909 User Manual Rev H PDF

Model 909 Single-Gas Analyzer
User Manual
Canada LP
A DIVISION OF AMETEK PROCESS & ANALYTICAL INSTRUMENTS
PN 903-8601, Rev. H Western Research
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© 2004–2010 AMETEK Canada LP, A Division of AMETEK Process & Analytical Instruments Printed in Canada
This manual is a guide for the use of the Model 909 Single-Gas Analyzer. Data herein has been verified and validated and is believed adequate for the
intended use of this instrument. If the instrument or procedures are used for purposes over and above the capabilities specified herein, confirmation of
their validity and suitability should be obtained; otherwise, AMETEK does not guarantee results and assumes no obligation or liability. This publication is
not a license to operate under, or a recommendation to infringe upon, any process patents.
ii | Model 909 Single-Gas Analyzer

Contents
Offices................................................................................................................................... ii
Safety Notes........................................................................................................................ xi
Electrical Safety................................................................................................................... xi
Grounding........................................................................................................................... xi
Personnel and Equipment Safety Information............................................................. xii
Warnings...................................................................................................................... xii
Cautions...................................................................................................................... xiv
Warning Labels.................................................................................................................. xv
Environmental Information............................................................................................ xv
Electromagnetic Compatibility (EMC).......................................................................... xvi
Special Warnings and Information............................................................................... xvii
Equipment Used in Hazardous Locations........................................................... xvii
EC Declaration of Conformity.....................................................................................xviii
Warranty and Claims........................................................................................................ xx
Chapter 1 Overview
Principles of Operation................................................................................................... 1-1
The Basis..................................................................................................................... 1-1
The Implementation................................................................................................. 1-2
Microcontroller Board and Host Controller Board............................................... 1-3
Sample Flow......................................................................................................... 1-3
Discrete Wavelengths........................................................................................... 1-4
Analyzer Features............................................................................................................. 1-5
Sample System and Electronics............................................................................... 1-5
About the Analyzer Sample System.............................................................................. 1-8
Aspiration Components and Functions................................................................. 1-8
Sample Conditioning Unit (SCU) and Sample Line............................................ 1-9
Calibration.................................................................................................................. 1-9
Air Supply........................................................................................................................ 1-11
Electronics Purge Air............................................................................................... 1-11
Aspirator Drive Air.................................................................................................. 1-11
Velocimeter Purge Air............................................................................................. 1-12
Status Relays................................................................................................................... 1-12
Chapter 2 Specifications
Methodology..................................................................................................................... 2-1
Standard Ranges . ..................................................................................................... 2-1
Analyzer Specifications................................................................................................... 2-2
Response Time........................................................................................................... 2-2
Measurement Accuracy............................................................................................ 2-2
Repeatability............................................................................................................... 2-2
Calibration.................................................................................................................. 2-2
Contents | iii
Linearity...................................................................................................................... 2-2
Zero Stability.............................................................................................................. 2-2
Temperature Drift...................................................................................................... 2-2
24-Hour Zero Drift.................................................................................................... 2-3
Analog Outputs......................................................................................................... 2-3
Digital Outputs (Communication Ports)................................................................ 2-3
Power Consumption................................................................................................. 2-3
Electrical Requirements............................................................................................ 2-3
Typical Sample Gas Flow Rate................................................................................. 2-3
Ambient Limits........................................................................................................... 2-4
Temperature.......................................................................................................... 2-4
Humidity.............................................................................................................. 2-4
Maximum Altitude.............................................................................................. 2-4
Sample Transport....................................................................................................... 2-4
Instrument Air Requirements.................................................................................. 2-4
Physical Dimensions (on backpan) . ...................................................................... 2-4
Status Relays............................................................................................................... 2-5
Temperature Control................................................................................................. 2-5
Output Parameter Ranges........................................................................................ 2-5
Measuring Cell Construction.................................................................................. 2-5
Measuring Cell Operating Temperature................................................................ 2-5
Pressure Compensation............................................................................................ 2-5
Approvals and Certifications................................................................................... 2-6
O2 Concentration Signal (Optional)....................................................................... 2-6
Speed of Response................................................................................................. 2-6
Accuracy............................................................................................................... 2-6
Repeatability......................................................................................................... 2-6
24-Hour Zero Drift.............................................................................................. 2-6
Temperature Drift................................................................................................. 2-6
Electrical Classification........................................................................................ 2-6
Velocimeter................................................................................................................. 2-7
Standard Range ................................................................................................... 2-7
Accuracy............................................................................................................... 2-7
Repeatability......................................................................................................... 2-7
Stability................................................................................................................ 2-7
Hysteresis............................................................................................................. 2-7
ATEX (KEMA) Certificates and Analyzer Markings................................................... 2-8
Purged Analyzers ATEX Certificate........................................................................ 2-8
Purged Analyzer Markings.................................................................................... 2-13
No Release.......................................................................................................... 2-13
Limited Release................................................................................................... 2-13
Heater Plate ATEX Certificate................................................................................ 2-14
Heater Plate Marking.............................................................................................. 2-16
Disconnect Enclosure Type 200 ATEX Certificate............................................... 2-17
Type 200 Disconnect Enclosure Marking............................................................. 2-19
iv | Model 909 Single-Gas Analyzer

Chapter 3 Installation & Start-Up
Safety Considerations...................................................................................................... 3-2
Pre-Installation Requirements....................................................................................... 3-3
Storage Prior to Installation..................................................................................... 3-3
Uncrating and Inspecting the Analyzer................................................................. 3-3
General Installation Information............................................................................ 3-4
Tools, Equipment and Supplies Required for Installation.................................. 3-4
Installing the Mechanical Components........................................................................ 3-5
Mounting the Analyzer............................................................................................ 3-5
Location and Environment................................................................................... 3-5
Installing the Optical Bench Assembly.................................................................. 3-8
Installing the Sampling System............................................................................. 3-13
Installing the Sample Conditioning Unit.......................................................... 3-14
Installing and Connecting the Sample and Vent Lines...................................... 3-15
Installing and Connecting Instrument Air........................................................ 3-17
Installing the Calibration (Span/Zero) Gas Lines.............................................. 3-18
Connecting I/O Signals, Alarm Relay Contacts, and AC Power............................. 3-19
Electrical Connections............................................................................................. 3-20
Start-Up and Verification.............................................................................................. 3-25
Purged Analyzer (Hazardous Location) Applications....................................... 3-26
Powering Up the Analyzer..................................................................................... 3-28
Start-Up Diagnostic Checklist............................................................................... 3-33
Sample System Leak Check................................................................................... 3-36
Manually Zeroing the Analyzer............................................................................ 3-38
Adjusting the Zero Gas Flow Rate........................................................................ 3-40
Adjusting the Sample Gas Flow Rate................................................................... 3-41
Setting 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

Introduction to the User Interface Panel...................................................................... 4-2
User Interface Components..................................................................................... 4-2
Flow Control Mode Indicators on the User Interface Panel............................... 4-4
Entering Data Using Base Ten (10) Exponents...................................................... 4-4
Entering / Returning to RUN Mode – Quick Reference..................................... 4-5
RUN / CFG Mode Quick Reference Sheet – Keystroke Combinations...................... 4-6
Entering CFG Mode – Quick Reference................................................................ 4-7
Entering CAL Mode – Quick Reference................................................................ 4-8
CAL Mode Quick Reference Sheet – Keystroke Combinations............................. 4-9
About CFG / CAL Mode Passwords...................................................................... 4-10
Changing the Password for CAL Mode.............................................................. 4-10
Changing the Password for CFG Mode.............................................................. 4-11
Contents | v
Working in the RUN / CFG Operating Modes.......................................................... 4-12
While Working in RUN Mode… ........................................................................ 4-12
While Working in ConFiGuration (CFG) Mode… .......................................... 4-13
Returning to RUN Mode From CFG Mode....................................................... 4-14
Defining RUN / CFG Mode Keystroke Terms..................................................... 4-15
RUN / CFG Mode – F1 Keystrokes.................................................................... 4-16
Configuring the Analyzer Control Functions............................................................ 4-27
Output Signal Assignment (OSA)......................................................................... 4-27
Analog Input Channels...................................................................................... 4-28
Display I/O Board Analog Input Signals��4-29
Micro-Interface Board Analog Input (MAI) Signals��4-30
Host Controller Board Analog Input (HAI) Signals��4-31
Calculated Results��4-31
Active Temperature and Pressure Compensation.............................................. 4-32
Measuring Cell Temperature Compensation...................................................... 4-32
Measuring Cell Pressure Compensation............................................................ 4-32
Mass Flow Rate........................................................................................................ 4-33
Entering Differential Pressure Transducer Range............................................. 4-33
Entering Temperature Transmitter Coefficients................................................. 4-34
Calculation Constants........................................................................................ 4-35
Entering KQ ��4-35
Entering KE ��4-35
Stream Temperature and Differential Pressure.................................................. 4-36
Stream Temperature (Voltage Input – HAI)....................................................... 4-36
Entering Stream Temperature AuxTAvg (T90)................................................. 4-36
Differential Pressure........................................................................................... 4-37
Entering Differential Pressure AuxTAvg (T90 Average)��4-37
Stream Temperature (Current Input – MAI)..................................................... 4-37
Velocimeter and Emissions Calibration............................................................... 4-38
DP Cell Initial Set-up........................................................................................ 4-39
Default Configuration��4-39
DP Zero and Span��4-40
Temperature Transmitter.................................................................................... 4-41
Flow & Emission Output Calibration................................................................ 4-43
Customizing Velocimeter Backpurge and AuxTAvg (T90) Settings.................. 4-45
Backpurge Interval��4-45
Backpurge Duration��4-45
AuxTAvg (T90) Averaging Time for the Differential Pressure Signal��4-45
vi | Model 909 Single-Gas Analyzer

Working in the CAL Operating Mode........................................................................ 4-47
Defining CAL Mode Keystroke Terms................................................................. 4-48
CAL Mode – F1 Keystrokes................................................................................ 4-49
Setting Up Analyzer Calibration Functions........................................................ 4-56
Flow Control (Sample) Modes............................................................................ 4-56
Analyzer Control Mode (Automatic Control by the Analyzer)��4-57
Continuous Backpurge Mode (Manual Control by the User)��4-57
Continuous Sample Mode (Manual Control by the User)��4-58
Continuous Zero Gas Flow Mode (Manual Control by the User)��4-58
Continuous Calibration Gas Flow Mode (Manual Control by the User)��4-59
Velocimeter Flow Control................................................................................... 4-60
Entering Calibration Gas Concentration........................................................... 4-60
Setting Calibration Gas Timers.......................................................................... 4-61
Integration Timer (IntTime)............................................................................... 4-62
Auto-Calibration Interval Timer (ACal)............................................................ 4-62
Time to Next Auto-Calibration��4-62
Auto-Zero Interval Timer (AZInt)..................................................................... 4-63
Time to Next Auto-Zero��4-63
Setting the Sample Delay Timer (SDelay)......................................................... 4-64
Manual Zero/Span............................................................................................. 4-65
Manual Zero��4-65
Manual Span��4-65
Spanning Dual Range........................................................................................ 4-67
Solenoid Valve Control....................................................................................... 4-70
Solenoid Assignments��4-70
Auto-Zero/Auto-Span........................................................................................ 4-71
Manual Start of Auto-Zero��4-72
Manual Start of Auto-Span��4-73
Auto-Calibration................................................................................................ 4-74
Timed Start of Auto-Calibration��4-74
Manual Start of Auto-Calibration��4-75
Remote Start of Auto-Calibration��4-76
Remote Start of Backpurge (Optional)............................................................... 4-76
Analog Output Channels................................................................................... 4-78
Setting Output Channel Full-Scale��4-78
Analog Output Calibration................................................................................ 4-79
Measuring Cell Temperature and Pressure........................................................ 4-81
Default Measuring Cell Temperature��4-81
Entering Default Cell Pressure��4-81
Probe Blow-Back Control (Optional)................................................................. 4-82
Contents | vii
Chapter 5 Maintenance & Troubleshooting
Safety Considerations...................................................................................................... 5-1
Maintenance...................................................................................................................... 5-2
Preventive Maintenance........................................................................................... 5-2
Analyzer Preventive Maintenance Schedule........................................................ 5-3
Expo-Telektron Safety Systems MiniPurge (Optional) Preventive
Maintenance Schedule.......................................................................................... 5-5
Before Performing Maintenance............................................................................. 5-5
Locating a Plug in the Sample System................................................................. 5-6
Detecting a Plug in the Sample System............................................................... 5-6
Preventing a Plug in the Sample System............................................................. 5-7
Changing Out Replaceable Parts............................................................................ 5-9
Measuring Cell Preventive Maintenance........................................................... 5-10
Source Lamp Replacement.................................................................................. 5-20
When Do the Source Lamps Need to be Replaced?��5-20
About the Source Lamps��5-20
Replacing the Source Lamps��5-21
Auto-Setup......................................................................................................... 5-27
Auto-Setup Completion Number��5-27
PMT Level and PMT Balance��5-28
Auto-Setup Fault Messages and Corrective Action��5-29
Initiating an Auto-Setup.................................................................................... 5-30
Manipulating the Completion Number, PMT Level, and PMT Balance��5-31
Heater Plate Heater Cartridge and RTD Replacement...................................... 5-33
Examining and Caring For the Flamepaths........................................................ 5-48
Disconnect Enclosure Flamepath (Joining Surfaces).......................................... 5-49
Troubleshooting and Diagnostics................................................................................ 5-50
Viewing Errors on the User Interface Panel........................................................ 5-50
Types of Errors (Alarms).................................................................................... 5-50
Viewing Current Error Messages...................................................................... 5-51
Viewing Historical Error Messages.................................................................... 5-52
Host Controller Board Alarm Conditions and Corrective Action................... 5-53
Microcontroller Board Alarm Conditions and Corrective Action................... 5-61
Analyzer Reset......................................................................................................... 5-65
Chapter 6 Chapter Service & Parts

Technical Support............................................................................................................. 6-1
Returning Equipment...................................................................................................... 6-2
Recommended Spare Parts............................................................................................. 6-4
Optical Bench/Measuring Cell Spare Parts............................................................ 6-5
Sample Conditioning Unit (SCU) Spare Parts...................................................... 6-6
Spare Analyzer Fuses................................................................................................ 6-7
Replacement Boards................................................................................................. 6-9
Chapter 7 Software Glossary

User Interface Panel Abbreviations............................................................................... 7-1
Abbreviations Used in This Manual.............................................................................. 7-2
viii | Model 909 Single-Gas Analyzer

Appendix A Options
O2 Concentration Measurement................................................................................... A-1
SSR Outputs.............................................................................................................. A-2
Entering Calibration Gas O2 Concentration......................................................... A-3
O2 Span Timer........................................................................................................... A-3
Auto-Calibration....................................................................................................... A-4
Manual O2 Sensor Zero/Span................................................................................. A-6
Manual O2 Sensor Zero (Air)..............................................................................A-6
Manual O2 Sensor Zero (Nitrogen/Air)...............................................................A-8
Dilution Air Correction................................................................................................ A-10
Correction Equation............................................................................................... A-10
Entering [O2 ] . .................................................................................................... A-11
Appendix B Serial Communication Interface (Modbus®)

Overview.......................................................................................................................... B-1
Analyzer Modbus Interface Parameters...................................................................... B-6
Modbus Address....................................................................................................... B-6
Communications Parameters.................................................................................. B-6
Modbus Functions........................................................................................................... B-7
Exception Code................................................................................................................ B-7
Holding Registers............................................................................................................ B-8
Units and Display Bit Image (Register 9).................................................................. B-22
Analyzer Status Bytes (Register 154).......................................................................... B-22
Solenoid Output Bit Image (Register 156)................................................................. B-23
Digital Input Bit Image (Register 157)........................................................................ B-24
Digital Output Bit Image (Registers 158, 159)........................................................... B-24
Gas Flow Control (Registers 189, 190)........................................................................ B-26
Appendix C Conversion Factors & Calculations

Conversion Factors......................................................................................................... C-1
SI Prefixes......................................................................................................................... C-4
Gas Mixtures.................................................................................................................... C-5
Average Molecular Weight...................................................................................... C-5
Specific Gravity......................................................................................................... C-5
Air Composition........................................................................................................ C-6
Gas Flow Rate Measurement........................................................................................ C-7
Mass Flow Rate.............................................................................................................. C-12
References...................................................................................................................... C-13
Appendix D Drawings
Analyzer Schematic (WX-14716)...................................................................................D-2
Analyzer (GP) Piping & Instrumentation Diagram...................................................D-3
Backpan Mounting Details, GP Analyzers..................................................................D-4
Overall Component Layout, GP Analyzers................................................................D-5
Electronics Enclosure Layout, GP Analyzers..............................................................D-6
User Interface Panel (WX-14151)..................................................................................D-7
AC Wiring, GP/Div 2/CE/Zone 1 Analyzers (WX-102853).........................................D-8
Contents | ix
Ribbon Cable Interconnect (WX-102836).....................................................................D-9
Sample/Vent Line Wiring, GP/Div 2 Analyzers (100-1254-5)..................................D-10
GP Lower Enclosure to Electronics Wiring, CE Analyzers (WX-102810).............D-11
Heater and Sensor Wiring, GP/Div 2 Analyzers (WX-102851)...............................D-12
Heater and Sensor Wiring, CE/Zone 1 Analyzers (WX-102852)............................D-13
Disconnect Enclosure Wiring, 120V, Zone 1 Analyzers (100-1343-5)....................D-14
Disconnect Enclosure Wiring, 240V, Zone 1 Analyzers (100-1344-5)....................D-15
Lower Cabinet Wiring, CE/GP Analyzers, 120V (100-1341-3)................................D-16
Lower Cabinet Wiring, CE/GP Analyzers, 240V (100-1342-3)................................D-17
Customer Signal Connections, GP/Div 2 Analyzers (WX-102822)........................D-18
Customer Signal Connections, CE/Zone 1 Analyzers (WX-102816)......................D-19
Signal Wiring, GP/Div 2/CE/Zone 1 Analyzers (WX-102815).................................D-20
± 15V and 5V Power Supply DC Wiring, GP/Div 2/CE/Zone 1 Analyzers
(WX-102811)...................................................................................................................D-21
24V Power Supply DC Wiring, CE/Zone 1 Analyzers (WX-102812).....................D-22
RS-232 Communications Cable Wiring (300-9480)...................................................D-23
RS-232/RS-485 Module Wiring, CE/Zone 1 & GP/Div 2 Analyzers (100-2185)....D-24
Wiring Diagram, All Seals, 120V, Zone 1 Analyzers (100-1343-9)..........................D-25
Wiring Diagram, All Seals, 240V, Zone 1 Analyzers (100-1344-9)..........................D-26
Optical Bench Board (100-1662)..................................................................................D-27
Micro-Interface Board (100-0116)...............................................................................D-28
Host Controller Board (Display Interface) (100-0138).............................................D-29
Microcontroller Board (100-0117)...............................................................................D-30
Termination Board (100-1534).....................................................................................D-31
Display I/O Board (100-0939).......................................................................................D-32
Measuring Cell/Lamp Assembly (WX-14856)...........................................................D-33
Optional Velocimeter Solenoid Block, 120 V (100-1933-1)......................................D-34
Optional Velocimeter Zeroing Layout, 120 V, 909/910 GP Analyzers
(100-1933-2).....................................................................................................................D-35
Optional Velocimeter Solenoid Block, 240 V (100-1934-1)......................................D-36
(100-1934-2).....................................................................................................................D-37
Zirconia Oxide O2 Sensor (Optional), Electronics Panel Layout (100-1160-1).....D-38
Zirconia Oxide O2 Sensor (Optional), Wiring Connections (100‑1160‑2).............D-39
Calibration Manifold Block, Flow Diagram (100-2141-1)........................................D-40
Calibration Manifold Block, Assembly Diagram (100-2141-2)...............................D-41
Supplemental Information
x | Model 909 Single-Gas Analyzer

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.
WARNING
! An operating procedure which, if not strictly observed, may result in damage to the equipment.
CAUTION
 Important information that should not be overlooked.

NOTE
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
Contents | xi
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
WARNING
within the enclosures.
If it is necessary to open the analyzer’s covers or doors while the circuits are live, first monitor
the area for flammable gases (and proceed only when the area is safe).
Purged Analyzer (Hazardous Location) Applications:

To work on the analyzer with it powered up and its Electronics Enclosure door open, the Purge
Bypass Switch must be in the BYPASS position.
When the Electronics Enclosure door is open, take appropriate precautions to avoid electrical
shock. Hazardous voltages are present inside.
! All electrical connections, adjustments, or servicing of the analyzer should be performed only
by properly trained and qualified personnel.
WARNING
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.
WARNING
! Before working on the analyzer, test the area for flammable gases. If an explosive gas atmo-
sphere is present, do not open any covers or doors without first disconnecting power and/or
WARNING
alternate power sources to the analyzer.
xii | Model 909 Single-Gas Analyzer

! Before working on the sample system, confirm that the system is purged with Zero Gas and is
isolated (blocked in) from the process.
WARNING
! 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-
WARNING
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.
WARNING
! Purged Analyzer (Hazardous Location) Applications:

[Special Conditions for Safe Use]
WARNING
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.

Do not apply power to the analyzer if there is damage (scratches, indentations, or wear) to any
WARNING
flamepath (on the Oven Heater or Disconnect Enclosure). Applying power to an analyzer with
a damaged flamepath is dangerous and could result in serious injury or death, or serious dam-
age to equipment.
Replace parts immediately if damage or wear is apparent. Contact AMETEK if there is any
doubt about the integrity of any flamepath.
Contents | xiii
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.
CAUTION
! For electrical-shock protection, the analyzer must be operated from a grounded power source
that has a securely connected protective-ground contact.
CAUTION
! 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
CAUTION
are not available at analyzer installation sites, the use of a wrist strap connected directly to a
ground is recommended. If a wrist strap is not available, you should at the very least touch the
metal chassis (to ground yourself) before handling or touching the boards.
! When handling the source lamps, it is very important not to touch the lamp windows because
residual oils from the fingers will absorb ultraviolet light. The window is the flat surface at the
CAUTION
end of the narrow glass tube. The lamp assembly is fragile and should be handled with care.

For Zone 1 Installations, all cable entry glands (one power cable entry and two signal cable
CAUTION
entries) into the flameproof Disconnect Enclosure must be Ex d certified. As per EN 60079-
14:1997, 10.3.2 “The cable entry system shall comply with … e) flameproof cable entry devices
incorporating compound filled seals around the individual cores or other equivalent sealing
arrangements”.
For Zone 2 Installations, use a suitable flameproof cable entry device with a sealing ring, as
per EN 60079-14:1997, 10.3.2, item “b)”; or, comply with local wiring regulations and electri-
cal codes.
In all cases, all unused cable entry ports must be plugged with a certified Ex d plug.
xiv | Model 909 Single-Gas Analyzer

Warning Labels
These symbols may appear on the instrument in order 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 Oberfläche
Environmental Information
This AMETEK product contains materials that can be reclaimed and recycled. In some cases the
product may contain materials known to be hazardous to the environment or human health.
In order to prevent the release of harmful substances into the environment and to conserve
our natural resources, AMETEK recommends that you arrange to recycle this product when it
reaches its “end of life”.
Waste Electrical and Electronic Equipment (WEEE) should never be disposed of in a munici-
pal waste system (residential trash). The Wheelie Bin marking on this product is a reminder to
dispose of the product properly after it has completed its useful life and been removed from
service. Metals, plastics, and other components are recyclable and you can do your part by doing
one of the following steps:
• 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 “end of life” product may be traded in for credit towards
the purchase of new AMETEK instruments. Contact 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 analyzer User Manual.
Contents | xv
Electromagnetic Compatibility (EMC)
! Read and follow the recommendations in this section to avoid performance variations or dam-
age to the internal circuits of this equipment when installed in harsh electrical environments.
CAUTION
The various configurations of the Model 909 Single-Gas Analyzers should not produce, or fall
victim to, electromagnetic disturbances as specified in the European Union’s EMC Directive (if
applicable to your application). [The NEC/CEC certification is Class I, Division 2, Groups C & D.
The KEMA (ATEX) certification for Zone 1 hazardous locations is Ex pd IIB T3.] Strict compliance
to the EMC Directive requires that certain installation techniques and wiring practices are used
to prevent or minimize erratic behavior of the Analyzer or its electronic neighbors. Below are
examples of the techniques and wiring practices to be followed.
In meeting the EMC requirements, the various Analyzer configurations described in this manual
rely heavily on the use of metallic shielded cables used to connect to the customer’s equipment
and power. Foil and braid shielded I/O and DC power cables are recommended for use in other-
wise unprotected situations. In addition, hard conduit, flexible conduit, and armor around non-
shielded wiring also provides excellent control of radio frequency disturbances. However, use of
these shielding techniques is effective only when the shielding element is connected to the equip-
ment chassis/earth ground at both ends of the cable run. This may cause ground loop problems in
some cases. These should be treated on a case-by-case basis. Disconnecting one shield ground may
not provide sufficient protection depending on the electronic environment. Connecting one shield
ground via a 0.1 microfarad ceramic capacitor is a technique allowing high frequency shield bond-
ing while avoiding the AC-ground metal connection. In the case of shielded cables the drain wire
or braid connection must be kept short. A two-inch connection distance between the shield’s end
and the nearest grounded chassis point, ground bar or terminal is highly recommended. An even
greater degree of shield performance can be achieved by using metallic glands for shielded cable
entry into metal enclosures. Expose enough of the braid/foil/drain where it passes through the
gland so that the shield materials can be wrapped backwards onto the cable jacket and captured
inside the gland, and tightened up against the metal interior.
Inductive loads connected to the low voltage “Alarm Contacts” are not recommended. However, if
this becomes a necessity, adhere to proper techniques and wiring practices. Install an appropriate
transient voltage suppression device (low voltage MOV, “Transzorb,” or R/C) as close as possible to
the inductive device to reduce the generation of transients. Do not run this type of signal wiring
along with other I/O or DC in the same shielded cable. Inductive load wiring must be separated
from other circuits in conduit by using an additional cable shield on the offending cable.
In general, for optimum protection against high frequency transients and other disturbances, do
not allow installation of this Analyzer where its unshielded I/O and DC circuits are physically
mixed with AC mains or any other circuit that could induce transients into the Analyzer or the
overall system. Examples of electrical events and devices known for the generation of harmful
electromagnetic disturbances include motors, capacitor bank switching, storm related transients,
RF welding equipment, static, and walkie-talkies.
xvi | Model 909 Single-Gas Analyzer

Special Warnings and Information
Equipment Used in Hazardous Locations

Refer to Chapter 2 – Specifications for details about the suitability of this equipment in hazard-
ous locations.
! Explosion Hazard – Do Not Disconnect Equipment Unless Power Has Been Switched Off or
the Area is Known to be Non-Hazardous.
WARNING
Risque d’explosion – Avant de déconnecter l’équipement, coupez le courant où vous assurez

! que l’emplacement est designé non dangereux.
Avertissement
All input and output wiring must be in accordance with Class I, Division 2 wiring methods
(CEC 18-152) and in accordance with the authority having jurisdiction.
Contents | xvii
EC Declaration of Conformity
xviii | Model 909 Single-Gas Analyzer

Contents | xix
Warranty and Claims
We warrant that any equipment of our own manufacture or manufactured for us pursuant to our specifications
which shall not be, at the time of shipment thereof by or for us, free from defects in material or workmanship un-
der normal use and service will be repaired or replaced (at our option) by us free of charge, provided that written
notice of such defect is received by us within twelve (12) months from date of shipment of portable analyzers or
within eighteen (18) months from date of shipment or twelve (12) months from date of installation of permanent
equipment, whichever period is shorter. All equipment requiring repair or replacement under the warranty shall be
returned to us at our factory, or at such other location as we may designate, transportation prepaid. Such returned
equipment shall be examined by us and if it is found to be defective as a result of defective materials or workman-
ship, it shall be repaired or replaced as aforesaid. Our obligation does not include the cost of furnishing any labor
in connection with the installation of such repaired or replaced equipment or parts thereof, nor does it include the
responsibility or cost of transportation. In addition, instead of repairing or replacing the equipment returned to us
as aforesaid, we may, at our option, take back the defective equipment, and refund in full settlement the purchase
price thereof paid by Buyer.
Process photometric analyzers, process moisture analyzers, and sample systems are warranted to perform the in-
tended measurement, only in the event that the customer has supplied, and AMETEK has accepted, valid sample
stream composition data, process conditions, and electrical area classification prior to order acknowledgment. The
photometric light sources are warranted for ninety (90) days from date of shipment. Resale items warranty is limited
to the transferable portion of the original equipment manufacturer’s warranty to AMETEK. If you are returning
equipment from outside Canada, a statement should appear on the documentation accompanying the equipment
being returned declaring that the goods being returned for repair are Canadian goods, the name of the firm who
purchased the goods, and the shipment date.
The warranty shall not apply to any equipment (or part thereof) which has been tampered with or altered after
leaving our control or which has been replaced by anyone except us, or which has been subject to misuse, neglect,
abuse or improper use. Misuse or abuse of the equipment, or any part thereof, shall be construed to include, but
shall not be limited to, damage by negligence, accident, fire or force of the elements. Improper use or misapplications
shall be construed to include improper or inadequate protection against shock, vibration, high or low temperature,
overpressure, excess voltage and the like, or operating the equipment with or in a corrosive, explosive or combustible
medium, unless the equipment is specifically designed for such service, or exposure to any other service or environ-
ment of greater severity than that for which the equipment was designed.
The warranty does not apply to used or secondhand equipment nor extend to anyone other than the original pur-
chaser from us. Should the Buyer’s technical staff require the on-site assistance of AMETEK’s agents or employees for
service calls covered by this warranty clause, the Buyer shall pay travel time plus actual travel and living expenses.
THIS WARRANTY IS GIVEN AND ACCEPTED IN LIEU OF ALL OTHER WARRANTIES, WHETHER EXPRESS OR
IMPLIED, INCLUDING WITHOUT LIMITATION AND WARRANTIES OF FITNESS OR OF MERCHANTABILITY
OTHER THAN AS EXPRESSLY SET FORTH HEREIN, AND OF ALL OTHER OBLIGATIONS OR LIABILITIES ON
OUR PART. IN NO EVENT SHALL WE BE LIABLE UNDER THIS WARRANTY OR ANY OTHER PROVISION OF
THIS AGREEMENT FOR ANY ANTICIPATED OR LOST PROFITS, INCIDENTAL DAMAGES, CONSEQUENTIAL
DAMAGES, TIME CHANGES OR ANY OTHER LOSSES INCURRED BY THE ORIGINAL PURCHASER OR
ANY THIRD PARTY IN CONNECTION WITH THE PURCHASE, INSTALLATION, REPAIR OR OPERATION
OF EQUIPMENT, OR ANY PART THEREOF COVERED BY THIS WARRANTY OR OTHERWISE. WE MAKE NO
WARRANTY, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTIES OF FITNESS OR
OF MERCHANTABILITY, AS TO ANY OTHER MANUFACTURER’S EQUIPMENT, WHETHER SOLD SEPARATELY
OR IN CONJUNCTION WITH EQUIPMENT OF OUR MANUFACTURE. WE DO NOT AUTHORIZE ANY
REPRESENTATIVE OR OTHER PERSON TO ASSUME FOR US ANY LIABILITY IN CONNECTION WITH
EQUIPMENT, OR ANY PART THEREOF, COVERED BY THIS WARRANTY.
xx | Model 909 Single-Gas Analyzer

Overview
This chapter discusses the principles of operation and features of the

Model 909 Single-Gas Analyzer, and a summary of how the entire system
operates. This chapter also provides an overview of the AMETEK sample
system and electronics and the various sub-systems that make up the
entire analyzer system.
Principles of Operation
The Basis
The Model 909 Single-Gas Analyzer measures, at two discrete wave-
lengths, the absorbances of ultraviolet radiation (light) by a gas sample.
The concentration of the component absorbing the light (absorber) is then
determined from relationships developed through application of the ideal
gas law in concert with the laws of Bouguer, Beer, and Lambert.
Thus, the absorbance, A, due to a single absorber is,
[ x ] kλ lP
A=
RT
where l is the path length of the light in the gas sample, [x] is the concen-
tration (mole percent [see Note]) of absorber x, kλ is the molar absorptivity
of absorber x at the measuring wavelength, λ, T, and P are the tempera-
ture and pressure of the gas sample, respectively, and R is the universal
gas constant.
 For an ideal gas, mole percent is equal to volume percent. At the nor-
mal operating conditions of the analyzer, the real gas mixture deviates
NOTE
from ideal behavior by less than 0.5 percent.
Overview | 1-1
For any given system at constant temperature and pressure, the equation
can be simplified to:
A = C kλ [ x ]
where C ≡ lP/RT is a constant depending only upon the system of units

employed. The concentration of the absorbing component may be deter-
mined from the absorption at the two measuring wavelengths.
The Implementation
The analyzer is comprised of two ultraviolet light sources, a Filter Block
containing two wavelength-selective filters, a Beam Splitter, front-sur-
faced mirrors, a gas Measuring Cell, and two matched photo detectors
(see Figure 1-1).
The Measuring Cell is contained within the analyzer ’s oven. A pressure

transducer monitors the pressure at the outlet of the Measuring Cell.
Figure 1-1.
Analytical schematic.
1-2 | Model 909 Single-Gas Analyzer

Microcontroller Board and Host Controller Board
The operation of the analyzer is controlled by two microprocessors. The

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

controlled zones. The sample temperature, from the stack duct to inside
the Analyzer Oven and Measuring Cell, must be maintained above the
water and acid dewpoint temperatures of the sample. The Analyzer Oven,
and thereby the Measuring Cell, are controlled (by an electric heater) at a
constant temperature in the range from 120 °C (248 °F) to 150 °C (302 °F).
The temperature sensor – a resistance temperature device (RTD) – used
in the Analyzer Oven is embedded in the Heater Plate. The temperature
sensor used in the Sample Line can be a thermistor or an RTD while the
Sample Conditioning Unit (SCU) must use an RTD.
Sample Flow
The sample gas is drawn from the stack duct through the Sample
Conditioning Unit (or stack sample probe, if used) and Sample Line to the
dual-chambered Measuring Cell. The gas sample enters the first chamber,
flows the length of the Measuring Cell, crosses to the second chamber,
flows the length of the Measuring Cell in the opposite direction and exits
from the Measuring Cell. When the sample gas reaches the aspirator, it
merges with the Aspirator Drive Air (Instrument Air or N2) and then is
dispersed to atmosphere via a Sample Vent Pipe.
Overview | 1-3
Discrete Wavelengths
To achieve measurements at discrete wavelengths, the placement of the

source lamps is such that, at any given time, the photodetectors are ex-
posed to light from only one lamp and filter combination (i.e., a discrete
wavelength).
As each pulse of light arrives, the Beam Splitter directs half the light to
the Reference detector and half through the gas sample to the Measure
detector. Because of the longer optical path length, light losses at the mir-
rors, and light losses through the Measuring Cell windows, the amount
of light received by the Measure detector is less than that received by the
Reference detector, even when there is no absorber in the gas sample.
To balance this effect, a screen that filters 30 % of the light is added to the
Reference path. At each wavelength, these optical-path factors produce
a constant difference between the amounts of light received by the two
detectors.
When an absorber is present in the gas sample, the amount of light re-
ceived by the Measure detector is reduced further, the magnitude of the
reduction being dependent upon the concentration of the absorber. Thus,
for each wavelength, the difference in the amounts of light received by
the two detectors (corrected for the optical-path factors) is used to deter-
mine the absorbance of the gas sample. Then, using the aforementioned
equations, the concentration of the absorber (for which the analyzer is
configured) is calculated.

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

Key features include:
Safe transport of the sample gas

May contain toxic percentage levels of either SO2, NO, or NO2, H2S,
NH3, or Cl2 – from the stack duct, through the analyzer’s sample sys-
tem, and to a vent to atmosphere or back to the stack duct.
Gas calibration system

Allows the introduction of calibration gases directly into the analyzer’s
sample system.
Auto-Calibration function
Automatically updates the calibration of the analyzer using Calibration
Gas mixtures. The Auto-Calibration function can be initiated on com-
mand by the user, at user-specified time intervals, or by the closure of
a remote dry (potential free) contact.
Auto-Zero function
Automatically updates the analyzer zero. The Auto-Zero function
can be initiated on command by the user or at user-specified time
intervals.
Remote Backpurge (Optional)

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

Up to three solenoid valves can be controlled by the analyzer. One of
the control outputs is reserved for the Zero Gas. The length of time
that each solenoid valve is on is determined by a separate, user-ad-
justable timer. Each of the solenoid-control outputs can be turned off
by the user if it is not being used. The timer controlling each solenoid
valve can be started manually by the user or automatically by the ana-
lyzer during Auto-Calibration.
Overview | 1-5
Auto-Calibration and Calibration Gas solenoid valve control functions
Support the use of a single-species calibration gas mixture. The ana-
lyzer is configured for a particular calibration gas mixture by the user.
Four independent analog output signal channels

The full-scale concentration for each output channel can be set by the
user to any value within the measurement range of the analyzer.
Easy Analog Output Calibration

The analog output channels are calibrated by entering the zero and
full-scale offsets for each output via the User Interface Panel keypad –
there are no potentiometers to adjust.
Sample control system that detects the state of up to five temperature-controlled

zones within the sample system
Temperature-controlled zones include the Sample Line, Analyzer
Oven, and Sample Conditioning Unit. There is also a spare temper-
ature-controlled zone. Additionally, there is a zone reserved for ap-
plications using a heated external probe with a dedicated temperature
controller.
The temperature-controlled zones are protected by independent

over-temperature circuits. If any of these zones are found to be out
of range, the analyzer automatically forces the sample system into
Backpurge mode to avoid contaminating the system.
User Interface Panel

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

Indicate faults, non-critical conditions, and operational status of the
analyzer.
Reliable electronics control system

Controls the overall operation of the analyzer.
Continuous purge of the Optical Bench Assembly, Measuring Cell Seal, and the
Electronics Enclosure with Instrument Air
Prevents contamination of the optical system and the electronics.
No pumps are used

Sample gas is transported throughout the sample system by means of
an Aspirator within the Analyzer Oven. This provides flow vacuum.

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

Calculations of the volumetric flow rate of the stack duct (stream) or
mass flow rate of the measured component in the stack duct.
Signals representative of the temperature and linear gas velocity of

 the stack duct or a separate external volumetric flow measuring device
NOTE
supplying flow signal to the Model 909 Analyzer are required for the
calculations. The analyzer includes the necessary hardware for mea-
suring the stack duct temperature and flow rate.
DCS Communication Interface (optional)

A RS-422 (or optional RS-485) port that can be used for remote com-
munication with a Distributed Control System (DCS), using Modicon
Modbus® protocol. The Modbus® protocol can be used with the
analyzer operating as a slave device, responding to Modbus® que-
ries within one second. (The Modbus® communication interface is
optional.)
Dilution Air Correction (optional, for use in General Purpose applications/analyz-

ers only)
Adjusts the concentration measured by the analyzer to a reference
excess-air condition based on the concentration of oxygen (O2) in
the sample. The O2 concentration of the sample can be measured by
an optional Zirconium Oxide sensor installed within the analyzer
Electronics Enclosure or by a separate, independent, external O2
Sensor.
Overview | 1-7
About the Analyzer Sample System
The sample gas is transported to and from the analyzer by an aspirator
housed within the heated Analyzer Oven.
 Figure 1-2 illustrates an example of a piping and instrumentation

configuration – your application may differ. To view the Piping &
NOTE
Instrumentation diagram for your application, refer to the Final “As-
Built” drawings in the “Supplemental Information” section of this
manual or the Documentation Package shipped with the analyzer.
The major components of the sample system and their functions are de-
tailed below. These components are for a variety of analyzer configuration
possibilities. Depending on your application, only some of these compo-
nents will be used.
Component Function
Sample Conditioning Unit (SCU)
The SCU – which mounts on the stack – is used to filter out
particulates, prevent liquid carry-over, or otherwise condition
the gas sample prior to transporting it through the Sample Line.
Sample Line Transports the sample gas to the analyzer at a temperature
above its dewpoint.
Aspirator (if used) Located within the Analyzer Oven, the Aspirator provides
suction to transport the sample gas through the sample path.
The aspirator uses Instrument Air to extract and drive the
sample gas from the stack duct, through the sample system,
and vent it to atmosphere (or return it to the stack duct).
Vent Pipe Vents the sample gas to atmosphere. Typically used in stack
gas sampling.
Vent Line (if used) Returns the sample gas to the stack duct.
Aspiration Components and Functions

The following components make up the Aspirator system. See Figure 1-2
for a typical layout of the Aspirator system (actual drawing may differ
for your application – refer to Final “As-Built” drawings shipped with the
analyzer).
Component Function
Aspirator/Backpurge Air Pressure Regulator
Used to adjust drive air flow rate.
Check Valve Stops sample gas from entering the instrument air system
if instrument air pressure is reduced below the stack duct
pressure.

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

Aspirator/Backpurge Rotameter
Used to adjust the flow rate of the aspirator air.
Flow Control Solenoid Allows aspirator air to be turned off and on automatically if the
analyzer is not ready to obtain a sample from the stack duct.
This solenoid must be energized for the analyzer to obtain a
sample of gas.
Tubing Connection This tube, usually 1/4" stainless steel, runs from the Flow
Control Solenoid to the Aspirator in the Analyzer Oven.
Aspirator Provides suction to circulate the sample gas.
Trickle Purge Provides a small flow of air to keep the backpurge connection
tubing free of condensate.
If an optional O2 Sensor is used, this trickle purge will also

cause its output to go high if aspiration is lost.
Sample Conditioning Unit (SCU) and Sample Line

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

cally by the analyzer at user-specified time intervals.
Overview | 1-9
Figure 1-2.
Piping & Instrumentation
diagram (GP Analyzers).
 Example drawing only. Refer to the Final As-Built drawings for your
application in the “Supplemental Information” section of this manual
NOTE
or the Documentation Package shipped with the analyzer.

Air Supply
Clean dry instrument air is normally used to drive the aspirator, to purge
the analyzer electronics, and to backpurge the sample system. The inlet air
pressure must be minimum 210 KPAG (30 PSIG) for General Purpose ap-
plications, or in the range of 420–840 KPAG (60–120 PSIG) for Hazardous
Locations. The air is split into three paths as it enters the analyzer:
Electronics Purge, Aspirator Drive, and Velocimeter Purge, each with its
own controlling regulator.
Electronics Purge Air

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

The Aspirator Drive Air provides suction to circulate the sample gas at a
controlled flow rate through the analyzer sample system. The Aspirator
Drive Air is fed through the analyzer manifold, where it is routed to the
aspirator inside the Analyzer Oven.
When the sample gas reaches the aspirator, it merges with the Aspirator
Drive Air (Instrument Air or N2) and then continues on through the gas
Vent Pipe which disperses the used sample gas to atmosphere (or Vent
Line back to the stack gas, if used).
Overview | 1-11
Velocimeter Purge Air
The Velocimeter Purge Air provides instrument air to backpurge (clear)
the pitot tubes or to perform a Zero/Span calibration on the Velocimeter.
The purge air is normally obtained from the Instrument Air supply air
via a separate regulator and flow restrictor mounted on the left side of
the Electronics Enclosure. The required purge air pressure is indicated by
a label on the analyzer backpan. The Electronics Enclosure air pressure
can be verified by connecting a pressure gauge (e.g., Magnahelix™) to
the fitting (gauge port) located on the lower right side of the Electronics
Enclosure. The Electronics Enclosure air pressure should typically be be-
tween 0.1 and 0.2 inches of water with respect to the air pressure outside
the cabinet.
Status Relays
The analyzer uses three relays which indicate the operational status of the
analyzer. Each relay provides a set of SPDT (Form C) dry (potential-free)
contacts. The relays are configured for fail-safe operation (i.e., energized
for the non-alarm condition).
The three sets of status relays used are:
Normal/Fault Status Relay

When the analyzer is operating in its normal Run state, this relay is
energized. This relay is de-energized if a Fault alarm condition exists
within the analyzer’s built-in diagnostic system (the analyzer requires
service). In RUN mode, S is displayed on the upper-right line of the
User Interface Panel to indicate this relay has become de-energized.
With the exception of an Over-Temperature fault (f Temp High) –

detected by the Over-Temperature RTD Daughter boards – on the
Sample Line, Vent Line (if used; or SCU), or Analyzer Oven, this
relay’s contacts reset automatically upon correction of the Fault alarm.
The Over-Temperature fault, however, must be reset manually. To reset
this relay, you must press SW300 on the Termination board, located in
the Electronics Enclosure.
When a Fault alarm condition exists (relay is de-energized), the sample

system will automatically switch to Backpurge mode if the analyzer ’s
Flow Control Mode is set to Analyzer (automatic) Control mode. A
lower case “b” will be displayed in the top-left corner of the RUN
mode screen to indicate the analyzer has automatically forced its Flow
Control Mode to Backpurge.

Run/Calibration Status Relay
energized. This relay switches to de-energized to indicate that calibra-
tion of the analyzer is in progress (as detected by the built-in diag-
nostic system), that a parameter has been changed in the CALibration
mode or ConFiGuration mode (also switches upon exiting CFG mode),
or the analyzer’s Flow Control (Sample) Mode is in Continuous Zero
Gas Flow mode or Continuous Sample mode.
Resetting of the contacts is delayed by the Sample Delay Timer

(SDelay) duration.
Run/Attention Status Relay

energized. This relay is de-energized if a Warning alarm condition
exists within the analyzer’s built-in diagnostic system (the analyzer
requires attention), or when the analyzer is operating in CFG or CAL
mode. This indicates to the control room that the analyzer is not oper-
ating in its normal Run state. The Run/Attention contacts will also be-
come de-energized if you manually force the analyzer’s Flow Control
mode to any mode other than Analyzer (automatic) Control mode.
When this relay changes state to de-energized, a lower case “m” will
be displayed in the top-left corner of the RUN mode screen.
Resetting of the contacts is delayed by the Sample Delay Timer

(SDelay) duration; otherwise, this relay’s contacts reset automati-
cally upon correction of the Warning alarm, upon switching back to
Analyzer (automatic) Control mode, and/or upon exiting CFG or CAL
mode.
Overview | 1-13
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Specifications
These performance characteristics are based on operation with factory-set

filtering time constants, a specified Measuring Cell path length of 40 cm,
and the sample gas in the Measuring Cell at predetermined temperatures
and pressures.
 For applications measuring other species not mentioned in this manu-

al, refer to the Documentation Package for a manual supplement.
NOTE

 Additional specifications for ATEX (KEMA) analyzers can be found
NOTE
in the ATEX certificates and analyzer labels under “ATEX (KEMA)
Certificates and Analyzer Markings,” later in this chapter.
Methodology
Dual beam, high resolution, non-dispersive UV.
(Optional Zirconia Oxygen Sensor.)
Standard Ranges
Maximum ranges are based on sample length (expressed in cm).
Minimum ranges are 1/50 of maximum ranges.
SO2 SO2 Range = 20 % SO2 / (Cell length), to a minimum of 250 PPM
NO NO Range = 20 % NO / (Cell length), to a minimum of 300 PPM
NO2 NO2 Range = 40 % NO2 / (Cell length), to a minimum of 300 PPM
H2S H2S Range @ 228 nm = 40 % H2S / (Cell length), to a minimum of
500 PPM
H2S Range @ 214 nm = 10 % H2S / (Cell length), to a minimum of
125 PPM
NH3 NH3 Range = 10 % NH3 / (Cell length), to a minimum of 125 PPM
Cl2 Cl2 Range = 40 % Cl2 / (Cell length), to a minimum of 500 PPM
Specifications | 2-1
Analyzer Specifications
Response Time
Dependent on sample gas flow rate and user-adjustable filtering time con-
stants. Typically less than 30 seconds to T90 (excluding sample system).
Measurement Accuracy
± 1.0 % of full-scale of standard ranges, typical (excluding drift and tem-
perature effects).
Repeatability
< ± 0.5 % full-scale of standard ranges.
Calibration
Calibration gases in nitrogen.
Linearity
< ± 1.0 % of reading
Zero Stability
Noise: < 0.2 % of full-scale of standard ranges.
Temperature Drift
SO2 = (40 PPM/Cell length)/°C
H2S @ 228 nm = (80 PPM/Cell length)/°C
H2S @ 214 nm = (30 PPM/Cell length)/°C
NO & NO2 = (120 PPM/Cell length)/°C
NH3 = (40 PPM/Cell length)/°C
Cl2 = (120 PPM/Cell length)/°C
 Use above specifications OR 3*(Customer full-scale/Maximum full-

scale), whichever is greater.
NOTE

24-Hour Zero Drift
SO2: 1.0 % of full-scale of standard ranges
NO, NO2, Cl2: 2.0 % of full-scale of standard ranges
NH3, H2S: 1.5 % of full-scale of standard ranges
 Use above specifications OR the equivalent of 10 °C Temperature

Drift (whichever is the lesser; with Auto-Zero disabled).
NOTE
Analog Outputs
Four isolated 4–20 mADC outputs, each capable of operating a
0–1000 ohm load. Can be self-powered or loop-powered (loop power sup-
plied by customer).
Digital Outputs (Communication Ports)

One RS-232 (or optional RS-485 for Modicon Modbus® protocol) port used
for service diagnostics.
One RS-422 port with Modicon Modbus® protocol (used for interface to
customer’s equipment).
Optional System 200 Configurator Software.
Power Consumption
600 W for analyzer only (excludes Sample Line, SCU, and Vent Line
power requirements).
Electrical Requirements
Nominal Frequency Range
120 VAC, ± 10 % 47–63 Hz
240 VAC, ± 10 % 47–63 Hz
Typical Sample Gas Flow Rate

3.0–5.0 litres/minute (0.1–0.2 SCFM)
Ambient Limits
Temperature
5–50 °C (41–122 °F)
Humidity
0–95 % RH
 Temperature drift is approximately 1 PPM/ °C for the species listed.

To achieve maximum accuracy and stability, install the analyzer in
NOTE
a temperature-controlled environment or zero the analyzer more
frequently.
Maximum Altitude
2000 m
Sample Transport
Air aspiration as the drive medium.
Instrument Air Requirements

Pressure: 413.6 KPAG (60 PSIG) minimum
Flow: 120 L/min (4.24 SCFM) minimum – may vary, depending
on application
Air Quality: As per ANSI/ISA S7.0.01 (1996) Quality Standard for
Instrument Air.
Physical Dimensions (on backpan)

Height: 1553.6 mm (61.17")
Width: 1117.6 mm (44")
Depth: 306 mm (12")
Weight: Approximately 160 kg (350 lb), entire system and
backpan only (may vary, depending on system).

Status Relays
The analyzer uses three relays which indicate the operational status of the
analyzer. Each relay provides a set of SPDT (Form C) dry (potential free)
contacts. The relays are configured for fail-safe operation (i.e., energized
for the non-alarm condition).
Temperature Control
Independent control of up to five temperature-controlled zones:
• Analyzer Oven
• Sample Line
• Sample Conditioning Unit (SCU)
• TZone3 (spare temperature-controlled zone)
• External, heated probe (optional)
Output Parameter Ranges

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

Stainless steel body with quartz windows. Other materials available to suit
applications.
Measuring Cell Operating Temperature

Typically 140 °C (284 °F).
Measuring Cell temperature is measured and controlled to within ±1 °C

(±1.8 °F) of the set point.
Pressure Compensation
Compensation for Measuring Cell pressure provided for SO2 only.
Range: 0–210 KPA (0–30 PSIA)
Pressure Transducer accuracy 0.25 % of full-scale.
Approvals and Certifications
NEC/CSA: NEC/CSA Class I, Zone 2 (Division 2), Groups C&D,
NFPA 496 Z‑Purge
KEMA: 02ATEX2341 X; Ex pd IIB T3
GOST: 1ExpydIIBT3
GOST Pattern Approval
CE Compliance:
Complies with all relevant European Directives
EMC: Electromagnetic Compatibility Directive:
EN61326 Industrial
LVD: Low Voltage Directive:
EN61010-1
O2 Concentration Signal (Optional)

An optional Zirconia Oxide Oxygen Sensor used on a wet basis and
linearized using Nernst’s equation. For technical data on this sensor, refer
to the Zirconia (Zr743) Oxygen Sensor Instruction Manual that is shipped
with the analyzer.
Speed of Response
90 % in 30 seconds or less (excluding sample system).
Accuracy
± 0.1 % O2 (excluding drift and temperature effects).
Repeatability
< ± 0.5 % full-scale of standard ranges.
24-Hour Zero Drift
1.0 % O2 (with Auto-Zero disabled).
Temperature Drift
0.0223 % O2 per °C
Electrical Classification
General Purpose applications/analyzers only.

Velocimeter
Standard Range
0–0.25 "H2O (minimum)

0–5 "H2O (maximum)
Accuracy
± 0.14 % of transducer, full-scale.
Repeatability
0.02 % of transducer, full-scale.
Stability
200 µV RMS (based on 0–5 VDC output).
Hysteresis
± 0.1 % of transducer, full-scale.
ATEX (KEMA) Certificates and Analyzer Markings
For installation sites with potentially explosive atmospheres that require
ATEX certification, AMETEK’s ATEX certificates for the Model 9xx-Series
Analyzers (and their marking) are included in the following pages.
Purged Analyzers ATEX Certificate

Purged Analyzer Markings
ATEX-certified Model 9xx-Series Purged Analyzers are marked with one of
the labels shown below, depending on the application.
No Release
Limited Release
Heater Plate ATEX Certificate

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

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

Installation & Start-Up
The Installation & Start-Up chapter contains information about the fol-
lowing topics:
• Where to find safety information in this guide before working with

the analyzer.
• How to store the analyzer before installation.
• Tools, equipment, and supplies required for installation.
• How to uncrate and inspect the analyzer for damage before installing.
• How to install the mechanical components and gas lines, and perform
a leak check on all of the fittings and connections before powering up
the analyzer.
• How to make all of the required electrical connections.
• How to apply power to the analyzer and configure it for operation.
• What to expect during normal operation.
! The installation of the analyzer must be in accordance with all of the

user and local regulatory standards and procedures. There are no
WARNING
operator-serviceable components inside the analyzer. Refer servicing
to qualified personnel.
Installation & Start-Up | 3-1

Safety Considerations
 Before beginning the installation of the analyzer and before powering

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

Pre-Installation Requirements
Storage Prior to Installation

If the analyzer is stored for any period of time prior to installation, it
must be housed in a temperature-controlled environment where it is not
subject to dripping or splashing liquids, corrosive gases, high humidity, or
excessive heat or cold.
Uncrating and Inspecting the Analyzer

The analyzer, along with its associated sample system, is shipped pre-
mounted on a backpan either alone in a crate or in a crated weatherproof
shelter. Upon receiving the analyzer system, remove the shipping crate
and check the exterior of the shelter and/or analyzer for damage. Open
the shelter and/or analyzer and check that all of the components within
are secure and that there is no physical damage. Check that all of the
components and wiring within the Analyzer Oven, Electronics Enclosure,
Sample/Vent Line Termination Box, and Disconnect Enclosure are secure
and that there is no physical damage.
The Optical Bench Assembly is shipped in a separate box. Remove the

shipping crate and check it for any physical damage.
! After the inspection, close and secure all covers and doors with at
least one screw. This will keep the electronics equipment secure and
CAUTION
will prevent damage to the doors, covers, electronic components, and
flamepaths (i.e., Disconnect Enclosure) during installation.
! For non-shelter systems, avoid damaging the analyzer’s piping and

instrumentation by lifting it out of its shipping crate using only its
CAUTION
backpan. DO NOT use any piping or instrument as a handle for
lifting.
! The analyzer and its backpan weighs approximately 160 kg (350 lb).
Use caution when lifting it from its crate.
WARNING

General Installation Information
! The electronic circuit boards and other static-sensitive components

should be stored and transported in static-shielding carriers or
CAUTION
packages.
! When handling the source lamps, it is very important not to touch

the lamp windows because residual oils from the fingers will absorb
CAUTION
ultraviolet light. The window is the flat surface at the end of the nar-
row glass tube. The lamp assembly is fragile and should be handled
with care.
Tools, Equipment and Supplies Required for

Installation
To install the analyzer, you need the following tools, equipment, and
supplies:
• Set of open-end wrenches, set of metric hexagonal wrenches, and set
of metric ball drivers.
• Torque wrench (for Type 200 Disconnect Enclosure), calibrated and set
to measure 80 in-lb (9.0 Nm, ±1.0 Nm).
• Wire Cutters, strippers, and crimpers.
• Flat blade instrument screwdriver.
• Thread lubricant (must not contain copper).
• Soft, non-abrasive cloth.
• Wrist Strap (for grounding).
• Detergent-based leak detector (Snoop® or another suitable leak detec-
tion agent is permissible).
• One flameproof power-disconnect switch (breaker), rated for at least
250 VAC, 20 A and certified for the hazardous area. For safety reasons
during maintenance, this switch allows the main AC power to be
disconnected from the analyzer. This switch is to be supplied by the
customer/end user.
• Supply of 1/4" or 3/8" 316 stainless steel tubing for the Instrument Air
line. If using 1/4" line, 1/4" NPT-F connectors are required; if using 3/8"
tubing, 3/8–1/4" NPT-F (reducing) connectors are required. Supplied
by the customer/end user.
• A supply of 1/4" 316 stainless steel tubing for the Calibration, Span,
Zero, and Aspirator Drive Air lines. Length will vary, depending on
the distance between the analyzer and the stack duct. Supplied by the
customer/end user. Supplied by the customer/end user.

Installing the Mechanical Components
While installing the mechanical components, refer to the associated il-
lustrations for the dimensions and locations of components. Specific
drawings for your analyzer are located in the “Supplemental Information”
section of this manual or the Documentation Package shipped with the
analyzer.
! Do not mount the Optical Bench in the Electronics Enclosure until

CAUTION after the analyzer has been mounted in its designated location.
Mounting the Analyzer

The analyzer system comes mounted on a backpan. See Figure 3-1 for the
backpan and mounting hole locations and dimensions, plus necessary
clearances on all sides that are required for service.
Location and Environment
The entire analyzer system (and its backpan) can be mounted directly on
a wall, in a specially designed cabinet, or in a custom-built shelter. In all
cases, the analyzer system must be installed indoors to ensure it is shield-
ed from harsh environmental elements.
 Regardless of which installation method is used, be sure to install the

NOTE
analyzer in a location that is as free as possible from vibrations.
The surrounding ambient temperature of the analyzer should be main-

tained between 5–50 °C (41–122 °F). If the analyzer system is mounted
within an AMETEK-designed shelter, these conditions are taken into con-
sideration in the design of shelter.
To mount the analyzer:
Non-Shelter Installations:
In a suitable, accessible location as close as possible to the sample gas
extraction point (to minimize the amount of sample lag time), mount the
analyzer on a vibration-free wall or instrument rack.

The minimum allowable door swing clearances are 706 mm (27.8" in the
front and at least 254 mm (10.0") at the top of the backpan (see Figure 3-1).
If possible, provide extra room to allow sufficient access for servicing the
analyzer.
AMETEK recommends mounting the analyzer 1500 mm (59") from the floor
to the centre of the Sample Line inlet connection on the Analyzer Oven.
Figure 3-1 illustrates a basic General Purpose (GP) analyzer layout.

 While the backpan and mounting hole locations and dimensions
NOTE
generally do not change, the plumbing and external wiring will likely
change for each installation.
Figure 3-1.
Analyzer (GP) backpan
mounting details.

Shelter Installations:
AMETEK recommends placing the analyzer shelter in a vibration-free
location.
 Figure 3-2 illustrates an example of a GP analyzer shelter instal-

lation. Actual drawings for your application can be found in the
NOTE
“Supplemental Information” section of this manual or in the
Documentation Package shipped with the analyzer.
Figure 3-2.
Shelter installation
details, GP analyzer.

Installing the Optical Bench Assembly
After the analyzer has been installed, the Optical Bench Assembly can be
mounted in the Electronics Enclosure and Analyzer Oven.
If your analyzer uses a Measuring Cell other than the typical cell
 illustrated in Figure 3-5, refer to the “Supplemental Information” sec-
NOTE
tion of this manual for the appropriate drawing.
! Make sure that all power to the analyzer is off before installing the
Optical Bench Assembly.
WARNING
To mount the Optical Bench Assembly:
1. Remove the outermost pivot pin from the blue Support Arm Yoke
mounted to the back of the Electronics Enclosure in the upper-left cor-
ner (see Figure 3-3). To do this, loosen the set screw securing the pivot
pin.
2. Attach the Optical Bench Assembly to the Support Arm Yoke by fitting
the Optical Bench Support Plate to the Support Arm Yoke and secur-
ing it with the pivot pin. Tighten the set screw. The Optical Bench
Assembly should swing freely.
3. Connect the AC power lines (using the connector plug) to TB100 on

the Optical Bench board (see Figure 3-4). Connect the ground wire.
4. Connect the ribbon cable from J102 on the Micro-Interface board to

J100 on the Optical Bench board (see Figure 3-4).

Figure 3-3.
Electronics enclosure,
GP analyzer backpan
layout.
 Figure 3-3 illustrates a typical General Purpose (GP) analyzer layout.

For other analyzer types, refer to the “Supplemental Information” sec-
NOTE
tion of this manual or the Documentation Package shipped with the
analyzer.

Figure 3-4.
Optical Bench board
component layout.
5. Mounting the Measuring Cell Assembly in the Analyzer Oven:
a. Remove the 3 mm holding screw from the Sample Cell RTD.

Remove the Flame Arrester (black plug) from the counter bore
hole in the Heat Transfer Block (on the Measuring Cell).
b. Swing the Optical Bench Assembly toward the Analyzer Oven and
then swing the Measuring Cell Assembly toward the Heater Plate.
Align the hole in the Heat Transfer Block with the Sample Cell
RTD tip and carefully push the Measuring Cell Assembly toward
the Heater Plate. Adjust the entire Measuring Cell/Optical Bench
Assembly as required to firmly seat the Measuring Cell Assembly
against the Heater Plate.
c. Using an Allen key, insert the 3 mm holding screw into the counter
bore hole in the Heat Transfer Block and thread it (until it is snug)
onto the Sample Cell RTD from which it was removed (see Figure
3‑5). Do not use a ball driver – the head can break off inside the
screw. Do not tighten the screw at this time.

Figure 3-5.
Optical Bench/
Measuring Cell/Lamp
assembly.

d. Adjust the Measuring Cell/Optical Bench Assembly so that the
silicon seal on the Measuring Cell Extension fits firmly into the
molded depressions in the Analyzer Oven wall and Electronics
Enclosure wall. The two ribs of the silicon seal should fit between
the inside and outside edges of the Electronics Enclosure wall.
Close the Electronics Enclosure door and engage the latches to
secure the Optical Bench Assembly in place.
 While closing the Electronics Enclosure door, verify that proper verti-
cal alignment of the Optical Bench Assembly is maintained.
NOTE
If necessary, vertically align the Optical Bench Assembly by loosening

the Optical Bench support bracket from the backpan and moving the
Optical Bench Assembly up or down as required. After aligning the
Optical Bench Assembly, retighten the support bracket.
e. After the Electronics Enclosure door is closed and secured, ensure

no gap exists between the Heat Transfer Block and the Sample
Cell RTD. The Measuring Cell Assembly must feel secure against
the Heater Plate. Gently push and pull on the Measuring Cell
Assembly to verify it is not loose. If necessary, use an Allen key
to tighten the 3 mm holding screw until the Measuring Cell
Assembly does not move when you push and pull on it. Do not
use a ball driver – the head can break off inside the screw. Do not
overtighten this screw as doing so will damage the threads on the
RTD.
f. Verify the Measuring Cell Assembly is properly fitted against the

Heater Plate and is firmly seated in the molded depressions in the
Analyzer Oven wall and Electronics Enclosure wall.
g. Verify there is no clearance between the Heat Transfer Block and

the Sample Cell RTD. There should be no movement. If there is
any movement, tighten the 3 mm holding screw again until the
Measuring Cell Assembly does not move when you push and pull
on it, being careful not overtighten it.
h. Replace the Flame Arrester (black plug) in the counter bole hole in
the Heat Transfer Block.
6. Connect 1/8" OD Teflon tubing from the purge connection outlet on

the purge controller to the Optical Bench purge fitting (see Figure 3‑5).
7. The installation information for the Sample Line and vent is described
under “Installing the Sampling System,” following this section.

Installing the Sampling System
 Drawings of the sample system components that make up your

analyzer system are included in the “Supplemental Information” sec-
NOTE
tion of this manual or the Documentation Package shipped with the
analyzer. If parts of the sample system are not supplied by AMETEK,
refer to the appropriate instructions and drawings included with
those components.
! All regulatory agency, personnel safety procedures, and installa-

tion/removal procedures must be followed during the installation/
WARNING
removal of the sample system components. A breathing apparatus
must be worn when installing/removing equipment from the sample
gas extraction point. The stack duct may be under positive pressure,
and injury or death from inhaling toxic gases in the stack duct could
result from attempting to install/remove equipment without the use of
a breathing apparatus.
 Ensure all appropriate fuses are opened before terminating any

wiring. Refer to the Fuse Legend on the inside of the analyzer’s
NOTE
Electronics Enclosure for locations of these fuses.

Installing the Sample Conditioning Unit
If the SCU is supplied by AMETEK, refer to appropriate drawings in the

“Supplemental Information” section of this manual or the Documentation
Package shipped with the analyzer. These drawings include important
information to follow during the installation of this unit.
If the SCU is not supplied by AMETEK, refer to instructions and drawings

that accompany the SCU.
To install the SCU:
1. Install the SCU on the stack duct.
 Ensure there is sufficient clearance around the SCU to allow for easy
removal and maintenance.
NOTE
2. Install and terminate the Pitot/Static line from the SCU to the
Velocimeter on the analyzer.
Install and terminate the SCU power, RTD, and thermocouple wiring
from the SCU to the Sample Line/SCU Termination Box on the ana-
lyzer backpan. Refer to the Sample/Vent Line Wiring drawings and
other related drawings for Over-Temp Wiring Details. These drawings
are located in the “Supplemental Information” section of this manual
or the Documentation Package shipped with the analyzer.

Installing and Connecting the Sample and Vent Lines
The Sample Line can be supplied by AMETEK or by the customer. This

section assumes that the Sample Line is supplied by AMETEK. An alter-
nate Vent Line installation is also available for applications that return the
used gas to the extraction point.
Most applications are configured to disperse the used sample gas to

atmosphere. In this case, the used sample gas is routed directly from the
Sample Outlet Fitting in the Analyzer Oven to the dispersal location (vent
pipe to atmosphere). These installation procedures briefly discuss using a
vent pipe.
! Do not lift or support the Sample Line by the tubing fitting. Doing so
may pull the fitting off the sample transport tube. A wire mesh cable
CAUTION
support must be installed on the line before lifting it and when a line
is to be suspended vertically. The Sample Line is custom-built for each
installation; they cannot be cut to length on site.
To avoid damaging the Sample Line, use two wrenches to ensure that
the fitting body does not turn on the Teflon line.
To install the Sample and Vent Lines:
1. Open the Electronics Enclosure door and open the Analyzer fuse to
ensure there can be no power supplied to the analyzer or the Sample
Line and SCU temperature-controlled zone circuits. Refer to the Fuse
Legend on the inside of the analyzer’s Electronics Enclosure door for
the locations of these fuses.
 Keep these fuses and/or flameproof power-disconnect switch (breaker)

open until the entire system has been installed, the leak check has been
NOTE
completed, and the analyzer is ready for normal operation.
2. Unwrap and lay out the Sample Line. Note that the electrical leads at
the end of the line must be at the analyzer.
3. Route the Sample Line from the sample gas extraction point (on the
stack duct) to the analyzer.
Ensure there are no loops, sags, or other traps in the Sample Line.
Provide support where needed.

4. Connect the Sample Line to the SCU (or stack sample probe, if used).
Refer to appropriate drawings for more information about the

Sample Line. If the Sample Line is supplied by AMETEK, refer
to the “Supplemental Information” section of this manual or the
5. Run a Vent Pipe between the analyzer and the disposal location (to
atmosphere).
Connect the Vent Pipe to the fitting at the disposal location.
6. Make the connections to the Sample Inlet/Outlet Fittings inside the

Analyzer Oven.
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 Pipe through the lower hole on the left side of the
Analyzer Oven. Connect it to the Sample Outlet Fitting.
Route the Sample Line through the hole marked “Sample Line” on the
side of the shelter and then through the upper hole on the left side of
the Analyzer Oven. Connect it to the Sample Inlet Fitting.
Route the Vent Pipe through the hole marked “Vent Line” on the side
of the shelter and then through the lower hole on the left side of the
Analyzer Oven. Connect it to the Sample Outlet Fitting.
! Do not add extra insulation to the Sample Line. This will result in a
local hot spot and cause premature failure of the line.
CAUTION
7. Terminate the Sample Line and SCU wiring as indicated in the

Sample/Vent Line Wiring drawing in Appendix D, or related drawings
located in the “Supplemental Information” section of this manual or
the Documentation Package shipped with the analyzer.
! Connect the ground lead from each line to the ground terminals before
connecting the heater leads.
CAUTION
 When terminating the temperature sensor (RTD) leads, either sensor in

a line may be used as the Control or Over-Temperature sensor (RTD).
NOTE

Installing and Connecting Instrument Air
The Instrument Air line is supplied by the customer. The tubing must
be 1/4" or 3/8" 316 stainless steel tubing with appropriate 1/4" NPT or
3/8‑to‑1/4" NPT (reducing) connectors.
The Instrument Air must meet the ANSI/ISA-S7.0.01 (1996) specifications

at all times. If the Instrument Air cannot meet these requirements, an inlet
filter system must be installed. Refer to the Plumbing Schematic located in
the “Supplemental Information” section of this manual (or in a separate
Documentation Package shipped with the analyzer).
The air must be supplied to the analyzer pressure regulator at a pressure

in the range of 420–840 KPAG (60–120 PSIG) and a flow rate of 60–120 L/
min (1–4 SCFM). These values may vary, depending on the application.
To install the Instrument Air line:
1. Route the Instrument Air line from the Instrument Air supply to the
analyzer.
2. Blow down (purge) the line to remove any liquids or particulate that
may be present in it line before connecting it to the analyzer.
3. Connect the Instrument Air line to the analyzer. The plumbing for the
purge systems and the aspirator drive air feed through the analyzer
manifold is already made by AMETEK.
Route Connect the Instrument Air line to the Instrument Air inlet fit-
ting on the analyzer.
Connect the Instrument Air line to the “Inst Air” port on the left side
of the shelter.
4. Connect the Instrument Air line to the Instrument Air supply.

Installing the Calibration (Span/Zero) Gas Lines
The Calibration (Span/Zero) Gas lines are supplied by the customer. The
gas lines must be 1/4" 316 stainless steel tubing.
To install the Calibration (Span/Zero) Gas lines:
1. Route the Span/Zero Gas lines from each supply tank to the analyzer.
2. Blow down (purge) the lines to remove any liquids or particulate that
may be present in them before connecting them to the analyzer.
3. Connect the appropriate Calibration Gas tube to the appropriate fit-

ting on the manifold block and to the supply tanks.

Connecting I/O Signals, Alarm Relay Contacts, and AC Power
The analog input/output signals, alarm relay contacts, and AC power
requirements are specific to each analyzer installation.

CAUTION
For Zone 1 Installations, all cable entry glands (one power cable
entry and two signal cable entries) into the flameproof Disconnect
Enclosure must be Ex d certified. As per EN 60079-14:1997, 10.3.2
“The cable entry system shall comply with … e) flameproof cable en-
try devices incorporating compound filled seals around the individual
cores or other equivalent sealing arrangements”.
For Zone 2 Installations, use a suitable flameproof cable entry device

with a sealing ring, as per EN 60079-14:1997, 10.3.2, item “b)”; or,
comply with local wiring regulations and electrical codes.
In all cases, all unused cable entry ports must be plugged with a certi-
fied Ex d plug.

Take extreme care to avoid damaging the threads on the cable entry
CAUTION
glands on the Disconnect Enclosure. Clean, defect-free threads are es-
sential to ensure a flameproof connection.
! For AC electrical supply cable and conduit requirements, refer to,

and comply with, local wiring regulations and electrical codes for the
WARNING
hazardous area.
Refer to the Electromagnetic Compatibility (EMC) page in the con-

 tents section of this manual for information that discusses the EMC
NOTE
Directive regarding techniques and wiring practices to be followed.

Electrical Connections
Termination points for the Remote Calibration/Remote Backpurge input
signal, analog output signals, alarm relay contacts, and AC power will
vary, depending on whether the analyzer is mounted only on a back-
pan or in a shelter, or if it is for use in a General Purpose or Hazardous
Location.
Drawings (Customer Signal Connections, Analyzer AC Wiring, and other

electrical connection drawings) that show the connections for the remote
calibration/remote backpurge input signal, analog output signals, and
alarm relay contact termination points are included in this section and in
Appendix D, the “Supplemental Information” section of this manual, or in
the Documentation Package shipped with the analyzer. If the analyzer is
installed in a shelter, refer to the customer-specific drawings, also included
in these locations.

Install and connect a flameproof power-disconnect switch (breaker),
CAUTION
rated for at least 250 VAC, 20 A, near the analyzer (supplied by the
customer). To satisfy local electrical codes, the switch must be certified
by the local authority for the appropriate hazardous area.
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.

Use a soft, nonabrasive cloth to gently clean the joining surfaces
CAUTION
(flamepath) of the Disconnect Enclosure and its door. Close the
door and replace at least one of the M10 screws while completing
the installation. This will ensure the flamepath is not inadvertently
damaged.

 All electrical connections should be performed only by properly
trained and qualified personnel and must be made in compliance with
NOTE
local wiring regulations and electrical code for the hazardous area,
and be approved by the Owner Company.
To make the signal, relay contact, and power connections:
1. General Purpose (GP) Analyzer Applications:

Open the Electronics Enclosure and open all of the fuses.

Open the Electronics Enclosure and open all of the fuses (or GFIs).
Loosen and remove all but one of the M10 x 40 mm hex socket head
cap screws that secure the door to the Disconnect Enclosure. 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 relay
contact conductors (see Figure 3-6 for GP/Div 2 analyzers).
General Purpose Analyzer Applications:

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

Route the input signals, analog output signal, and alarm relay contact
conductors to the Disconnect Enclosure.
Install a cable gland(s) on the signal/relay cable(s) as per the manu-

facturer’s instructions. Connect the cable gland(s) to the signal/relay
cable entry(ies) on the Disconnect Enclosure.
Route the input/output signals and alarm relay conductors into the
Apply sealing compound in the signal/relay cable gland(s) as per the

manufacturer’s instructions.
Terminate the signal/relay connections inside the Disconnect

Enclosure.

3. Terminate the AC power conductors. Refer to the Analyzer AC Wiring
drawing (Figure 3-7) – and other related customer-specific drawings –
in Appendix D, the Supplemental Information section of this manual,
or in the Documentation Package shipped with the analyzer.
! Before making the AC power connections, open (turn off) the flame-
proof switch (breaker, if used) to the analyzer, and open the Analyzer
WARNING
and Oven Heater fuses.
Do not apply power to the system until after all of the wiring has been
installed, connected, and verified, and only if the purging system is
ready for operation.

Route the AC power conductors to the Electronics Enclosure and ter-
minate the wires.
According to 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
Route the AC power conductors into the Disconnect Enclosure.
Apply sealing compound in the cable gland as per the manufacturer’s
instructions.
Terminate the AC power connections inside the Disconnect Enclosure.
4. Plug all unused cable entry ports with certified Ex d plugs.
5. Purged Analyzer (Hazardous Location) Applications only:
Before closing the Disconnect Enclosure door, use a soft, non-abrasive
cloth to gently clean its joining 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
80 in-lb, ±9 in-lb (9.0 Nm, ±1.0 Nm).

Figure 3-6.
Customer signal
connections, GP/Div 2
analyzers.
 Figure 3-6 is for GP/Div 2 analyzers only; for CE or Zone 1 refer to

Customer Signal Connections, CE/Zone 1 Analyzers in Appendix C.
NOTE
For other applications, refer to the electrical connection drawings
included in the “Supplemental Information” section of this manual or

Figure 3-7.
AC Wiring, GP/Div 2/CE/
Zone 1 Analyzers.
 PD refers to Purgeable Deluxe analyzers (General Purpose & Division 2).

NOTE

Start-Up and Verification
This section describes equipment and controls on the analyzer system
that require adjustments and settings before, during, and after power-up.
Refer to Figure 3-8 for the locations of analyzer equipment or controls that
require adjustments.
 Figure 3-8 illustrates a basic General Purpose (GP) analyzer layout.

While the Electronics Enclosure layout generally does not change
NOTE
for different applications, the plumbing, instrumentation, and ex-
ternal wiring may differ. For the actual layout of your application,
refer to the “Supplemental Information” section of this manual or the
Figure 3-8.
Model 909 Analyzer
(GP), overall component
layout.

Purged Analyzer (Hazardous Location) Applications
The Electronics Enclosure and its Optical Bench and Measuring Cell
Extension are continuously purged with Instrument Air to adequately
dilute any flammable gases that may have been released into these areas.
This function effectively prevents an internal explosion when the analyzer
is powered up and operating under normal sampling conditions.
The purge air supply is normally obtained from the Instrument Air supply
connected directly to the Expo-Telektron MiniPurge system.
The required purge air supply pressure is indicated in drawings for your
analyzer located in the “Supplemental Information” section of this manu-
al or in the Documentation Package shipped with the analyzer.
AMETEK analyzers that require purged enclosures in hazardous locations

use an Expo-Telektron MiniPurge system to perform this function. After
the MiniPurge system has been connected to the instrument air supply, its
purge timer will begin – after the ALARM/PRESSURIZED indicator on the
MiniPurge system turns from red (alarm condition) to green (pressurized).
During this first stage, the MiniPurge system will purge any flammable
gases that may have entered the Electronics Enclosure while its door was
open. After this time period has elapsed, the PURGE COMPLETE indica-
tor will turn green. At this point, the analyzer will power up (providing all
fuses have been engaged) and any external flameproof switches (or break-
ers, if installed) have been closed.
Working with the purged enclosure open is typically limited to instal-

lation, start-up, and certain troubleshooting and maintenance proce-
dures. In these cases, the Purge Bypass Switch (Figure 3-9) must be in the
BYPASS position (and appropriate safety conditions must have been met,
as per company policy).
AC
SS T IV
PA E
BY
Figure 3-9.
Purge Bypass Switch
label.

For normal analyzer operation, the Purge Bypass Switch must be in the
ACTIVE position and the key must be removed (follow company policy).
To ensure safe operating conditions, the analyzer will not power up until
the MiniPurge system has been connected to the instrument air supply
and has completed its purge stage (the PURGE COMPLETE indicator will
be green) and the ALARM/PRESSURIZED indicator is green (enclosure is
pressurized).
After powering up the analyzer for the first time, certain checks must be
performed with the Electronic Enclosure door open to ensure the ana-
lyzer is operating properly. These checks are discussed in the following
power-up procedure. If problems are encountered during power-up, refer
to the “Start-Up Diagnostic Checklist,” later in this chapter, for help in
diagnosing and correcting problems.
! Always disconnect power and/or external power sources to the ana-

lyzer before opening any covers or doors on the analyzer to check or
WARNING
perform maintenance 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). 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 is open, take appropriate precautions

to avoid electrical shock. Hazardous voltages are present inside.
! Do not apply power to the analyzer if there is damage (scratches,

indentations, or wear) to any flamepath (on the Oven Heater or
WARNING
Disconnect Enclosure). Applying power to an analyzer with a dam-
aged flamepath is dangerous and could result in serious injury or
death, or serious damage to equipment.

Powering Up the Analyzer
Before operating the analyzer for the first time, following a power-up or
reset, or after maintenance, you must manually backpurge the analyzer ’s
sample system with Zero Gas and adjust the sample gas flow rate. If start-
up problems occur, refer to “Start-Up Diagnostic Checklist,” later in this
chapter, for problems and corrective action to fix any problems.
! For verification and troubleshooting purposes during power up, it

will be necessary to work with the analyzer’s covers and doors open.
WARNING
Before powering up the analyzer, test the area for flammable gases.
If an explosive gas atmosphere is present, do not apply 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.
To power up the analyzer and verify it is operating properly:
1. With the Electronics Enclosure open:

Close the Analyzer fuse to apply main AC power to the analyzer.
Note that power is applied to the Sample Line and SCU temperature-
controlled circuits when AC power is applied to the analyzer. Refer to
the Fuse Legend on the inside of the analyzer’s Electronics Enclosure
door for the location of this fuse.

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
WARNING
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 analyzer enclosure may not be opened when an explosive atmo-

sphere is present.

Close the Analyzer fuse. Refer to the Fuse Legend on the inside of the
analyzer’s Electronics Enclosure door for the location of this fuse.
Apply main AC power to the analyzer by closing the flameproof

power-disconnect switch (breaker).
2. Immediately following power-up, the Host Controller board software

version number will appear on the top line of the User Interface Panel
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.
NOTE
If the “Reset in Progress” message still does not appear, check the AC
wiring to ensure it is properly connected.
To check the AC wiring, take all necessary safety precautions to power

down the analyzer and open the Analyzer fuse and the Oven Heater
fuse.
! Wait 5 minutes to allow the high-voltage capacitors in the source-

lamp power supply to discharge.
WARNING
Review the Analyzer (AC) Power Connections drawing(s) and check

the wiring terminations from the power supply source to the analyzer.
! If the “Reset in Progress” message still does not appear, take neces-
sary precautions and check the AC wiring to ensure it is properly
WARNING
connected.
Take all necessary safety precautions and power up the analyzer (as
discussed previously). Check the User Interface Panel again to see if
the message appears. If it does, continue with the next step.

3. Close the Oven fuse to supply power to this temperature-control zone
circuit.
 When the analyzer system is first powered up, the alarm warning
“w Oven Heater” may be displayed on the User Interface Panel. This
NOTE
warning will clear when the Analyzer Oven temperature controlled
zone is within its normal operating range.
Check the User Interface Panel for indications of other alarms. Alarms
are indicated by a reverse-video S ( S ) on the upper-right line. To
view alarms that have been detected, press F5 4 (and press each of the
keys numbered 1..8) and/or F5 5 (and press each of the keys numbered
1..7) from RUN mode to view the current Host Controller board and/
or Microcontroller board status/error code conditions.
4. While observing the electronics within the Electronics Enclosure,

check the source lamps to ensure 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 problems with the wiring.
5. Allow the entire sample system to warm up to normal operating tem-

perature and stabilize. This should take approximately 2 hours. The
Sample Line and Vent Line (or SCU, if used) zones typically warm up
quicker than the Measuring Cell zone.
Meanwhile, perform the following checks to ensure the analyzer

temperature-control zone circuitry is operating properly. Record the
value indicated for each zone to use as a reference later while compar-
ing the temperature value.
a. From the User Interface Panel, view the set points for each temper-
ature-control zone by pressing F4 0 (from RUN mode) to view the
TStPt screen.
The TStPt screen defaults to the Sample Line temperature-control
zone. You can also view this parameter by pressing 1.
Press 2 to view the Vent Line (or SCU) temperature-controlled
zone.
Press 4 to view the Measuring Cell temperature-controlled zone.
 The third temperature-controlled zone (“3” = TZone3) is a spare.

NOTE

b. Next, check and record the current temperature readings. This will
help you determine if the signal wiring is properly terminated and
if all of the circuitry is operating properly.
To do this, press F6 8 from RUN mode to view the Microcontroller

Board Analog Inputs (MAI) and pay particularly close attention to
the temperatures of the Sample Line, Vent Line (or SCU, if used),
and Measuring Cell. The lowest temperature you will see for any
zone is 7 °C (45 °F). If this temperature does not increase, check the
wiring for proper connections. If the display reads “181.4”, it may
indicate a shorted RTD for that temperature zone.
6. After approximately two hours (at which time the system should have
reached its normal operating temperature), and if all of the alarm
conditions have cleared (check the User Interface Panel), recheck the
temperature of each zone.
To do this, press F6 8 to view the Microcontroller Board Analog Inputs

(MAI) and then press keypad numbers 1 through 4 and record the
value for each zone. Compare the values 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 the Set Point values.
7. If all of the temperature zones have reached normal operating tem-

peratures and there are still no alarm conditions or other problems,
perform a leak (pressure) check to ensure there are no leaks in the
system.
To perform this test, follow the procedures listed under “Sample

System Leak Check,” later in this chapter. Then, return to this proce-
dure and complete the remaining steps.
8. Close and secure all covers and doors on the Electronics Enclosure,
Analyzer Oven, Disconnect Enclosure, and Sample/SCU Termination
Box.

While the Disconnect Enclosure is open, take extreme care to avoid
CAUTION
scratching or damaging the joining surfaces (flamepath). Before clos-
ing the door, gently clean these areas with a soft, non-abrasive cloth
and make sure they are free of debris.

9. Purged Analyzer (Hazardous Location) Applications Only:
Return the Purge Bypass Switch to the ACTIVE position and remove
the key (follow company policy).
10. Open the isolation valve on the sample gas extraction equipment
(e.g., SCU) to allow sample gas from the stack duct into the analyzer ’s
sample system.
! For systems using a Sample Conditioning Unit (SCU), the SCU will
be hot. Take precautions to avoid burning yourself.
WARNING
11. Manually Zero the analyzer as described under “Manually Zeroing

the Analyzer,” later in this chapter.
12. Adjust the Aspirator Drive Air Regulator to achieve normal operating
flow rates as described under “Adjusting the Sample Gas Flow Rate,”
later in this chapter.

Start-Up Diagnostic Checklist
This diagnostic checklist describes problems that may be encountered
while powering up the analyzer and/or preparing it for normal operation.
If the analyzer experiences problems during power-up, review this check-
list and perform the corresponding corrective action to fix any problems.
Problem Encountered
“Reset in Progress” message does not appear on the User Interface Panel
immediately after applying AC power, or after attempting a manual system
reset.
Corrective Action
Simultaneously press • and Ent. If this message still does not appear, take
necessary precautions and check the AC wiring to ensure it is properly
connected.
Problem Encountered
If a reverse-video S ( S ) is displayed on the User Interface Panel, view the
current Host Controller board and/or Microcontroller board status/error
code conditions for current alarms.
The S character will typically be displayed upon start-up due to low tem-
peratures in the temperature-controlled zones.
Corrective Action
To view current alarms, press F5 4 from RUN mode (and press each of the
keys numbered 1..8) and/or F5 5 (and press each of the keys numbered 1..7).
For detailed information about these alarms, refer to the alarm conditions
and corrective action in the Maintenance & Troubleshooting chapter of this
manual.
Problem Encountered
One or both source lamps are not firing.
Corrective Action
Take appropriate safety precautions and check for proper wiring connections.
If the wiring is okay, check the connections of the lamps in their sockets.
Review the section titled “Replacing the Source Lamps” in Chapter 5 of this
manual to make adjustments to the lamps. Perform an Auto-Setup if neces-
sary to ensure the lamps are operating at peak efficiency.

Problem Encountered
The LEDs on the Termination board are not on.
Corrective Action
Take appropriate safety precautions and check for proper I/O wiring
connections.
Also, press the OverTemp Reset switch (SW300) on the Termination board
(inside the Electronics Enclosure) to re-energize any tripped circuits. See
Figure 3-10 for the location of this switch.
Problem Encountered
Temperature zone values do not increase.
Corrective Action
Take appropriate safety precautions and check for proper wiring connections
for the appropriate 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 the related RTD for a short. If
necessary, replace the RTD with an AMETEK-approved replacement part.

Figure 3-10.
Over Temp alarm
reset switch (SW300),
Termination board.

Sample System Leak Check
The analyzer sample system has been pressure-checked for gas leaks at
the factory – with the Optical Bench/Measuring Cell Assembly connected
– as part of AMETEK’s quality assurance procedures.
However, the Optical Bench/Measuring Cell Assembly has been removed

for shipping (in its own crate) and fittings can loosen during transport.
Also, the Sample Line, Vent, Instrument Air, Calibration Gas, and Zero
Gas lines are installed on-site. Therefore, it is important that you perform
a leak check on the entire sample system prior to powering up the ana-
lyzer for the first time, or following the replacement of any lines/fittings or
Measuring Cell parts.
! Preventing leaks in the sample handling system is critical to ensure

proper analyzer operation. If sample gas migrates into the Optical
CAUTION
Bench Assembly or Reflector Block due to a leak in the Measuring
Cell Assembly, the optics will become damaged and most likely require
replacement. Most leaks are preventable with the regular replacement
of the Measuring Cell o-rings.
After all piping and electrical connections have been made:
1. With the analyzer powered up, open the Aspirator Drive Air
Regulator to allow instrument air into the sample system.
2. Cap the Sample Line at the SCU and cap the Vent Line at the Sample
Vent Pipe.
3. Use the Aspirator Drive Air Regulator to increase the instrument air
pressure to 70 KPAG (10 PSIG).
! To avoid damaging the pressure transducer, do not set the pressure

higher than 105 KPAG (15 PSIG).
CAUTION
4. While working from the User Interface Panel, view RUN mode, press
F6 8 6 to view the CellP (Measuring Cell Pressure) screen and record
the numeric value displayed. This value is the absolute pressure
reading in mmHg (or "Hg). The reading on the User Interface Panel is
automatically updated every second.

5. Block in the instrument air by closing the Drive Air Isolation Valve
(green handle) and observe the pressure reading on the User Interface
Panel. Allow the pressure within the analyzer’s sample system and the
Measuring Cell to equilibrate (approximately 5 minutes) before tak-
ing the initial reading. Meanwhile, continue to observe the Measuring
Cell Pressure reading on the User Interface Panel. If the reading drops
less than 10 mmHg (0.39 "Hg) in 4–5 minutes, the system is sufficiently
leak-tight.
However, if the reading steadily decreases, there is a leak somewhere

in the system.
6. Using a suitable detergent-based leak detection fluid (e.g. Snoop®),

perform a leak check on all of the other fittings except the fittings that
are hot, such as those on the Measuring Cell. To test the zones that are
hot, observe the Measuring Cell Pressure (CellP) reading – press
F6 8 6 from CFG mode – 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 zones must be cooled
CAUTION
down before using a leak detection fluid on the fittings.
If the Measuring Cell is suspect, check all fittings to ensure they are
tight and repeat the procedures of testing/repairing/testing until all
leaks have been eliminated.
7. After the analyzer has passed the pressure leak test, remove the
cap from the Sample Line at the SCU (and reconnect it to the SCU).
Remove the cap from the Vent Line and reconnect it to the Sample
Vent Pipe.

Manually Zeroing the Analyzer
The CALibration mode is used for performing the manual Zero func-
tion, which forces the analyzer to purge the sample system with Zero
Gas (Continuous Zero Gas Flow mode). The Zero function removes any
residual contaminants in the sample system.
All temperature zones must be at their operating set points before per-
forming a Manual Zero. If necessary, view the temperature zones to
ensure that all zones are at their operating temperatures.
This procedure assumes Instrument Air is used as the Zero Gas.
 Pressing Esc at any time during this procedure will abort the proce-
dure and return to CAL mode normal display.
NOTE
To manually zero the analyzer:
1. Ensure that the Zero Gas cylinder is turned on.
2. Set the analyzer Flow Control Mode to Continuous Zero Gas mode by
entering the following keystrokes from the User Interface Panel:
a. From RUN mode, enter F6 • and then enter the CALibration mode
password “• •” (at the “PSWD0” prompt). Press Ent to enter CAL
mode.
b. Enter F5 2 to display the FlowCtrl (Flow Control) mode screen.

From this screen, you can view the current operating mode.
Record the numeric value displayed for FlowCtrl.
c. Force the analyzer to manually zero the sample system with Zero
Gas by keying in Del 10 Ent (10 = Continuous Zero).
Run the manual zero for 10 minutes at a flow rate of 2.5 L/min

(5 SCFH). For more information about setting the Zero Gas flow
rate, refer to “Adjusting the Zero Gas Flow Rate,” later in this
section.
d. Press Ent again to return to CAL mode normal screen.

3. Press F2 0 to initiate the Manual Zero. The User Interface Panel will
prompt “Man/Zero?”. Observe the readings on the bottom line of the
User Interface screen. When the readings have stabilized at or near
zero, press:
Ent for Yes The analyzer will count down from 15 seconds to
zero (Integration Timer duration) during which
time the readings are averaged. (The timer defaults
to 15 seconds if the Integration Timer is set to zero.)
The zero values will be adjusted automatically and
the screen will revert to CAL mode normal display.
Esc for No The function is aborted and the zero values are not
adjusted.
If the User Interface Panel displays a “w ZDrift/SpnErr” error mes-

sage, manually re-zero the analyzer again by pressing F2 0 Ent.
4. Record the analyzer’s initial Measure and Reference PMT signal

readings, as described under the section titled “Recording Initial
Readings,” later in this chapter.
5. Return the analyzer to Analyzer Control (automatic control) by enter-

ing F5 2 Del 0 Ent, where “0” = Analyzer Control mode.
6. Press Ent again to return to CAL mode normal screen and then Esc to
return to RUN mode.
The zero process is complete and the analyzer is now on-line.
7. Turn off the Zero Gas.

Adjusting the Zero Gas Flow Rate
When the flow control solenoid is in a de-energized state, instrument air
flows into the sample path via a flow controlling rotameter and a mani-
fold located within the Analyzer Oven. The flow rate of Zero Gas must
be high enough to adequately backpurge the Measuring Cell of sample
gas to obtain a “good zero”. A good zero can be defined as a state where
the concentration outputs of the analyzer are stable and further increases
in Zero Gas flow rate do not reduce the concentrations observed on the
analyzer User Interface Panel. To obtain a good zero gas flow rate, adjust
the rotameter for a flow rate of 5–7.5 L/min (10–15 SCFH).
Since excess air flow into the analyzer’s sample system will cool the
Measuring Cell and Analyzer Oven, the optimum Zero Gas flow rate is
the lowest consistent with a good zero.
During warm-up of the sample system or when the analyzer is in

Standby, a lower zero flow rate may be desired to avoid a cooling effect of
prolonged introduction of air into the sample system. All that is important
during these conditions is that the sample system is kept free of contami-
nation by the sample gas.
Set the response time first to ensure a good zero.


NOTE
Some applications may require a higher flow rate.

Adjusting the Sample Gas Flow Rate
The Aspirator Drive Air Regulator is used to control the sample gas flow
rate through the system. A good sample gas flow rate (3.0–5.0 L/min
(0.1–0.2 SCFM)) will ensure a measurement response time is approxi-
mately 30 seconds. To obtain a response time within this range, adjust the
Aspirator Air to the appropriate pressure in the range of 7–35 KPAG (1–5
PSIG).

CAUTION
The analyzer pressure – measured by the pressure transducer – may also

be used to set the sample flow rate. This is accomplished by first measur-
ing the stack duct pressure with no aspiration (Drive Air Isolation Valve
closed) and then adjusting the Aspirator Drive Air Regulator with the
Drive Air Isolation Valve open to obtain a pressure of 5–10 mmHg less
than the value obtained with the valve closed. To view the Measuring Cell
pressure (CellP), enter CFG mode and press F6 8 6.
Setting Sample Response Time
Sample response time may also be used as a parameter for setting the
Aspirator Air pressure. Response time is determined by switching the ana-
lyzer from Continuous Backpurge mode to Continuous Sample mode and
recording the time it takes the analyzer to display the first reading after
the switch to Continuous Sample mode.
To check the sample response time, view the RUN mode normal display
and observe the output concentration changes. If the sample response
time is adequate (first response after a Zero function is approximately
30 seconds), no further adjustment is necessary for a Sample Line of less
than 10 metres.
 The sample response time may vary, depending on Sample Line

length.
NOTE

Normal Operation
After the analyzer is set up and started, the analyzer ’s User Interface
Panel defaults to RUN mode. During normal operation in RUN mode, the
top line of the User Interface Panel displays the output parameter names,
while their corresponding values are displays on the bottom line. This is
referred to as the RUN mode normal display. The User Interface Panel is
updated once per second.
In RUN mode, parameters or variables can only be viewed, they cannot

be changed. Parameters or variables can be changed only under the CAL
or CFG modes. Passwords are required to enter CAL and CFG modes.
 To help you determine in the future if there are problems with your
analyzer, it is important to observe and record initial readings (when
NOTE
the analyzer sample system is clean) for the photomultiplier tube
(PMT) signal optical filters and the sample response time.
Recording Initial Readings

Before operating the analyzer, it is important to observe the analyzer to
understand what normal operating conditions are, and how to use this
information to help you determine problems with the analyzer.
AMETEK recommends that you observe and record this information

every month to obtain a history of the readings. From these recordings,
you will be able to determine if there are problems with the analyzer, such
as diminishing photomultiplier tube (PMT) signals, or increasing sample
response time. These problems typically indicate maintenance is required.
Keep the log book in a safe location until you need to review it for pat-
terns of diminishing PMT signals or a longer sample response time.
Recording PMT Signals
To check and record the initial PMT signal readings:
1. Manually zero the analyzer.
2. While the zero is in progress, observe the PMT signal readings.
To do this, view the Show Signals screen by pressing F6 1 from RUN

mode. The software defaults to Filter 1 (Measure filter). Record the
values for the Measure PMT and Reference PMT signals.

Press 2 to view the signals for Filter 2 (Reference filter). Record the
values for the Measure PMT and Reference PMT signals.
Press 3 to view the Baseline Measurement, which looks at Measure/

Reference PMT signals in an off-state.
3. Record these signals in a log book every month.
It is important to record these values during a manual Zero function

 to simulate the same conditions during the original recordings. If the
NOTE
values are recorded using the sample gas, the results may be skewed
because the composition of the gas can vary. All signals should return
to within 5 % of the values recorded the previous month.
Recording Initial Sample Response Time
The analyzer’s sample response time can be used for two functions. One
function is to help you set the sample gas flow rate (as discussed earlier in
this chapter, under “Setting Sample Response Time”). The other function
is to help you determine if the typical response time is increasing, which
may indicate a plug in the sample system.
Typically, a good response time is approximately 30 seconds (excluding

sample system) when the sample system is clean and operating at peak
efficiency (response time 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. Record the time it takes the
analyzer to display the first reading after the analyzer’s Flow Control
function switches from “zero” to “sample”.
 It is important to record the response time only after performing a

manual Zero function to simulate the same conditions during the
NOTE
original recordings.

3. If the sample response time is adequate (first reading after a Zero
function and after the analyzer’s Flow Control function switches from
“zero” to “sample” is approximately 3 seconds), no further adjustment
is necessary.
 The sample response time may vary, depending on Sample Line

length.
NOTE
4. Record these signals in a log book every month.
Analyzer Configuration
Completed Analyzer Configuration and EEPROM Data Sheets are
shipped with each analyzer. These configuration sheets list all of the
settings that have been made to the analyzer at the factory (to meet
customer requirements). These sheets are located in the “Supplemental
Information” section of this manual and in the Documentation Package
shipped with the analyzer.
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 in order to override the factory defaults.
If necessary, refer to the original Configuration and EEPROM Data Sheets

to revert the analyzer back to its original settings.

CONTROLLER / USER INTERFACE
The Controller / User Interface chapter contains information about the

following topics:
• User Interface Panel, entering commands to view screens, password

information, including how to change passwords.
• Keystroke combination Quick Reference Sheets listing keystroke com-

mands used to view and/or change information from the three soft-
ware operation modes.
• Functions of keypad keys and accessing them from the User Interface
Panel.
• Analyzer operating temperatures, alarm set points, and default pa-

rameter settings.
 Before working from the User Interface Panel, read the section titled
“Introduction to the User Interface Panel” which discusses keypad key
NOTE
functions.
This section also discusses how to enter the ConFiGuration (CFG)

and CALibration (CAL) mode, and how to quickly return to RUN
mode from anywhere in the software.
Pressing Ent after making changes (while working in CFG or CAL

 mode) will cause the configuration data to be saved in non-volatile
NOTE
memory – the old values will be lost.
If the configuration data are not saved, the previous configuration

data will be used following a system reset or power-up.
Controller / User Interface | 4-1

Introduction to the User Interface Panel
Figure 4-1.
User Interface Panel
Layout.
User Interface Components

The User Interface Panel is made up of two areas:
• The dot matrix display consists of two lines, each capable of displaying
up to 20 alphanumeric characters. The information displayed depends
on your current mode of operation.
- 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.
If the analyzer switches to Backpurge mode, the User Interface

Panel displays a “b” on the upper-left line.
If the analyzer detects an error by the built-in diagnostics system,

it displays S (a reverse-video S) on the top-right line. To view the
alarm that has been detected, press F5 4 (1..8) and/or F5 5 (1..7)
from RUN mode to view the current Host Controller board and/or
Microcontroller board status/error code conditions.

- The bottom line displays the results of the outputs.
Under normal operating conditions in RUN mode, the bottom

line continually displays the value of each output parameter being
monitored/controlled by the analyzer.
The error messages “NoData” and “CommFault” – both serious

system errors, derived from the Host Controller board – are the
only two alarm messages that are automatically displayed on the
bottom line when they are detected. When viewed from the Host
Controller Status (HStatus) screen (F5 4, from RUN mode), these
errors are displayed as “f RxData” and “f Comm Fault”.
Other information may also be displayed on the bottom line depend-

ing on the mode of operation or the keystroke command entered.
• The 21-key keypad allows you to view and/or input (change) infor-
mation from any of the three main modes of operation. The display
is updated once per second; therefore, the display of the result of a
keystroke sequence may be delayed for up to one second. The keypad
consists of the following keys:
Key Description
• The decimal (‘•’) key can be used to enter a decimal character, as part
of a command (used in conjunction with one of the Function keys), or as
part of a password.
– The minus (‘–’) key can be used as part of a negative number, as part
of a command (used in conjunction with one of the Function keys), or as
part of a password.
0–9 Numeric keys 0–9 are used to enter numerical data, as part of a
Function key command to activate a function whose value you wish to
view or change, or as part of a password.
1, F2, F3,
F
F4, F5, F6 The Function keys are used to access the various modes and functions
where you can view or change data or operating parameters.
Press one of these keys, in addition to the ‘•’ key, ‘–’ key, or one of the
numeric keys 0–9, to activate a function whose value you wish to view
or change.
From RUN / CFG mode, the ‘F6 0’ keystroke combination will return
the display to the normal display of the mode you are viewing.
Esc The Escape key allows you to discard any changes you make to
operating parameters, but only before they have been saved. The
Esc key also allows you to answer No to a prompt on the screen
(whenever ‘?’ appears following information), and to back out of certain
menus.
Del The Delete key is used to delete an existing value from memory when
you are changing an operating parameter.
Ent The Enter key allows you to save any changes you make to operating
parameters. The Ent key can also be used to answer Yes to a prompt
on the screen (whenever ‘?’ appears following information).

Flow Control Mode Indicators on the User Interface
Panel
When in RUN mode, the first character of the top row of the User
Interface Panel indicates the mode of gas flow (Flow Ctrl). The characters
that can be displayed are:
• If the character is blank, it indicates the analyzer is operating in auto-

matic Sample mode (Analyzer Control mode).
• b = Analyzer-selected (automatic) Backpurge Flow mode.
• B = User-selected (manual) Continuous Backpurge Flow mode.
• S = User-selected (manual) Continuous Sample Flow mode.
• C = User-selected (manual) Continuous Calibration Gas Flow
mode (Gas #1 or Gas #2).
• Z = User-selected (manual) Continuous Zero Gas Flow mode.
! Do not operate the analyzer in Continuous Sample mode for an

extended period of time before all of the temperature-controlled zones
WARNING
have stabilized at their set point temperature. Doing so may result in
the analyzer becoming plugged.
Entering Data Using Base Ten (10) Exponents

Data for certain fields can be entered using base ten (10) exponents. The
F5 key serves as the exponential operator (10n). For example, to enter the
numerical value for -1.3765 x 104, enter:
-1.3765 F5 4 Ent

Entering / Returning to RUN Mode – Quick Reference
When the analyzer is first powered up, the User Interface Panel defaults
to RUN mode. From this mode, you can view analyzer system data,
temperature set points, current operating values, or alarms (current or
historical). Information viewed from RUN mode cannot be changed while
working from this menu. This menu also contains certain data that is used
primarily for troubleshooting the analyzer. A password is required to
enter this mode.
Refer to the RUN / CFG Mode Quick Reference Sheet (Figure 4-2) for all
of the commands that make up the RUN mode. For detailed informa-
tion about working in RUN mode, refer to “Working in the RUN / CFG
Operating Modes,” later in this chapter.
Function commands with a range [e.g., HS (1..8)] indicate you can view or
change more than one parameter from that menu without having to re-
enter the Function key (for that function) each time. For example, to view
the Host Controller Status (HS) menu (press F5 4) and press any numeric
key (1..8) to view the status of a specific alarm. Then, press another nu-
meric key to view the status of another alarm, etc.
To view one of the menus in RUN mode:
1. From RUN mode, press the Function key and one of the other keys
(•, -, 1–9) for the menu you want to view.
Example:
To view the temperatures for each of the temperature-controlled zones
assigned to the Microcontroller board’s analog inputs, press F6 8. The
software will default to the first temperature-controlled zone, “s/lT1”
(Sample Line).
To view other analog input values, press its corresponding numerical

key 2..8. You do not have to press F6 8 again.
2. To view a different RUN mode menu, press the corresponding

Function key and one of the other keys. If the new menu has sub-
menus, press one of the numeric keys to view other related data.
To return to the RUN mode normal display from any menu in RUN
mode, press F6 0. To return to the RUN mode normal display from
anywhere in the software, repeatedly press Esc until RUN mode is
returned.

RUN / CFG Mode Quick Reference Sheet – Keystroke
Combinations
Figure 4-2 is a Quick Reference Sheet that lists each of the available key-
stroke combinations you can use to perform various tasks from RUN and
CFG modes. The RUN and CFG modes are almost identical. You can only
view information from RUN mode but you can change it from CFG mode
(a password is required to enter CFG mode).
For detailed descriptions of each keystroke combination, refer to “Defining

RUN / CFG Mode Keystroke Terms,” later in this chapter.
The differences between RUN and CFG mode are denoted by

 “(RUN)” and “(CFG)” under the Function key headings (Figure 4-2).
NOTE
The specific function (Term) for each mode is listed under “(RUN)”
and “(CFG)”. If “(RUN)” and “(CFG)” are absent, the function is the
same for both modes.
“–” indicates the keystroke combination is not used.
Key F1 F2 F3 F4 F5 F6
RUN CFG
RUN CFG AI:Msr HCHist
• — Auto-Setup
MB Addr —
(1..6) (1..9)
PSWD0 PSWD0?
(CAL) (CAL)
RUN CFG
PTPara Com Para AuxTAvg MCHist
– TCol PSWD1 PSWD1?
(1..4) (1..3) (1..3) (1..9)
(CFG) (CFG)
TStPt Normal Display
0 KFtr Cell — SN
(1..4) RUN/CFG
Ftr KVal Kp Sig
1 Temp Zones HC Ver
(1..2) (1..2) (1..4) (1..3)
LmpB Ti TR (Show Trn)
2 Samples — MC Ver
(1..2) (1..4) (1..2)
Td Show Res
3 LmpMax Delay — RTime
(1..4) (1..9)
TType HS e
4 PmtLvl — —
(1..4) (1..8) (Show MEmiss)
Adap TDuty MS o
5 PmtBal —
(1..2) (1..8) (1..7) (Show O2Cor)
Output CPRg
6 SigMax — — —
(1..4) (1..2)
STcf
7 Kq Alc — MDI —
(1..5)
AlcG DPRg LmpP Show MAIn
8 Ke —
(1..2) (1..2) (1..2) (1..8)
SetPt O2Para TCycle Show HAIn
9 Units —
(1..2) (1..3) (1..5) (1..8)
Figure 4-2.
RUN / CFG mode quick
reference sheet –
keystroke combinations.

Entering CFG Mode – Quick Reference
The ConFiGuration (CFG) mode contains information nearly identical to
that in the RUN mode menu but with a few exceptions. For instance, the
CFG mode menu also contains the Auto-Setup function, and allows you
to change the passwords required to enter CFG and CAL modes.
The major difference between CFG and RUN mode is that in CFG mode,
you can change (configure) certain information.
For detailed information about working in CFG mode, refer to “Working

in the RUN / CFG Operating Modes,” later in this chapter.
Example:
To change an existing temperature set point value for the Analyzer
Measuring Cell temperature-controlled zone:
1. From RUN mode, press F6 – . The message “PSWD1” appears.
2. Press • • (factory default password) or the new password, if changed.

An “*” is displayed for each character entered.
3. Press Ent to enter CFG mode. “CFG” will be displayed on the top line,
while the output results from RUN mode will continue to be dis-
played on the bottom line. This is the CFG mode normal display.
4. Press F4 0 4 to display the Measuring Cell set point temperature.

This menu defaults to parameter “1” (Sample Line).
5. Press Del to delete the existing value (default = 155.00 °C), and then
enter the new value (for example, “153.00”) at the “TStPt4?” prompt.
6. To save the change, press Ent and then Esc to back out of this menu.
At the “Save ConFig?” prompt, press Ent again to confirm the change.
To discard the changes, press Esc.
To return to CFG mode normal display from any menu in CFG mode,
press F6 0. To return to the RUN mode normal display from anywhere in
the software, repeatedly press Esc until RUN mode is returned.

Entering CAL Mode – Quick Reference
The CALibration (CAL) mode allows you to enter the variables required
to tailor the analyzer for a specific application and to calibrate the
instrument.
For detailed information about working in CAL mode, refer to “Working

in the CAL Operating Mode,” later in this chapter.
Function commands with a range [e.g., Scale (1..4)] indicate you can view
or change more than one parameter from that menu, without having to
re-enter the Function key (for that function) each time. For example, view
the Scale menu (press F5 1) and press 4 to view the full-scale range for
Output 4. Then, press any numeric key (1..4) to view the full-scale range
for another output, etc.
Example:
To change the analyzer’s Flow Control Mode to Continuous Backpurge:
1. From RUN mode, press F6 •. The message “PSWD0” appears.
2. Press • • (factory default password) or the enter the new password, if

changed. An “*” is displayed for each character entered.
3. Press Ent to enter CAL mode. “CAL” will be displayed on the top line,
played on the bottom line. This is CAL mode normal display.
4. Press F5 and then 2 to display the FlowCtrl (Flow Control mode)

screen. When you enter this menu, this function displays the current
setting (e.g., “0”, which indicates the analyzer is in Analyzer Control
mode).
5. Press Del to delete the current setting.
6. Press 1 to change the setting to Continuous Backpurge mode.
7. Press Ent to save the setting.
8. Press Esc to return to RUN mode. The screen will display “B” on the
upper-left line to indicate that the analyzer has been manually forced
to Continuous Backpurge mode.
To return to the RUN mode normal display from anywhere in the soft-
ware, repeatedly press Esc until RUN mode returns.

CAL Mode Quick Reference Sheet – Keystroke Combinations
Figure 4-3 is a Quick Reference Sheet that lists each of the available key-
stroke combinations from CAL mode. While working in CAL mode, the
information can be changed (a password is required to enter and work in
CAL mode).
For detailed descriptions of each keystroke combination, refer to “Defining

CAL Mode Keystroke Terms,” later in this chapter.
 “—” indicates the keystroke combination is not used.

NOTE
Key F1 F2 F3 F4 F5 F6
• — — — — — —
– — — — — — —
Izero
0 Auto/Zero? Man/Zero? Timer0 — —
(1..4)
Scale Ispan
1 Auto/Span1? Man/Span1? Timer1 Conc1
(1..4) (1..4)
ZCalDrift
2 Auto/Span2? Man/Span2? Timer2 Conc2 FlowCtrl
(1..2)
PrbT SCalDrift
3 — — — AdjDisable
(1..3) (1..2)
VTp O2CD
4 Vel/Zero? — — Sol:O2Z
(1..2) (1..2)
5 Vel/Span? — VTi — Sol:O2S O2ZVolt
To
6 Vel/BkPurge? — IntTime — O2SFactor
(1..2)
SFactor
7 PrbBlowBk? — SDelay DPSpn VelCtrl
(1..2)
O2 Conc
8 — Man/SpanO2? AZInt Temp DPZ
(1..2)
9 Auto/Cal? Man/ZeroO2? ACal Bw Pres DPSFactor
Figure 4-3.
CAL mode quick
reference sheet –
keystroke combinations.

About CFG / CAL Mode Passwords
Access to the CALibration (CAL) or ConFiGuration (CFG) mode is protect-
ed by a password. The passwords to enter and work in either mode can
be entered from RUN mode only.
The factory-default password is “• •” for both modes, but it can be

changed. AMETEK recommends that you change the passwords as soon
as you become familiar with the operation of the analyzer. A different
password should be used for each mode and access to CFG mode should
be limited to only trained technicians or electricians. Passwords, which are
limited to 9 characters, can be changed only from CFG mode.
If you enter the password incorrectly, the message “<INVALID>” will be

displayed on the User Interface Panel. Carefully re-enter the password.
The example below assumes that the factory-default password is valid.

Once the passwords have been changed, the appropriate new password
must be used to access CAL or CFG mode. Once you change the pass-
words for each mode, be sure to record and keep them in a safe place.
 Pressing Ent will cause the passwords to be saved in non-volatile

memory – the old passwords will be lost. If the passwords are not
NOTE
saved, the previous passwords will be used following a system reset or
power-up. This applies to the password for both CAL and CFG modes.
Changing the Password for CAL Mode
To change the password for CAL mode:
1. From RUN mode, press F6 – • • and press Ent to enter CFG mode.
Press F6 • (this is the command to change the CAL mode password).
The message “PSWD0?” appears.
2. Enter a new password (up to 9 characters). You cannot use the

Function keys as part of a password. Record the new password and
store it in a safe place.
3. Press Ent. The new password is entered and the message “PSWD0?”
appears again.
4. Enter the new password a second time and press Ent. Press Ent again
to return to CFG mode normal display.
If this password does not match the first entry of the new password,
the message “<UNCHANGED>” is displayed.

5. Press Esc The User Interface Panel will prompt you to accept the
changes (“Save Config ?”).
If Yes, press Ent to accept the new password. The display will exit CFG
mode and return to RUN mode.
If No, press Esc to discard the changes. The display will exit CFG
Changing the Password for CFG Mode
To change the password for CFG mode:
1. From RUN mode, press F6 – • • and press Ent to enter CFG mode.
Press F6 – (this is the command to change the CFG mode password).
The message “PSWD1?” appears.
2. Enter a new password (up to 9 characters). The Function keys cannot

be used as part of a password. Record the new password and store it
in a safe place.
3. Press Ent. The new password is entered and the message “PSWD1?”
appears again.
4. Enter the new password a second time and press Ent. Press Ent again
to return to CFG mode normal display. If this password does not
match the first entry of the new password, the message
“<UNCHANGED>” is displayed.
5. Press Esc. The User Interface Panel will prompt you to accept the
changes (“Save Config ?”).
If Yes, press Ent to accept the new password. The display will exit CFG
If No, press Esc to discard the changes. The display will exit CFG

Working in the RUN / CFG Operating Modes
The RUN and ConFiGuration (CFG) modes, with a few exceptions, con-
tain nearly identical information. RUN is the default and normal operat-
ing mode. No password is required to work from RUN mode. A password
is required to enter CFG mode, where you can make changes to factory-
default settings.
While Working in RUN Mode…

The RUN mode allows you to view the parameters or variables that have
been configured for your analyzer; they cannot be deleted or modified
from this mode. Changes to the parameters or variables that can be seen
in RUN mode must be done in CFG mode.
During normal operation in RUN mode, the top line of the User Interface
Panel screen displays the current status of the analyzer. For example, the
screen will display a character that indicates the specific Flow Control
Mode the analyzer is currently operating in (see “Flow Control (Sample)
Mode” later in this chapter for details). The top line also indicates if a fault
or warning alarm has been detected by the analyzer, by displaying S on
the upper-right line.
When entering keystrokes in RUN mode, the User Interface Panel will re-
turn to the RUN mode normal display under the following circumstances:
• If you press a Function key that is not valid for your system.
• If you press a numeric key that is not valid for your system.
• If a keystroke sequence is not completed within 10 seconds.
The parameters that can be viewed by pressing F6 1 through F6 9 are dis-
played on the bottom line. The 10-second time-out feature does not affect
these functions. The selected parameter is displayed and updated once
per second until another parameter or the RUN mode normal display is
selected.
To return to the RUN mode normal display from any menu in RUN mode,
press F6 0.

Examples of keystroke combinations that can be initiated in RUN mode
are listed below.
Press To
F5 0 View the analyzer serial number (SN).
F5 1 View the Host Controller board software version number (HC/909V).
F5 2 View the Microcontroller board software version number (MC900V).
F5 4 View the Host Controller board status error/code conditions (HS).
F5 5 View the Microcontroller board status error/code conditions (MS).
F2 0 View the total axial length (cm) of the gas space in the Measuring Cell,
displayed in cm.
While Working in ConFiGuration (CFG) Mode…

CFG mode is used to enter or change operation constants and configura-
tion data that can be seen in RUN mode. You can also change the two
factory-default passwords (for CAL and CFG modes) while working in
CFG mode. Do not change any functions that are not discussed in this sec-
tion without express written consent from AMETEK. The settings for your
analyzer have been configured at the factory to meet specified customer
requirements. Changing the factory-set configuration could cause the ana-
lyzer to operate incorrectly.
Access to CFG mode is protected by a password. The password may be

entered while working from RUN mode only. The factory-default pass-
word is “• •”. If you have changed the password, use the new password
to access CFG mode.
 Access to CFG mode should be restricted to trained technicians or

electricians.
NOTE
While working in CFG mode, all information associated with this mode
is displayed on the top line of the User Interface Panel screen, including
“CFG” to signify the current mode. The temperature values from the RUN
mode normal display will continue to be displayed on the bottom line.

To access CFG mode, do the following:
1. From RUN mode, press F6 –. The message “PSWD1” appears.

3. Press Ent to enter CFG mode. “CFG” will be displayed on the top line,
played on the bottom line. This is the CFG mode normal display.
When entering keystrokes in CFG mode, the display will return to CFG
mode normal display under the following conditions:
 While in CFG mode, the Cal Status Relay is turned On.

NOTE
Returning to RUN Mode From CFG Mode
To return to RUN mode, press Esc. If any changes have been made to
CFG mode menu settings, the message “SAVE CONFIG?” appears. Press
Ent to answer Yes and then press Esc again to return to RUN mode. Or,
press Esc to answer No. If no changes have been made, the software will
return immediately to RUN mode.
 Pressing Ent will cause the configuration data to be saved in non-

NOTE volatile memory – the old values will be lost.
If the configuration data are not saved, the previous configuration

data will be used following a system reset or power-up.

Defining RUN / CFG Mode Keystroke Terms
For the purpose of this guide, “Term” is defined as screen headings (abbre-
viated titles) or parameters that are displayed on the User Interface Panel.
The following pages list the various keystroke combinations available in
RUN and CFG modes, along with their terms and definitions of each. As
indicated earlier, RUN and CFG modes are almost identical; however,
remember that the information contained and viewed in RUN mode can
only be changed when working in CFG mode (a password is required).
The differences between RUN and CFG modes are denoted by “(RUN)”
and “(CFG)” under the Keystrokes heading in the following pages. Next
to the “(RUN)” and “(CFG)” identifiers are the specific function (Term) for
each mode, followed by a description of the function.
If the keystroke commands do not include “(RUN)” and “(CFG)”, the

functions are the same for both modes.
 Definitions preceded by ‘**’ in the RUN / CFG mode keystroke

descriptions are used primarily for diagnosing problems with the
NOTE
analyzer.
Only the keystroke combinations that are functional in RUN and CFG
modes are listed in the following pages.
Factory-default values (if applicable) for the analyzer have been indicated
for each keystroke. Please consult with your AMETEK representative or
the factory before changing any factory-default values.

RUN / CFG Mode – F1 Keystrokes
Note the differences for the F1 • keystroke in RUN and CFG modes. The
Auto-Setup function is not available in RUN mode.
Keystroke Term Definition
F1 • (RUN) Not Used —
F1 • (CFG) Auto-Setup The Auto-Setup function optimizes PMT gains and the source lamp currents. Always initiate
an Auto-Setup after any lamps, optical filters, or PMTs have been installed or replaced.
This function is available in CFG mode only.
F1 – PTParaz This temperature-controlled zone is used only with systems employing a heated external
probe with a dedicated temperature controller (controlled by analyzer). For these systems,
this menu item displays a variety of temperature control parameters, where ‘z’ = 1..4. The
parameters and their default values are:
1 = Probe Temperature signal low scale for 0 (zero) V

2 = Probe Temperature signal high scale for full-scale V
3 = Probe Temperature low alarm set point
4 = Probe Temperature high alarm set point
F1 0 KFtrz ** Position of the key filter which gives the weakest signal for a given source lamp current,
where ‘z’ is the filter being used (1..2).
1 = Measure Filter 1
2 = Reference Filter 2
F1 1 Ftrz ** The default source lamp pulse current-control signal (V) for each filter, where ‘z’ = 1..2.
The normal operating range is between 0.5 V and Lamp Max (6.0 V – may vary, check
EEPROM Data Sheets for actual value), with the control signal for the key filter being Lamp
Max.
1 = Measure Filter 1
2 = Reference Filter 2
F1 2 LmpBz ** The base-current set point (V) for each source lamp, which is the minimum operating cur-
rent, where ‘z’ = 1..2.
1 = Lamp 1 (closest to the Measuring Cell)

2 = Lamp 2 (farthest from the Measuring Cell)
Note: If your analyzer is configured to measure H2S, both lamps are Cadmium; if your
analyzer is configured to measure SO2, both lamps are Magnesium.
F1 3 LmpMax ** Voltage to which the lamp pulse current-control signal for the key filter location is set dur-
ing the Auto-Setup. The nominal value is 6.0 V (may vary, check EEPROM Data Sheets for
actual value).
F1 4 PmtLvl ** The photomultiplier tube (PMT) gain control signal (V), which is based on the signal from
the PMT when the key filter is in the light path. Normal values after a successful Auto-Setup
are from 4.0–7.0 VDC.
F1 5 PmtBal ** A secondary PMT control signal (V) which adjusts the PMT gain to equalize the PMT sig-
nals from the filters with the lowest and highest transmittances are in the light path. Normal
values after a successful Auto-Setup are from 4.0–7.0 VDC.
F1 6 SigMax ** The signal from the PMT with the highest gain is set to SigMax when each filter is in the
light path while the Auto-Setup is in progress. SigMax should be between 8.0 and 9.0 V
(check EEPROM Data Sheets for actual value).
F1 7 Kq The constant for the volume-flow-rate calculation based on stack duct data, stack duct
physical data, and units of measurement.
F1 8 Ke The units conversion constant for calculation of component mass flow (Mass/Amount).

F1 9 Units Units of measurement used for displaying 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 items.
Bit 4
Value Definition
16 0 = Remote Auto-CAL
16 = Remote Backpurge/Zero Flow
For example, if the analyzer is configured for Metric units, Normal concentration result in
PPM, Display 3 items, Remote Auto-CAL, the result would be:
Bit 0 + Bits 2,1 + Bit 3 + Bit 4 [0 + 0 + 8 + 0 = 8].
The unit for input and output parameters (Metric or Imperial) is set at the factory, and
should not be changed by the user (i.e., do not change from a Metric unit to an Imperial
unit). If a change is required, consult with your AMETEK representative, or contact the
factory.
The user can, however, change the concentration units freely back and forth between PPM
and mole percent (e.g., from Units = 0 to Units = 2, or from Units = 1 to Units = 3, or vice
versa).

F2 • MBAddr Modicon Modbus® slave address – can be any value between 0–255. 0 (zero) will disable
the Modbus® communication interface. For addresses 1–127, select the RS‑232 port; for
addresses 128–255 select the RS-422 port.
F2 – ComParaz n The communication setup parameters for the Baud Rate, Stop Bits, and Parity of the serial
communication port, where ‘z’ = 1..3 and where ‘n’ = 0..3.
n = 0..3 Baud Rate Stop Bits Parity

z = 1 z = 2 z=3
0 9600 Invalid None
1 4800 1 Odd
2 2400 1.5 None
3 1200 2 Even
Note: Any changes to the parameters must be saved to the EEPROM and the analyzer
must be reset to make the changes take effect.
To reset the analyzer, press the • and Ent keys simultaneously.
F2 0 Cell ** Axial length of the Measuring Cell gas space, displayed in cm.
F2 1 Temp Zones z The Temperature Zone code defines the number of temperature-controlled zones used by
the analyzer, where ‘z’ = the sum of the Temperature Zone code (0, 2, 4, 6, or 32) plus the
Standard Bench Type Code (24).
The typical displayed value is ‘28’ ((‘4’ = 3 temperature-controlled zones: 1, 2, 4) + (‘24’ =
Motorless Bench)). For systems with the manual Blow-Back function enabled, the displayed
value is ‘26’ ((‘2’ = 2 temperature-controlled zones: 1, 4) + (‘24’ = Motorless Bench)). For
more information, refer to “Probe Blow-Back Control” later in this chapter.
Note: To operate the Model 909 Analyzer with an extra temperature control zone, wire
the RTD input into the SKO terminals J105 5, 6 (AC voltage). For these systems,
the displayed value is ‘62’ ((‘6’ = 4 temperature-controlled zones: 1, 2, 3, 4) +
(‘24’ = Motorless Bench) + (‘32’ = Temperature zone 3 [reverse logic])). The extra
temperature zones are not available when the Isolation and Blow-back
functions are turned on.
The definition for each bit is:

0 = No temperature control
2 = 2 temperature-controlled zones (1, 4) – also used for Probe Blow-Back function
4 = 3 temperature-controlled zones (1, 2, 4)
6 = 4 temperature-controlled zones (1, 2, 3, 4)
32 = Temperature zone 3 (heating logic, heater plate)
The 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-control zones are:

Zone 1 = Sample Line
Zone 2 = Sample Conditioning Unit (SCU)
Zone 3 = TZone3 – Spare
Zone 4 = Oven Temperature
Probe Isolation Control (filter flood):

b6 Probe Style
0 = Non-EPA style Probe Isolation Control
64 = EPA style Probe Isolation Control (i.e., filter flood)

Standard Bench Type Code:
24 = Motorless Bench
Note: The Standard Bench Type Code lists the default Bench Type for the Model 909
Analyzer. Do not change the value without direction from your AMETEK repre-
sentative or from factory personnel.
F2 2 Samples ** Number of times the PMT signal is measured while a filter is completely within the light
path.
F2 3 Delay ** The time interval from when a filter becomes completely within the light path to the first
PMT-signal measurement. The interval is shown as multiples of 1.6 microseconds (µs).
F2 4 Not Used —
F2 5 Adapz Adaptive filtering parameters, where ‘z’ = 1..2.
1 = Relates to absorbance level.

2 = Relates to maximum filter time constant.
F2 6 Outputz The Output Signal Assignment (OSA) code for each of the four current outputs, where
‘z’ = 1..4. Allows the customer to define which of the calculated results (parameters) will be
available as output signals. These outputs are application-specific. Refer to “Output Signal
Assignment (OSA),” later in this chapter, for more information. The parameters are:
1 = Output1
2 = Output2
3 = Output3
4 = Output4
F2 7 Alc The Automatic Lamp Control Enable function displays the operational status of the
Automatic Lamp Control function. This parameter is automatically turned on by Auto-Setup,
and should be on during normal operation. However, this function should be turned off while
replacing PMTs or source lamps.
0 = Off
1 = On
Note: This manual does not describe procedures to replace the PMTs. Contact
AMETEK for instructions before attempting to replace the PMTs.
F2 8 AlcGz ** Automatic Lamp Control gain setting for each filter, where ‘z’ = 1..2.
1 = AlcG1
2 = AlcG2
F2 9 SetPz ** Signal (V) obtained from the Reference PMT for each filter after the Auto-Setup, where
‘z’ = 1..2. These values are updated automatically by Auto-Setup. The Automatic Lamp
Control function adjusts the lamp pulses to maintain the Reference PMT signals to these
values.
1 = SetPt1
2 = SetPt2

F3 • Not Used —
F3 – TCold The Measuring Cell temperature at which the analyzer’s Flow Control (Sample) Mode will
switch between Continuous Sample mode and Continuous Backpurge mode, providing
each remaining zone is within 5 % of its set point value. Entering ‘0’ results in the analyzer
using 5 % of the Measuring Cell temperature set point as the switch temperature.
F3 0 Not Used —
F3 1 KValz ** The molar absorptivity of the species of interest at the wavelengths used, where
‘z’ = 1..2.
1 = KVal1 (Measure filter)

2 = KVal2 (Reference filter)
F3 2 Not Used —
F3 3 Not Used —
F3 4 Not Used —
F3 5 Not Used —
F3 6 Not Used —
F3 7 Not Used —
F3 8 Not Used —
F3 9 Not Used —

F4 • AI:Msrz ** The Microcontroller or Host Controller channel number for the analog input signals,
where ‘z’ = 1..6. Setting the analog input signals to zero (‘0’) disables the function. Refer to
“Active Temperature and Pressure Compensation,” later in this chapter, for more informa-
tion about enabling/disabling these functions.
1 = O2 Measurement and Dilution Air Computation (optional)

Internal sensor (Zr733) AI:Msr1 = 24, or
External sensor (linear) AI:Msr1 = 34, or
Internal sensor (Zr734) AI:Msr1 = 44
2 = Measuring Cell Temperature

AI:Msr2 = 4
3 = Measuring Cell Pressure

AI:Msr3 = 6
4 = Stream Temperature
Current Input (MAI) AI:Msr4 = 7
Voltage Input (HAI) AI:Msr4 = 22
5 = Differential Pressure
AI:Msr5 = 21
6 = External Probe Temperature (optional)

AI:Msr6 = 8 (RTD Input), or
AI:Msr6 = 18 (Voltage Input)
F4 – AuxTAvgz ** External signal averaging time (seconds) for the auxiliary inputs, where ‘z’ = 1..3. The
averaging time can be set from 0–255 seconds. Setting this averaging time to zero (0) turns
this function off.
1 = Allows the O2 input signal to be filtered (optional).

2 = Allows the optional External Flow Rate or optional External Stream Temperature to
be filtered.
3 = Allows the Differential Pressure to be filtered.
F4 0 TStPtz ** The control set point for the four temperature-controlled zones, where ‘z’ = 1..4. If the set
point is zero, that zone is not used. The zones and their default values are:
1 = Sample Line (default = 150.00 °C)

2 = SCU (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-
controlled zone, where ‘z’ = 1..4. The parameters and their default values are:
1 = Sample Line (default = 10.00 %)

2 = SCU (default = 10.00 %)
3 = TZone3 – Spare (default = 10.00 %)
4 = Measuring Cell (default = 10.00 %)
F4 2 Tiz ** The Integral term of the PID temperature control algorithm for each temperature-con-
trolled zone, where ‘z’ = 1..4. The parameters and their default values are:
1 = Sample Line (default = 1000.00 seconds)

2 = SCU (default = 1000.00 seconds)
3 = TZone3 – Spare (default = 1500.00 seconds)
4 = Measuring Cell (default = 2500.00 seconds)
F4 3 Tdz ** The differential (Derivative) term of the PID temperature control algorithm for each
temperature-controlled zone, where ‘z’ = 1..4. The parameters and their default values are:
1 = Sample Line (default = 0 seconds)

2 = SCU (default = 0 seconds)
3 = TZone3 – Spare (default = 0 seconds)
4 = Measuring Cell (default = 0 seconds)

F4 4 TTypez n ** The type of temperature sensor used for each temperature-controlled zone, where ‘z’ =
Temperature Zones 1..4.
1 = Sample Line
2 = SCU
3 = TZone3 – Spare
4 = Measuring Cell
and where ‘n’ = 0..3 (default = 2 for each of these temperature-controlled zones):
0 = Not Used
1 = Not Used
2 = RTD for 300-4872 Rev. B board or 300-5769 board (assembly # 100-1096)
3 = Thermistor for 300-4872 Rev. B board or 300-5769 board (assembly # 100-1097)
F4 5 TDutyz Temperature duty cycles, where ‘z’ = 1..8.
‘z’ = 1..4
This is the default duty cycle (%) of each temperature-controlled zone during steady-state
operation at the set point. The zones and their starting (default) values are:
1 = Sample Line (default = 30 %)

2 = SCU (default = 30 %)
3 = TZone3 – Spare (default = 30 %)
4 = Oven (default = 30 %)
‘z’ = 5..8
This is the maximum duty cycle allowed for each temperature-controlled zone. The zones
and their default values are:
5 = Sample Line (default = 85 %)

6 = SCU (default = 85 %)
7 = TZone3 – Spare (default = 85 %)
8 = Oven (default = 85 %)
F4 6 CPRgz ** The Measuring Cell pressure transducer low and high value (mmHg or "Hg) correspond-
ing to 0.0 VDC and 5.0 VDC respectively, where ‘z’ = 1..2.
1 = Low value (0.0 VDC)

2 = High value (5.0 VDC)
F4 7 STcfz The coefficients to linearize the reading from the stack duct temperature transducer, where
‘z’ = 1..5. The values are factory-set and must not be changed.
1 = Low Value (default = 0.0)

2 = High Value (default = 50.00)
3 = Not used
4 = Not used
5 = Not used
F4 8 DPRgz The stack duct differential pressure transducer low and high value (mmH2O or "H2O) cor-
responding to 0.0 VDC and 5.0 VDC, where ‘z’ = 1..2.
1 = Stack duct low differential pressure.

2 = Stack duct full-scale differential pressure.
F4 9 O2Paraz Zirconia Oxygen Sensor (O2 Sensor) parameters, where ‘z’ = 1..3. (For use with General
Purpose applications/analyzers only.)
1 = The specified O2 concentration to which the measured

SO2 concentration is corrected.
2 = The concentration corresponding to zero voltage output
(0.25 percent) of the O2 Sensor.
3 = The concentration corresponding to the full-scale voltage output
(25 percent) of the O2 Sensor.

F5 • HCHistz n History buffer for the last nine non-zero Host Controller board status codes where
‘z’ = 1..9, with ‘1’ being the oldest and ‘9’ being the most recent, and where ‘n’ = the sum
value of status code.
F5 – MCHistz n History buffer for the last nine non-zero Microcontroller board status codes where
‘z’ = 1..9, with ‘1’ being the oldest and ‘9’ being the most recent, and where ‘n’ = the sum
value of status code.
F5 0 SN The analyzer serial number.
F5 1 HC909Ae V The Host Controller board software version number.
F5 2 MC900e V The Microcontroller board software version number.
F5 3 RTime Total run time of the analyzer since the last reset or system power-up. The format is: Days
Hours:Minutes (### ##:##)
F5 4 HSz The possible Host Controller board status/error code conditions (HStatus), where ‘z’ =
1..8. For each ‘z’, the appropriate Error Message is displayed if the error condition exists. If
the error condition does not exist, the message “HSz OK” appears.
Refer to the “Maintenance & Troubleshooting” chapter for descriptions of these error condi-
tions and corrective action to take.
The possible error 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)
8 = w Tmp3 High (Warning) – optional
F5 5 MSz The possible Microcontroller board status/error code conditions (MStatus), where ‘z’ =
1..7. For each ‘z’, the appropriate Error Message is displayed if the error condition exists. If
the error condition does not exist, the message “MSz OK” appears.
Refer to the “Maintenance & Troubleshooting” chapter for descriptions of these error condi-
tions and corrective action to take.
The possible error conditions and their descriptions include:
1 = f Pulse Timing (Fault)

2 = f On-board ADC (Fault)
3 = f On-chip ADC (Fault)
4 = w PMT Signals (Warning)
5 = f Comm Error (Fault)
6 = w Lamp Control (Warning)
7 = f Oven Heater (Fault)
F5 6 Not Used —

F5 7 MDI ab The Microcontroller Board’s Digital Input status code, where ‘a’ and ‘b’ are the status of
the inputs. The analyzer has two external digital inputs that are designed to accept a dry
(potential free) contact closure. Input 1 is reserved for future use. Input 2 is for remote start
of the Auto-Zero (Calibration) or remote start of the Backpurge (optional).
a (Input 1) = Reserved for internal use.
b (Input 2) = Remote Start of Auto-Zero (Calibration)

0 (external contact is open – normal analyzer operation)
1 (external contact is closed – Auto-Zero is initiated after 5-second delay)
or
Remote Start of Backpurge

0 (external contact is open – 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..2.
1 = Lamp 1
2 = Lamp 2
F5 9 TCyclez Current temperature control duty cycle (%) for each temperature-controlled zone, where
‘z’ = 1..5.
1 = slCycle – Sample Line (default = 0 %)

2 = scuCycle – Sample Conditioning Unit (default = 0 %)
3 = tmp3Cycle – Spare (default = 0 %)
4 = celCycle – Measuring Cell (default = 100 %)
5 = htrCycle – Heater Plate, Oven (default = 100 %)

Note the differences for the F6 •, F6 –, and F6 0 keystrokes in RUN

 and CFG modes.
NOTE
F6 • (RUN) PSWD0 (CAL) This is the CAL mode entry password prompt, seen only after you press ‘F6 •’ from RUN
mode. From RUN mode, enter these keystrokes to enter and work in CAL mode. The
factory-default password is • •.
F6 • (CFG) PSWD0? This is the CAL mode change password prompt, seen only after you press ‘F6 •’ from
CFG mode. While working in CFG mode, these keystrokes will call up the “PSWD0?”
prompt, which will allow you to change the CAL mode entry password.
The new password can be up to nine characters. The Function keys cannot be used as part
of the password. The new password must be entered twice before it is accepted.
F6 – (RUN) PSWD1 (CFG) This is the CFG mode entry password prompt, seen only after you press ‘F6 –’ from
RUN mode. From RUN mode, enter these keystrokes to enter and work in CFG mode. The
factory-default password is • •.
F6 – (CFG) PSWD1? This is the CFG mode change password prompt, seen only after you press ‘F6 –’ from
CFG mode. While working in CFG mode, these keystrokes will call up the “PSWD1?”
prompt, which will allow you to change the CFG mode entry password.
The new password can be up to nine characters. The Function keys cannot be used as part
of the password. The new password must be entered twice before it is accepted.
F6 0 (RUN) Normal Display This keystroke combination returns the RUN mode normal display from anywhere in the
software. (Note that ‘Normal Display’ is not displayed on the screen.)
While in RUN mode, the name of the calculated result or parameter is displayed on the top
line; its value is displayed on the bottom line.
F6 0 (CFG) Normal Display This keystroke combination returns the CFG mode normal display. (Note that ‘Normal
Display’ is not displayed on the screen.)
The data associated with this mode are displayed on the top line of the User Interface
Panel. The output values from RUN mode continue to be displayed on the bottom line.
F6 1 Sigz Displays the Measure and Reference PMT signal for each filter, where ‘z’ = 1..3. The signals are
displayed on the bottom line of the User Interface Panel (the Measure PMT signal is on the left;
the Reference PMT signal is on the right). Normal values are in the range of 5.0–9.84 VDC.
1 = Filter1 (Measure filter) – Measure PMT/Reference PMT signals
2 = Filter2 (Reference filter) – Measure PMT/Reference PMT signals
3 = Baseline Measurement (looks at Measure/Reference PMTs in an off-state)
F6 2 TR z (Show Trn) ** Displays the transmittance (Show Transmittance) for the filter. The transmittance is
shown on the bottom line of the User Interface Panel, where ‘z’ = 1..2.
1 = Filter1 (Measure filter)
2 = Filter2 (Reference filter)
F6 3 Show Resz The Show Results menu displays the calculated result of the signal used, where ‘z’
(z = 1..9) is the numeric code assigned to the result. (Note that ‘Show Res’ is not dis-
played.) The name of the result and its value will be displayed and updated at one-second
intervals until either another result is selected or ‘F6 0’ is pressed to return to the RUN
mode normal display.
1 = [Signal displayed here – application-specific (e.g., SO2)]
2 = n/a (Not Used)
3 = n/a (Not Used)
4 = n/a (Not Used)
5 = n/a (Not Used)
6 = n/a (Not Used)
7 = n/a (Not Used)
8 = Flow
9 = O2 (optional)

F6 4 e The Show MEmiss menu displays the mass emission rate of a species (e.g., concentration
of species-A times mass emission factor (Ke) for species-A.
F6 5 o The Show O2Cor menu displays the O2 corrected concentrations of SO2 (optional), (e.g.,
SO2 ##).
F6 6 Not Used —
F6 7 Not Used —
F6 8 z Show MAIz The Show Microcontroller Board’s Analog Inputs (MAI) function allows you to view the
analog input values. (Note that the actual MAI description (e.g., ‘s/lT1’) is displayed on
the screen, not “Show MAI”.) To return to the RUN mode normal display, press ‘F6 0’.
To view the operating temperature for each of the temperature-control zones or for the
Heater Plate, press the key associated to that parameter.
To view the Stack Stream Temperature, press ‘6’ while viewing this screen.
To view the status of the Over-Temperature relay (OT, either normal or tripped), press ‘5’
while viewing this screen.
MAI (z) Message Zone
1 s/lT °C Sample Line
2 scuT °C SCU
3 Tmp °C Spare
4 CellT °C Measuring Cell
5 OT normal Sample Line,

or SCU,
OT tripped Oven
6 StrT °C Stack Stream Temperature

or
CellP mmHg Measuring Cell
7 HtrT °C Oven Heater
8 MAI8 °C Reserved for

(optional) External Probe Temperature
For MAI 6 (CellP), the pressure signal is displayed in mmHg (or "Hg) when active
pressure compensation is enabled; when active pressure compensation is not
enabled, the signal is displayed in volts.
F6 9 z Show HAI z The Show Host Controller Board’s Analog Inputs (HAI) function allows you to view the
analog input values (voltages or scaled parameters, where ‘z’ = 1..8). (Note that the actual
HAI description is displayed on the screen, not “Show HAI” but “HAI” is displayed if
the input is Reserved.) To return to the RUN mode normal display, press ‘F6 0’.
HAI (z) Message Zone
1 DiffP mmHg (or "Hg) Differential Pressure

(optional)
2 StrT °C Stack Stream Temperature

(voltage option)
3 HAI3 Reserved
4 O2 Internal O2 Concentration (Zr733)

(optional) or
External O2 Concentration
or
Internal O2 Concentration (Zr734)
5..8 HAI5..HAI8 Reserved

Configuring the Analyzer Control Functions
Output Signal Assignment (OSA)

A number of results (or parameters) are calculated by the analyzer. Each
result can assume one of two output types:
• Instantaneous
An instantaneous output tracks the analyzer response during an Auto-
Zero or Auto-Span sequence.
• Track-and-Hold
A track-and-hold output records the concentration value that was
calculated just before an Auto-Zero/Auto-Span was initiated. It re-
tains this value for the duration of the Auto-Zero/Auto-Span and the
Sample Delay Time.
The parameter can be assigned to any of the four output channels. The
assignment is made by displaying the output number and assigning a nu-
meric code that corresponds to the result. Figure 4-4 defines the calculated
result codes. An undefined result code will default to a primary code, us-
ing the last digit that was entered. For example, a code of 83 will default to
a primary code of 3.
CODE
Instantaneous Track-and-Hold
Primary Mass O2 Primary Mass O2
Definition Results Flow Rate Corrected Results Flow Rate Corrected
Output Not Used 0 0 0 0 0 0
Low Range so2 1 11 21 51 61 —
concentration
(* see Note)
High Range SO2 2 12 22 52 62 —
concentration
(* see Note)
Not Used 2–7 — — — — —
Flow Rate 8 — — — — —
O2 (Optional) 9 — — 59 — —
* Note: Species displayed (so2, SO2) is determined by species being measured.
Figure 4-4.
Calculated Result
(Parameter) Codes.
The codes in Figure 4-4 assign the result to both the User Interface
 Panel and analog outputs. To assign a result to the analog output
NOTE
only, add 100 to the codes.

A calculated result (parameter) can be assigned to more than one output.
For example, the SO2 concentration can be assigned to both Channel 1
and Channel 2.
Example 1:
To assign the track-and-hold SO2 signal to analog Output 1 and the User
Interface Panel and return to CFG mode normal display, key in:
F2 6 1 Del 51 Ent Ent
Example 2:
To assign the SO2 concentration to analog Output 1 and the User Interface
Panel and return to CFG mode normal display, key in:
Analog Input Channels
There are eight (8) system analog input channels on the Micro-Interface
board. These analog inputs can be viewed on the User Interface Panel by
pressing F6 8 1..8 from RUN mode. The jumper positions are listed in the
following pages (under “Display I/O Board Analog Input Signals” and
“Micro-Interface Analog Input (MAI) Signals”) so they can be restored by
the user if they should become dislodged (during transit, for example).
! The analog input channels are configured at the factory – the analyzer
will not operate properly if the jumpers or inputs are changed from
CAUTION
the factory settings.
 The position of the jumper on the header is referenced by “Top,”

“Middle,” and “Bottom.” “Top” always refers to the position nearest
NOTE
the jumper header label on the board.

Display I/O Board Analog Input Signals
The Display I/O board inputs are labeled 1 to 4 and each has three jump-
er-selectable ranges: 0–1 V, 0–5 V, and 0–10 V.
The ranges are marked on the board beside each jumper position (see
Figure 4-5). The jumper headers and their positions are described below.
Display I/O Board Jumper Positions
Input Channel Jumper Header Jumper Position Range (VDC)
1 JP200 Middle 0–5

(pitot tube differential pressure)

(stack duct temperature)
Purgable version only

(Reserved)
4 JP203 Top 0–1

(internal O2 concentration
or optional external O2 concentration)
Figure 4-5.
Display I/O board.

Micro-Interface Board Analog Input (MAI) Signals
The Micro-Interface board inputs are labeled 5 to 8 and each has three
jumper-selectable ranges: 0–1 V, 0–5 V, and 0–10 V.
The ranges are not marked on the board. The jumper headers (on the
Micro-Interface board) and their positions are described below (see also
Figure 4-6).
Micro-Interface Board Jumper Positions
Input Channel Jumper Header Jumper Position Range (VDC)
5 P100 Bottom 0–10
6 P101 Middle 0–5

(cell pressure)
7 P102 Middle 0–5

(heater temperature)
8 P103 Middle 0–5
Display Process Operating Temperature:

The stack duct temperature is assigned to the Micro-Interface analog
input 7. The temperature for this zone is displayed by pressing F6 8 7.
Display Measuring Cell Pressure:

The Measuring Cell operating pressure is assigned to Micro-Interface
analog input number 6 and is displayed by pressing F6 8 6. The pressure
signal is displayed in mmHg ("Hg) when active pressure compensation is
enabled. When active pressure compensation is not enabled, the signal is
displayed in volts.
Figure 4-6.
Micro-Interface board.

Host Controller Board Analog Input (HAI) Signals
The Host Controller analog input voltages can be displayed by pressing

F6 9 z, where z is the analog input number (z = 1..8). The parameter as-
signed to the input and the signal level (volts or scaled parameter units) is
displayed.
Display Process Stream Temperature (Voltage Input):

The stream temperature for a voltage input is assigned to the Host
Controller analog input 2. The temperature for this zone is displayed by
pressing F6 9 2.
Display Differential Pressure:

The differential pressure is assigned to Host Controller analog input 1
and is displayed by pressing F6 9 1. The pressure signal is displayed in
mmH2O ("H2O).
Calculated Results
The results, or parameters, calculated by the analyzer depend on the

software option installed. Any result can be displayed by pressing F6 3 z
where z (z = 1..9) is the numeric code assigned to the result. The name
of the result and its value will be displayed and updated at one-second
intervals until either another result is selected or F6 0 is pressed to return
to RUN mode normal display. Mass flow rate parameters can be viewed
by pressing F6 4 z (z = 1..9).

Active Temperature and Pressure Compensation
There are two ways to compensate for Measuring Cell temperature and
pressure variations. The first is to use default (constant) temperature
and pressure values. The second is to assign the measured pressure and/
or temperature signals to analog input channels on the Microcontroller
board. This setup is done from CFG mode.
Because the compensation functions are enabled and disabled individu-

ally, one or both of the measured values (temperature/pressure) can be
used.
If only active temperature compensation is enabled, the default

Measuring Cell pressure signal will be used for calculation of the results. If
only active pressure compensation is enabled, the default Measuring Cell
temperature signal will be used for calculation of the results.
Analog Input Channel Numbers
Analog Input Signal Must Be Assigned To

To Measure AI:Msr 1..6 (F4 ·) Analog Input Channel
O2 Measurement and dilution air computation 1 24

(optional)
Measuring Cell Temperature 2 4
Measuring Cell Pressure 3 6
Measuring Cell Temperature Compensation
To enable active temperature compensation and return to CFG mode nor-

mal display, key in:
F4 • 2 Del 4 Ent Ent
To disable active temperature compensation and return to CFG mode

normal display, key in:
Measuring Cell Pressure Compensation
To enable active pressure compensation and return to CFG mode normal

display, key in:
To disable active pressure compensation and return to CFG mode normal

display, key in:

Mass Flow Rate
The mass flow rate (F6 4) function calculates the volume flow rate of the
process stream and the mass flow rate of measured components in the
process stream. The volume flow rate and mass flow rate can be calcu-
lated using any system of units (such as the Imperial system or Système
Internationale). The component concentration, volume flow rate, and
mass flow rate can be shown simultaneously on the User Interface Panel.
Refer to Appendix C – Conversion Factors and Calculations for explana-
tion of the equations and calculations.
Entering Differential Pressure Transducer Range
The software reads a voltage which represents the differential pressure

measured in the stack. The high-scale value (5 volts) and the low-scale
value (0 volts) of the differential pressure transducer must be entered to
provide a reference point so the software can convert the voltage reading
to engineering units. Either mmH2O or "H2O can be used, depending on
the units selected during initial setup.
The following examples describe keystroke combinations to enter the full-

scale range of the stack duct differential pressure transducer.
Example 1:
To enter a value of 0 mmH2O for the stack duct low differential pressure
(DPRg1) and return to CFG mode, key in:
Example 2:
To enter a value of 25.4 mmH2O for the high differential pressure (DPRg2)
and return to RUN mode normal display, key in:
F4 8 2 Del 25.4 Ent Esc

Entering Temperature Transmitter Coefficients
One of two temperature transducers can be used: current output or volt-
age output. The current output temperature transducer used to measure
the process stream temperature is not linear. Polynomial coefficients are
used in a matrix to linearize the temperature transducer output. The volt-
age temperature transducer is linear and only the first two coefficients are
used; the others must be zero. The coefficients are entered at the factory
and are listed in the EEPROM Data Sheets, located in the “Supplemental
Information” section of this manual or in the Documentation Package
! The coefficients are supplied for reference only and should be changed
only upon direct instruction from the factory.
CAUTION
! Access to CFG mode should be restricted to trained technicians.

CAUTION
The temperature-transmitter coefficients have been calculated at the
factory.
Changing the factory-set configuration could cause the analyzer to

operate incorrectly.
If it becomes necessary, the coefficients can be changed.
Example:
To set coefficient 2 (STcf2) to -7.2156 and return to CAL mode normal
display, key in:
F4 7 2 Del -7.2156 Ent Ent

Calculation Constants
The volume flow rate calculation constant (KQ) and the mass flow rate
calculation constant (KE) depend on the process stream composition, the
specified component, process stream duct dimensions, and units of mea-
surement for the various factors. These constants are specific to a given
application.

CAUTION
Pressing Ent will cause the new values for KQ and KE to be saved as
 part of the configuration data, in non-volatile memory; the old values
NOTE
will be lost.
If the new values are not saved into the configuration, they will be
used temporarily until they are changed or until the next power up or
manual reset. After a power up or reset, the previous values (stored in
non-volatile memory) will again come into effect.
Entering KQ
Example:
To enter a value of KQ = 1200 and return to CFG mode normal display,
key in:
F1 7 Del 1200 Ent Ent
Entering KE
Example:
To enter a value of KE = KMMw = 0.369 for the component and return to
CFG mode normal display, key in:
F1 8 Del 0.369 Ent Ent

Stream Temperature and Differential Pressure
The measured process stream temperature and the measured pitot tube
differential pressure (DP) are two of the parameters used to calculate the
mass flow results.
To enable the measured stream temperature and differential pressure for

calculating the results, the Host Controller analog input (HAI) channel
number for the stream temperature (voltage input) and differential pres-
sure signals must be assigned to the algorithm.
To enable the measured stream temperature only for calculating the

results, the Microcontroller analog input (MAI) channel number for
the stream temperature (current input) signal must be assigned to the
algorithm.
Stream Temperature (Voltage Input – HAI)
To enable stream temperature measurement and return to CFG mode

To disable the stream temperature measurement and return to CFG mode

Entering Stream Temperature AuxTAvg (T90)
Example:
To enter an AuxTAvg (T90) averaging time of 2 seconds for the stream
temperature signal and return to CFG mode normal display, key in:
F4 – 2 Del 2 Ent Ent

Differential Pressure
To enable pitot tube Differential Pressure measurement and return to CFG

mode normal display, key in:
To disable Differential Pressure measurement and return to CFG mode

Entering Differential Pressure AuxTAvg (T90 Average)
Example:
To enter an AuxTAvg (T90) averaging time of 2 seconds for the Differential
Pressure signal and return to CFG mode normal display, key in:
F4 – 3 Del 2 Ent Ent
Stream Temperature (Current Input – MAI)
To enable Stream Temperature measurement and return to CFG mode

To disable Stream Temperature measurement and return to CFG mode


Velocimeter and Emissions Calibration
The analyzer’s Velocimeter is located on the inside right panel of the
Electronics Enclosure. The differential pressure (DP) Cell requires
±15 VDC excitation voltage and outputs 0–5 VDC. Calibration of a DP
Cell output is performed by entering the measured zero, span, and full-
scale values for the output channel. These values are used to scale the
output to the correct values.
 The Velocimeter has been calibrated at the factory and will be re-
calibrated upon initial installation at the site. This section includes
NOTE
procedures to perform a re-calibration as required.
Testing equipment required to calibrate the Velocimeter, temperature

transducer, and emissions includes:
• Multimeter.
• Properly scaled manometer.
• Analyzer EEPROM Data Sheets (shipped with the analyzer, or located

in the Supplemental Information section of this manual).
• DP Cell instructions and layout.
• Thermocouple calibrator.

DP Cell Initial Set-up
Default Configuration
Before application-specific calibrations are performed, some initial settings

are required. The following are the recommended factory defaults.
! Application-specific conditions might require non-standard settings. If

this is the case, do not replace these settings with the factory defaults.
CAUTION
Use the following procedure to verify and/or modify the settings. See
“Customizing Velocimeter Backpurge and AuxTAvg (T90) Settings,”
later in this chapter, for guidelines on determining new settings.
To set up the DP Cell for calibration:
1. The pitot tube differential pressure analog input 5 (AI:Msr5) must be

assigned to analog input channel 21. Verify this setting is correct by
keying in F4 • 5 from CFG mode.
If it is correct, proceed to the next step. If not, key in Del 21 Ent Ent
and proceed to the next step.
2. Verify that the AuxTAvg (T90) averaging time for the differential pres-
sure is 2 seconds by keying in F4 – 3 from CFG mode.
If it is correct, proceed to the next step. If not, continue by keying in

Del 2 Ent Ent and proceed to the next step.
3. Verify that the duration of the pitot tube backpurge (VTp1) is 60 sec-
onds by keying in F3 4 from CAL mode.

Del 60 Ent Ent and proceed to the next step.
4. Verify that the time interval between pitot tube backpurge (VTi) se-
quences is 10 minutes by keying in F3 5 from CAL mode.

the Del 10 Ent Ent and proceed to the next step.
5. Verify the differential pressure value to which the transducer is spanned

(DPSpn). This value is listed in the Analyzer EEPROM Data Sheets
shipped with the analyzer. To check this, key in F4 7 from CAL mode.
If it is correct, press Ent to clear the User Interface Panel display for the
next operation. If not, key in Del ## Ent Ent to complete the setup
(where ‘##’ is the value listed on the Analyzer EEPROM Data Sheets).

DP Zero and Span
To calibrate the DP Cell:
1. Set the Velocimeter flow control mode (VelCtrl) to Analyzer Control

(automatic). From CAL mode key in F6 7 Del 0 Ent Ent.
2. Set the differential pressure transducer span factor (DPSFactor) to 1.

From CAL mode key in F6 9 Del 1 Ent Ent.
3. Connect a manometer to the positive calibration port of the

Velocimeter and apply zero calibration pressure (no pressure) to the
positive calibration port. From CAL mode press F1 4 (Vel/Zero?) Ent to
manually zero the differential pressure output.
4. Increase the calibration pressure applied to the positive calibration

port until the manometer indicates a pressure equal to the span pres-
sure shown on the Analyzer EEPROM Data Sheets (shipped with
the analyzer). (Use the same pressure as used in Step 5 of “Default
Configuration,” earlier in this chapter.) Manually span the differential
pressure output. From CAL mode key in F1 5 (Vel/Span?).
5. From CAL mode, press F6 9 to display the differential pressure span

factor (DPSFactor).
The DPSFactor should be between 0.75 and 1.25 if the calibration was
performed correctly. If the DPSFactor is not within this range, correct
any malfunction and then repeat Steps 2–4 until an acceptable calibra-
tion is completed.
6. Disconnect the manometer from the positive calibration port.
7. Press Esc to return to RUN mode.

Temperature Transmitter
The temperature transmitter (Stack Thermocouple Module is located on

the terminal rail of the backpan in the lower portion of the Electronics
Enclosure (see drawing “Electronics Enclosure Layout, GP Analyzers” in
Appendix D). The voltage temperature transducer is linear and only the
first two coefficients are used; the others must be zero. The coefficients
are entered at the factory and are listed in the Analyzer EEPROM Data
Sheets (shipped with the analyzer).

CAUTION
The temperature-transmitter coefficients have been calculated at the
factory.

It may be necessary to change the temperature-transmitter coefficients for

calibration (STcf). To do this:
1. From CFG mode key in F4 7 1 to view coefficient 1 (Low Value, STcf1).

The default value should be set to ‘0.0’. If it is correct, check coefficient
2. If it is not, change it to ‘0.0’ by keying in Del 0 Ent Ent.
Key in F4 7 2 to view coefficient 2 (High Value, STcf2). The default

value should be set to ‘50.0’. If it is correct, proceed with the next step.
If it is not, change it to ‘50.0’ by keying in Del 50 Ent Ent.
2. To measure the process stream temperature analog input 4 (AI:Msr4 )

must be assigned to analog input channel 22. To do this key in
F4 • 4 Del 22 Ent Ent.
3. Set the AuxTAvg (T90) averaging time for the stream temperature to 2
seconds. To do this key in F4 – 2 Del 2 Ent Ent.
4. Disconnect the thermocouple leads from terminals 1 and 3 on the

Stack Thermocouple Module and connect the voltage output leads
from the temperature calibrator to these terminals, observing the po-
larity indicated. Refer to drawing “Signal Wiring, GP/Div 2/CE/Zone 1
Analyzers (WX-102815)” in Appendix D.
Configure the calibrator and adjust the output temperature to the

expected stack operating temperature.

5. Display the Stream Temperature value by pressing F6 9 2 from RUN
mode. If the temperature indicated on the temperature calibrator
doesn’t quite match the display readout, perform an adjustment.
The following adjustment example is for a 0 °C to 750 °C temperature

transmitter.
a. Set the calibrator to 0 °C and observe the offset in temperature by

pressing F6 9 2 from RUN mode.
b. From CFG mode, enter the numerical value from Step 5-a in STcf1
by keying in F4 7 1 Del nnn Ent, where nnn is the numerical value
from Step 5-a.
Example:
The calibrator temperature is 0.0 °C and the temperature transduc-
er temperature is 6 °C. STcf1 equals the offset of 6.
c. Adjust the calibrator to a nominal operating temperature (for ex-

ample, 677 °C).
d. Make adjustments to STcf2 with the formula:
calibrator value
STcf 2 = x 150
temperature transmitter readout
Example:
The nominal operating temperature (calibrator value) is 677 and
the temperature transducer readout is 680,
677
STcf 2 = x 150
680
STcf2 = 149.33

Flow & Emission Output Calibration
The following procedure uses the active SO2, DP, and Temperature signals
as parameters for verifying the calculated outputs of process gas volume
flow and mass emissions. Steps 1–4 assume these results have been as-
signed to these analog output channels.
Perform the verification calculations using a calculator and the formulas

provided in the Analyzer EEPROM Data Sheets (shipped with the ana-
lyzer). Compare the results to the analyzer calculated outputs. A variance
between the calculated outputs generated by manual calculation and the
analyzer outputs indicates a configuration problem or a malfunction.
Verify the full-scale range for each of the four outputs. To do this, enter
CAL mode and:
1. Key in F5 1 1 to display the full-scale SO2 concentration (Scale1).
If it is correct, proceed to the next step. If not, key in Del nnn Ent Ent
(where nnn is the new full-scale SO2 concentration) and proceed to
the next step.
2. Key in F5 1 2 to display the full-scale Process Gas Volume Flow

(Scale2).
(where nnn is the new full-scale Process Gas Volume Flow) and pro-
ceed to the next step.
3. Key in F5 1 3 to display the full-scale Mass Emission (Scale3).
(where nnn is the new full-scale Mass Emission) and proceed to the
next step.
4. Key in F5 1 4 to display Output 4 (Scale4).
This output is not used in the standard configuration of the Model

909 Analyzer as an SO2 analyzer and the full-scale must be set to ‘0’. If
this output is used as an application-specific output, the full-scale can
be verified and changed following the procedure stated for the other
three outputs (Steps 1–3).

5. Return to RUN mode by pressing Esc.
From RUN mode press F6 9 1 to display the current Differential

Pressure value. Record this value.
Press F6 9 2 and record the current Stream Temperature.
Press F6 0 and record the values for SO2, Stack Volume Flow, and
Emissions.
6. Refer to the EEPROM Data Sheets and calculate the Process Gas
Volume Flow rate Q using the Differential Pressure and Stream
Temperature readings (from Step 5) and the KQ factor from the
EEPROM Data Sheets.
DP
Q = KQ
T
7. Using the calculated Process Gas Volume Flow rate Q and the SO2
reading (from Step 5) and the KE factor from the EEPROM Data
Sheets (shipped with the analyzer), calculate the emission (E) rate.
E = K E SO 2 Q
8. Compare these calculated values to the displayed values recorded

in Step 5. Because active parameters are used, small changes may
have occurred during the time taken to display and record the values
and these small changes can result in minor differences between the
analyzer calculated values and the manually calculated values. If large
differences occur, they will be the result of:
• Incorrect configuration of one or more of the variables involved.
• A software or hardware malfunction.
• KQ and KE factors entered are different than those on the Analyzer

EEPROM Data Sheets (shipped with the analyzer).

Customizing Velocimeter Backpurge and AuxTAvg (T90)
Settings
Application-specific conditions may require backpurge interval, back-

purge duration, or AuxTAvg (T90) signal averaging times different from
the factory defaults to maximize performance and reliability of the
Velocimeter.
Backpurge Interval
This is the time interval between pitot tube backpurge sequences. This
interval can be set from 0–255 minutes. Setting the interval to zero (0)
turns this function off. The factory default is 10 minutes. This function is
labelled VTi and is accessed from CAL mode by pressing F3 5.
Backpurge Duration
This is the duration of the pitot tube backpurge event. Backpurge air is
supplied to the pitot tubes for this duration. The air supply is then turned
off for 25 % of this time to allow pressure equalization in the pitot tubes
and connecting lines. This duration can be set from 0–255 seconds. Setting
this interval to zero turns this function off. The factory default for the
backpurge duration is 60 seconds. This function is labelled VTp and is ac-
cessed from CAL mode by pressing F3 4.
AuxTAvg (T90) Averaging Time for the Differential Pressure Signal
This is the averaging time applied to the Differential Pressure (DP) signal
and it is used to filter out the small fluctuations in the measured pressure
that result from turbulence in the process gas flow. As the AuxTAvg (T90)
time is increased, the sensitivity to changes in DP is decreased since the
DP signal is averaged over a longer time period. The averaging time can
be set from 0–255 seconds. Setting this averaging time to zero (0) turns
this function off. This function is labelled AuxTAvg and is accessed from
CFG mode by pressing F4 – 3.
These parameters are interrelated in the following way:
When a backpurge cycle is initiated, the solenoids switch the DP Cell

pressure inputs to the positive and negative calibrate ports (which are
normally left open to atmosphere) and the pitot lines are connected to the
backpurge air supply 5 seconds later.

The flow rate (Q) output is held at the last value prior to the start of the
backpurge cycle. When the backpurge duration time elapses, the back-
purge air is turned off and the solenoids remain in the backpurge position
for an additional 25 % of the set backpurge duration time. This allows any
residual backpurge pressure in the pitot lines to vent and allows the pres-
sure in the pitot lines to equilibrate to the actual sensed DP levels.
The solenoids then switch back to connect the DP Cell pressure inputs to
the pitot lines. The Q output signal will be held for an additional period
of two times (multiplied by) the set AuxTAvg (T90) averaging time. This
extra hold time prevents the DP Cell zero output, which is produced dur-
ing the backpurge cycle, from influencing the averaged on line DP output.
The Q output is held for a total time per backpurge cycle as follows:
Hold time total = 5 seconds + (Backpurge Duration) + (25 % of

Backpurge duration) + (2 x AuxTAvg)
The backpurge interval time must be greater than the total hold time for
the DP signal to track the actual DP from the pitot tubes.
Example:
Using the factory defaults:
Backpurge interval, 10 minutes (600 seconds)
Backpurge duration, 60 seconds
AuxTAvg, 2 seconds
Out of every 10 minute cycle the Q output will be held for 60 seconds +
(0.25 x 60) seconds + (2 x 2) seconds + 5 seconds = 84 seconds total
In this case the Q signal is held for 84 seconds and then tracks the actual
process Q for 516 seconds (8 minutes and 36 seconds) out of each 10‑min-
ute cycle.

Working in the CAL Operating Mode
The CALibration (CAL) mode is used to enter the variables required to tai-
lor the analyzer for a specific application and to calibrate the instrument.
While working in CAL mode, any function or result associated with this
mode is displayed on the top line of the User Interface Panel. The output
values from the normal display of RUN mode continue to be displayed on
the bottom line.
Access to CAL mode is protected by a password. The password may be

entered only while working from RUN mode. The factory-default pass-
word is “• •”. If you have changed the password, use the new password
to access CAL mode.
To access CAL mode, do the following:
1. From RUN mode, press F6 • . The message “PSWD0” appears.

3. Press Ent to enter CAL mode. “CAL” will be displayed on the top line,
played on the bottom line. This is the CAL mode normal display.
When entering keystrokes in CAL mode, the User Interface Panel will
return to CAL mode normal display under these conditions:
 Changes made while in CAL mode are saved in the non-volatile

memory only when Esc is pressed to return to RUN mode.
NOTE

Defining CAL Mode Keystroke Terms
For the purpose of this guide, “Term” is defined as screen headings (titles)
or parameters that are displayed on the User Interface Panel screen. The
following pages list the various keystroke combinations available in CAL
mode, along with their terms and definitions of each. Information con-
tained in CAL mode can be changed only when working in CAL mode (a
password is required).
 Definitions preceded by “**” in the CAL mode keystroke descriptions

are used primarily for diagnosing problems with the analyzer.
NOTE
 The Zero and Span results for automatic or manual calibrations

can be affected by the status of the Calibration Adjustment Disable
NOTE
(AdjDisable) function. For more information about this func-
tion, refer to the F5 3 keystroke description under “CAL Mode – F5
Keystrokes” later in this chapter.

CAL Mode – F1 Keystrokes
F1 • Not Used —
F1 – Not Used —
F1 0 Auto/Zero? The Auto Zero function allows you to initialize the analyzer to automatically introduce Zero
Gas into the sample system. The Zero Gas solenoid is turned on and off automatically dur-
ing the sequence.
The zero offset is adjusted based on the average reading during the last 25 percent of the
Timer0 countdown only if AdjDisable is set to ‘0’.
F1 y Auto/Spany? The Auto-Span function allows you to initialize the analyzer to automatically introduce
Calibration Gas into the sample system, where ‘y’ = 1..2:
1 = Auto/Span1? (F1 1) – Used in applications with Low Range SO2 and optional
O2 Sensor (General Purpose applications).
2 = Auto/Span2? (F1 2) – Used in applications with High Range SO2 and optional
Only the Span function for ‘y’ is performed. The Calibration Gas solenoid valve connected
to SSR output ‘y’ is turned on and off automatically during the 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 when AdjDisable is set to ‘0’.
F5 4 (Sol:O2Z) and F5 5 (Sol:O2S) define which AutoSpan to use for O2 Zero and O2
Span.
F1 3 Not Used —
F1 4 Vel/Zero? Permits the user to manually zero the differential pressure (DP) cell. The readings are
based on the average reading during the last 5 seconds of the command.
F1 5 Vel/Span? Permits the user to manually span the differential pressure (DP) cell. The readings are
based on the average reading during the last 5 seconds of the command.
F1 6 Vel/BkPurge? Permits manual backpurging of the pitot tubes. Press Ent to initiate a manual backpurge of
the pitot tubes.
F1 7 PrbBlow Bk? The manual Probe Blow-Back function is used on systems using a stack sample probe with
a blow-back function. When you press F1 7 from this menu, the prompt “PrbBlow Bk?”
is displayed. Press Ent to initiate a manual probe blow-back. The manual blow-back se-
quence, which uses the automatic Probe Blow-Back Timer settings, will be performed once
and then revert to the automatic settings (see CAL : F3 3 for descriptions of timers).
F1 8 Not Used —
F1 9 Auto/Cal? The Auto-Calibration function allows you to initialize the analyzer to automatically cycle
sequentially through the Auto-Zero and Auto-Span functions. Only the functions with timers
set to non-zero durations are included.
The zero offset and calibration will be automatically adjusted only if AdjDisable is set to ‘0’.

F2 • Not Used —
F2 – Not Used —
F2 0 Man/Zero? Permits the user to manually zero the analyzer. The analyzer zero is automatically adjusted
based on the average reading during the IntTime duration after a Yes response only if
AdjDisable is set to ‘0’. The Zero Gas must be introduced manually into the analyzer
sample system. Refer to “Manually Zeroing the Analyzer” in Chapter 3 for details about how
to perform a manual zero on the analyzer.
F2 y Man/Spany? Permits the user to manually span the analyzer, either Low Range (so2) or High Range
(SO2), where ‘y’ = F2 1 or F2 2 (see below). The analyzer calibration is automatically
adjusted based on the average reading during the Integration Time (IntTime) duration
after a Yes response only if AdjDisable is set to ‘0’. The Calibration (Span) Gas must be
introduced manually into the analyzer sample system using the FlowCtrl function. Refer to
“Manual Span,” later in this chapter, for details about how to perform a manual span on the
analyzer.
F2 1 = Man/Span1? (so2)
F2 2 = Man/Span2? (SO2)
F2 3 Not Used —
F2 4 Not Used —
F2 5 Not Used —
F2 6 Not Used —
F2 7 Not Used —
F2 8 Man/SpanO2? Permits the user to manually span the O2 Sensor (if used, for use in General Purpose ap-
plications/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 Zero Gas. The Calibration (Span) Gas must be introduced manually into the ana-
lyzer sample system. Refer to “O2 Manual Zero/Span” in Appendix A for details about how
to perform a manual Span O2 on the analyzer.
F2 9 Man/ZeroO2? Permits the user to manually zero (air point calibration) the O2 Sensor (if used, for use in
General Purpose applications/analyzers only) at the analyzer. The sensor zero is auto-
matically adjusted based on the average reading during the IntTime duration after a Yes
response only if AdjDisable is set to ‘0’. Man/Zero must be used to calibrate the sensor
if Nitrogen is used for the Zero Gas. The Zero Gas must be introduced manually into the
analyzer sample system. Refer to “O2 Manual Zero/Span” in Appendix A for details about
how to perform a manual Zero O2 on the analyzer.

F3 • Not Used —
F3 – Not Used —
F3 y Timery Sets the length of time the solenoid valve (controlling a Zero or Calibration Gas) connected
to SSR output ‘y’ is energized during the Auto-Zero, Auto-Span, and Auto-Calibration func-
tions, where ‘y’ = 0..2.
0 = Timer0 (F3 0)
1 = Timer1 (F3 1) – Used in applications with Low Range so2 and optional
2 = Timer2 (F3 2) – Used in applications with High Range SO2 and optional
Timer0 is the zero solenoid timer, while Timer1 and Timer2 are the Calibration Gas
mixture solenoid timers. The duration can be set from 0–255 minutes in one-minute incre-
ments. Setting the duration to ‘0’ turns the specific timer off.
F3 3 PrbTz The Probe Blow-Back Timers allow you to set up the blow-back feature for systems using
a stack sample probe with a blow-back function (optional), where ‘z’ = 1..3. These settings
are used by the automatic and manual Probe Blow-Back function.
1 = PrbT1 = The Probe Blow-Back Interval parameter allows you to enter the interval-
time between blow-backs, in minutes (maximum value = 999). When an interval-time
is entered, it is displayed along with a countdown timer (time remaining until the next
blow-back).
2 = PrbT2 = The Probe Blow-Back Duration parameter allows you to enter the duration
(in seconds) of each blow-back.
3 = PrbT3 = The Probe Blow-Back Pulse Width parameter allows you to enter the dura-
tion (in seconds) the analyzer will allow the blow-back system to build up pressure
between pulses (air bursts, which blow back debris into the stack).
F3 4 VTpz The duration of the pitot tube backpurge and the delay following the backpurge in which the
system will wait before resuming operation, where ‘z’ = 1..2. The duration may be set from
0–255 in one-second increments. Setting the duration to ‘0’ turns the function off:
1 = Velocimeter backpurge duration.
2 = Velocimeter backpurge delay (set between 0–120 seconds, depending on Sample
Line length).
F3 5 VTi The time interval between pitot tube backpurge sequences. This parameter can be set from
0–255 minutes in one-minute intervals. Setting the value to ‘0’ turns the function off.
This function also includes a timer that displays the time remaining until the next backpurge
(mmm:ss).
F3 6 IntTime Sets the time period (seconds) over which the reading for each of the manual Zero/Span
functions is averaged. Setting this interval to ‘0’ turns the function off.
F3 7 SDelay Sets the time delay (minutes) for the CAL relay to continue indicating that a calibration is in
progress after completion of the calibration function. This permits a smooth transition from
the Zero/Span Gas back to the sample gas. The delay can be set from 0–255 minutes in
one-minute increments. Setting the delay to ‘0’ turns the function off.
F3 8 AZInt Sets the time interval (hours) between Auto-Zero sequences. This permits Auto-Zero to be
performed more frequently than Auto-Calibration. The interval can be set from 0–999 hours
in one-hour increments. Setting this interval to ‘0’ turns the function off.
The Auto-Zero function will be included in the Auto-Calibration sequence if Auto-Zero is
enabled and Timer0 duration is not zero.
Also used to view the time remaining until the next Auto-Zero (hours and minutes).
F3 9 ACal The Auto-Calibration Interval setting sets the time interval (hours) between Auto-
Calibrations. The interval can be set from 0–999 hours in one-hour increments. Setting the
interval to ‘0’ turns the function off.
Also used to view the time remaining until the next timed Auto-Calibration (hours and
minutes).

F4 • Not Used —
F4 – Not Used —
F4 0 Not Used —
F4 y Concy The concentration of the component y (ppm or %) in the Calibration Gas mixture, either
Low Range (so2) or High Range (SO2), where ‘y’ = F4 1 or F4 2 (see below).
The concentration is entered in decimal notation. 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 = CalConc1 (so2)
F4 2 = CalConc2 (SO2)
F4 3 Not Used —
F4 4 Not Used —
F4 5 Not Used —
F4 6 Not Used —
F4 7 DPSpn The differential pressure span value (mmH2O or “H2O) to which the differential pressure
transducer is spanned.
F4 8 O2Concz The concentration of O2 (%) in the Calibration Gas mixture. The concentration is entered in
decimal notation. The maximum concentration which can be entered is 999 999, where ‘z’ =
1..2.
1 = O2 concentration for span point Calibration Gas.

2 = O2 concentration for air point Calibration Gas (typically 20.95 %).
F4 9 Bw Used in applications where the emission rate is calculated using a fuel factor. Bw is the
water content in the air used in the combustion process.

F5 • Not Used —
F5 – Not Used —
F5 0 Not Used —
F5 1 Scalez The full-scale range for each of the four outputs. If an output is not used, its full-scale range
should be set to zero, where ‘z’ = 1..4. For example, if Scale 1 = 1000 ppm, output 1 would
read 20 mA at 1000 ppm and 4 mA at 0 ppm. These outputs are application-specific.
1 = Scale1
2 = Scale2
3 = Scale3
4 = Scale4
F5 2 FlowCtrlz The analyzer system Sample Flow Control Mode, where ‘z’ = 0..2, 10..12, 100..102, or
110..112.
The following codes apply to sample systems using an Aspirator to transport the sample
gas:
0 = Analyzer Control Mode (automatic control by the analyzer)

1 = Continuous Backpurge Mode (manually set by the user)
2 = Continuous Sample Mode (manually set by the user)
10 = Continuous Zero Gas Flow Mode (manually set by the user) – probe tip
11 = Continuous Calibration Gas #1 Flow Mode (manually set by the user) – probe tip
12 = Continuous Calibration Gas #2 Flow Mode (manually set by the user) – probe tip
The following codes apply to sample systems using a Sample Block Valve:
100 = Analyzer Control Mode (automatic control by the analyzer)
101 = Continuous Sample Block-Off Mode (manually set by the user)
102 = Continuous Sample Mode (manually set by the user)
110 = Continuous Zero Gas Flow Mode (manually set by the user) – local
111 = Continuous Calibration Gas #1 Flow Mode (manually set by the user) – local
112 = Continuous Calibration Gas #2 Flow Mode (manually set by the user) – local
F5 3 AdjDisablez The Calibration Adjustment Disable function can be set to allow (or prevent) automatic ad-
justment of the analyzer Zero offset transmittances and Span factors for all Zero and Span
operating modes (automatic or manual calibration), where ‘z’ = ‘0’ or ‘1’.
To allow automatic adjustments of the analyzer Zero offset and calibration, set this function
to ‘0’.
To prevent automatic adjustments of the analyzer Zero offset and calibration, set this func-
tion to ‘1’.
F5 4 Sol:O2Z Assigns a solenoid to the O2 Zero Gas. The software confirms the assignment during an
Auto-Calibration action.
If N2 is used as Zero Gas, then the assigned solenoid value entered must be ‘10’ (pseudo-
solenoid) to prevent inadvertent Auto-Calibration.
F5 5 Sol:O2S Assigns a solenoid to the O2 Span Gas. The software confirms the assignment during an
Auto-Calibration action.
If the Span Gas is attached to Solenoid 2, for example, the O2 Sensor is span calibrated
when Auto-Span is initiated by itself or as part of the Auto-Calibration sequence. (The O2
Sensor is optional, and is for use in General Purpose applications/analyzers only.)
If N2 is used as Span Gas, then the assigned solenoid value entered must be ‘11’ (pseudo-
solenoid) to prevent inadvertent Auto-Calibration.

F5 6 T0z ** The measuring wavelength transmittance value with Zero Gas for each filter, where
‘z’ = 1..2. Adjusted automatically whenever the analyzer is Zeroed if AdjDisable is set to ‘0’.
1 = Filter 1
2 = Filter 2
F5 7 SFactorz The span (calibration) factor for the calculated result (component concentration), either Low
Range (so2) or High Range (SO2), where ‘z’ = 1..2 (see below). Adjusted automatically
whenever the analyzer is Spanned if AdjDisable is set to ‘0’.
1 = SFactor1 (so2)
2 = SFactor2 (SO2)
F5 8 Temp The default temperature for the Measuring Cell (°C or °F). This value is used in place of the
measured Measuring Cell temperature when active temperature compensation is disabled.
Default = 140 °C.
F5 9 Pres The default absolute pressure for the Measuring Cell (mmHg or "Hg). This value is used
in place of the measured Measuring Cell pressure when active pressure compensation is
disabled. Default = 760.00 mmHg.

F6 • Not Used —
F6 – Not Used —
F6 0 IZeroz The measured current (mA) in the current output loop when the output is set to zero scale
during the Zero calibration procedure, where ‘z’ = Output Channels 1..4. Refer to the Output
Signal Assignment code for the outputs assigned to these channels (press F2 6 from CFG
mode). The actual mA value is displayed next to the corresponding output channel when 4
mA (Zero function) is activated.
1 = Output Channel 1
F6 1 z ISpanz The measured full-scale current (mA) in the current output loop when output is set to full-
scale during the Span calibration procedure, where ‘z’ = Output Channels 1..4. Refer to
the Output Signal Assignment code for the outputs assigned to these channels (press F2 6
from CFG mode). The actual mA value is displayed next to the corresponding output chan-
nel when 20 mA (Span function) is activated.
F6 2 ZCalDriftz After an Auto-Cal, Auto-Zero, or Manual Zero the Zero Cal Drift factor of the calculated
result since the last Zero Calibration, either Low Range (so2) or High Range (SO2), is re-
corded here, where ‘z’ = 1..2 (see below). The drift results are displayed in PPM or %. The
Zero Cal Drift is determined only when AdjDisable is set to ‘0’.
1 = ZCD1 (so2)
2 = ZCD2 (SO2)
F6 3 SCalDriftz After an Auto-Cal, Auto-Span, or Manual Span the Span Cal Drift factor of the calculated
result since the last Span Calibration, either Low Range (so2) or High Range (SO2), is
recorded here, where ‘z’ = 1..2 (see below). The drift result is displayed in PPM or %. The
Span Cal Drift is determined only when AdjDisable is set to ‘0’.
1 = SCD1 (so2)
2 = SCD2 (SO2)
F6 4 O2CDz The O2 Cal Drift is used only when AdjDisable is set to ‘0’, where ‘z’ = 1..2. After an Auto-
Cal, the O2 signal drift of the calculated result since the last Auto-Cal is recorded here. The
signal drift result is displayed in ppm.
1 = O2CD 1 (O2 Zero)

2 = O2CD 2 (O2 Span)
F6 5 O2ZVolt The O2 Sensor voltage output offset at zero (air point). It is determined by the software
when zero calibration of the O2 Sensor is performed. (The O2 Sensor is optional, and is for
use in General Purpose applications/analyzers only.)
F6 6 O2SFactor The O2 Sensor span factor. It is determined by the software when span calibration of the
O2 Sensor is performed. (The O2 Sensor is optional, and is for use in General Purpose
applications/analyzers only.)
F6 7 VelCtrl Velocimeter flow control mode.
0 = Analyzer Control (automatic)

1 = Continuous Backpurge
F6 8 DPZ The differential pressure transducer zero offset value.
F6 9 DPSFactor The differential pressure transducer span factor.

Setting Up Analyzer Calibration Functions
This section describes the various functions and controls available while
working from CAL mode.
Flow Control (Sample) Modes
The Flow Control mode determines the state of the sample gas flow. It can
be controlled automatically by the analyzer (Analyzer Control mode) or
forced to any of the manual modes by the user. Each mode is described in
detail in the following pages.
Depending on the method used to transport the sample gas (Aspirator or

Sample Block Valve), the codes will vary.
While viewing the Flow Control mode (CAL mode menu) from the User
Interface Panel, the screen will display a code (e.g., 0 = Analyzer Control
mode) that indicates a the current operating mode:
FlowCtrl Definition/Flow Control Mode

Code Gas Transport (set automatically by analyzer or Indicating Character
(CAL F5 2) Method manually by user) on User Interface Panel
0 Aspirator Analyzer Control (automatic) blank = Sample (by analyzer)

b = Backpurge (by analyzer)
1 Aspirator Continuous Backpurge (manual) B (* See Note)
2 Aspirator Continuous Sample (manual) S
10 Aspirator Continuous Zero Gas Flow – probe tip (manual) Z
11 Aspirator Continuous Calibration Gas #1 Flow – probe tip (manual) C
12 Aspirator Continuous Calibration Gas #2 Flow – probe tip (manual) C
100 Sample Block Valve Analyzer Control (automatic) blank = Sample (by analyzer)
b = Backpurge (by analyzer)
101 Sample Block Valve Continuous Sample Block-Off (manual) B (* See Note)
102 Sample Block Valve
Continuous Calibration Gas #1 Flow – local (manual) C
112 Sample Block Valve Continuous Calibration Gas #2 Flow – local (manual) C
 * The ‘B’ character is also displayed when the Remote Backpurge

function (optional) is activated by the user via a remote dry (potential
NOTE
free) contact opening.

Analyzer Control Mode (Automatic Control by the Analyzer)
When the analyzer’s Flow Control Mode is set to Analyzer Control, the
analyzer automatically determines and sets the mode of operation by
monitoring the state of the Fault alarm relay contacts. If there is no Fault
alarm, the analyzer will operate in automatic Continuous Sample. When
in Continuous Sample mode, there is no indicating character on the User
Interface Panel.
If the analyzer detects a Fault alarm while it is operating in Analyzer

Control mode (automatic sample), it will automatically switch to
Continuous Backpurge. When errors are detected, a reverse-video S ( S )
is displayed on the upper-right line of the User Interface Panel. When the
analyzer automatically switches its Flow Control mode to Backpurge, the
User Interface Panel displays a “b” on the upper-left line (as opposed to a
“B”, which indicates a manual Backpurge).
The analyzer will not switch back to Continuous Sample mode until the
Fault alarm has been corrected (cleared).
Because a low temperature is defined as a fault, the analyzer will switch to

Continuous Backpurge for the length of time required for all temperature-
controlled zones to stabilize at their set points.
To set the analyzer’s Flow Control to Analyzer Control and return to CAL
mode normal display, key in from CAL mode:
F5 2 Del 0 Ent Ent
Continuous Backpurge Mode (Manual Control by the User)
When the analyzer’s Flow Control Mode is set to Continuous Backpurge,

the analyzer is zeroed with instrument air. It will not automatically switch
to Continuous Sample mode.
When you force the analyzer into Continuous Backpurge, a “B” will be
displayed on the upper-left line of the User Interface Panel to indicate a
manual backpurge (as opposed to a “b”, which indicates an analyzer-con-
trolled – or automatic – backpurge).
To manually force the analyzer to zero the sample system, use the keypad
on the User Interface Panel to key in from CAL mode:
F5 2 Del 1 Ent Ent

Continuous Sample Mode (Manual Control by the User)
When the analyzer’s Flow Control Mode is set to Continuous Sample,

a sample is continuously extracted from the stack duct and passed
through the analyzer sample system; it will not automatically switch to
Continuous Backpurge mode.
When the user has forced the analyzer into Continuous Sample, “S” will
be displayed on the upper-left line of the User Interface Panel to indicate
the analyzer has been manually set to sample continuously.
To manually force the analyzer to continuously sample from the stack

duct, use the keypad on the User Interface Panel to key in from CAL
mode:
F5 2 Del 2 Ent Ent
! Operating the analyzer in Continuous Sample mode for an extended

period of time before all of the temperature-controlled zones have sta-
CAUTION
bilized at their set point temperatures, could result in plugging of the
sample system and/or the analyzer.
Continuous Zero Gas Flow Mode (Manual Control by the User)
When the analyzer’s Flow Control Mode is set to Continuous Zero Gas
Flow, the analyzer is zeroed with Zero Gas. It will not automatically
switch to Continuous Backpurge mode.
When you force the analyzer into Continuous Zero Gas Flow, “Z” will be
displayed on the upper-left line of the User Interface Panel to indicate the
analyzer has been manually set to zero the analyzer sample system with
Zero Gas.
To manually force the analyzer to zero the sample system with Zero Gas,
use the keypad on the User Interface Panel to key in from CAL mode:
F5 2 Del 10 Ent Ent

Continuous Calibration Gas Flow Mode (Manual Control by the User)
When the analyzer’s Flow Control Mode is set to Continuous Calibration

Gas Flow, the analyzer sample system is purged with Calibration Gas 1
or Calibration Gas 2. It will not automatically switch to Continuous
Backpurge mode.
When you force the analyzer into Continuous Calibration Gas Flow (Gas 1
or Gas 2), “C” will be displayed on the upper-left line of the User Interface
Panel to indicate the analyzer has been manually set to purge the analyzer
sample system with calibration gas.
To manually force the analyzer to Continuous Calibration Gas #1 and

return to CAL mode normal display, key in:
F5 2 Del 11 Ent Ent
To manually force the analyzer to Continuous Calibration Gas #2 and

return to CAL mode normal display, key in from CAL mode:
F5 2 Del 12 Ent Ent

Velocimeter Flow Control
The operating mode for the Velocimeter can be controlled by the analyzer
(automatic) or, forced to backpurge by the user:
Analyzer Control
When operating in the Analyzer Control mode, the Velocimeter is
backpurged at the time interval specified by the Velocimeter timer
(VTi, F3 5 from CAL mode).
To set the Velocimeter control mode to automatic and return to CAL

F6 7 Del 0 Ent Ent
Backpurge
When operating in the Backpurge mode, the Velocimeter is purged
with instrument air to clear the pitot tubes or to perform a Zero/Span
calibration.
To set the Velocimeter control mode to Backpurge and return to CAL

F6 7 Del 1 Ent Ent
Entering Calibration Gas Concentration
You must enter the concentration of the component you are using in
the calibration gas mixture before initiating a calibration sequence. The
concentration can be expressed in ppm (v/v) or percent (%), depending
on the units selected. The maximum value allowed is 999 999; fractional
values are entered using normal decimal notation (e.g., 1.495).
! If a calibration gas is not used, the concentration must be set to zero.

CAUTION
Example:
To enter a value of 1.495 % for the component and return to CAL mode
normal display, key in from CAL mode:
F4 1 Del 1.495 Ent Ent

Setting Calibration Gas Timers
There are three independent timers used for automatic calibration of the
analyzer. Each establishes the time period (duration) for which a solenoid
valve controlling the calibration gas mixture is energized during the Auto-
Zero, Auto-Span, and Auto-Calibration sequences. The timer duration
depends on the time required for the calibration gas mixture to reach the
analyzer and to obtain a stable reading.
Timer0 establishes the length of time the analyzer Zero Gas solenoid
valve is turned on during the Auto-Zero sequence. Timer1 and Timer2
establish the lengths of time (duration) that calibration gas mixtures are
turned on during the Auto-Span 1 and Auto-Span 2 sequence.
 Timer 1 and its associated span function (Auto-Span 1) are used in

applications with low range SO2 and optional O2 Sensor (General
NOTE
Purpose applications).
Timer 2 and its associated span function (Auto-Span 2) are used in

applications with high range SO2 and optional O2 Sensor (General
F5 4 (Sol:O2Z) and F5 5 (Sol:O2S) define which AutoSpan to use for

O2 Zero and O2 Span.
The time can be set from 0–255 minutes in one-minute increments. Setting
a timer duration to ‘0’ turns the timer off, disabling the function. The aver-
age reading for Auto-Zero, Auto-Span 1, and Auto-Span 2 will be taken
during the last 25 percent of the timer duration.
 The Timer must be assigned a value that allows the signals to be

stable during the last 25 percent of the countdown.
NOTE
 If a calibration gas is not used, the associated timer must be turned Off.
NOTE
Setting the timers is done from CAL mode.
Example 1:
To set Timer0 duration to 3 minutes and return to CAL mode normal dis-
play, key in from CAL mode:
F3 0 Del 3 Ent Ent
Example 2:
Timer2 is not required for control of a calibration gas mixture. Its duration
must be set to zero (turned off). To set Timer2 to ‘0’ and return to CAL
F3 2 Del 0 Ent Ent

Integration Timer (IntTime)
The Integration Timer (IntTime) allows you to set the duration over
which readings are averaged during manual calibration functions. The
IntTime can be set to a duration from 0–65535 seconds in one-second
increments. Setting the duration to ‘0’ causes the default averaging time of
15 seconds to be used.
Example:
To set the IntTime to 25 seconds and return to CAL mode normal display,
key in from CAL mode:
F3 6 Del 25 Ent Ent
Auto-Calibration Interval Timer (ACal)
The ACal timer sets the interval (hours) between timed Auto-Calibration
sequences. The ACal timer can be set to an interval from 0–999 hours in
one-hour increments. Setting the interval to ‘0’ turns the ACal timer off,
disabling a timed start of the Auto-Calibration sequence. A timed Auto-
Calibration will start only when the analyzer is operating in RUN mode
without any Faults.
The Auto-Zero sequence is included in the Auto-Calibration sequence if

the Auto-Zero function is enabled by setting Timer0 to a non-zero value.
If the Auto-Calibration and Auto-Zero sequences are scheduled to run at
the same time, the Auto-Calibration sequence takes precedence.
Example:
To set the ACal timer interval to 3 hours and return to CAL mode normal
display, key in from CAL mode:
F3 9 Del 3 Ent Ent
Time to Next Auto-Calibration
The time remaining until the next Auto-Calibration can be displayed from
CAL mode at any time by pressing F3 9. The User Interface Panel does
not provide a running count of the time remaining until the next Auto-
Calibration – you must press F3 9 to view the time remaining until the
next Auto-Calibration.
Pressing Ent returns the CAL mode normal display; pressing Esc returns
RUN mode normal display.

Auto-Zero Interval Timer (AZInt)
This timer sets the interval (hours) between timed Auto-Zero sequences,
and allows the Auto-Zero function to be performed more frequently than
the Auto-Calibration. The timer can be set to an interval from 0–999 hours
in one-hour increments. Setting the interval to zero (0) turns the timer
off, disabling a timed start of the Auto-Zero sequence. A timed Auto-Zero
will start only when the analyzer is operating in RUN mode without any
Faults.
The Auto-Zero sequence is included in the Auto-Calibration sequence if

the Auto-Zero function is enabled by setting Timer0 to a non-zero dura-
tion. If the Auto-Calibration and Auto-Zero sequences are scheduled to
run at the same time, the Auto-Calibration sequence takes precedence.
Example:
To set the AZInt timer interval to 1 hour and return to CAL mode normal
F3 8 Del 1 Ent Ent
When you enter F3 8, the existing timer interval is displayed (hours)

 and the time remaining until the next Auto-Zero is displayed (hours
NOTE and minutes).
Time to Next Auto-Zero
The time remaining until the next Auto-Zero can be displayed from CAL
mode at any time by pressing F3 8. The User Interface Panel does not pro-
vide a running count of the time remaining until the next Auto-Zero; you
must press F3 8 to view the time remaining until the next Auto-Zero.
Pressing Ent returns the CAL mode normal display, pressing Esc returns
the RUN mode normal display.

Setting the Sample Delay Timer (SDelay)
The SDelay timer determines the period of time after the completion of
a calibration sequence that the CAL Status Relay will wait before indicat-
ing that a calibration is complete. The time delay will also be in effect if a
calibration sequence is aborted. This allows any external recording devices
to mark the point at which the analyzer is again monitoring a represen-
tative sample, permitting a smooth transition from calibration gas back
to sample gas. The User Interface Panel and analog outputs continue to
show the actual concentration at the analyzer unless the track-and-hold
result codes are assigned to the display and analog outputs.
The User Interface Panel gives no indication that the delay is occurring or
that it has occurred. The time delay depends on the time required for the
sample gas to reach the analyzer and a stable reading to be obtained.
The time delay can be set from 0–255 minutes in one-minute increments.
Setting the delay to ‘0’ turns off the SDelay timer. If the delay is ‘0’, the
CAL status relay will indicate that the calibration is complete immediately
following the end of the calibration sequence.
Example:
To set the SDelay timer to 4 minutes and return to CAL mode normal
F3 7 Del 4 Ent Ent

Manual Zero/Span
The Manual Zero and Manual Span functions do not activate the sole-
noid valves. The gases must be introduced manually into the analyzer
and allowed to flow through the sample system until a stable reading is
displayed. The time required for calibration gas to reach the analyzer and
for a stable reading to be achieved and displayed is dependent upon the
volume of the sample system and calibration gas flow rate. The gas flow
rate, temperature and pressure should be as close as possible to the nor-
mal operating conditions.
 The calibration gas mixture component concentration must be entered

before performing the Manual Span function.
NOTE
Manual Zero
Refer to “Manually Zeroing the Analyzer” and “Adjusting the Zero Gas
Flow Rate” in Chapter 3 for information about how to perform a manual
zero on the analyzer.
Manual Span
To perform a Manual Span:
1. Ensure that the calibration gas supply is connected and turned on.
Turn off the Aspirator Air.
2. Press F5 2 and record the numeric value displayed for FlowCtrl.
3. Force the analyzer to manually span the sample system with Calibration
Gas by keying in F5 2 Del 11 Ent, where ‘11’ = Calibration Gas #1 or
where ‘12’ = Calibration Gas #2.
4. Press F2 1 to initiate the manual span. The User Interface Panel will
prompt “Man/Span1?”.

5. Observe the concentration reading for the component on the bottom
line of the User Interface Panel. When it has stabilized at or near the
concentration of component “1” in the Calibration Gas mixture, press:
Ent for Yes The analyzer will count down to zero (IntTime duration)
during which time the reading is averaged. The calibra-
tion value for the component will be adjusted automati-
cally and the CAL mode normal display returned.
Esc for No The function is aborted and the calibration value for
the component is not adjusted.
6. Turn off the calibration gas mixture with component “1”. The span
process for the component is complete.
7. Return the analyzer to the original Flow Control Mode by keying in

F5 2 Del n Ent where ‘n’ is the numerical value recorded earlier.

Spanning Dual Range
The Model 919 Single-Gas Analyzer has been designed to be linear over
its normal operating range, and typically needs to be spanned with only
one gas. However, some applications require spanning the analyzer with
two independent span gases. The optional Dual Span functionality ac-
commodates this.
The Model 919 Analyzer has only one analytical result but can be spanned
at two different concentrations, typically one Low Range Span and one
High Range Span. Both span-corrected concentrations can be displayed
on the User Interface Panel and assigned to the V/I outputs. On the User
Interface Panel, the Low Range output is indicated by “so2” while the High
Range output is indicated by “SO2”.
 The following procedure uses SO2 as the measured species, where

the first (Low) Range is displayed as “so2”, while the second (High)
NOTE
Range is displayed as “SO2”.
For other species, the Low Range and High Range is displayed
similarly. For example, if NO2 is being measured, the Low Range is
displayed as “no2” and the High Range is displayed as “NO2”.
To perform a dual-range span:
1. Set the span gas concentration for Species 1 and 2, and do a Manual
Span:
a. Key in F6 • • • Ent to enter Calibration mode. Run zero gas and

manually zero the analyzer as described under “Manual Zero”
earlier in this chapter.
b. Manually reset both Span Factors to 1.0.
For the Low Range Span Factor (SFactor1 – so2), key in:
F5 7 1 Del 1.0 Ent
For the High Range Span Factor (SFactor2 – SO2), key in:
F5 7 2 Del 1.0 Ent

c. Set the Span Concentrations to the corresponding tag concentra-
tion listed on the calibration cylinder.
For example:
If the tag concentration listed on the cylinder for the Low Range
Span Concentration (Conc1 – so2) is 25 ppm , key in:
F4 1 Del 25.0 Ent
If the tag concentration listed on the cylinder for the High Range
Span Concentration (Conc2 – SO2) is 100 ppm, key in:
F4 2 Del 100.0 Ent
d. Run calibration (span) gas and do a Manual Span:
Run the Low Range so2 calibration gas for 2 minutes or until the
reading stabilizes, and then key in F2 1 Ent to do a Manual Span.
Run the High Range SO2 calibration gas for 2 minutes or until the
reading stabilizes, and then key in F2 2 Ent to do a Manual Span.
After the Manual Span is complete, turn off the span gas. For com-
plete details, refer to “Manual Span” earlier in this chapter.
2. Set the span gas concentration for Species 1 and 2, and do an Auto-
Span:
a. Key in F6 • • • Ent to enter Calibration mode. Run zero gas and

manually zero the analyzer, as described under “Manual Zero”
b. Manually reset both Span Factors to 1.0.
For the Low Range Span Factor (SFactor1 – so2), key in:
F5 7 1 Del 1.0 Ent
For the High Range Span Factor (SFactor2 – SO2), key in:
F5 7 2 Del 1.0 Ent

c. Set the Span Concentrations to the corresponding tag concentra-
tion listed on the calibration cylinder.
For example:
If the tag concentration listed on the cylinder for the Low Range
Span Concentration (Conc1 – so2) is 25 ppm , key in:
F4 1 Del 25.0 Ent
If the tag concentration listed on the cylinder for the High Range
Span Concentration (Conc2 – SO2) is 100 ppm, key in:
F4 2 Del 100.0 Ent
d. Run calibration (span) gas and do an Auto-Span:
Run the Low Range so2 calibration gas for 2 minutes or until the
reading stabilizes, and then key in F1 1 Ent to do an Auto-Span.
Run the High Range SO2 calibration gas for 2 minutes or until the
reading stabilizes, and then key in F1 2 Ent to do an Auto-Span.
After the Auto-Span is complete, turn off the span gas. For com-
plete details, refer to “Auto-Zero/Auto-Span” later in this chapter.
3. Return the analyzer Flow Control Mode to its original setting and
prepare the analyzer for normal operation.

Solenoid Valve Control
There are three solid state relay (SSR) outputs available for switching the
solenoid valves controlling the flows of the calibration gas mixtures. Each
SSR output is controlled by a Calibration Gas Timer. The SSR output, its
function, and the Calibration Gas Timer assigned to each are listed below.
SSR Output and Timer Assignments
SSR Output Function Timer Cal Gas
0 Auto-Zero 0
1 Auto-Span 1 1
2 Auto-Span 2 2
 SSR Output 0 is reserved for use with the zero gas.

NOTE


For the Auto-Calibration function to operate correctly, the analyzer must

know which component is in which gas cylinder. This is accomplished by
assigning the SSR output (switching the calibration gas solenoid valve) to
the calculated result for which the calibration gas is required.
For example, if the Solenoid Valve for controlling the Result 1 CAL Gas
mixture is switched by SSR output 2, SSR output 2 will be assigned to
Result 1.
Solenoid Assignments
The existing Auto-Calibration functions will now work as follows:

• AutoSpan1 (F1 1) – energize solenoid #1 and span-calibrate to Conc1
by adjusting SFactor1 if Conc1 is positive.
• AutoSpan2 (F1 2) – energize solenoid #2 and span-calibrate to Conc2
by adjusting SFactor2 if Conc2 is positive.
• AutoCal (F1 9) – energize solenoid #0, #1, and #2 in sequence, and
zero- and span-calibrate the zero, Conc1, and Conc2 accordingly.

Auto-Zero/Auto-Span
This feature allows the operator to initiate an automatic calibration se-

quence. However, the calibration gas mixture component concentration
and a value for the calibration gas timers must be entered before an Auto-
Zero/Auto-Span function can be initiated.
If the duration for a calibration gas timer is set to a non-zero value, and
the component concentration is specified as zero, the function will be per-
formed, and the span factor for that component will be reset to 1.0.
There is a global variable called Adjust Disable which, if disabled (set

 to ‘0’), the zero offset and span will not be corrected at the end of a
NOTE
calibration sequence. This allows the analyzer to control the calibra-
tion gas flow so an external Data Acquisition System can record the
actual analyzer output signals during a calibration sequence and to
monitor for “calibration out of range” conditions.
When an Auto-Zero/Auto-Span function is performed, the following se-

quence of events occurs automatically:
1. The solenoid valve assigned to the function selected is turned on to let
the Zero or calibration gas mixture flow through the Measuring Cell.
The User Interface Panel gives no indication that the solenoid valve
has been turned on.
2. The Timer duration for the function being performed is displayed on
the first line of the User Interface Panel and is counted down to zero.
3. The analyzer Zero or Span is adjusted to the proper value based on
the average of the readings during the last 25 % of the time period
(minutes) of the countdown. Upon completion of the Auto-Zero/
Auto-Span functions, the CAL mode normal display is returned. The
Integration Timer (IntTime) does not affect the averaging time for the
Auto-Zero/Auto-Span functions.
4. The CAL status relay will stay on for an additional period of time as
determined by the Sample Delay Timer to allow for a smooth transi-
tion from the Zero or calibration gas mixture back to the sample gas.
The User Interface Panel gives no indication that this is occurring.
Pressing Esc at any time during this procedure will abort the func-
 tion and return to CAL mode normal display.
NOTE

The Calibration Gas mixture component concentrations and a value
for the Calibration Gas timers must be entered before an Auto-Zero/
Auto-Span function can be performed.
The Flow Control Mode must be controlled by the analyzer (i.e.,

FlowCtrl must have a value of zero).

Manual Start of Auto-Zero
A manual start of the Auto-Zero sequence resets the AZInt timer to its
initial value. The start of the next Auto-Zero will be timed from the begin-
ning of the manual start.
For example, if the AZInt 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 manually, the AZInt timer will be reset, and the time
remaining until the next timed Auto-Calibration remains 2 hours.
 Pressing Esc at any time during this procedure will abort the func-
NOTE
tion and return to CAL mode normal display.
To manually start the Auto-Zero sequence, key in from CAL mode:
1. F1 0, to display the timer duration.
2. Press Ent. The software prompts “Auto/Zero?”.
3. To enable the Auto-Zero sequence, press Ent.
Timer0 will begin to count down to zero time. The analyzer zero offset
is adjusted automatically based on the average of the reading during
the last 25 % of the countdown.
Or, press Esc to abort the Auto-Zero sequence; the zero offset is not
adjusted.
Upon completion of the sequence, press another Function key combina-

tion, or press Esc to return to RUN mode normal display.

Manual Start of Auto-Span

NOTE


To manually start the Auto-Span sequence, key in from CAL mode:
1. F1 1 or F1 2 to display the timer duration.
2. Press Ent. The software prompts “Auto/Span1?” or “Auto/Span2? ”.
3. To enable the Auto-Span sequence, press Ent.
Timer1 (Auto/Span1?) or Timer2 (Auto/Span2?) will begin to count

down to zero time. The analyzer span value is adjusted automati-
cally based on the average of the reading during the last 25 % of the
countdown.
Or, press Esc to abort the Auto-Span sequence; the span value is not
adjusted.
Upon completion of the sequence, press another Function key combina-

tion, or press Esc to return to RUN mode normal display.

Auto-Calibration
The Auto-Calibration function automatically performs first an Auto-Zero,

followed by Auto-Span 1 and Auto-Span 2. A function can be eliminated
from the sequence by setting its associated timer is ‘0’. The sequence of
events for the component is the same as described for Auto-Zero/Auto-
Span.

NOTE


This function can be started manually, automatically on a timed basis, or

by a remote dry (potential-free) contact closure. Upon completion of the
calibration sequence, the Cal status relay will continue to indicate that a
calibration is in process until the Sample Delay Time has expired.
Timed Start of Auto-Calibration
The analyzer automatically initiates the Auto-Calibration sequence on

a timed basis. The ACal timer sets the time interval between calibration
sequences. This function can be set up by pressing F3 9 from CAL mode,
and then entering a value (hours) for the automatic-timed start of the
Auto-Calibration sequence.
If the ACal timer is set to an interval other than zero, the first Auto-
Calibration sequence occurs after the ACal interval from the time the
analyzer is powered up or reset as long as no fault conditions are present.
Subsequent Auto-Calibration sequences will be initiated at every Auto-
Calibration time interval.
Example:
If the ACal timer is set to “3” and the analyzer is powered up or reset, the
first Auto-Calibration will occur at 3 hours if all temperatures are reached.
The Auto-Calibration sequence will occur at 3-hour intervals unless this
value is changed.

Manual Start of Auto-Calibration
A manual start of the Auto-Calibration sequence does not reset the ACal
timer to its initial value. The start of the next Auto-Calibration will be
timed from the continuing countdown of the original ACal timer setting.
The Auto-Calibration sequence can be started manually by pressing F1 9
Ent from CAL mode.
Example:
If 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 manually, 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 cause it to abort
and return to CAL mode normal display.
NOTE
To initiate the Auto-Calibration sequence:
1. Press F1 9. The User Interface Panel prompts “Auto/Cal?”.
2. Press Ent for Yes. The sequence is started.
or
Press Esc for No. The sequence is aborted and adjustments are not
made. The CAL mode normal display is returned.
Upon completion of the sequence, the User Interface Panel returns the

Remote Start of Auto-Calibration
The Auto-Calibration sequence can also be initiated by a remote, dry

(potential-free) contact closure connected to Digital Input 2, Pins 10 and
11 on J108 of the Termination board (see Figure 4-7). The contact must
remain closed for at least 2 seconds (up to 5 seconds). A remote start of
the Auto-Calibration sequence does not reset the ACal timer to its initial
value. The start of the next Auto-Calibration will be timed from the con-
tinuing countdown of the original ACal timer setting.
Example:
If 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, the ACal timer will continue to count down
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 a timed internal function such as the Auto-Velocimeter Backpurge is

in progress when a remote start is requested (by closing the dry contact
connected to Digital Input 2) the request will be registered but will not
initiate any activity until the currently active internal function has been
completed. Once the currently active function has been completed the
remote start request will be accepted and acknowledged by a change in
state of the CAL status contact.
 If the remote start is requested by a Distributed Control System

(DCS) which is also calculating calibration drift values, you must en-
NOTE
sure that the DCS is the only source of Auto-Calibration requests. The
ACal timer must be set to ‘0’ for this application. For more informa-
tion refer to “Timed Start of Auto-Calibration,” earlier in this section.
Remote Start of Backpurge (Optional)
If configured, this function allows the user to initiate a backpurge of the

analyzer sample system from a remote location. This is done to remove
any residual contaminants in the sample system, such as in the case of a
gas alarm, for example. This function is initiated by a remote dry (poten-
tial free) contact opening, connected to Digital Input 2, Pins 10 and 11 on
J108 of the Termination board (see Figure 4-7).
To enable the Remote Backpurge option, add a value of “16” to the Units
value (F1 9 from CFG mode). Refer to F1 9 under “RUN / CFG Mode – F1
Keystrokes,” earlier in this chapter.

Figure 4-7.
Customer signal
connections, GP/Div 2
analyzers, Termination
board.
 Figure 4-7 is for GP/Div 2 analyzers only; for CE or Zone 1 refer to

Customer Signal Connections, CE/Zone 1 Analyzers in Appendix C.
NOTE
For other applications, refer to the electrical connection drawings
included in the “Supplemental Information” section of this manual or

Analog Output Channels
There are four independent isolated 4–20 mADC outputs which can be
self-powered or loop-powered. The user must provide the loop supply
for the loop-powered output. The default signal assignment is configured
to meet the specifications of the end user. If the output signal assignment
must be changed, refer to “Output Signal Assignment (OSA),” earlier in
this chapter.
Setting Output Channel Full-Scale
The full-scale range for the output parameter assigned to each channel
can be set individually within the measuring range of the analyzer. The
measurement will be entered in either ppm or percent, depending on
the units selected in the software. For example, Output Channel 1 can be
scaled to 500 ppm full-scale, Output Channel 2 can be scaled to 300 PPM
full-scale or, all four outputs can be scaled the same.
Example 1:
To set the full-scale range for Output Channel 1 to 500 PPM, and return to
CAL mode normal display, key in:
Example 2:
To set the full-scale range for Output Channel 3 to 300 PPM, and return to

Analog Output Calibration
Calibration of an analog output is performed by entering the measured

zero and full-scale signals for the current output channel. Enter these val-
ues in decimal form. Use a current meter to calibrate the current output
signals. These values are used to offset the output to the correct values.
! If the measured current output is less than 20 mA when the output

is set to full-scale, it cannot be increased above that value. The V/I
CAUTION
module must be replaced if this value is unacceptable. The output
channels have been calibrated at the factory and will be re-calibrated
upon initial installation at the site. Further re-calibration is required
only when a V/I module or the Termination board is replaced.
Pressing Esc at any time during the procedure will abort the proce-
 dure and return to CAL mode normal display. The existing calibra-
NOTE
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
(refer to Figure 4-7 for termination points) and press:
Zero current output F6 0 z Current output zero scale value is displayed, where ‘z’ is the
Zero current output (IZero) 1..4.
Del Sets the current analog output channel to zero scale (4 mA).
“nnn” Key in the Zero scale value (mA) that was measured by the
meter.
Ent Zero scale value is entered and displayed.
Span current output F6 1 z Current output full-scale value displayed, where ‘z’ is the
Span current output (ISpan) 1..4.
Del Sets the current analog output channel to full-scale

(20 mA).
“nnn” Key in the full-scale value (mA) that was measured by the
meter.
Ent Full-scale value is entered and displayed.
Calibration complete Ent To return to CAL mode normal display, or

Esc To return to the RUN mode normal display, or
Press another Function key to perform another function.

Example 1:
To calibrate the current output signal for Output Channel 1 and return to
F6 0 1 Del Sets the output to zero scale.
3.97 Ent The current meter reading is 3.97 mA.
F6 1 1 Del Sets the output to full-scale.
Ent Returns the CAL mode normal display.
Example 2:
To calibrate the current output signal for Output Channel 2 and return to
F6 0 2 Del Sets the output to zero scale.
F6 1 2 Del Sets the output to full-scale.
Ent Returns the CAL mode normal display.

Measuring Cell Temperature and Pressure
The Measuring Cell operating temperature and pressure are two of the
parameters used to calculate the analyzer results. The default values
stored as part of the analyzer configuration can be used, or the measured
Measuring Cell temperature and/or pressure can be used.
When the default values are used, the Measuring Cell temperature and
pressure are treated as constants. The default values are listed under the
headings “Cell Temperature” and “Cell Pressure” on the EEPROM Data
Sheets (in the Documentation Package shipped with the analyzer).
When active temperature and pressure compensation are required, the

measured values for each are used. If the measured values are to be used,
refer to “Active Temperature and Pressure Compensation,” earlier in this
chapter.
Default Measuring Cell Temperature
The default Measuring Cell temperature is 140 °C (284 °F). Do not change
this value.
Entering Default Cell Pressure
The Measuring Cell pressure shown on the Analyzer EEPROM Data

Sheet is the absolute pressure of the sample in the Measuring Cell in
mmHg. Depending on the units selected, the pressure may have to be
converted to "Hg before entering the value. To convert the pressure from
"Hg to mmHg, multiply by 25.4.
Example:
To enter a Measuring Cell pressure (Cell Press) of 700 mmHg (absolute)
and return to CAL mode normal display, key in:
F5 9 Del 700 Ent Ent

Probe Blow-Back Control (Optional)
 For applications using the Probe Blow-back function, it is enabled at

the factory (by disabling Temperature Zone 2).
NOTE
For more information about enabling this function, refer to the F2 1

description under “RUN / CFG Mode – F2 Keystrokes,” earlier in
this chapter.
The Probe Blow-back control can be set up to be performed automatically,

at timed intervals and for timed durations. This is done by setting the
parameters for three timers (Interval, Duration, Pulse Width) from CAL
mode (F3 3). After these timers have been set to non-zero values, the ana-
lyzer will initiate a Probe Blow-back at the preset intervals. For more infor-
mation about these timers, refer to “CAL Mode – F3 Keystrokes,” earlier in
this chapter. See Figure 4-8 for an example timing chart.
A Probe Blow-back can also be started manually by the user, by keying in

F1 7 Ent from CAL mode. The manual blow-back function will perform
one cycle, determined by the Duration Timer setting (CAL mode, F3 3). To
abort a manual blow-back, press the Esc key.
The Probe Blow-back control signal is available at terminals 3 (-) and 4

 Probe Blow-back Timing
(+) of J106 on the Termination board (also used as the SSR control for
NOTE
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.
Probe Blow-back Interval (min)

CAL Relay
Sample Delay
(sec)
Probe Isolation
Solenoid
Probe Blow-back Duration (sec)

Probe Blow-back
Air Solenoid
Probe Blow-back Pulse Width (sec)
2x Probe Blow-back Pulse Width

nOTE: Illustration only. not to scale.
Figure 4-8.
Probe Blow-back
Timing Chart, example.

Maintenance & Troubleshooting
The Maintenance & Troubleshooting chapter discusses preventive main-

tenance to keep the analyzer system operating at peak efficiency, how to
check for plugging in the analyzer’s sample system, and how to replace
internal parts. This chapter also discusses how to view error messages to
diagnose and troubleshoot problems with the analyzer.
Safety Considerations
 Before performing any maintenance, service, or troubleshooting on

the Model 909 Analyzer, review and follow all personnel and equip-
NOTE
ment safety information under “Personnel and Equipment Safety
Information” following the Table of Contents near the beginning of
this manual. This information describes procedures to follow to avoid
personal injury and/or damage to the equipment. All regulatory
agency and personnel safety procedures for your jurisdiction
must be followed.
Personnel should be thoroughly familiar with the operation of the

analyzer before performing the maintenance procedures described in
this section.
Maintenance & Troubleshooting | 5-1

Maintenance
Generally, there is limited maintenance required to ensure the analyzer
remains operating at peak efficiency, other than that described in the
Analyzer Preventive Maintenance Schedule. This section discusses pre-
ventive maintenance to follow to ensure continued and proper operation
of the analyzer. This section also describes parts that require replacing
and the frequency in which they should be replaced, according to the
Analyzer Preventive Maintenance Schedule.
Preventive Maintenance
To reduce the occurrence of problems with the Model 909 Analyzer,
AMETEK recommends that you follow the Analyzer Preventive
Maintenance Schedule as outlined in the following pages. Since most ana-
lyzer problems originate within the sample handling system, the primary
objective of the Analyzer Preventive Maintenance Schedule is proper care
of the sample system.
The risk of developing a collection of liquids in low spots or plugging in

the sample system can be reduced by sloping the Sample Line from the
sample extraction point to the analyzer.
! Preventing leaks in the sample handling system is critical to proper

analyzer operation. The analyzer’s sample system must be leak
CAUTION
checked whenever it has been dismantled for maintenance or repair.
Refer to the “Analyzer Preventive Maintenance Schedule” for suggested

actions and their frequency when caring for the Model 909 Analyzer.
Details and exploded-view drawings to assist you when changing out
parts can be found in appropriate sections later in this chapter.

Analyzer Preventive Maintenance Schedule
Frequency Task
Daily Check for Warning or Fault Alarms
Check the top right corner of the analyzer’s User Interface Panel for
a reverse-video S ( S ) character. If this character appears, view the

software diagnostics to check for current alarms that will help you
isolate the problem. The keypad commands are F5 4 1..8 (HStatus)
and F5 5 1..7 (MStatus) from RUN mode. Refer to “Troubleshooting &
Diagnostics” in this chapter for information about error messages and
the suggested corrective actions.
Check the history buffers for recurring alarms. The history buffers
contain alarms that have been reset. To view historical alarms, use the
F5 • 1..9 (HCHist) and F5 – 1..9 (MCHist) commands while working
from RUN mode.
Monthly Check the PMT Signals
Note: The Manual Supplement “Model 9xx-Series Analyzer Lamp
Maintenance” suggests to Zero the analyzer daily to provide
the greatest insight into tracking the status of the lamps, optics,
and detector. If possible, zero the analyzer daily or at least more
frequently than monthly.
Manually force the analyzer to purge the sample system with Zero Gas
(Continuous Zero Gas Flow mode) by using the keypad on the User
Interface Panel to enter F5 2 Del 10 Ent from CAL mode.
View the Show Signals (Sig) command in RUN mode (F6 1 1..3) and
record the analyzer PMT signals. All signals should return to within
5 % of the values recorded the previous month. If the Measure PMT
signals show significant loss, the Measuring Cell may be contaminated.
Cleaning the Measuring Cell window(s) can be delayed until the signals
are less than 50 % of their “clean” measured value. Refer to your log
book to examine the monthly recordings.
Return the analyzer Sample Flow Control mode back to its original
setting by entering F5 2 Del 0 Ent from CAL mode (where ‘0’ = Analyzer
Control mode). Press Esc to return the User Interface Panel back to the
Monthly Auto-Setup
Initiate an Auto-Setup to optimize the PMT (photomultiplier tube)
gains and the source lamp currents. After the Auto-Setup is complete,
record the results related to the PMT and lamp configuration in a chart.
Refer to the Manual Supplement “Model 9xx-Series Analyzer Lamp
Maintenance” for more information about Auto-Setups and optimizing
lamps, plus an example of a Lamp & PMT Configuration chart to record
these findings.
Monthly Check Analyzer Response Time
Perform a Manual or Auto Zero on the analyzer. After the Zero is
complete, determine the sample response time by switching the
analyzer from Continuous Backpurge mode to Continuous Sample
mode. Observe the RUN mode normal display and record the time it
takes the analyzer to display the first reading after the switch. Typically,
a good response time is approximately 30 seconds (excluding sample
system). A response time that is slower than normal may suggest
plugging problems in the analyzer’s sample system.
Refer to “Manually Zeroing the Analyzer” and “Adjusting the Sample
Gas Flow Rate” in Chapter 3. Also, refer to “Locating a Plug in the
Sampling System,” later in this chapter for more information.

Frequency Task
Monthly Pressure Gauges
Check the Aspirator Pressure and Electronics Enclosure Purge Air
Pressure gauges.
Aspirator air pressure should be set in the range of 7–35 KPAG (1–5
PSIG) to ensure a measurement response time of approximately 30
seconds. Refer to “Adjusting the Sample Gas Flow Rate” in Chapter 3
for more details.
Electronics Enclosure Purge Air pressure is set at a nominal 105 KPAG
(15 PSIG).
CAUTION:
To avoid damaging the pressure transducer, do not set the
pressure higher than 105 KPAG (15 PSIG).
Monthly Temperature-Controlled Zones
Check the operating temperatures of all temperature-controlled zones to
ensure they are all within 5 % of their set points. Record and compare
the current temperatures to the actual settings.
Every Three Months
Sample Conditioning Unit (SCU), Optional
If your analyzer uses an 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 gaskets
at 6-month intervals, minimum.
Depending on sample stream contamination levels (i.e., sample response
time is continually decreasing), it may be necessary to replace the filters
and clean the SCU more frequently. This may be evident if response time
is longer than normal, or if a good zero cannot be achieved.
If your system uses an SCU (or another type of sample gas extraction
unit) from a manufacturer other than AMETEK, refer to the accompanying
manual for information on the frequency of regular maintenance.
Every Six Months Sheltered Systems
If your analyzer system is installed in a custom shelter, check the air
filters for the shelter purge and air conditioning systems and replace
them if necessary. Depending on the location of the site and its
environmental conditions, it may be necessary to check and replace
these filters more frequently.
Every Six Months Sample Line
Inspect the Sample Line for sags, sharp bends, or damage to the outer
skin. If necessary, take appropriate safety precautions and replace the
lines. Perform a leak check on all associated fittings after replacing any
line(s).
9–12 Months Source Lamps
Replace the source lamps. The source lamps may need to be replaced
sooner if information from the analyzer’s diagnostics indicates
related alarms (i.e., “w Lamp Control” or “w PMT Signals”). Refer to
“Replacing the Source Lamps,” later in this chapter.
Every Year Measuring Cell
Clean the Measuring Cell and the rest of the analyzer’s sample system.
This schedule is a minimum requirement. If other conditions are found
to be present, as outlined under the section titled “Measuring Cell
Preventive Maintenance,” cleaning may be required more frequently.
At the same time, replace the o-rings.

Frequency Task
Other Flamepath Gap
During each analyzer maintenance, use a feeler gauge to check the
flamepath gap of the following locations. The gap must not exceed
0.1 mm; if the gap exceeds this value, contact AMETEK for advice. See
“Examining and Caring For the Flamepaths,” later in this chapter, for
more information.
• Disconnect Enclosure flange (enclosure door and housing joining
surfaces).
• Heater Plate Assembly flange (upper/lower Heater Plate joining
surfaces, inside the Analyzer Oven).
Expo-Telektron Safety Systems MiniPurge (Optional)

Preventive Maintenance Schedule
Frequency Task
— If your analyzer uses an Expo-Telektron Safety Systems MiniPurge
System, refer to the Expo-Telektron Safety Systems MiniPurge Manual
for recommended preventive maintenance, and how to change out
replaceable parts. This manual is shipped with the analyzer.
Before Performing Maintenance
! Under normal operating conditions, lethal concentrations of H2S

and other toxic gases from the stack duct may be present within the
WARNING
analyzer’s sample system.
Before working on the sample system, manually force the analyzer to

purge the sample system with Zero Gas (force its Flow Control Mode
to Continuous Zero Gas Flow from CAL mode), isolate it (block it in)
from the stack duct, and disconnect the power. Follow this procedure
prior to changing out any analyzer components or replacing any
replaceable parts (as part of regular preventive maintenance), or per-
forming leaks checks following the replacement of instrument air or
other adjustments to any of the connections points in the analyzer’s
sample system. If this is not possible, a breathing apparatus must be
worn while servicing the sample system.
The sample system is defined as all components in the analyzer sys-

tem through which sample gas passes.

Locating a Plug in the Sample System
If analyzer problems occur, they are most likely related to improper

sample system operation, such as plugs or leaks. Plugs in the sample
system cause problems in analyzer response time, either to changing stack
duct conditions or to Zero Gas. Leaks are potentially dangerous and will
eventually lead to corrosion problems.
Detecting a Plug in the Sample System
This is best done by observing the analyzer’s measurement response time

immediately following a Zero function. A typical response time is approxi-
mately 30 seconds (excluding sample system). Observe your analyzer and
learn what a normal response time is. Use the recorded response time as a
reference for detecting the formation of plugs in the sample system.
If the sample response time is longer than normal, it is most likely due to
plugging somewhere in the sample system. The next step is to locate and
remove the plug. The portion of the sample system with the highest risk
of plugging is the sample inlet. One way to confirm that a plug is in the
sample inlet is to cap the Vent Line and Zero the analyzer.
 If your application disperses the used sample gas to atmosphere via a

stack or low pressure flare header, disconnect the Vent Pipe at the Vent
NOTE
port in the Analyzer Oven and temporarily install a cap.
Observe the Cell Pressure reading (press F6 8 6 from RUN mode), and if
the reading approaches the Zero Gas supply pressure, a plug is present
somewhere in the sample inlet.

CAUTION
After confirming that the plug is somewhere in the sample inlet, take
 all appropriate safety precautions and dismantle the sample system,
NOTE
starting at the SCU.
Plugs in the sample outlet (or vent side) of the sample system are rare.
Plugs in the vent system cause the aspirator drive air to flow back into the
Measuring Cell and, essentially, simulate a Zero Gas Flow or Backpurge
condition.

Preventing a Plug in the Sample System
This is done by supplying and maintaining the necessary heat tracing to

the Sample Line.
The operating temperature of the SCU and Vent Valve (if used) assemblies
should be at least 10 °C (18 °F) above the process temperature to ensure
optimum sample system performance. The SCU and Vent Valve (if used)
assemblies should be insulated using the insulation supplied by AMETEK,
plus additional insulation (by customer) if necessary.
Check current operating temperatures and compare them to the set point
temperatures for each temperature zone.
To check the analyzer’s sample system for possible plugging:
1. While working from the User Interface Panel, manually force the ana-
lyzer to purge the sample system with Zero Gas (Continuous Zero Gas
Flow mode) by using the keypad on the User Interface Panel to enter
the following keystrokes:
a. From RUN mode, press F6 • and then enter the CALibration mode
mode.
b. Press F5 2 to display the FlowCtrl (Flow Control Mode) screen.
c. Press Del to delete the current setting and then press 10

(10 = Continuous Zero Gas Flow mode) at the “FlowCtrl?”
prompt. “S” will be displayed on the User Interface Panel. Press
Ent to save the change.
d. Press Ent again to return to CAL mode normal screen and then
Esc to return to RUN mode.
2. The rotameter should be active with flow indication.
3. Cap the Sample Line at the SCU. Observe the flow on the rotameter. If
the flow reduces to a stop, a large plug has occurred somewhere in the
sample system.
Remove the cap from the Sample Line and reconnect it to the SCU.

4. Disconnect the Vent Line from the Vent Pipe and temporarily install a
cap on the line.
 If your application disperses of the used sample gas directly to atmo-

sphere or via a stack, disconnect the Vent Pipe at the Vent port in the
NOTE
Analyzer Oven and temporarily install a cap.
Observe the flow on the rotameter. If the flow reduces to a stop, a

large plug has occurred somewhere in the sample system.
5. After locating the cause of the restriction or plug (and after cleaning
or replacing the part or line), pressure/leak test the fittings or connec-
tions that were loosened or replaced. To do this, follow the procedures
under “Sample System Leak Check” in Chapter 3.
6. Remove the cap from the Vent Line and reconnect it to the Sample
Vent Pipe.
7. Return the analyzer Flow Control setting to Analyzer Control mode

by entering the following keystrokes:
a. From RUN mode, enter F6 • and then the CALibration mode

mode.
b. Enter F5 2 to display the FlowCtrl (Flow Control Mode) screen.
c. Press Del to delete the current setting and then press 0

(0 = Analyzer Control mode) at the “FlowCtrl?” prompt. Press Ent
to save the change.
8. Check the sample response time. Record the response time, Aspirator
Air pressure, Cal Gas pressure, and Cal Gas flow rate settings. The
recorded values can be used later as a reference while testing response
time.

Changing Out Replaceable Parts
The following sections discuss the parts that should be changed out, ac-
cording to the schedule listed in the “Analyzer Preventive Maintenance
Schedule.” These descriptions focus on the AMETEK sample system.
As indicated in the “Preventive Maintenance Schedule” for the Expo-

Telektron Safety Systems MiniPurge System, refer to the purging system’s
manual (shipped with the analyzer) for required maintenance and proce-
dures on how to change out replaceable parts.
! Preventing leaks in the sample system is critical to ensure proper

analyzer operation. If sample gas migrates into the Optical Bench
CAUTION
Assembly or Reflector Block due to a leak in the Measuring Cell
Assembly, the optics will become damaged and most likely require
replacement. Most leaks are preventable with regular cleaning and
replacement of the Measuring Cell o-rings.
! If the User Interface Panel displays Warning or Fault alarm er-

ror messages that indicate a faulty component requires replacement
CAUTION
[described under “Microcontroller Board Alarm Conditions and
Corrective Action” or “Host Controller Board Alarm Conditions
and Corrective Action” later in this chapter], review this manual for
replacement procedures.
For complex maintenance procedures not discussed in this manual,

such as replacing heaters, RTDs, or electronics boards, consult with
your AMETEK distributor or representative. Or, contact the factory
for assistance and information about returning the assembly/analyzer
to the factory for repair.

Measuring Cell Preventive Maintenance
The o-rings in the Measuring Cell should be replaced every year to avoid
a leak in the sample system. If the sample system operates above atmo-
spheric pressure, sample gas can leak from the Measuring Cell into the
Analyzer Oven.
While the Measuring Cell is disassembled, clean its chambers and parts.
Refer to Figure 5-1 for assistance in locating and identifying the hardware
components that make up the Measuring Cell.
Clean the Measuring Cell and its windows:
• If the analyzer responds slowly to zero when the sample system is free
of restrictions, or
• If evidence of contamination is present in the Sample Line, or
• Every year as indicated in the “Analyzer Preventive Maintenance

Schedule.”
Replace the o-rings in the Measuring Cell:
• If, during an unscheduled cleaning (see cleaning requirements above),

the parts are found to be damaged. For example, the Measuring
Cell Windows are scratched, cracked, or chipped, or the o-rings are
damaged.
• Every year as indicated in the “Analyzer Preventive Maintenance

Schedule.”
 If your system uses a White Cell Assembly for the Measuring Cell,
refer to the “Supplemental Information” section of this manual or the
NOTE
Documentation Package shipped with the analyzer for a drawing and
information on cleaning the Measuring Cell and replacing its o‑rings.

Figure 5-1.
Measuring Cell
Assembly.

To clean the Measuring Cell and replace its o-rings:
1. While working from the User Interface Panel, check and record the
current Flow Control mode. To do this:
password “• •” (at the “PSWD0” prompt). Press Ent to CAL mode.
b. Enter F5 2 to display the FlowCtrl (Flow Control) mode screen.

2. Manually Zero the analyzer for 2–3 minutes. Information on how to do

this is described under “Manually Zeroing the Analyzer” in Chapter 3.
3. After the Zero is complete, cap the Sample Line at the SCU and cap
the Vent Line at the Sample Vent Pipe.
4. Power down the analyzer:
! Before powering down the analyzer, test the area around the analyzer
for flammable gases. If an explosive gas atmosphere is present, do not
WARNING
power down the analyzer or any alternate power sources that sup-
ply power to the analyzer components. Proceed only when the area is
found to be safe.
General Purpose (GP) Analyzer Applications:

Open the Electronics Enclosure and disconnect power from the
analyzer and its temperature-controlled zone circuitry by opening
the Analyzer and Oven Heater fuses. Refer to the Fuse Legend on the
inside of the analyzer’s Electronics Enclosure door for the locations of
these fuses.

Open the flameproof power-disconnect switch (breaker). Open the
Electronics Enclosure.

WARNING

5. Wearing insulated gloves, open the Analyzer Oven door and allow the
Analyzer Oven to cool down enough to ensure safe handling.
! The analyzer sample system will be under positive pressure.

WARNING
The Analyzer Oven enclosure and components within the Analyzer
Oven are hot; take precautions to avoid burning yourself.
6. General Purpose Analyzers Only:

Turn off the Instrument Air supply to the analyzer and then close the
Aspirator Air valve.

The Instrument Air supply must always remain on for the Purge
Bypass Switch to operate properly.
7. After the Oven has cooled down enough to work on, disconnect the
Measuring Cell from the Oven:
! The analyzer sample system will be under positive pressure; take

precautions to avoid injury.
WARNING
a. Disconnect the Sample and Vent Line tubes from their fittings on
the Measuring Cell.
b. Remove the Heat Transfer Block Plug from the counter bore hole
in the Heat Transfer Block and then remove the 3 mm holding
screw using only an Allen key. Do not use a ball driver – the head
can break off inside the screw.
c. Wearing insulated gloves, grasp the Measuring Cell Assembly

and carefully pull it straight out from the Heater Plate (located in
the counter bore hole in the Heat Transfer Block). Once the Heat
Transfer Block has cleared the Cell RTD, swing the Optical Bench
Assembly outward, away from the analyzer, using the Support
Arm Yoke (hinge mechanism) that mounts it to the Electronics
Enclosure backpan.
 Various lengths of screws are encountered during disassembly. Take

note of where each length is used and be sure to replace the ap-
NOTE
propriate screws in their original locations when reassembling the
Measuring Cell later.

8. Remove the three M4 x 12 mm screws that secure the Measuring Cell
Extension to the Heat Transfer Block. Remove the Measuring Cell.
To help maintain the temperature inside the Oven, close the Oven
door while working on the Measuring Cell.
 In the next steps, place the Cell parts on a soft, non-abrasive cloth.
NOTE
9. Hold the Measuring Cell vertically so that the Heat Transfer Block is
up and remove the three M4 x 12 mm screws that secure the Heat
Transfer Block to the Measuring Cell. Remove the Heat Transfer Block.
10. Use an o-ring removal tool to remove the outer o-ring from the
Measuring Cell. Take care not to scratch or damage the o-ring groove
or joining surface of the Heat Transfer Block.
Carefully remove the Cell Window from the Measuring Cell by grasp-
ing it by its outer edge and lifting it out of the Measuring Cell. Avoid
touching the window surfaces.
Use an o-ring removal tool to remove the inner o-ring from the
Measuring Cell.
Inspect the Window for any chips, cracks, or scratches. Place the
Window on a soft, non-abrasive cloth – and set it aside in a safe loca-
tion – to avoid damaging it.
Inspect the o-rings for flexibility and for any signs of damage (nicks,
cuts, scratches). Set the o-rings aside with the Window for cleaning.
! Replace chipped, cracked, or scratched windows when reassembling

the Measuring Cell.
CAUTION
11. While holding the Measuring Cell vertically so that the Reflector
Block end is up, remove the three M4 x 20 mm screws that secure the
Reflector Block to the Measuring Cell. Remove the Reflector Block.
12. Still with the Reflector Block end up, carefully remove the o-rings and
Cell Window from the Measuring Cell, similar to the other o-rings and
Cell Window.
Inspect the Window and o-rings and set them aside with the other
o‑rings and Window.

13. Wash the Measuring Cell windows with a non-abrasive agent (such
as Isopropanol). Rinse the windows with distilled water of at least
pharmaceutical grade. If the windows are chipped or cracked, replace
them with new ones (Part No. 300-0281).
14. Inspect the interior of the Measuring Cell for foreign material and
clean its interior using a non-abrasive agent such as Isopropanol and
water solution, or reagent-grade acetone.
Flush and thoroughly rinse the interior of the Measuring Cell with
distilled water of at least pharmaceutical grade. Allow all components
to dry thoroughly before reassembling them.
15. Install a new o-ring (Part No. 300-1503) in the o-ring groove on the flat
surface of the Reflector Block.
With the Measuring Cell held vertically so that the Reflector Block end
of the Measuring Cell is up (the end opposite the sample tube fittings),
install a new o-ring by using your thumbs to push it into the o-ring
groove until it is completely seated in the groove.
While holding the edge of the window, carefully place it in the

Measuring Cell.
Orient the Reflector Block with its “peak-line” at 90° to a line through
the Sample and Vent Line fittings, and place the Reflector Block onto
the Measuring Cell. Ensure the Measuring Cell Window does not
slide out of position when the Reflector Block is placed against the
Measuring Cell.
Secure the Reflector Block to the Measuring Cell using three

M4 x 20 mm screws. Tighten the screws evenly.
16. Install a new o-ring (Part No. 300-1503) in the o-ring groove in the
Heat Transfer Block.
Invert the Measuring Cell so the end with the Sample and Vent Line
fittings is up and install a new o-ring in the o-ring groove in the
Measuring Cell.
With the Measuring Cell held vertically, grasp the edge of the window
and carefully place it in the o-ring groove in the Measuring Cell.
Orient the Heat Transfer Block – with the counter bore access hole at
90° to a line through the fittings – and place it over the Measuring Cell.
(The two larger-diameter holes in the Measuring Cell must align with
the two larger-diameter holes in the Heat Transfer Block.) Ensure the
Measuring Cell Window does not slide out of position when the Heat
Transfer Block is placed against the Measuring Cell.
Secure the Heat Transfer Block to the Measuring Cell using three
M4 x 12 mm screws. Tighten the screws evenly.

17. Reconnect the Measuring Cell to the Sample Cell RTD on the Heater
Plate. To do this:
a. Orient the Measuring Cell with the Reflector Block to the left, the
sample tube fittings vertical, and the counter bore access hole in
the Heat Transfer Block facing away from the analyzer. Replace the
screws and tighten them evenly.
b. Swing the Measuring Cell toward the Analyzer Oven.
Using an Allen key, insert the 3 mm holding screw into the counter
onto the Sample Cell RTD. Do not use a ball driver – the head can
break off inside the screw. Do not tighten the screw at this time.
 IMPORTANT
Positioning of the Heat Transfer Block in the Analyzer Oven is criti-
NOTE
cal. Improper positioning of the Heat Transfer Block can result in:
• Poor contact between the Sample (Measuring) Cell RTD tip and
• Poor alignment of the Measuring Cell Extension seal in the

Analyzer Oven and Electronics Enclosure cabinets.
c. Adjust the Measuring Cell/Optical Bench Assembly so that the


Temporarily close the Electronics Enclosure door and tighten its
screws to secure the Measuring Cell/Optical Bench Assembly in
place.
 While closing the Electronics Enclosure door, verify that proper verti-
cal alignment of the Optical Bench Assembly is maintained.
NOTE
If necessary, vertically align the Optical Bench Assembly by loosening

d. Verify there is no clearance between the Heat Transfer Block and

the Sample Cell RTD. The Measuring Cell Assembly must feel
secure against the Heater Plate. Gently push and pull on the
Measuring Cell Assembly to verify it is not loose.
If necessary, use an Allen key to tighten the 3 mm holding screw

until the Measuring Cell Assembly does not move when you push
and pull on it. Do not use a ball driver – the head can break off
inside the screw.
! Do not overtighten this screw, as doing so will damage the threads on

the RTD.
CAUTION
Replace the Flame Arrester (black plug) in the counter bole hole in
e. Use appropriate wrenches to reconnect the Sample Line and Vent

Line tubing to the Measuring Cell. Remove the Sample and Vent
Line caps and reconnect them to their respective locations.

Turn on the Instrument Air supply to the analyzer and open the

19. Power up the analyzer:
! For verification and troubleshooting purposes during power up, it will

be necessary to work with the analyzer’s covers and doors open. Before
WARNING
powering up the analyzer, test the area for flammable gases. If an ex-
plosive gas atmosphere is present, do not apply power to the analyzer
or any alternate power sources that supply power to the analyzer
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.

Open the Electronics Enclosure and close the Analyzer fuse to apply
AC power to the analyzer and its Sample Line and SCU temperature-
control zone circuits. Do not apply power to the Oven circuitry at this
time, until after the Leak Check has been performed.

! The analyzer may only be energized by using the Purge Bypass

WARNING

sphere is present.

power-disconnect switch (breaker). This will apply power to the ana-
lyzer and its Sample Line and SCU temperature-control zone circuits.
Do not apply power to the Oven circuitry at this time, until after the
Leak Check has been performed.
20. Perform a leak check on the fittings that you just reconnected by
following the procedures under “Sample System Leak Check,” in
Chapter 3.
After you are sure there are no leaks, return to this procedure and
continue with the remaining steps.

21. Power up the Analyzer Oven. Close the Electronics Enclosure door
and tighten the three M6 screws on the door to secure the Optical
Bench Assembly in place. Close the Analyzer Oven door (secure its
latches). Close and secure all other doors and covers on the analyzer, if
not already done.
Allow the analyzer to warm up to operating temperature and stabi-

lize. This should take approximately 2 hours. When the analyzer is at
operating temperature, open the isolation valve on the Vent Valve (if
applicable). Open the isolation valve on the Sample Valve (or SCU) to
allow sample gas into the analyzer sample system.
22. Return the analyzer to the original Flow Control Mode by entering
CAL mode and keying in F5 2 Del n Ent, where ‘n’ is the numeric
value of the Flow Control Mode recorded earlier. Press Esc to return to
the normal RUN mode.

the Analyzer,” in Chapter 3.
24. Adjust the Aspirator Drive Air Regulator to achieve normal operat-
ing flow rates [3.0–5.0 L/min (0.1–0.2 SCFM)] as described under
“Adjusting the Sample Gas Flow Rate,” in Chapter 3.

Source Lamp Replacement
The typical life span of the source lamps is approximately 9–12 months of
continuous operation. However, a source lamp can exhibit signs of degra-
dation after 5 to 6 months.
 For more information about lamp maintenance, refer to the Model

9xx-Series Analyzers “Lamp Maintenance Manual Supplement” in-
NOTE
cluded in the Supplemental Information section of this manual. This
supplement focuses specifically on signals related to the transmission
of light through the optical path, and how the long-term change in
these signals can be used to diagnose lamp failure, window fouling,
and other degradation of the analytical response of the analyzer.
When Do the Source Lamps Need to be Replaced?
Indications of Source Lamp failures are:

• Unstable lamp voltage (check voltage levels);
• Unstable analyzer output under Zero Gas conditions (“w Zero drift”
warning error is displayed); or
• The “w Lamp Control” (Automatic Lamp Control) MStatus warning
message is displayed on the User Interface Panel.
About the Source Lamps
• Source Lamp 1 is the one closest to the Measuring Cell.

• The cathode of each Source Lamp must be centred on the optical axis
of the Beam Splitter for optimal operation of the analyzer. The cathode
and the outer envelope of the Source Lamp are not necessarily con-
centric or consistent from lamp to lamp.
• A new Source Lamp must be aligned to ensure optimal operation of
the analyzer.
• This procedure assumes that the factory-default password (• •) for
entry to CAL or CFG mode is valid. If a password has been changed,
the new password must be used.
• If the analyzer is configured to measure H2S, both lamps are Cadmium
(Cd).
• If the analyzer is configured to measure SO2, both lamps are
Magnesium (Mg).

Replacing the Source Lamps
Refer to Figure 5-2 for assistance in locating and identifying the hardware
components encountered while replacing the source lamps. This proce-
dure assumes that the factory-default password (• •) for entry to CAL or
CFG mode is valid. If a password has been changed, the new password
must be used.
Figure 5-2.
Lamp Assembly.

To replace Source Lamps:
! Before proceeding, test the area around the analyzer for flammable
gases. If an explosive gas atmosphere is present, do not power down
WARNING
the analyzer or any alternate power sources that supply power to the
analyzer components. Proceed only when the area is found to be safe.

Open the Electronics Enclosure and open the Analyzer and Oven
Heater fuses to disconnect power from the analyzer and the Oven
circuit. Refer to the Fuse Legend on the inside of the analyzer’s
Electronics Enclosure door for the locations of these fuses.


WARNING
2. Loosen the Lamp Retaining Screw and rotate the Lamp Retaining
Bracket 90 degrees. Remove the Lamp Socket Assembly.
3. Loosen the Lamp Clamping Screws and remove the faulty lamp(s) by
rotating and sliding it downward.
! Do not rotate or pull on the base of the source lamp because this may
cause it to separate from the glass envelope. Grasp the glass envelope
CAUTION
when rotating or pulling the source lamp.

4. Install the new lamp(s). Make sure that the narrow end of each lamp is
pushed completely into the holder.
! When handling a source lamp, it is very important not to touch the

lamp window because residual oils from the fingers will absorb ultra-
CAUTION
violet 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.
5. Lightly tighten each Lamp Clamping Screw to secure each lamp. Do

not overtighten; the spring should not be collapsed.
6. Reinstall each Lamp Socket Assembly. Rotate the Lamp Retaining

Bracket 90 degrees (to its original position) and tighten the Lamp
Retaining Screw to secure the Lamp Socket Assemblies. Do not over-
tighten; the spring should not be collapsed. The lamp must be allowed
to move so it can be adjusted later in this procedure.
!It is necessary to work with the Electronics Enclosure door open after
replacing source lamps so that adjustments can be made to the lamps.
WARNING
Before powering up the analyzer, test the area for flammable gases.
If an explosive gas atmosphere is present, do not apply 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.
inside.

Open the Electronics Enclosure and close the Oven Heater fuse. Close
the Analyzer fuse to apply AC power to the analyzer and the Oven
Heater circuitry. Note that power is also applied to the Sample Line
and SCU temperature-controlled circuits when AC power is applied to
the analyzer.


WARNING

sphere is present.

power-disconnect switch (breaker).
current sample system operating mode (Flow Control) and then
change it to Continuous Zero Gas Flow mode. To do this:
a. From RUN mode, press F6 • and then enter the CALibration mode
password “• •” at the “PSWD0” prompt. (If PSWD0 [• •] has been
changed from the factory default, use the new password.) Press
Ent to enter CAL mode.
b. Enter F5 2 and record the current numeric value displayed for

Flow Control Mode.
c. Manually force the analyzer to zero the sample system with Zero
Gas (Continuous Zero Gas Flow) by using the keypad on the User
Interface Panel to enter F5 2 Del 10 Ent from CAL mode.
Allow the analyzer to purge with Zero Gas for 2–3 minutes and
then close the isolation valves on the Sample Probe Valve and Vent
Line Valve (if used, or cap the Sample and Vent Lines) to isolate
the analyzer from the stack duct.
 If your application disperses the used sample gas to atmosphere via a

stack or low pressure flare header, disconnect the Vent Pipe at the Vent
NOTE
port in the Analyzer Oven and temporarily install a cap.
Allow the analyzer to stabilize for 5 minutes before continuing.

9. Enter CFG mode by entering F6 – • • Ent (or use new password, if
it was changed), and then initiate an Auto-Setup by pressing F1 •.
Continue with this procedure only after the completion number is
between 0.75 and 1.25. A normal completion is 0.75, ±0.25.
For detailed information about performing an Auto-Setup and how to

make adjustments to obtain a completion number within this range,
refer to “Auto-Setup” later in this chapter.
10. Turn off the Automatic Lamp Control function (Alc Enable) by press-
ing F2 7 Del 0 Ent Ent from CFG mode. The Alc Enable function must
be off to ensure the analyzer is not making automatic adjustments
while you are setting the Measure and Reference signals to operate at
optimum ratios to each other, as described in the following steps.
11. Display the PMT signal by pressing F6 1 z, where “z” is Filter 1 or

Filter 2.
The message “SIGz m.mmm r.rrr” is displayed, where “z” is the

filter location, “m.mmm” is the Measure PMT signal, and “r.rrr” is the
Reference PMT signal. The PMT signal values displayed on the User
Interface Panel are updated at one-second intervals.
Example:
If replacing Lamp 1, the PMT signal for Filter 1 is displayed by press-
ing F6 1 1. For Lamp 2, press F6 1 2.
! If either the Measure (m.mmm) or Reference (r.rrr) PMT signal

becomes equal to or greater than 10.000 VDC at any time while align-
CAUTION
ing it, decrease the PMT level (press F1 4 from CFG mode to view the
PMT level). Allow the signals to stabilize and continue.
12. Slightly loosen the Lamp Clamping Screw. Loosen the Lamp Retaining
Screw and rotate the retaining bar 90 degrees.
13. Slowly rotate the new lamp to obtain the maximum signal from the
Measure PMT (value on the left side of the User Interface Panel). Since
the User Interface Panel is updated at one-second intervals, 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.
NOTE
14. Loosen the Locking Screw located between the two source lamps.

15. To obtain the maximum signal from the Measure PMT, adjust the
Lamp Adjusting Screw for the lamp that is being replaced.
16. For the second lamp, repeat Steps 10, 13, and 15.
17. Tighten the Locking Screw located between the two source lamps.
18. Return the Lamp Retaining Bracket to its original position and secure
it using the Lamp Retaining Screw. Tighten the Lamp Clamping Screw
to secure the lamps. Do not overtighten these screws; the springs
should not be collapsed.
19. Allow the analyzer to operate for 30–45 minutes and then initiate
another Auto-Setup, which automatically turns on the Alc Enable
function. Continue with these procedures only after the completion
number is between 0.75–1.25. A normal completion is 1.00, ±0.25.
For detailed information about performing an Auto-Setup and how to

make adjustments to obtain a completion number within this range,
refer to “Auto-Setup” later in this chapter. Return to this procedure
after the Auto-Setup is complete.
20. Press Esc Ent. The message “SAVE CONFIG?” will appear.
Press Ent to save the new configuration, and return to RUN mode
normal display.
21. Purged Analyzer (Hazardous Location) Applications Only:

Return the Purge Bypass Switch to the ACTIVE position and remove
the key (follow company policy).
22. Remove the cap from the Vent Line and reconnect it to the Sample
Vent Pipe. Remove the cap from the Sample Line and reconnect it to
the SCU to allow sample gas from the stack duct into the analyzer
sample system.
23. Close and secure the Electronics Enclosure with its screws.
24. Return the analyzer Flow Control Mode to Analyzer Control (auto-
matic) by entering CAL mode and keying in F5 2 Del 0 Ent. Press Esc
to return to RUN mode.
25. Zero and Span the analyzer (Span function is optional; depends on
application).
26. Adjust the Aspirator Drive Air Regulator to achieve normal operating
flow rates.
The procedure is complete.

Auto-Setup
The Auto-Setup function optimizes PMT (photomultiplier tube) gains and

the source lamp currents after the source lamps have been replaced or
adjusted. Always initiate an Auto-Setup after any lamps, optical filters, or
PMTs have been installed or replaced. This function is available in CFG
mode only.
When the Auto-Setup is initialized, the Automatic Lamp Control (Alc

Enable) function is automatically turned on. To view the current status
of this function, press F2 7 from RUN mode. To change the status of this
function, enter CFG mode and press F2 7 Del n Ent Ent, where “n” is “0”
(Off) or “1” (On).
Auto-Setup Completion Number
At the end of every Auto-Setup the analyzer displays a completion num-

ber that is the product of the lowest and highest transmittance. A normal
completion is 1.00, ±0.25.
 IMPORTANT
Although a good completion number is indicative of a successful
NOTE
Auto-Setup, do not rely on it solely.
Always check the PMT Level and PMT Balance after every Auto-
Setup. Refer to “PMT Level and PMT Balance,” following this sec-
tion, for details on acceptable levels of these two signals.
If the completion number is outside of this range it is an indication that

the Measure and Reference PMT signals are not at optimum ratios to each
other. The most common cause of an abnormal completion number is
initiating Auto-Setup when the Measuring Cell has not been properly
backpurged. This results in completion numbers lower than normal.
The most likely cause of a higher-than-normal completion number is mis-

placement of the PMTs in their respective sockets. Although the sensitiv-
ity of each PMT is similar, the Measure path PMT typically has a slightly
higher gain than does the Reference path PMT. Swapping the PMTs from
the factory-set positions can produce higher-than-normal completion
numbers.

PMT Level and PMT Balance
PMT Level and PMT Balance are adjusted only during the Auto-Setup
sequence. The range of operation for both these parameters is 0–10 VDC.
Normal values for both, after a successful Auto-Setup, are from 4.0–7.0
VDC. The analyzer will function with values outside this range, but it is a
sign that a change has likely occurred in the transmission of light within
the Optical Bench Assembly. Severe changes in PMT Level and PMT
Balance are as important to notice as the absolute value.
The PMT Level signal adjusts the gain of both PMTs simultaneously in the
same direction. PMT Balance adjusts the gain of the two PMTs in opposite
directions.
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 (F1 4, F1 5 from RUN mode) after completion of the Auto-
Setup.
If, after completion of the Auto-Setup, these signals are outside the normal
range of operation, check:
• Was the Auto-Setup done with Zero Gas flowing through the sample
system?
• Are the Measuring Cell windows clean?
• Are the PMTs in their original sockets? (i.e., is the higher gain PMT in
the Measure path?)
• Do the source lamps need replacement? If not, are the source lamps
aligned?
• Have there been any leaks from the Measuring Cell? If so, check the
condition of:
- The Lenses and Optical Filters in the Optical Bench.
- The mirrors, windows, and o-rings in the Measuring Cell (includ-

ing Reflector Block) and Beam Splitter Assembly.

Auto-Setup Fault Messages and Corrective Action
While the Auto-Setup function is in progress, two error messages can

appear:
• LVL adjust fault
• BAL adjust fault
If during the operation of the Auto-Setup either the PMT Level adjust-
ment or PMT Balance signal goes to minimum or maximum, the corre-
sponding adjust fault message appears on the User Interface Panel.
If either or both of these messages appear:
• Ensure that the Measuring Cell was backpurged with Zero Gas.
• Display the source lamp pulse current-control signal for each filter
location. To display these signals, press F1 1 z from RUN mode, where
“z” = 1..2.
• Make sure the source lamps are not burned out.
• Ensure the lamp sockets are attached securely to the lamps.
• Ensure the lamps are inserted completely into the detector assembly.
• Make sure the lamp power supply cables are connected and not
damaged.
• Ensure the PMT high-voltage (J101, J102) and ribbon (J103) cables are
connected and not damaged.
• Make sure the Measuring Cell windows are clean and not damaged.
• Ensure the Measuring Cell is clean.
Correct any faults and initiate the Auto-Setup function.

Initiating an Auto-Setup
To initiate an Auto-Setup, key in from the User Interface Panel:
1. Press F6 – • • Ent to enter CFG mode. (If PSWD1 has been changed
from the factory default, the new password must be used.)
2. Press F1 • to start the Auto-Setup.
 The Auto-Setup function starts immediately upon entering F1 •.

Do not press any keys while it is in progress.
NOTE
The process takes about 5 minutes to complete. The following six mes-
sages appear during the process:
1. “Adjusting LVL” 4. “Adjusting LVL”

2. “Adjusting LMP” 5. “Adjusting LMP”
3. “Adjusting BAL” 6. “Completion= b”
3. Upon completion of the Auto-Setup, if the value of “b” in Message 6

is not between 0.75–1.25, move the jumper on headers P300 or P301
of the Optical Bench board to an alternate position, install another
jumper on P300, or change the position 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.
4. Restart Auto-Setup (press F1 •). Repeat this procedure until “b” is be-
tween 0.75–1.25.
 P300 may have up to four jumpers installed; at least one must be

present at all times.
NOTE
P301 has two jumper positions, but only one jumper position is used.
Do not put both jumpers on P301.

5. After the value of “b” is between 0.75–1.25, press Ent Esc. The message
“SAVE CONFIG?” will appear.
6. Press Ent for “Yes” (to save the new configuration), and then press Esc
to return to the RUN mode normal display.
Manipulating the Completion Number, PMT Level, and PMT Balance
Changing the jumper position provides coarse gain adjustment of the

Reference PMT and therefore changes the completion number result,
PMT Level, and PMT Balance. There are six jumper positions that can
accommodate one jumper each. At least one jumper is required. Adding
jumpers increases the supply voltage available to the Reference path PMT.
This reduces the completion number, increases the PMT Balance and, to a
small degree, decreases the PMT Level. The opposite occurs if jumpers are
removed or if a single jumper is moved up from Position 1 to Position 6.
Figure 5-3 lists the effect on completion number in relation to different
jumper positions.

Jumper Positions
P300 P301
1 2 3 4 5 6
x x x x x Lower
higher PMT
x x x x Completion
balance
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
Figure 5-3. x x
Optical Bench board x x
higher
P300/P301 jumper Lower PMT
x x Completion
positions. balance
number
x x
 At least one jumper must be in P300 and P301 at all times.

NOTE

Heater Plate Heater Cartridge and RTD Replacement
Replacement of the Heater Plate Assembly’s Heater Cartridges and RTDs

is sometimes required as part of repairs to the analyzer. Generally, there is
no maintenance required for the Heater Plate, unless any of these compo-
nents fail.
This procedure describes how to remove the Heater Plate, replace its
Heater Cartridges and RTDs, and how to ensure proper positioning and
mounting of the Heater Plate Assembly while replacing it.
To replace the Heater Cartridges and RTDs in the Heater Plate Assembly:
current Flow Control Mode. To do this:
password • • (at the “PSWD0” prompt). Press Ent to display CAL
mode.
b. Enter F5 2 to display the FlowCtrl (Flow Control) Mode screen.

2. Manually zero the analyzer. Information on how to do this is de-

scribed under “Manually Zeroing the Analyzer” in Chapter 3.
3. After the zero process is complete, cap the Sample Line at the SCU
and cap the Vent Line at the Sample Vent Pipe.
! Before powering down the analyzer, test the area around the analyzer
for flammable gases. If an explosive gas atmosphere is present, do not
WARNING
power down the analyzer or any alternate power sources that sup-
ply power to the analyzer components. Proceed only when the area is
found to be safe.

Open the Electronics Enclosure and open the Analyzer and Oven
Heater fuses to disconnect power from the analyzer and the Oven
circuit. Note that disconnecting AC power from the analyzer also dis-
connects power from the Sample Line and SCU temperature-control
zone circuits. Refer to the Fuse Legend on the inside of the analyzer’s
Electronics Enclosure door for the locations of these fuses.


WARNING
5. Wearing insulated gloves, open the Analyzer Oven door and allow the
Analyzer Oven to cool down enough to ensure safe handling of the
Heater Plate and other components inside the Oven.
! The analyzer sample system will be under positive pressure.

WARNING
The Analyzer Oven enclosure and components within the Analyzer
Oven are hot; take precautions to avoid burning yourself.

Turn off the Instrument Air supply to the analyzer and then close the

The Instrument Air supply must always remain on for the Purge
Bypass Switch to operate properly.
7. After the Analyzer Oven has cooled down enough to work on, discon-
nect the Sample and Vent Line tubes from the Sample Inlet and Vent
Outlet tubes on the left side of the Analyzer Oven. Pull the Sample
and Vent Lines out of the Analyzer Oven.
Disconnect the Sample and Vent Line tubes from the Measuring Cell.
Disconnect the Aspirator Air tube from the Aspirator Air fitting inside
the Analyzer Oven.

8. Remove the Measuring Cell Assembly from the Heater Plate. The
holding screw used to secure the Measuring Cell to the Heater Plate
is located in the counter bore hole in the Heat Transfer Block. Remove
the black plug and then remove this screw using only an Allen key.
Do not use a ball driver – the head can break off inside the screw.
Wearing insulated gloves, grasp the Measuring Cell Assembly and

carefully pull it straight out from the Heater Plate. Once the Heat
Transfer Block has cleared the Sample (Measuring) Cell RTD, swing
the Optical Bench Assembly outward, away from the analyzer, us-
ing the hinge mechanism that mounts it to the Electronics Enclosure
backpan.
Various lengths of screws are encountered during disassembly. Take

 note of where each length is used and be sure to replace the ap-
NOTE
propriate screws in their original locations when reassembling the
Measuring Cell later.
9. Remove the two M6 x 16 and two M6 x 40 screws that secure the

flameproof Seal Cover to the flameproof Seal Body (see Figure 5-4).
Loosen the gland nut on the Seal Body.
10. Move the C-clip from its groove in the Thermal Insulating Tube to
the space slightly above the groove (see Figure 5-5). Remove the Seal
Cover from the Seal Body.
11. Record the termination point of each wire on the Seal PWB Assembly,
located within the Seal Body. Also, tag the wire(s) of any RTDs and/or
Heater Cartridges that will be re-used (if any) with their termination
points. This will be useful later when replacing the Heater Cartridges
and RTDs.
Disconnect the RTD, Heater Cartridge, and Ground wires from the
Seal PWB Assembly.

Figure 5-4.
Flameproof Heater/Seal
Assembly, 100-1098-1.

Figure 5-5.
Flameproof Heater/Seal, overall
assembly, WX-14324-1.

12. Unscrew the Thermal Insulating Tube from the Lower Heater Plate
and move it downward; this will partially remove the wires from the
tube.
Remove the Oven Plug (see Figure 5-5).
Rotate the Seal Body/Thermal Insulating Tube away from the analyzer
to allow more room to remove the Heater Plate. Take care to avoid
damaging the wires.
 The Thermal Insulation Tube can remain in the Seal Body.

NOTE
13. Remove the four M6 x 35 hex socket head cap screws and lock wash-
ers that secure the Heater Plate to the Oven wall.
The Heater Plate is ready to be removed from the Oven.
14. Position the wires in the Seal Assembly in a way to prevent damage to
them when removing the Heater Plate Assembly.
Tilt the top of the Heater Plate toward you and pull the Heater Plate
Assembly up and out of the Analyzer Oven.
Move the Heater Plate Assembly to a work bench or another similar

area where it can be disassembled to replace the Heater Cartridges
and RTDs.
15. Disassemble the Heater Plate Assembly and replace the Heater
Cartridges and RTDs.
a. Use a 5 mm ball driver to remove the eight M6 x 25 hex socket

head cap screws (four on each side) that secure the two halves of
the Heater Plate together.
Separate the two halves of the Heater Plate and carefully pull all of
the wiring through the Lower Heater Plate.

b. Remove the faulty RTD(s):
To remove a RTD, wrap a small piece of rubber around the RTD
tip, grip the tip with channel-lock pliers, and loosen the RTD tip.
Use short needle-nose pliers to remove the RTD Base. Repeat this
procedure for each RTD that is being replaced.
IMPORTANT
 If replacing the external RTD (“Sample Cell RTD”), do not remove
NOTE
the RTD wire at this time.
Note that the “Sulfur Condenser RTD” is an option used only for
Model 900 and Model 930 Analyzers with an oven mounted SKO
(Sulfur Knock-out).
If replacing the internal RTDs (Overtemp and Heater), unscrew

the RTDs from the Upper Heater Plate.
c. Remove the two Heater Cartridges from their channels in the

Upper Heater Plate.
d. Replace the RTDs. Refer to Figures 5-5, 5-6, and 5-7 when replacing
the RTDs.
To replace the internal Overtemp and Heater RTDs:

Thread each RTD base into the bottom of the Upper Heater Plate
and tighten each one using short needle-nose pliers.
Looking from the front of the Heater Plate, label the wire from the
RTD on the right side “Overtemp” and the RTD on the left side
“Heater” (see Note in Figure 5-5).
To replace the external Sample Cell RTD:

Push the RTD wire through the Upper Heater Plate.
Cut the RTD head off the faulty RTD. Tape the termination end of
the new RTD wire to the RTD end of the old RTD wire. Use the old
wire to pull the wire on the new RTD through the Upper Heater
Plate as you remove the old wire.
Apply Loctite 271 (AMETEK Part No. 300-4478) on the small

(lower) threads of the RTD Base (see Figure 5-7). Rotate the RTD
Assembly counter-clockwise 3 or 4 turns (carefully twisting the
wire in the process – DO NOT over stress the wire) and then
screw (clockwise) the RTD Base into the Upper Heater Plate.
Hand-tighten the RTD.

Using short needle-nose pliers, tighten the RTD Base until it is snug.
Apply Loctite 271 on the large (upper) threads of the RTD Base.
Turn the RTD Tip clockwise onto the RTD Base and hand-tighten it.
To protect the RTD Tip, wrap a small piece of rubber around it,
lightly grip it with channel-lock pliers, and tighten it until it is snug.
Looking from the front of the Heater Plate, label the wire from the
RTD on the right-centre side “Sample Cell” (see Figure 5-5).
The hole for the oven mounted Sulfur Condenser RTD – for Model
 900 and Model 930 Analyzers with an oven mounted SKO (Sulfur
NOTE
Knock-out) – is plugged with a Heater Blanking Plug (AMETEK Part
No. 300-5730).
e. If the Ground wire is damaged, replace it.

Strip 1/8" insulation from the end of the 30-inch length of high
temperature wire (AMETEK Part No. 300-4182). Use a crimping
tool to crimp an uninsulated ring terminal on the wire. Secure
the ring terminal to the bottom of the Upper Heater Plate with
a M4 x 8 hex socket button head cap screw (AMETEK Part No.
300‑0006) and a #8 shake-proof washer (AMETEK Part No.
300‑0265). Tighten it with a 2.5 mm ball driver.
f. Install the Heater Cartridges in the Heater Cartridge channels in

the Upper Heater Plate and tape together the two wires from each
heater to ensure each heater is wired to the proper termination
points.
g. Install a 3/4" anti-short (AMETEK Part No. 300-5292) around all of

the wires and into the bottom hole in the Lower Heater Plate to
protect the wires from getting damaged during handling.
h. Feed all wires from the RTDs, Heater Cartridges, and Ground
through the hole in the Lower Heater Plate (that leads to the
Thermal Insulating Tube). With the two halves of the Heater Plate
facing each other, ensure all of the wires are carefully positioned
in the wire channel in the Lower Heater Plate. Reassemble the two
halves of the Heater Plate, being careful not to pinch any wires be-
tween the two plates, and secure them together with eight M6 x 25
hex socket head cap screws. Tighten the screws with a 5 mm ball
driver.
 The Heater Cartridge and RTD replacement is now complete. Next,

prepare the Oven Enclosure for the replacement of the Heater Plate.
NOTE

Figure 5-6.
Flameproof Heater/
Seal, assembly layout,
WX-14324-1A.
16. Ensure that the front face of the oven liner is flush with the front face
of the outer shell of the Analyzer Oven.
17. With the top of the Heater Plate tilted toward you, place the bottom of
the Heater Plate in the bottom of the Analyzer Oven while taking care
to ensure the wires are not damaged. Tilt the Heater Plate backward
until it is resting against the Oven wall.
Align the Heater Plate with the mounting holes on the back of the
Analyzer Oven and replace the four lock washers and M6 x 35 hex
socket head cap screws to secure the Heater Plate to the Oven wall.
Gently push and pull on the Heater Plate while tightening the screws.
This will ensure it is properly seated against the Oven wall.

Figure 5-7.
RTD assembly
diagram, WX-14280.
18. Rotate the Seal Body/Thermal Insulating Tube toward the Analyzer
Oven until the top of the Thermal Insulating Tube is in line with the
threaded holes in the bottom of the Oven.
19. Guide the wires from the Heater Plate through the Thermal Insulating
Tube.
Ensure the threads of the Thermal Insulating Tube are clean and then
thread the tube back into the Heater Plate, taking care not to cross-
thread the threads. Tighten the tube until an increase in resistance is
felt. Do not overtighten it.
Tighten the gland nut on the Seal Body.
20. Replace the Oven Plug.

21. Reconnect the Measuring Cell to the Sample Cell RTD on the Heater
Plate. To do this:
a. Orient the Measuring Cell with the Reflector Block to the left, the
sample tube fittings vertical, and the counter bore access hole in
the Heat Transfer Block facing away from the analyzer. Replace the
screws and tighten them evenly.
b. Swing the Measuring Cell toward the Analyzer Oven.
Using an Allen key, insert the 3 mm holding screw into the counter
onto the Sample Cell RTD. Do not use a ball driver – the head can
break off inside the screw. Do not tighten the screw at this time.
 IMPORTANT
Positioning of the Heat Transfer Block in the Analyzer Oven is criti-
NOTE
cal. Improper positioning of the Heat Transfer Block can result in:
• Poor contact between the Sample (Measuring) Cell RTD tip and
• Poor alignment of the Measuring Cell Extension seal in the

Analyzer Oven and Electronics Enclosure cabinets.
c. Adjust the Measuring Cell/Optical Bench Assembly so that the

Temporarily close the Electronics Enclosure door and tighten its

screws to secure the Measuring Cell/Optical Bench Assembly in
place.
While closing the Electronics Enclosure door, verify that proper

 vertical alignment of the Optical Bench Assembly is maintained. If
NOTE
necessary, vertically align the Optical Bench Assembly by loosening

d. Verify there is no clearance between the Heat Transfer Block and
the Sample Cell RTD. The Measuring Cell Assembly must feel
secure against the Heater Plate. Gently push and pull on the
Measuring Cell Assembly to verify it is not loose.
If necessary, use an Allen key to tighten the 3 mm holding screw

until the Measuring Cell Assembly does not move when you push
and pull on it. Do not use a ball driver – the head can break off
inside the screw. Do not overtighten this screw, as doing so will
damage the threads on the RTD.
Replace the Flame Arrester (black plug) in the counter bole hole in
e. Use appropriate wrenches to reconnect the Sample Line and Vent

Line tubes to the fittings on the Measuring Cell.
f. Route the Sample and Vent Lines through their respective holes
on the left side of the Analyzer Oven. Use appropriate wrenches
to reconnect the Sample Line to the Sample Inlet tube in the
Analyzer Oven and the Vent Line to the Vent Outlet tube.
g. Reconnect the Aspirator Air tube to the Aspirator Air fitting inside
the Analyzer Oven.
22. Terminate the Heater Plate RTD and Heater Cartridge wires (and the
Ground wire, if it is also being replaced) to the Seal PWB Assembly.
Refer to Figure 5-8 for the locations of the termination points.
23. Replace the Seal Cover over the Seal Body and secure it to the Seal
Body by first tightening the two M6 x 16 screws on the left face.
Next, replace the two M6 x 40 screws on the top of the cover. Move
the C-clip back to its original position in the groove in the Thermal
Insulating Tube.

Turn on the Instrument Air supply to the analyzer and open the

Figure 5-8.
Oven Heater and Temperature
Sensor wiring, WX-14161.

! For verification purposes during power up, it will be necessary to

work with the analyzer’s covers and doors open. Before powering up
WARNING
the analyzer, test the area for flammable gases. If an explosive gas
atmosphere is present, do not apply power to the analyzer or any al-
ternate power sources that supply power to the analyzer components.
Proceed only when the area is found to be safe.
inside.

Open the Electronics Enclosure and close the Analyzer fuse to apply
AC power to the analyzer and its Sample Line and SCU temperature-
control zone circuits. Do not apply power to the Oven circuitry at this
time, until after the Leak Check has been performed.


WARNING

sphere is present.

power-disconnect switch (breaker). This will apply power to the ana-
lyzer and its Sample Line and SCU temperature-control zone circuits.
Do not apply power to the Oven circuitry at this time, until after the
Leak Check has been performed.

26. Perform a leak check on the fittings that you just reconnected by
following the procedures under “Sample System Leak Check,” in
Chapter 3.
After you are sure there are no leaks, return to this procedure and
continue with the remaining steps.
27. Power up the Analyzer Oven by closing its fuse (refer to the Fuse
Legend). Close the Electronics Enclosure door and tighten the three
M6 screws on the door to secure the Optical Bench Assembly in place.
Close the Analyzer Oven door (secure its latches). Close and secure all
other doors and covers on the analyzer, if not already done.
Allow the analyzer to warm up to operating temperature and stabi-

lize. This should take approximately 2 hours. When the analyzer is at
operating temperature, open the isolation valve on the Vent Valve (if
applicable). Open the isolation valve on the Sample Valve (or SCU) to
allow sample gas into the analyzer sample system.
28. Return the analyzer to the original Flow Control Mode by entering
CAL mode and keying in F5 2 Del n Ent, where ‘n’ is the numeric
value of the Flow Control Mode recorded earlier. Press Esc to return to
the normal RUN mode.

the Analyzer,” in Chapter 3.
30. Adjust the Aspirator Drive Air Regulator to achieve normal operat-
ing flow rates [3.0–5.0 L/min (0.1–0.2 SCFM)] as described under
“Adjusting the Sample Gas Flow Rate,” in Chapter 3.

Examining and Caring For the Flamepaths
The analyzer is designed with flamepaths that will prevent flame propa-
gation from within the analyzer and its Ex d Disconnect Enclosure to the
outside, should an internal explosion occur.
The flamepaths on the analyzer consist of:
• The Ex d Disconnect Enclosure joining surfaces (enclosure door and
housing) and its cable entry ports, seal entries, and pressure switch
entries.
During each analyzer maintenance, use a feeler gauge to check the
flamepath gap of the Disconnect Enclosure flange (enclosure door and
housing joining surfaces). The gap must not exceed 0.1 mm; if the gap
exceeds this value, contact AMETEK for advice. See Warning below.
• All separable joints in the Heater Plate Assembly and Seal Body. These
parts include the joining surfaces of the Heater Plate, the joining
surfaces of the Seal Body and its cover, the RTD mounting locations
(whether RTDs are installed or their holes are plugged), and both the
threaded and cylindrical end of the Thermal Insulation tube between
the Heater Plate and Seal Body.
During each 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 on or in
CAUTION
the Heater Plate/Seal Assemblies. Clean, defect-free threads are essen-
tial to ensure a flameproof connection.
! When performing equipment maintenance in hazardous areas, all

safety standards and procedures must be followed, as specified by the
WARNING
Owner Company, local electrical-inspection authority, and National/
EU regulations.
! Do not apply power to the analyzer if there is damage (scratches, in-

dentations, or wear) to any flamepath. Applying power to an analyzer
WARNING
with a damaged flamepath is dangerous and could result in serious
injury or death and/or serious damage to equipment.
Replace the parts immediately if damage or wear is apparent. Contact

AMETEK immediately if there is any doubt about the integrity of any
flamepath.

Disconnect Enclosure Flamepath (Joining Surfaces)
Any time the Ex d Disconnect Enclosure is opened, inspect the flamepath

for scratches, indentations, or other damage.
! If it is necessary to use a cleaning agent, make sure the power to the

analyzer is off. Also, the agent must be nonabrasive and must not at-
CAUTION
tack aluminum (example, a suitable agent is Isopropanol). Following
any maintenance and/or cleaning – and after the cleaning fluid has
evaporated completely – immediately close the Disconnect Enclosure.
! While the Disconnect Enclosure is opened for maintenance or repair,

take extreme care to avoid scratching or damaging the joining surfaces
CAUTION
(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 inadvertently scratching or damaging the flamepath.
Before closing the door, gently clean these areas with a soft, nonabra-
sive cloth and make sure they are free of debris.
! Before opening the Disconnect Enclosure, follow all necessary safety

procedures to ensure the area is nonhazardous (main power to the
WARNING
analyzer is off, explosive gas atmosphere is not present, etc.).
Before performing maintenance on the analyzer, shut off the power to

the analyzer and all alternate power supplies (if used).

Troubleshooting and Diagnostics
This section describes how the Model 909 Analyzer detects and displays
errors associated with its operation, what the errors mean, and action
to take to correct the errors. This section also discusses how to view the
alarms from the User Interface Panel and how to reset the analyzer if a
system reset is required.
Generally, most troubleshooting and diagnostics can be done by working

from the User Interface Panel on the front of the analyzer’s Electronics
Enclosure. Typical diagnostic errors to watch for include sample and
temperature-control related errors.
 Additional diagnostics screens can be viewed from the User Interface

Panel if problems cannot be corrected by performing general diagnos-
NOTE
tics. For more information about these diagnostics functions, refer to
the RUN / CFG Mode Keystrokes and CAL Mode Keystrokes descrip-
tions in Chapter 4. These diagnostics are indicated by ‘**’ preceding
their definitions.
Viewing Errors on the User Interface Panel

The analyzer sample and temperature control system incorporates a
built-in diagnostics function that continuously monitors the operation of
all analyzer operating parameters. Errors generated by operating param-
eters that exceed the factory-set parameter set points are displayed on the
User Interface Panel screen. These errors are generated by either the Host
Controller board (HStatus) or the Microcontroller board (MStatus).
Types of Errors (Alarms)
When errors are detected, a reverse-video S ( S ) is displayed on the

upper-right line of the User Interface Panel.
Descriptions of current alarm conditions can be viewed in the HStatus

(F5 4 1..8) and MStatus (F5 5 1..7) sub-menus of RUN mode. The error
description is preceded by “w” for a WARNING (e.g., “w Out of Range”)
or “f ” for a FAULT (e.g., “f Comm Fault”).
Alarms that have been reset or corrected are stored in their correspond-
ing History Buffers (HCHist or MCHist), also in RUN mode. The History
Buffers will store up to a maximum of nine alarms in each. These alarm
conditions can be viewed at any time from the User Interface Panel, which
makes this an excellent diagnostic tool.

There are two categories of alarms:
Warning Alarms
Warning Alarms indicate that the analyzer requires servicing – the
data may be suspect under this condition. As indicated earlier, the
alarm indicator S is displayed on the screen when an warning error is
detected by the system.
Fault Alarms
Fault Alarms indicate that a failure has occurred and the analyzer is
not operating properly – the results are not valid. As indicated earlier,
the alarm indicator S is displayed on the screen when a fault error is
detected by the system. Fault errors also cause the Normal/Fault relay
contacts to switch, and the sample system will automatically switch
to Backpurge mode if the current Flow Control Mode setting is “0”
(Analyzer Control).
Viewing Current Error Messages
To view the current status of error messages detected by the Host

Controller or Microcontroller board, follow the command syntax example
below:
1. From RUN mode:

To view the Host Controller board error status (HS), press F5 4.
To view the Microcontroller board error status (MS), press F5 5.
2. While viewing the error status of either board, press the appropriate nu-
meric keys to view the status for the error associated with that keystroke.
For the Host Controller board, press any key in the range of 1..8. Press
other numbers on the keypad within this range to view the status of
other errors.
For the Microcontroller board, press any key in the range of 1..7. Press
other numbers on the keypad within this range to view the status of
other errors.
If an error is current, its description will be displayed next to its as-

sociated number. If the error condition does not exist, the message
“HSz OK” (for Host Controller board errors) or “MSz OK” (for
Microcontroller board errors) appears next to its associated number.
3. To back out of either of these menus, press Esc or enter a new

Function command.

Viewing Historical Error Messages
Except for the High Temperature fault (f Temp High), all errors detected
by the analyzer’s diagnostics function will reset automatically once the
problem is resolved. By using keypad commands F5 • and F5 –, while
working from RUN mode, the analyzer allows you to view past error
status messages.
A history buffer is used for Host Controller board status messages

(HCHist z, where “z”= 1..9) and for Microcontroller board status mes-
sages (MCHist z, where “z” = 1..9). Each history buffer contains a maxi-
mum of nine error status codes. The codes displayed represent past error
conditions, with “1” being the oldest and “9” being the most recent. If
more than nine error status codes accumulate in a buffer, the oldest code
is deleted.
If two or more errors are detected simultaneously, the displayed error

status code is a sum of the primary error codes. To resolve a non-primary
status code into its primary error codes, subtract the largest primary error
code from the displayed number. Continue to subtract the largest primary
code from the remainder until a primary error code is left.
Example:
The displayed Host Controller board status code is 20. The errors detected
are:
20
- 16 f Temp Low (Fault – Host Controller)
4 f Comm Fault (Fault – Host Controller)
To view a history of the last error messages (up to nine maximum) detect-
ed by the Host Controller or Microcontroller board, follow the command
syntax example below:
1. From RUN mode:

To view the Host Controller History (HCHist) menu, press F5 •.
To view the Microcontroller History (MCHist) menu, press F5 –.
2. Up to a maximum of nine error messages can be displayed from either

history menu. Error messages are numbered “1..9”, with “1” being
the oldest and “9” being the most recent. To view the error messages,
press any key in the range of “1..9”.

Host Controller Board Alarm Conditions and
Corrective Action
This section lists valid error messages and descriptions (Condition/
Description), Alarm Type (Fault or Warning), and Suggested Corrective Action
for each. The Host Controller Status Codes (HS Code) and Host Controller
numbers (HStatus) to press on the keypad to view the current status or
errors are also listed.
The possible Host Controller board error conditions are polled individu-
ally with the keypad command F5 4 z, where “z” (z = 1..8) is defined by
HStatus. For each “z”, the corresponding error message description is
displayed if the error condition exists; otherwise the message “HSz OK”
appears.
 The “w” or “f ” preceding a message indicates a ‘w’arning or ‘f ’ault

NOTE
alarm condition.
HS Code HStatus Alarm Type Condition / Description & 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 (Condition/Description) being viewed
does not exist (where ‘z’ is the HStatus number – 1..8 – assigned to that
alarm). This is not an alarm condition.
Corrective Action:
No action is required.
1 1 Warning w EEPROM Full
This Warning condition indicates the number of times that configura-

tion data has been rewritten to the EEPROM (non-volatile memory) has
exceeded the safe number. The EEPROM should be replaced as soon as
possible (99 % of the acceptable 20K writes is used).
Corrective Action:
Take appropriate safety precautions, open the Electronics Enclosure cover,

and:
• Replace the EEPROM as soon as possible. The EEPROM is located on

the Host Controller board, inside the Electronics Enclosure. If you wish
to retain current settings following the replacement of the EEPROM,
record any values that you have changed BEFORE YOU REMOVE
THE EEPROM.
• After receiving and installing the new EEPROM, re-enter the parameters
to ensure your analyzer will operate the same as it did prior to replacing
the EEPROM. The factory-set default values will be used until the new
values are entered.
Alternatively, you can send the configuration values and P.O. number for
the EEPROM to AMETEK at the same time. At the factory AMETEK will
program the customer-specific parameters in the EEPROM. In this case,
you will only have to install the EEPROM; the parameters will take effect
immediately upon power-up.

2 2 Warning w Out of Range
This Warning condition indicates that the concentration of the output ex-
ceeds its full-scale range by more than ± 5 %.
Corrective Action:
• The parameters have exceeded the normal operating range. From the
User Interface Panel, check that the full-scale range is correct for the
current sample. To check the outputs, enter F5 1 1..4 from CAL mode.
If this warning persists during normal operation, contact the factory. A
range change and recalibration may be required.
4 3 Fault f Comm Fault
This Fault condition indicates that the Host Controller board cannot estab-
lish reliable communications with the Microcontroller board.
When this serious system fault is detected, “CommFault” will be displayed

immediately on the lower line of the User Interface Panel. The “Com-
mFault” error message indicates the same system error condition as
“f Comm Fault” (in the HStatus menu).
Corrective Action:

and (refer also to the Ribbon Cable Interconnect drawing in Appendix D, if
necessary):
• Check the ribbon cable between P203 on the Host Controller board (on
the door inside the Electronics Enclosure) and J104 on the Micro-Inter-
face board (mounted to the Electronics Enclosure backpan) for proper
connections and inspect it for damage (cuts, nicks, burn marks, etc.).
• Check the actuators on switch S100 on the Micro-Interface board and

ensure that they are positioned toward the middle of the board. See
Figure 5-9 for the location of this switch.
8 4 Fault f RxData Fault
This Fault condition indicates that the Host Controller board is not receiv-
ing analytical data from the Microcontroller board.
When this serious system fault is detected, “NoData” will be displayed im-
mediately on the lower line of the User Interface Panel. The “NoData” error
message indicates the same serious system error as “f RxData Fault” (in
the HStatus menu).
Corrective Action:

necessary):
• Check the ribbon cable between the Optical Bench board (J103) and
the PMT (photomultiplier tube) buffer (J1) for proper connections and
inspect it for damage (cuts, nicks, burn marks, etc.).
• Check the PMT high-voltage connections at the Optical Bench board

(J101, J102) for proper connections.
the Micro-Interface board (J102) for proper connections and inspect it
for damage (cuts, nicks, burn marks, etc.).

16 5 Fault f Temp Low
This Fault condition indicates that one or more of the temperature-con-

trolled zones is operating below its set point value by more than 5 % of the
set point value.
If the TCold parameter is used, the Sample Line and SCU still use 5 % of
the set point as an alarm point. However, the Analyzer Oven temperature
uses the TCold value as an alarm set point.
This error will occur during a cold start, but will clear when the operat-
ing temperature of all controlled zones are within their normal operating
ranges.
If this alarm is caused by low temperatures in any of the temperature-

controlled zones, the analyzer will automatically switch to Backpurge mode
to ensure the system does not become plugged due to a low temperature
in one of its zones.
This error can also be caused by a power interruption or a power spike.
Corrective Action:
• From the User Interface Panel:
- Check current operating temperatures for each temperature zone and

compare them to their set point temperatures.
- Check each of the associated configuration parameters for tempera-

ture 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 Enclosure

cover, and:
- Check the fuse(s) for the zone(s) which caused the alarm. Refer to
the Fuse Legend on the inside of the analyzer’s Electronics Enclosure
door for the locations of these fuses.
• Other checks/corrective action:
- Check the electrical connections between the heater and the Sample
Line, SCU, and Analyzer Oven. Check for proper connections and
damage to the lines and wiring.
For over-temperature wiring details, refer to the Sample/Vent Line Wir-

ing drawing (Figure 5-10a) for GP/Div 2 analyzers or the Disconnect
Enclosure Wiring drawing (Figure 5-10b) for 120 V, Zone 1 analyz-
ers. For 240 V, Zone 1 analyzers and other related drawings, refer to
Appendix D, the “Supplemental Information” section of this manual, or
- Using an Ohm Meter, measure the resistance of the temperature

sensor (RTD) for the zone(s) which caused the alarm (enter F4 4 1..4
from RUN mode). Test it for an open circuit. If the RTD is faulty, con-
tact AMETEK for assistance.
- Replace the Temperature Daughter board(s). Contact the factory

to verify operation before removing this board.
- Replace the Termination board. Contact the factory to verify op-

eration before removing this board.

32 6 Fault f Temp High
This Fault condition indicates that one or more of the temperature-con-

trolled zones has exceeded its over-temperature limit of 177 °C/350 °F.
This alarm is generated by the Temperature Daughter board(s). Upon

detection of this alarm, the analyzer automatically switches to Backpurge
mode and also de-energizes the over-temperature relay for the zone that
has exceeded its limit. This cuts power to the corresponding heater(s).
The alarm must be manually reset by pressing SW300 on the Termination

board (Figure 5-11), located within the Electronics Enclosure. This will also
re-energize the Sample Line and SCU over-temperature relays, which will
restore power to the Sample Line and SCU heaters.
Corrective Action:
• From the User Interface Panel:
- Check the current operating temperature for each temperature zone

and compare it to its set point temperature.
- Check each of the associated configuration parameters for tempera-

ture 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 Enclosure

cover, and:
- Check the green LEDs for each circuit, located on the Termination
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 OverTemp circuit. Refer to the Fuse Legend on
the inside of the analyzer’s Electronics Enclosure door for the loca-
tions of these fuses.
• Other checks/corrective action:
- Check the electrical connections between the heater and the Sample
Line, SCU, and Analyzer Oven. Check for proper connections and
damage to the wiring.
For over-temperature wiring details, refer to the Sample/Vent Line Wir-

ing drawing (Figure 5-10a) for GP/Div 2 analyzers or the Disconnect
Enclosure Wiring drawing (Figure 5-10b) for 120 V, Zone 1 analyz-
ers. For 240 V, Zone 1 analyzers and other related drawings, refer to
Appendix D, the “Supplemental Information” section of this manual, or
- Using an Ohm Meter, measure the resistance of the temperature

sensor (RTD) for the zone(s) which caused the alarm (enter F4 4 1..4
from RUN mode). Test it for an open circuit. If the RTD is faulty, con-
tact AMETEK for assistance.
- Replace the Temperature Daughter board(s). Contact the factory

to verify operation before removing this board.
- Replace the Termination board. Contact the factory to verify op-

eration before removing this board.

64 7 Warning w ZDrift/SpnErr
This Warning condition indicates excessive Zero Drift or Span Error. Exces-
sive Zero Drift is indicated if Zero Gas transmission values attained after a
Zero function differ by more than ±10 % from the previous values. A Span
Error occurs if a span factor attained after a Span function is ≤ 0.85 or
≥ 1.15.
Corrective Action:
• Check that the proper gases are being used for the calibration functions.
• Check the analyzer to determine if the Measuring Cell, its optics, and/
or sample system are contaminated. Refer to the “Analyzer Preventive
Maintenance Schedule” and “Measuring Cell Preventive Maintenance”
in this chapter for more information to help you determine if any of these
areas need to be cleaned. Procedures to clean these parts are listed
128 8 Warning w TZone3
This Warning condition indicates a high temperature condition on Tempera-

ture-Controlled Zone 3.
Corrective Action:
• This temperature zone is currently spare; the alarm is currently not used.
Figure 5-9.
Micro-Interface board.

Figure 5-10a.
Sample/Vent Line Wiring,
GP/Div 2 Analyzers.

Figure 5-10b.
Sample/Vent Line Wiring, 120V
(Disconnect Enclosure), Zone 1
Analyzers.

Figure 5-11.
Over Temp alarm
reset switch (SW300),
Termination board.

Microcontroller Board Alarm Conditions and
Corrective Action
This section lists valid error messages and descriptions (Condition/
Description), Alarm Type (Fault or Warning), and Suggested Corrective Action
for each. The Microcontroller Status Codes (MS Code) and Microcontroller
numbers (MStatus) to press on the keypad to view the current status or
errors are also listed.
The possible Microcontroller board error conditions are polled individu-

ally with the keypad command F5 5z, where ‘z’ (z = 1..7) is defined by
MStatus. For each ‘z’, the corresponding error message description is
displayed if the error condition exists; otherwise the message “MSz OK”
appears.
 The ‘w’ or ‘f ’ preceding a message indicates a ‘w’arning or ‘f ’ault

alarm condition.
NOTE
MS Code MStatus Alarm Type Condition / Description & Suggested Corrective Action
0 — — MSz OK
If the MS Code returned is ‘0’ and the message displayed is “MSz OK”, it
indicates that no Warning or Fault (Condition/Description) exists (where
‘z’ is the MStatus number – 1..7 – assigned to that alarm). This is not an
alarm condition.
Corrective Action:
No action is required.
1 1 Fault f Pulse Timing
This Fault condition indicates that there is a problem with control parameter
updating and pulse timing. This can be caused by a power interruption.
Corrective Action:
• Reset the analyzer by simultaneously pressing • and Ent on the User

Interface Panel. The message “Reset In Progress” should be displayed
within one second after these keys have been pressed.
2 2 Fault f On-board ADC
This Fault condition indicates one or both of the discrete analog-to-digital

converters (ADC) is not responding.
Corrective Action:

and:
• Replace the Microcontroller board. Contact the factory to verify

operation before removing this board.

4 3 Fault f On-Chip ADC
Two possible errors may be occurring, either:
• The Microcontroller board’s internal analog-to-digital (ADC) converter

is not responding.
and/or
• One or more of the operating temperature sensing RTDs has failed,

causing its temperature zone to read “181.4 °C” on the User Interface
Panel (seen by pressing F6 8 z from CFG mode, where ‘z’ = Microcon-
troller Analog Inputs 1..8). Upon detection of either fault, the analyzer will
automatically switch the system into the Backpurge mode until the error
has been corrected.
Note: A temperature zone can indicate “181.4ºC” but not trigger this
alarm if its set point (TStPt, F4 0, RUN mode) is set to zero, such
as is typically the case for a spare temperature zone.
Corrective Action:

and:
• Replace the Microcontroller board. Contact the factory to verify

operation before removing this board.
and/or
• From RUN mode, press F4 0 and then press 1..4 to check the set point
value for each temperature-controlled zone. If a heated external probe
is used, press F1 – and then press 3 and then 4 to check the Probe
Temperature (low/high) alarm set point values.
From RUN mode, press F6 8 and then press 1..8 to check the current
temperature for each temperature-controlled zone (including the External
Probe, if used).
• Using an Ohm meter, measure the resistance of the temperature sensor

(RTD) for the zone(s) which caused the alarm and test it for an open
circuit. If the RTD is faulty, contact AMETEK for assistance.
• Replace the Temperature Daughter board(s). Contact the factory to

verify operation before removing this board.
• Replace the Termination board. Contact the factory to verify opera-

tion before removing this board.

8 4 Warning w PMT Signals
This Warning condition indicates the highest signal from either the Mea-
sure or Reference PMT (photomultiplier tube) is outside its normal range
(5.0–9.84 VDC). To check these values, press F6 1 from RUN mode.
Corrective Action:

necessary):
the PMT buffer (J1) for proper connections and inspect it for damage
(cuts, nicks, burn marks, etc.).

the Micro-Interface board (J102) for proper connections and inspect it
for damage (cuts, nicks, burn marks, etc.).
From the User Interface Panel:
• Check to make sure that the Automatic Lamp Control (ALC) is On. To do
this:
From the RUN mode, press F2 7 to view the ALC Enable function.
- ALC is On if ‘ALC 1’ is displayed.
- ALC is Off if ‘ALC 0’ is displayed.
If the ALC setting is ‘0’, enter CFG mode and press F2 7 to view the
ALC Enable function. Then, press Del 1 Ent Ent to turn it On.
16 5 Fault f Comm Error
This Fault condition indicates that the Microcontroller board cannot estab-
lish reliable communications with the Host Controller board.
Corrective Action:

necessary):
• Check the ribbon cable between P203 on the Host Controller board (on
the door inside the Electronics Enclosure) and J104 on the Micro-Inter-
face board (mounted to the Electronics Enclosure backpan) for proper
connections and inspect it for damage (cuts, nicks, burn marks, etc.).
• Check that the actuators on switch S100 on the Micro-Interface board

are positioned toward the middle of the board. See Figure 5-9 for the
location of this switch.

32 6 Warning w Lamp Control
This Warning condition indicates that one or both lamp pulse current-
control signals has exceeded its Lamp Maximum signal set point. Nominal
value is 6.0 V (may vary, check EEPROM Data Sheets for actual value).
This error may occur during a cold start, but should clear after the source
lamps have stabilized.
Corrective Action:

necessary):
• Check that the lamp sockets are attached securely to the lamps and that
the Lamp Retaining Bar is in place.
• Check that the lamps are inserted completely into the detector assembly.
the PMT buffer (J1) for proper connections and inspect it for damage
(cuts, nicks, burn marks, etc.).

From the User Interface Panel:
• The 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.
To initiate an Auto-Setup, enter CFG mode and press F1 •. The Auto-
Setup starts immediately.
64 7 Fault f Oven Heater
This Fault condition indicates the Oven Heater Plate temperature is ap-
proaching its over-temperature limit of 177 °C (350 °F); a soft shutdown of
the heater will occur. A soft shutdown of the heater will also occur when the
Oven door is open.
A soft shutdown means the system will shut down the heater to ensure the
temperature of the heater plate does not continue to increase and exceed
its temperature rating.
This error will occur during a cold start, but will clear after all of the temper-
ature-control zones have stabilized within their normal operating range.
Corrective Action:

and:
• Using an Ohm Meter, measure the resistance of the Measuring Cell RTD
and test it for an open circuit. If the RTD is faulty, contact AMETEK for
assistance.

Analyzer Reset
Should a situation arise where the Host Controller board or the
Microcontroller board must be reset, simultaneously press • and Ent on
the User Interface Panel. The message “Reset In Progress” should be dis-
played within one second after these keys have been pressed.
! Do not randomly reset the analyzer during normal operation.

Typically, the only resets required are in cases where the Host
CAUTION
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.


Service & Parts
This chapter discusses what to do if you need technical support from

AMETEK, or if you are returning parts for service. This chapter also lists
the recommended spare parts to have on hand to ensure all consumable
and replaceable parts are available for service according to the “Analyzer
Preventive Maintenance Schedule” in Chapter 5.
Technical Support
AMETEK Western Research is committed to providing you the best tech-
nical support in the industry. If you need service or application assistance,
contact your local or nearest AMETEK Service Centre or the AMETEK
factory AMETEK at (403) 235-8400 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.
NOTE
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 are unable to find an
explanation for your problem in this manual, please gather the following
information prior to contacting AMETEK:
• Model number of the analyzer.
• Serial number of the analyzer.
• Purchase order number.
• AMETEK part number for the specific component you are enquiring
about, if known.
• Information describing the problem.
• Billing address, shipping address, and telephone number.
Service & Parts | 6-1

Returning Equipment
If you need to return parts or equipment for repair, you will need a
Return Material Authorization (RMA) number. This will ensure your
equipment is serviced and returned to you in a prompt and efficient man-
ner. To obtain an RMA number, contact your local or nearest AMETEK
Service Centre and have the following information available:
• Model number of the analyzer.
• Serial number of the analyzer.
• Purchase order number.
• Billing address, shipping address, and telephone number.

?? ANSWERS TO YOUR QUESTIONS ??
The choice is yours...

Whether by phone or in person, we can meet the needs required to keep your
analyzer running at peak performance. Our factories are located in Calgary,
Alberta and Newark, Delaware with a Sales & Service Centre in Houston,
Texas. Depending on the programs you select, we will have a factory-trained
MINUTES OR HOURS, representative talking to you within minutes – 24 hours a day, 365 days a year
WE’RE THERE FOR YOU or on-site within 24 hours. We stock parts at all three locations.
ANYTIME / ANYWHERE
AMETEK SERVICE & AFTERMARKET SALES SUPPORT
• PRE-lNSTALLATlON INSPECTIONS • ASAP

To ensure you order the correct analyzer with the AMETEK SERVICE ASSISTANCE PROGRAM.
options your operation requires, schedule a factory- AMETEK’s exclusive ASAP program lets you select
trained Service Engineer to inspect the proposed a service package from a menu of service options.
analyzer location. The on-site charge for this visit ASAP options include 24 hour phone support, 24
can be deducted from the start-up charge if you hour on-site guarantee, rapid parts shipment, and
select that option. many more service benefits. ASAP plans may be
written to provide coverage for a single analyzer,
• START UPS or all of the AMETEK process analyzers at your
Your decision to buy an AMETEK analyzer is greatly facility.
appreciated. After the time and money spent on your
analyzer, wouldn’t you expect a fast and successful • AFTERMARKET SALES
start up? We can ensure that will happen! Schedule Our Aftermarket Sales group will keep you supplied
us to be there before you power up the system. We with the parts to maintain your analyzer to factory
will guarantee a satisfactory commissioning of your specifications. This is also the group that will keep
analyzer. your analyzer current with upgrades and retrofits.
• WARRANTY VALIDATION • TECHNICAL SUPPORT
Upon start-up, we will validate your 1 year warranty. Just call AMETEK and a factory trained Service
AMETEK’s warranty policy covers all parts and on- Engineer will be there to answer your questions.
site time. Incurred costs will be the responsibility of With over 200 years of combined field service ex-
the customer. perience, our engineers are available to provide
operational support or troubleshooting expertise.
• WARRANTY EXTENSIONS
AMETEK offers a 2 or 3 year warranty extension • TRAINING
for your analyzers. The warranty is identical to the We will train your service technicians at our
original policy supplied with the analyzer. Contact Technology Transfer Centres located in Calgary,
AMETEK Service for more details. Newark, or at your facility. Our TTCs have equip-
ment similar to yours for hands-on training. A
• SPARE PARTS diploma will be presented upon completion of the
These parts allow each customer to properly main- course.
tain their analyzers according to the recommended
Preventive Maintenance Schedule (listed in the
manual), to ensure optimal operations.
PROCESS INSTRUMENTS
Canada: 1-800-661-9198 U.S.A.: 1-800-537-6044

Recommended Spare Parts
This section lists the recommended spare parts to have readily available
for the Model 909 Analyzer.
 IMPORTANT SPARE PARTS INFORMATION

Spare Parts for your analyzer may vary from those included in
NOTE
this section. This can be due to applications using non-standard
Measuring Cells or optional equipment.
If the analyzer uses a Sample Conditioning Unit (SCU) or “Probe,”

refer to either the “AMETEK SCU (Probe) Preventive Maintenance
Parts” list or the “M&C Probe Preventive Maintenance Parts” list,
depending on the probe type used for the application.
Before ordering spare parts (for applications measuring gas species

other than SO2 or H2S), refer to the “Supplemental Information”
section of this manual or the Documentation Package shipped with
the analyzer for a Custom Recommended Spare Parts list. If included,
use those Part Numbers; if not, use the Part Numbers listed in this
section.

Optical Bench/Measuring Cell Spare Parts
AMETEK recommends having the following spare parts available to
ensure your analyzer will operate at peak efficiency. The replacement of
these parts is required as part of the Analyzer Preventive Maintenance
Schedule. It is also necessary to have these parts on hand in case the parts
become damaged or contaminated, and need to be replaced.
The “Drawing No.” in parentheses below the Part No. in the “Preventive
Maintenance Parts” list indicates the drawing to refer to in Appendix D
for the location of the part in the analyzer. Or, refer to the Note following
certain lists for drawing numbers.
 In the event of natural degeneration, damage, or other failure of a

Source Lamp, AMETEK recommends changing out both Source
NOTE
Lamps to ensure optimal operation.
(*) Note the ordering part numbers for the different Source Lamps
and order only the appropriate type and quantity of Source Lamps.
To verify the lamp type, open the analyzer and check the label on the
lamps.
120 VAC/240 VAC Analyzer

Preventive Maintenance Parts
Part No.
(Drawing No.) Description Qty (1 Year) Qty (2 Year)
Note: Lamp type is dependent on species being measured.
100-0688 SO2 applications

(WX-14856) Magnesium (Mg) Source Lamp 2 4
(Optical Bench – Lamp1, Lamp 2) [See (*) Note] [See (*) Note]
OR
300-2070 H2S applications
(WX-14856) Cadmium (Cd) Source Lamp 2 4
(Optical Bench – Lamp1, Lamp 2) [See (*) Note] [See (*) Note]
300-0281 Cell Window, Fused Silica 4 6
(WX-14856) (Measuring Cell)
100-1911 O-Ring size 125, Baled Teflon Coated AFLAS 8 16
(WX-14856) (Measuring Cell)
Content is subject to change without notice.

Sample Conditioning Unit (SCU) Spare Parts
AMETEK recommends having the following spare parts available (for
either the AMETEK SCU or M&C Probe) to ensure the SCU (Probe) will
operate at peak efficiency. The replacement of these parts is required as
part of the Preventive Maintenance Schedule. It is also necessary to have
these parts on hand in case the parts become damaged or contaminated,
and need to be replaced.
AMETEK 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
These parts are required only if an AMETEK SCU (Probe) is used. Content is subject to change without notice.
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 Seal O-Ring, 39 mm 1 2
300-9269 Lid Seal O-Ring, 55 mm 1 2
These parts are required only if an M&C Probe is used. Content is subject to change without notice.

Spare Analyzer Fuses
AMETEK recommends having on-site the spare fuses used in the analyz-
er. These fuses do not need to be changed out at regular intervals, but are
necessary in the event that a replacement is required.
120 VAC/240 VAC Analyzer Fuses

120 V 240 V
Description Part No. Fuse Type Part No. Fuse Type
Analyzer (TB2-1) 300-8572 1.6 A 300-4189 0.75 A
Over-Temp Power Supply 300-1519 63 mA 300-5097 32 mA
(TB2-2)
Oven Heater (TB2-3) 300-4550 4 A 300-4548 2A
Termination Solenoids 300-4189 0.75 A 300-5557 400 mA
(TB2-4)
Calibration Solenoids 300-4189 0.75 A 300-4189 0.75 A
(TB2-5)
O2 Sensor (TB2-6) 300-5465 3.15 A 300-5924 1.6 A
(*) 24 VDC Power Supply 300-4189 0.75 A 300-5557 400 mA
(TB2-7)
All analyzer fuses located at TB2 in the Electronics Enclosure (see the Electronics Enclosure Layout drawing and Analyzer
AC Wiring WX-102853 drawing in Appendix D) for locations of these fuses.
(*) Note: Purgable Deluxe (PD = GP or Div 2 only) Analyzers do not use the 24V fuse or the 24V Power Supply.
Sample and Vent Line (or SCU) Fuses

Part No. Fuse Type
300-9291 6A
300-9443 8A
300-9292 10 A
300-9293 16 A
300-6312 20 A
Sample Line fuse is located at TB3-30 on GP/Div 2 analyzers, or at TB5-1 on Zone 1 analyzers.
Vent Line fuse is located at TB3-50 on GP/Div 2 analyzers or at TB6-1 on Zone 1 analyzers.
See Sample/Vent Line wiring drawings for your application, in Appendix D.
 The Sample and Vent Line (or SCU) fuses are typically no longer
used; however, if fuse terminals are retrofitted for these temperature
NOTE
zone circuits, the fuse required will depend on line length, voltage,
and power consumption. If the original factory-installed or retrofitted
fuse blows, remove it to determine the fuse type required.

AMETEK Sample Conditioning Unit (SCU) Fuse (Probe), Optional
120 V 240 V
Sample Conditioning Unit 300-9443 8 A 300-9291 6A
This fuse is located in the AMETEK SCU and is only required if an SCU is used.
Optical Bench Board Fuses (100-1662)

120 V 240 V
Main Board (F200) 300-8778 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
See Optical Bench board layout (100-1662) in Appendix D.
Disconnect Enclosure Fuse (Zone 1 and CE analyzers)

Customer Signal Termination Board (100-1215-2)
Part No. Fuse Type
300-5790 125 mA
This fuse is located at F100 on the Customer Signal Termination board,
in the Disconnect Enclosure.

Replacement Boards
 These boards apply to 120 VAC and 240 VAC analyzers, and are
required only in the event of failure or damage to a board.
NOTE
Board Replacement Part Numbers

Part No. Description Qty
100-0116 Micro-Interface Board, Type “A” 1
100-0117 Microcontroller Board 1
100-0136 Keypad Board 1
100-0138 Host Controller Board (Display Interface) 1
100-1534 Termination Board (Hi-Temp) 1
100-1662 Optical Bench Board 1
100-0140 Dual PMT Buffer Board 1
100-0939 Display I/O Expansion Board 1
100-1096 Temperature Daughter Board (4 RTDs) 1
OR
100-1097 Temperature Daughter Board (2 RTDs, 2 Thermistors) 1
100-1215* Customer Termination Board (Zone 1) 1
(Disconnect Enclosure)
100-1214* Sample/Vent Line RTD Termination Board (Zone 1) 1
(Disconnect Enclosure)
Refer to the Overall Component Layout drawing and the Ribbon Cable Interconnect drawing (WX-102836) for the location
of the boards in the analyzer.
* Used with Zone 1 analyzers only.


Software Glossary
User Interface Panel Abbreviations

This listing describes all of the screen titles and characters displayed on
the User Interface Panel.
Complete details of all screen titles, messages, and abbreviations are

described under “Defining RUN / CFG Mode Keystroke Terms” and
“Defining CAL Mode Keystroke Terms” in Chapter 4.
Term/Character Definition
b Analyzer-selected (automatic) Backpurge Flow mode, displayed on the
upper-left line while the analyzer is operating in Analyzer Control mode.
B User-selected (manual) Continuous Backpurge Flow mode, displayed
on the upper-left line when the user manually changes the Sample
Control function to Continuous Backpurge Flow mode.
This character is also displayed when the Remote Backpurge function is

activated by the user via a remote dry (potential free) contact opening.
C User-selected (manual) Continuous Calibration Gas Flow mode (Gas
#1 or Gas #2), displayed on the upper-left line when the user manually
changes the Sample Control function to Continuous Calibration Gas
Flow mode.
CAL CALibration mode
CFG ConFiGuration mode
f Precedes an error message, which indicates the error is a ‘f’ault alarm
(e.g., “f Temp Low”).
RUN RUN mode
S User-selected (manual) Continuous Sample Flow mode, displayed on
the upper-left line when the user manually changes the Sample Control
function to Continuous Sample Flow mode.
S Reverse-video S – The detection of an on error by the built-in error

detection system is indicated by this character at the right end of the top
line.
w Precedes an error message, which indicates the error is a ‘w’arning
alarm (e.g., “w PMT Signals”).
Z User-selected (manual) Continuous Zero Gas Flow mode, displayed on
the upper-left line when the user manually changes the Sample Control
function to Continuous Zero Gas Flow mode.
Software Glossary | 7-1

Abbreviations Used in This Manual
Abbreviation Full Term
ADC analog-to-digital converter
A/D analog-to-digital
BRAM battery backed random access memory
D/A digital-to-analog
DCS Distributed Control System
Div 2 (Analyzer) Division 2
DP differential pressure
EEPROM electrical-erasable-programmable-read-only memory
GP (Analyzer) General Purpose
HAI Host Controller Board Analog Inputs
MAI Microcontroller Board Analog Inputs
Modbus® Modbus is a registered trademark of Modicon, an AEG
company.
PD (Analyzer) Purgeable Deluxe (General Purpose and/or Division 2)
PID proportional, integral, differential
PMT photomultiplier tube
RTD resistance temperature device
SCU Sample Conditioning Unit
SPDT single pole double throw
SRAM static random access memory
SSR solid-state relay
SKO sulfur knock out (sulfur condenser)

Appendix A – Options
O2 Concentration Measurement
The O2 concentration can be measured using a Zirconia Oxide O2 Sensor
installed in the Analyzer Oven, and displayed on the User Interface Panel.
(The O2 Sensor is optional, and is for use in General Purpose applications/
analyzers only.) The manual for the O2 Sensor (if used) accompanies the
analyzer when this option is installed at the factory.
 Drawings of the Zirconia Oxide O2 Sensor (Electronics Panel Layout

and Wiring Connections) are located in Appendix D.
NOTE
Calibration of the O2 Sensor requires the use of two calibration gas mix-
tures. The first gas is air; the second gas is an O2 calibration gas mixture.
The air is used to obtain the air reference point. Since the O2 concentra-
tion is determined relative to air, this air reference point establishes the
O2 Sensor zero point. The usual concentration of O2 in dry air is 20.95
mole percent. The calibration gas mixture O2 concentration usually is cho-
sen to be near the normal O2 concentration of the stack duct.
 The Model 909 Analyzer and O2 calibration gases must not contain
any component that may interfere with the correct operation of the O2
NOTE
Sensor. Refer to the Zirconia O2 Sensor Instruction Manual.
Appendix A – Options | A-1

SSR Outputs
The analyzer must be configured for which solenoid valve controls which
calibration gas mixture. The solenoid valves are controlled by the analyzer
solid state relay (SSR) outputs. If instrument air is used as the zero gas,
then the O2 zero gas solenoid is assigned to SSR output ‘0’. Nitrogen (N2)
or another inert gas may be used to zero the ultraviolet portion of the
analyzer system.
When nitrogen is used as the zero gas the O2 Sensor cannot be cali-
brated during an Auto-Cal sequence. SSR output ‘10’ (pseudo SSR) must
be assigned to the O2 zero gas solenoid to prevent inadvertent Auto-
Calibration. The solenoids controlling the calibration gas mixtures are
assigned to SSR outputs 1 or 2 are preset at the factory.
To determine SSR output assignments, enter CAL mode and key in:
F5 4 The message “Sol:O2Z b” will be displayed, where ‘b’ = ‘0’ or

‘10’, and is the O2 zero gas solenoid valve SSR output assign-
ment. SSR output ‘0’ will always be assigned when the ultravi-
olet portion of the analyzer is zeroed with air. SSR output ‘10’
(pseudo SSR) will always be assigned when the ultraviolet
portion of the analyzer is zeroed with nitrogen.
F5 5 The message “Sol:O2S b” will be displayed, where ‘b’ = ‘1’ or

‘2’, and is the span gas solenoid valve SSR output assignment.
Record this value.
Press Ent to return to CAL mode normal display or Esc to return to RUN
mode normal display.
A-2 | Model 909 Single-Gas Analyzer

Entering Calibration Gas O2 Concentration
The concentration of O2 in the two-Calibration Gas mixture (O2Conc)
used with the analyzer must be entered before initiating a calibration
sequence. The O2 concentration unit of measurement is mole percent and
the maximum value allowed is 25 mole percent. Fractional values are en-
tered using the normal decimal notation (i.e., 10.45 mole percent).
 If a Calibration Gas is not used, the O2 concentration must be set to

zero.
NOTE
Example 1:
To enter a value of 20.95 O2 concentration (mole percent) in the zero air
and return to CAL mode normal display, key in:
Example 2:
To enter a value of 3.22 O2 concentration in the O2 calibration gas mixture
(mole percent) and return to CAL mode normal display, key in:
O2 Span Timer
The O2 Span Timer establishes the time period for which the Solenoid
Valve controlling the O2 Calibration gas is energized during the Auto-
Span and Auto-CAL sequences. The O2 Span Timer duration depends
on the time required for the CAL Gas to reach the analyzer and to obtain
a stable reading. Setting the O2 Span Timer to a non-zero duration au-
tomatically adds calibration of the O2 Sensor to the Auto-CAL sequence
when it is enabled.
The duration may be set from 0–255 minutes in one-minute increments.

Setting the duration to zero turns the O2 Span Timer Off.
Example:
To set Timer2 (O2 Span Timer) to 3 minutes and return to CAL mode nor-
mal display, key in:
F3 2 Del 3 Ent Ent

Auto-Calibration
The Auto-Calibration function turns on, in sequence, each of the solenoid
valves controlling the calibration gas mixtures. The concentration of the
component in the calibration gas mixtures and the timers must be set to
proper values before initiating an Auto-Calibration.
When an Auto-Calibration is performed the following sequence of events

occurs automatically:
1. The corresponding solenoid is turned on to let the Zero/Span gas flow

through the analyzer system.
2. The corresponding timer duration is displayed on the first line of the

display and is counted down to zero.
3. The zero or span is adjusted to the proper value based on the average
of the readings during the last 25 % of the time period of the count-
down. Upon completion of the Auto-Zero/Auto-Span functions, CAL
mode normal display is returned. The Integration Timer (IntTime)
does not affect the averaging time for the Auto-Zero/Auto-Span
functions.
NOTE
4. The CAL status relay will stay on for an additional delay time (min-
utes) as determined by the Sample Delay Timer (SDelay) to allow for
a smooth transition from the Zero/Span gas back to the sample gas.
The analyzer display gives no indication that this is occurring. Only
those timers that are set to a non-zero value will be included in the
sequence. When air is used as the zero gas for the ultraviolet portion
of the analyzer system, it is also used to calibrate the air point for the
O2 Sensor. Then, calibration gases are used to determine the span fac-
tors for the component for which the analyzer is configured, namely
O2. A sample Zero and Span sequence where air is used as the zero
gas is illustrated in Figure A-1.
 The Model 909 Analyzer and O2 Sensor are zeroed simultaneously

but spanned individually.
NOTE
When nitrogen is used as the zero gas for the ultraviolet portion of the
Model 909 Analyzer, calibration of the O2 Sensor air point (zero) can-
not be included in any of the Auto-Calibration sequences. A manual
Zero/Span must be performed to calibrate the O2 Sensor.

Sample Auto Zero and Span Sequence Sample
Mode Mode
SSR Output 0 SSR Output 1 SSR Output 2

Timer0 Timer1 Timer2
Sol Valve 0 Sol Valve 1 Sol Valve 2
UV Zero
O2 Zero (Air)
UV Span
(e.g. SO2)
O2 Span with
O2 Cal gas
Figure A-1.
Example zero/span
sequence.

Manual O2 Sensor Zero/Span
The Manual Zero and Span functions for the O2 Sensor do not activate
the Solenoid Valves. The gases must be introduced manually into the
analyzer – using the FlowCtrl function – and allowed to flow through the
sample system until a stable reading is displayed. The time required for
gas to reach the analyzer and a stable reading to be displayed, is depen-
dent upon the volume of the sample system and the gas flow rate. The
Calibration Gas concentration must be entered before performing the
Zero/Span function.
 IMPORTANT
The Zero function must be performed before the Span function.
NOTE
NOTE
Manual O2 Sensor Zero (Air)
To manually Zero the ultraviolet portion of the analyzer system and Zero
and Span the O2 Sensor:
1. Zero the ultraviolet portion of the analyzer:
a. Turn on the Zero Gas (air).
b. Enter CAL mode and press F5 2 and record the numeric value
displayed (FlowCtrl).
c. Force the analyzer sampling mode to Continuous Zero Gas Flow

mode by keying in Del 10 Ent.
d. Press F2 0. The display will prompt “Man/Zero?”.
e. Observe the concentration reading(s) on the bottom line of the

display. When the reading(s) have stabilized at or near air point
(20.95 %), press:
Ent for Yes Timer0 will begin to count down to zero time. The
analyzer and O2 Sensor values will be adjusted
automatically based on the average of the reading
during the countdown if AdjDisable is set to ‘0’.
Esc for No The function is aborted; the analyzer value is not

adjusted.

2. Zero the O2 Sensor:
a. Press F2 9. The display will prompt “Man/ZeroO2?”.
b. Observe the O2 concentration reading on the bottom line of the

display. When the O2 reading has stabilized at or near air point
(20.95 %), press:
Ent for Yes The timer will count down to zero during which
time the readings are averaged. The air point values
will be adjusted automatically if AdjDisable is set to
‘0’.
Esc for No The function is aborted; the O2 Sensor value is not

adjusted.
c. Turn off the Zero Gas (air).
3. Span the O2 Sensor:
a. Connect the O2 Calibration Gas to the Zero Gas inlet and turn on
the O2 Calibration Gas.
b. Press F2 8. The display will prompt “Man/SpanO2?”.
c. Observe the O2 concentration reading on the bottom line of the

display. When the O2 reading has stabilized at or near the O2 con-
centration in the calibration gas mixture press:
Ent for Yes Timer y will begin to count down to zero. The O2
span value will be adjusted automatically based on
the average of the reading during the countdown if
AdjDisable is set to ‘0’.
Esc for No The function is aborted; the O2 Sensor value is not

adjusted.
d. Turn off and disconnect the O2 Calibration Gas.
4. Reconnect the zero gas (air) and turn it on.
5. Press F5 2 Del z Ent (where ‘z’ is the value recorded in Step 2) to re-
turn the analyzer to the original sampling mode.
6. Press Esc to return to RUN mode normal display.
The Analyzer Zero, O2 Zero, and O2 Span are complete.

Manual O2 Sensor Zero (Nitrogen/Air)
 Sol:O2Z must be assigned the pseudo-solenoid number ‘10’ before

proceeding with the Zero function.
NOTE
Nitrogen (N2) or another inert gas can be used to zero the UV portion of
the analyzer. Because there are only four SSR outputs available for con-
trolling solenoid valves, a manually operated 3-way valve must be in-
stalled at the Zero Gas inlet of the solenoid manifold block.
When nitrogen is used as the zero gas the O2 Sensor cannot be calibrated
during an Auto-Cal sequence. SSR output ‘10’ (pseudo SSR) must be as-
signed to the O2 zero gas solenoid before proceeding with the zero func-
tion to prevent inadvertent Auto-Calibration. The solenoids controlling
the calibration gas mixtures are assigned to SSR outputs 1 or 2 are preset
at the factory.
To assign SSR Output ‘10’ to the O2 zero gas solenoid valve and return to
RUN mode, enter CAL mode and key in:
F5 4 Del 10 Ent
To manually Zero the ultraviolet portion of the analyzer system and Zero
and Span the O2 Sensor:
1. Zero the ultraviolet portion of the analyzer:
a. Turn on the Zero Gas (N2).
b. Enter CAL mode and press F5 2 and record the numeric value
displayed (FlowCtrl).
c. Force the analyzer sampling mode to Continuous Zero Gas Flow

mode by keying in Del 10 Ent.
d. Press F2 0. The display will prompt “Man/Zero?”.
e. Observe the concentration reading(s) on the bottom line of the

display. When the reading(s) have stabilized at or near air point
(20.95 %), press:
Ent for Yes The timer will count down to zero during which
time the readings are averaged. The zero values will
be adjusted automatically if AdjDisable is set to ‘0’.
Esc for No The function is aborted; the values are not adjusted.
f. Turn off the Zero Gas (N2).

2. Zero the O2 Sensor:
a. Turn on the air.
b. Press F2 9. The display will prompt “Man/ZeroO2?”.
c. Observe the O2 concentration reading on the bottom line of the

display. When the O2 reading has stabilized at or near air point
(20.95 %), press:
Ent for Yes The timer will count down to zero during which time
the readings are averaged. The air point values will
be adjusted automatically if AdjDisable is set to ‘0’.
Esc for No The function is aborted; the values are not adjusted.
d. Turn off the air.
3. Span the O2 Sensor
a. Turn on the O2 Calibration Gas.
b. Force the analyzer sampling mode to Continuous Calibration Gas

Flow by keying in F5 2 Del nn Ent (where ‘nn’ is ‘11’ or ‘12’ de-
pending on which calibration gas cylinder contains the O2 calibra-
tion gas).
c. Press F2 8. The display will prompt “Man/Span O2?”.
d. Observe the O2 concentration reading on the bottom line of the

display. When the O2 reading has stabilized at or near the O2 con-
centration in the calibration gas mixture press:
Ent for Yes The timer will count down to zero during which time
the readings are averaged. The O2 span value will be
adjusted automatically if AdjDisable is set to ‘0’.
Esc for No The function is aborted; the value is not adjusted.
e. Turn off the O2 Calibration Gas.
4. Turn on the Zero Gas (N2).
5. Press F5 2 Del z Ent (where ‘z’ is the value recorded in Step 2) to re-
turn the analyzer to the original sampling mode.
6. Press Esc to return to RUN mode normal display.
The Analyzer Zero, O2 Zero, and O2 Span are complete.

Dilution Air Correction
The Dilution Air Correction function corrects the component concentra-
tions measured by the analyzer to a specific dilution air condition based
on the measured O2 concentration and a specified O2 concentration in
the stack duct. The specified O2 concentration corresponds to a specific
amount of Dilution Air. Dilution Air is excess (combustion) air or air added
to the stack duct after the (combustion) process. It is not air used to dilute
the sample before analysis by the analyzer. The measured component
concentration, dilution-air-corrected component concentration, and the
concentration of O2 in the stack duct may be displayed simultaneously on
the User Interface Panel. An “o” (lower case “O”) appearing immediately
before a calculated result name indicates a dilution-air-corrected result.
The O2 concentration is measured by a sensor installed in the Analyzer

Oven, or by a separate, independent O2 analyzer.

CAUTION
Changing the factory-set configuration may cause the analyzer to
Correction Equation
The measured component ‘x’ concentration is corrected to a specified
dilution air condition using the following equation:
⎛ 20.95 − [O2 ]spec ⎞

[ x]c = [ x]m ⎜⎜ ⎟⎟
⎝ 20.95 − [O2 ]m ⎠
where: [x]c = the measured concentration of component ‘x’ corrected to

the specified O2 concentration;
[x]m = the measured concentration of component ‘x’;
20.95 = the concentration of O2 in air (mole percent);
[O2]spec = the specified process duct O2 concentration to which the
measured component ‘x’ concentration is corrected (mole
percent); and
[O2]m = the measured concentration of O2 (mole percent).
 For a given application, (20.95 – [O2]spec) is a constant.

NOTE
If [O2]m > 20.95, the correction will not be applied and [x]c = [x]m.

Entering [O2 ]
To enter [O2]spec to which the measured concentrations are corrected (ex-
ample, [O2]spec = 0 (percent)), enter CFG mode and key in:
F4 9 1 Del 0 Ent Ent Esc Ent


Appendix B – Serial Communication
Interface (Modbus®)
 The Modicon Modbus® communication interface is optional. This

information applies only to analyzers with this function added.
NOTE
Overview
This Appendix describes the Modicon Modbus® communication inter-
face on the following Model 9xx-Series Analyzers and their derivatives:
900ADA\930, 909\910, 919\920, 921CE\921CE WM (Wall Mount)\922CE. Use
the information as it applies to your analyzer.
The communication protocol implemented is Modicon Modbus® as de-

fined in “Modicon Modbus Protocol Reference Guide” (PIMBUS-300). The
Modbus protocol transmission mode implemented is Remote Terminal
Unit (RTU) with the analyzer operating as a slave device.
The standard connection type between a customer DCS\SCADA\DAS\PLC

and a Model 9xx-Series Analyzer can be either a 9 pin RS-232 or a 4-wire
RS-422. For Model 900ADA\930, 909\910, and 919\920 Analyzers, refer to
Figure B-1 (WX-102822) and Figure B-2 (300-9480) for customer connection
pin-outs and cabling requirements. For Model 921CE\921CE WM\922CE
Analyzers, refer to Figure B-3 (WX-14821).
The RS-422 port receiver pins, Rx±, must be terminated with a terminat-
ing resistor of 120 W when the port is connected to customer equipment.
An optional RS-232/RS-485 converter can be connected to the RS-232 port
for an RS-485 multi-drop system with a 4-wire installation being the pre-
ferred choice.
The converter must be able to:

• Provide a logic high signal to the RS-232 CD pin.
• Use RS-232 RTS pin to control its transceiver.
• Be selected as the line terminating node.
Appendix B – Serial Communication Interface (Modbus®) | B-1

 References to software menus that you can use to configure serial
communication parameters use the same abbreviations as the User
NOTE
Interface Panel. The main menu (mode) is listed first, followed by the
parameter.
For example, you can set the analyzer Modbus address from
the ConFiGuration mode. This software menu item is listed as
[CFG : MBAddr (keystroke is F2 • for Model 909\910, 919\920,
921CE\921CE WM\922CE; F4 • for Model 900\930)]. For informa-
tion on the keystrokes that must be entered to view parameters, refer
to Chapter 4 of this manual.
 References to “9xx” in this appendix indicate that the function is

NOTE used by all 900-Series Analyzers. References to 921CE (Rack Mount
style analyzers) indicate the functions are also used by 921CE WM
(Wall Mount style analyzers); however, certain functions used by the
921CE WM are not used by the 921CE Rack Mount version.
B-2 | Model 909 Single-Gas Analyzer

Figure B-1.
Customer signal connections,
GP/Div 2 analyzers (Models
900ADA\930, 909\910,
919\920), WX-102822.
 The customer connections shown in Figure B-1 apply to GP/Div 2

analyzers only; for all other applications, refer to the electrical con-
NOTE
nection drawings included in Appendix D, the “Supplemental
Information” section of this manual, or the Documentation Package

Figure B-2.
RS-232 service cable
to analyzer wiring,
300-9480.

Figure B-3.
Rear panel descriptions
(Model 921CE\921CE WM\922CE
Analyzers), WX-14821.

Analyzer Modbus Interface Parameters
A number of analyzer Modbus interface parameters needs to be set up in
order to establish communication with the Modbus master.
Modbus Address
The analyzer needs to be assigned a Modbus address [CFG : MBAddr]
(keystroke is F2 • for Model 909\910, 919\920, 921CE\921CE WM (Wall
Mount)\922CE; F4 • for Model 900\930)], which can be a number from
0–255 with the following definitions:
Modbus Address Definition
0 Disable Modbus interface
1–127 Enable Modbus interface on RS-232 port
128–255 Enable Modbus interface on RS-422 port
Communications Parameters
While the number of Data Bits is always 8, the Baud Rate, number of Stop
Bits, and Parity [CFG : ComParaz, where ‘z’ = ComPara1, ComPara2, or
ComPara3 (keystroke is F2 – for Model 909\910, 919\920, 921CE\921CE WM
(Wall Mount)\922CE; F4 – for Model 900\930)] of the analyzer Modbus se-
rial communications port are selectable:
Baud Rate Stop Bits Parity

Value (ComPara1) (ComPara2) (ComPara3)
0 9600 Invalid None
1 4800 1 Odd
2 2400 1.5 None
3 1200 2 Even
The default communication parameter settings (or Value) are “0”, “1”,
and “0” for ComPara1, ComPara2, and ComPara3, respectively (i.e., 9600
Baud, 1 Stop Bit, and no Parity, on both RS-232 and RS-422 ports). When a
change is made to one of these parameters, the change must first be saved
to the analyzer’s EEPROM and then the analyzer must be reset before the
new settings will take effect.

Modbus Functions
Because the Modbus protocol is designed for communication among
Programmable Logic Controllers (PLCs), not all Modbus function
codes supported by a slave PLC are applicable to the Model 9xx-Series
Analyzers. Only the following relevant function codes are implemented,
as requested by “Class 0” functions from Modbus serial protocol for Open
Modbus/TCP systems (i.e., multiple-register read/write functions):
Code Definition
03 Read multiple holding registers (4x references)
06 Write one holding register (4x references)
16 Write multiple holding registers (4x references)
Accordant to Modbus protocol specification, all address references in

Modbus messages are numbered relative to zero. For example, the first
holding register in a Modbus slave being referenced as “40001” would be
addressed as “0”.
Exception Code
The Model 9xx-Series Analyzers Modbus protocol implementation sup-
ports these exception codes:
Code Definition
01 Illegal Function
02 Illegal Address
03 Illegal Value
06 Busy, rejected message
Unsupported function requests from the Modbus master result in excep-

tion code “01” (Illegal Function) being returned. Exception code “02”
(Illegal Address) is returned when the requested address is outside the
allowed range or writing to a read-only location. When the values to be
written to holding registers are outside the appropriate ranges, exception
code “03” (Illegal Value) is returned. Exception code “06” (Busy, rejected
message) is returned if the analyzer is unable to proceed with the calibra-
tion action requested by the Modbus master.

Holding Registers
Because RAM space on the analyzer is limited and not all DCS\SCADA\
DAS\PLC systems support Modbus floating point value transfer some
floating point values, generated and used by the analyzer, are scaled
up and converted into integer values to load into Modbus Registers for
transmission. The register values must be scaled back at the receiving end
to yield the actual values. The size of a Modbus holding register is 16-bit,
which can assume a value from -32768 to +32767 in two’s complement.
The holding register definitions, units of measurement, and scaling factors
are listed in the following pages along with the applicable analyzer model
number.
The registers are used for specific analyzer functions, as follows:
• Registers 0–8, 10–45, 229–231, 288–289, and 429–449 are used for ana-
lyzer results.
• Registers 46–159 and 232–287 are used for analyzer diagnostic

measurements/information.
• Registers 160–228 and 450–457 are used for analyzer calibration (CAL)
parameters.
• Registers 9, 290–428, and 458–659 are used for analyzer configuration

(CFG) parameters.
Modbus protocol does not natively support the transfer of floating point
values; therefore, most Modbus master systems divide the Registers into
integer section and floating point section. That is, those systems require
that all Registers holding floating point values be located above certain
register locations. However, the boundary is vendor dependent. To make
the analyzer Modbus register layout work with all such Modbus master
systems, two steps are taken. First, all analyzer Modbus Registers hold-
ing floating point values are grouped and located at the higher Register
locations, regardless whether they are CAL or CFG parameters. Second,
Modbus addresses for all Registers wrap round 1000. That is, when a
Modbus master requests a Register above 1000, it is translated back to a
location within the first 1000 locations. For example, Register #7888 is
translated back to Register #888.
Two Registers are needed to hold one 32-bit floating-point value; there-
fore, the order of the Registers holding one floating-point value is imple-
mented in the de facto standard way on the analyzer (i.e., the first Register
holds the lower 16 bits while the second Register holds the upper 16 bits
of a 32-bit floating-point value). When requesting a floating-point value,
the analyzer supports the standard Modicon PLC method (i.e., the two
consecutive 16-bit Registers are requested).

The references to footnotes ‘a’, ‘b’, ‘c’, ‘d’, ‘e’, ‘f ’, ‘g’, ‘h’, ‘i’, ‘j’, and ‘k’ in
the Holding Register Definitions (in the following pages) are:
a For PPM values with “finer” Units and display selection, scaling is shown in [ ]. For %
values with “coarser” Units and display selection, scaling is shown in [ ].
b Units of measurement for stream flow rate, mass emission, emission rate, and stream
velocity are application dependent.
c Kq’s and Ke’s must be adjusted in such a way that the analyzer display shows ‘nnnn’
for stream flow rate and mass emission rate at full-scale (i.e., display no digit after the
decimal point).
d Refer to the section “Units and Display Bit Image (Register 9),” later in this appendix.
e Each register holds a pair of status code history values. The upper byte (bits 15-8) con-
tains the older one while the lower byte (bits 7-0) contains the newer one of the pair.
For example, Register #90 holds HC status code history values [1] and [2]; value [1] is
in the upper byte, and value [2] is in the lower byte.
f Refer to the section “Analyzer Status Bytes (Register 154),” later in this appendix.
g Refer to the section “Solenoid Output Bit Image (Register 156),” later in this appendix.
h Refer to the section “Digital Input Bit Image (Register 157),” later in this appendix.
i Refer to the section “Digital Output Bit Image (Registers 158, 159),” later in this
appendix.
j Refer to the section “Gas Flow Control (Registers 189, 190),” later in this appendix.
k An ASCII character string must be read as a block of registers. The Modbus registers
containing a species or sensor name are NUL terminated ASCII character text strings.
To conform to the Modicon Modbus® PLC convention (16-bit wide), each register
contains 2 characters. The upper byte (bits 15–8) is the first character to be displayed
while the lower byte (bits 7–0) is the second character to be displayed. The number of
characters indicated for each parameter includes the NUL-terminated ASCII character
string.

Reg Definition Units Scaling Access
0 Concentration Result 1 ppm; 1 [10]; r

(910\920, 922CE: standard range SO2) % 1000 [100] a
(900ADA\930: SO2)
(921CE\921CE WM, 909\919: Low span range SO2)

(910\920, 922CE: NO2) % 1000 [100]
(900ADA\930: H2S)
(921CE\921CE WM, 909\919: High span range SO2)

(910\920, 922CE: NO) % 1000 [100]
(900ADA\930: COS)

(910\920, 922CE: extended range SO2) % 1000 [100]
(900ADA\930: CS2)

(910\920, 922CE: application dependent) % 1000 [100]
(900ADA\930: Sv)

(9xx: NDr) % 1000 [100]

(910\920, 922CE: NOx) % 1000 [100]
Air Demand
(900ADA\930)
7 Stream Flow Rate b

1 c r
(909\919, 910\920, 922CE, 921CE)
Trend ppm; 1 [10]; r

(900ADA\930) % 1000 [100]
8 Oxygen Concentration % 1000 r

(909\919, 910\920, 922CE, 921CE\921CE WM)
9 Units and Display Selection – d – r

(9xx)
10–16 Mass Emission of Results 1–7 from Flow Rate b

1 c r
(910\920, 922CE)
(921CE\921CE WM, 909\919: Mass Emission of
low span range SO2 in Reg10)
(921CE\921CE WM, 909\919: Mass Emission of
high span range SO2 in Reg11)
17–19 Reserved – – –
20–26 O2 Correction of Results 1–7 ppm; 1 [10]; r

(910\920, 922CE) % 1000 [100]
(921CE, 909\919: Low span range of
O2 Corrected SO2 in Reg20)
(921CE, 909\919: High span range of
O2 Corrected SO2 in Reg21)
30–36 Emission Rate of Results 1–7 from F-factors b

1 c r
(920)
(919: Emission Rate of low span range O2 Corrected SO2
using Kf in Reg30)
(919: Emission Rate of high span range O2 Corrected SO2
using Kf in Reg31)

46–47 Analyzer HC Run Time sec – r

(9xx: Reg. #46=lower 16-bit; Reg. #47=upper 16-bit)
48–49 Analyzer MC Run Time sec – r

(9xx: Reg. #48=lower 16-bit; Reg. #49=upper 16-bit)
50–89 Track & Hold Results of Registers 0–39 Reg 0–39 Reg 0–39 Reg 0–39
(921CE\921CE WM, 909\919: Low span range of
Track & Hold SO2 in Reg50)
(921CE\921CE WM, 909\919: High span range of
Track & Hold SO2 in Reg51)

Track & Hold Mass Emission of SO2 in Reg60)
Track & Hold Mass Emission of SO2 in Reg61)

Track & Hold O2 Corrected SO2 in Reg70)
Track & Hold O2 Corrected SO2 in Reg71)
(919: Low span range of Track & Hold Emission Rate of

O2 Corrected SO2 using Kf in Reg80)
(919: High span range of Track & Hold Emission Rate of
O2 Corrected SO2 using Kf in Reg81)
90–94 HC Status Code History Values 1..9 Coded Status – r

(9xx) Value e
95–99 MC Status Code History Values 1..9 Coded Status – r

(9xx) Value e
100 S/L Temperature °C,°F 10 r

(900ADA\930, 909\919, 910\920)
101 V/L or SCU Temperature °C,°F 10 r

(900ADA\930, 909\919, 910\920)
102 Temperature Control Zone 3 Temperature °C,°F 10 r

(900ADA\930, 909\919, 910\920)
103 Cell Temperature °C,°F 10 r

(9xx)
104 Cell Pressure mmHg, 10 r

(9xx) "Hg
105 Stream Temperature °C,°F 10 r

(909\919, 910, 922CE, 921CE)
106 Differential Pressure mmH2O, 100, r

(909, 910, 922CE, 921CE) "H2O 1000
107 Probe Temperature °C,°F 10 r

(900ADA\930, 909\919, 910\920)
108 Oven Heater Temperature °C,°F 10 r

(900ADA\930, 909\919, 910\920)
109 Stream Velocity b

100 r
(919, 920)
110 Filter Wheel Speed RPM 1 r

(900ADA\930, 910\920, 922CE)
111–116 Lamp pulse for Optical Filters 1 to 6 mV 1 r

(900ADA\930, 910\920, 922CE)
(909\919, 921CE: pulses 1 & 2 only)

117 S/L Heater Duty Cycle % 1 r

(900ADA\930, 909\919, 910\920)
118 V/L or SCU Heater Duty Cycle % 1 r

(900ADA\930, 909\919, 910\920)
119 TZone3 Heater Duty Cycle % 1 r

(900ADA\930, 909\919, 910\920)
120 Oven/Sample Cell Heater Duty Cycle % 1 r

(900ADA\930, 909\919, 910\920)
121–126 Reference PMT Signal of Optical Filters 1 to 6 mV 1 r

(900ADA\930, 910\920, 922CE)
(909\919, 921CE: Signals 1 to 3 only)
127–132 Measurement PMT Signal of Optical Filters 1 to 6 mV 1 r

(900ADA\930, 910\920, 922CE)
(909\919, 921CE: Signals 1 to 3 only)
133–134 Reserved – – r
135 Oven Plate Heater Duty Cycle % 1 r

(900ADA\930, 909\919, 910\920)
136 ASR Probe Heater Duty Cycle % 1 r

(900ADA\930, 919)
137–143 Zero Calibration Drift Concentration of Results 1 to 7 ppm; 1 [10]; r

(910\920, 922CE) % 1000 [100]
(921CE\921CE WM, 909\919: Zero Calibration Drift of
low span range SO2 in Reg137)
(921CE\921CE WM, 909\919: Zero Calibration Drift of
high span range SO2 in Reg138)
144–150 Span Calibration Drift Concentration of Results 1 to 7 ppm; 1 [10]; r

(910\920, 922CE) % 1000 [100]
Span Calibration Drift of SO2 in Reg144)
Span Calibration Drift of SO2 in Reg145)
151 O2 Zero Calibration Drift % 1000 r

(909\919, 910\920,922CE, 921CE)
152 O2 Span Calibration Drift % 1000 r

(909\919, 910\920, 922CE, 921CE)
153 Operating Mode: 0=RUN, 1=CAL, 2=CFG – 1 r

(9xx)
154 Analyzer Status Bytes f – 1 r

(9xx)
High Byte = HC status, Low Byte = MC status
155 Reserved – – r
156 Solenoid Output Bit Image g – – r

(9xx)
157 Digital Input Bit Image h – – r

(9xx)
158 Digital Output Bit Image: lower 16-bit i – – r,w

(9xx)
159 Digital Output Bit Image: upper 16-bit i – – r,w

(9xx)

160 Span Gas Concentration of Result 1 ppm; 1 [10]; r,w

(910\920, 922CE: standard range SO2) % 1000 [100]
(900ADA\930: SO2)
(921CE\921CE WM, 909\919: Span Gas Concentration of
low span range SO2)

(910\920, 922CE: NO2) % 1000 [100]
(900ADA\930: H2S)
(921CE\921CE WM, 909\919: Span Gas Concentration of
high span range SO2)

(910\920, 922CE: NO) % 1000 [100]
Default SO2 Track & Hold Concentration ppm; 1 [10]; r,w

(900ADA\930) % 1000 [100]

(910\920, 922CE: extended range SO2) % 1000 [100]
Default H2S Track & Hold Concentration ppm; 1 [10]; r,w

(900ADA\930) % 1000 [100]

Static Sv Concentration ppm 1 r,w

(900ADA\930)

Static COS Concentration ppm 1 r,w

(900ADA\930)

(910\920, 922CE: NOx) % 1000 [100]
Static CS2 Concentration ppm 1 r,w

(900ADA\930)
167 Differential Pressure Signal Span Value mmH2O, 100 r,w

(909, 910) "H2O
(Reserved, see Reg. 444–445)
Air Demand Factor

(900ADA\930) – 1000 r,w
168 O2 Air Point Concentration % 1000 r,w

(909\919, 910\920, 922CE, 921CE)
OpRatio – 1000 r,w

(900ADA\930)
169 O2 Span Gas Concentration % 1000 r,w

(909\919, 910\920, 922CE, 921CE)
OpOffset ppm; 1 [10]; r,w

(900ADA\930) % 1000 [100]

170 Timer0 min 1 r,w

(9xx)

(909\919, 910\920, 922CE, 921CE)

(909\919, 910\920, 922CE, 921CE)

(922CE)
Velocimeter Backpurge Delay sec 1 r,w

(909, 910, 921CE WM)
174 Sample Delay min 1 r,w

(9xx)
175 Auto-Zero Interval hr 1 r,w

(9xx)
176 Auto-Calibration Interval hr 1 r,w

(909\919, 910\920, 922CE, 921CE)
177 Integration Timer sec 1 r,w

(9xx)
178 Velocimeter Backpurge Duration sec 1 r,w

(909, 910, 921CE WM)
179 Velocimeter Backpurge Interval min 1 r,w

(909, 910, 921CE WM)
180–185 Calibration Solenoid # for Results 1–6 – 1 r,w

(910\920, 922CE)
186 Calibration Solenoid # for O2 Zero – 1 r,w

(909\919, 910\920, 922CE, 921CE)
187 Calibration Solenoid # for O2 Span – 1 r,w

(909\919, 910\920, 922CE, 921CE)
188 Calibration Adjustment Disable – 1 r,w

(909\919, 910\920, 922CE, 921CE)
189 Gas Flow Control – j 1 r,w

(9xx)
190 Velocimeter Flow Control – j 1 r,w

(909, 910, 921CE WM)
191 Ambient Air Moisture Content or % 1000 r,w

Stack Gas Moisture Content
(909\919, 910\920, 922CE, 921CE)
192 Probe Blow-Back Interval min 1 r,w

(909\919, 910\920)
193 Probe Blow-Back Duration sec 1 r,w

(909\919, 910\920)
194 Probe Blow-Back Pulse Width sec 1 r,w

(909\919, 910\920)
195 Default Cell Temperature °C,°F 10 r,w

(9xx)
196 Default Cell Pressure mmHg, 10 r,w

(9xx) "Hg "H2O

197–202 Zero Transmittance of Optical Filters 1 to 6 – 1000 r,w

(900ADA\930, 910\920, 922CE)
(909\919, 921CE: Zero Transmittance 1 & 2 only)
203–208 Span Factor of Concentration Results 1 to 6 – 1000 r,w

(910\920, 922CE)
(900ADA\930: Span Factor 1 & 2 only)
(921CE\921CE WM, 909\919: Span Factor of low span range SO2)
(921CE\921CE WM, 909\919: Span Factor of high span range SO2)
209 Differential Pressure Signal Zero Offset mmH2O, 100, r,w

(909, 910, 921CE WM) “H2O 1000
210 Differential Pressure Signal Span Factor – 1000 r,w

(909, 910, 921CE WM)
211 O2 Signal Zero Offset mV 1 r,w

(909\919, 910\920)
O2 Zero Calibration Offset % 1000

(922CE, 921CE)
212 O2 Calibration Span Factor – 1000 r,w

(909\919, 910\920, 922CE, 921CE)
213–216 Zero Calibration of Current (I) Output Channels 1 to 4 mA 1000 r,w

(9xx)
217–220 Span Calibration of Current (I) Output Channels 1 to 4 mA 1000 r,w

(9xx)
221–224 Zero Calibration of Voltage (V) Output Channels 1 to 4 mV 1 r,w

(922CE, 921CE)
225–228 Zero Calibration of Voltage (V) Output Channels 1 to 4 mV 1 r,w

(922CE, 921CE)
229–231 Reserved – – –
232–235 Analyzer MC Analog Inputs 1 to 4 – 1 r

(9xx)
236–239 Analyzer HC Analog Inputs 1 to 4 – 1 r

(910\920, 909\919)
240–245 Transmittance of Optical Filters 1 to 6 – 10000 r

(900ADA\930, 910\920, 922CE)
(909\919, 921CE: pulse 1 to 3 only)
246–251 Absorbance of Optical Filters 1 to 6 – 10000 r

(900ADA\930, 910\920, 922CE)
(909\919, 921CE: pulse 1 to 3 only)
252–261 Front Panel Display Line 1 ASCII character k – r

(9xx: 20 characters)
262–271 Front Panel Display Line 2 ASCII character k – r

272–279 Host-Controller Software Version ASCII character k – r

280–287 Micro-Controller Software Version ASCII character k – r


290 Analyzer Modbus Device Address – – r

(9xx)
291 Serial Communication Baud Rate – – r

(9xx)
0=9600 baud
1=4800 baud
2=2400 baud
3=1200 baud
292 Serial Communication Stop Bits – – r

(9xx)
1=1 stop bit
2=1.5 stop bits
3=2 stop bits
293 Serial Communication Parity – – r

(9xx)
0=none
1=odd
3=even
299 EEPROM Write Counter – – r

(9xx)
300 Analyzer Action request – – r,w

(9xx)
b0=save to EEPROM
b1=auto-setup of optical bench
b2=return to RUN mode
b3=reset analyzer
b4-b15=reserved
301 Key filter (9xx) – 1 r,w
302–307 Lamp Control Pulse for Optical Filters 1 to 6 mV 1 r,w

(900ADA\930, 910\920, 922CE)
(909\919, 921CE: pulse 1 & 2 only)
308–309 Lamp Pulse Base Control for lamps 1 to 2 mV 1 r,w

(9xx)
310 Maximum Lamp Pulse mV 1 r,w

(9xx)
311 PMT Level Control mV 1 r,w

(9xx)
312 PMT Balance Control mV 1 r,w

(9xx)
313 Maximum PMT Signal mV 1 r,w

(9xx)
314 Units and Display Selection – d – –

(9xx)
315 Cell Length cm," 100 r,w

(9xx)
316 Bench Type Selection – d – r,w

(9xx)
317 PMT Signal Acquisition Samples – 1 r,w

(9xx)

318 PMT Signal Acquisition Delay – 1 r,w

(9xx)
319 Filter Wheel Averaging Time Constant – 1 r,w

(900ADA\930, 910\920, 922CE)
320 T90 Time Constant sec 1 r,w

(900ADA\930, 910\920, 922CE)
321 ALC Enable – – r,w

(9xx)
322–327 ALC Gain for Optical Filters 1 to 6 – 1 r,w

(900ADA\930, 910\920, 922CE)
(909\919, 921CE: Gain 1 & 2 only)
328–333 ALC Set Point for Optical Filters 1 to 6 mV 1 r,w

(900ADA\930, 910\920, 922CE)
(909\919, 921CE: Set Point 1 & 2 only)
334 NDr Compensation Enable – – r,w

(900ADA\930, 910\920, 922CE)
335 SO2 Linearization Enable – – r,w

(910\920, 922CE)
Interferent Compensation Enable1

(921CE)
Sv Compensation Enable
(900ADA\930)
336 NO Linearization Enable – – r,w

(910\920, 922CE)
Interferent Compensation Enable2

(921CE)
COS Compensation Enable

(900ADA\930)
337 SO2 Crosstalk Compensation Enable – – r,w

(910\920, 922CE)
CS2 Compensation Enable

(900ADA\930)
338 NDr Timer1 [Tavg] sec 1 r,w

(900ADA\930, 910\920, 922CE)
339 NDr Timer2 [Update] sec 1 r,w

(910\920, 922CE)
340 Analog Input Channel for Measuring O2 – 1 r,w

(910\920, 909\919, 922CE, 921CE)
Trend type d
(900ADA\930)
341 Analog Input Channel for Measuring Cell Temperature – 1 r,w

(9xx)
342 Analog Input Channel for Measuring Cell Pressure – 1 r,w

(9xx)
343 Analog Input Channel for Measuring Stream Temperature – 1 r,w

(910, 909, 922CE, 921CE)
Analog Input Channel for Measuring Stream Velocity

(920, 919)

344 Analog Input Channel for Measuring Differential Pressure – 1 r,w

(910, 909, 922CE, 921CE)
345 Analog Input Channel for Measuring Volumetric Flow Rate – 1 r,w
(920, 919, 922CE, 921CE)
346 Analog Input Channel for Measuring Probe Temperature – 1 r,w

(910\920, 909\919)
Analog Input Channel for Measuring Interferent

(921CE)
347 Averaging Time Constant for O2 Measurement sec 1 r,w

(910\920, 909\919, 922CE, 921CE)
Averaging Time Constant for Sv

(900ADA\930)
348 Averaging Time Constant for Stream Temperature sec 1 r,w

(910, 909, 922CE, 921CE)
Averaging Time Constant for Stream Velocity

(920, 919)
Averaging Time Constant for COS

(900ADA\930)
349 Averaging Time for Differential Pressure sec 1 r,w

(910, 909, 922CE, 921CE)
Averaging Time Constant for CS2

(900ADA\930)
350 O2 Concentration for Correction Calculation % 1000 r,w

(910\920, 909\919, 922CE, 921CE)
351–352 O2 Measurement Range [Low/High] % 1000 r,w

(910\920, 909\919, 922CE, 921CE)
353–354 Cell Pressure Measurement Range [Low/High] mmHg, 10 r,w

(9xx) "Hg
355–356 Differential Pressure Measurement Range [Low/High] mmH2O, 100,1000 r,w

(910\920, 909\919, 922CE, 921CE) "H2O
357–358 Probe Temperature Measurement Range [Low/High] °C,°F 10 r,w

(910\920, 909)
359–360 Probe Temperature Lower and Upper Limits °C,°F 10 r,w

(910\920, 909)
361 Cell Temperature Lower Limit [Tcold] °C,°F 10 r,w

(900ADA\930, 910\920, 909\919)
362–365 Temperature Measurement Type for Zones 1 to 4 – 1 r,w

(900ADA\930, 910\920, 909\919)
366–369 Temperature Control Set Points for Zones 1 to 4 °C,°F 10 r,w

(900ADA\930, 910\920, 909\919)
370–373 Temperature Control Start-Up Duty Cycle for Zones 1 to 4 % 1 r,w

(900ADA\930, 910\920, 909\919)
374–377 Temperature Control Maximum Duty Cycle for Zones 1 to 4 % 1 r,w

(900ADA\930, 910\920, 909\919)

378–381 Result Assignment of Analog Output Channels 1 to 4 – 1 r,w

(9xx)
382–385 Species Name for Gas 1 ASCII character k – r,w

(9xx: 7 characters)

(900ADA\930, 910\920, 922CE: 7 characters)




406–413 Analyzer Serial Number ASCII character k – r,w

414–418 CAL Mode Password ASCII character k – r,w

419–423 CFG Mode Password ASCII character k – r,w

424 Averaging Time for Volumetric Flow Rate sec 1 r,w

(920, 919, 922CE, 921CE)
425 Averaging Time for Cell Temperature Measurement sec 1 r,w

(922CE, 921CE)
426 Averaging Time for Cell Pressure Measurement sec 1 r,w

(922CE, 921CE)
427–428 Cell Temperature Measurement Range [Low/High] °C,°F 10 r,w

(922CE, 921CE)
429–430 Cell Length cm," floating-point value r,w

(9xx)
431–432 Cell Pressure Measurement Range [Low] mmHg, floating-point value r,w
(9xx) "Hg
433–434 Cell Pressure Measurement Range [High] mmHg, floating-point value r,w
(9xx) "Hg
435–436 Differential Pressure Measurement Range [Low] mmH2O, floating-point value r,w
(910\920, 909\919, 922CE, 921CE) "H2O
437–438 Differential Pressure Measurement Range [High] mmH2O, floating-point value r,w
(910\920, 909\919, 922CE, 921CE) "H2O
439–443 Reserved – – –
444–445 Differential Pressure Signal Span Value mmH2O, floating-point value r,w
(909, 910, 921CE WM) "H2O
446–447 Differential Pressure Signal Zero Offset mmH2O, floating-point value r,w
(909, 910, 921CE WM) "H2O
448–449 Default Cell Pressure mmHg, floating-point value r,w

(9xx) "Hg
450–457 Scale for Analog (I and V) Output Channels 1 to 4 – floating-point value r,w
(9xx)

458–469 Matrix Row 1 Elements 1 to 6 – floating-point value r,w

(900ADA\930, 910\920, 922CE)
(909\919, 921CE: k-value 1 & 2 only)

(900ADA\930, 910\920, 922CE)

(900ADA\930, 910\920, 922CE)

(900ADA\930, 910\920, 922CE)

(900ADA\930, 910\920, 922CE)

(900ADA\930, 910\920, 922CE)
530–533 Temperature Compensation Coefficients 1 to 2 – floating-point value r,w

(910\920)
Adaptive Filtering Coefficients 1 to 2

(909\919, 921CE)
534–551 Cross Interference Compensation Vector 1 Elements 1 to 9 – floating-point value r,w

(900ADA\930)
Linearization Coefficients 1 to 6
(910\920, 922CE: six values only)
Linearization Coefficients 1 to 7
(921CE: seven values only)
552–559 Cross Interference Compensation Vector 2 Elements 1 to 4 – floating-point value r,w

(900ADA\930)
Interferent Input Measurement Range [Low/High]

(921CE)
560–571 Absorbance Offset Vector Elements 1 to 6 – floating-point value r,w

(900ADA\930)
Static N2O Concentration

(910\920: one value only)
572–581 Stream Temperature Measurement Coefficients 1 to 5 – floating-point value r,w

(910, 909)
(922CE, 921CE, 919: Low/High range values)
582–589 Stream Velocity Measurement Parameters 1 to 4 – floating-point value r,w

(920, 919: Low/High range values, Cross-section area, Kv)
590–593 Volumetric Flow Rate Measurement Range [Low/High] – floating-point value r,w
(920, 919, 922CE, 921CE)
594–595 Kq (910, 909, 922CE, 921CE) – floating-point value r,w
596–609 Ke for Concentration Results 1 to 7 – floating-point value r,w

(910\920, 922CE)
(909\919, 921CE: one value only)
610–623 Kf for Concentration Results 1 to 7 – floating-point value r,w

(920)
(919: one value only)

624–631 Temperature Control Kp Values for Zones 1 to 4 – floating-point value r,w

(900ADA\930, 910\920, 909\919)
632–639 Temperature Control Ti Values for Zones 1 to 4 – floating-point value r,w

(900ADA\930, 910\920, 909\919)
640–647 Temperature Control Td Values for Zones 1 to 4 – floating-point value r,w

(900ADA\930, 910\920, 909\919)
648–659 ASR Probe Temperature Control Parameters – floating-point value r,w

[Set Point, Kp, Ti, Td, Start-Up Duty Cycle
& Maximum Duty Cycle]
(900ADA\930, 919)
Registers #0 to #89 are results calculated by the analyzer and Registers #100
to #109 are analog inputs measured by the analyzer. Their values are updat-
ed once per second. Registers #110 to #120 are diagnostic variables and are
updated once every four seconds. Registers #121 to #152 are calibration re-
lated variables and they are modified only after a calibration action has been
performed by the analyzer. Registers #160 to #194 are variables the Modbus
master can alter either to customize the analyzer calibration process or to alert
the analyzer of changing process operating conditions.
The gas species assigned to concentration results listed in the above

 Holding Registers table assume default configuration for that analyz-
NOTE
er model. They are subject to reassignment to customize the analyzer
to an application.
For low concentration (White Cell) and high concentration (Short Cell) ap-
plications, the analyzer configuration parameter [CFG : Units] (keystroke
is F1 9) can be set up to provide finer or coarser resolution on the concen-
tration results shown on the User Interface Panel and stored in Modbus
holding registers. In low concentration applications, PPM concentration
registers may be scaled with a factor of 10 instead of the normal scale
of 1 to give finer resolution results. In high concentration applications,
% concentration registers may be scaled with a factor of 100 instead of the
normal scale of 1000 to prevent register value overflow.
Digital I/O bit images are duplicated in Registers #157, #158, and #159.
The content of these registers are updated once per second.

Units and Display Bit Image (Register 9)
Bit Value Definition
0 1 0 = Metric Units
1 = Imperial Units
1, 2 2,4* 0 = Normal Concentration Result in PPM

2 = Normal Concentration Result in %
4 = Finer (Low) Concentration Result in PPM
6 = Coarse (High) Concentration Result in %
3 8 0 = Display 4 Items
8 = Display 3 Items
4 16 0 = Remote ACAL
16 = Remote Backpurge/Zero Flow
* Sum of Bits 1 and 2 decimal value.
Analyzer Status Bytes (Register 154)

Analyzer Microcontroller board status (low) byte:
Definition
Bit Value 0 = Normal; 1 = [F]ault \ [W]arning
0 1 [F] filter wheel speed out of range

(9xx with filter wheel)
[F] pulse timing

(909\919, 921CE)
1 2 [F] on-board ADC not responding

(9xx)
2 4 [F] on-chip A/D not responding

(9xx)
3 8 [W] PMT signals out of range

(9xx)
4 16 [F] MC-HC communication problem

(9xx)
5 32 [W] automatic lamp control out of range

(9xx)
6 64 [F] oven heater too hot

(909\919, 910\920, 900ADA\930)
7 128 reserved for internal use

(9xx)

Analyzer Host Controller board status (high) byte:
Definition
Bit Value 0 = Normal; 1 = [F]ault \ [W]arning
0 256 [W] EEPROM full

(9xx)
1 512 [W] analog output out of range

(9xx)
2 1,024 [F] HC-MC communication problem

(9xx)
3 2,048 [F] analytical data not received

(9xx)
4 4,096 [F] temperature zone too low

(909\919, 910\920, 900ADA\930)
5 8,192 [F] temperature zone too high

(909\919, 910\920, 900ADA\930)
6 16,384 [W] excessive zero drift or span error

(9xx)
7 32,768 [W] SKO temperature high

(900ADA\930)
[W] TZone3 temperature high

(909\919)
Solenoid Output Bit Image (Register 156)

0 1 Zero (922CE, 921CE, 910\920, 909\919)
1 2 Span1 (922CE, 921CE, 910\920, 909\919)
2 4 Span2 (922CE, 921CE, 910\920, 909\919)
3 8 Span3 (922CE, 921CE); Sample (910\920, 909\919)
4 16 Reserved
5 32 Reserved
6 64 Reserved
7 128 Reserved
8 256 Reserved
9 512 M&C Probe Isolation (910\920, 909\919)
10 1,024 M&C Probe Blow-Back (910\920, 909\919)
11 2,048 Reserved
12 4,096 Velocimeter Solenoid 1 (910\909, 921CE WM)
13 8,192 Velocimeter Solenoid 2 (910, 909, 921CE WM);

Sample (900ADA\930)
14 16,384 Reserved
15 32,768 Reserved
Note: If all solenoids (bits) are off, the analyzer is in backpurge.

Digital Input Bit Image (Register 157)
There are two digital inputs on the Model 9xx-Series Analyzers:
0 1 Over-Temperature Trip Signal 1 = normal

(900ADA\930, 909\919, 910\920) 0 = tripped
1 2 Remote Auto-Calibration Contact 1 = start (closed)

(921CE, 922CE) 0 = normal (open)
(900ADA, 909, 910, 919, 920
if Units Bit 4 is Cleared)
Remote Backpurge Contact 1 = normal (closed)

(900ADA, 909, 910, 919, 920 0 = backpurge (open)
if Units Bit 4 is Set)
Digital Output Bit Image (Registers 158, 159)

Register 158 (Digital Output Bit Image: lower 16-bit)
0 1 Auto-Calibration (909\919, 910\920, 922CE, 921CE)
1 2 Auto-Zero (9xx)
2 4 Auto-Span 1 (909\919, 910\920, 922CE, 921CE)
3 8 Auto-Span 2 (909\919, 910\920, 922CE, 921CE)
4 16 Auto-Span 3 (922CE, 921CE)
5 32 Reserved
6 64 Reserved
7 128 Reserved
8 256 Man-Zero (9xx)
9 512 Man-Span 1 (9xx)
10 1,024 Man-Span 2 (9xx)
11 2,048 Man-Span 3 (910\920, 922CE)

SO2 XTalk Reduction (900ADA\930)
12 4,096 Man-Span 4 (910\920, 922CE)
13 8,192 Man-Span 5 (910\920, 922CE)
14 16,384 Man-Span 6 (910\920, 922CE)
15 32,768 Reserved

Register 159 (Digital Output Bit Image: upper 16-bit)
0 1 Man-Span O2 (909\919, 910\920, 922CE, 921CE)
1 2 Man-Zero O2 (909\919, 910\920, 922CE, 921CE)
2 4 Reserved
3 8 Reserved
4 16 Velocimeter Zero (909, 910, 921CE WM)
5 32 Velocimeter Span (909, 910, 921CE WM)
6 64 Velocimeter Backpurge (909, 910, 921CE WM)
7 128 Probe Blow-Back (909\919, 910\920)
8 256 CAL Relay (909\919, 910\920)

AUTO\MAN Relay (900ADA\930)
9 512 ATTEN Relay (900ADA\930, 909\919, 910\920)

CAL Relay (922CE, 921CE)
10 1024 FAULT Relay (9xx)
11–15 — Reserved
• Bits #0 to #15 (Register 158) and #0 to #7 (Register 159) indicate the

current analyzer calibration action status.
- One (1) indicates the associated action is in progress.
- Zero (0) indicates that the action is inactive.
Writing a “1” to one of these bits starts the addressed calibration ac-
tion. The bit stays set for as long as the calibration action is in progress
so that the Modbus master can read the bit to determine if the action
has been completed.
If the Modbus master initiates the same action before that action is
complete, the message is acknowledged but the action does not re-
start. Since only one calibration action can be active at any given time,
the lowest action bit in the request takes precedence.
• Writing a “0” while the addressed calibration action is in progress can-

cels the action.
However, only a calibration action initiated from the Modbus inter-

face can be cancelled from the Modbus interface. A calibration action
started at the analyzer using a keypad command, on a timed basis or
by remote digital input, cannot be cancelled using Modbus.

• Before initiating a calibration action, the Modbus master must read
bits #0 to #15 (Register 158) and #0 to #7 (Register 159) to ensure that
no action is in progress at that time. If a calibration action is already in
progress, a busy message is returned. When the analyzer encounters a
fault condition as indicated by bit #10 (Register 159, FAULT Relay), a
calibration action cannot be started by the Modbus master and a busy
message is also returned.
• Status bits #8 to #10 (Register 159) are set when the corresponding
relay status is true. The conditions under which these relays operate
are described in Chapter 1 of this manual.
Gas Flow Control (Registers 189, 190)

Value Definition
0 Analyzer Control
1 Continuous Backpurge
2 Continuous Sample
10 Continuous Zero
11 Continuous Span Gas 1
12 Continuous Span Gas 2

Appendix C – Conversion Factors
& Calculations
Conversion Factors
PARAMETER TO CONVERT FROM: TO: MULTIPLY BY:
AMOUNT of SUBSTANCE lb mol kmol 0.453 592 4
g mol kmol 0.001
(for Ideal gas) m of gas (0 °C, 101.325 kPa)
3
kmol 0.044 615 8
m3 of gas (15 °C, 101.325 kPa) kmol 0.042 493 2
ft of gas (60 °F, 1.0 atm)
3
kmol 0.001 195 30
AREA ft2 m 2 0.092 903 04

in2 mm2 645.16
in2 cm2 6.451 6
yd2 m2 0.836 172 4
CAPACITY bbl (42 gal US) m3 0.158 987 3

fl oz (UK) cm 3
28.413 05
fl oz (US) cm3 29.573 53
gal (UK) m 3
0.004 546 092
gal (UK) L 4.546 092
gal (US) m3 0.003 785 412
gal (US) L 3.785 412
CONCENTRATION grains/100 ft3 mg/m3 22.883 51

lb mol/ft
3
kmol/m 3
16.018 46
ppm percent 0.000 1
ppm by volume cm /m 3 3
1.0
ppm by weight mg/kg 1.0
weight percent kg/kg 0.01
Appendix C – Conversion Factors & Calculations | C-1

DENSITY (Gases) lb/ft3 kg/m3 16.018 46
DENSITY (Liquids) lb/gal (UK) kg/L 0.099 776 44

lb/gal (US) kg/L 0.119 826 4
lb/ft3 kg/L 0.016 018 46
g/cm 3
kg/L 1.0
DENSITY (Solids) lb/ft3 kg/L 0.016 018 46
ENERGY BTU kJ 1.055 056

cal kJ 0.004 184
kcal kJ 4.184
kWh kJ 3600.0
FLOW RATE bbl/d t/a 58.030 36

bbl/h m h 3
0.158 987 3
gal (UK)/min m3h 0.272 765 5
gal (US)/min m h 3
0.227 124 7
ft3/h m3h 0.028 316 85
ft /h
3
L/min 0.471 947 5
ft3/min L/s 0.471 947 5
lb/h t/d 0.010 886 22
lb mole/h kmol/h 0.453 592 4
ton (2240 lb)/d kg/h 42.335 290 7
ton (2000 lb)/d kg/h 37.799 366 7
LENGTH ft m 0.304 8
in mm 25.4
yd m 0.914 40
MASS grain mg 64.798 91

lb kg 0.453 592 4
oz (avoirdupois) g 28.349 52
oz (troy) g 31.103 48
ton (2240 lb) t 1.016 047
ton (2000 lb) t 0.907 184 7
POWER BTU/min kW 0.017 584 27

BTU/s kW 1.055 056
hp kW 0.746
million BTU/h MW 0.293 071 1
C-2 | Model 909 Single-Gas Analyzer

PRESSURE ATM kPa 101.325
bar kPa 100.0
cm of H2O (4 °C) kPa 0.098 063 8
in of Hg (32 °F) kPa 3.386 388 157
in of Hg (60 °F) kPa 3.376 85
in of H2O (39.2 °F) kPa 0.249 082
in of H2O (60 °F) kPa 0.248 84
mm of Hg = torr (0 °C) kPa 0.133 322 4
psi kPa 6.984 757
SPECIFIC HEAT CAPACITY BTU/lb * °F kJ/kg * °C 4.186 8

kcal/kg * °C kJ/kg * °C 4.184
kW * h/kg * °C kJ/kg * °C 3 600.0
BTU/lb mol * °F kJ/kmol * °C 4.186 8
cal/g mol * °C kJ/kmol * °C 4.184
SPEED ft/s m/s 0.304 8

in/s mm/s 2.54
mile/h km/h 1.609 344
TEMPERATURE °R K 0.555 555 555

°F-32 °C 0.555 555 555
Fahrenheit degree Celsius degree 0.555 555 555
VOLUME ft3 m 3 0.02831685

in
3
cm 3
16.387 06
yd3 m3 0.764 554 9

SI Prefixes
FACTOR
(by which unit is multiplied) PREFIX SYMBOL EXAMPLE
One million million (billion) 1012 tera T
One thousand million 10

9
giga G gigahertz (GHz)
One million 10
6
mega M megawatt (MW)
One thousand 10
3
kilo k kilometre (km)
One hundred 10
2
hecto* h
Ten 10
1
deca* da decagram (dag)
UNITY 1
One tenth 10-1 deci* d decimetre (dm)
One hundredth 10
-2
centi* c centimetre (cm)
One thousandth 10
-3
milli m milligram (mg)
One millionth 10-6 micro µ microsecond (µs)
One thousand millionth 10-9 nano n nanosecond (ns)
One million millionth 10-12 pico p picofarad (pF)
One thousand million millionth 10-15 femto f
One million million millionth 10-18 atto a

* To be avoided wherever possible.

Gas Mixtures
Average Molecular Weight

The weighted average molecular weight, Mm, of a mixture of n compo-
nents is defined by:
n
[ xi ] M i
Mm = ∑ 100
,
i=1 (Equation 1)
where:
[xi] = concentration of component i in the mixture (mole per-
cent); and
Mi = molecular (formula) weight of component i (kg/kmol).
Specific Gravity
The specific gravity, Gs, of a substance, s, is defined by:
ρs
Gs = ,
ρr
(Equation 2)
where:
s = density of substance s; and
r = density of a reference material r at a specified tempera-
ture and pressure.
For liquids, the reference material is usually H2O at 3.98 °C and 101.325 kPa.
Under these conditions the H2O is at maximum density2, 1.000 00 g/mL (or
equivalently, 0.999 973 g/cm3).
For gases, it is convenient to use dry air as a reference, although this

does present some problems occasionally because air is a mixture (see
“Components of Atmospheric Air” list, under “Air Composition,” later in
this Appendix). At 0 °C and 101.325 kPa, the density of dry air2 is 1.293 1
kg/cm3.
If it is assumed that the gases are ideal, it can be shown that the specific
gravity of gas j relative to air is defined by:
Mj Mj
Gj = = .
M air 28.965 (Equation 3)
The weighted average molecular weight of air, Mair, was calculated from
the composition of air4 in the “Components of Atmospheric Air” list (un-
der “Air Composition”) using Equation 1.

Air Composition
Components of Atmosphere Air
Constituent Content
(Percent) (ppm)
N2 78.084 ± 0.004
O2 20.946 ± 0.002
CO2 0.033 ± 0.001
Ar 0.934 ± 0.001
Ne 18.18 ± 0.04
He 5.24 ± 0.004
Kr 1.14 ± 0.01
Xe 0.087 ± 0.001
H2 0.5
CH4 2
N 20 0.5 ± 0.1
(Exclusive of water vapor)4

Gas Flow Rate Measurement
The flow rate of a sample stream frequently is determined by using a pitot
tube. Unlike orifice or venturi meters, which effectively measure average
gas speeds through constrictions in ducts, the pitot tube measures the gas
speed at a single point within a flowing gas stream. To obtain an average
gas speed requires that a number of measurements be made at different
points on a given cross-sectional plane. The number of measurements
required to define the gas speed profile adequately depends upon the dis-
tance of the measurement plane from upstream or downstream obstruc-
tions, duct size, duct shape and speed-profile shape. Criteria for selecting
the number of measurements usually are specified by local regulatory
agencies5,6.
In general, the measurement plane should be eight duct diameters down-

stream from, and two duct diameters ahead of, any flow obstructions.
The cross-sectional area is then subdivided into equal-area segments (see
Figure B-1).
Figure B-1.
Cross Sectional view
of rectangular and
round ducts.
For rectangular ducts, measurements are made at the centroids of the

sub-areas. For round ducts, the measurements are made where the cen-
troid arcs of the annular sub-areas intersect two mutually perpendicular
lines which both pass through the centre of the measurement plane. The
dashed lines in the sketches delineate the sub-areas and the ‘+’ signs indi-
cate the points for the measurements.

The working equation for the pitot tube is:
Z f T f i ∆ Pi
vi = U F ,
Pf M (Equation 4)
where:
vi = linear gas speed at pitot tube tip location, i (m/s) [ft/s];
F = Pitot tube calibration factor (dimensionless);
Zf = compressibility of gas at Tfa and Pf (dimensionless);
Tfi = local temperature of flowing gas stream at point i (K)
[°R];
Tfa = average temperature of sample stream (see Equation 6)
(K) [°R];
Pf = static pressure of the gas stream (KPA) [PSIA];
Pi = differential pressure between the impact pressure head
and the local static pressure of the stream at point i
(KPA) ["H2O];
M = molecular weight of gas stream (kg/kmol) [lb/lb mol];
and
U = a constant that depends upon the system of units
employed.
(For the above metre-kilogram-second (SI) units,
U = 128.952 1)
[For the above foot-pound-second (imperial) units,
U = 59.907 04]
The pitot tube calibration factor (F) is determined empirically, often in a

wind tunnel. For standard pitot tubes, F generally is between 0.98 and
1.00 but, for the Stausscheibe (S-type) pitot tubes routinely used for source
emission tests, F usually is between 0.75 and 0.85.
Equation 4 is useful3 in the gas speed range of 40 to 60 m/s (15 to 200 ft/s).
Below this range, another method of measurement is required. In the 60
to 230 m/s (200 to 750 ft/s) range, Equation 4 requires modification to ac-
count for compression of the gas. Above 230 m/s (750 ft/s), special methods
are required to account for shock wave interferences.

The volumetric flow rate of the sample stream at stream conditions, Qf , is
computed from:
Q f = va A ,
(Equation 5)
where:
Qf = volume flow rate of sample stream at Tfa and Pf (m3/s)
[ft3/s];
va = average linear gas speed through measurement plane
(m/s) [ft/s]; and
A = cross-sectional area of duct at plane of measurement
(m2) [ft2].
Since the Pitot tube and temperature readings are obtained at the cen-
troids of the equal areas, the average temperature and average gas speed
are defined by:
n
∑T i
T fa =
i=1
,
n (Equation 6)
and
n
∑v i
va =
i=1
,
n (Equation 7)
where:
n = the number of measurements.
It is standard practice to express the volumetric flow rate at specified ref-

erence conditions rather than at the sample stream conditions. Thus:
Tr Pf Zr
Q = va A ,
T fa P r Z f (Equation 8)
where:
Q = volume flow rate of sample stream at Tr and Pr (m3/s)
[ft3/s];
Tr = reference temperature (K) [°R];
Pr = reference pressure (KPA) [PSIA]; and
Zr = compressibility factor at Tr and Pr (dimensionless).

The molar flow rate of the sample stream is then obtained from:
Q
Qm = ,
Z rV I (Equation 9)
where:
Qm = molar flow rate of sample stream (kmol/s) [lb mol/s]; and
VI = ideal gas molar volume at Tr and Pr (m3/kmol) [ft3/lb
mol].
Usually the reference conditions and the sample stream conditions are
such that the sample fluids can be assumed to behave ideally. That is, the
temperature is equal to or greater than 0 °C (32 °F) and the pressure is
near atmospheric pressure. In these cases, the compressibility factors (Zf
and Zr) are assumed to be unity.
There are two common alternatives to Equation 7 for obtaining the aver-
age gas speed, va. One alternative is used to reduce the number of calcula-
tions when manual measurements are carried out. In this approach, an
average square root of the differential pressures, (Pia)1/2 is computed:
1/2
∑ ∆ Pi
( ∆ Pi a ) = i=1
.
n (Equation 10)
Then (Pia)1/2 is used once in Equation 10 with the results of Equation 6 to

calculate the average gas speed.
The second alternative is used for continuous monitoring systems. In this

approach, the Pitot tube is positioned at a fixed point and an additional
factor, Fp, is incorporated into the equation. This position factor corrects
the gas speed measured at the fixed point to the average gas speed as
determined by measurements from full traverses of the sample stream us-
ing another pitot tube. Moreover, for continuous monitoring systems, the
usual output desired is the volumetric flow rate at the specified reference
conditions.

By combining Equations 4, 6, and 8 and incorporating the position factor,
the continuous monitoring working equation becomes:
A F p UF Z r T r Pf ∆ P pt
Q = ,
Pr Zf M Tfa (Equation 11)
where:
Q = volume flow rate of sample stream at Tr and Pr
(m3/s) [ft3/s];
Ppt = Pitot tube differential pressure at the fixed point (KPA)
["H2O];
Fp = Pitot tube position factor (dimensionless).
For a given system, the sample stream molecular weight and static pres-
sure usually are assumed to be constant so that Equation 11 reduces to:
∆ P pt
Q = KQ ,

Tfa (Equation 12)
where:
A F p UF Z r T r Pf
KQ = .
Pr Zf M (Equation 13)

Mass Flow Rate
The mass flow rate of any given component, Ex, in the sample stream is
obtained from:
E x = K U [x] Q p , (Equation 14)
where:
Qp = flow rate of sample stream;
KU = units conversion factor, which depends upon the de-
sired units for Ex and the units in which [x] and Qp are
expressed; and
[x] = concentration of component x in the sample stream.
For the special case of x = SO2, ES (the sulfur equivalent of SO2) to be
expressed in t/d of S1, [SO2] expressed in mole percent, and Qp expressed
in m3/s at 21.1 °C and 101.325 KPA, KU = 1.14737. (If, for x = SO2, ES (the
sulfur equivalent of SO2) is to be expressed in LTD (* see Note) of S1, [SO2]
is expressed in mole percent, and Qp is expressed in ft3/s at 70 °F and 1.0
atm, then KU = 0.031 974 9.)
 (*) LTD = long ton per day; long ton = 2 240 lb.
NOTE
For use in Equation 14, both the concentration and the stream flow rate
must be on the same basis. If Qp is the total flow rate including H2O vapor,
and [x] is measured on a dry basis, [x] must be corrected to the wet basis
by multiplying by Cw:
 [ H 2 O] 
Cw = 1 - ,
 100  (Equation 15)
where:
[H2O] = the H2O concentration in the sample stream (mole
percent).
If Qp is just the dry flow rate excluding H2O vapor, and [x] is measured on
a wet basis, [x] must be corrected to the same dry basis by dividing by Cw
(Equation 15).

References
1. H. Paskall, 1981. (Curve fit to data on pp.1470-3 of reference 2.)
2. Norbert Adolph Lange and Gordon M. Forker (eds.). Handbook of Chemistry (Tenth edi-
tion). New York, N.Y.: McGraw-Hill, Inc., 1967
3. Robert H. Perry, Cecil H. Chilton and Sidney D. Kirkpatrick (eds.). Chemical Engineers’
Handbook (4th edition). New York, N.Y.: McGraw-Hill, Inc., 1963.
4. Charles D. Hodgman, Robert C. Weast, Robert S. Shankland and Samuel M. Selby
(eds.). Handbook of Chemistry & Physics (44th edition). Cleveland, Ohio: Chemical
Rubber Publishing Co., 1962. p. 3505.
5. Source Sampling Code. Alberta Environment, Industrial Waste Management Branch,
Standards and Approvals Division, Publication SSC-1/76, Edmonton, Alberta, 1976.
6. Code of Federal Regulations. Title 40, “Protection of Environment”, Chapter 1,
Environmental Protection Agency (40 CFR 50.1). Revised as of July 1, 1974.



Appendix D – Drawings
This Appendix includes many drawings that are included in the main
body of this manual. Certain drawings in this manual are examples only,
and do not illustrate all possible applications or depict all hazardous
locations.
 IMPORTANT
Drawings that are job-specific (called “Final As-Built”) are located
NOTE
in the “Supplemental Information” section of this manual and in the
Documentation Package shipped with the analyzer. Use these draw-
ings in place of similar “example” drawings used in this manual.
Appendix D – Drawings | D-1

Analyzer Schematic (WX-14716)
D-2 | Model 909 Single-Gas Analyzer

Analyzer (GP) Piping & Instrumentation Diagram
 Example drawing only. Refer to customer-specific Final “As-Built” draw-

ing for your application, shipped with the analyzer.
NOTE

Backpan Mounting Details, GP Analyzers

NOTE

Overall Component Layout, GP Analyzers

NOTE

Electronics Enclosure Layout, GP Analyzers
 Example drawing only. While the Electronics Enclosure layout gener-

ally does not change for different applications, the plumbing, instru-
NOTE
mentation, optional components, and external wiring may differ.
Refer to customer-specific Final “As-Built” drawing for your application,

User Interface Panel (WX-14151)

AC Wiring, GP/Div 2/CE/Zone 1 Analyzers (WX-102853)

Ribbon Cable Interconnect (WX-102836)

Sample/Vent Line Wiring, GP/Div 2 Analyzers (100-1254-5)

GP Lower Enclosure to Electronics Wiring, CE Analyzers (WX-102810)

Heater and Sensor Wiring, GP/Div 2 Analyzers (WX-102851)

Heater and Sensor Wiring, CE/Zone 1 Analyzers (WX-102852)

Disconnect Enclosure Wiring, 120V, Zone 1 Analyzers (100-1343-5)

Disconnect Enclosure Wiring, 240V, Zone 1 Analyzers (100-1344-5)

Lower Cabinet Wiring, CE/GP Analyzers, 120V (100-1341-3)

Lower Cabinet Wiring, CE/GP Analyzers, 240V (100-1342-3)

Customer Signal Connections, GP/Div 2 Analyzers (WX-102822)

Customer Signal Connections, CE/Zone 1 Analyzers (WX-102816)

Signal Wiring, GP/Div 2/CE/Zone 1 Analyzers (WX-102815)

± 15V and 5V Power Supply DC Wiring, GP/Div 2/CE/Zone 1
Analyzers (WX-102811)

24V Power Supply DC Wiring, CE/Zone 1 Analyzers (WX-102812)

RS-232 Communications Cable Wiring (300-9480)

RS-232/RS-485 Module Wiring, CE/Zone 1 & GP/Div 2 Analyzers
(100-2185)

Wiring Diagram, All Seals, 120V, Zone 1 Analyzers (100-1343-9)

Wiring Diagram, All Seals, 240V, Zone 1 Analyzers (100-1344-9)

Optical Bench Board (100-1662)

Micro-Interface Board (100-0116)

Host Controller Board (Display Interface) (100-0138)

Microcontroller Board (100-0117)

Termination Board (100-1534)

Display I/O Board (100-0939)

Measuring Cell/Lamp Assembly (WX-14856)

Optional Velocimeter Solenoid Block, 120 V (100-1933-1)

(100-1933-2)

Optional Velocimeter Solenoid Block, 240 V (100-1934-1)

(100-1934-2)

Zirconia Oxide O2 Sensor (Optional), Electronics Panel Layout
(100-1160-1)

Zirconia Oxide O2 Sensor (Optional), Wiring Connections
(100‑1160‑2)

Calibration Manifold Block, Flow Diagram (100-2141-1)

Calibration Manifold Block, Assembly Diagram (100-2141-2)


Supplemental Information
This section consists of information that supports the operation of this

analyzer. All information in this chapter comprises the Documentation
Package.
Information typically included in this section includes:

• Manual Supplements – that describe and illustrate installation, opera-
tion, and maintenance procedures for specific components or optional
equipment that make up your sample system.
Supplements are typically used for Measuring Cells, nonstandard or
optional equipment, or information that is intended to replace similar
information – or add to existing information – in the User Manual.
• Other customer-specific information may also be included
(application-specific).
Additional information, typically included in the Documentation Package

shipped with the analyzer, can include:
• Quality Control Documentation (Configuration; Testing; Material
Traceability, if required; Testing, Programmable Device and Gas Run
Data Sheets).
• EEPROM Data Sheets, which list the factory-default configuration set-
tings of all programmable parameters.
• Configuration Data Sheet, which list the Analyzer Information (Serial
Number, Software version), configuration of the Optical Bench,
Species (Matrix), Compensations, Analytical Parameters, Temperature
Control, Analog Inputs, Gas Calibration, and communication
(Modbus®) information.
• Operator Interface Quick Reference Sheet, which lists all of the Function
keystrokes to access analyzer parameters from the User Interface
Panel, and various other analyzer information.
• Customer-specific Final “As-Built” drawings for the entire system.
Supplemental Information | S-1

S-2 | Model 909 Single-Gas Analyzer

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Model 909 Single-Gas Analyzer

ii | Model 909 Single-Gas Analyzer

iv | Model 909 Single-Gas Analyzer

Chapter 4 CONTROLLER / USER INTERFACE

vi | Model 909 Single-Gas Analyzer

Chapter 6 Chapter Service & Parts

Chapter 7 Software Glossary

viii | Model 909 Single-Gas Analyzer

Appendix B Serial Communication Interface (Modbus®)

Appendix C Conversion Factors & Calculations

x | Model 909 Single-Gas Analyzer

 Important information that should not be overlooked.

! Verify ground continuity of all equipment before applying power.

Purged Analyzer (Hazardous Location) Applications:

xii | Model 909 Single-Gas Analyzer

! Purged Analyzer (Hazardous Location) Applications:

! Purged Analyzer (Hazardous Location) Applications:

! Purged Analyzer (Hazardous Location) Applications:

xiv | Model 909 Single-Gas Analyzer

Protective Conductor Terminal

Caution – Risk of electric shock

Caution – Refer to accompanying documents

CAUTION – Hot Surface

xvi | Model 909 Single-Gas Analyzer

Equipment Used in Haza­­rdous Locations

Risque d’explosion – Avant de déconnecter l’équipement, coupez le courant où vous assurez

xviii | Model 909 Single-Gas Analyzer

xx | Model 909 Single-Gas Analyzer

This chapter discusses the principles of operation and features of the

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

where C ≡ lP/RT is a constant depending only upon the system of units

The Measuring Cell is contained within the analyzer ’s oven. A pressure

1-2 | Model 909 Single-Gas Analyzer

The operation of the analyzer is controlled by two microprocessors. The

The Microcontroller board controls the temperature of the temperature-

To achieve measurements at discrete wavelengths, the placement of the

1-4 | Model 909 Single-Gas Analyzer

Sample System and Electronics

Safe transport of the sample gas

Gas calibration system

Remote Backpurge (Optional)

Calibration Gas Solenoid valve control

Four independent analog output signal channels

Easy Analog Output Calibration

Sample control system that detects the state of up to five temperature-controlled

The temperature-controlled zones are protected by independent

User Interface Panel

Three status relays

Reliable electronics control system

No pumps are used

1-6 | Model 909 Single-Gas Analyzer

Mass Flow Calculation (optional)

Signals representative of the temperature and linear gas velocity of

DCS Communication Interface (optional)

Dilution Air Correction (optional, for use in General Purpose applications/analyz-

 Figure 1-2 illustrates an example of a piping and instrumentation

Aspiration Components and Functions

1-8 | Model 909 Single-Gas Analyzer

Used for pressure checking the analyzer sample system.

If an optional O2 Sensor is used, this trickle purge will also

Sample Conditioning Unit (SCU) and Sample Line

For diagnostic purposes, the calibration gas flow is introduced automati-

1-10 | Model 909 Single-Gas Analyzer

Equipment Used in Hazardous Locations