal concentration result 4 Finer Low concentration result PPM 6 Coarse High concentration result Sum of Bits 1 and 2 decimal value Bit 3 Value Definition 8 0 Display 4 items 8 Display 3 item...

Page 125: ... the current Bench Code value defines which PMT is designated as Measure and Reference the number of temperature zones and the filter positions assigned to each source lamp Standard Bench Type Code Code b6 64 b5 32 b4 16 b3 8 b2 4 b1 2 b0 1 4 0 0 0 0 1 0 0 The value in brackets beside each bit number is its decimal weighting The typical value displayed is 4 4 3 temperature zones 1 2 4 For systems ...

Page 126: ...he code is the decimal equivalent of an 8 bit binary number which defines the bench type in regard to the temperature control parameters The temperature zones are Zone 1 Sample Line Zone 2 Vent Line or SCU if used Zone 3 TZone3 Spare Zone 4 Oven Temperature Filter Position Assignment b4 b3 b4 b3 Lamp 1 Lamp 2 0 0 1 3 5 4 6 2 0 1 3 5 4 6 1 2 1 0 1 3 4 5 6 2 The Filter Position code defines the filt...

Page 127: ...e in the concentration Larger values reduce the noise level on the output signal but at the same time increase the response time F2 6 Outputz The Output Signal Assignment OSA code for each current output where z 1 4 Allows you to determine which of the calculated results parameters will be available as output signals These outputs are application specific Refer to Output Signal Assignment OSA in t...

Page 128: ...1 F3 6 row z 1 6 column F3 1 M1 M1 1 6 F3 2 M2 M2 1 6 F3 3 M3 M3 1 6 F3 4 M4 M4 1 6 F3 5 M5 M5 1 6 F3 6 M6 M6 1 6 F3 7 N2O Conc Static compensation for ammonia NH3 applications This parameter compensates for interference of N2O in the measurement of ammonia default 0 off This parameter should only be used when it is known that there is N2O present in the stream and the approximate concentration is...

Page 129: ...Point for each temperature zone where z 1 4 If the Set Point is 0 that zone is not used 1 Sample Line default 150 00 C 2 Vent sample return Line default 150 00 C or SCU optional default 150 00 C 3 TZone3 Spare default 10 00 C 4 Measuring Cell default 155 00 C F4 1 Kpz The Proportional term of the PID temperature control algorithm for each temperature zone where z 1 4 1 Sample Line default 10 00 2 ...

Page 130: ...lt 30 4 Oven default 30 z 5 8 This is the maximum duty cycle allowed for each temperature zone The zones and their default values are 5 Sample Line default 85 6 Vent sample return Line or SCU if used default 85 7 TZone3 Spare default 85 8 Oven default 85 F4 6 CPRgz The Measuring Cell pressure transducer low and high value mm Hg or inches Hg cor responding to 0 0 VDC and 5 0 VDC respectively where ...

Page 131: ...te Alarm Message is displayed if the alarm condition exists If the alarm condition does not exist the message HSz OK appears Refer to Chapter 5 for descrip tions of alarm conditions The possible alarm conditions include 1 w EEPROM Full Warning 2 w Out Of Range Warning 3 f Comm Fault Fault 4 f RxData Fault Fault 5 f Temp Low Fault 6 f Temp High Fault 7 w ZDrift SpanErr Warning F5 5 MSz Microcontrol...

Page 132: ...n Backpurge is initiated 1 external contact is closed normal analyzer operation the Flow Control mode changes to automatic Analyzer Control Code Contact Status ab Input 1 Input 2 00 Open Open 01 Open Closed 10 Closed Open 11 Closed Closed F5 8 LmpPz Current lamp pulse V for each filter as generated by the Automatic Lamp Control where z 1 6 1 Filter 1 4 Filter 4 2 Filter 2 5 Filter 5 3 Filter 3 6 F...

Page 133: ...FG mode this command will call up the PSWD1 prompt which al lows you to change the CFG mode entry password See Changing the Password for CFG CAL Mode in this chapter for information about passwords F6 0 RUN Normal Display This command returns the RUN mode normal display from anywhere in the software While in RUN mode the name of the calculated result or parameter is displayed on the top line its v...

Page 134: ...splays the mass emission rate n for the species where z 1 7 e g concentration of species A times mass emission factor Ke for species A 1 e so2 5 e H2S 2 e NO2 6 e NDr Neutral Drift 3 e NO 7 e NOx 4 e SO2 F6 5 oz n The Show O2Cor menu displays the O2 corrected concentrations n of SO2 and NOx where z 1 7 e g SO2 1 o so2 5 o H2S 2 o NO2 6 o NDr Neutral Drift 3 o NO 7 o NOx 4 o SO2 F6 6 fz n The Show ...

Page 135: ...ater Hot Oven 6 CellP mmHg Measuring Cell 7 HtrT C Reserved 8 MIA8 C Reserved for optional External Probe Temperature Voltage Input or External Probe Temperature Voltage Input For MAI 6 the pressure signal is displayed in mm Hg or inches Hg when active pressure compensation is enabled when active pressure compensation is not enabled the signal is displayed in volts F6 9 z Show HAIz The Show Host C...

Page 136: ...primary code using the last digit that was entered For example a code of 83 will default to a primary code of 3 Figure 4 4 Calculated Result Parameter Codes Definition CODES User Interface and Analog Output Analog Output Only Instantaneous Result Instantaneous O2 Corrected Output T H Result T H O2 Corrected Output Instantaneous Result T H T H O2 Corrected Output Not Used 0 0 0 0 0 0 0 Result 1 low...

Page 137: ... outputs are forced to use the operator entered fixed values The outputs will hold at these values for the duration of the Auto Zero and the Sample Delay Time SDelay Example 1 To assign the track and hold SO2 signal to Output 1 and the User Interface and return to CFG mode normal display press F2 6 1 Del 51 Ent Ent Example 2 To assign the NO2 concentration to Output 3 only and return to CFG mode n...

Page 138: ...ry settings The jumper positions are presented here only so they can be restored by the user if they should become dislodged during transit for example Each input channel has 3 jumper selectable ranges 0 1 V 0 5 V 0 10 V The jumpers of interest are labelled P100 and P101 Figure 4 5 ranges are not marked on the board The jumper positions are referenced by Top Middle Bottom where Top is the position...

Page 139: ...e Top is the position nearest the jumper label on the board Figure 4 6 Display I O Board Jumper Positions Input Channel Jumper Header Jumper Position Range VDC 1 JP200 Middle 0 5 external stream velocity optional 2 JP201 Middle 0 5 external stream temperature or external flow rate optional 3 JP202 Middle 0 5 Reserved 4 JP203 Top 0 1 internal O2 concentration or optional external O2 concentration F...

Page 140: ... CAL mode parameters listed in this section are identified by the com mand Keystroke used to view the main screen the abbreviated name Term of the screen and a Definition of each parameter indicates the command is not used Definitions preceded by are used primarily for diagnosing prob lems with the analyzer therefore these functions do not need to be accessed frequently NOTE To work in CAL mode a ...

Page 141: ...sequence The analyzer calibration is automatically adjusted based on the average reading during the last 25 percent of the countdown after a Yes response only if AdjDisable is set to 0 If a multi component calibration gas mixture is used the spans for all components in the mixture are done simultaneously Isolation Blow Back Solenoid Optional This system is used in place of the AutoSpan2 function o...

Page 142: ...ows you to manually Span the O2 Sensor if used General Purpose applications analyzers only at the analyzer The sensor Calibration is automatically adjusted based on the average reading during the IntTime duration after a Yes response only if AdjDisable is set to 0 Man Span must be used to calibrate the sensor if Nitrogen is used for the Span gas The Calibration Span gas must be introduced manually...

Page 143: ... the Blow Back system to build up pressure between pulses air bursts which blow back debris into the stack F3 4 F3 5 F3 6 IntTime Sets the duration seconds over which the reading for each Manual Zero or Span is aver aged Setting the timer to 0 turns the function off F3 7 SDelay Sets the time delay for the CAL relay to continue indicating that a calibration is in progress after the calibration is c...

Page 144: ... 1 F4 6 The concentration is entered in decimal form The maximum concentration which can be entered is 999 999 If a Calibration gas is not used the concentration must be set to 0 F4 1 Conc1 F4 4 Conc4 F4 2 Conc2 F4 5 Conc5 F4 3 Conc3 F4 6 Conc6 F4 7 F4 8 O2Concz The concentration of O2 or PPM in the Calibration gas mixture where z 1 2 The concentration is entered in decimal notation The maximum co...

Page 145: ...ems using an Aspirator where n 0 2 0 Analyzer Control mode automatic control by analyzer 1 Continuous Backpurge mode manually set by operator 2 Continuous Sample mode manually set by operator 10 Continuous Zero Gas Flow mode manually set by operator probe tip 11 Continuous Calibration Gas 1 Flow mode manually set by operator probe tip 12 Continuous Calibration Gas 2 Flow mode manually set by opera...

Page 146: ...st be 11 pseudo sole noid to prevent inadvertent Auto Calibration F5 6 T0z The measuring wavelength transmittance value with Zero gas for each filter where z 1 6 Adjusted automatically whenever the analyzer is Zeroed if AdjDisable is set to 0 1 T01 4 T04 2 T02 5 T05 3 T03 6 T06 F5 7 SFactorz The Span calibration factor for each calculated result component concentration where z 1 6 Adjusted automat...

Page 147: ... The Zero Cal Drift where z 1 7 After an Auto Cal the Zero Drift of all calculated results since the last Auto Cal are recorded The drift result is displayed in or PPM 1 ZCD1 5 ZCD5 2 ZCD2 6 ZCD6 3 ZCD3 7 ZCD7 4 ZCD4 F6 3 SCDz The Span Cal Drift where z 1 7 After an Auto Cal the Span Drift of the calculated result since the last Auto Cal is recorded The drift result is displayed in or PPM 1 SCD1 5...

Page 148: ...purge B See Note manual by operator 2 Aspirator Continuous Sample S manual by operator 10 Aspirator Continuous Zero Gas Flow probe tip Z manual by operator 11 Aspirator Continuous Calibration Gas 1 Flow probe tip C manual by operator 12 Aspirator Continuous Calibration Gas 2 Flow probe tip C manual by operator 100 Sample Block Valve Analyzer Control blank Sample by analyzer automatic by Analyzer b...

Page 149: ...ause of the alarm has been corrected cleared If a fault alarm is triggered the analyzer will switch from automatic Sample mode sample gas flowing to automatic Backpurge mode zero gas flowing If the alarm automatically clears resets itself the analyzer will switch back to automatic Sample mode If the analyzer is in automatic Backpurge mode sample gas stops flowing and the sample system is flushed w...

Page 150: ...nuous Sample sample gas will continuously flow through the analyzer sample system it will not switch to automatic Backpurge mode When you manually force the analyzer into Continuous Sample S is displayed on the top left line To manually force the analyzer to this mode press CAL F5 2 Del 2 Ent Ent Do not operate the analyzer in Continuous Sample Flow mode for an extended period of time before all t...

Page 151: ...ously back purged with Calibration Gas 1 or Calibration Gas 2 it will not automati cally switch to another mode When you manually force the analyzer into Continuous Calibration Gas Flow Gas 1 or Gas 2 C is displayed on the top left line To manually force the analyzer to Continuous Calibration Gas 1 press CAL F5 2 Del 11 Ent Ent To manually force the analyzer to Continuous Calibration Gas 2 press C...

Page 152: ...used only when the optional O2 Sensor is used General Purpose applications analyzers only The duration for these timers can be set from 0 255 minutes in one min ute increments Set the duration to 0 to turn the timer off disable the function The average reading for Auto Zero Auto Span1 and Auto Span2 will be taken during the last 25 percent of the timer duration The Timer must be assigned a value t...

Page 153: ...to Zero is included in the Auto Calibration if the Auto Zero is en abled by setting Timer0 to a non zero value If the Auto Calibrations and Auto Zeroes are scheduled to run at the same time the Auto Calibration takes precedence Example To set ACal Timer interval to 3 hours and return to CAL mode normal display press CAL F3 9 Del 3 Ent Ent Auto Zero Interval Timer AZInt The AZInt timer sets the int...

Page 154: ...ing a representative sam ple permitting a smooth transition from Calibration gas back to Sample gas The User Interface and analog outputs continue to show the actual concentrations at the analyzer unless the track and hold result codes are assigned to the display and analog outputs The User Interface gives no indication the delay is occurring or that it has occurred The time delay depends on the t...

Page 155: ...ual Zero on the analyzer Manual Span Although it is unnecessary from an analytical perspective to calibrate the span of the analyzer on a regular basis since the response factors to the various gases do not change calibration may be necessary to demonstrate the response of the analyzer to Calibration gas There may also be occa sions where the SO2 cross talk needs to be checked after changes to the...

Page 156: ...at a flow rate of 2 5 L min 0 08 SCFM Reduce the Zero flow rate to 1 5 L min 0 05 SCFM Check for a change in concentration reading There should be very little change in baseline If there is a significant change continue with the 2 5 L min 0 08 SCFM flow rate for another 10 minutes When the analyzer is in Continuous Zero Gas mode there may be air pressure at the Calibration Gas Port Do not open the...

Page 157: ...isable is set to 0 The calibration value for the component will be adjusted automatically and the screen will revert to the CAL mode normal display Esc for No The function is aborted and the calibration value for the component is not adjusted 5 Turn off the Calibration gas mixture with component y The span process for the component is complete If required repeat this procedure for each component 6...

Page 158: ...nd 3 respectively in the Calibration gas mixture must previously have been set to 0 Observe the NOx concentration reading on the bottom line of the User Interface When it has stabilized at or near the concentration of NOx in the Calibration gas mixture press Ent for Yes The IntTimer duration will count down to 0 during which time the reading is averaged if AdjDisable is set to 0 The calibration va...

Page 159: ...output is accurate over the entire SO2 concentration ranges If your analyzer is equipped with a Measuring Cell other than a 40 cm cell contact the factory to obtain new high range and low range span points To perform a dual range span 1 From CAL mode enter the component concentration of Species 1 Conc1 from the tag concentration of the calibration cylinder Example If the tag concentration is 250 p...

Page 160: ...on is 250 ppm key in F4 4 Del 250 Ent Ent 7 Perform a Manual Zero by turning on the Zero gas and pressing F2 0 Run Zero gas through the analyzer for at least 5 minutes When the readings have stabilized at or near 0 press Ent Turn off the Zero gas 8 Span the high range SO2 by turning on the Calibration gas mixture and pressing F2 4 Run the high range Span gas through the analyzer for at least 5 min...

Page 161: ...pan 2 2 Auto Span 2 Timer2 used only with O2 Sensor General Purpose applications For the Auto Calibration function to operate correctly the SSR Output switching the solenoid valve must be assigned to the calculated result for which the Calibration gas is required For example if the solenoid valve for controlling the Result 1 e g SO2 concentration Calibration gas mixture is switched by SSR Output 2...

Page 162: ...factory and cannot be changed by the user To determine the names from RUN mode press each Keystroke Sequence and record the Name displayed on the bottom line Result 7 F6 3 7 is the sum of Result 2 and Result 3 an SSR output cannot be assigned to Result 7 If NDR NDR2 or NDR3 appears ignore these as they are for diagnostic purposes only Calculated Result Parameter Names Result Keystroke Number Seque...

Page 163: ...here z is the calculated result num ber 1 6 and n is the assigned SSR output number 0 2 If the assignment is correct continue with Step e b Del The display prompts for the new SSR output number c n The SSR output number is keyed in d Ent The SSR output number is entered and displayed e Ent To return to the CAL mode normal display or Esc To return to RUN mode normal display or Fx To perform another...

Page 164: ...on and return the CAL mode normal display by pressing F5 0 3 Del 1 Ent Ent Example 2 The names for the calculated results are Result 1 SO2 concentration Result 2 NO2 concentration Result 3 NO concentration A calibration gas mixture is required only for calibration of the SO2 output The solenoid valve controlling the SO2 Calibration gas mixture is con nected to SSR Output 2 1 Assign SSR Output 2 to...

Page 165: ...bration gas mixture is connected to SSR Output 2 and the solenoid valve for controlling the NOx Calibration gas mixture is connected to SSR output 1 1 Assign SSR Output 2 to Result 1 SO2 concentration by pressing F5 0 1 Del 2 Ent 2 Assign SSR Output 1 to Result 2 or 3 NO2 or NO concentration and return the CAL mode normal display by pressing F5 0 2 Del 1 Ent Ent Assigned to result 2 For this examp...

Page 166: ...omponent e g NO2 was previously entered as 0 the Span for that component NO2 would remain at 1 0 There is a global variable called Adjust Disable which if set to 1 the Zero Offset and Span will not be corrected at the end of a calibra tion sequence This allows the analyzer to control the calibration gas flow so an external Data Acquisition System can record the actual analyzer output signals durin...

Page 167: ...gas mixture concentrations must be entered and the SSR outputs must be assigned before starting an Auto Calibration The Flow Control mode must be controlled by the analyzer i e FlowCtrl must be set to 0 The Auto Zero Auto Span can be started manually automatically on a timed basis or by a remote dry potential free contact closure Upon completion of the sequence the CAL Status relay will continue t...

Page 168: ... func tion and return to CAL mode normal display To manually start the Auto Zero from CAL mode 1 Press F1 0 to display the timer duration 2 Press Ent The software prompts Auto Zero 3 To enable the Auto Zero press Ent Timer0 will begin to count down to 0 The analyzer Zero Offset is ad justed automatically based on the average of the readings during the IntTime duration or the last 15 seconds of the...

Page 169: ...Auto Span2 will begin to count down to 0 The analyzer Span Value is adjusted automatically based on the average of the reading during the last 25 of the countdown Or press Esc to abort the Auto Span the Span Value is not adjusted All outputs associated with the Calibration gas cylinder assigned to SSR z will be calibrated at the same time Upon completion of the sequence press another command or pr...

Page 170: ...ll continue to indicate that a calibration is in process until the SDelay timer has expired Timed Start of Auto Calibration The analyzer automatically initiates the Auto Calibration sequence on a timed basis The ACal Timer is the time interval between calibration sequences To set this function press F3 9 CAL mode and then enter a value hours for the automatic timed start of the Auto Calibration If...

Page 171: ...Calibration is 30 minutes and the Auto Calibration is started manu ally In this case the ACal Timer will continue to count down and the time remaining until the next timed Auto Calibration remains 30 minutes Pressing Esc at any time during this procedure will abort the func tion and return to CAL mode normal display To manually start the Auto Calibration 1 Press F1 9 CAL mode The software prompts ...

Page 172: ...g Example The ACal Timer is set at 2 hours the time remaining until the next timed Auto Calibration is 30 minutes and the Auto Calibration sequence is started by a contact closure This will reset the ACal Timer and the time remaining until the next timed Auto Calibration remains 30 minutes If a timed Auto Calibration is in progress the remote contact closure will be ignored If the remote start is ...

Page 173: ...Controller User Interface 4 65 Figure 4 8 Customer signal connections ...

Page 174: ...l display The existing calibra tion values and any new values entered up to the point of pressing Esc will be retained To calibrate the current output signal for Output Channel z where z is the output channel number 1 4 connect the current meter to the output see Figure 4 8 for termination points and press Zero current output F6 0z Current output zero scale value is displayed where z is the Zero c...

Page 175: ...ets the output to full scale 19 92 Ent The current meter reading is 19 92 mA Ent Returns the CAL mode normal display Example 2 To calibrate the current output signal for Output Channel 2 and return to CAL mode normal display press F6 0 2 Del Sets the output to zero scale 4 06 Ent The current meter reading is 4 06 mA F6 1 2 Del Sets the output to full scale 20 18 Ent The current meter reading is 20...

Page 176: ...ey The Probe Blow Back control signal is available at terminals 3 and 4 of J106 on the Termination board also used as the SSR control for a heated Vent Line or Sample Conditioning Unit The signal switches from 0 VDC to 15 VDC when the Probe Blow Back feature is activated The Probe Isolation signal is typically available at terminals 5 N and 6 L of J105 on the Termination board Refer to Final As Bu...

Page 177: ...shoot the analyzer Before performing any maintenance service or troubleshooting on the analyzer review and follow all safety information in this chapter and under Personnel and Equipment Safety Information following the Table of Contents This information describes procedures to follow to avoid personal injury and or damage to the equipment All regula tory agency and personnel safety procedures for...

Page 178: ...ing the circuit boards do not subject them to static discharge The ideal solution is a static safe work area Since such areas typically are not available at analyzer installation sites the use of a wrist strap connected directly to a ground is recommended If a wrist strap is not available you should at the very least touch the metal chassis to ground yourself before handling the boards Preventive ...

Page 179: ...top right corner of the User Interface for the S character If S appears view the HStatus and MStatus screens for current alarms to help isolate the problem See Troubleshooting and Diagnostics in this chapter for alarm messages and corrective action Check the history buffers HCHist and MCHist for recurring alarms The history buffers contain alarms that have been reset Monthly Check the PMT Signals ...

Page 180: ... PSIG Monthly Temperature Zones Check and record the temperatures of all temperature zones and ensure they are all within 5 of their Set Point values Every 3 Months Sample Conditioning Unit SCU Optional If your analyzer uses a SCU change the filter elements in the SCU Probe If the gaskets are damaged replace them at the same time Clean the parts that make up the filter assemblies Replace the gaske...

Page 181: ...his chapter Other Heated Acid Gas HAG Sample Probe Optional Replace the o rings and filters Refer to the HAG Sample Probe Installation and Maintenance Guide for recommended preventive maintenance requirements Other Sample Vent Isolation Valves The isolation valves in the Sample Probe if used or SCU and Vent Valve if used assemblies typically do not require regular maintenance However if it is susp...

Page 182: ...g the ambient temperature around the analyzer and the operating temperatures for each analyzer temperature zone From the MAI screen check the real time temperature for each Temperature Zone and compare it to its Set Point temperature on the TStPt screen Also verify the ambient temperature surrounding the analyzer and the operating temperature of its sample system is at least 10 C 18 F above the pr...

Page 183: ...s longer response times The section of the sample system with the highest risk of plugging is the sample inlet and the section of the sample inlet most prone to plugging is the Sample Probe Valve or SCU One way to confirm that a plug is in the sample inlet is to close the Vent Valve s isolation valve or cap the Vent Line and Zero the analyzer Plugs in the sample outlet or vent side of the sample s...

Page 184: ...g on the analyzer see Chapter 4 Measuring Cell Maintenance This procedure discusses a Standard Range Measuring Cell 40 cm or smaller Figure 5 1 For other types of Measuring Cells refer to Manual Supplements in the analyzer Documentation Package Replace clean parts in the Measuring Cell Every year Any time an unscheduled cleaning is performed If the analyzer responds slowly to a Zero when the sampl...

Page 185: ...ated Acid Gas Sample Probe After the Zero is complete close the Sample Valve and then the Vent Valve on the HAG Sample Probe to isolate the analyzer from the process duct 2 Power down the analyzer General Purpose GP Analyzers Open the Electronics Enclosure and disconnect power from the analyzer and its temperature zone circuitry by opening the Analyzer Oven Heater and HAG Probe if used fuses and b...

Page 186: ...l driver the head can break off inside the screw c Wearing insulated gloves grasp the Measuring Cell and carefully pull it straight out from the Heater Plate and Cell RTD Figure 5 9 Once the Measuring Cell has cleared the Cell RTD swing the Optical Bench Assembly outward away from the analyzer d Remove the 3 M4 x 12 screws that secure the Heat Transfer Block to the Cell Extension and remove the Me...

Page 187: ...Maintenance and Troubleshooting 5 11 Figure 5 1 Measuring Cell assembly ...

Page 188: ...used Rinse the Windows with pharmaceutical grade distilled water and set them aside If the Measuring Cell has a Mirror or Window Mirror combina tion Stand the Mirror vertically and apply 2 propanol ultra pure Isopropyl Alcohol to its surface Gently place a Kimwipes EX L tissue or an equivalent extra low lint tissue on the Mirror surface and allow it to absorb the alcohol and gently pull the Kimwip...

Page 189: ... Window P N 300 0281 Orient the Heat Transfer Block with the Heat Transfer Block Plug access hole at 90 to a line through the fittings the two larger diameter holes in the Measuring Cell must align with the two larger diameter holes in the Heat Transfer Block Connect it to the Measuring Cell with 3 M4 x 12 screws Tighten the screws evenly 8 Reconnect the Measuring Cell to the Optical Bench and sec...

Page 190: ...de and outside edges of the Electronics Enclosure wall Temporarily close the Electronics Enclosure door and tighten its screws to secure the Optical Bench in place While closing the Electronics Enclosure door verify that proper verti cal alignment of the Optical Bench is maintained If necessary vertically align the Optical Bench by loosening the Optical Bench support bracket from the backpan and m...

Page 191: ...ged Analyzers Insert the key into the Purge Bypass Switch and switch it to the BYPASS position follow company policy Special Conditions for Safe Use The analyzer may only be energized by using the Purge Bypass Switch with permission of the works manager or his proxy The per mission may only be given when it is made sure that during the time the system is energized by using this switch an explosive...

Page 192: ...ple Valve or remove the cap and reconnect the Sample Line to the Sample port in the Analyzer Oven to allow sample gas into the analyzer sample system Optional systems with Heated Acid Gas Sample Probe When the analyzer is at operating temperature open the Vent Valve on the HAG Sample Probe and then open its Sample Valve to allow sample gas into the analyzer sample system 14 Purged Analyzers Only R...

Page 193: ...on the HStatus screen The w Lamp Control alarm is displayed on the MStatus screen About the Source Lamps Source Lamp 1 is the one closest to the Measuring Cell Figure 5 2 The cathode of the Source Lamp must be centered on the optical axis of the Beam Splitter for optimal operation of the analyzer The cathode and glass envelope are not necessarily concentric or consistent on each lamp New source la...

Page 194: ...d Acid Gas Sample Probe After the Zero is complete close the Sample Valve and then the Vent Valve on the HAG Probe to isolate the analyzer from the process duct 2 Power down the analyzer General Purpose GP Analyzers Open the Electronics Enclosure and disconnect power from the analyzer and its temperature zone circuitry by opening the Analyzer Oven Heater and HAG Probe if used fuses and by removing...

Page 195: ...alyzers Only Turn off the Instrument Air supply to the analyzer and then close the Aspirator Air valve Purged Analyzers The Instrument Air supply must always remain on for the Purge Bypass Switch to operate properly The Purge Bypass Switch must be in the BYPASS position ...

Page 196: ...ling the source lamp 5 Install the new lamps a Make sure that the narrow end of each lamp is inserted completely into the Detector Assembly Do not touch the flat window at the end of the lamp b Lightly tighten each Lamp Clamping Screw to secure each lamp Do not overtighten the spring should not be collapsed c Replace each Lamp Socket and secure them by rotating the Lamp Retaining Bracket 90 degree...

Page 197: ...ions for Safe Use The analyzer may only be energized by using the Purge Bypass Switch with permission of the works manager or his proxy The per mission may only be given when it is made sure that during the time the system is energized by using this switch an explosive atmosphere is not present or when the necessary protective measures against explosion hazard have been taken hot permit The analyz...

Page 198: ...nd the application For the filter sequence for your application view the Bench Type Code press F2 1 in RUN mode and then refer to the Filter Position Assignment descriptions see F2 1 under RUN CFG Mode F2 Commands in Chapter 4 11 Turn off the Automatic Lamp Control Alc The Alc Enable function must be off to ensure the analyzer does not make automatic adjust ments while you are setting the Measure ...

Page 199: ...er Interface is updated at one second inter vals use slow small movements pausing each turn to view the new value Because the Automatic Lamp Control Alc Enable function is turned Off the displayed signal may not be perfectly steady 15 Loosen the Locking Screw between the two lamps 16 To obtain the maximum signal from the Measure PMT adjust the Lamp Adjusting Screw for the lamp being replaced 17 To...

Page 200: ...systems with Heated Acid Gas Sample Probe When the analyzer is at operating temperature open the Vent Valve on the HAG Sample Probe and then open its Sample Valve to allow sample gas into the analyzer sample system 23 Purged Analyzers Only Return the Purge Bypass Switch to the ACTIVE position and re move the key follow company policy 24 Manually Zero the analyzer and then manually Span the analyze...

Page 201: ...on number is 1 00 0 25 IMPORTANT Although a good completion number is indicative of a successful Auto Setup do not rely on it solely Always check the PMT Level and PMT Balance after every Auto Setup See PMT Level and PMT Balance following this section for details on acceptable levels of these two parameters If the completion number is outside of this range it is an indication that the Measure and ...

Page 202: ...of both PMTs simultaneously in the same direction PMT Balance adjusts the gain of the two PMTs in opposite directions by controlling a virtual ground circuit on the Optical Bench board It is possible to achieve an acceptable completion number yet have an unacceptable PMT Level and or PMT Balance signal Always check both of these values after an Auto Setup If the PMT signals are outside their norma...

Page 203: ...PMT Balance signal goes to minimum or maximum the LVL adjust fault or BAL adjust fault message can appear on the User Interface If one or both of these messages appear ensure that The Measuring Cell was purged with Zero gas Display the source lamp pulse current control signal for each filter location Ftr The source lamps are not burned out Each lamp socket is attached securely to each lamp The lam...

Page 204: ...of the jumper on P301 for a drastic change Note that when changing the jumpers Increasing the jumper position increases the completion number Decreasing the jumper position decreases the completion number Adding a jumper decreases the completion number Restart Auto Setup CFG F1 Repeat this procedure until b is between 0 75 1 25 then continue with Step 3 P300 can have up to four jumpers installed a...

Page 205: ...fine adjustment to the PMT supply voltages at one jumper combination The jumper combinations affect the Auto Setup in terms of reducing the completion number increasing or decreasing the resulting PMT Balance and to a lesser degree the PMT Level Figure 5 3 describes the effect on the PMT Balance and PMT Gain in rela tion to different jumper positions To achieve an acceptable completion number PMT ...

Page 206: ... P301 jumper positions vs PMT Balance Jumper Positions P300 P301 1 2 3 4 5 6 X X X X X X X X X Higher PMT Balance X X X X Lower Completion Number X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X Lower PMT Balance X X Higher Completion Number NOTE ...

Page 207: ...from the process duct Optional systems with Heated Acid Gas Sample Probe After the Zero is complete close the Sample Valve and then the Vent Valve on the HAG Probe to isolate the analyzer from the process duct 2 Power down the analyzer General Purpose GP Analyzers Open the Electronics Enclosure and disconnect power from the analyzer and its temperature zone circuitry by opening the Analyzer Oven H...

Page 208: ...nect the AC power line connector plug from TB100 on the Optical Bench board c Disconnect terminals of yellow green ground wire that runs from the Electronics Enclosure to the Optical Bench d Optional If using the Optical Bench Purge disconnect the purge line black tube from the Optical Bench Purge Fitting 6 After the Oven has cooled down enough to work on disconnect the Measuring Cell from the Hea...

Page 209: ...analyzer To help maintain the temperature inside the Oven close the Oven door while working on the Measuring Cell 7 While holding the Optical Bench by its upper portion or Measuring Cell remove the outermost pivot pin from the blue Support Arm Yoke and carefully remove it from the analyzer While removing the Optical Bench from the Electronics Enclosure do not support the assembly by its circuit bo...

Page 210: ...ce one Bushing on the Chopper Shaft followed by a new Bearing P N 300 9437 the Chopper Wheel another new Bearing and the other Bushing Replace the Spring Washer and the Snap Ring on the Chopper Shaft e Replace the new Drive Belt o ring P N 300 1528 by first placing it in the Chopper Wheel groove and then rolling it over the Pulley and into the groove Use care to avoid stretching the Drive Belt Rot...

Page 211: ...Maintenance and Troubleshooting 5 35 Figure 5 5 Optical Bench Chopper Assembly Maintenance Diagram ...

Page 212: ... from J102 on Micro Interface board to J100 on Optical Bench board AC power line connector plug to TB100 on Optical Bench board Connect the yellow green ground wire using the disconnect terminals c Optional If using connect the purge line black tube to the Optical Bench Purge Fitting 10 Install the Measuring Cell in the Analyzer Oven a Open the Oven door Swing the Optical Bench toward the Electron...

Page 213: ...cs Enclosure door and tighten its screws to secure the Optical Bench in place While closing the Electronics Enclosure door verify that proper verti cal alignment of the Optical Bench is maintained If necessary vertically align the Optical Bench by loosening the Optical Bench support bracket from the backpan and moving the Optical Bench up or down as required After aligning the Optical Bench retigh...

Page 214: ...Analyzers Insert the key into the Purge Bypass Switch and switch it to the BYPASS position follow company policy Special Conditions for Safe Use The analyzer may only be energized by using the Purge Bypass Switch with permission of the works manager or his proxy The per mission may only be given when it is made sure that during the time the system is energized by using this switch an explosive atm...

Page 215: ... Sample Valve or remove the cap and reconnect the Sample Line to the Sample port in the Analyzer Oven to allow sample gas into the analyzer sample system Optional systems with Heated Acid Gas Sample Probe When the analyzer is at operating temperature open the Vent Valve on the HAG Probe and then open its Sample Valve to allow sample gas into the analyzer sample system 15 Purged Analyzers Only Retu...

Page 216: ...r computer if there is a flammable gas atmosphere present 1 Manually Zero the analyzer After the Zero is complete close the isolation valve on the Sample Probe SCU and the Vent Valve or cap the Sample and Vent Lines to isolate the analyzer from the process duct Optional systems with Heated Acid Gas Sample Probe After the Zero is complete close the Sample Valve and then the Vent Valve on the HAG Pr...

Page 217: ...urged Analyzers The Instrument Air supply must always remain on for the Purge Bypass Switch to operate properly 5 Open the Electronics Enclosure door 6 After the Oven has cooled down enough to work on The analyzer sample system will be under positive pressure take precautions to avoid injury a Disconnect the Measuring Cell tubing b Remove the Heat Transfer Block Plug from the Heat Transfer Block a...

Page 218: ...wire s of RTDs and or Heater Elements that will be re used with their termination points to use when replacing them later Disconnect the faulty RTD and or Heater Element wires from the Heater Termination board 9 Remove the 4 M6 x 35 screws and lock washers that secure the Heater Plate to the Oven wall Figure 5 8 10 On the front of the Heater Plate remove the 4 M6 x 25 screws that secure the Upper ...

Page 219: ...er Elements and RTDs Figures 5 8 and 5 9 Replacing a faulty Heater Element a Remove the faulty Heater Element from its channel in the Upper Heater Plate and carefully pull its wire out from the Seal Body and through the Lower Heater Plate b Install a new Heater Element P N 300 8684 in the channel it was removed from c Label the Heater Element wire Overtemp Heater or Heater as required Replacing in...

Page 220: ...RTD wire to the RTD end of the old RTD wire Use the old wire to pull the new RTD wire through the Upper Heater Plate as you remove the old wire Label the new RTD wire Sample Cell d Apply Loctite 271 P N 300 4478 on the small lower threads of the RTD Base Rotate the Base counter clockwise 3 4 turns take care not to over stress the wire and then screw clockwise the Base into the Upper Heater Plate H...

Page 221: ...g 5 45 Figure 5 6 illustrates a typical Oven Instrumentation layout for CE Zone 1 analyzers For your system refer to Final As Built drawings in the analyzer Documentation Package NOTE Figure 5 6 Oven Instrumentation layout CE Zone 1 ...

Page 222: ... to pinch any wires between the two plates and secure them together with the 8 M6 x 25 screws Tighten the screws 15 Reinstall the Heater Plate in the Oven Slightly loosen the Seal Body gland nut inside the Electronics Enclosure and tilt the top of the Heater Plate toward the back of the Oven OPTIONAL If the entire Heater Plate was removed from the Oven to work on it reassemble Heater Plate see Ste...

Page 223: ... Analyzer Oven a Open the Oven door Swing the Optical Bench toward the Electronics Enclosure and then swing the Measuring Cell toward the Oven Figure 5 6 Align the hole in the Heat Transfer Block with the Cell RTD tip on the Heater Plate and carefully push the Measuring Cell toward the RTD Adjust the entire Measuring Cell Optical Bench Assembly as required to firmly seat the Measuring Cell against...

Page 224: ...racket c Verify there is no clearance between the Heat Transfer Block and the Cell RTD The Measuring Cell must feel secure against the Heater Plate Gently push and pull on the Measuring Cell to verify it is not loose If there is any movement tighten the M4 x 25 screw again until the Measuring Cell does not move being careful not to over tighten it Over tightening this screw will damage the threads...

Page 225: ...Maintenance and Troubleshooting 5 49 Figure 5 7 2 Heater Termination board Terminal Strips J1 J2 wiring layout Figure 5 7 1 Flameproof Heater Seal Assembly 100 1190 1 ...

Page 226: ...5 50 Model 920 Multi Gas Analyzer Figure 5 8 Flameproof Heater Seal Assembly layout WX 14324 1A ...

Page 227: ...Maintenance and Troubleshooting 5 51 Figure 5 9 Flameproof Heater Seal internal component layout 100 1622 1A ...

Page 228: ...5 52 Model 920 Multi Gas Analyzer Figure 5 10 Oven Heater and Temperature Sensor wiring WX 14161 ...

Page 229: ...ch and switch it to the BYPASS position follow company policy Special Conditions for Safe Use The analyzer may only be energized by using the Purge Bypass Switch with permission of the works manager or his proxy The per mission may only be given when it is made sure that during the time the system is energized by using this switch an explosive atmosphere is not present or when the necessary protec...

Page 230: ...e Probe When the analyzer is at operating temperature open the Vent Valve on the HAG Probe and then open its Sample Valve to allow sample gas into the analyzer sample system 24 Purged Analyzers Only Return the Purge Bypass Switch to the ACTIVE position and re move the key follow company policy 25 Manually Zero the analyzer 26 Change the Flow Control setting back to Analyzer Control mode 27 Adjust ...

Page 231: ...analyzer maintenance use a feeler gauge to check the flamepath gap of the Heater Plate Assembly flange upper lower Heater Plate joining surfaces inside the Analyzer Oven The gap must not exceed 0 1 mm if the gap exceeds this value contact AMETEK for advice See Warning below Take extreme care to avoid damaging the threads on the cable entry glands on the Disconnect Enclosure and all threaded parts ...

Page 232: ...ter the cleaning fluid has evaporated completely immediately close the Disconnect Enclosure While the Disconnect Enclosure is open for maintenance or repair take extreme care to avoid scratching or damaging the joining surfaces flamepath If at any time the Disconnect Enclosure door is open but is not being worked on close and secure it with at least one screw This will reduce the risk of inadverte...

Page 233: ...age For all parts the maximum surface roughness must be 6 3 μm or less Use A2 stainless steel fasteners with yield stress 450 MPa 65 300 psi The minimum flamepath lengths and gaps for the different parts that make up the Heater Plate and its Seal Assembly are Heater Top Heater Bottom The flamepath length must 12 1 mm or greater and the gap must not exceed 0 1 mm Thermal Tube Seal Body The flamepat...

Page 234: ...unctions refer to the RUN CFG and CAL Mode Command descriptions in Chapter 4 These diagnostics are indicated by preceding their definitions When alarms are detected the alarm indicator S is displayed on the top right line of the User Interface Typical diagnostic alarms to watch for include sample and temperature related alarms Generally most troubleshooting and diagnostics can be done by work ing ...

Page 235: ...imary status code into its primary alarm codes subtract the largest primary alarm code from the displayed number Continue to subtract the largest primary code from the remainder until a primary alarm code is left Example The displayed Host Controller board status code is 20 The alarms detect ed are 20 16 f Temp Low Fault Host Controller 4 f Comm Fault Fault Host Controller ...

Page 236: ...he message HSz OK appears On the User Interface the w or f preceding an alarm indicates a w arning or f ault condition HS Code HStatus Alarm Type Condition Description and Suggested Corrective Action 0 HSz OK If the HS Code returned is 0 and the message displayed is HSz OK it indicates that the Warning or Fault being viewed does not exist where z is the HStatus number 1 7 assigned to that alarm Th...

Page 237: ... tions and inspect it for damage cuts nicks burn marks etc Ensure the actuators on switch S100 on the Micro Interface board are positioned toward the middle of the board See Figure 5 11 for the location of this switch 8 4 Fault f RxData Fault This serious system Fault condition indicates the Host Control ler board is not receiving analytical data from the Microcontroller board When this Fault is d...

Page 238: ...nd compare it to its Set Point temperature TStPt screen Check each of the associated configuration parameters for temperature control These parameters may have been lost as a result of a power interruption or a power spike Take appropriate safety precautions open the Electronics Enclo sure and Check the fuse for the zone which caused the alarm Other checks corrective action Check the electrical co...

Page 239: ...r a power spike Take appropriate safety precautions open the Electronics Enclo sure and Check the green LED for each circuit located on the Termina tion board S L LED302 V L LED301 Oven LED300 to verify which zone is experiencing problems Press SW300 on the Termination board to re energize the tripped circuits Check the fuse for the Over Temp circuit Other checks corrective action Check the electr...

Page 240: ... differ by more than 10 from the previous values A Span Error occurs if a Span Factor attained after a Span is 0 85 or 1 15 Corrective Action Ensure the proper gases are being used for the calibration Check the analyzer to determine if the Measuring Cell its optics and or sample system is contaminated Refer to Analyzer Preven tive Maintenance Schedule and Measuring Cell Maintenance in this chapter...

Page 241: ...leshooting 5 65 Figure 5 12 1 Sample Vent Line Wiring Disconnect Enclosure Zone 1 Analyzer H G N DISCONNECT ENCLOSURE 900 910 920 930 ZONE 1 ANALYZERS ANALYZER AC G G H N H N G SAMPLE LINE CONNECTIONS VENT LINE CONNECTIONS ...

Page 242: ...BOX SEE NOTE 1 9XX HI TEMP 9XX HI TEMP BK 18 W 18 N O N O N O W 18 BK 12 BK 12 TB3 TB3 TB3 TB3 W 18 8 9 10 12 16 6 7 5 13 11 15 14 19 20 21 3 NOTES ISOLATION SEE NOTE 3 1 2 IF USING A SAMPLE LINE OR VENT LINE w o TS PLACE A JUMPER BETWEEN TERMINALS 19 20 AND 24 25 IN THE SAMPLE VENT LINE TERMINATION BOX ALL WIRES ARE PART OF WIRING HARNESS 301 1636 INDICATES THE IDENTIFICATION TAG THAT IS SUPPLIED...

Page 243: ...Maintenance and Troubleshooting 5 67 Figure 5 13 Over temp alarm reset switch SW300 Termination board ...

Page 244: ...m exists otherwise the message MSz OK appears On the User Interface the w or f preceding an alarm indicates a w arning or f ault condition MS Code MStatus Alarm Type Condition Description and Suggested Corrective Action 0 MSz OK If the MS Code returned is 0 and the message displayed is MSz OK it indicates that the Warning or Fault being viewed does not exist where z is the MStatus number 1 7 assig...

Page 245: ...t Point is set to 0 typical for a spare temperature zone Corrective Action Take appropriate safety precautions open the Electronics Enclo sure and Replace the Microcontroller board and or Check the current temperature Show MAI screen for each temperature zone and compare it to its Set Point tempera ture TStPt screen If a heated external probe is used press F1 3 4 to check the Probe Temperature low...

Page 246: ...onnections and inspect it for damage cuts nicks burn marks etc From the User Interface From RUN mode ensure that Automatic Lamp Control ALC is On ALC 0 ALC Off ALC 1 ALC On If the ALC setting is 0 Off change it to 1 On from CFG mode 16 5 Fault f Comm Error The Microcontroller board cannot establish reliable communica tions with the Host Controller board Corrective Action Take appropriate safety pr...

Page 247: ...e light levels may be too low as a result of natural aging of the lamps This is an indication that the lamps should be replaced as soon as possible As a temporary solution initiate an Auto Setup to increase the PMT gain to compensate for the reduced light levels The Auto Setup starts immediately upon pressing F1 64 7 Fault f Oven Heater The Oven Heater Plate temperature is approaching its over tem...

Page 248: ...he User Interface The message Reset In Progress should be dis played within one second after pressing these keys Do not randomly reset the analyzer during normal operation Typically the only resets required are in cases where the Host Controller or Microcontroller boards have been replaced In this case it is necessary to shut down the analyzer The analyzer will reset upon normal power up CAUTION ...

Page 249: ... or 1 800 661 9198 or contact your local AMETEK Western Research representative For office locations and contact information refer to the Offices page near the beginning of this manual or visit us at www ametekpi com Before contacting AMETEK with questions regarding the installation operation or maintenance troubleshooting of your analyzer system carefully review the contents of this manual If you...

Page 250: ...n RMA number This will ensure your equipment is serviced and returned to you in a prompt and efficient manner To obtain a RMA number contact your local or nearest AMETEK Service Centre and have the following information available Analyzer Model number Analyzer Serial number Purchase order number Billing address shipping address and telephone number ...

Page 251: ...on site charge for this visit can be deducted from the start up charge if you select that option START UPS YourdecisiontobuyanAMETEKanalyzerisgreatly appreciated Afterthetimeandmoneyspentonyour analyzer wouldn t you expect a fast and successful start up We can ensure that will happen Schedule us to be there before you power up the system We will guarantee a satisfactory commissioning of your analy...

Page 252: ...on For drawings that illustrate the location of all spare parts in the ana lyzer see Preventive Maintenance in Chapter 5 Content is subject to change without notice Optical Bench Measuring Cell Spare Parts The replacement of these parts is required as part of the Analyzer Preventive Maintenance Schedule Chapter 5 It is also necessary to have these parts on hand in case the parts become damaged or ...

Page 253: ... Assembly in Optical Bench 0 2 Measuring Cell Spare Parts Part No Description QTY 1 Year QTY 2 Year 300 0281 Cell Window Fused Silica Measuring Cell 4 6 100 1911 O Ring Size 125 Baked Teflon Coated Aflas Measuring Cell 8 16 Expo Technologies MiniPurge System With eTimer Spare Parts AMETEK recommends replacing the Battery Pack in the Expo Technologies MiniPurge System which provides power to the sy...

Page 254: ...hese parts on hand in case the parts become damaged or contaminated and need to be replaced earlier than listed in the recommended schedule SCU Probe by AMETEK Part No Description QTY 1 Year QTY 2 Year 300 0962 Filter Element 10 20 300 9256 Gasket Set Viton 4 8 M C Probe Part No Description QTY 1 Year QTY 2 Year 300 9266 Ceramic Filter Element 1 2 300 9267 Filter Element Gasket 1 2 300 9268 Lid Se...

Page 255: ...xe PD GP Div 2 only analyzers do not use the 24 V Power Supply or 24 V fuse These fuses are located at TB2 see AC Wiring drawing in Chapter 3 Sample and Vent Line or SCU Fuses Part No Fuse Type 300 9291 6 A 300 9443 8 A 300 9292 10 A 300 9293 16 A 300 6312 20 A Sample Line fuse if used is located at TB3 30 on GP Div 2 analyzers TB5 1 on Zone 1 analyzers Vent Line fuse if used is located at TB3 50 ...

Page 256: ... 125 mA 300 8777 63 mA Photomultiplier Tube F300 300 3214 0 2 A 300 3214 0 2 A Lamp F201 300 9524 32 mA 300 9524 32 mA For the location of the Optical Bench board and the location of these fuses see the Optical Bench Chopper Assembly Maintenance Diagram and the Optical Bench board 100 1662 layout drawing under Chopper Assembly Maintenance in Chapter 5 Disconnect Enclosure Fuse Zone 1 and CE Analyz...

Page 257: ...ical Bench Assembly Electronics Enclosure 1 100 0140 Dual PMT Buffer Board Detector Block Assembly part of Optical Bench 1 Assembly Electronics Enclosure 100 0939 Display I O Expansion Board Electronics Enclosure 1 100 1096 Temperature Daughter Board 4 RTDs Electronics Enclosure 1 OR 100 1097 Temperature Daughter Board 2 RTDs 2 Thermistors Electronics Enclosure 1 100 1215 Customer Termination Boar...

Page 258: ...ture Wire 16 AWG 30 300 4182 Ring Terminal 8 300 0265 Lock Washer 4 mm 300 0006 M4 x 8 Screw 300 4478 Loctite 271 Used for internal Overtemp and Heater RTDs and external Sample Cell RTD or Sulfur Condenser RTD if used Used for external Sample Cell RTD or Sulfur Condenser RTD if used Required only if lost or damaged re use if not damaged Refer to drawings in Optical Bench Chopper Assembly Maintenan...

Page 259: ...ous Sample Block Off mode This character is also displayed when the Remote Backpurge optional is activated by the user via a remote dry contact opening C Flow Control mode User selected manual Continuous Calibration Gas Flow mode Gas 1 or Gas 2 CAL CALibration mode CFG ConFiGuration mode f Precedes an alarm message which indicates the alarm is a f ault alarm e g f Temp Low RUN RUN mode S Flow Cont...

Page 260: ...information for the system shipped with the analyzer DP differential pressure EEPROM electrical erasable programmable read only memory GP General Purpose analyzer HAI Host Controller Analog Input HAG Probe Heated Acid Gas Probe MAI Microcontroller Analog Input Modbus Communication protocol PD Purgeable Deluxe analyzer General Purpose and Division 2 PID proportional integral differential PMT photom...

Page 261: ...ains drawings that are not included in the main body of this manual If your Documentation Package includes Final As Built job specif ic drawings use those for installation and maintenance diagnostic purposes in place of similar example drawings in this manual NOTE ...

Page 262: ...A 2 Model 920 Multi Gas Analyzer Ribbon Cable Interconnect WX 102836 ...

Page 263: ...Appendix A Drawings A 3 GP Lower Enclosure to Electronics Wiring CE Analyzers WX 102810 ...

Page 264: ...A 4 Model 920 Multi Gas Analyzer Heater and Sensor Wiring GP Div 2 Analyzers WX 102851 ...

Page 265: ...Appendix A Drawings A 5 Heater and Sensor Wiring CE Zone 1 Analyzers WX 102852 ...

Page 266: ...A 6 Model 920 Multi Gas Analyzer Lower Cabinet Wiring CE GP Analyzers 120V 100 1341 3 ...

Page 267: ...Appendix A Drawings A 7 Lower Cabinet Wiring CE GP Analyzers 240V 100 1342 3 ...

Page 268: ...A 8 Model 920 Multi Gas Analyzer Signal Wiring PD GP Div 2 CE Zone 1 Analyzers WX 102815 ...

Page 269: ...T BOARD S V TB 100 1214 RTD TERMINATION DISCONNECT BOARD TERMB 100 1534 CUSTOMER TERMINATION BOARD DTR1 2 100 1096 OR 100 1097 RTD DAUGHTER BOARD LEGEND Purged Enclosure Disconnect Enclosure Enclosure Disconnect Enclosure Purged SEAL 2 SEAL 1 SEAL 3 Disconnect Enclosure S V Line Termination Box Disconnect Enclosure ON M900 930 DENOTES A NUMBER THAT IS TAGGED ON A WIRE 2 ...

Page 270: ...A 10 Model 920 Multi Gas Analyzer 15V and 5V Power Supply DC Wiring GP Div 2 CE Zone 1 Analyzers WX 102811 ...

Page 271: ...Appendix A Drawings A 11 24V Power Supply DC Wiring CE Zone 1 Analyzers WX 102812 ...

Page 272: ...A 12 Model 920 Multi Gas Analyzer RS 232 Communications Cable Wiring 300 9480 ...

Page 273: ...Appendix A Drawings A 13 RS 232 RS 485 Module Wiring CE Zone 1 GP Div 2 Analyzers 100 2185 ...

Page 274: ...A 14 Model 920 Multi Gas Analyzer Microcontroller Board 100 0117 ...

Page 275: ...Appendix A Drawings A 15 Host Controller Board Display Interface 100 0138 ...

Page 276: ...A 16 Model 920 Multi Gas Analyzer Model 9xx Series Analyzer Type 200 Disconnect Enclosure Details ...

Page 277: ...order the Analyzer Documentation Package CD ROM all files in PDF format this information is included in the Supplemental Information folder on the CD Supplemental Information Where Can I Find It in Chapter 1 describes the documents listed below This section can include Manual Supplements Analyzer Programming Parameters sheet EEPROM Data Sheets Signed Final QC Quality Control Document Final As Buil...

Page 278: ...S 2 Model 920 Multi Gas Analyzer This page intentionally left blank ...

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