Ametek 888 User manual

Model 888 Tail Gas Analyzer
Class I, Division 2, GPS A, B, C, D
User Manual
PN 883056902 REV. H
Process Instruments
Western Research
455 Corporate Boulevard
Newark, DE 19702

2 | Model 888 Tail Gas Analyzer Class I, Division 2
© 2015 AMETEK Process & Analytical Instruments Division
This document contains Essential Health and Safety information for the use of the AMETEK Model 888 DIV 2 Tail Gas Analyzer. Data
herein has been veried and validated and is believed adequate for the intended use of this instrument. If the instrument or procedures
are used for purposes over and above the capabilities specied herein, conrmation of their validity and suitability should be obtained;
otherwise, AMETEK does not guarantee results and assumes no obligation or liability. This publication is not a license to operate under, or
a recommendation to infringe upon, any process patents.
OFFICES
USA - Delaware
455 Corporate Blvd., Newark DE 19702
Tel: [phone]
Fax: [phone]
USA - Pennsylvania
150 Freeport Road, Pittsburgh PA 15238
Tel: [phone]
Fax: [phone]
CANADA - Alberta
2876 Sunridge Way N.E., Calgary, AB T1Y 7H9
Tel: [phone]
Fax: [phone]
WORLDWIDE SALES AND SERVICE LOCATIONS
USA - Texas
Tel: [phone], Fax: [phone]
CHINA
Beijing / Tel: [phone], Fax: [phone]
Chengdu / Tel: [phone], Fax: [phone]
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FRANCE
Tel: [phone], Fax: [phone]
GERMANY
Tel: [phone], Fax: [phone]
MIDDLE EAST - Dubai
Tel: [phone], Fax: [phone]
SINGAPORE
Tel: [phone], Fax: [phone]
www.ametekpi.com

Contents |3
Contents
Safety Notes .......................................................................................................... 7
Grounding..............................................................................................................7
Important Safety Information ................................................................................. 8
Storage Information ............................................................................................... 9
Warning Labels.................................................................................................... 10
Special Warnings and Information....................................................................... 15
Warranty and Claims ........................................................................................... 16
CHAPTER 1 Overview
Model 888 Tail Gas Analyzer ..............................................................................1-1
Electronics Enclosure...................................................................................1-2
Photometer...................................................................................................1-2
Xenon Lamp Assembly ................................................................................1-3
Detector Assembly .......................................................................................1-3
Lamp & Detector Mounting ..........................................................................1-3
User Interface/Host Display .........................................................................1-4
Sensor Board ...............................................................................................1-4
Sample Conditioning (Oven) Enclosure.......................................................1-4
Flow Diagrams .............................................................................................1-5
Light Tube/Mirror Block Assembly................................................................1-6
Demister.......................................................................................................1-6
Sample Cell..................................................................................................1-6
Steam Blowback Valve.................................................................................1-8
Heat Exchangers..........................................................................................1-8
Customer Connections Enclosure................................................................1-9
Customer Drawing Package ......................................................................1-10
Operation..........................................................................................................1-10
Timing Sequence.............................................................................................. 1-11
Sample Flow .............................................................................................. 1-11
CHAPTER 2 Specications
Model 888 Tail Gas Analyzer ..............................................................................2-1
CHAPTER 3 Installation and Start-Up
Prior to Installation..............................................................................................3-1
Analyzer Site Preparation ............................................................................3-2
Unpacking and Inspection............................................................................3-2
Space Requirements....................................................................................3-2
Installation Guidelines ........................................................................................3-4
Sample Tap Preparation...............................................................................3-5
Installation Procedure.........................................................................................3-6
Installing the Probe ......................................................................................3-7
Installing the Demister................................................................................ 3-11
Electrical Connections ...............................................................................3-13
System Start-Up and Operation .......................................................................3-15

4 | Model 888 Tail Gas Analyzer Class I, Division 2
Leak Checking ...........................................................................................3-15
System Operation.............................................................................................3-16
Analyzer Security - Passwords.........................................................................3-16
Starting Normal Operation .........................................................................3-16
Setting the Sample Gas Flow ..............................................................3-18
Analyzer Timing..........................................................................................3-20
Normal Timing Sequence ....................................................................3-21
Calibration Span Adjustment ............................................................................3-23
Calibration Procedure ................................................................................3-23
Analyzer Troubleshooting and Maintenance ....................................................3-26
Sample System Leakage Test....................................................................3-28
CHAPTER 4 Controller / User Interface
Refer to 883056904 User Interface Manual for details on the AMEVision interface
Passwords ..........................................................................................................4-1
CHAPTER 5 Alarms
Alarm Relays ......................................................................................................5-1
Alarm Conditions and Responses ......................................................................5-3
CHAPTER 6 Troubleshooting
Diagnostic Functions ..........................................................................................6-1
Problems and Possible Causes..........................................................................6-2
Oven/Cell Temperature Not Reaching Setpoint ...........................................6-2
Demister Temperature Not Reaching Setpoint.............................................6-2
Low Light Conditions....................................................................................6-3
Cleaning the Optical Surface.................................................................6-4
Check the Optical Alignment .................................................................6-4
CHAPTER 7 Parts Replacement
Part Numbers ....................................................................................................7-2
Parts Drawings ...................................................................................................7-3
APPENDIX A Wiring Diagrams
APPENDIX B H2S and SO2Calculations
Concentration Measurement ............................................................................. B-1
Absorbance Calculation .............................................................................. B-1
APPENDIX C Analyzer Timing
Timing States / Periods...................................................................................... C-1
Period 1 – Special Flush ............................................................................. C-1
Period 2 – Flush and Zero........................................................................... C-1
Period 3 – Sample Flush............................................................................. C-2
Period 4 – Measure..................................................................................... C-2
Zero and Photo-Span Calibration ......................................................... C-2
Operation Sequences........................................................................... C-3

Contents |5
Period 5 – Flush and Zero........................................................................... C-3
Period 6 – Track Zero.................................................................................. C-3
Period 7– Photo-Span Calibration............................................................... C-3
Period 8 – Track Photo-Span Calibration.................................................... C-4
Steam Blowback................................................................................... C-4
Period 9 – Pre-Steam Flush........................................................................ C-4
Period 10 – Steam Blowback...................................................................... C-4
Period 11 – Post Steam Flush..................................................................... C-4
Special Periods.................................................................................................. C-5
Period 12 – Continuous Flush..................................................................... C-5
Period 13– Continuous Hold ....................................................................... C-5
Period 14 – Continuous Sample ................................................................. C-5
APPENDIX D Parameter IDs / Modbus Addresses
APPENDIX E Alarm Codes

6 | Model 888 Tail Gas Analyzer Class I, Division 2
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Contents |7
About This Document
This document describes the user instructions for the safe operation of the
Model 888 Analyzer intended for use in Class I, Division 2 areas.
The procedures and information discussed in this document are the pro-
cedures to install, operate, and perform maintenance on the Model 888
Analyzer including all relevant safety warnings and cautions to ensure
the safety of personnel and the analyzer in Class I, Division 2 locations.
Safety Notes
Warnings, cautions, and notes contained in this document and in the User
Manual emphasize critical instructions as follows:
An operating procedure which, if not strictly observed, may result in
personal injury or environmental contamination.
An operating procedure which, if not strictly observed, may result in
damage to the equipment.
Important information that should not be overlooked.
Grounding
Instrument grounding is mandatory. Performance specifications and
safety protection are void if instrument is operated from an improp-
erly grounded power source.
Verify ground continuity of all equipment before applying power.
!
WARNING
!
CAUTION
!
WARNING

8 | Model 888 Tail Gas Analyzer Class I, Division 2
Important Safety Information
Before working on the analyzer, read and understand the following
Notes, Warnings, and Cautions, regarding safety and other required infor-
mation.
Additional Notes, Warnings, and Cautions included in individual proce-
dures in this manual indicate special conditions to consider during instal-
lation, before opening the analyzer covers or doors, and while working on
the analyzer.
High voltages are present in the analyzer housings. Always discon-
nect power and/or external power sources to the analyzer before open-
ing any covers or doors on the analyzer to check or perform mainte-
nance on any components within the enclosures.
If it is necessary to open the analyzer’s covers or doors while the cir-
cuits are live, first monitor the area for flammable gases and proceed
only when the area is safe.
When the Electronics Enclosure and/or other enclosures are open, take
appropriate precautions to avoid electrical shock. Hazardous voltages
are present inside.
All electrical connections, adjustments, or servicing of the analyzer
should be performed only by properly trained and qualified personnel.
All electrical connections, materials, and methods (plus all safety
standards and procedures) must be made in compliance with local
wiring regulations and electrical code for the hazardous area, as speci-
fied by the Owner Company, local electrical-inspection authority, and
National/EU regulations.
Follow appropriate regulatory and/or company procedures to lock out
the analyzer while working on the analyzer electronics.
Verify ground continuity of all equipment before applying power.
For electrical shock protection, the analyzer must be operated from
a grounded power source that has a securely connected protective
ground contact.
!
WARNING
!
WARNING
!
WARNING

Contents |9
The glass Xenon Flash Lamp is under high internal pressure which
could result in flying glass fragments if ruptured. Handle the tube
with care to avoid dropping it, subjecting it to impacts, applying
excessive force to it, or scratching it.
While handling a flash lamp, always wear protective devices (face
mask, clothing) to prevent possible injury, especially to hand and face
areas.
Before working on the sample system, confirm that the system has
been purged with zero fluid and is isolated (blocked in) from the pro-
cess.
The analyzer oven enclosure and components inside the analyzer oven
are hot; always wear protective devices to avoid burning yourself.
Check the sample probe installation. Ensure that all connections are
tight and there are no leaks before opening the sample inlet and return
valves.
The sample gas contains highly toxic and corrosive substances.
Proper personal protective equipment including fresh air breathing
apparatus, eye protection, and skin protection MUST BE worn when
installing the sample tap and/or opening the main oven chamber for
inspection or maintenance.
The sample gas contains highly toxic and corrosive substances. Ana-
lyzed sample must be returned to the process or vented to a safe area.
Storage Information
Humidity may damage the installed Optical filters. Any such dam-
age is not covered by warranty. Please consult Ametek customer
service or your local representative for service advice.
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
WARNING

10 | Model 888 Tail Gas Analyzer Class I, Division 2
Warning Labels
These symbols may appear on the instrument to alert you of existing
conditions.
PROTECTIVE CONDUCTOR TERMINAL
(BORNIER DE L’ECRAN DE PROTECTION)
Schutzerde
CAUTION - Risk of electric shock
(ATTENTION-RISQUE DE DÉCHARGE ÉLECTRIQUE)
Achtung - Hochspannung Lebensgefahr
CAUTION - Refer to accompanying documents
(ATTENTION-SE RÉFERER AUX DOCUMENTS JOINTS)
Achtung (Beachten Sie beiliegende Dokumente)
CAUTION - Hot Surface
(ATTENTION-SURFACE CHAUDE)
Achtung - Heiße Oberäche
Environmental Information (WEEE)
This AMETEK product contains materials that can be reclaimed and recycled. In some
cases the product may contain materials known to be hazardous to the environment
or human health. In order to prevent the release of harmful substances into the
environment and to conserve our natural resources, AMETEK recommends that you
arrange to recycle this product when it reaches its “end of life.”
Waste Electrical and Electronic Equipment (WEEE) should never be disposed of in a
municipal waste system (residential trash). The Wheelie Bin marking on this product is
a reminder to dispose of the product properly after it has completed its useful life and
been removed from service. Metals, plastics and other components are recyclable and
you can do your part by one of the following these steps:
• When the equipment is ready to be disposed of, take it to your
local or regional waste collection administration for recycling.
• In some cases, your “end-of-life” product may be traded in for
credit towards the purchase of new AMETEK instruments. Con-
tact your dealer to see if this program is available in your area.
• If you need further assistance in recycling your AMETEK product,
contact our office listed in the front of the instruction manual.
!
CAUTION