Ametek 900 Manual

Model 900 Air Demand Analyzer
Model 930 Sulfur Pit Analyzer
Operator’s Guide
With Essential Health and Safety Requirements
PN 903-8745, Rev. G
Canada
A DIVISION OF AMETEK PROCESS & ANALYTICAL INSTRUMENTS
Western Research

ii | Model 900 ADA / Model 930 Sulfur Pit Analyzers
© 2013–2019 AMETEK Canada, A Division of AMETEK Process & Analytical Instruments Printed in Canada
This manual is a guide for the use of the Model 900 Air Demand Analyzer (ADA) and Model 930 Sulfur Pit 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.
O󰀩ces
For other offices not listed here, visit us at www.ametekpi.com.
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Contents | iii
Contents
Offices .................................................................................................................................. ii
Safety Notes .....................................................................................................................viii
Electrical Safety................................................................................................................viii
Grounding........................................................................................................................viii
Personnel and Equipment Safety Information............................................................. ix
Warnings ...................................................................................................................... ix
Cautions ....................................................................................................................... xi
Warning Labels................................................................................................................. xii
Environmental Information ........................................................................................... xii
UV Source Lamps Disposal ............................................................................................ xii
Electromagnetic Compatibility (EMC)......................................................................... xiii
Special Warnings and Information............................................................................... xiv
Equipment Used in Hazardous Locations............................................................ xiv
EU Declaration of Conformity ....................................................................................... xv
Warranty and Claims.....................................................................................................xvii
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 and Vent Lines ............................................................................................ 1-8
ASR900 Sample Probe.............................................................................................. 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
Calibration........................................................................................................................ 2-2
Linearity............................................................................................................................ 2-3
Measuring Cell Construction ........................................................................................ 2-3
Stability ............................................................................................................................. 2-3
Cross-Talk.......................................................................................................................... 2-3
Temperature Drift............................................................................................................ 2-3
24-Hour Zero Drift .......................................................................................................... 2-4
Customer Connections................................................................................................... 2-4
Analog Outputs ........................................................................................................ 2-4
Digital Communication ........................................................................................... 2-4

iv | Model 900 ADA / Model 930 Sulfur Pit Analyzers
Maximum Sample Gas Pressure ................................................................................... 2-4
Electrical Requirements.................................................................................................. 2-4
Maximum Start-Up Power ..................................................................................... 2-4
Supply Voltage .......................................................................................................... 2-4
Status Relays .................................................................................................................... 2-5
Sample Gas Flow Rate.................................................................................................... 2-5
Ambient Limits ................................................................................................................ 2-5
Temperature............................................................................................................... 2-5
Humidity.................................................................................................................... 2-5
Maximum Altitude ................................................................................................... 2-5
Sample Transport ............................................................................................................ 2-5
Instrument Air Requirements ....................................................................................... 2-5
Physical Dimensions (on Backpan).............................................................................. 2-5
Cable Entry Ports, Type 200 Disconnect Enclosure.................................................... 2-6
Approvals and Certifications......................................................................................... 2-6
ATEX and IECEx Certificates and Analyzer Markings....................................... 2-7
Purged Analyzers ATEX and IECEx Certificates and Markings ....................... 2-7
Systems with 30 psia Pressure Transducer (Maximum 63 kPag
Sample Gas Pressure) ..................................................................................2-15
Systems with 100 psia Pressure Transducer (Maximum 350 kPag
Sample Gas Pressure) ..................................................................................2-15
Heater Plate ATEX and IECEx Certificates and Marking................................ 2-16
Disconnect Enclosure Type 200 ATEX and IECEx Certificates and Marking . 2-23
CHAPTER 3 INSTALLATION AND START-UP................................................................... 3-1
Safety Considerations..................................................................................................... 3-2
Pre-Installation Requirements....................................................................................... 3-2
Storage Prior to Installation .................................................................................... 3-2
Uncrating and Inspecting the Analyzer................................................................ 3-3
Tools and Equipment Required.............................................................................. 3-4
Installing the Mechanical Components....................................................................... 3-5
Installing the Analyzer............................................................................................. 3-5
Location and Environment.................................................................................. 3-5
Installing the Optical Bench Assembly ................................................................. 3-8
Installing the Sample System................................................................................ 3-13
Installing the ASR900 Sample Probe................................................................ 3-13
Installing the Sample and Vent Lines................................................................ 3-13
Installing the Instrument Air Line ................................................................... 3-19
Installing the Span Gas Line............................................................................. 3-20
Connecting I/O Signals, Alarm Relay Contacts, and AC Power ............................ 3-21
Start-Up and Verification ............................................................................................. 3-27
Purged Analyzers ................................................................................................... 3-28
Powering Up the Analyzer.................................................................................... 3-30
Start-Up Diagnostic Checklist .......................................................................... 3-35
Sample System Leak Check .................................................................................. 3-38
Manually Zeroing the Analyzer........................................................................... 3-40

Contents | v
Setting the Zero Gas Flow Rate............................................................................ 3-41
Setting the Sample Gas Flow Rate and Sample Response Time..................... 3-41
Normal Operation......................................................................................................... 3-42
Recording Initial Readings.................................................................................... 3-42
Recording PMT Signals.................................................................................... 3-42
Recording Initial Sample Response Time .......................................................... 3-43
Analyzer Configuration ............................................................................................... 3-44
CHAPTER 4 CONTROLLER / USER INTERFACE............................................................. 4-1
Introduction to the User Interface................................................................................ 4-2
User Interface Components.................................................................................... 4-2
Messages/Information Displayed on the User Interface.................................... 4-4
Navigating From the User Interface...................................................................... 4-5
Working in RUN Mode....................................................................................... 4-6
Working in CFG Mode........................................................................................ 4-6
Working in CAL Mode ........................................................................................ 4-7
Navigation Examples .......................................................................................... 4-8
Entering Passwords to Change Analyzer Parameter Settings........................... 4-10
Changing the Password for CFG / CAL Mode.............................................4-10
RUN / CFG Mode Quick Reference Sheets – Keystroke Commands ................ 4-11
RUN / CFG Mode – Standard Software Version.........................................4-12
RUN / CFG Mode – COS/CS2Software Version ........................................4-13
CAL Mode Quick Reference Sheets – Keystroke Commands ............................ 4-14
CAL Mode – Standard Software Version.....................................................4-14
CAL Mode – COS/CS2Software Version ....................................................4-15
Working in the RUN / CFG Operating Modes ......................................................... 4-16
RUN / CFG Mode – F1 Commands ..................................................................... 4-17
RUN / CFG Mode – F2 Commands ..................................................................... 4-19
RUN / CFG Mode – F3 Commands ..................................................................... 4-22
RUN / CFG Mode – F4 Commands ..................................................................... 4-23
RUN / CFG Mode – F5 Commands ..................................................................... 4-25
RUN / CFG Mode – F6 Commands ..................................................................... 4-27
Configuring the Analyzer Control Functions ................................................... 4-29
Output Signal Assignment (OSA)..............................................................4-29
Assigning Output Signals With the Track-and-Hold Function Enabled/
Disabled .......................................................................................................4-30
Analog Input Channels – Micro-Interface Board.............................................. 4-32
Display Operating Temperature ..................................................................4-32
Display Measuring Cell Pressure................................................................4-32
Working in the CAL Operating Mode ....................................................................... 4-33
CAL Mode – F1 Commands.................................................................................. 4-33
CAL Mode – F2 Commands.................................................................................. 4-34
CAL Mode – F3 Commands.................................................................................. 4-35
CAL Mode – F4 Commands.................................................................................. 4-36

vi | Model 900 ADA / Model 930 Sulfur Pit Analyzers
CAL Mode – F5 Commands.................................................................................. 4-37
CAL Mode – F6 Commands.................................................................................. 4-38
Setting Up Analyzer Calibration Functions ....................................................... 4-39
Flow Control (Sample) Modes........................................................................... 4-39
Analyzer Control Mode ...............................................................................4-40
Continuous Backpurge/Zero Flow Mode (Manual Control by Operator)...4-40
Continuous Sample Flow Mode (Manual Control by Operator).................4-41
Setting Calibration Gas Timers............................................................................. 4-42
Integration Timer (IntTime).............................................................................. 4-42
Timer0 ............................................................................................................... 4-42
Auto-Zero Interval Timer (AZInt).................................................................... 4-43
Manual Zero/Span.................................................................................................. 4-44
Manual Zero...................................................................................................... 4-44
Manual Span..................................................................................................... 4-44
Auto-Zero................................................................................................................. 4-47
Manual Start of Auto-Zero ............................................................................... 4-48
Timed Start of Auto-Zero .................................................................................. 4-48
Remote Start of Auto-Zero................................................................................ 4-49
Analog Output Calibration ................................................................................... 4-51
CHAPTER 5 MAINTENANCE AND TROUBLESHOOTING............................................... 5-1
Safety Considerations..................................................................................................... 5-1
Preventive Maintenance ................................................................................................ 5-2
Analyzer Preventive Maintenance Schedule....................................................... 5-3
Expo Technologies MiniPurge®System With eTimer (Optional) Preventive
Maintenance Schedule......................................................................................... 5-5
Preventing, Detecting, and Locating a Plug in the Sample System................. 5-6
Changing Out Replaceable Parts ........................................................................... 5-8
Measuring Cell Maintenance.............................................................................. 5-8
Replacing the Source Lamps.............................................................................. 5-17
When Do 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
Replacing Parts in the Heater Plate................................................................... 5-40
ASR900 Sample Probe Preventive Maintenance .............................................. 5-55
Examining and Caring For the Flamepaths ....................................................... 5-56
Disconnect Enclosure Flange Flamepath (Joining Surfaces)............................. 5-57
Heater Plate Flange Flamepath (Joining Surfaces)............................................ 5-58

Contents | vii
Troubleshooting and Diagnostics ............................................................................... 5-59
Host Controller Board Alarm Conditions and Corrective Action .................. 5-61
Microcontroller Board Alarm Conditions and Corrective Action .................. 5-69
Analyzer Reset ...............................................................................................................
CHAPTER 6 SERVICE AND PARTS.................................................................................... 6-1
Technical Support............................................................................................................ 6-1
Returning Equipment..................................................................................................... 6-2
?? ANSWERS TO YOUR QUESTIONS ??................................................................... 6-3
AMETEK SERVICE and AFTERMARKET SALES SUPPORT............................ 6-3
Recommended Preventive Maintenance Spare Parts ............................................... 6-4
Optical Bench/Measuring Cell Spare Parts........................................................... 6-4
Expo Technologies MiniPurge®System With eTimer Spare Parts.................... 6-5
Spare Analyzer Fuses ............................................................................................... 6-6
Replacement Boards................................................................................................. 6-7
Oven Heater Spare Parts ......................................................................................... 6-8
Ordering a Hard Copy of the Analyzer Operator’s Guide ............................... 6-8
CHAPTER 7 GLOSSARY ...................................................................................................... 7-1
User Interface Abbreviations......................................................................................... 7-1
Abbreviations and Terms Used in This Manual ......................................................... 7-2
APPENDIX A – DRAWINGS...................................................................................................A-1
Ribbon Cable Interconnect (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 Seals, Zone 1 Analyzers (100-1343-12).................................... A-9
± 15V and 5V Power Supply DC Wiring, GP/Div 2/CE/Zone 1 Analyzers
(WX-102811) .................................................................................................................. A-10
24V Power Supply DC Wiring, CE/Zone 1 Analyzers (WX-102812)..................... A-11
RS-232 Communications Cable Wiring (300-9480).................................................. A-12
RS-232/RS-485 Module Wiring, CE/Zone 1, GP/Div 2 Analyzers (100-2185) ...... A-13
Microcontroller Board (100-0117) .............................................................................. A-14
Host Controller Board (Display Interface) (100-0138) ............................................ A-15
Model 9xx-Series Analyzer Type 200 Disconnect Enclosure Details.................... A-16
SUPPLEMENTAL INFORMATION ........................................................................................S-1

viii | Model 900 ADA / Model 930 Sulfur Pit Analyzers
Safety Notes
WARNINGS, CAUTIONS, and NOTES contained in this manual emphasize critical instructions
as follows:
An operating procedure which, if not strictly observed, may result in personal injury or envi-
ronmental contamination. Essential Health and Safety Requirements are also included in
– but are not limited to – Warnings.
An operating procedure which, if not strictly observed, may result in damage to the equipment.
Important information that should not be overlooked.
Electrical Safety
High voltages are present in the analyzer housings. Always shut down power source(s) before
performing maintenance or troubleshooting. Only a qualified electrician should make electrical
connections and ground checks.
Any use of the equipment in a manner not specified by the manufacturer may impair the safety
protection originally provided by the equipment.
Grounding
Instrument grounding is mandatory. Performance specifications and safety protection are void if
instrument is operated from an improperly grounded power source.
Verify ground continuity of all equipment before applying power.
!
WARNING
!
CAUTION

NOTE
!
CAUTION

Contents | ix
Personnel and Equipment Safety Information
This section describes important safety information to avoid personal injury and damage to the
equipment while installing, operating, maintaining, or servicing the equipment. All safety regu-
lations, standards, and procedures at the analyzer location must be followed.
All personnel involved with the installation, start-up, operation, maintenance, service, or trou-
bleshooting of the analyzer must review and follow these Warnings and Cautions.
Warnings
Review and follow these Warnings to avoid personal injury or environmental contamination.
Always disconnect main AC power and/or external power sources to the analyzer before open-
ing any covers or doors on the analyzer to check or perform maintenance on any components
within the enclosures.
If it is necessary to open the 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 “BYPASS” position.
When the Electronics Enclosure door is open, take appropriate precautions to avoid electrical
shock. Hazardous voltages are present inside.
All electrical connections, adjustments, or servicing of the analyzer should be performed only
by properly trained and qualified personnel.
All electrical connections, materials, and methods (plus all safety policies and procedures) must
be made in compliance with local wiring regulations and electrical code for the hazardous area,
and be approved by the Owner Company.
Follow appropriate regulatory and/or company procedures to lock out the analyzer while work-
ing on its electronics.
Before working on the sample system, confirm that the system is purged with Zero gas and is
isolated (blocked in) from the sample stream.
!
WARNING
!
WARNING
!
WARNING
!
WARNING

x | Model 900 ADA / Model 930 Sulfur Pit Analyzers
Because ultraviolet radiation can harm your eyes, avoid direct viewing of the light emanating
through the end window of the source lamp. If the source lamp must be viewed while ener-
gized, wear safety glasses that block ultraviolet radiation.
The Analyzer Oven enclosure and components within the Analyzer Oven are hot; take precau-
tions to avoid burning yourself.
Purged Analyzer (Hazardous Location) Applications
[Special Conditions for Safe Use]
The analyzer may only be energized by using the Purge Bypass Switch with permission of
the works manager or his proxy. The permission may only be given when it is made sure that
during the time the system is energized by using this switch an explosive atmosphere is not
present or when the necessary protective measures against explosion hazard have been taken
(“hot permit”).
The analyzer enclosure may not be opened when an explosive atmosphere is present.
Purged Analyzer (Hazardous Location) Applications
Do not apply power to the analyzer if there is damage (scratches, indentations, or wear) to any
flamepath (on the Oven Heater or Disconnect Enclosure). Applying power to an analyzer with
a damaged flamepath is dangerous and could result in serious injury or death, or serious dam-
age to equipment. See “Examining and Caring for the Flamepaths” in Chapter 5.
Replace parts immediately if damage or wear is apparent. Contact AMETEK if there is any
doubt about the integrity of any flamepath.
!
WARNING
!
WARNING
!
WARNING
!
WARNING