Ametek 931S Manual

Model 931S Single-Gas UV Analyzer
Model 932S Multi-Gas UV Analyzer
Operator’s Guide
With Essential Health and Safety Requirements
PN 903-8750, Rev. F
Canada
A DIVISION OF AMETEK PROCESS & ANALYTICAL INSTRUMENTS
Western Research

ii | Model 931S / Model 932S UV Analyzers
© 2013–2018 AMETEK Canada, A Division of AMETEK Process & Analytical Instruments Printed in Canada
This manual is a guide for the use of the Model 931S UV Single-Gas and Model 932S UV Multi-Gas Analyzers. 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 obliga-
tion or liability. This publication is not a license to operate under, or a recommendation to infringe upon, any process patents.
O󰀩ces
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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 ........................................................................................................................ x
Warning Labels.................................................................................................................. xi
Environmental Information (WEEE) ............................................................................. xi
UV Source Lamps Disposal ............................................................................................. xi
Electromagnetic Compatibility (EMC).......................................................................... xii
Special Warnings and Information............................................................................... xiii
Equipment Used in Class I, Division 2 Hazardous Locations........................... xiii
EU Declaration of Conformity ...................................................................................... xiv
Warranty and Claims...................................................................................................... xvi
CHAPTER 1 OVERVIEW....................................................................................................... 1-1
About the Analyzer......................................................................................................... 1-2
About the Analyzer Sample System............................................................................. 1-4
Working in This Manual ................................................................................................ 1-6
Supplemental Information – Where Can I Find It?................................................... 1-7
CHAPTER 2 SPECIFICATIONS ........................................................................................... 2-1
Methodology.................................................................................................................... 2-1
Standard Range Measuring Cell................................................................................... 2-1
Response Time................................................................................................................. 2-1
Accuracy............................................................................................................................ 2-1
Repeatability .................................................................................................................... 2-1
Calibration........................................................................................................................ 2-2
Linearity............................................................................................................................ 2-2
Stability ............................................................................................................................. 2-2
Cross-Talk.......................................................................................................................... 2-2
Temperature Drift............................................................................................................ 2-2
24-Hour Zero Drift .......................................................................................................... 2-3
Customer Connections................................................................................................... 2-3
Analog Outputs ........................................................................................................ 2-3
Status Relay Contacts............................................................................................... 2-3
Digital Communication ........................................................................................... 2-3
Electrical Requirements.................................................................................................. 2-4
Maximum Start-Up Power ...................................................................................... 2-4
Supply Voltage/Maximum Current ....................................................................... 2-4

iv | Model 931S / Model 932S UV Analyzers
Maximum Sample Gas Temperature............................................................................ 2-4
Sample Gas Flow Rate.................................................................................................... 2-4
Ambient Limits ................................................................................................................ 2-5
Temperature............................................................................................................... 2-5
Humidity.................................................................................................................... 2-5
Maximum Altitude ................................................................................................... 2-5
Zero Gas............................................................................................................................ 2-5
Sample Transport ............................................................................................................ 2-5
Sample Pressure Requirement...................................................................................... 2-5
Instrument Air Requirements ....................................................................................... 2-6
Pressure Compensation (Optional).............................................................................. 2-6
Temperature Control ...................................................................................................... 2-6
Physical Dimensions (on Backpan) ............................................................................. 2-6
Hydrogen Sensor (Optional)......................................................................................... 2-7
Accuracy..................................................................................................................... 2-7
Cross-Talk................................................................................................................... 2-7
Temperature Drift..................................................................................................... 2-7
24-Hour Drift............................................................................................................. 2-7
Carbon Dioxide Sensor (Optional)............................................................................... 2-7
Accuracy..................................................................................................................... 2-7
Cross-Talk................................................................................................................... 2-7
Temperature Drift..................................................................................................... 2-7
24-Hour Zero Drift ................................................................................................... 2-7
Approvals and Certifications......................................................................................... 2-8
ATEX and IECEx Certificates and Analyzer Markings....................................... 2-9
CSA Certificate and Analyzer Marking............................................................... 2-17
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
General Installation Information ........................................................................... 3-4
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 ................................................................. 3-7
Installing the Sample System.................................................................................. 3-9
Installing the Optional Heated Acid Gas Sample Probe ......................................3-9
Installing the Sample and Vent Lines.................................................................3-11
Preparing the Optional Heated Measuring Cell for Operation .........................3-11
Installing the Zero/Aspirator Drive Gas Line....................................................3-12

Contents | v
Electrical Connections .................................................................................................. 3-13
Input/Output Signal Connections ....................................................................... 3-14
Optional Interface Capabilities ..........................................................................3-15
Gas Sensor Interface Options ......................................................................3-15
Digital Input Options..................................................................................3-15
Digital Communication ......................................................................................... 3-16
Hardware Configuration (Modbus Serial Communication) ..............................3-16
Hardware Configuration (Modbus TCP Communication) ................................3-20
Multiple-Analyzer (Multi-Drop) System Configuration...................................3-20
AC Power Connection and Fusing....................................................................... 3-23
European Installation.........................................................................................3-24
North American Installation ..............................................................................3-24
S93XS System 200 Configurator Software Installation............................................ 3-26
Minimum PC Requirements for Configurator Software.................................. 3-26
Installing the Configurator Software .................................................................. 3-27
Removing the Configurator Software................................................................. 3-29
Start-Up and Verification ............................................................................................. 3-30
Powering Up the Analyzer.................................................................................... 3-30
Start-Up Diagnostic Checklist ...........................................................................3-40
Sample System Leak Check......................................................................................... 3-42
Adjusting Analyzer Controls for Normal Operation .............................................. 3-45
Setting the Sample Gas Flow Rate and Sample Response Time..................... 3-45
Setting the Zero Gas Flow Rate............................................................................ 3-46
Normal Operation......................................................................................................... 3-47
Recording Initial Readings.................................................................................... 3-47
Recording PMT Signals.....................................................................................3-47
Recording Initial Sample Response Time ...........................................................3-48
Analyzer Configuration ............................................................................................... 3-49
CHAPTER 4 CONTROLLER / USER INTERFACE............................................................. 4-1
System 200 Configurator Software Overview – Getting Started ............................ 4-2
Navigating in the Software..................................................................................... 4-2
Starting the Configurator Software and Establishing Communication
Between the Analyzer and Computer .................................................................. 4-4
Closing the Configurator Software........................................................................ 4-6
Configurator Software Troubleshooting ...............................................................4-7
General Tab................................................................................................................ 4-9
Modbus Serial / Modbus TCP Communication Setup.......................................4-11
User Interface .......................................................................................................... 4-14
Setting Up the Main Window............................................................................4-14
Viewing Device Activities ..................................................................................4-15
Saving Analyzer Configuration Parameters ......................................................4-16
Restoring Analyzer Configuration Parameters..................................................4-16

vi | Model 931S / Model 932S UV Analyzers
Modifying Analyzer Device Settings ......................................................................... 4-18
Working From the Setup Tab ................................................................................ 4-18
Saving Analyzer Configuration Parameters to an ASCII File ...........................4-21
Printing Analyzer Configuration Parameters....................................................4-21
Refreshing Configuration or Calibration Parameters.........................................4-22
Saving Configuration or Calibration Parameters to EEPROM.........................4-22
Optical Bench .....................................................................................................4-23
Cell/Miscellaneous (Compensations) Parameters...............................................4-28
Temperature Control ..........................................................................................4-31
Optical Bench Temperature Control ............................................................4-33
Measuring Cell (Oven) Temperature Control (Optional) ...........................4-34
Heated Acid Gas Sample Probe Temperature Control (Optional) ...............4-36
Output Setup .....................................................................................................4-37
Sensors Setup .....................................................................................................4-40
Modbus Settings.................................................................................................4-46
Matrix ................................................................................................................4-47
Analytical Parameters.........................................................................................4-48
Analog Inputs.....................................................................................................4-49
Setting Gas Calibration Parameters ...................................................................4-51
Alarm Setting and Stream Switch Parameters...................................................4-57
Analyzer Information .........................................................................................4-62
Viewing Analyzer Data ................................................................................................ 4-64
Status Tab ................................................................................................................. 4-64
Analyzer Data Tab................................................................................................... 4-70
Optical Bench Data Tab ......................................................................................... 4-73
CHAPTER 5 CALIBRATION ................................................................................................. 5-1
Calibrating the Analyzer and Gas Sensors.................................................................. 5-2
Manual Zero Gas Calibration ................................................................................. 5-3
Manual Span Gas Calibration................................................................................. 5-4
Sensors Calibration................................................................................................... 5-7
Analog Output Calibration.......................................................................................... 5-10
Current Calibration ................................................................................................ 5-10
Voltage Calibration ................................................................................................. 5-12
CHAPTER 6 MAINTENANCE AND TROUBLESHOOTING............................................... 6-1
Safety Considerations..................................................................................................... 6-1
Preventive Maintenance ................................................................................................ 6-2
Analyzer Preventive Maintenance Schedule....................................................... 6-3
Preventing, Detecting, and Locating a Plug in the Sample System................. 6-5
Changing Out Replaceable Parts ........................................................................... 6-7
Measuring Cell Maintenance...............................................................................6-7
Source Lamp Replacement..................................................................................6-14
When Do Source Lamps Need to be Replaced?............................................6-14
About the Source Lamps ..............................................................................6-15
Replacing the Source Lamps........................................................................6-15

Contents | vii
When is an Auto-Setup Required / Not Required?......................................6-24
PMT Level and PMT Balance .....................................................................6-24
Auto-Setup Fault Message and Corrective Action ......................................6-26
The Auto-Setup Sequence ............................................................................6-26
Cancel Auto-Setup.......................................................................................6-27
Manipulating the PMT Level and PMT Balance........................................6-28
Source Lamp Alignment ..............................................................................6-30
Chopper Assembly Maintenance – Model 932S Analyzers Only ......................6-32
Examining and Caring For the Flamepaths ....................................................... 6-40
Upper/Lower Electronics Enclosure Flamepaths (Joining Surfaces)..................6-42
Troubleshooting and Diagnostics ............................................................................... 6-43
Host Controller Board Alarm Conditions and Corrective Action .................. 6-45
Microcontroller Board Alarm Conditions and Corrective Action .................. 6-56
Analyzer Reset ........................................................................................................ 6-65
CHAPTER 7 SERVICE AND PARTS.................................................................................... 7-1
Technical Support............................................................................................................ 7-1
Returning Equipment..................................................................................................... 7-2
?? ANSWERS TO YOUR QUESTIONS ??................................................................... 7-3
AMETEK SERVICE & AFTERMARKET SALES SUPPORT................................ 7-3
Recommended Preventive Maintenance Spare Parts ............................................... 7-4
Optical Bench Spare Parts....................................................................................... 7-4
Spare Analyzer Fuses............................................................................................... 7-5
Replacement Boards................................................................................................. 7-6
Ordering a Hard Copy of the Analyzer Operator’s Guide ............................... 7-6
APPENDIX A – DRAWINGS...................................................................................................A-1
Lower Enclosure Layout (WX-14838) – North American (CSA)/European
(Zone 1/ATEX)................................................................................................................. A-2
Analyzer Wiring Diagram (WX-102860-1).................................................................. A-3
TC Sensor Wiring Diagram (WX-102860-2)................................................................ A-4
IR Sensor Wiring Diagram (WX-102860-3) ................................................................. A-5
Optional HMI and Ethernet Gateway Wiring Diagram (WX-102860-4) ............... A-6
RS-232 Cable Communications Connections (300-9480) ......................................... A-7
Optical Bench Board (100-1662)................................................................................... A-8
PMT Buffer Board (100-0140) ....................................................................................... A-9
Inlet and Vent Flame Arrestor Locations for Environmental Purge Option
(100-1783-1A)................................................................................................................. A-10
SUPPLEMENTAL INFORMATION ........................................................................................S-1

viii | Model 931S / Model 932S UV 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.
!
CAUTION
!
CAUTION

NOTE
!
WARNING

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 alternate power sources (example, for relay con-
tacts) to the analyzer before removing any sample system assemblies and components from the
analyzer, or before opening any covers on the analyzer.
If it is necessary to open the Upper/Lower Ex d Enclosures while the circuits are live, test the
area for explosive gases and proceed only when it is found to be safe. When the Ex d Enclosures
are open, take appropriate precautions to avoid electrical shock. Hazardous voltages are present
inside.
Any 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.
Before working on the sample system, confirm that the system is purged with Zero gas and is
isolated (blocked in) from the process.
Because ultraviolet radiation can harm your eyes, avoid direct viewing of the light emanating
through the end window of the source lamp. If the source lamp must be viewed while ener-
gized, wear safety glasses that block ultraviolet radiation.
For Division 1/Zone 1 Installations, all cable entry glands (one power cable entry and two
signal cable entries) into the flameproof Disconnect Enclosure must be Ex d certified. Conduit
or cable seals that comply with the flameproof enclosure cable entry sealing requirements of the
local authority must be installed at the entries to the enclosure. In all cases, each unused cable
entry port must be plugged with a certified Ex d plug.
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
WARNING

x | Model 931S / Model 932S UV Analyzers
If the analyzer uses the optional Measuring Cell heater, take precautions to avoid burning
yourself; the Measuring Cell and Heater Assembly are hot.
Cautions
Review and follow these Cautions to avoid damaging the equipment.
The electronic circuit boards and other static-sensitive components should be stored and trans-
ported in static-shielding carriers or packages.
For electrical-shock protection, the analyzer must be operated from a grounded power source
that has a securely connected protective-ground contact.
If it becomes necessary to handle any of the electronic circuit boards, do not subject the boards
to static discharge. The ideal solution is a static-safe work area. Since such areas typically are
not available at field installation sites, the use of a wrist strap connected directly to a ground
is recommended. If a wrist strap is not available, you should at the very least touch the metal
chassis (to ground yourself) before handling or touching the boards.
When handling the source lamps, it is very important not to touch the lamp windows because
residual oils from the fingers will absorb ultraviolet light. The window is the flat surface at the
end of the narrow glass tube. The lamp assembly is fragile and should be handled with care.
Do not exceed the maximum working pressure rating of the sample system under any circum-
stances:
• Systems with optional Filterblock Assembly: 13 790 KPAG (2000 PSIG).
• Systems without optional Filterblock Assembly: 20 700 KPAG (3000 PSIG).
Pressure requirements vary from each analyzer application. In all cases, refer to Final “As-
Built” drawings for pressure ratings for your system.
If the analyzer is equipped with the Environmental Purge option, clean air or nitrogen can be
supplied to the inlet flame arrester at a pressure of 7–70 KPAG (1–10 PSIG).
!
CAUTION
!
CAUTION
!
CAUTION
!
CAUTION
!
CAUTION
!
CAUTION
!
WARNING