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Ametek 888 User Manual

Atex/iecex tail gas analyzer
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Model 888 Tail Gas Analyzer
ATEX/IECEx
User Manual
Process Instruments
Western Research
455 Corporate Boulevard
Newark, DE 19702
PN 883056901 REV. F

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  • Page 1 Model 888 Tail Gas Analyzer ATEX/IECEx User Manual Process Instruments Western Research 455 Corporate Boulevard Newark, DE 19702 PN 883056901 REV. F...
  • Page 2 © 2014 AMETEK Process & Analytical Instruments Division This document contains Essential Health and Safety information for the use of the AMETEK Model 888 ATEX Tail 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;...

  • Page 3: Table Of Contents

    Electromagnetic Compatibility (EMC) ..............11 Classified, Hazardous Area Protection ............... 13 Components and Functions ................13 Warranty and Claims ................... 15 CHAPTER 1 Overview Model 888 Tail Gas Analyzer ................1-1 Electronics Enclosure...................1-2 Photometer....................1-2 Xenon Lamp Assembly ................1-3 Detector Assembly ..................1-3 Lamp &...
  • Page 4 Oven/Cell Temperature Not Reaching Setpoint ...........6-2 Demister Temperature Not Reaching Setpoint ..........6-2 Low Light Conditions ..................6-3 Cleaning the Optical Surface ..............6-4 Check the Optical Alignment ..............6-5 CHAPTER 7 Parts Replacement Part Numbers ....................7-3 4 | Model 888 ATEX/IECEx Tail Gas Analyzer...
  • Page 5 APPENDIX A Wiring Diagrams APPENDIX B H S and SO Calculations Concentration Measurement ................B-1 Absorbance Calculation ................B-1 Excess H S, Excess SO , Ratio (H S/SO ) and Total (H S + SO ) ..B-2 Air Demand ..................B-2 APPENDIX C Analyzer Timing Timing States / Periods ..................
  • Page 6 6 | Model 888 ATEX/IECEx Tail Gas Analyzer...

  • Page 7: About This Document

    (Zone 1). The procedures and information discussed in this document are the pro- cedures to install, operate, and perform maintenance on the Model 888 Analyzer including all relevant safety warnings and cautions to ensure the safety of personnel and the analyzer in explosive atmosphere locations.

  • Page 8: Important Safety Information

    Verify ground continuity of all equipment before applying power. For electrical shock protection, the analyzer must be operated from a grounded power source that has a securely connected protective WARNING ground contact. 8 | Model 888 ATEX/IECEx Tail Gas Analyzer...
  • Page 9 ATTENTION Humidity may damage the installed Optical Filters. Any such dam- age is not covered by Ametek’s warranty. Please consult Ametek or WARNING your local Ametek represenitive for further advise. Contents...

  • Page 10: Warning Labels

    Achtung - Heiße Oberfläche Environmental Information (WEEE) This AMETEK product contains materials that can be reclaimed and recycled. In some cases the product may contain materials known to be hazardous to the environment or human health. In order to prevent the release of harmful substances into the environment and to conserve our natural resources, AMETEK recommends that you arrange to recycle this product when it reaches its “end of life.”...

  • Page 11: Electromagnetic Compatibility (Emc)

    CAUTION when installed in harsh electrical environments. The various configurations of the Model 888 should not produce, or fall victim to, elec- tromagnetic disturbances as specified in the European Union’s EMC Directive. 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.

  • Page 12: Classified, Hazardous Area Protection

    Classified, Hazardous Area Protection Components and Functions The Zone 1 version of the Model 888 is designed to be, and comply with requirements for, electrical equipment in Zone 1 classified hazardous areas. The methods of protection used include type “p” (pressurized), and type “d”...
  • Page 13 The analyzer may only be energized with permission of the works manager or his proxy. Permission may only be given when it has been WARNING determined that an explosive atmosphere is not present or when the necessary protective measures against explosion hazards have been taken (“hot permit”) during the time that the system is energized.

  • Page 14: Warranty And Claims

    (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 the United State, a statement should appear on the documentation accompanying the equipment being returned declaring that the goods being returned for repair are American goods, the name of the firm who purchased the goods, and the shipment date.

  • Page 15: Chapter 1 Overview

    OVERVIEW Model 888 Tail Gas Analyzer uses photometric analysis to The AMETEK Model 888 Tail Gas Analyzer continuously monitor hydrogen sulfide, H S, and sulfur dioxide, SO , pres- ent in the tail gas stream of a Claus plant. Electronics Enclosure...

  • Page 16: Electronics Enclosure

    (3) a wavelength selection device to isolate the desired wavelength region; and (4) a detector (or sensor) that is sensitive to the wavelength region. 1-2 | Model 888 ATEX IECEx Tail Gas Analyzer...

  • Page 17: Xenon Lamp Assembly

    In this analyzer, the photometer spans from the electronics enclosure to sample conditioning enclosure. The electronics enclosure houses the source and detector assemblies. The sample conditioning enclosure houses the light tube, mirror-block, and sample cell assemblies. All of the photometer components are rigidly connected for optical stability. Xenon Lamp Assembly The source module consists of a high quality 3 mm arc xenon flash lamp, 0.1 uF close-coupled capacitor, and trigger electronics (with 50 Hz flash...

  • Page 18: Lamp & Detector Mounting

    Sample Conditioning (Oven) Enclosure Sample Cell Oven Enclosure Aspirator Heat Exchanger Cell Isolation/Steam Demister Blowback Low Pressure Operator Heater Aspirator Zero Flush Heat Exchanger Flange RTD Figure 1-4. Oven Enclosure (interior) 1-4 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 19 Figure 1- 5a Flow Diagram. No Steam Blowback Figure 1- 5b Flow Diagram. With Steam Blowback Overview...

  • Page 20: Light Tube/Mirror Block Assembly

    The standard probe is a ½” 316 stainless steel tube with a wall thickness of 0.035”. The probe has a standard length of 36” and can be trimmed to final length at installation. Longer probe lengths are also available upon request. 1-6 | Model 888 ATEX IECEx Tail Gas Analyzer...

  • Page 21: Demister

    Demister The demister is used to condense sulfur vapor in the sample stream by lowering the sample gas temperature to 129 °C. The demister cooling is done by injecting air around the central demister tube that has been fitted with heat transfer fins. Two coalescing pads (one Teflon®...

  • Page 22: Steam Blowback Valve

    (CV1) using PV1 to control the flow. The aspirator gas supply is heated before contacting the aluminum aspirator and pipe flange that must remain at oven temperature. 1-8 | Model 888 ATEX IECEx Tail Gas Analyzer...

  • Page 23: Customer Connections

    Customer Connection Enclosure         Figure 1-7a. Customer Connection Enclosure. All customer power and signal connections are made within the customer connection enclosure located below the electronics enclosure. Signal con- nections are provided for Ethernet, Modbus, Alarm Relays, Analog Out- puts, and Remote Inputs.
  • Page 24 Figure 1-7b Interconnect Wiring Diagram. 1-10 | Model 888 ATEX IECEx Tail Gas Analyzer...

  • Page 25: Customer Drawing Package

    Customer Drawing Package The standard customer drawing package includes four drawings. System Block Diagram: Provides overview for complete system and end user utility requirements. Field Unit Arrangement: Displays the external and Internal arrange- ment of system componants and provides main system dimensions. Field Unit Installation: Provides installation instructions for system and probe installation.

  • Page 26: Operation

    Continuous Note Controlling Energized Closed De-energized Closed Closed Hold Hold Continuous Note Controlling Energized Closed De-energized Closed Open Hold Sample Figure 1-8.1: Analyzer Timing and Control Summary With Steam Blowback 1-12 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 27 PV1-Aspirator SV1 Demister SV2-Flush Solenoid Proportional Normally Time Normally Open Valve, Normally Period Name Closed Closed Special Controlling De-energized Open Closed Flush Flush & Controlling De-energized Open Closed Zero Sample Controlling Energized Closed Open Flush Track Controlling Energized Closed Open Sample Flush &...
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  • Page 29: Chapter 2 Specifications

    SPECIFICATIONS Model 888 Tail Gas Analyzer Standard Range: 0-2% H S and 0-1% SO Ranges High Range: 0-4% H S and 0-2% SO Other ranges available upon request. All performance specifications are based on normal Performance operation that includes periodic zero and photo span calibration.
  • Page 30 -20° to +60°C ( -4° to +140°F ) Conditions The analyzer must be shaded from direct sunlight. Electronics and oven enclosures, backplate, and keypad are 316 stainless steel. Enclosures Customer connection enclosure is made from cast aluminum. 2-2 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 31 Power Consumption (specified at time of purchase) 120 VAC (105-132 VAC), 47-63Hz, 500W 240 VAC (209-264 VAC), 47-63Hz, 500W Instrument Air Supply Instrument Air 60 lb max. (60psig) (414kPa) Pressure 379-517 kPa (55 to 75 psig / 3.8-5.2 barg) Air Consumption (Fast Purge) = 1.023 kg/min and 2.262 lbm/min Air Consumption (Trickle Purge) = 0.00138 kg/min and 0.00304 lbm/min...
  • Page 32 Figure 2-1, 888-ATEX Label 2-4 | Model 888 ATEX IECEx Tail Gas Analyzer...

  • Page 33: Installation And Start-Up

    WARNING Refer service requirements to qualified personnel. Read this entire section before beginning installation of the Model 888 Analyzer. Failure to do so, and / or use of the analyzer in a manner not specified in this manual, may impair the protection against fire,...

  • Page 34: Analyzer Site Preparation

    Analyzer Site Preparation The 888 Tail Gas Analyzer is approved for installation in hazardous areas classified as Zone 1, ( Per ATEX & IECEX). The analyzer must be installed on a horizontal run of the tail gas pipe. A site plan should be prepared defining the system mounting location and provisions for power/data interconnect wiring.
  • Page 35 Installation and Start Up...
  • Page 36 3-4 | Model 888 ATEX IECEx Tail Gas Analyzer...

  • Page 37: Installation Guidelines

    If using an existing sample tap, make sure that it is internally free of solidified sulfur. The Model 888 returns the sample to process through the annular space around the O.D. of the probe tube. In most cases, the 1/2-inch O.D.

  • Page 38: Sample Tap Preparation

    This will prevent plugging the sample tap with solid sulfur which would interfere with commissioning the analyzer. AMETEK recommends that a heated, 1-inch ball valve with a 2-inch, 150 lb. raised face flange (AMETEK PN 203176001 Steam Jacketed Ball Valve or equivalent) be installed on the nozzle.
  • Page 39 necessary to stand the analyzer off the process pipe by more than 12 inches, use a steam jacketed spool piece. If nozzle length is less than six inches, a heat trace is not necessary. If the nozzle is six to 12 inches, it should be heat-traced at a minimum of 150 °C.

  • Page 40: Installation Procedure

    54.25 N-m (40 ft.-lbs). The integrity of the connection between the analyzer sample inlet flange to the tail gas pipe flange is critical as it provides the primary CAUTION support for the analyzer. 3-8 | Model 888 ATEX IECEx Tail Gas Analyzer...

  • Page 41: Installing The Probe

    Connect clean dry instrument air supply to the 1/4-inch bulkhead on the right-hand side of the cabinet. If air supply quality is in ques- tion, connect through two air/oil separators. Back out the air regulator screw so that air lines on the analyzer are not pressurized. Remove the screws from the cell oven cover plate at the top of the oven enclosure.
  • Page 42 Fully tighten the flange compression fitting. This etched mark will be used for probe removal and replacement. Figure 3-2a. Inlet, Valve and Vent Location- No Steam Blowback 3-10 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 43 Figure 3-2b. Inlet, Valve and Vent Location- With Steam Blowback Installation and Start Up 3-11...
  • Page 44 Pressure Transducer, 0-50 psia 273291001 Gauge, Aspirator, 0-30 psig 251744000 PCV3 Pressure Regulator, Purge, 0-60 psig 203188003 Gauge, Purge, 0-60 psig 273472001 Table 1. Parts Legend - Refer to Figure 3-2. 3-12 | Model 888 ATEX IECEx Tail Gas Analyzer...

  • Page 45: Installing The Demister

    Installing the Demister The demister is a white insulated assembly (Figure 3-3). The sample goes through the demister at a lower temperature than the rest of the oven. If there are droplets of sulfur in the sample stream, they will condense and fall away from the sample.
  • Page 46 Remove handle of the steam-jacketed main sample ball valve to en- sure valve cannot be closed while the sample probe is in place. Secure handle nearby so that it is available when needed. 3-14 | Model 888 ATEX IECEx Tail Gas Analyzer...

  • Page 47: Purge Installation

    Purge Installation Figure 3-4. X-Purge Installation. Maximum non-hazardous area voltage must not exceed 250 V. Installation in accordance with Canadian Electrical Code (CEC), Part I for installation in Canada. Install in accordance with the NEC (ANSI/NFPA 70) and (ANSI/ISA RP 12.6) for installation in the United States.

  • Page 48: Electrical Connections

    Cable glands suitable for use in a Zone 1 area must be used for all field wiring. The enclosure has been machined to accept M25-size glands. The Customer Connection Enclosure of the 888 must be terminated in accordance with country and local electrical codes. WARNING ...
  • Page 49 AWG), and separate earth/protective ground (PE) (14 AWG). The Ana- lyzer must be externally connected to an M5 stud via an 11 AWG wire located to the right side of the customer connections enclosure. Refer to Figure 3-5 for connection details. DO NOT CONNECT SPLIT- PHASE POWER TO THIS ANALYZER.

  • Page 50: System Start-Up And Operation

    Close both the sample inlet and return valves on the analyzer. • Supply 50 psig to the utility gas inlet and lock it in using the shut-off valve. • Monitor the pressure gauge for any drops in pressure. 3-18 | Model 888 ATEX IECEx Tail Gas Analyzer...

  • Page 51: Purging The Electronic Enclosure

    Purging the Electronic Enclosure A purge controller and vent system maintain a positive pressure prevent- ing explosive gases from entering the electronics enclosure. On start-up, the purge controller will automatically monitor the purge gas flow to ensure a minimum of five (5) air exchanges before providing power to the electronics enclosure .

  • Page 52: Adjusting The Purge Controller

    Once power has been applied, the purge controller will start a fast purge of the electronics enclosure. If a fast purge does not start: Check the blue “safe pressure” indicator on the purge controller to ensure that it is turned on. 3-20 | Model 888 ATEX IECEx Tail Gas Analyzer...

  • Page 53: System Operation

    If the blue safe pressure indicator is not turned on: Locate the adjustment valve at the top of the purge controller. Use a flat- blade screwdriver to adjust the pressure. (MAX 60psig) Turn the valve slowly counter-clockwise until the blue indicator turns on ensuring that the purge enclosure senses sufficient pressure.

  • Page 54: Starting Normal Operation

    (nominally 150°C). Refer to the logic table (Fig. 3-9b or 3-9e) alongside the flow diagram in the customer drawing package or Tabel on Page 3-25 of this manual. 3-22 | Model 888 ATEX IECEx Tail Gas Analyzer...

  • Page 55: Setting The Sample Gas Flow

    When the analyzer components reach operating temperature, the control- ler will perform an auto-zero of the photometer and then enter Period 3, Sample Flush. Sample will not flow through the cell until positive flow is attained by adjusting the aspirator pressure. CAUTION Allow 2-4 hours for complete thermal stabilization of sample cell and demister.
  • Page 56 10 PSI above the process pressure. Make sure the Aspirator Overide is in the NO position. Neutral, de-activated position Check that the flow setpoint is set to 1.5. 3-24 | Model 888 ATEX IECEx Tail Gas Analyzer...

  • Page 57: Analyzer Timing

    Figure 3-9a. Configure Pressures screen Press # to exit to the Home screen . Analyzer Timing All Model 888 analyzer functions are broken down into 14 timing periods. See Logic Table below. • Periods 1 - 4 are the normal Sample cycle and Zero cycle periods.
  • Page 58 Pre-Steam Controlling De-energized Open Closed Flush Steam Controlling De-energized Open Closed Blow Back Post Steam Controlling De-energized Open Closed Flush Logic Table-Fig. 3-9c (For Analyzer With Out Steam Blow Back. 3-26 | Model 888 ATEX IECEx Tail Gas Analyzer...

  • Page 59: Normal Timing Sequence

    SV3-Steam PV1-Aspirator FV3-Steam SV1 Dem- SV2-Flush Solenoid Blowback Proportional ister Blowback Valve Normally Solenoid Valve Time Normally Steam Blowback Period Name Open Normally Normally Closed Normally Closed Closed Closed Special Controlling De-energized Open De-energized Closed Closed Flush Flush & Zero Controlling De-energized Open...
  • Page 60 Period 9 - flushes the system with air Period 10 - Steam is flushed back through the demister and probe Period 11 flushes the system with air again before beginning the calibration cycle by jumping to Period 5. 3-28 | Model 888 ATEX IECEx Tail Gas Analyzer...

  • Page 61: Calibration Span Adjustment

    If your analyzer requires steam blowback to run more than once a day, please contact the Ametek Service Department. WARNING Calibration Span Adjustment The Model 888 has an optional calibration span adjustment that is per- formed manually. Use cylinders of H S and SO of known concentrations to validate and/or adjust the calibration of the analyzer.

  • Page 62: Calibration Procedure

    Calibration Procedure From the Model 888 HOME screen, use the navigation keys to move to the CONFIGURE button and press the ENTER key to access the CONFIGURATION sub-menu (Figure 3-10a) Figure 3-10a. Calibration Screen. Figure 3-10b. Calibration Configuration. Press ENTER again to access the Calibration Configuration screen (Figure 3-10b).
  • Page 63 Press the ENTER key to activate the continuous flush. The gold side of the slider will move to the right to indicate that the flush is activated. Flush is activated Remove the cap from the Utility port on the right hand side of the cell oven.
  • Page 64 17. Use the arrow keys to move to the SAMPLE MEASURE button and press the ENTER key to select it. The analyzer is now back in service. 18. To EXIT, press the CANCEL key (#) to return to the HOME screen. 3-32 | Model 888 ATEX IECEx Tail Gas Analyzer...

  • Page 65: Analyzer Troubleshooting And Maintenance

    Analyzer Troubleshooting and Maintenance Generally, little maintenance is required to ensure the analyzer remains operating at peak efficiency, other than that described in the “Removal and Replacement of Major System Components.” This maintenance, which includes parts that require scheduled replacement and cleaning, is intended to ensure continued and proper operation of the analyzer.

  • Page 66: Other Maintenance

    Hazardous voltages are present inside. If a procedure for a certain maintenance task is not described in the ana- lyzer User Manual, contact AMETEK Service Personnel for details about performing the required maintenance. When performing equipment maintenance in hazardous areas, all...
  • Page 67 Close both the sample inlet valve (FV1) and sample return valves (FV2) located inside the oven. Connect the external Utility port to a source of regulated instrument air set to 50 PSIG. Refer to Figure 3-13. Open valve A to pressurize the system for at least 15 seconds. Record pressure displayed on “Test Gauge”.
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  • Page 69: Chapter 4 Controller / User Interface

    CONTROLLER/USER INTERFACE Refer to 883056904 User Interface Manual for details on the AMEVision interface. Controller/User Interface...
  • Page 70 This page intentionally left blank. Controller/User Interface...

  • Page 71: Chapter 5 Alarms

    ALARMS Alarm Relays There are four (4) alarm relays maintained by the analyzer. All relays are failsafe; this means that an open contact indicates a problem. • Relay 1 is dedicated as a System Alarm • Relay 2 is dedicated as a Data Valid Alarm. •...

  • Page 72: Alarm Conditions And Responses

    • Level 4: This is a user configurable alarm. Relay 3 or Relay 4 may change state. Refer to the 888 User Interface Manual for instructions on how to set up programmable relays. 5-2 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 73 Level 1 Alarms The analyzer has an internal 1 second clock to time the state Alarm Timer Stopped machine periods. This timer can be disabled via the service menu. The alarm will persist until the timer is enabled. The cell temperature is below its lower limit. Low cell tem- Cell Temperature Alarm perature may cause Sulfur mist to condense onto the optical surfaces.
  • Page 74 This is a indicates that there is a cold spot at the flange that Flange Temperature Alarm may lead to a plugging condition. The 888 varies the number of flashes for each detector to ensure adequate light levels at each photodiode. A high flash High Flash Count Warning count usually indicates that optical surfaces need cleaning.

  • Page 75: Chapter 6 Troubleshooting

    TROUBLESHOOTING Diagnostic Functions The Model 888 includes a number of diagnostic functions that can be ac- cessed through the user interface. Refer to the Diagnose menus in Chap- ter 4 of this manual for a more detailed description. These diagnostics can be used to test analog outputs, relay operation, solenoid valve operation, proportional valve operation, lamp functionality, and detector operation.

  • Page 76: Problems And Possible Causes

    • Check the active alarms for a RTD failure alarm. An open or shorted RTD will be displayed as 999 °C on the Config- ure_Status menu. 6-2 | Model 888 ATEX IECEx Tail Gas Analyzer...

  • Page 77: Low Light Conditions

    Low Light Conditions The Xenon Flash Lamp emits ultraviolet light. Never look directly into the lamp while it is flashing CAUTION A low light alarm indicates a possible issue with the Xenon Lamp or an obstruction in the optical pathway. An obstruction can be caused by de- posits on the optical surfaces or by a mechanical misalignment.

  • Page 78: Cleaning The Optical Surface

    There is a focusing lens in the lamp assembly mounting collar as well. Recommended Optical Surface Cleaning Instruction All ooptical sutfaces wihin the 888 should be cleaned using a Kimwipe or similar optical grade cleaning sheet that has been wetted with acetone or isopropyl alcohol.

  • Page 79: Check The Optical Alignment

    ing sheet that has been wetted with acetone or isopropyl alcohol should make contact with any optical surface. Ensure that no streaking has occured on the optical surface. This can be easily seen by rotating the cleaned optic and shining a light on it. If a residue is on the surface continue to clean the optic with a new wetted cleaning sheet until the surface is free from any streaks.
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  • Page 81: Chapter 7 Parts Replacement

    PARTS REPLACEMENT Do not open the enclosure door unless the area is known to be free of hazardous gases. Units with purge controllers need to be programmed for Bypass to power the electronics. CAUTION There are hazardous voltages inside the electronics enclosure. Only a qualified technician should work on the analyzer while it is powered CAUTION There are hot surfaces present in the oven enclosure.
  • Page 82 Signal Disconnect Assembly 883110901 Aspirator 407300902 Demister Assembly 883026901 RTD, Sample Cell 883095001 RTD, Flange 883095002 RTD, Demister 273402001 Pressure Transmitter 273415001 Solid State Relay 273291001 Proportional Valve 883038901 Manifold Valve 3-way 301-0424 7-2 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 83 24 Volt Power Supply 273524001 Heater (120 V models) 883024901 Heater( 230 V models) 883024902 Cell Assembly (High Range) 883034902 Cell Assembly (Low Range) 883034901 Temp. Signal Converter 273563001 Conax Gland Seal 200859002 ◙ Parts Replacement...
  • Page 84 Sample Cell 880042001 200887001 880042001 Figure 7-1 Sample Cell - 883034901 (Standard Range) 7-4 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 85 Mirror Block 883074002 880042001 Figure 7-2 Mirror Block - 883023902 Parts Replacement...
  • Page 86 Electronics Enclosure Interior 883047901 883048901 883038901 273415001 403225901 273291001 883049901 273524001 Figure 7-3 Electronics Enclosure Interio 7-6 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 87 Amevision Electronic Assembly 8000-122-SE 301-0382 Figure 7-4. 8000-122 SE Circuit Assembly Parts Replacement...
  • Page 88 LCD Display Detail 1000-701-JE Display Cable 1000-617-JE LCD Display 8000-122-SE Figure 7-5. Display and Cable. 7-8 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 89 Keypad 273398001 Keypad Figure 7-6. Keypad - 273398001 Parts Replacement...
  • Page 90 Sensor Board Figure 7-7. Sensor Electronic Assembly - 883047901 7-10 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 91 Detector Board Figure 7-8. Detector Board - 883048901 Parts Replacement 7-11...
  • Page 92 DC/DC Converter Assembly Figure 7-9. DC/DC Converter Assembly - 883049901 7-12 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 93 Lamp Power Supply Figure 7-10. Lamp Power Assembly - 100-2061 Parts Replacement 7-13...
  • Page 94 Signal Disconnect do not install TB5 10cm LONG, 18awg TWISTED TOGETHER. STRIP ENDS 5mm. Figure 7-11a & b- 888 Signal Disconnect- 883110901 7-14 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 95 Figure 7-11a & b- 888 Signal Disconnect- 883110901 Parts Replacement 7-15...
  • Page 96 Sample Oven Enclosure - Interior 883026901 Demister 407300902 Aspirator 271446001 Sample Inlet Valve 883024901 or 883024902 Heater (120 Vac or 240 Vac) 273383001 Sample Return Valve Figure 7-12. Sample Oven Components 7-16 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 97 Manifold Block Detail Figure 7-13. Pilot Valve Locations Parts Replacement 7-17...
  • Page 98 Flange RTD Figure 7-14. Flange Formed RTD - 883095002 Cell RTD Figure 7-15. Sample Cell Formed RTD - 883095001 Demister RTD Figure 7-16. Demister RTD - 273402001 7-18 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 99 Fuses 301-0862 301-0860 25780JE 4 Amp 1 Amp 5 Amp Heater Electronics Main 203429001 Varistor (3 plcs) Figure 7-17. AC Terminals inside Electronics Enclosure Parts Replacement 7-19...
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  • Page 101 WIRING DIAGRAMS This appendix contains the wiring diagrams for all the standard and op- tional models of the Model 888 Tail Gas Analyzer. Wiring Diagrams Appendix A-1...
  • Page 102 Figure A-2. Power and Signal Junction Box Appendix A-2 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 103 Figure A-3. Wiring Diagram Zone 1 Wiring Diagrams Appendix A-3...
  • Page 104 Figure A-4. Wiring Diagram Zone 1 Appendix A-4 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 105 Figure A-5. Wiring Diagram Zone 1 Wiring Diagrams Appendix A-5...
  • Page 106 Figure A-6. Wiring Diagram Zone 1 Appendix A-6 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 107 Figure A-7. Wiring Diagram Zone 1 Wiring Diagrams Appendix A-7...
  • Page 108 Figure A-8. Wiring Diagram Zone 1 Appendix A-8 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 109 Figure A-9. Wiring Diagram Zone 1 Wiring Diagrams Appendix A-9...
  • Page 110 This page intentionally left blank Appendix A-10 | Model 888 ATEX IECEx Tail Gas Analyzer...

  • Page 111: Concentration Measurement

    S AND SO CALCULATIONS Concentration Measurement There are four detectors and bandpass filters used to measure the concen- tration of H S and SO . The signal from each of the detectors is measured by individual analog-to-digital converters and those values are used to calculate concentration.

  • Page 112: Excess H

    S + SO + 2 H The Model 888 can provide an analog output that can be used to regulate the amount of air needed by the reaction furnace to produce the correct ratio of H S to SO...

  • Page 113: Air Demand

    Claus Process, i.e Plant Factor = acid gas acid gas Air demand is defined as -∆A. The equation implemented by the Model 888 is shown below: = d {plant factor(Process ratio [SO Air Demand ] - [H S] ) - Excess Air} The configuration parameters can be found in Chapter 4 in the Config- ure _Calibration_Special Values menu.
  • Page 114 This page intentionally left blank. Appendix B-4 | Model 888 ATEX IECEx Tail Gas Analyzer...

  • Page 115: Appendix C Analyzer Timing

    ANALYZER TIMING Timing States / Periods The Model 888 uses a state machine of 14 states to control the operation of the analyzer. These fourteen states are referred to as “periods” in the user manual. Timers are responsible for many of the events that cause state transitions.

  • Page 116: Period 3 - Sample Flush

    Once time in Period 8 elapses, the period will continue either revert to Period 3 or continue to Period 9. Only analyzers equipped with the steam blowback option, can be con- figured to advance to Period 9. Appendix C-2 | Model 888 ATEX IECEx Tail Gas Analyzer...

  • Page 117: Operation Sequences

    Operation Sequences Zero Calibration Period 5 →Period 6→Period 3 Photo-Span Calibration (not configured for steam blowback period) Period 5→Period 6 →Period 7→Period 8→Period 3 Photo-Span Calibration (configured for a steam blowback period) Period 5→Period 6→Period 7→Period 8→Period 9→Period 10→Period 11→Period 5 Period 5 –...

  • Page 118: Period 8 - Track Photo-Span Calibration

    The data valid contact will be open and the analog outputs held at their last valid value during Periods 12 through 14. Period 12 – Continuous Flush The sample system is continuously flushed by instrument air during this period. Appendix C-4 | Model 888 ATEX IECEx Tail Gas Analyzer...

  • Page 119: Period 13- Continuous Hold

    Period 13– Continuous Hold All solenoid valves are de-energized during this period. Period 14 – Continuous Sample Process gas is continuously flowed through the sample cell during this period. Manual Operation Set Modbus register 273 (Manual Operation) for the following values to perform manual operation: MANUAL IDLE = 0, MANUAL ZERO = 1,...
  • Page 120 This page intentionall left blank. Appendix C-6 | Model 888 ATEX IECEx Tail Gas Analyzer...

  • Page 121: Appendix D Parameter Ids / Modbus Addresses

    PARAMETER IDS / MODBUS ADDRESSES Parameter IDs & Modbus Addresses Appendix D-1...
  • Page 122 Appendix D-2 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 123 Parameter IDs & Modbus Addresses Appendix D-3...
  • Page 124 Appendix D-4 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 125 Parameter IDs & Modbus Addresses Appendix D-5...
  • Page 126 Appendix D-6 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 127 ALARMS Alarm Severity Level 1 Alarms This is the highest level or severity of alarm. A Level 1 alarm indicates either a hardware failure or a system error that prevents the analyzer from making a valid H S or SO concentration measurement.
  • Page 128 Excessive Flash Warning indicating that the light intensity is dropping • Low Flange Temperature warning indicating the possibility of a blockage • Detector Temperature alarm indicating that the accuracy of the con- centration measurements may be affected. E-2 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 129 Level 4 Alarms A Level 4 alarm is a programmable alarm. There are two programmable alarms provided. These alarms can be mapped to a parameter via the local display interface. Alarm operation can be selected to be normally open or normally closed.
  • Page 130 This page intentionally left blank. E-4 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 131 Low Light Alarm [3] The Model 888 analyzer adjusts light intensity automatically by chang- ing the number of lamp flashes per second. If the optical surfaces slowly become fouled, the number of flashes per second is increased to maintain light intensity on the detectors.
  • Page 132 Causes for this condition could be a defective solid state relay or excessive cooling air flow. The alarm will clear itself once the temperature is in range. E-6 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 133 Cell Flow Alarm [7] The Model 888 analyzers regulate sample flow by adjusting a proportional valve in the aspirator drive air. Ideally, the sample flow rate is approxi- mately 1.5 SLPM. If the proportional valve reaches its maximum or mini- mum control range and the flow is incorrect, a Level 2 alarm occurs.
  • Page 134 There are two redundant sensors in the heater. User intervention is needed to clear the alarm condition. The RTD could be defective or one of the three RTD wires may have been disconnected. E-8 | Model 888 ATEX IECEx Tail Gas Analyzer...
  • Page 135 RTD wires may have been disconnected. Manifold Pressure Alarm [15] The Model 888 analyzer uses pneumatic control valves. The software monitors the manifold pressure for these valves. The manifold pressure alarm occurs if the pressure drops below the minimum operating pressure for the valves.
  • Page 136 High Flash Count Warning [19] The Model 888 analyzer adjusts the number of flashes-per-second to achieve ad- equate light intensity at the detector. If the optical system is fouled, the required flash count will increase. If a flash rate is within 10 flashes of the maximum, a Level 3 alarm occurs.

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