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Ametek 900 User Manual

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

Table of Contents

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Ametek 900 Specifications

General IconGeneral
Accuracy±0.02% of reading ±1 digit
Resolution0.1 RPM (below 1000 RPM), 1 RPM (above 1000 RPM)
Display5-digit LCD
Operating Temperature32°F to 122°F (0°C to 50°C)
RPM Range5 to 99, 999 RPM
Measurement Range5 to 99, 999 RPM

Summary

Safety and Precautions

Electrical Safety

Describes electrical hazards and safety measures for analyzer operation.

Grounding

Details mandatory grounding procedures for instrument safety and performance.

Personnel and Equipment Safety Information

General safety guidelines and regulations for personnel and equipment.

Warnings

Critical instructions to avoid personal injury or environmental damage.

Cautions

Important operating procedures to avoid equipment damage.

Warning Labels

Explanation of symbols used to alert users of existing conditions.

Environmental Information

Information on product recycling and environmental responsibility.

UV Source Lamps Disposal

Guidelines for environmentally safe disposal of UV source lamps.

Electromagnetic Compatibility (EMC)

Recommendations to avoid performance variations due to EMC.

Special Warnings and Information

Important safety information and specific warnings.

Equipment Used in Hazardous Locations

Suitability and installation requirements for hazardous locations.

CHAPTER 1 OVERVIEW

About the Analyzer

Overview of the AMETEK analyzer components and function.

Sample Flow

Description of how sample gas moves through the analyzer system.

About the Analyzer Sample System

Details on the components of the analyzer's sample system.

Temperature Control System

Explanation of how the analyzer maintains optimal operating temperatures.

Sample and Vent Lines

Information on heated lines for sample and vent gas transport.

ASR900 Sample Probe

Details on the probe used for sample extraction and return.

Measuring Cell

Description of the component where measurement takes place.

Working in This Manual

Guidance on using manual icons and understanding its structure.

Supplemental Information – Where Can I Find It?

Guide to locating additional technical documentation for the analyzer.

CHAPTER 2 SPECIFICATIONS

Methodology

Describes the analytical method used by the analyzer.

Standard Ranges

Lists typical concentration ranges for different gas measurements.

Response Time

Specifies the time constants for analyzer gas response.

Accuracy

Defines the precision of the analyzer's measurements.

Repeatability

States the consistency of analyzer measurements.

Calibration

Notes on calibration requirements and procedures.

Linearity

Describes the analyzer's measurement linearity.

Measuring Cell Construction

Details the materials and design of the measuring cell.

Stability

Information on the analyzer's measurement stability.

Cross-Talk

Describes potential interference between gas measurements.

Temperature Drift

Specifies how temperature affects analyzer readings.

24-Hour Zero Drift

Defines acceptable drift in zero readings over 24 hours.

Customer Connections

Information on external connections for analog and digital signals.

Analog Outputs

Details the 4-20 mA analog output signals.

Digital Communication

Describes RS-232 and RS-422 communication ports.

Maximum Sample Gas Pressure

Specifies the allowable pressure for sample gas.

Electrical Requirements

Details power supply and consumption specifications.

Maximum Start-Up Power

Specifies the peak power draw during analyzer startup.

Supply Voltage

Lists the required input voltage ranges for the analyzer.

Status Relays

Describes the analyzer's operational status indication relays.

Sample Gas Flow Rate

Specifies the recommended flow rate for sample gas.

Ambient Limits

Defines the acceptable environmental operating conditions.

Temperature

Specifies the operating temperature range for the analyzer.

Humidity

Specifies the operating humidity range for the analyzer.

Maximum Altitude

Defines the maximum operating altitude.

Sample Transport

Describes the method used for sample gas transport.

Instrument Air Requirements

Specifies the pressure and flow requirements for instrument air.

Physical Dimensions (on Backpan)

Provides the physical size and weight of the analyzer.

Cable Entry Ports, Type 200 Disconnect Enclosure

Details cable entry specifications for the disconnect enclosure.

Approvals and Certifications

Lists the certifications and approvals obtained by the analyzer.

ATEX and IECEx Certificates and Analyzer Markings

Information on hazardous location certifications.

Heater Plate ATEX and IECEx Certificates and Marking

Specific ATEX/IECEx details for the heater plate.

Disconnect Enclosure Type 200 ATEX and IECEx Certificates and Marking

Specific ATEX/IECEx details for the disconnect enclosure.

CHAPTER 3 INSTALLATION AND START-UP

Safety Considerations

Crucial safety information before installation and operation.

Pre-Installation Requirements

Steps to take before installing the analyzer.

Storage Prior to Installation

Guidelines for storing the analyzer before installation.

Uncrating and Inspecting the Analyzer

Procedures for safely uncrating and inspecting the analyzer.

Tools and Equipment Required

Lists necessary tools and supplies for installation.

Installing the Mechanical Components

Steps for installing the analyzer's physical components.

Installing the Analyzer

General instructions for mounting the analyzer system.

Location and Environment

Guidance on selecting an appropriate installation site.

Installing the Optical Bench Assembly

Detailed steps for installing the optical bench.

Installing the Sample System

Procedures for connecting the sample system components.

Installing the ASR900 Sample Probe

Instructions for installing the sample probe.

Installing the Sample and Vent Lines

Steps for connecting the sample and vent lines.

Installing the Instrument Air Line

Guidance on connecting the instrument air supply.

Installing the Span Gas Line

Instructions for connecting the span gas supply.

Connecting I/O Signals, Alarm Relay Contacts, and AC Power

How to make electrical and signal connections.

Start-Up and Verification

Procedures for powering up and verifying analyzer operation.

Purged Analyzers

Specific start-up procedures for purged analyzer systems.

Powering Up the Analyzer

Steps to power up the analyzer and perform initial checks.

Start-Up Diagnostic Checklist

Troubleshooting guide for common start-up issues.

Sample System Leak Check

Procedure to ensure the sample system is leak-free.

Manually Zeroing the Analyzer

Steps to perform a manual zero calibration.

CHAPTER 4 CONTROLLER / USER INTERFACE

Introduction to the User Interface

Overview of the analyzer's user interface layout and components.

User Interface Components

Description of the display area and keypad functions.

Messages/Information Displayed on the User Interface

Explains characters and messages shown on the UI.

Navigating From the User Interface

Guidance on moving between different screens and modes.

Working in RUN Mode

How to view data and operate the analyzer in RUN mode.

Working in CFG Mode

Procedures for configuring analyzer settings in CFG mode.

Working in CAL Mode

Steps for calibrating the analyzer in CAL mode.

Navigation Examples

Practical examples of navigating the user interface.

Entering Passwords to Change Analyzer Parameter Settings

How to access configuration settings using passwords.

Changing the Password for CFG / CAL Mode

Steps to change user interface passwords.

RUN / CFG Mode Quick Reference Sheets – Keystroke Commands

Reference for common keystroke commands in RUN/CFG modes.

CAL Mode Quick Reference Sheets – Keystroke Commands

Reference for common keystroke commands in CAL mode.

Working in the RUN / CFG Operating Modes

Detailed guide to operating in RUN and CFG modes.

RUN / CFG Mode – F1 Commands

Description of F1 commands for RUN/CFG modes.

RUN / CFG Mode – F2 Commands

Description of F2 commands for RUN/CFG modes.

RUN / CFG Mode – F3 Commands

Description of F3 commands for RUN/CFG modes.

RUN / CFG Mode – F4 Commands

Description of F4 commands for RUN/CFG modes.

RUN / CFG Mode – F5 Commands

Description of F5 commands for RUN/CFG modes.

RUN / CFG Mode – F6 Commands

Description of F6 commands for RUN/CFG modes.

Configuring the Analyzer Control Functions

How to set up analyzer control functions.

Output Signal Assignment (OSA)

How to assign parameters to analog outputs.

Analog Input Channels – Micro-Interface Board

Information on analog inputs to the micro-interface board.

Working in the CAL Operating Mode

Guide to performing calibration procedures.

CAL Mode – F1 Commands

Description of F1 commands for CAL mode.

CAL Mode – F2 Commands

Description of F2 commands for CAL mode.

CAL Mode – F3 Commands

Description of F3 commands for CAL mode.

CAL Mode – F4 Commands

Description of F4 commands for CAL mode.

CAL Mode – F5 Commands

Description of F5 commands for CAL mode.

CAL Mode – F6 Commands

Description of F6 commands for CAL mode.

Setting Up Analyzer Calibration Functions

How to configure calibration parameters.

Flow Control (Sample) Modes

Explanation of analyzer flow control modes.

Analyzer Control Mode

Details on automatic analyzer control mode.

Continuous Backpurge/Zero Flow Mode (Manual Control by Operator)

How to manually set continuous backpurge mode.

Continuous Sample Flow Mode (Manual Control by Operator)

How to manually set continuous sample flow mode.

Setting Calibration Gas Timers

Configuring timers for automatic calibration.

Integration Timer (IntTime)

Setting the averaging duration for manual calibrations.

Timer0

Setting the duration for the zero gas solenoid valve.

Auto-Zero Interval Timer (AZInt)

Setting the interval between timed auto-zeros.

Manual Zero/Span

Procedures for manual zero and span calibration.

Manual Zero

Step-by-step guide for manually zeroing the analyzer.

Manual Span

Instructions for manually spanning the analyzer.

Auto-Zero

Description of the automatic calibration process.

Manual Start of Auto-Zero

How to manually initiate an auto-zero sequence.

Timed Start of Auto-Zero

How the analyzer automatically starts auto-zero.

Remote Start of Auto-Zero

Initiating auto-zero via remote contact.

Analog Output Calibration

Calibrating the analog output signals.

CHAPTER 5 MAINTENANCE and TROUBLESHOOTING

Safety Considerations

Safety guidelines before performing maintenance.

Preventive Maintenance

General maintenance schedule for optimal analyzer operation.

Analyzer Preventive Maintenance Schedule

Detailed schedule for routine analyzer maintenance tasks.

Preventing, Detecting, and Locating a Plug in the Sample System

Methods to prevent and identify sample system blockages.

Changing Out Replaceable Parts

Guidance on replacing worn or faulty components.

Measuring Cell Maintenance

Procedures for cleaning and maintaining the measuring cell.

Replacing the Source Lamps

Steps for replacing the analyzer's source lamps.

Source Lamp Replacement

Detailed procedure for replacing source lamps.

Chopper Assembly Maintenance

Maintenance procedures for the chopper assembly.

Replacing Parts in the Heater Plate

Steps for replacing components within the oven heater plate.

Troubleshooting and Diagnostics

Guide to identifying and resolving analyzer issues.

Microcontroller Board Alarm Conditions and Corrective Action

Troubleshooting microcontroller board alarms.

CHAPTER 6 SERVICE and PARTS

Technical Support

Contact information and procedures for obtaining technical assistance.

Returning Equipment

Process for returning equipment for repair or service.

?? ANSWERS TO YOUR QUESTIONS ??

Frequently asked questions and support contacts.

AMETEK SERVICE and AFTERMARKET SALES SUPPORT

Overview of AMETEK's service offerings.

ASAP

Description of the AMETEK Service Assistance Program.

AFTERMARKET SALES

Information on purchasing replacement parts and upgrades.

TECHNICAL SUPPORT

Details on contacting AMETEK technical support.

TRAINING

Information on technician training programs.

PRE-lNSTALLATlON INSPECTIONS

Service for pre-installation site surveys.

START UPS

AMETEK services for analyzer startup.

WARRANTY VALIDATION

Validation of the analyzer's warranty upon startup.

WARRANTY EXTENSIONS

Information on purchasing extended warranties.

SPARE PARTS

Recommended spare parts for preventive maintenance.

Recommended Preventive Maintenance Spare Parts

List of recommended parts for maintenance.

Optical Bench/Measuring Cell Spare Parts

Spare parts for the optical bench and measuring cell.

Spare Analyzer Fuses

List of spare fuses for the analyzer.

Optical Bench Board Fuses (100-1662)

Specific fuses for the optical bench board.

Replacement Boards

Part numbers for replacement electronic boards.

Oven Heater Spare Parts

Spare parts for the oven heater plate.

Ordering a Hard Copy of the Analyzer Operator’s Guide

How to order a physical copy of the manual.

CHAPTER 7 GLOSSARY

User Interface Abbreviations

List of abbreviations displayed on the analyzer's user interface.

Abbreviations and Terms Used in This Manual

Glossary of terms and abbreviations found in the manual.

APPENDIX A – DRAWINGS

Ribbon Cable Interconnect (WX-102836)

Diagram showing ribbon cable connections between analyzer components.

GP Lower Enclosure to Electronics Wiring, CE Analyzers (WX-102810)

Wiring diagram for the GP lower enclosure to electronics.

Heater and Sensor Wiring, GP/Div 2 Analyzers (WX-102851)

Wiring diagram for heater and sensor connections in GP/Div 2 analyzers.

Heater and Sensor Wiring, CE/Zone 1 Analyzers (WX-102852)

Wiring diagram for heater and sensor connections in CE/Zone 1 analyzers.

Lower Cabinet Wiring, CE/GP Analyzers, 120V (100-1341-3)

Wiring diagram for the lower cabinet at 120V.

Lower Cabinet Wiring, CE/GP Analyzers, 240V (100-1342-3)

Wiring diagram for the lower cabinet at 240V.

Signal Wiring, PD/GP/Div 2/CE/Zone 1 Analyzers (WX-102815)

Wiring diagram for signal connections across various analyzer types.

Wiring Diagram, All Seals, Zone 1 Analyzers (100-1343-10)

Comprehensive wiring diagram for Zone 1 analyzers.

24V Power Supply DC Wiring, CE/Zone 1 Analyzers (WX-102812)

DC wiring diagram for the 24V power supply.

RS-232 Communications Cable Wiring (300-9480)

Wiring diagram for the RS-232 communication cable.

Microcontroller Board (100-0117)

Diagram illustrating the microcontroller board layout.

Host Controller Board (Display Interface) (100-0138)

Diagram illustrating the host controller board layout.

Model 9xx-Series Analyzer Type 200 Disconnect Enclosure Details

Detailed diagrams of the disconnect enclosure components.

SUPPLEMENTAL INFORMATION

Manual Supplements

Additional documentation for non-standard equipment.

Analyzer Programming Parameters sheet

Sheet listing critical analyzer operating parameters.

EEPROM Data Sheets

Documents detailing factory default configuration settings.

Signed Final QC (Quality Control) Document

Quality control documentation for the analyzer.

Final As-Built drawings

Customer-specific drawings for the analyzer system.

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