In-72 Gas Analyzer System

LONG TERM STORAGE INSTRUCTIONS
The analyzer system itself is intended to be installed

indoors, on the inside of the shelter.
Equipment installed on the outside of the analyzer
shelter is rated minimum Nema 4 and able to
withstand the elements that will be encountered at the
end users final installation site. Consideration for long
term storage of the analyzer system as an entirety,
should include ensuring that the door and all other
entries to the system are secured shut, and all
electrical and gas entries are sealed to prevent the
ingress of moisture or any other foreign objects or
matter that could be detrimental to the analyzer and
all other equipment housed inside the system.
For long term storage, the Analyzer Systems should
be kept in a sealed container, preferably indoors, in
an area free of moisture and elements such as rain,
wind, dust, excessively frigid temperatures, and direct
sunlight.
Servomex 2500 Series

Process Gas Analysers
Installation Manual
Ref:02500/005C/2
Order as part 02500005C
WARNING, CAUTIONS AND NOTES

This publication includes WARNINGS, CAUTIONS and NOTES which provide,
where appropriate, information relating to the following:
WARNINGS: Hazards which will result in personal injury or death.
CAUTIONS: Hazards which will result in equipment or property damage.
NOTES: Alert the user to pertinent facts and conditions.
WARNING
LETHAL VOLTAGES: THE ELECTRICAL POWER USED IN THIS

EQUIPMENT IS AT A VOLTAGE HIGH ENOUGH TO ENDANGER LIFE.
BEFORE CARRYING OUT MAINTENANCE OR REPAIR THE EQUIPMENT

MUST BE DISCONNECTED FROM THE ELECTRICAL SUPPLY. TESTS
MUST BE MADE TO ENSURE THAT DISCONNECTION IS COMPLETE.
IF FOR ANY REASON THE POWER SUPPLY CANNOT BE

DISCONNECTED, FUNCTIONAL TESTING, MAINTENANCE AND REPAIR
OF THE ELECTRICAL UNITS IS ONLY TO BE UNDERTAKEN AS A LAST
RESORT AND MUST BE CARRIED OUT BY PERSONS FULLY AWARE
OF THE DANGER INVOLVED.
NOTE
This instruction manual for the 2500 Series range of analysers covers installation,
routine maintenance and fault diagnosis procedures, and it should be thoroughly
read and retained by the personnel responsible.
ii
Table of Contents
SECTION 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.3
Basic Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.4
Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.4.1
Heated Sample Cell Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.4.2
Heated Sample Cell Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.4.3
Optional Output Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.4.4
Compensation Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.4.5
Application Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
SECTION 2 INSTALLATION GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.2
Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.2.1
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.2.2
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.2.3
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.3
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.4.1
Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.4.2
Mounting Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.5
Instructions Specific to Hazardous Area Installations . . . . . . . . . . . . . . . . . . . 2.7
2.6
ATEX Label Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
SECTION 3 INSTALLATION ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.1
Electrical Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.2
Signal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3.2.1
Analogue Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.2.2
Analogue Output Link Selections on Sensor Interface
Board (SIB) PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3.2.3
Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
3.2.4
Relay Output Link Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
3.3
Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11
3.3.1
Range Change Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12
3.3.2
Autocalibration Initiation Input . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12
3.3.3
Password Keyswitch Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
3.3.4
Sample Flow Sensor Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
3.3.5
Solenoid Valve Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
3.3.6
Externally Powered Solenoid Valve Connections . . . . . . . . . . . . .3.14
3.3.7
Internally Powered Solenoid Valve Connections . . . . . . . . . . . . . . 3.15
3.4
Digital Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16
3.4.1
RS-232 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
3.5
Pressure Transducer Connections (If Supplied) . . . . . . . . . . . . . . . . . . . . . 3.23
iii
SECTION 4 INSTALLATION GAS CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . 4.1

4.1
Purge Connections (EU1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1.1
General Purge Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.2
End Boss Purge Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.2.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.2.2
End Boss Scrubbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.2.3
End Boss Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
4.2.4
End Boss Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
4.3
Steam Heated Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.4
Process Stream Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.4.1
Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.4.2
High Integrity Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.5
Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
SECTION 5 FAULT DIAGNOSIS AND CELL MAINTENANCE . . . . . . . . . . . . . . 5.1
5.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.2
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.3
General Fault Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.4
Serious Fault (Shutdown) Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
5.5
Cell Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
5.6
Routine Leak Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
SECTION 6 SPARES LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
6.1
Spares List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
6.1.1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
6.1.2
Sample Cell Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.1.3
Source Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.1.4
Detector Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.1.5
Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.1.6
Scrubbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.2
Recommended Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
SECTION 7 INSTRUMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.1
Generic 2500 Series Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.1.1
Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.1.2
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.1.3
Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.1.4
Performance Characteristics (each component) . . . . . . . . . . . . . . . 7.2
7.1.5
Performance Characteristics EMC . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.1.6
Sample Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
7.1.7
Sample and Ambient Performance . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
7.1.8
Solenoid Valve Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
7.1.9
Analogue Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.1.10
Serial Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.1.11
Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.1.12
Ingress Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.1.13
Optical Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.1.14
485 Purge Controller (2500 EU1 Only) . . . . . . . . . . . . . . . . . . . . . . 7.5
7.1.15
Alternative Purge Controller (2500 EU1 Only) . . . . . . . . . . . . . . . . 7.5
iv
SECTION 8 CE MARKING AND OTHER SAFETY APPROVALS . . . . . . . . . . . . 8.1

8.1
EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.2
Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.3
Pressure Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.4
ATEX Directive and other non-European Hazardous Area approvals . . . . . . . 8.2
List of Figures
Figure 1.1
Figure 1.2
Figure 2.1
Figure 2.2
Figure 3.1a
Figure 3.1b
Figure 3.2
Figure 3.3
Figure 3.4
Figure 3.5
Figure 3.6
Figure 4.1
Figure 4.2
Figure 5.1
2500 Overall View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

2500 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
2500 Positioning Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
2500 Mounting Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
2500 AC Power and Valve Connections (Purged Filter) . . . . . . . . . . . 3.3
2500 AC Power and Valve Connections (Non-Purged Filter) . . . . . . . 3.4
2500 Series Terminal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Signal Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
SIB and Optional Output PCB's . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
Autocalibration Valve Configuration . . . . . . . . . . . . . . . . . . . . . . . . . .3.16
Typical Pressure Transducer Assembly . . . . . . . . . . . . . . . . . . . . . . . 3.24
Purge Connection Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Cell End Boss Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
General Cell Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
List of Tables
Table 3.1
Table 3.2
Table 3.3
Table 3.4
Table 3.5
Table 3.6
Table 3.7
Table 3.8
Table 3.9
Table 3.10
Table 5.1
Table 5.2
Table 5.3
Table 6.1
Table 6.2
Table 6.3
Table 6.4
Table 6.5
Table 6.6
Table 6.7
Table 7.1
Table 7.2
Table 7.3
Table 7.4
Table 7.5
Table 8.1
vi
Analogue Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8

Relay Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
External Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
Externally Powered Solenoid Valve Connections . . . . . . . . . . . . . . 3.14
Internally Powered Solenoid Valve Connections . . . . . . . . . . . . . .3.15
Serial Data Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17
Fault Number Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
ASCII Characters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22
RS232 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22
Pressure Transducer Connections . . . . . . . . . . . . . . . . . . . . . . . . . 3.23
Diagnostic Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
General Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
Serious Fault Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
General Spares List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Sample Cell Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Source Unit Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Detector Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Window Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Scrubber Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Recommended Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
General Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . 7.1
Performance Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Sampling Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Sample and Ambient Influence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Serial Output Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
02500 Safety Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SECTION 1
1.1
INTRODUCTION
Introduction
This manual contains information regarding installation and hardware configuration of

the Servomex 2500 Series analysers (2500GEN/EU1/EU2/FM2, 2510GEN/EU1/EU2/
FM2/HTV, 2520GEN/EU2/FM2, 2550GEN/EU1/EU2/FM2 variants).
GEN General Purpose/Safe area use.
HTV High Temperature Variant.
EU2 Certified for UK/European Zone 2 areas.
EU1 Certified for UK/European Zone 1 areas.
FM2 Certified for US Class 1 Div.2 areas.
Note that the EU1, EU2 and FM2 versions can also be used where flammable samples
are to be monitored in otherwise safe areas.
The Servomex 2500 Series has been designed and manufactured using Servomex
quality systems, which have been certified to ISO9001.
A separate Quickstart manual is also supplied with the 2500, 2520 and 2550 analysers,
reference part number 02500/003C. This details software configuration and operation
of the analyser. An alternative Quickstart manual is supplied with the 2510 analysers,
reference part number 02510/003C. Extra copies of either may be ordered from
Servomex.
Some variants are supplied with a Safety Certificate Manual, reference part number
02500/008C that details the hazardous area approvals and declarations applicable.
Details of the hardware and instructions for servicing, by qualified personnel only, are
presented in the 2500 Service Manual. This may be ordered from Servomex, reference
part number 02500/002C.
Technical assistance and spare parts are available from Servomex outlets (or their
local agents) listed on the back cover.
Use this manual for:
Installation
To take commissioning to the point where the analyser is

powered and operational. The installer is advised to read
this manual completely before commencing installation.
Use the Quickstart manual for:

Configuration
How to set up the clock, passwords, alarm levels, analogue

outputs, relays and other parameters.
Calibration
How to use the manual and automatic calibration/checking

facilities.
Review
How to review configuration and set-up information.
1.1
1.2
General Description
The Servomex 2500 Series is a single beam, multi wavelength process analyser
suitable for monitoring up to three components in a gas sample stream (2550). It is
supplied configured to the customer's precise analytical requirements for a stated
analysis in a specific background stream.
The general layout of the 2500 Series is shown in Figure 1.1. It has been designed for
modern industrial environments with the emphasis on rugged construction, reliable
performance, simple operation and easy servicing. The analyser is controlled using an
on-board microprocessor, which gives flexibility to the user, enabling him/her to
configure the operation of the 2500 to suit the particular process environment. The
2500 is operated via a very simple control panel, which is mounted on the analyser
itself.
The gas or liquid sample to be analysed must be passed continuously through the
analyser's sample cell. The 2500 is designed for continuous 24 hour/day operation and
should not normally be switched off. Versions of the 2500 analyser are suitable for use
in safe and hazardous areas. They are also designed to I.P. 65. (without electrical cell
heater, I.P. 50 with cell heater).
Figure 1.1
2500 Overall View
Note that the EU1, EU2 and FM2 versions can also be used when flammable samples
are to be monitored in otherwise safe areas (see Safety Certificate Manual).
1.2
WARNING
The EU1 versions are intended for use with a suitably certified Purge Control
System (PCS). Do not install a EU1 version in a hazardous area without a
purge controller.
The analyser's software is menu driven and has been designed to be as intuitive as
possible, enabling the user to fully operate and control the 2500 with the minimum of
familiarisation.
NOTE
Full technical specifications for 2500 Series Analysers are presented in section 7 of this
manual.
1.3
Basic Construction
The basic construction of the 2500 is shown in Figure 1.2. It comprises 2 cast end
assemblies (with hinged opening/removable covers), connected by a rigid mounting
beam, or chassis. The sample cell is mounted between the 2 end assemblies and is
removable for cleaning. This configuration results in a single optical axis, i.e. straight
through beam design, with no alignment adjustments necessary. The source end (right
side) contains the soft U.V. or infrared source, which generates a broad beam of
energy across the appropriate spectrum. This is mounted on the chopper box
assembly, which contains the interference filters, mounted on a rotating chopper wheel.
These filters select the appropriate wavelengths for the analysis for which the 2500 is
configured. In most applications, there is one measurement wavelength and one
reference wavelength for each measured component.
The infrared or visible beam, alternating in wavelength, is then focused through the
sample cell, where energy at the measurement wavelength is selectively absorbed by
the components being analysed. The remaining energy falls on the detector in the
detector end.
The sample cell is a simple thick metal construction (316 stainless steel as standard)
fitted with optical windows (each 6 mm thick) to allow passage of the beam. It is
supported between the 2 ends of the 2500 by short cylindrical bosses, which may be
scrubbed or purged, depending on application. The whole cell assembly is easily
removed by loosening the two bosses and lifting it away, as described in Section 5.
1.3
Figure 1.2
2500 Construction
The detector end (left side) contains the detector assembly and also the main
electronic circuit boards. The display and control panel is also mounted in the hinged
lid of this end.
1.4
Options and Accessories
The 2500 supplied may have been fitted with customer specified options and/or
accessories. The full list of available items with brief descriptions is given here.
WARNING
The surface temperature of heated cells can reach or exceed 100C
The following symbol is used on the heated cell:
CAUTION, HOT SURFACE
1.4.1
Heated Sample Cell Electrical
Where fitted, this is powered and controlled by the 2500 itself and is suitable for gas
samples. It may be used in both general purpose and some hazardous areas. The
normal temperature setting for common gas applications is 60C, although it may be
supplied set to any temperature from 30 180C for HTV variants or from 30 130C
for other versions.
1.4
1.4.2
Heated Sample Cell Steam
Where fitted, this is a steam heating coil which must be supplied with low pressure
steam by the user and vented to atmosphere, to maintain a cell temperature of
approximately 100C. This allows cell heating in hazardous areas up to Zone 1/Div. I
classification, and is normally used with the EU1 version only.
1.4.3
Optional Output Cards
As standard, all 2500 Analysers have 2 analogue mA (current) outputs and 3 relay
contact pairs. The analogue outputs are user configured as described in the Quickstart
manual. The relay contacts are user-assigned to any combination of concentration
alarms, Fault alarm, or calibration in progress, as similarly described in the Quickstart
manual. These standard outputs originate from the Sensor Interface Board (SIB PCB)
of the 2500.
An additional output PCB is available as option:
The 02000/916 PCB provides an extra 2 x (mA) plus 2 x (relay) outputs
This additional output PCB can be fitted into the normally vacant slot 2 in the 2500.
These extra outputs are configured along with the standard outputs in the usual way
(See Quickstart manual).
NOTE
Any or all of these analogue outputs may be configured as a voltage output by hardware
link selection, as an alternative to current output.
1.4.4
Compensation Options
The output of any infrared analyser is affected by changes in sample pressure and
sample temperature, unless compensation is applied. Alternatively, these parameters
can be kept constant by a suitable sample conditioning system. Ambient (barometric)
pressure will also affect sample pressure in the analyser if a gas sample is being simply
vented to atmosphere. The following compensation options may be fitted to a 2500.
Sample Pressure Compensation
A solid state pressure transducer is fitted and plumbed into one sample cell connection.
A continuous pressure measurement over the range of the standard transducer, 0 -345
kPa (0 50 psia), is made by the 2500. During calibration in the factory, an empirical
sample pressure/span concentration relationship is determined and stored in memory
to calibrate the compensation. Suitable for gas sample measurements only.
This option is detailed in Section 3.5
1.5
.
WARNING
Standard transducers are not suitable for oxygen service.
Sample Temperature Compensation
A type 'K' thermocouple in stainless steel sheath is supplied, and a continuous

temperature measurement is made by the 2500 over the range -50 to 200C (-58 to
392F). During calibration in the factory, an empirical sample temperature/span
concentration relationship is determined and stored in memory to calibrate the
compensation. Suitable for gas or liquid samples, and for safe and hazardous area
installations. Not available with heated cell.
1.4.5
Application Options
A range of standard and special application options is available with the 2500 and it will
have been supplied configured with one particular option to make the customerspecified measurements. Full details of the application configuration (i.e. optical
materials, operating wavelengths, cell path length, wetted materials etc.) will be found
on the Product Specification document in the front of this manual.
1.6
SECTION 2
2.1
INSTALLATION GENERAL
Introduction
This section provides all the information required to install the 2500 analyser. The
installer is advised to read this section through completely before commencing the
installation.
2.2
Preparation
2.2.1
Tools
Installation of the 2500 requires the use of standard hand tools only, and an Allen key
provided with the instrument to open the end case covers. Preparation of suitable
mounting holes in support brackets or panels may require appropriate power tools.
2.2.2
Safety Precautions
The electrical power used in this equipment is at a voltage high enough to endanger
life therefore normal electrical safety precautions must be observed. Where necessary
a warning is placed prior to the procedure it refers to as shown in the following example:
WARNING
Always ensure that the electrical mains power supply is disconnected before
commencing work.
WARNING
Electrostatic hazard: Clean display and keypad using a clean cloth moistened
with water.
2.2.3
Unpacking and Inspection

WARNING
2500 analysers weigh at least 25 kg (55 lb) and care must be taken when
handling. Use 2 people if necessary and only lift using the yellow handles
provided, not the sample cell.
Lift in the approved manner and remove the 2500 analyser from its packing and inspect
for any damage incurred during transit. If any damage has occurred inform Servomex
or their agents immediately. Retain packing, in case it is required to return the analyser
to the supplier.
2.1
After the initial visual inspection, carry out the following checks. Beware gas strut
action of the hinged covers.
Check that the serial number of the 2500 (located inside source end and also
marked on the external rating label) corresponds to the serial number given in
the Manufacturing Data Sheet found at the front of this manual.
Check that the specification sheet details are in order and agree with the
purchase requirements. Pay particular attention to the Manufacturing Data
Sheet supplied, and any Special Instrument Process Sheets attached.
Check that the accessories are present and undamaged. Standard 2500
accessories provided are: Fuse kit, Allen key, Plastic plugs (refer to section
2.4.2) and Ferrites (refer to section 3.2).
2.3
Electrical Connections
CAUTION
Specific voltage rating information is given on the label located on the outside of the
2500 Analyser and copied within the enclosure. Ensure that the analyser is correctly
configured for the supply voltage.
The 2500 Analyser has no integral switch for disconnecting the electrical supply.
The installer must include a means of isolating the electrical power by means of a
switch or circuit breaker located close to the 2500 Analyser. It must be marked as
the disconnecting device for the analyser and be easily accessible
The electrical supply to the 2500 Analyser MUST be protected by a suitable fuse or
over current protection device rated at no greater than 6 Amps.
Where the main electrical supply is not referenced to ground, an isolating transformer
must be fitted and its secondary winding suitably earthed. The following mains power
cable requirements must be met:
Three core cable with Line/Live (L), Neutral (N), Earth/Ground (E) conductors.
The cable voltage rating should conform to the supply voltage. The type of
cable used should conform to current local regulations, and be suitable for the
installation environment. For use in areas exposed to weather or mechanical
stress, armoured or sheathed cable is recommended.
All electrical cables enter the body of the 2500 Analyser via user-supplied cable
glands. These cable glands must be air tight and/or suitably approved if the
units are to be purged and/or mounted in hazardous areas.
The electrical supply connection terminals are suitable the following cable:
Flexible conductors
0.5 to 1.5mm2 (20 to 16 AWG)
Solid conductors
0.5 to 2.5mm2 (20 to 14 AWG)
Cables should be suitable for temperatures of at least 75C.
2.2
2.4
Installation
WARNINGS
The 2500 Series analysers are not suitable for use in hazardous areas
unless the correct certification labels have been affixed by Servomex
and a suitable purge control system is installed (EU1 versions).
The installer must be satisfied that the 2500 analyser installation

conforms to the relevant safety requirements, national electrical code
and any other local regulations, and that the installation is safe for any
extremes of conditions which may be experienced in the operating
environment of the analyser.
If the equipment is used in a manner not specified by the manufacturer

the protection provided by the equipment might be impaired.
Many process samples, gas streams and test samples are toxic,
asphyxiant, corrosive, flammable or a combination of some or all of
these. It is the responsibility of the installer to ensure that adequate
precautions are taken during installation of the 2500 analyser,
connection of samples, and during any other checks or tests. All
sample line connections must be checked for no leaks.
2.4.1
Positioning
Sensible positioning and an accurate and secure installation will minimise

maintenance, instrument breakdowns and will provide reliable service.
The location should be reasonably vibration free, subject to minimal fluctuations in
ambient temperature and provide reasonable access to the instrument and the
availability of any required services.
If the 2500 is to be mounted outside it must be suitably protected from all extremes of
climatic conditions by a suitable insulated enclosure, paying particular attention to the
ambient temperature range and the rate of temperature change specifications.
EU2 versions must be protected against the entry of solid particles or liquids by a
suitable cover or enclosure where necessary.
EU1 versions must be used with either a Servomex 485 Purge Control Unit with the
associated Servomex 486 Relay Unit, or another suitable Purge Control System, which
must meet the necessary pressurisation requirements, and is supplied with the
necessary pressurisation and control components.
FM2 versions fitted with electically heated sample cells must be installed in locations
which provide adequate protection against the entry of solid foreign bodies and liquids
capable of impairing safety.
2.3
WARNING
EU1 Zone 1 versions must be used with either the Servomex 485 Purge
Control Unit with the associated Servomex 486 Relay Unit, or a third-party
purge controller, which meets the necessary pressurisation and certification
requirements as detailed in the Safety Certificate Manual.
If the 2500 has been supplied with a Servomex 485 Purge Unit with the associated
Servomex 486 Relay Unit, installation information is provided in a separate manual
part no. 00485001C, supplied with the analyser system.
If a gas sample conditioning system is to be connected it must be designed to provide
a filtered, clean, non-condensing sample for the analyser with no risk of a possible
carry- over of condensate into the sample cell.
If a liquid sample conditioning system is to be connected it must be designed to provide
a filtered, single-phase sample for the analyser.
2.4.2
Mounting Details
The following paragraphs provide mounting information for the 2500 Analyser. Use the
yellow lifting handles to manoeuvre the 2500 into position, using two people where
necessary.
The analyser may be mounted vertically or horizontally, ideally at chest height for best
visibility and ease of access, but with some restrictions (refer to Fig 2.1).
CAUTION
For Liquids the analyser should be mounted horizontally with the cell
inlet port at the bottom.
For Gases the analyser should be mounted horizontally with the cell
inlet port on top, especially if there is risk of particulates or
condensates in the sample.
The 2500 may be mounted vertically for gas samples, provided the cell
outlet is at the bottom. This is only suitable if there is no risk of
particulates or condensates in the gas sample.
2.4
When mounting the analyser ensure that the panel or brackets employed are adequate
to take the weight and there is a minimum clearance above the casing of 500mm (20")
to provide space to open the end covers.
Fig 2.2 provides mounting details and a table of mounting hole spacings for the various
cell lengths. Be sure to identify the correct hole spacing.
When the 2500 is to be vertically mounted the display may be rotated 90 to bring it into
a legible position. This is done by removing the internal metal cover and ribbon cable
clamp, and removing the retaining bracket. The display unit can then be withdrawn a
little and rotated. Reassemble the disturbed components in reverse order, carefully
folding the ribbon cable to prevent any stress on it.
Figure 2.1
2500 Positioning Restrictions
2.5
Figure 2.2
2500 Mounting Details
Once mounted, the two yellow lifting handles and their spacers MUST be removed by
unscrewing the securing screws. Press the black pop-in plugs supplied into the vacant
screw holes and retain the handles for possible future use.
2.6
2.5
Instructions Specific to Hazardous Area Installations

(Reference European ATEX Directive 94/9/EC, Annex ll, 1.0.6.)
The following instructions apply to equipment covered by certificate numbers: Sira

02ATEX1395X and Sira 03ATEX2236X
2.5.1
The equipment may be located where flammable gases and vapours of

groups llA, llB and llC may be present. The equipment is only certified for use
in ambient temperatures in the range -20C to +55C for type 'p' approval and
-5C to +55 C for type 'n' approval, and should not be used outside these
ranges.
(Note performance specification is 0C to +55C)
2.5.2
The equipment has not been assessed as a safety-related device (as

referred to by Directive 94/9/EC, Annex ll, clause 1.5).
2.5.3
Installation of this equipment shall be carried out by suitably trained

personnel in accordance with the applicable code of practice (EN 60079-14
within Europe).
2.5.4
Repair of this equipment shall be carried out by the manufacturer or in

accordance with the applicable code of practice (IEC 60079-19).
2.5.5
If the equipment is likely to come into contact with aggressive substances,

then it is the responsibility of the user to take suitable precautions that prevent
it from being adversely affected, thus ensuring that the type of protection is
not compromised.
Aggressive substances
e.g. acid liquids or gases that may attack metals,

or solvents that may affect polymeric materials.
Suitable Precautions
e.g. regular checks as part of the routine

inspections or establishing from the material's
data sheet that it is resistant to specific
chemicals.
2.7
2.6
ATEX Label Information
2.6.1
EU1 T5 (Unheated Cell)
2.6.2
EU1 T4 (Heated Cell)
2.8
2.6.3
EU2 T3
2.6.4
EU2 T4
2.9
2.10
SECTION 3
INSTALLATION ELECTRICAL
WARNINGS
Lethal voltage: mains AC power supplies are potentially lethal. The

installer must ensure that the power supply has been isolated before
commencing installation.
The installer must be satisfied that the 2500 analyser installation

conforms to the relevant safety requirements, national electrical code
and any other local regulations, and that the installation is safe for any
extremes of conditions which may be experienced in the operating
environment of the analyser.
WARNING
The following symbols are used on the warning label fitted on the inside of the
Source End Enclosure Cover.
CAUTION, ELECTRIC SHOCK HAZARD
CAUTION, CONSULT MANUAL
3.1
Electrical Power Connections
For convenience the gas struts may be removed during installation by carefully levering
them off. Ensure that the cable used is suited to the installation environment, and is the
correct rating. Ensure that the fuse is suited to current rating of the analyser and that
all glands and cable connections are secured firmly.
The mains power connection to this instrument is made via an electrical filter unit
attached to the outside of the case. The power cable into this unit does not need to be
screened.
3.1
WARNING (EU1 VERSION)

AC Power for Zone 1 (EU1) versions may only be connected via a suitably
certified Purge Control System. Refer to the PCS manual for details. The
mains power connection to the instrument is made via the purged electrical
filter unit attached to the outside of the case.
Refer to Figure 3.1 a) or b) for illustration.
To connect the 2500 analyser to the mains supply:
1.
Isolate the mains AC supply at source.
2.
Remove filter unit cover.
3.
Fit suitable cable gland to the mains filter unit.
4.
Insert cable through gland and secure.
5.
Wire to terminals.
6.
The mains AC supply is connected internally to TB30. The voltage selection is

made by wire link on TB31 as illustrated in Figure 3.1 a) or b).
7.
Connect the 2 external earthing studs to earth/ground. The RF earth provided

must be locally earthed using as suitable solid conductor connected to a local
physical earth to ensure optimum RFI protection. The external system earth must
be connected to the mounting panel / cubicle / frame / local Intrinsically Safe
earth, as appropriate.
DO NOT APPLY POWER YET.
NOTE
When installed in hazardous locations, appropriate wiring practice must be used

(e.g. within Europe installation must be in accordance with IEC 60079-14)
3.2
Figure 3.1a
2500 AC Power and Valve Connections (Purged Filter)

3.3
Figure 3.1b
3.4
2500 AC Power and Valve Connections (Non-Purged Filter)
Figure 3.2
2500 Series Terminal Locations

3.5
3.2
Signal Connections
NOTE
All signal cables must have a braided overall screen or armour. The screen must be
terminated at the point of entry to the case. This will be by using a gland, which
makes a connection between the cable screen and the case. Beware of ground/
earth loops if the screens are also connected at the user end.
Where two cables are passed through a single entry, a metal gland specifically
intended for two separate cables shall be used.
To minimise the effects of interference from the RF fields, a Steward type 28B0562200 or equivalent ferrite sleeve (Servomex Part No. 2824-0017) shall be placed
over each mA output cable pair. Refer to Figure 3.3.
Figure 3.3
3.6
Signal Cable Connections
3.2.1
Analogue Outputs
Figure 3.4
SIB and Optional Output PCB's
Each analogue output is supplied set for current output and may be configured by the
user to be 0-20mA or 4-20mA, and be assigned a particular range of operation, in
software. This is described in the Quickstart manual. In addition, a "Range 2" setting
for each analogue output can also be configured in software. Maximum impedance is
1k ohm for current output. If desired, each analogue output may be changed to voltage
output of either 0-10V or 2-10V, minimum impedance 1M ohms. This is done by
soldering links into position "LINK 10" and "LINK 11" on the relevant SIB (Sensor
Interface Board) PCB or Option PCB for the first and second analogue output
respectively. See Section 3.2.2. In every case, fit a suitable gland, insert, secure and
strip a suitable cable pair before connecting the cores to the appropriate terminals.
3.7

Where the 2500 is in a Zone 1 area, a suitable Relay Box should be used to isolate
the outputs. This Relay Box should be switched from the Purge Control System.
Each analogue output (and each relay output) has an individual identity in software.
This identity is a number, which relates to the "slot" in which the PCB (SIB or Option
PCB) containing the actual output (or relay) physically resides.
For example, the first analogue output is from the standard SIB PCB which resides in
"slot 1" and therefore its software identity is "1.1" (i.e. first slot first output channel). The
second analogue output is "1.2", and the first relay output is "1.3", etc.
The following tables show the physical locations for connections to the analogue
outputs.
Table 3.1 Analogue Output Connections
Output
Software ID
Analogue 1
1.1
TB 24-4 (+) and TB 24-3 (-)
Analogue 2
1.2
TB 24-2 (+) and TB 24-1 (-)
Analogue 3*
2.1
TB 22-1 (+) and TB 22-2 (-)
Analogue 4*
2.2
TB 22-3 (+) and TB 22-4 (-)
*option PCB
Terminal locations are as illustrated in Figure 3.2.
3.8
Terminal Connections
3.2.2
Analogue Output Link Selections on Sensor Interface Board (SIB) PCB
After connecting up the required analogue outputs, the user should make the following
hardware link selections on the SIB PCB and (where fitted) Option PCB(s). Refer to
Figure 3.3.4 for general schematic of both these types of PCB. Carefully remove the
PCB for link selection and be sure to replace it in the correct slot and in the correct
orientation.
Current/Voltage
Each output may be individually selected as current (0/4-20mA) or voltage
(0/2-10V). Factory setting is CURRENT.
Analogue o/p No.1
Analogue o/p No.2
Current:
Link 10 OPEN
Voltage:
Link 10 CLOSED (solder link)
Current:
Link 11 OPEN
Voltage:
Link 11 CLOSED (solder link)
Action on System Failure

To enhance fail-safe operation, each output may be selected to drive HIGH
(to 20.5mA/10.2V) or LOW (to 0 mA/0V.) if the 2500 detects a system failure
(Shutdown state, i.e. serious fault and measurement invalid). Factory setting is
HIGH.
Analogue o/p No.1
HIGH on Shutdown: SW1/3 OFF

LOW on Shutdown: SW1/3 ON
Analogue o/p No.2
HIGH on Shutdown: SW1/2 OFF

LOW on Shutdown: SW1/2 ON
Delay on Fail Safe Action

The detection of system failure (Shutdown, i.e. serious fault/measurement
invalid) is practically instantaneous and therefore a sufficiently large, rapid,
mains transient or brown-out may also cause the fail-safe action described
above to occur immediately. In installations where this would be undesirable,
the fail-safe action may be delayed for 5 seconds to overcome such possible
transient effects.
Factory setting is NO DELAY.
Both Analogue o/p
DELAY on fail-safe:
SW1/1 OFF
NO DELAY on fail-safe:
SW1/1 ON
3.9
3.2.3
Relay Outputs
NOTE
Each relay output is supplied set for NC (i.e. Normally Closed under "Safe"
condition) operation, and may be assigned to a particular alarm or signalling
function in software. This is described in the Quickstart manual.
User selection of NC or NO operation is described in Section 3.2.4. As with the
analogue outputs, each relay has its own software identity relating to the slot in which
the PCB, on which it is physically located, resides. The following tables show the
physical locations for connections to the relay outputs. All relay outputs are rated
240VAC/1.0A or 30VDC/1.0A. In each case, fit suitable glands and cable and connect
to the relevant terminals. Select the correct procedure according to the architecture.
Table 3.2 Relay Output Connections
Output
Software ID
Terminal Connections
Relay 1
1.3
TB 23-1 and TB 23-2
Relay 2
1.4
TB 23-3 and TB 23-4
Relay 3
1.5
TB 23-5 and TB 23-6
Relay 4*
2.3
TB 22-5 and TB 22-6
Relay 5*
2.4
TB 22-7 and TB 23-7
*option PCB
Terminal locations are as illustrated in Figure 3.2.
3.2.4
Relay Output Link Selection
After connecting up the required relay output, the NC/NO selections may be altered on
the SIB PCB and (where fitted) output Option PCB(s). Refer to Figure 3.4 for general
schematic and carefully remove and replace the PCB as before, if a change is to be
made.
Normally Closed/Normally Open (NC/NO)
The factory setting of all relay output wire links is soldered in the NC position. This
means that the contacts will open to signal an alarm. The contacts will also be open if
there is no power applied to the 2500, i.e. they are fail-safe. If, however, it is required
to change to NO operation (i.e. close to signal an alarm) this can be done by cutting
and reordering the wire links as listed below.
3.10
WARNING
Setting the relays to Normally Open (N.O.) operation will mean that there is no
fail-safe action since any loss of cable continuity will prevent an alarm being
signalled.
NOTE
Regardless of N.O./ N.C. setting, the relays will always be in "alarm" state wherever
there is no power applied to the 2500, or when they are unassigned.
Relay o/p No. 1
N.C. Link 3 A
N.O. Link 3 B
Relay o/p No. 2
N.C. Link 4 A
N.O. Link 4 B
Relay o/p No. 3
N.C. Link 5 A
N.O. Link 5 B
3.3
Control Connections
NOTE
All control cables must have a braided overall screen or armour. The screen must be
makes a connection between the cable screen and the case. Beware of ground/earth
loops if the screens are also connected at the user end.
As standard the following connections are provided on the 2500, and these are made
to the 2500 Analyser PCB's utilising a suitable gland in an adjacent hole. Refer to
Figure 3.2 and Table 3.3.
Table 3.3 External Control Connections
PCB
Function
Connections
Transmitter PCB
02500904A
Range Change
TB26 1
TB25 3
Transmitter PCB
02500904A
Autocalibration Initialise
TB26 2
TB25 3
Transmitter PCB
02500904A
Password Keyswitch
TB26 3
TB25 3
Power Control PCB

02500911A
Flow Failure
TB36 1
TB36 2
3.11
3.3.1
Range Change Input
Every analogue output can be independently scaled in software to represent some or

all of the calibrated range of the instrument, as described in the Quickstart manual.
However, under some process conditions (e.g. plant start-up) it may be desirable to
have different output ranges on demand. When the Range Change Input is used all
analogue outputs will change to their user-designated "Range 2" settings. Note that
"Range 2" settings can be identical to "Range 1" settings if desired.
NOTE
"Range 2" is selected as long as contacts remain closed.
Range 2 settings selected by Contact closure between:
TB26 1 and TB25 3
3.3.2
Autocalibration Initiation Input
Autocalibration/Autocheck may be triggered by the user from the control panel or by

using the 2500's own real time clock system. Alternatively, it may be triggered at will
using a manual remote switch or by a host device, closing a contact.
Autocalibration initialised by contact closure between:
TB26 2 and TB25 3
NOTE
Contacts must be closed for at least 2 seconds but no more than 59 seconds.
Remote initiation starts the "one cycle" routine using all the user-set
parameters. It will not repeat unless contact closure is made again.
User is advised to set the Autocalibration period in software to zero

(i.e. internal timer disabled) when using remote Autocalibration initiation,
to prevent duplication of Autocalibrations.
3.3.3
Password Keyswitch Input
As an alternative to the use of passwords via the control panel, a simple Keyswitch can
be connected which enables access to both Operator and Supervisor levels without
password demands. The user must first set SW1/8 to ON on the Microprocessor PCB,
to enable this feature. See the Quickstart Manual for more details.
Keyswitch setting selected by Contact closure between: TB26 3 and TB25 3
3.12
.
WARNING
If the Keyswitch is left "ON" (contacts closed), access is continuously
available to all normally protected areas of the software.
3.3.4
Sample Flow Sensor Input
If the sampling system supplying the process sample to the 2500 is fitted with a loss of
flow sensor, this can be connected to the 2500 to enable the "loss of sample flow"
diagnostic to operate, which in turn triggers the analyser's Fault alarm. See Figure 3.1.
2500 Power Control PCB 02500911A
Loss of flow diagnostic triggered by contact closure between: TB36 1 and TB36 2.
NOTE
In common with all fault diagnostics this alarm will only be cleared by restoration of
flow/opening of contacts.
WARNING
Where the 2500 analyser is in a hazardous area, suitable protection concepts
must be used to connect the loss of flow sensor to the 2500 analyser.
3.3.5
Solenoid Valve Drives
Autocalibration routines are provided as standard on the 2500, and if they are to be
used, suitable 3-way solenoid valves can be plumbed into the sampling system as
shown in Fig 3.5. Two or three valves may be used and all should be located
conveniently close to the 2500. Each valve is switched via the 2500 Power Control PCB
relays as illustrated. The valves are selected for operation by the 2500 as shown in
Table 3.4 and Table 3.5. Connect the valves to the appropriate terminals using suitable
screened cables and glands, and attach screens to the nearest earth stud with the
minimum length of screen. See Figure 3.1.
The Autocalibration relay contacts are rated at 240VAC/1.0A, 30VDC/1.0A. The
contacts are fitted with an R-C snubber (100R + 47nF) to provide transient protection
when used with AC solenoids. 220/240Vac solenoid valves with a power rating less
than about 6VA are not recommended because the 'leakage' current through the
snubber may prevent low power solenoids from de-energising correctly.
Solenoid valves may use an external power source, or the internal 24VDC/12VA power
source may be used. When using the internal power source, ensure that the 12VA
rating is not exceeded. DC solenoid valves must have built-in suppression diodes fitted
across the coil to protect the relay contacts.
3.13
WARNING
If installation is in a hazardous area, use suitable certified solenoid valves.
NOTE
Valve (SV3) reverts to OFF in Shutdown (Serious Fault) condition. The use of the
optional 3rd "Sample/Inert valve will prevent sample entering the 2500 sample cell
while the cell or chopper box under temperature diagnostic is activated, i.e. heated
cell is not fully warmed up. This can be used whether or not Autocalibration is used
and will be appropriate in some applications: e.g.
if there is a possibility of condensation forming in the sample cell during warm

up, then nitrogen or another purge gas must be used to flush the cell during
it's warming up period.
if a hazardous sample is being monitored, the cell should be purged in the

event of a serious fault.
3.3.6
Externally Powered Solenoid Valve Connections
Connect via solenoid valve relays as detailed. Ensure that the relay rating is not
exceeded.
Table 3.4 Externally Powered Solenoid Valve Connections
Valve State (ON=Current Flow Through
Solenoid)
3.14
Span/Zero
Valve SV1
TB34 1
TB34 2
Cal/Sample
Valve SV2
TB34 3
TB34 4
Sample/Inert
Valve SV3
TB34 5
TB34 6
Cell or Chopper Box

Under Temperature
either
either
OFF(Inert)
NORMAL STATE OFF
OFF (Zero)
ON(Sample)
ON(Sample)
Zero Sample Required
OFF (Zero)
ON(Cal.)
ON(Sample)
Span Sample Required
ON(Span)
ON(Cal.)
ON(Sample)
3.3.7
Internally Powered Solenoid Valve Connections
Connect to solenoid valve relays SV1, SV2 and SV3 as detailed below. Take care to
ensure that internal 12VA (total) rating of the 24VDC supply is not exceeded.
Table 3.5 Internally Powered Solenoid Valve Connections
Valve State (ON=Current Flow Through
Solenoid)
Span/Zero
Valve SV1
TB34 1 (-)
TB36 6 (+)
Cal/Sample
Valve SV2
TB34 3 (-)
TB36 5 (+)
Sample/Inert
Valve SV3
TB34 5 (-)
TB36 5(+)
Cell or Chopper Box

Under Temperature
either
either
OFF(Inert)
NORMAL STATE OFF
OFF (Zero)
ON(Sample)
ON(Sample)
Zero Sample Required
OFF (Zero)
ON(Cal.)
ON(Sample)
Span Sample Required
ON(Span)
ON(Cal.)
ON(Sample)
NOTE
To ensure internally powered solenoid valve function, fit links between:
TB34 2 and TB36 4
TB34 4 and TB36 3
TB34 6 and TB36 3
CAUTION
TB36 terminals 5 and 6 (+24V) are always live and should not be grounded.
3.15
Figure 3.5
3.4
Autocalibration Valve Configuration
Digital Connections
NOTE
All digital cables must have a braided overall screen or armour. The screen must be
makes a connection between the cable screen and the case. Beware of ground/earth
loops if the screens are also connected at the user end.
Digital connections in RS/EIA-232 format are provided for attaching a local portable
printer to receive set-up information directly down loaded from the 2500, or to report
measurement and analyser status information to a DCS or datalogger.
3.4.1
RS-232 Connection
See the Quickstart manual for configuration of the RS-232 port and operation of this
function. See Figure 3.2 and Table 3.9 for connections. The format of the serial data
stream is as follows:
3.16
Table 3.6 Serial Data Format

Item
Size
Description
<CR>
1 byte
Carriage return character (ASCII code 13).
date;
8 bytes
dd/mm/yy or mm/dd/yy depending on user

settings.
time;
8 bytes
hh:mm:ss
number of
components
1 byte
1 byte Number of components fitted

(range 1-3)
<CR><LF>
2 bytes
Carriage return and Line Feed characters

(ASCII codes 13 and 10 respectively).
component 1 formula; Max 6 bytes
Chemical formula defined for component 1.
component 1
concentration;
Max 5 bytes
Concentration for component 1 as defined

for measure display.
component 1 units;
Max 3 bytes
Units defined for component 1.
component 1 alarm
status;
4 bytes
One byte for each alarm. Set to alarm

number (1,2,3 or 4) when alarm is raised,
<space> when alarm not raised
component 1
Autocalibration
status;
1 byte or
15 bytes
Indicates Autocalibration phase.

0 = Not in Autocalibration
1 = In span preflush
2 = In zero cal
3 = zero corrected. This is then followed by
two additional values, which are separated
by commas, each 6 bytes that represent the
zero before calibration and the zero after
calibration respectively.
4 = In span cal
5 = span corrected. This is then followed by
span before calibration and the span after
6 = In post flush
<CR><LF>
2 bytes

Note: The data for components 2 and 3 will only be present on a 2550
instrument.

(if fitted)
3.17

component 2
concentration;
Max5 bytes

for measure display. (if fitted)
component 2 units;
Max 3 bytes
Units defined for component 2. (if fitted)
component 2 alarm
status;
4 bytes

<space> when alarm not raised. (if fitted)
component 2
Autocalibration
status;
1 byte or
15 bytes

0 = Not in Autocalibration l
2 = In zero cal
4 = In span cal
6 = In post flush
<CR><LF>
2 bytes


(if fitted)
component 3
concentration;
Max 5 bytes

for measure display. (if fitted)
component 3 units;
Max 3 bytes
Units defined for component 3. (if fitted)
component 3 alarm
status;
4 bytes

<space> when alarm not raised. (if fitted)
3.18

component 3
Autocalibration
status;
1 byte or
15 bytes

0 = Not in Autocalibration
2 = In zero cal
4 = In span cal
6 = In post flush
<CR><LF>
2 bytes

Note: End of 2550 specific data

fault status;
1 byte
fault numbers;
Set to 'F' when fault is active, <space> when

no fault active
List of fault numbers of active faults,
separated by ','. Fault numbers are defined
in table 3.7.
<CR><LF>
2 bytes

Chopper
temperature; C;
Max 4 bytes
Chopper temperature as displayed in

diagnostic display.
Compensation
temperature; C;
Max 4 bytes
Compensation (detector) temperature as

displayed in diagnostic display.
cell/sample
temperature; C;
Max 5 bytes
Cell/sample temperature as displayed in

diagnostic display.
source voltage; V;
Max 5 bytes
Source voltage as displayed in diagnostic

display.
Intensity 1;Intensity 2; Max 6*6

Intensity 3;Intensity 4; bytes
Intensity 5;Intensity 6;
Intensity channel values diagnostic values

representing up to six input positions used
for measure and reference signals.
<CR><LF>

2 bytes
3.19

checksum;
4 bytes
ASCII representation of 16 bit checksum

(modulo 65536), calculated by adding all
data preceding the checksum together.
<CR><LF>
2 bytes

<CR><LF>
2 bytes

Serial port parameters are as follows:

Baud rate: 2400
Parity: Even
Stop Bits: 1
Data Bits: 8
Handshake: hardware
Example Data:
Note: Checksums have not been calculated
Normal Operation Example Output
<CR>09/01/99;13:42:30;2;<CR><LF>CO;0.5;%; 2 4;0;<CR><LF>CO2;3.8;%; ;0;<CR><LF> ;;<CR><LF>50.0;51.5;183.2;5.0;
123456;521452;319322;4235421;478525;368965;<CR><LF>????;<CR><LF><CR><LF>
3.20
Table 3.7
Fault Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
Fault Number Reference

Display Message
OPTICAL BENCH POWER FAILURE
SOURCE VOLTAGE HIGH
SOURCE VOLTAGE LOW
INFRARED SOURCE FAILURE
CHOPPER MOTOR OUT OF LOCK
SAMPLE FLOW FAILURE
CHOPPER TEMP HIGH
CHOPPER TEMP LOW
CHOPPER TEMP SENSOR FAILURE
CELL TEMP HIGH
CELL TEMP LOW
CELL TEMP SENSOR FAILURE
SAMPLE TEMP SENSOR FAILURE
PRESSURE SENSOR FAILURE
BAD REFERENCE VOLTAGE
COMPENSATION T SENSOR FAILURE
DETECTOR SIGNAL HIGH
DETECTOR SIGNAL LOW
Reserved
Reserved
Reserved
AUTO CAL BAD PREFLUSH
ZERO OUT OF TOLERANCE
SPAN OUT OF TOLERANCE
Reserved
Reserved
Reserved
Reserved
Reserved
PASSWORD VIOLATION
SYSTEM CLOCK INOPERATIVE
SYSTEM ADC INOPERATIVE
DEFAULT SYSTEM DATA CORRUPTION
CALIBRATION DATA CORRUPTION
UTILITY DATA CORRUPTION
ALARM/RELAY DATA CORRUPTION
ANALOGUE ASSIGN DATA CORRUPTION
BAD SPAN SPAN IGNORED
3.21
Some characters defined by the 2500 are non-standard characters, i.e. not part of the
ASCII character set. These either occupy the ASCII codes above 127 or redefine an
ASCII code as another character. When these characters are used, for example in the
component formula, they will be substituted with a valid ASCII character prior to output
on the RS232. The non-standard characters and their substitute values are as follows:
Table 3.8 ASCII Characters
ASCII Code
Character
Substitute Character
126
<space>
127
<space>
128
129
130
131
132
133
134
135
136
137
138
<space>
139
<space>
140
<space>
141
??
<space>
142
<space>
143
<space>
Table 3.9 RS232 Connections

2500 Terminals
Connector
External RS232 Terminals
0V (Ref.)(0VR)
TB20 1
Signal GND/0V
Clear to Send (CTS)
TB20 3
Data Terminal Ready (DTR)
Transmit (Tx)
TB20 4
Receive (Rx)
3.22
WARNING
Do not use an uncertified dcs, datalogger or printer in a hazardous area.
3.5
Pressure Transducer Connections (If Supplied)
The pressure transducer cabling is terminated to the source end right hand side (RHS)
of the analyser.
The pressure transducer is supplied pre-wired to the analyser. The cabling is
connected to PCB 02500911A TB35 as shown in Table 3.10
.
Table 3.10
PCB 02500911A
Pressure Transducer Connections
Interconnecting Cable
Pressure Transducer
TB35 5 (signal +)
Identified '1'
Terminal 1 (+)
TB35 1 (signal -)
Identified '2'
Terminal 2 (-)
The general layout of the pressure transducer option is illustrated in Figure 3.6.
3.23
Figure 3.6
3.24
Typical Pressure Transducer Assembly
SECTION 4
4.1
INSTALLATION GAS CONNECTIONS
Purge Connections (EU1)
The next phase of the installation is to connect up any safety purge system required for
safe operation in a hazardous area.
4.1.1
General Purge Connections

Where appropriate, the user must refer to the detailed instructions provided
in the manual supplied with the Servomex 485/486 purge units or other Purge
Control System, and use them in conjunction with the following instructions.
Figure 4.1
Purge Connection Schematic
4.1
The general schematic for a hazardous area purge system is shown in Figure 4.1.
WARNINGS (FIGURE 4.1)
1.
If this component is mounted in a hazardous area it should be protected

by one of the norms listed in EN 50014.
2.
Cable glands used in EEx 'd' apparatus shall be approved Ex 'd'

components, which maintain the degree of protection necessary.
3.
All cable glands for use in electrical cable entries shall be of a type, which
seals and clamps the cable.
NOTES (FIGURE 4.1)

1.
The PCS shall include an automatic device, which operates when the
overpressure falls below the minimum prescribed value. This device operates
in turn a pressure switch, which can be used for alarm and/or isolation
purposes.
2.
Where the PCS is used to protect the 2500 bench unit only, the protective gas
supply shall be connected from the PCS to the 2500. The minimum level of
overpressure shall be monitored at or close to the outlet aperture of the 2500.
The maximum level of overpressure shall be monitored at or close to the inlet
and the PCS shall incorporate a limiting device to ensure that the maximum
overpressure specified in normal service (80 mBar) is not exceeded.
3.
A protective device shall be fitted to the purge exhaust aperture to prevent

sparks or incandescent particles from being ejected from the pressurised
enclosure.
4.
The PCS shall require to be put through a purge cycle after a pressure loss
before power can be restored to the instrument.
5.
The PCS shall contain a pressure sensing element which is factory set, to a
level not less than the specified minimum (50 Pa, 0.5 Mb) and shall measure
pressure at the point in the system where the lowest pressure occurs.
6.
The PCS shall supply a flow rate of protective gas, not less than 10 SLPM, and
shall incorporate an automatic device to monitor flow during the purge time
specified below.
7.
The PCS shall maintain the minimum specified overpressure during the purge
phase and afterwards.
8.
The PCS shall incorporate a purge timer, which shall be set to not less than
16 minutes. The purge timer shall be set to zero if either the minimum
overpressure or minimum purge flow is not maintained.
9.
The PCS shall incorporate a device to ensure that power is not connected to
the apparatus being protected until the specified purge time has elapsed.
4.2
4.2
End Boss Purge Connection
Depending on application, fittings for 1/8" o.d. tube may be provided to purge the end
bosses on either side of the sample cell and these should now be connected. Refer to
the following application notes and Figure 4.2 where necessary.
4.2.1
Introduction
The 2500 measuring cell is mounted on two short tubes or "end bosses" which
preserve the integrity of the optical system, while providing thermal isolation. The
measuring cell and the analyser enclosure are both independently sealed using
windows or lenses and elastomeric seals. The end bosses form the interface between
the two, and the implications of a cell window leak must be considered when
flammable, corrosive or toxic gases are measured.
Under ideal circumstances, the gas in the end bosses should be totally transparent to
the wavelengths of infrared energy used for the measurement. However, simply filling
the bosses with nitrogen and sealing them is not always satisfactory, because the
elastomeric seals are permeable and atmospheric gases such as carbon dioxide or
water vapour can leak in. Specifically, a problem will arise when the gas being
measured is also carbon dioxide or water vapour, or when the measurement is cross
sensitive to either of those gases: the effect of a gradual ingress of the atmospheric
gases will be seen as drift in the measurement. A further problem arises with low-level
measurements of carbon monoxide. In this case it is out-gassing of carbon monoxide
from the seals themselves which can cause drift.
4.2.2
End Boss Scrubbers
Problems, relating to cross interference within the end bosses, can usually be resolved
by fitting chemical "scrubbers" to the end bosses. These are small metal housings
packed with a chemically active material, which absorbs or reacts with the problem gas.
A number of materials are available which absorb water vapour (molecular sieve),
carbon dioxide (soda lime) and carbon monoxide (Hopcalite).
When a 2500 is specified, a suitable scrubber material is stipulated for the end bosses,
where necessary, and the analyser will be delivered with these scrubbers fitted.
NOTE
If the analyser is dismantled for any reason, the scrubbers must not be left exposed
to normal atmosphere for more than a few minutes or they will be exhausted.
Similarly, after long-term use they may need to be replaced, and this must always
be with the correct type.
4.3
4.2.3
End Boss Vents
When a flammable, severely corrosive or toxic gas or liquid is present in the

sample cell, either as the sample or a background gas, additional issues arise.
The construction of the cell window seal is such that any leak of the seal or failure of
the window will result in the sample gas entering the end boss, but not being released
to the surrounding atmosphere or directly into the analyser enclosure. This is a
deliberate safety feature of the design. However it is necessary that steps are taken to
deal with the leak so that no permanent hazard arises, and permanent sealing of the
end bosses and the use of scrubbers is not generally acceptable. Instead, the end
bosses will be supplied with adaptors for connecting vent or purge lines.
If the measurement is not affected by atmospheric gases, then a single vent connection
of at least 4mm I.D. should be made to each end boss, which will vent to atmosphere
in a safe location where release of the sample will not cause a hazard. If the sample
pressure exceeds 50kPa (7 psig), the vent should be 8mm I.D., and the sample cell
outlet connection should be fitted with a non return valve, and the sample cell inlet
connection should be fitted with a restrictor which will limit the total flow to less than
10 litres/min in the event of total window failure.
4.2.4
End Boss Purge
If the measurement is affected by atmospheric gases, then in addition to the vent

described above, the second connection to each end boss should be connected to a
supply of dry (1) nitrogen (2) regulated to a flow of 100ml/min using a suitable flow
meter. Ensure that the end boss purge is always vented to atmospheric pressure and
the pressure within the end boss dead volume space does not exceed 2.5psig.
Suitable precautions should be made to ensure that, in the unlikely event of a
catastrophic failure of the cell window /sealing, sample gas is prevented from
contaminating the purge gas supply.
(1)
Dry means a dew point of below -30 deg C.
(2)
Dry CO2-free air may also be used in most applications except low-level CO2.
Hazardous Area Certification flammable samples, additional note

The analysers are certified for use in either Zone 2 / Div II or Zone 1. In all cases this
certification does not permit the analyser (or any part of its enclosure) to be exposed to
a permanently flammable atmosphere. Sealing the end-bosses with scrubbers when
measuring a flammable sample would mean that should there be a cell window leak,
the part of the enclosure that the end boss seals against would become exposed to a
permanently flammable atmosphere. Venting or purging the end bosses resolves this
issue.
4.4
NOTE
Vent lines, if required, should be connected to end boss bottom tappings. Purge gas
should be connected to top tappings when required. When not required, top tappings
should be plugged.
IF FITTED, COMMENCE END BOSS PURGE FROM THIS POINT ONWARDS.
WARNING
Where the sample is corrosive or toxic, the vent lines from the end bosses
must take away any potential leakage to a safe disposal point.
Figure 4.2
Cell End Boss Connection
4.5
4.3
Steam Heated Cell
Some 2500's are fitted with steam heated cells, and at this stage suitable low pressure
steam, typically at 14-21kPa, 2-3 psig venting to atmosphere after the cell, should be
connected ready for use, but do not pass steam into the heating coil yet. Fittings for
1/8" o.d. tube are normally provided.
4.4
Process Stream Connection
4.4.1
Basic Operation
The process stream connections to and from the 2500 sample cell inlet and outlet
should now be made. The inlet and outlet are 1/4" o.d. stubs. Connections will normally
be from a local sample conditioning system. Ensure that any pressure compensation
transducer is correctly fitted. Ensure that all connections are made securely with the
correct compression fittings, of suitable materials. Gas samples should enter the cell
from above. (Refer to Figure 2.1).
Do NOT pass process samples into the 2500 yet.
4.4.2
High Integrity Operation
This is the recommended mode of operation and where appropriate, the process
sample can be routed via the "Sample/Inert" solenoid valve, controlled by the 2500,
which will only permit sample to enter the sample cell when it is fully warmed up and
no serious faults are present. See Section 3.3.5.
Do NOT pass process samples into the 2500 yet.
WARNING
In either case for toxic/flammable samples ensure that the sample inlet line
has a suitable restrictor inserted to limit sample flow in case of catastrophic
failure of sample tubing/cell connections.
4.5
Power-Up
1.
Confirm that all electrical and plumbing connections have been correctly made as
described in the preceding sections.
2.
Ensure purge gas is applied to the Purge Controller (Where Fitted).
3.
Apply power to the 2500 (via the Purge Control System for EU1 Versions).
4.
Apply steam to any steam-heated cells fitted.
5.
The 2500 will show the start-up and Identity display as follows:
Self-checks (Fault and Alarm LEDs tested)
System O.K.
Analyser identity/Software revision number.
Serial number and order number.
Calibration (measurand, range, units).
Commence measurement.
4.6
6.
The normal measurement display will then appear and the 2500 will be
operational.
NOTES
The measurement will not be valid at this point since process sample is not
yet flowing.
If a heated cell is fitted, it will not yet be up to temperature and the intermittent
"warming up" message will be displayed. Depending on set point and/or
environment this may take several hours to reach temperature and the
message to cease.
The 2500 chopper box will also take up to 2 hours to reach specified
temperature and the "warming up" message will also be displayed until this is
accomplished.
WARNING
Check for no leaks of sample at full operating pressure and temperature
before proceeding. This is especially important for toxic/flammable samples.
While the analyser is warming up, the software configuration to suit the user's particular
requirements may now be accomplished. Proceed to the Quickstart Manual for details
of configuration. Note that during the warming up period, all outputs and alarms are live
and fully operational. All diagnostics are also operational, EXCEPT cell temperature
and chopper box temperature. These last two diagnostics only become operational
once the temperature set points have been reached or after 2 hours (for chopper box)
or 10 hours (for cell) have elapsed from power-up.
At this point process sample may be turned on and allowed to flow through the
2500 sampling system.
NOTE
Where the 3rd (sample/inert) solenoid valve is in use (see Section 3.3.5) the inert
medium will automatically be supplied to the analyser until the cell reaches correct
temperature.
4.7
4.8
SECTION 5
5.1
FAULT DIAGNOSIS AND CELL MAINTENANCE
Introduction
A fault will be signalled wherever any parameter measured by the 2500's diagnostics
becomes out of tolerance. Any Fault condition will be indicated by the Fault LED on the
control panel being illuminated.
The Fault signal can be assigned to a Relay, as described in the Quickstart Manual.
Faults are categorised as either:
1.
General Faults parameter out of tolerance, intervention is required as

soon as possible. The analyser is still operational and measuring.
2.
Serious Faults (Shutdown) performance seriously degraded,

measurement withdrawn and analogue outputs driven HIGH (or low, as
configured in Section 3.2.2).
NOTE
For detailed instructions on all Service and Maintenance operations for suitably
skilled personnel, please refer to the 2500 Series Service Manual part number
02500/002C.
5.2
Diagnostics
The diagnostics listed in Table 5.1 can be interrogated via the DIAGNOSTICS function
in DISPLAY menu. See Quickstart Manual.
5.1
Table 5.1 Diagnostic Displays

Display
Description
CHOPPER TEMP C
Chopper box temperature
COMPENSATION C
Detector temperature
CELL TEMP C
Cell temperature (if enabled)
SAMPLE TEMP C
Sample Temperature *
[Measurement 1] ABS au
Absolute absorbance units (M1)
Absolute absorbance units (M2) *
Absolute absorbance units (M3) *
SAMPLE PRESSURE (units)
Sample pressure *
SOURCE VOLTS V
Source voltage
MOTOR DRIVE %
SET POINT %
Motor drive power and set point
DETECTOR SIG M1
Detector signal level (M1) measurement
DETECTOR SIG M2
Detector signal level (M2) measurement *
DETECTOR SIG M3
Detector signal level (M3) measurement *
DETECTOR SIG R1
Detector signal (R1) reference
DETECTOR SIG R2
Detector signal (R2) reference *
DETECTOR SIG R3
Detector signal (R3) reference *
TEMP CORR M1
Temperature Correction (M1)
TEMP CORR M2
Temperature Correction (M2) *
TEMP CORR M3
Temperature Correction (M3) *
TEMP CORR R1
Temperature Correction (R1)
TEMP CORR R2
Temperature Correction (R2) *
TEMP CORR R3
Temperature Correction (R3) *
* (IF FITTED).
5.2
5.3
General Fault Conditions
When the Fault LED is illuminated, the DISPLAY FAULTS function should be used to
determine the nature of the fault. The diagnostics (Section 5.2) may assist in defining
the cause, together with the comments given in Table 5.2. Action to cure the fault
should be taken as soon as possible.
Table 5.2 General Fault Messages
Display Message
History Log
Entry
Description/comments
SOURCE VOLTAGE
HIGH
SOURCE HIGH
Possible Power Control PCB fault
SOURCE VOLTAGE
LOW
SOURCE LOW
SAMPLE FLOW
FAILURE
FLOW FAIL
User Sample Flow Alarm active
CHOPPER TEMP HIGH
CH TEMP HIGH
Ambient temp. too high/control

problem
CHOPPER TEMP LOW
CH TEMP LOW
Ambient temp. too low/control

problem
CHOPPER TEMP
SENSOR FAILURE
CH TEMP FAIL
Chopper sensor failed/

disconnected/outside range.
CELL TEMP HIGH
CELL T HIGH
CELL TEMP LOW
CELL T LOW
CELL TEMP SENSOR

FAILURE
CELL T FAIL
Cell sensor failed/disconnected/

outside range
SAMPLE TEMP
SENSOR FAILURE
SAMPLE T FAIL
Sample sensor failed/disconnected/

outside range
PRESSURE SENSOR
FAILURE
NO PRESSURE
Sample sensor failed/disconnected/

outside range
BAD REFERENCE
VOLTAGE
REF OLT FAIL
Possible Transmitter PCB fault
DETECTOR SIGNAL
LOW
DET SIG LO
Probable cell contamination clean

cell
COMPENSATION T
SENSOR FAILURE
COMP T FAIL
Detector sensor failed/disconnected
ZERO OUT OF
TOLERANCE
ZERO OUT TOL
Failed Autocalibration bad zero

sample use One Cycle or Manual
Zero
5.3
Table 5.2 General Fault Messages

SPAN OUT OF
TOLERANCE
SPAN OUT TOL
Failed Autocalibration bad span

sample use One Cycle or Manual
Span
AUTOCAL BAD
PREFLUSH
BAD PREFLUSH
Failed Autocalibration bad

preflush use One Cycle
PASSWORD
VIOLATION
BAD PASSWORD
3 consecutive Password failures
SYSTEM CLOCK
INOPERATIVE
BAD CLOCK
Reset time or replace Clock chip
DEFAULT SYSTEM
DATA CORRUPTION
BAD SYS DATA
Factory calibration corrupt use

Associate
SYSTEM ADC
INOPERATIVE
BAD ADC
Possible SIB PCB fault
CALIBRATION DATA
CORRUPTION
BAD CAL DATA
User calibration corrupt repeat

calibration
UTILITY DATA
CORRUPTION
BAD UTI DATA
Utility file corrupt renew all entries
ALARM/RELAY DATA
CORRUPTION
BAD RLY DATA
Alarms/Relays file corrupt-renew all

entries
ANALOGUE ASSIGN
DATA CORRUPTION
BAD ANL DATA
Analogue output file corrupt-renew

all entries
BAD SPAN SPAN

IGNORED
BAD SPAN
Coarse span adjustment limit

exceeded Check span sample
NOTE
DETECTOR SIGNAL LOW may briefly occur at power-up.
5.4
5.4
Serious Fault (Shutdown) Conditions
If the Fault LED is illuminated and the Analogue Outputs have been driven HIGH (or
LOW, depending on selection), a Serious Fault exists and the Measurement Display
will show "Measurement Invalid".
Immediate action should be taken to rectify the fault, and qualified service personnel
should be called.
The SERIOUS FAULT messages listed in Table 5.3 will result in a Shutdown.
Table 5.3 Serious Fault Displays
Display Message
History Log
Entry
Description/comments
INFRARED SOURCE
FAILURE
SOURCE FAIL
Source failure
CHOPPER MOTOR
OUT OF LOCK
OUT OF LOCK
Motor or timing failure
DETECTOR SIGNAL
HIGH
DET SIG HI
Possible loss of IR filter, loss of

liquid sample.
NOTE
Detector Signal High may also occur and cause temporary shutdown on
liquid analysers if there is no liquid sample in the cell, e.g. at initial power-up.
Check for loss of flow if sensor fitted. Try Manual Zero on good zero sample if
sample flowing.
The user interface remains operational during Shutdown and can be used to
diagnose the likely cause of the fault via the Fault Display and Fault History.
5.5
Cell Maintenance
As a guide the cell should be removed for cleaning when the Reference detector
signals (Section 5.2) fall below 50% of their original values. In aggressive sample
conditions, the loss of signal may be due to general corrosion or pitting of the cell
windows. In this case the cell windows may have to be replaced. Otherwise, the cell
and windows can be dismantled and carefully cleaned and all items (except O-rings)
re-used. See Figure 5.1 for general construction of the cell.
5.5
Figure 5.1
General Cell Construction
CAUTION
Use only Servomex supplied spare parts. The use of inferior replacement
components may degrade the performance and safety of the instrument.
5.6
WARNING
Lethal voltages: mains AC power supplies are potentially lethal. The

maintainer must ensure that all mains power supplies are disconnected
from the supply before maintenance work is started.
Purge the measuring cell and associated pipework with an inert gas
before work is started.
It is the users responsibility to ensure that work is carried out in an

adequately ventilated space taking due account of risks associated
with release of flammable or toxic samples. Attention is also drawn to
the risks associated with the release of asphyxiants.
To remove the cell assembly from the 2500 proceed as follows:

Flush the cell thoroughly with Nitrogen and disconnect the process connections. Where
fitted, remove cell heater connection plug from the socket at the source end and allow
sufficient time for it to cool (this may take some hours). Remove any purge connections
from the end bosses if fitted. Slacken 3 x M6 socket screws securing the cell bosses at
either end of the sample cell.
Carefully disconnect the cell thermocouple from the cell body. Support the cell
assembly and pull the bosses inward from the ends of the 2500 sufficient to enable the
cell to be removed and taken to a workshop for maintenance. If necessary, slacken the
screws holding the source end casting onto the mounting chassis to permit easy
removal.
CAUTION
Do not pull or strain heater connection leads at any stage.
If the scrubbers (if fitted) are not to be removed, leave the bosses on the analyser and
blank the open ends of the bosses using the 2 blanking plugs (02500460), supplied
with the Special Tools Kit S2500979, to preserve the existing scrubbers. Otherwise
take the entire cell and boss assembly to a workshop.
Working on a clean bench in a suitable environment, dismantle the cell. Pull the end
bosses off the cell body. Note that these items are one-piece stainless steel. If the
bosses are fitted with absorbent scrubbers, these should be removed and replaced
(A variety of types may be fitted see spares list for appropriate part numbers).
WARNING
Special materials are used for the windows. Some of these are toxic
(i.e. germanium, barium fluoride, zinc selenide, etc.) these substances must
be handled in accordance with the relevant local standards.
5.7
The windows are usually ground from optical grade single crystal material and as such
may be EXTREMELY EXPENSIVE. The windows may have special anti-reflective
coatings and they may easily be damaged by brittle fracture. The standard material
chosen by Servomex is Calcium Fluoride. This material is non-toxic and reasonably
robust. However, some applications may require materials such as Germanium,
Barium Fluoride, Zinc Selenide, etc. which are toxic and must be handled with extreme
care. See the Manufacturing Data Sheet at the front of this manual for details of the
windows fitted.
Windows should be kept optically clean, i.e. free from dirt, scratches, grime, grease,
fingerprints etc. When handling windows it is recommended that cotton gloves or finger
cots be worn.
WARNING ZINC SELENIDE

If windows of zinc selenide are fitted and have been damaged by acidic attack
(e.g. acidic condensate or organic acids have entered the cell) it will be likely
that some of the zinc selenide will be reduced to selenium metal. This is
highly toxic and on no account should attacked zinc selenide material be
handled with bare fingers. Such material should be bagged and disposed of
according to local regulations.
Cleaning of the cell windows should be carried out using cotton buds or lens tissue,
detergent and/or a suitable solvent such as Isopropanol. Avoid abrasive cleaning
compounds, as these will damage the optical surface.
WARNING
The use of some solvents (iso-propyl alcohol, alcohol etc.) constitutes a
hazard. These substances must be handled in accordance with the relevant
local standards.
To remove the cell windows proceed as follows:
Ensure that the end bosses have been removed from the cell body. Starting at one end
first, unscrew and remove one locking ring with a cell key (supplied in Special Tools Kit
Servomex p/n S2500979). Remove the 5 wavy washers, spacer, and 'O' ring being
careful not to damage them or the window. To remove the window, seal the outlet and
with the cell in a vertical position, connect a hand operated aspirator (Servomex p/n
2387-0514) to the inlet. Apply a gentle pressure to lift the window up squarely and
remove it. Finally remove the PTFE gasket. Dismantle the other end of the cell in a
similar manner.
The 'O' ring spacer is threaded internally. The Special Tools Kit Servomex p/n
S2500979 contains an extractor, which screws into the spacer to aid removal.
The windows may now be carefully cleaned. The cell body may also be cleaned as
necessary.
5.8
Ensure all items are thoroughly clean and dry before reassembly, which is the reverse
procedure but with the following points noted:
The windows should be 'floated' into place squarely using a hand aspirator or
equivalent, reversing the removal procedure.
Use new 'O' rings and other cell sealing kit items making sure that all dust, hairs
etc, are rigorously excluded from them. Ensure the window surfaces are also
free from solvent residues or finger grease.
The locking ring has a coated thread to prevent seizure PTFE tape is not
required. The locking ring should be tightened down in stages, pausing for a
moment between stages until the metal faces of the cell body and locking ring
meet when fully tightened, with no gap between them. Where Teflon 'O' rings
are being used, this will require significant torque, with longer pauses. DO NOT
use the cell inlet/outlet stubs as levers.
After re-assembly, perform a leak check on the cell using a manometer before installing
it in the 2500. Do not submerge the cell or fill it with water.
Re-installation of the complete cell assembly onto the 2500 is the reverse of the
dismantling process with the added requirement that, unless fitted with a purge, the end
bosses should be briefly flushed with clean dry nitrogen after the cell has been
mounted and then new absorbent scrubbers should be quickly screwed into them. Be
sure to fully tighten the screws holding the source end casting onto the mounting
chassis if they have been slackened.
Finally, connect up the cell thermocouple to the cell body, reconnect the cell heater
plug (where fitted) and connect up any purge connections and the process
connections. Return the analyser to service as described in Section 4.5.
Reset zero if necessary on a true zero sample.
5.6
Routine Leak Checks

WARNING
It is the users responsibility to keep all sample connections to the 2500

sample cell, purge connections (if fitted) to the end bosses and steam coil
connections completely free from leaks. All plumbing connections should
therefore be regularly inspected for signs of leakage and urgent corrective
action taken if any are found. This is especially important for process
samples, which are flammable, toxic, liquid, or any combination of these.
5.9
5.10
SECTION 6
6.1
SPARES LISTS
Spares List
The following spares list applies to all versions of the 2500 covered by this manual.
The 2500's Model and Serial Number MUST be advised when ordering spares.
NOTE
For ATEX versions EU1 and EU2 only those boards listed may be used as spares
6.1.1
General
Table 6.1 General Spares List
Description
Part Number
Power Supply
S2000925
Display PCB
02501903
Display/Keypad Assembly
S2501999
Keypad Assembly
02501998
Sensor Interface PCB
02000934
Option PCB
02000916
Transmitter PCB
S2500904A
Motor Connection PCB
S2500906
Power Control PCB
S2500911A
Interconnecting Ribbon Cable Assembly 1-256mm path
S2500928A
Interconnecting Ribbon Cable Assembly 512mm path
S2500928B
Interconnecting Ribbon Cable Assembly 1000mm path
S2500928C
Display Ribbon Cable Assembly
S2500929
Interconnecting Cableform 1-256mm path
S2500944A
Interconnecting Cableform 512mm path
S2500944B
Interconnecting Cableform 1000mm path
S2500944C
Fixings Kit (All fasteners)
S2500974
Seals Kit (All Seals excluding Cell Seals)
S2500975
Chopper Box Insulation
S2500977
Transformer, 115/230 volts
00608333
Transformer, 100/200 volts
00608334
6.1
Table 6.1 General Spares List
6.1.2
Special Tools Kit
S2500979
Enclosure Earth Studs
S2500984
Pressure Transducer
S2500985
Chopper Motor
S2500986
Chopper Box Seals Kit
S2500988
Gas Strut Kit
S2500989
Motor Connection PCB
S2500906
Fuse Kit
02501996
Multi component Adaptor PCB (2550 only)
S2550901
10 x Gas Filter Correlation Adaptor PCB (2510 only)
S2510901A
40 x Gas Filter Correlation Adaptor PCB (2510 only)
S2510901B
Processor PCB + Firmware (2510 only)
S2510965A
Processor PCB + Firmware (2500, 2520, 2550)
S2500965A
Thermal Fuse (98C)
2536-0329
Sample Cell Spares

Table 6.2 Sample Cell Spares
6.2
Description
Part Number
Thermocouple (300mm Sheath)
02500502
Cell Servicing Kit
S2500981
Cell Seals Kit (Viton + PTFE)
S2500982A
Cell Seals Kit (Chemraz)
S2500982B
Special Tools Kit
S2500979
PTFE Tape
1835-3026
Hand Aspirator
2387-0514
6.1.3
Source Units
(Refer to Final Specification Sheet)
Table 6.3 Source Unit Spares
6.1.4
Description
Part Number
Long Wave, CaF2
S2500931C
Long Wave, BaF2
S2500931B
Long Wave, ZnSe
S2500931A
Short Wave, CaF2
S2500943A
Short Wave, Glass
S2500943B
Soft UV CaF2 (2520 Only)
S2520933
Detector Units
Table 6.4 Detector Spares

Description
Part Number
CaF2
S2501905A
CVDFET
S2501905C
KRS-5
S2501905B
Photodiode (2520 Only)
S2600905
6.3
6.1.5
Windows
Table 6.5 Window Spares
6.1.6
Description
Part Number
CaF2
S2500980A
BaF2
S2500980B
ZnSe
S2500980C
IR Quartz
S2500980D
Glass
S2500980E
Germanium
S2500980F
Sapphire
S2500980G
Scrubbers
Table 6.6 Scrubber Spares
6.4
Detector / Cell Boss Scrubber (H2O) Marked 'W'
S1200921
Detector / Cell Boss Scrubber (H2O/CO2) Marked 'CW'
S1200922
Detector / Cell Boss Scrubber (H2O/CO2/CO) Marked 'H'
S1200924
Scrubber Sachet Kit, H2O Mix
1723-8010
Scrubber Sachet Kit, H2O/CO2 Mix
S2000511
Scrubber Sachet Kit, H2O/CO2/CO Mix
S2000512
6.2
Recommended Spares
Quantity for 2 years.
Table 6.7 Recommended Spares

Item
Part Number
1-3 Analysers
4-9 Analysers
Fuse Kit
02501996
Cell Servicing Kit
S2500981
PTFE Tape
1835-3026
Chopper Motor
S2500986
Cell sealing Kit
Refer to application
Hand Aspirator
2387-0514
Windows
Chopper Box Scrubber
Detector & Cell Boss

Scrubber
Source
Detector
Microprocessor PCB
Sensor Interface PCB
02000934
Power Supply
S2000925
NOTE
Scrubbers should be used as soon as received, or otherwise they must be stored in
their original unopened packaging in an airtight container, or preferably in a
desiccator. Scrubbers should be used on a "first in, first out" basis.
6.5
6.6
SECTION 7
INSTRUMENT SPECIFICATIONS
7.1
Generic 2500 Series Performance
7.1.1
Environmental Specifications
Table 7.1 General Environmental Specifications
Operating Temperature
GEN, EU1, EU2, FM2, HTV 0-55C (32-131F)
Operating Humidity
0-95% RH, non-condensing
Storage Temperature
-40C(-104F) to +70C (158F)
Storage Humidity
0-95% RH, non-condensing
Altitude
Up to 3000 M
Installation Category II
Pollution Degree II
Over-voltage impulse to withstand up to 2500V

in accordance with IEC 60664-1
Rate of Ambient Temperature

Change
Less than 25C/h, (45F/h) Change
Warm-up Time
Typically 2-10h, depending on application and

environment
7.1.2
Dimensions
Length:
Max 1618mm, (63.7") min 615mm (24.2")
Height:
241mm (9.5")(allow 500 mm (20")

to open end covers)
Width:
248mm (9.8")
Weight:
from 25 kg (55 lb)
7.1.3
Power Supply
115/230V AC 15%, 50/60Hz or 100/200V AC 15%, 50/60Hz.

120 VA without optional electrically heated cell.
300 VA with optional electrically heated cell.
Power Supply
Voltage Effects:
Less than 1% fsd for 15% change.
Power Supply
Frequency Effects:
Less than 1% fsd for 47 to 53 Hz or 57 to 63 Hz.
7.1
7.1.4
Performance Characteristics (each component)

Table 7.2 Performance Characteristics
Intrinsic Error*
Less than 1% fsd
Repeatability
0.5% fsd
Output Fluctuation (Noise)
Less than 1% fsd (peak-peak) at minimum T90
Linearity Error
Typically less than 1% fsd
Short Term Zero Drift:
Less than 1% fsd per week
Response Time (T90)
User adjustable from 11s minimum (electronic

only, excludes sampling)
Obscuration
Less than 3% fsd zero error for 50% broadband

obscuration of cell windows
Influence Errors
Dependant on application (see specification

details)
* error when used under reference conditions.
2510 HCL measurement less than 2% fsd (peak-peak) at minimum T90.
7.1.5
Performance Characteristics EMC
Configuration of equipment:
Fitted with an unscreened power cable. Also included were two separate mA
output cables, each individually screened. Each signal pair was fitted with
ferrite bead (Servomex part No. 2824-0017). The screens and drain wires were
terminated at the glands.
Results:
Met the requirements of EN 61326, Table 4, Class B (Equipment for use in
domestic establishments) in respect of conducted and radiated emissions.
Met the requirements of EN 61326, Table A1 (Equipment for use in industrial
establishments) in respect of electrostatic discharges, fast transients/bursts,
surges, conducted RF disturbances, voltage dips and interrupts.
An additional error of 3% FS over the intrinsic error given in Table 7.2 may be
observed at some frequencies under the influence of radiated RF fields
specified for industrial environments.
Connection of additional or other signal/control cables and pressure
compensation could lead to a deterioration in performance at some RF
frequencies.
7.2
7.1.6
Sample Specification
Table 7.3 Sampling Specification
Sample Temperature
0-180C/32-356F (see sampling influences)
Sample Pressure
0-150 psig/0-10 barg (normal) (For special high

pressure operation consult Servomex)
Sample Flow (typical)
GAS 0.2-5.0 litres/min

LIQUIDS 0.3-1.0 litres/min
(Constant flow rate preferred)
Sample Wetted Materials
Refer to Final Specification Sheet
7.1.7
Sample and Ambient Performance

Table 7.4 Sample and Ambient Influence
Sample Pressure
Stability
Output may change up to 1.6% fsd for a 1% change in

sample (Gas Analysers) pressure. With optional
empirical sample pressure compensation, effect is
reduced to 1% fsd or less for a 20% change in sample
pressure for most typical samples.
Sample Temperature
Stability
Output may change up to 0.3% fsd for gases for a 1C

change in sample temperature. With optional empirical
sample temperature compensation, effect is reduced to
1% fsd or less for a 20C change in sample
temperature for most typical samples.
Sample Flow Stability
Depends on cell volume and vent conditions but for

unheated cells the primary effect is less than 1% fsd
change in output for flow rate changes of 10%.
Ambient Temperature
Influence
Less than 1% fsd zero drift due to rate of ambient

temperature change of 25C/hr (45F/hr) over a
maximum of 25C (45F) change.
7.1.8
Solenoid Valve Relays
3 x Solenoid valve relays with volt free contacts rated 240VAC/1.0A, 30VDC/1.0A.
1 x 24VDC/12VA auxiliary supply for solenoid valves
7.3
7.1.9
Analogue Outputs
2 x mA outputs, plus 3 x relay outputs. Optionally additional 2 x mA, plus 2 x relay

outputs.
All analogue mA outputs are assignable and selected as 0-20mA or 4-20mA (max.
impedance 1KOhm) or alternatively 0-10V or 2-10V (min. impedance 1MOhm).
Dual ranges on every Analogue output. Optional additional mA outputs should be
specified for 3 component analysers.
All relay outputs are assignable contact pairs selected by links as NC or NO, and are
rated 240VAC/1.0A, 30VDC/1.0A.
7.1.10
Serial Output
Single ASCII data logging output port (RS232).

Table 7.5 Serial Output Specification
7.1.11
Baud Rate
2400
Parity
Even
Stop Bits
Data Bits
Handshake
Hardware
Inputs
Terminals for external switch contacts are provided for:
Range change
Autocalibration/Autocheck initiate
Key switch (password)
Flow Sensor
7.1.12
Ingress Protection
Designed to IP65 (without electrical cell heater, IP50 with electrical cell heater).
7.1.13
Optical Purge
Where used, end bosses require total 200cm3/min clean, dry purge gas (see Section 4.2)
delivered at 1-3 psig.
7.4
7.1.14
485 Purge Controller (2500 EU1 Only)
Requires maximum of 40 l/min clean dry Nitrogen or clean dry Air at 3-7 barg,
depending on application.
7.1.15
Alternative Purge Controller (2500 EU1 Only)
Minimum flow rate = 10 SLPM for 11 minutes.

Minimum overpressure = 0.5 mBar.
Maximum overpressure = 80 mBar.
Refer to Certification Manual (Certificate SIRA 02ATEX1395X) for definitive
requirements and operational parameters.
7.5
7.6
SECTION 8 CE MARKING AND OTHER SAFETY APPROVALS

All 2500, 2510 and 2550 Analysers are CE marked and comply with all appropriate
European Community Directives.
8.1
EMC Directive
Electromagnetic Compatibility Directive 89/336/EEC (as amended by 92/31/EEC and

93/68/EEC) by the application of the following standard:
EN 61326: 1997 +A1: 1998 +A2: 2001 Calling:
Emissions; Table 4, Class B. Equipment used in establishments directly
connected to a low voltage supply which supplies buildings for domestic
purposes;
Immunity: Table A1 Industrial Environments.
8.2
Low Voltage Directive

NOTE
Assessment under the Low Voltage Directive is not required for CE marking if the
equipment is approved under the ATEX Directive for use in potentially explosive
atmospheres
Low Voltage Directive 73/23/EEC and the CE Marking Directive 93/68/EEC by the
application of the following standards:
EN 61010-1 (equivalent to IEC 61010-1)
Safety requirements for electrical equipment for measurement, control and
laboratory use general requirements:
2500, 2510 and 2550 Analysers are rated in accordance with:
IEC 60664 for Installation Category II, which is characterised as being local level (i.e.
not distribution level), appliances and portable equipment with over-voltage impulse
withstand up to 2500V.
8.3
Pressure Directive
All the relevant design aspects of the 2500 series analysers have been assessed in
respect of the requirements of the Pressure Equipment Directive (97/23/EC). These
products are excluded from the scope of this directive when installed and operated
within their published specifications.
8.1
8.4
ATEX Directive and other non-European Hazardous Area approvals
ATEX Directive 94/9/EEC

NOTE
Depending on the variant ordered an additional Safety Certificate Manual may be
supplied. This contains all the relevant safety certificates and declarations for the
EU1, EU2 and FM2 variants.
WARNING
The installer and/or the user of the analyser must be satisfied that the
installation complies with any "Special Conditions for Safe Use" or
"Schedules of Limitations" contained in the Certificates included in the
separate certification manual.
Table 8.1 02500 Safety Approvals
Variant
GEN/HTV
EU1
EU2
Certification
Only suitable for installation in a non-hazardous area.
The 2500, 2510 and 2550 EU1 version is ATEX CAT 2
equipment certified to Type 'p' standard EN 50016 and is
suitable for use in European and UK Zone 1 areas. The
analyser is marked EEx p ia [ia] IIC.
The EU2 version is ATEX CAT 3 equipment certified to
Type 'n' standard EN 50021, and is suitable for use in
Zone 2 areas. The analyser is marked
EEx nCL IIC T3 for cell temperatures up to 130C and
EEx nCL IIC T4 for cell temperatures up to 80C.
A special condition of this certification is that the analyser
must be protected against the entry of solid particles or
liquids by a suitable cover or enclosure where necessary.
The 02500 Series FM2 version is approved for operation
in US Class 1 Div. II location, without safety purging.
FM2
8.2
02500 Series FM2 units fitted with electrically heated

sample cells must be installed in locations which provide
adequate protection against the entry of solid foreign
bodies and liquids capable of impairing safety.
Servomex 2500 Series

Process Gas Analyser
Service Manual
This Service Manual applies to the following
Analysers: 2500, 2510, 02520 and 2550
Ref : 02500 / 002C / 1
Order as part No. 02500 002C
WARNINGS, CAUTIONS AND NOTES

This publication includes WARNINGS, CAUTIONS AND NOTES which provide,
where appropriate, information relating to the following:
WARNINGS
Hazards which will result in personal injury or death.
CAUTIONS
Hazards which will result in equipment or property damage.
NOTES :
Alert the user to pertinent facts and conditions.
WARNING
1.
LETHAL VOLTAGES: THE ELECTRICAL POWER USED IN THIS EQUIPMENT IS AT A

VOLTAGE HIGH ENOUGH TO ENDANGER LIFE.
2.
BEFORE CARRYING OUT SERVICING OR REPAIR THE EQUIPMENT MUST BE

DISCONNECTED FROM THE ELECTRICAL SUPPLY. TESTS MUST BE MADE TO
ENSURE THAT DISCONNECTION IS COMPLETE.
3.
IF FOR ANY REASON THE POWER SUPPLY CANNOT BE DISCONNECTED,

FUNCTIONAL TESTING, MAINTENANCE AND REPAIR OF THE ELECTRICAL UNITS
IS ONLY TO BE UNDERTAKEN AS A LAST RESORT AND MUST BE CARRIED OUT
BY PERSONS FULLY AWARE OF THE DANGER INVOLVED.
4.
THIS MANUAL COVERS SERVICING OF ANALYSERS WHICH HAVE CERTIFICATION

FOR USE IN HAZARDOUS AREAS. THE ENGINEER MUST ENSURE THAT ALL
INSTRUCTIONS REFERRING TO SERVICING OF COMPONENTS AFFECTING
CERTIFICATION ARE RIGOROUSLY ADHERED TO.
NOTE
This service manual is for use with the 2500 Single Beam Infrared, 2510 Gas Filter Infrared, 2520
Soft UV Analyser and 2550 Multicomponent Infrared analysers.
All analysers in the 2500 Series are built using, wherever possible, standard components. The main
exterior differences: The 2510 analyser has additional sample cell insulation and a larger metal cell
cover. On the inside: The 2510 and 2550 analysers utilise an additional printed circuit board
mounted on the Transmitter PCB to adjust the signal gain. The 2510 detector housing is plated steel
whereas others are aluminium. 2520 analysers utilise different source and detector assemblies
from the other analysers.
Refer to Section 9 - Parts Lists, for a detailed breakdown of the analyser components.
This manual covers disassembly procedures for the equipment, and brief technical descriptions of
component parts of the equipment. It should be thoroughly read and retained by the Service
Engineer.
I
NOTES
II
CONTENTS
Section
1.
Introduction
2.
Description
3.
Fault Diagnosis
4.
Cell Maintenance
5.
Disassembly - Major Components
6.
Chopper Box
7.
Reassembly - Leak Testing and Flushing
8.
Printed Circuit Boards
9.
Parts Lists
10.
Engineering Drawings
III
NOTES
IV
SECTION 1: INTRODUCTION
LIST OF CONTENTS
Section
Page
1.1
INTRODUCTION...........................................................................................................................1.3
1.2
HAZARDOUS AREAS..................................................................................................................1.4
1.3
USING THIS MANUAL .................................................................................................................1.4
1.4
ROUTINE LEAK CHECKS...........................................................................................................1.4
1. 1
NOTES
1. 2
1.1
INTRODUCTION
This 2500C Series Service Manual is intended for use by Servomex trained service personnel.
The manual contains technical descriptions, disassembly and assembly instructions, fault
diagnosis charts, repair procedures, tools and test equipment lists as well as necessary drawings
and illustrations.
It is recommended that during servicing, service personnel have access to the relevant 2500C
Infrared Analyser User Manual, and in addition they should be familiar with general operating
principles of the equipment, display messages and the use of the keypad.
Before undertaking service or repair of the analyser it is recommended that reference is made to
the appropriate section of this manual for details of procedures that may be relevant. The analyser
is a sophisticated device containing sensitive electronic and optical components and extreme care
should be taken when handling these components. Contaminants such as dirt/fingerprints left
on optical assemblies will cause degraded performance.
Printed circuit boards (PCB=s) containing CMOS devices can be damaged by static electricity even
when the power is off. For this reason avoid touching any circuitry on the PCB=s. To discharge any
static that you may hold, touch an unpainted part of analyser (chassis earth point).
Before beginning work, confirm with the customer the location of the analyser and the equipment's
configuration (precise analytical set-up for a stated analysis in a specific background stream).
The versions covered by this manual are:
02500C/ 02510C/ 02520C/ 02550C GEN
02500C/ 02510C/ 02520C/ 02550C EU2
02500C/ 02510C/ 02520C/ 02550C FM2
02500C/ 02510C/ 02550C EU1
General Purpose/Safe Area.

Certified for UK/European Zone 2 areas.
Certified for US Class 1 Div. II areas.
Certified for UK/European Zone 1 areas.
The following abbreviations are used throughout this manual:

PCB
fsd
hex
hex.skt
wrt
DVM
htr
VA
VD
VP
VI(A/B)
:
:
:
:
:
:
:
:
:
:
:
Printed Circuit Board

Full Scale Deflection (full span)
Hexagonal (e.g. hexagonal Allen key)
Hexagonal Socket Head
With Respect To/compared to
Digital Volt Meter (suitable for mains AC and lower voltages)
Heater
Voltage Supply (analogue circuits)
Voltage Supply (digital circuits)
Voltage Supply (power circuits)
Voltage Supplies (isolated)
Where items are referenced with a part No. this No. is a Servomex part No. unless otherwise
specified.
1. 3
1.2
HAZARDOUS AREAS
WARNING
BEFORE STARTING ANY WORK WHATSOEVER, ASCERTAIN WHERE THE
EQUIPMENT IS INSTALLED. IF INSTALLED IN A HAZARDOUS AREA
OBTAIN THE NECESSARY PROTECTIVE CLOTHING REQUIRED SUITABLE
FOR THAT PARTICULAR AREA AND NOTE ANY RESTRICTIONS ON USE
OF TOOLS OR EQUIPMENT.
NOTE: It is possible that the EU2 and FM2 versions are being used when flammable samples are
to be monitored in otherwise safe areas.
1.3
USING THIS MANUAL

The layout of this manual is in a sectional (modular) format but with intersectional referencing
where applicable.
Key sections are:
Section 3: Fault Diagnosis

Section 4: Cell Maintenance
Section 5: Disassembly
Section 6: Chopper Box
However, non-Servomex service engineers should read "Section: 2 Description" first to become
familiar with 2500 series construction.
Once problems have been diagnosed, the service engineer should move on to the relevant
sections. Any spares that may be required are listed in Section 9.
1.4
ROUTINE LEAK CHECKS

It is the user's responsibility to keep all sample connections to the analyser's sample cell,
purge connections (if fitted) to the end bosses and steam coil connections completely free
from leaks. All plumbing connections should therefore be regularly inspected for signs of
leakage and urgent corrective action taken if any are found. This is especially important for
process samples which are flammable, toxic, liquid, or any combination of these.
It is recommended that the following parts be leak checked annually and replaced if
necessary:End boss scrubbers,
Purge port seals,
Chopper box blanking plug seal,
(Refer to section 9 for component part Nos.)
1. 4
SECTION 2: DESCRIPTION
LIST OF CONTENTS
Section
Page
2.1
GENERAL .....................................................................................................................................2.5
2.2
DESCRIPTION ..............................................................................................................................2.5
2.2.1
2.2.2
2.2.3
2.2.4
2.2.5
2.2.6
2.2.7
2.2.8
2.2.9
2.2.10
Introduction ......................................................................................................................2.5
Source-End Assembly.....................................................................................................2.5
Power Control PCB..........................................................................................................2.6
Source Assembly.............................................................................................................2.6
Sample Cell Assemblies..................................................................................................2.6
Detector-End Assembly...................................................................................................2.7
Mains Transformer...........................................................................................................2.7
Transmitter PCB ..............................................................................................................2.7
Detector Box Assembly ...................................................................................................2.8
Keypad and Display PCB Assembly...............................................................................2.8
LIST OF ILLUSTRATIONS
Figure
2.1
2.2
Page
Overall View..................................................................................................................................2.3
Keypad and Display ....................................................................................................................2.4
2. 1
NOTES
2. 2
Figure 2.1 Overall View

2. 3
16 Character
2 line VF Display
Hard key to select
Measurement Display
Hard key to select
Menu Display
Fault warning LED
Alarm warning LED
Up/Down/Left/Right
Cursor keys to select menu
options and increase/decrease
numerical values
Key to enter data or accept highlighted option within Menu
Key to escape or return to previous level within Menu
Key will also return display to Top Level Menu from lower menu levels
Fig 2.2 Keypad & Display

2. 4
2.1
GENERAL
This section provides information on what the analyser contains and how the analyser is
assembled. It would be helpful for the service engineer to read completely through this section
before continuing.
The 2500 series process analysers are single beam, dual or multi-wavelength infrared process
analysers, suitable for monitoring single components, multi-components or a component group in a
gas or liquid sample.
Samples to be analysed are normally passed continuously through the analyser's sample cell for
24 hours a day and the analyser is not normally switched off.
General layout of the equipment is shown in Fig 2.1. The analyser is microprocessor controlled
which provides flexibility in configuring the analyser to suit various process environments.
Operation is via a control panel mounted on the analyser.
2.2
DESCRIPTION
2.2.1
Introduction
The analyser (Fig.2.1) comprises two end assemblies, source and detector, connected by a
mounting chassis. The sample cell is mounted between the two end assemblies.
The source-end assembly houses the source (which generates the broad beam of energy across
the complete spectrum), Power Control PCB and the chopper box assembly.
The sample cell is secured between the two end assemblies and can be removed for servicing.
The detector-end assembly houses the detector box assembly, main electronic printed circuit
boards (PCB) and keypad/display panel assembly.
2.2.2
Source - End Assembly

The source-end assembly (02501/940) houses the chopper box assembly, source assembly and
Power Control PCB. In addition the source-end assembly forms the mount for the cell
thermocouple connector, pressure transducer connector, external cable earth and the sample cell.
The left hand side panel contains entry glands for electrical cables.
2. 5
2.2.3
Power Control PCB

The Power Control PCB (02500/911A) is mounted horizontally. At one end it locates in 2 brackets
attached to the rear wall and is secured to the floor of the unit via spacers using 3 M4 x 16 hex.skt
captive screws. The board provides the mount for 2 ribbon cable plugs PL1, PL2, and 2 cable
connectors PL3 and PL4. PL1 and PL2 provide ribbon cable connections to the Transmitter PCB
and detector box; PL3 and PL4 allow cable connections to the mains transformer and source
assembly.
2.2.4
Source Assembly
Three types of source assembly can be fitted; a sealed Long Wave, Short Wave or Soft UV type.
They are secured to the chopper box lid with 3 hex.skt M3 x 12 screws.
The sealed long wave source assembly is conical in shape with a tapered end, having a flanged
rim containing fixing holes for connection to the chopper box lid. The other end provides electrical
connections to Power Control PCB PL4 via a 4-way cable and plug. Three different types of
lenses can be fitted dependent on requirements. Component parts are sealed with adhesive
potting during manufacture.
The short wave source assembly ( 02500/943) consists of an M29 Quartz Tungsten Halogen lamp
rated 6V, 10W, but under-run on the 2500C at around 4.6V. It is mounted on a PCB via a terminal
block. The PCB / lamp is fitted into a machined block which is mounted to the chopper box. Early
versions of the PCB / lamp assembly mounted to the chopper box using a bracket. There are 2
types of SW source arrangement, one with a CaF2 lens, one with a crown glass lens, but the actual
source bulb is the same in both cases.
The Soft UV Sealed Source assembly consists of a Gas Filled Tungsten Lamp, fitted into a special
housing. The lamp is normally run at 4.4V. Component parts are sealed with adhesive potting
during manufacture.
2.2.5
Sample Cell Assemblies

The cell assemblies have a range of different path lengths. Servomex Drawing No. 02500/834
shows path lengths of 1 to 64mm and Servomex Drawing No.02500/835 shows path lengths of
128 to 1000mm. Sample cells are of thick stainless steel, monel, hastelloy or titanium construction
fitted with 6mm thick windows. Eight different types of windows can be fitted depending on
customer requirements. Window types are:
CaF2 (Calcium Fluoride)
BaF2 (Barium Fluoride)
ZnSe (Zinc Selenide)
Infrasil Quartz
Crown Glass
Germanium
UV Quartz
Sapphire
A thermocouple connector and 2 sample fluid process connections are fitted to each cell.
2. 6
Cells are mounted between the source and detector ends using flanged cylindrical cell bosses and
secured in position using 3 M6 x 12 hex.skt screws. These bosses may be fitted with screw-in
chemical scrubbers (absorbers) or purge fittings.
Heated versions of these cells may be fitted - Electrically Heated and Steam Heated.
2.2.6
Detector - End Assembly

The detector-end assembly (02501/941) contains a mains transformer, Transmitter PCB,
Microprocessor PCB, Sensor Head Interface Board (SIB PCB), plug-in Power Supply, Optional
PCB=s (if fitted), Display PCB, keypad and detector box assembly.
Externally, the detector-end rear panel forms the mount for the sample cell and the mounting
chassis. Internally, the rear panel supports the detector box assembly and 2 brackets which
provides support for the Transmitter PCB. Right hand side panel contains entry glands which
allow electrical cables to be inserted for connections that may be required. When not in use they
are plugged.
2.2.7
Mains Transformer
The mains transformer is mounted in the base of the unit, enclosed within a metal frame, beneath
the Transmitter PCB. The transformer is secured in position by 2 bolts that pass through the base
of the unit.
2.2.8
Transmitter PCB
The Transmitter PCB (02500/904A) is mounted horizontally above the mains transformer and at
one end locates in 2 brackets mounted on the rear panel and is secured to the floor of the unit via
spacers using 2 M4 x 16 hex.skt screws. The PCB provides the mount for three 96-way
connectors SK1, SK3, SK5 and two 48-way connectors SK2, SK4; the Microprocessor, SIB, Option
and Power Supply PCB=s respectively are vertically located. The PCB=s are enclosed by a three
sided metal cage; the Power Supply PCB provides the fourth side, and is thermally connected to
the detector end enclosure. The PSU is fixed to the heatsink using 2 M4 x 12 screws. The cage
sides have PCB guide runners mounted which provides alignment as the PCB=s are being fitted. A
securable hinged lid completes the cage. There are also three ribbon plugs PL1, 2 and 3 which
provide ribbon cable connections to Power Control PCB, Display PCB and detector box.
2. 7
2.2.9
Detector Box Assembly

The detector box assembly is mounted on the inside rear panel of the detector-end. The detector
box comprises a detector block, Detector PCB assembly, 02501/905 for 2500, 2510 and 2550
analysers or 02600/905 for 2520 analyser) scrubber assembly (if fitted), adaptor and dowel pin (if
fitted), detector boss and lens assembly. The detector block, cylindrical in shape, locates in the
aperture provided in the rear panel of the box and is secured using 3 hex.skt M4 x 10 screws. The
Detector PCB assembly is mounted on the face of the detector block, positioned over an Ò' ring
and secured with 3 hex.skt M3 x 6 screws. A 16-way ribbon cable provides interconnections to the
Transmitter PCB. An earth protection lead is routed from the PCB to the RFI earth terminal in the
detector end assembly. The scrubber assembly (if fitted), with bonded seal, passes through an
aperture in the `top' of the box and screwed into the detector block. A lid is fitted to the box and
secured in place with 4 hex.skt M4 screws.
The 2510 detector assembly is similar in all above respects except that the detector box is
manufactured from plated steel and the lid is secured by two M3 screws mounted on the top edge.
Note: The scrubber and leak test port are not fitted to purge certified analysers, these are replaced
by a purge adaptor and flexible purge duct fitted between the detector box and the detector end
enclosure.
2.2.10 Keypad and Display Assembly

The Keypad and Display Assembly is mounted in the hinged lid and enclosed with a vented metal
cover. The assembly comprises of a mounting plate fitted with a transparent window, keypad and
Display PCB Assembly.
The window is sealed to the mounting plate with an >O= ring and retained by means of a bracket
and six M4 x 6mm hex skt screws. The Display PCB Assembly is mounted on the plate using four
M4 x 12mm hex skt screws.
The display, which is mounted on the Display PCB Assembly, is a 2-line 16 character vacuum
flourescent display which ensures good visibility under all conditions.
The keypad (see Figure 2.2) comprises of eight single function >hard= keys, four of which are
identified as Measure, Menu, Exit and Enter, and four cursor direction keys. Operation of the keys
requires only a light pressure and they give tactile feedback when pressed.
The keypad is bonded to the mounting plate and connected to the Display PCB Assembly via a 10way connector. The connecting ribbon is encapsulated as it passes through the mounting plate.
Interconnections between this assembly and the Transmitter board are via a 50-way ribbon cable
2. 8
SECTION 3: FAULT DIAGNOSIS

LIST OF CONTENTS
Section
Page
3.1
INTRODUCTION...........................................................................................................................3.4
3.2
GENERAL FAULTS......................................................................................................................3.4
3.3
SERIOUS FAULTS .......................................................................................................................3.8
3.4
DIAGNOSTICS..............................................................................................................................3.8
Figure
Page
3.1
2500, 2520 and 2550 Menu Map..................................................................................................3.2
3.2
2510 Menu Map.............................................................................................................................3.3
3. 1
Fig 3.1 2500, 2520 and 2550 Menu Map

3. 2
Fig 3.2 2510 Menu Map

3. 3
3.1
INTRODUCTION
This section is basically an expanded version of sections found in the 2500 User Manual. The
following charts should be used by the service engineer to check the more easily remedied faults
by undertaking the actions suggested. The service engineer should initially decide the nature of the
fault and then use the charts to arrive at the correct diagnostic solution. Additional information can
be obtained with reference to the relevant section of this manual.
Using the charts
The first column, Fault (Display Message), indicates the type of fault and how it is displayed. The
second column provides a diagnosis of the fault and column three sets out remedial actions
including reference to other sections of this manual and User Manual from where additional
information can be obtained.
3.2
GENERAL FAULTS
General faults category covers parameters out of tolerance with the analyser remaining operational
and measuring.
WARNING
TB32/1 SUPPLIES 110V AC NOMINAL
SEVERE SHOCK HAZARD
3. 4
General Faults (cont)

Fault
(Display Message)
Diagnosis
Action
Source voltage high
Source voltage high
1 Check fuses F30 and F32.

2 Check switch SW3 and SW4
settings. Refer to Section 8.1.10.1 and
8.10
3 Change Power Control PCB.
Source voltage low
Source voltage low
1 Check fuses F30 and F32.

2 Check switch SW3 and SW4
settings. Refer to Section 8.1.10.1 and
8.10
Sample flow failure
User sample flow alarm

active
Check short circuit between TB36

pins 1 and 2. Refer to Section
8.1.10.2 and 8.10
Chopper temp high
Ambient too high or other

fault
1 Check fuse F32

2 Check PL2/PL3 for positive
connection
3 Refer to Section 8.1.10.3
Chopper temp low
Ambient temp too low or

other fault
1 Check fuse F32

2 Check PL2/PL3 for positive
connection
Chopper temp
sensor failure
Failed, disconnected, or
out of range
1 Check sensor connection

2 Check sensor or change if necessary
Cell temp high
Cell over temperature
1 Check fuse F31

2 Check cell heater connections at
TB32 and TB33
4 Change Power Control PCB
Cell temp low
Cell under temperature
1 Check fuse F31

2 Check cell heater connections at
TB32 and TB33
Cell temp sensor

failure
Failed, disconnected or
out of range

2 Check sensor; change if necessary
3. 5

Fault
(Display Message)
Diagnosis
Action
Sample temp
sensor failure
out of range

Pressure sensor
failure
out of range

Bad reference
voltage
This is a check on the

4mA level in the 4 - 20
mA current loop from
the Transmitter PCB to
the SIB PCB
1 Change Power Supply PCB

2 Check wiring of the DIN Controller
(if used)
3 Change Transmitter PCB
4 Change SIB PC
Detector signal low
Likely cell contamination

or severe source
degradation
1 Check signal at TP4 wrt TP2 on the

Transmitter PCB. Refer to Fig. 8.6(b).
Refer to section 8.1.10.5
2 Clean cell; refer to Section 4.1
Detector temp
sensor failure
out of range
1 Check sensor connections

2 Check sensor, or change if necessary
Source temp high
Possible Power Control

PCB failure or strong
reference interference
1 Check source voltage

2 Check SW3 and SW4 settings refer to
Section 8.1.10.5 and 8.10
Source temp low
Possible Power Control

PCB failure or strong
reference interference
or severe source
degradation
1 Check source voltage

2 Check SW3 and SW4 settings refer to
Section 8.1.10.5 and 8.10
Zero out of tolerance
Failed Autocal,
Bad zero sample
Use One Cycle or Manual Zero;

refer to 2500C User Manual
Span out of tolerance
Failed Autocal,
Bad Span sample
Use One Cycle or Manual Span;

refer to 2500C User Manual
Autocal bad preflush
Failed Autocal,
bad preflush
1 Use One Cycle

2 Check solenoids and span gas
3 Refer to User Manual
3 consecutive password
failures
WARNING Unauthorised personnel

attempting access
Microprocessor PCB
clock IC faulty
1 Change Microprocessor PCB

2 Refer to Section 8.5.3
Password violation
System clock
inoperative
3. 6

Fault
(Display Message)
Diagnosis
Action
System AD
inoperative
Possible SIB PCB fault
Change SIB PCB
Default system
data corruption
Factory calibration
corrupt
Use ASSOCIATE function to

reconstruct default data. Refer to
Section 8.2.3 and User Manual
Calibrate data
corruption
User calibration corrupt
1 Re-calibrate; refer to User Manual

2 If corruption repeated after entry
change Microprocessor PCB
Utility data corruption
Utility file corrupt
1 Renew all entries; refer to user

manual
Alarm/relay data
corruption
Alarm relays corrupt

manual
Analogue assign data

corruption
Analogue output file

corrupt

manual
3. 7
3.3
SERIOUS FAULTS (SHUTDOWN)

If any of the following messages are displayed it indicates serious degraded performance.
Measurement is withdrawn and analogue output driven high or low depending on configuration.
The service engineer should initially decide the nature of the fault.
Fault
(Display Message)
Diagnosis
Action
Infrared Source
Failure
Source driver failure (low)
Refer to sections 8.1.9, 8.1.10.1, 8.1.10.6

& 8.10
Chopper Motor Out of

Lock
Failure of motor, timing or

control circuit
Refer to sections 8.1.9 & 8.1.10.7
Detector Signal High
Loss of IR filter from

chopper wheel or loss of
liquid sample or high
absorbance gas
background from cell
Refer to section 8.1.10.8
3.4
DIAGNOSTICS
The diagnostic reference chart below can be interrogated via the SETUP/DISPLAY/DIAGNOSTICS function of the 2500 menu map. Refer to Fig.3.1 of this section and
Section 4.6 of the User Manual. The chart provides the service engineer with information
regarding how and where the measurements are taken.
Using the chart
The first column shows display messages, the second column describes function and the third
column provides the location of measurement being made and relevant comments.
3. 8
Diagnostics (cont)
Display
Description
Operation
Chopper
Temp C
Chopper box
temperature
Normal working temperature

65EC approx. Measured by the AD590
transducer device mounted on the
Motor Connection PCB.
Detector Temp C
Detector temperature, as
a compensating
temperature
Normal reading approx 10EC above

external local ambient.
Measured by AD590 on the Detector
PCB. Used for ambient compensation.
Cell Temp C
Cell temperature
Measured by type K thermocouple in

cell thermowell. Connected to the Power
Control PCB.
Sample Temp C
Sample temperature
(if option fitted)
Measured by type K thermocouple via

fitting on cell port. Connected to the
Power Control PCB.
Ambient
Pressure (units)
Ambient pressure
(if option fitted)
Measured by transducer mounted on

Power Control PCB. Used for sample
barometric pressure compensation.
Sample
Pressure
Sample pressure
(if option fitted)
Measured by transducer via fitment on

cell port and connected to Power
Control PCB.
Source Volts V
Source voltage
Factory set on Power Control PCB

according to source type. Should not be
adjusted. Refer to Section 8.1.10.1.
Motor Drive %
Motor drive power.
Motor drive will vary around a

percentage level under normal
conditions.
Set Point %
Set point
Set point is a factory set benchmark.
Detector Sig M
Detector signal level

(M = measurement)
Signal measurements in absolute units.

Will decrease with increasing
measurement component.
Detector Sig
R1 or R
Detector signal
(R1 = reference 1)
R1 signal intensity in absolute units.

Should remain roughly constant.
3. 9
NOTES
3. 10
SECTION 4: CELL MAINTENANCE

LIST OF CONTENTS
Section
Page
4.1
CLEANING THE SAMPLE CELL ................................................................................................4.4
4.2
CELL PRESSURE AND TEMPERATURE TRANSDUCER FAULTS.......................................4.8
4.3
ELECTRICALLY HEATED CELL FAULTS ................................................................................4.8
LIST OF FIGURES
Figure
4.1
Page
General Cell Construction.............................................................................................................4.3
4. 1
NOTES
4. 2
Fig.4.1 General Cell Construction

4. 3
4.1
CLEANING THE SAMPLE CELL

This section is basically as that found in the 2500 User Manual but with Service Manual references
incorporated.
The DETECTOR SIGNAL LOW fault is a primary indication of a badly contaminated sample cell.
However, before proceeding to dismantle and clean the cell, it should be confirmed that this is the
case, by looking at the detector signals levels in Section 3.4, Diagnostics. Typical reference
detector signals under normal working conditions can be anywhere in the range 500,000 to
900,000 depending on application.
As a guide the cell should be removed for cleaning when the reference detector signals fall below
50% of their original values. In aggressive sample conditions, the loss of signal may be due to
general corrosion or pitting of the cell windows. In this case the cell windows may have to be
replaced. Otherwise, the cell and windows can be dismantled and carefully cleaned and all items
(except O rings) re-used. See Fig 4.1 for general construction of the cell.
WARNING
LETHAL VOLTAGES: MAINS AC POWER SUPPLIES ARE LETHAL.
THE SERVICE ENGINEER MUST ENSURE THAT ALL MAINS POWER SUPPLIES
ARE DISCONNECTED FROM THE SUPPLY BEFORE WORK IS STARTED.
PURGE THE MEASURING CELL AND ASSOCIATED PIPEWORK WITH AN INERT
GAS BEFORE WORK IS STARTED.
IT IS THE SERVICE ENGINEERS RESPONSIBILITY TO ENSURE THAT WORK IS
CARRIED OUT IN AN ADEQUATELY VENTILATED SPACE - TAKING DUE
ACCOUNT OF RISKS ASSOCIATED WITH RELEASE OF FLAMMABLE OR TOXIC
SAMPLES. ATTENTION IS ALSO DRAWN TO THE RISKS ASSOCIATED WITH THE
RELEASE OF ASPHYXIANTS.
BURN HAZARD: SOME 2500 SERIES CELLS MAY BE HEATED TO 180EC AND
WILL TAKE SEVERAL HOURS TO COOL AFTER BEING SWITCHED OFF. IN
PARTICULAR, THE CELL INLET/OUTLET CONNECTIONS AND THE CELL END
BOSSES SHOULD NOT BE TOUCHED WHILE HOT.
CAUTION
The Service Engineer is reminded to use only Servomex supplied spare parts. The use
of inferior replacement components may degrade the performance and safety of the
instrument.
4. 4
To remove the cell assembly from the analyser proceed as follows with reference to Fig. 4.1 and
Fig. 5.1:
1
Isolate the process sample and flush the cell thoroughly with nitrogen, clean dry air, or
some appropriate inert medium.
Disconnect the process connections.
If fitted, disconnect the cell heater connector from the source end.
Do not strain heater connection leads.
WARNING
Very hot cells may take some hours to cool.
Allow enough time for the cell to cool before continuing.
If fitted, remove end boss purge connections.
Using a 5mm hex tool, slacken the three M6 screws securing the cell bosses at either end
of the sample cell.
If necessary, using a 5mm hex tool, slacken the four M6 screws connecting the mounting
chassis at the source end.
Carefully disconnect the thermocouple from the cell body and ensure it is protected from
damage.
Remove the cell complete with end bosses, end boss scrubbers (if fitted) are not to be
removed. The entire assembly can now be taken to the workshop. Caution, the end
bosses will need to be manually retained on the cell.
Alternatively, remove the end bosses from the cell and re-assemble to the enclosures. Fit
the blanking plugs, supplied with maintenance kit part No. 02500944, to preserve existing
scrubbers.
Working on a clean bench in a suitable environment, dismantle the cell. Pull the end
bosses off the cell body. Note that these items are one piece stainless steel. If the bosses
are fitted with absorbent scrubbers, these should be removed and replaced (Refer to
Section 9.2.).
WARNING
SPECIAL MATERIALS ARE USED FOR THE WINDOWS. SOME OF THESE
ARE TOXIC (I.E. GERMANIUM, BARIUM FLUORIDE, ZINC SELENIDE, ETC.) THESE
SUBSTANCES MUST BE HANDLED IN ACCORDANCE WITH THE RELEVANT LOCAL
STANDARDS.
4. 5
The windows are usually ground from optical single crystal material and as such may be
EXTREMELY EXPENSIVE. The windows may have special anti-reflective coatings and they may
easily be damaged by brittle fracture. The standard material chosen by Servomex is calcium
fluoride. This material is non-toxic and reasonably robust. However, some applications may
require materials such as germanium, barium fluoride, zinc selenide, etc. which are toxic and must
be handled with extreme care. See the specification sheets at the front of the User Manual for
details of the windows fitted.
Windows should be kept optically clean, i.e. free from dirt, scratches, grime, grease, fingerprints
etc. When handling windows it is recommended that cotton gloves or finger cots be worn.
WARNING - ZINC SELENIDE
If windows of Zinc Selenide are fitted and have been damaged by acidic
attack (e.g. acidic condensate or organic acids have entered the cell) it will
be likely that some of the Zinc Selenide will be reduced to Selenium metal.
This is HIGHLY TOXIC and on no account should attacked Zinc Selenide
material be handled with bare fingers. Such material should be bagged and
disposed of according to local regulations.
Cleaning of the cell windows should be carried out using cotton buds or lens tissue, detergent
and/or a suitable solvent such as Isopropanol or Arklone/Freon TF (1,1,2-Trichloro-1,2,2,
-Trifluoroethane). Avoid abrasive cleaning compounds as these will damage the optical surface.
WARNING
THE USE OF SOME SOLVENTS (ISO-PROPYL ALCOHOL, ALCOHOL ETC.)
CONSTITUTES A HAZARD. THESE SUBSTANCES MUST BE HANDLED IN
ACCORDANCE WITH THE RELEVANT LOCAL STANDARDS.
To remove the cell windows proceed as follows:
4. 6
Check that end bosses have been removed from the cell body.
Unscrew and remove, the locking ring from one end, with the special key supplied in
Special Tools kit (S2500979).
Remove the 5 wavy washers, spacer and 'O' ring, avoiding damage to the window. Seal
the cell outlet and stand the cell in a vertical position.
Connect a hand operated aspirator ( 2387-0514) to the inlet.
Apply gentle pressure to lift the window up squarely. Remove the window.
Remove the PTFE seat gasket.
The windows may now be carefully cleaned. The cell body may also be cleaned as
necessary.
Repeat instructions 1 to 7 for the other end of the cell.

Ensure all items are thoroughly clean and dry before reassembly, which is the reverse
procedure but with the following points noted:
The windows should be floated into place squarely using a hand aspirator or equivalent,
reversing the removal procedure.
Use new O rings and other cell sealing kit items making sure that all dust, hairs etc, are
rigorously excluded from them. Ensure the window surfaces are also free from solvent
residues or finger grease.
The latest design of the locking ring has a coated thread to prevent seizure - PTFE tape is
not required. FOR NON-COATED ITEMS ONLY - the threads should be covered with only
2 turns of PTFE tape (1835-3026) and the ring tightened down in stages, pausing for a
minute between stages until the metal faces of the cell body and locking ring meet when
fully tightened, with no gap between them. Where Teflon 'O' rings are being used, this will
require significant torque, with longer pauses. DO NOT use the cell inlet/outlet stubs as
levers.
After re-assembly, perform the leak check on the cell using a manometer, before installing it in the
analyser. Refer to Section 1.4 (routine leak checks) of this manual.
Do not submerge the cell or fill it with water.
Re-installation of the complete cell assembly onto the analyser is the reverse of the dismantling
process with the added requirement that, unless fitted with a purge, the end bosses should be
briefly flushed with clean dry nitrogen after the cell has been mounted and then new absorbent
scrubbers should be quickly screwed into them (refer to Section 7). Be sure to fully tighten the
screws holding the source end onto the mounting chassis if they have been slackened.
Finally, connect up the cell thermocouple to the cell body, reconnect the cell heater plug (where
fitted) and connect up any purge connections and the process connections. Return the analyser to
service as described in the 2500 Series Installation Manual. Reset zero if necessary on a true zero
sample.
4. 7
4.2
CELL PRESSURE AND TEMPERATURE TRANSDUCER FAULTS

Any fault diagnosed as a transducer failure should first be investigated by checking that the
transducer has not become simply disconnected or that the prevailing pressure or temperature
conditions are outside the working range. Otherwise, the transducer itself should be exchanged for
a known functioning unit to confirm whether or not the transducer has failed.
4.3
ELECTRICALLY HEATED CELL FAULTS

The standard electrically heated cell is factory set to operate at a fixed temperature for the
specified application in the range 30-130EC, and must not be adjusted in the field. Any suspected
fault should be investigated at the heater connections on the Power Control PCB first (see Section
8.1.8) by checking availability of power and continuity of heater windings. Also check fuse F31 on
the Power Control PCB.
All standard heated cells are protected by a pair of sacrificial thermal fuses. The temperature (T)
rating of the fuses depends on the T-rating of the analyser. Analysers rated T4 must not be
operated at cell temperatures above 80EC while 130EC is the limit for analysers rated T3. If these
limits are exceeded for a length of time, the fuses may fail and in this case the cell may need repair
by Servomex. Continuity of the heater winding will confirm this fault.
Heated cells, protected by thermal fuses, are fitted to 02500C GEN, 02500C EU2 and
02500C FM2 analysers
Power is normally supplied to the heater winding direct from the Power Control PCB at either 30,
60 or 110V, depending on the length of sample cell. Refer to Section 8.1.8.
Special heated sample cells operating from 130 to 180EC may be fitted to 02500 GEN analysers.
These are fitted with painted aluminium covers, and do not have thermal fuses. They are normally
used for high temperature emissions measurements.
4. 8
SECTION 5: DISASSEMBLY - MAJOR COMPONENTS

LIST OF CONTENTS
Section
Page
5.1
INTRODUCTION........................................................................................................................ 5.11
5.2
PREPARATION ......................................................................................................................... 5.11

5.2.1
5.2.2
5.2.3
5.2.4
5.3
Tools and Equipment.................................................................................................... 5.11

Safety Precautions........................................................................................................ 5.11
Analyser Location and Inspection................................................................................ 5.12
Electrical Mains AC Supply Disconnection.................................................................. 5.12
DISASSEMBLY.......................................................................................................................... 5.12
5.3.1
5.3.2
5.3.3
5.3.3.1
5.3.3.2
5.3.4
5.3.4.1
5.3.4.2
5.3.4.3
5.3.4.4
5.3.4.5
5.3.4.6
5.3.4.7
2500 Analyser ................................................................................................. 5.13

Sample Cell Assembly .................................................................................... 5.13
Source End Assembly..................................................................................... 5.13
Source Assembly ............................................................................................ 5.13
Power Control PCB......................................................................................... 5.14
Detector End Assembly .................................................................................. 5.15
Power Supply .................................................................................................. 5.15
Option PCB (if fitted), SIB PCB, Processor PCB ........................................... 5.15
Transmitter PCB.............................................................................................. 5.16
Transmitter PCB Cage.................................................................................... 5.16
Mains Transformer.......................................................................................... 5.16
Detector Box.................................................................................................... 5.17
Keypad and Display PCB Assembly .............................................................. 5.18
5. 1
Figure
Page
5.1(a) Source End - Exploded View ........................................................................................................5.4

5.1(b) Source End - Exploded View ........................................................................................................5.5
5.2(a) Detector End - Exploded View......................................................................................................5.6
5.2(b) Detector End - Exploded View......................................................................................................5.7
5.3
Chopper Box - Exploded View......................................................................................................5.8
5.4
Detector Box - Exploded View ......................................................................................................5.9
5.5
AC Voltage Connections............................................................................................................ 5.10
5. 2
NOTES
5. 3
Figure 5.1(a) Source End - Exploded View

5. 4
Figure 5.1(b) Source End - Exploded View

5. 5
Figure 5.2(a) Detector End - Exploded View

5. 6
Figure 5.2(b) Detector End - Exploded View

5. 7
Figure 5.3 Chopper Box - Exploded View

5. 8
Figure 5.4 Detector Box - Exploded View

5. 9
Figure 5.5 AC Voltage Connections

5. 10
WARNING
These service and disassembly instructions are for use by trained and
experienced service engineers. To avoid injury and electric shock do not
perform any action not contained in the instructions, unless suitably
qualified.
5.1
INTRODUCTION
This section provides disassembly instructions for the 2500 series analysers. Instructions are
given in a logical sequence beginning with the removal of the sample cell followed by the source
end assembly and then the detector end assembly with direction for each subsequent item given
under its own heading. Reassembly is the reverse of disassembly except where specific cautions
are noted.
To familiarise themselves with disassembly procedure, Service Engineers should read through this
section before commencing.
5.2
PREPARATION
5.2.1
Tools and Equipment

Tools
Servicing of the analyser requires standard hand tools only: a 5mm Hex tool to open end case
covers has been supplied with the analyser.
Equipment
DVM with 4.5 digit display
Cotton gloves or finger cots
Cotton buds or lens tissue
Clean dry Nitrogen at low pressure
5.2.2
Safety Precautions
The electrical supply to this equipment is at a high enough voltage to endanger life therefore
normal electrical safety precautions must be observed. Where necessary a warning is placed prior
to the procedure it refers to as shown in the following example:
WARNING
ALWAYS ENSURE THAT THE ELECTRICAL MAINS POWER SUPPLY IS
DISCONNECTED BEFORE COMMENCING WORK.
5. 11
5.2.3
Analyser Location and Inspection

Depending on location it may be preferable or necessary to move the analyser to a more suitable
area so that servicing may be carried out safely. If so, obtain help to move the analyser. Locate
and re-fit the yellow transit handles originally supplied attached to the analyser. Remove black
pop-in plugs to do so.
Inspect the analyser. Check serial number details against service requirements.
5.2.4
Electrical Mains AC Supply Disconnection

WARNING
LETHAL VOLTAGE: MAINS AC POWER SUPPLIES ARE POTENTIALLY
LETHAL. THE SERVICE ENGINEER MUST
ENSURE THAT THE POWER SUPPLY HAS
BEEN ISOLATED BEFORE COMMENCING
SERVICING OR DISASSEMBLY.
Locate and switch off the isolation switch and disconnect the mains supply to the analyser at AC
source. Ensure that the process stream is isolated where necessary.
5.3
DISASSEMBLY
WARNING
5. 12
THE SERVICE ENGINEER MUST BE SATISFIED THAT THE 2500 SERIES

ANALYSER INSTALLATION AFTER REASSEMBLY CONFORMS TO
THE RELEVANT SAFETY REQUIREMENTS, NATIONAL ELECTRICAL
CODE AND ANY OTHER LOCAL REGULATIONS, AND THAT THE
INSTALLATION IS SAFE FOR ANY EXTREMES OF CONDITIONS
WHICH MAY BE EXPERIENCED IN THE OPERATING ENVIRONMENT
OF THE ANALYSER.
THE SERVICE ENGINEER MUST ENSURE THAT ANY CERTIFICATION

LABELS AFFIXED ON INSTALLATION REMAIN SO AFFIXED.
MANY PROCESS SAMPLES, GAS OR LIQUID STREAMS AND TEST

SAMPLES ARE TOXIC, ASPHYXIANT, CORROSIVE, FLAMMABLE OR
A COMBINATION OF SOME OR ALL OF THESE. IT IS THE
RESPONSIBILITY OF THE SERVICE ENGINEER TO ENSURE THAT
ADEQUATE PRECAUTIONS ARE TAKEN DURING DISASSEMBLY,
ASSEMBLY, CHECKS OR TESTS AND SUBSEQUENT REINSTALLATION OF THE 2500 SERIES ANALYSER AND CONNECTION
OF SAMPLES. ALL SAMPLE LINE CONNECTIONS MUST BE
CHECKED FOR NO LEAKS.
5.3.1
2500, 2510, 2520, 2550 Analysers

To disconnect the analyser from the AC mains supply:
5.3.2
Ensure the mains AC supply is isolated at source
Remove 4 screws retaining mains filter unit cover
Using a suitable size slotted screwdriver, loosen the screws on the terminal block inside
the mains filter unit, remove and insulate the mains supply leads.
Sample Cell Assembly

For instructions to remove the sample cell and cell windows please refer to Section 4: Cell
Maintenance.
5.3.3
Source-End Assembly
5.3.3.1 Source Assembly

Refer to Fig. 5.3
Standard sources are long-life sealed units and serviced by replacement if necessary.
Note that special short wave sources No. 02500/943 are serviced by simple bulb replacement and
recalibration. Do not touch with bare fingers.
Removal of Long wave and Soft UV sources:
1
Unplug the electrical cable from PL4 on the Power Control PCB (item 6b Fig. 5.1a).
Unscrew and remove the 3 hex.skt screws (item 4). Note: On long wave source, it may be
helpful to remove the leak test plug (items 9 and 10) to enable a full turn with the hex key.
Place assembly and screws on one side for re-connection which is the reverse of
disconnection. Ensure the leak test plug is reinstalled.
Note:
The Chopper Box must be flushed with Nitrogen after source reinstallation. See Section
7. The analyser should be checked for span and zero after returning to operation.
5. 13
Removal of Short Wave source:

1
Remove the faulty source bulb by releasing its legs from the screwed terminal block which
holds it.
Using cotton gloves, or holding it with tissue paper, take the new source out of its packet
and mount it in exactly the same position as the old source.
Note: DO NOT touch the new halogen source bulb with bare fingers or irreparable
degradation will occur!
Power up the analyser. Observe the illumination of the new source bulb to confirm
satisfactory replacement. Allow the unit to fully warm up.
Inspect the received detector signal levels (which should be typically 250,000-500,000) If
the highest signal (Meas. 1 or Ref. 2) is not around 500,000 try to increase this signal by
making fine adjustments to the orientation of the source. Do this by loosening the screws
which hold the mounting bracket to the source body and by sliding the mounting bracket
vertically and/or horizontally to gain maximum signal. Make small adjustments and allow
several seconds for the diagnostics to respond after each movement. Lock the screws at
position of maximum signals.
If this maximum is still significantly below 500,000 very carefully adjust the detector gain
potentiometer beneath the sealing label on top of the detector housing (item 20 in Fig.
5.2(b)) in the detector end of the analyser, to achieve the correct value. Conversely, if the
signal is too high, reduce it with the detector gain pot. Make sure that the correct zero
sample is flowing through the analyser sample cell all the time. Note that significant
adjustments of this potentiometer will significantly affect the calibration of the analyser.
The analyser should be checked for span and zero after returning to operation.
5.3.3.2 Power Control PCB

Refer to Fig. 5.1(a & b).
To remove the Power Control PCB (item 6):
5. 14
Disconnect all wires, except wire links, from terminal blocks. Label or record all locations
to ensure reconnections are correct.
Unplug all cable connectors. With the exception of PL1, press in side latches to release.
For PL1 press down side latches to release.
Unscrew the 3 captive screws (item 6c) spaced along the front edge of the PCB securing
it to the floor of the end-assembly.
Insert a finger of one hand under the corner of the PCB in the cut-out provided and with
the other hand, grasp TB34 and together pull the PCB out.
5.3.4
On reinstallation, ensure the back of the PCB properly engages in the support brackets in
the back of the end-assembly.
Detector End Assembly
5.3.4.1 Power Supply

Refer to Fig. 5.2(a).
To remove the Power Supply (item 33):
1
At the metal cage (item 30), loosen the M3 hex.skt screws (item 30b) each side and open
the lid.
Remove the 2 hex.skt screws (item 33a) securing the Power Supply to the heatsink
(item 33b)
Grasp the Power Supply firmly, pull upwards to unplug it.
5.3.4.2 Option (if fitted), Sensor Interface Board (SIB) and Processor PCB=s
Caution
Although the SIB and Option PCB locations are identified on the Transmitter
PCB they are fitted with identical edge connectors and can be transposed. No
damage will be done to the PCB=s electrically if they are but the analyser will
not function correctly (identified by a fault message being displayed).
To remove the PCB=s (Items 31,32 and Option PCB):
1
At the metal cage (item 30), loosen the hex.skt screws (item 30b), each side and open the
lid.
Grasp the PCB firmly with both hands, pull upwards to unplug from the connector.
Before reassembly ensure that connector pins are not damaged in any way.
5. 15
5.3.4.3 Transmitter PCB

To remove the PCB (item 28):
1
Carry out actions 5.3.4.1 and 5.3.4.2 if required.
Disconnect all wires. Label or record all locations to ensure reconnections are correct.
Unplug all cable connectors. To release PL1 and PL2 press side latches down and out.
For PL3 press latches in to release.
Unscrew the 2 captive screws (item 28a), one on each front corner of the PCB, securing it
to floor of the end-assembly.
Grasp the metal cage and pull the PCB upwards and out from support brackets.
On reinstallation, ensure the back of the PCB properly engages in the support brackets in
the back of the end-assembly.
5.3.4.4 Transmitter PCB Cage

To remove the cage (item 30):
1
Carry out action 5.3.4.3.
Turn the PCB assembly upside down to rest on the cage.
Using a slotted screwdriver remove the 4 screws (item 30a) securing the cage to the PCB.
Separate the cage and PCB.
5.3.4.5 Mains Transformer

Refer to Fig. 5.2(b)
To remove the mains transformer (item 21):
5. 16
Carry out actions 5.3.4.1 to 5.3.4.3 inclusive.
Unscrew the 2 nuts and washers (item 26a) securing the transformer cover (item 26), and
take the cover off.
Separate the plug and socket connection fitted to the bracket (items 22 - 24) mounted
alongside the transformer.
Disconnect the earth tag from the earth stud.
Unscrew the two M5 hex.skt screws (item 21a) from the underside of the case which
secure the transformer. Remove the transformer.
5.3.4.6 Detector Box

Refer to Fig 5.4.
To remove the detector box:
1
Carry out actions 5.3.4.1 to 5.3.4.3 inclusive, referring to Fig. 5.2.
Unscrew the 4 screws (item 4, Fig. 5.4) securing the lid (item 3) using a 3mm hex tool,
and remove the lid (2510 analyser type secured with 2 screws located on top edge).
Unscrew the 3 screws (item 6) securing the Detector PCB assembly (item 5) to the
detector mounting block (item 12) and take the PCB from the box.
Remove the leak test port adaptor and dowel pin (items 7 and 8) and remove absorbent
scrubber (items 9 and 10).
Note: The scrubber and leak test port are not fitted to purge certified analysers, these are
replaced by a purge adaptor and flexible purge duct fitted between the detector box and
the detector end enclosure.
Loosen a purge duct clamp to allow the detector box to be removed.
Loosen the screws (item 2) securing the detector block assembly and box to the detector
mounting boss (item 15).
Holding the assembly, fully unscrew the already loosened screws. The assembly and box
can now be separated and both items removed.
After reassembly, the detector block must be flushed and sealed with Nitrogen. Refer to
Section 7. If the detector is replaced, the analyser should be checked for span and zero
after returning to operation.
5. 17
5.3.4.7 Keypad and Display PCB Assembly

CAUTION
The display panel mounted on the PCB is made of glass and therefore fragile.
Handle with care during disassembly.
Refer to Fig. 5.2 (a and b)

To remove the Display PCB and Keypad (items 17 and 18):
5. 18
At the detector end cover unscrew the 4 screws securing the cover and allow the cover to
rise. Beware of gas strut action (item 5).
To provide a comfortable working position, disconnect one end of the gas strut. To do this,
insert the blade of a screwdriver or similar between the strut and the side of the chassis
and ease the strut from the locating stud. This will allow the cover to be fully opened.
Carefully rest the opened cover on the source end assembly or sample cell.
Unscrew the 4 hex.skt screws (item 16a) securing the vented metal cover (item 16) to the
detector - end cover and 2 screws securing the ferrite clamp (items 17c and 17d).
Remove the ferrite clamp and screws. Take care not to drop the ferrite clamp as it may be
damaged.
Carefully unplug the ribbon cable (item 17b) from the Display PCB.
At the Display PCB, unscrew the 4 hex.skt screws (item 17a) securing the Display PCB to
the Keypad (item 18). Carefully lift the Display PCB and disconnect the keypad ribbon
connector from the back of the PCB. When refitting the Display, remember to connect the
keypad ribbon cable before securing the Display PCB. Note that it is much easier to refit
the Display PCB to the Keypad before securing the Keypad into the cover. Also note the
earth wire on one of the Display PCB securing screws.
Unscrew the 4 hex.skt screws (item 18a) securing the Keypad to the cover and remove
the Keypad. Note the rubber O-ring gasket in the groove on the front of the Keypad. When
refitting the Keypad, ensure the O-ring gasket is correctly located in the groove and tighten
the 4 hex skt screws equally to ensure the Keypad seats correctly in the cover.
Carefully reconnect the ribbon cable connector to the Display PCB, arrange the ribbon
cable and refit the ferrite clamp.
Refit the vented metal cover. Refit the gas strut.
SECTION 6: CHOPPER BOX

LIST OF CONTENTS
Section
Page
6.1
INTRODUCTION...........................................................................................................................6.2
6.2
DESCRIPTION ..............................................................................................................................6.2
6.3
DISASSEMBLY.............................................................................................................................6.3
6. 1
NOTES
6. 2
6.1
INTRODUCTION
The chopper box No. 02500/920 is mounted in the source end and contains the solid-state
interference filters located on a rotating chopper wheel. Appropriate wavelengths configured for
analysis are selected by these filters. The infrared source assembly is mounted on the box lid.
6.2
DESCRIPTION
The chopper box assembly comprises: machined chopper box; chopper box lid; motor mounting
plate, filter mount and cut off filter, motor and filter disc assembly; Motor Connection PCB; lens
assembly; scrubber sachet port. Two heater resistors are mounted in open ended recesses in the
top and bottom of the box.
The motor assembly (with ribbon cable)(S2500986) locates in an open ended elongated hole on
the mounting plate and is secured in position with 2 M3 x 6 screws. The ribbon cable passes
through an opening in the side panel and connects to the Motor Connection PCB.
The Motor Connection PCB (S2500906) is fitted to the right hand side of the box, sealed via an Ò'
ring, effectively forming a side panel, with 3 M4 x 6 pan head screws. Locating dowels are
provided for correct alignment.
The mounting plate (02500410) also forms the mount for the cut-off filter and filter retaining plate.
The cut-off filter, often basically triangular in shape, is first placed over a recessed machined
aperture. The filter retaining plate (Servomex Part No. 01201414) is then placed over it and
secured with 2 pan head M3 x 5 screws. The plate, complete with the aforementioned items, is
fitted to the box with 4 M4 x 16 hex.skt captive screws.
The filter disc assembly is positioned on the motor drive spindle and secured with 3 hex.skt M3 x 5
screws. The measure and reference interference filters are mounted on the outer side of the disc,
facing away from the motor, with wavelengths engraved next to each one.
The lens assembly, comprising mounted lens, sleeve, spacer and Ò' rings, is fitted to the rear of
the box and held in position with 2 M4 x 16 hex.skt screws.
A scrubber sachet (if fitted) is located in the port on the left side of the box, retained and sealed
with an >O= ring with an M25 brass blanking plug. The plug can be removed using a 10mm hex
key. Note: Purge certified units are not fitted with either a scrubber sachet or blanking plug, the
blanking plug being replaced by a purge adaptor and flexible purge duct.
The chopper box lid (02500/407) provides a circular recessed mount for the source assembly and
a leak test port with mating plug and adaptor. The lid is secured to the box using 4 hex.skt M4 x 16
captive screws.
The resistors (2666 - 2255) are 10 ohm 15 watt devices and are secured directly to the box each
with 2 pan head M2 x 6 screws. The resistors act as heating elements for the box. Temperature of
the box is sensed by a thermistor mounted under one of the resistors. Resistors and thermistor
are connected via the Motor Connection PCB.
6. 3
6.3
DISASSEMBLY
Refer to Fig. 5.3.
1
Disconnect source cable from PL4 on the Power Control PCB (see Section 5.3.3.1).
At the lid (item 2), unscrew the 4 captive screws (items 5 and 6) using 3mm hex tool and
remove the lid, with the source attached. Store carefully. On no account touch a short
wave source lamp with bare fingers.
Using the 2.5mm hex tool remove the 3 screws (item 18) securing the filter disc assembly
(item 17) from the motor drive spindle. Carefully hold the filter disc lightly at the edges to
prevent rotation while doing this. Do not touch the filters.
Align the cut-out section of the filter disc with the opto-coupler (item 35) and carefully pull
off the disc without touching the filters. Put in a safe place and protect filters from damage
by wrapping with lens tissue or soft clean cloth. Note correct orientation (engraved
markings and filters usually on the front).
Carefully unplug the motor assembly ribbon cable connector from the Motor Connection
PCB (item 25).
At the mounting plate (item 15) unscrew the 4 captive screws (items 14 and 6) and
remove plate and motor assembly (item 16). Do not touch the fixed cut-off (bandpass)
filter.
Unscrew the 2 pan head screws (item 36) retaining the motor to the mounting plate.
Remove the motor, by gently pushing it backwards out of the mounting hole and then
sideways via the slot.
On reinstallation, ensure the filter disc is correctly orientated, i.e. measure and reference
infrared filters facing away from the motor. (NB some wheels have filters on both sides,
with bandpass filters towards the motor).
10
The completely reassembled chopper box must be flushed and sealed with clean dry
nitrogen after reassembly. Refer to Section 7.
Note: Purge certified analysers have a vented chopper box assembly, therefore flushing
and leak testing is unnecessary.
Note : If any changes to the filters have been necessary, a complete recalibration must be
conducted, - Consult Servomex.
6. 4
SECTION 7: REASSEMBLY - LEAK TESTING AND FLUSHING

LIST OF CONTENTS
Section
Page
7.1
INTRODUCTION...........................................................................................................................7.3
7.2
LEAK TESTING ............................................................................................................................7.3
7.3
FLUSHING ....................................................................................................................................7.3
7.4
SCRUBBER REPLACEMENT ....................................................................................................7.3
7.5
VOIDS ............................................................................................................................................7.3
7.5.1
7.5.2
7.5.3
Cell Assembly .................................................................................................................7.3

Detector Assembly ..........................................................................................................7.4
Chopper Box assembly ...................................................................................................7.4
7. 1
NOTES
7. 2
7.1
INTRODUCTION
The analyser contains a number of sealed voids (dead spaces) which are in the optical path and
these are the chopper box, detector box and 2 cell end bosses.
If any of these voids are opened during servicing or repair they must be leak tested and
flushed and sealed with clean dry nitrogen after reassembly and have their scrubbers
replaced, if fitted.
7.2
LEAK TESTING
A leak test port is fitted to the chopper box lid and to the detector block, with a 4mm stainless
dowel which may be removed by pressing on the red release collet and pulling on the dowel pin
simultaneously. A 4mm OD tube may be fitted to the leak test port; the tube is automatically sealed
via an >O= ring contained in the leak test port. To refit the dowel pin, press into position using
gentle pressure. Ensure that voids are not contaminated during leak testing.
Procedure
Leak tests should be carried out in a stable temperature environment otherwise erroneous results
may occur.
Connect a manometer to the void and pressurise to 6 feet of water gauge (3 psig/20kPa). Allow
approximately 1 minute for the manometer to stabilise and note the manometer level. After
approximately 30 minutes there should be no detectable pressure drop. If available , the use of
Helium leak test equipment should be considered as an alternative.
Note: Purge certified analysers have vented chopper box and detector assemblies, therefore leak
testing of these items is unnecessary.
7.3
FLUSHING
Pass clean dry nitrogen through the void at a flow rate in excess of 1l/min. Supply pressure not to
exceed 5 psi. Seal void immediately after flushing so as to avoid the ingress of air.
7.4
SCRUBBER REPLACEMENT
It is recommended that when a void is opened the scrubber (if fitted), is always replaced. Spare
scrubbers supplied on delivery of the analyser should only be used if they are still sealed in their
original packaging and stored in an airtight container. Scrubbers have a G1/8 (1/8" BSPP) thread
and are sealed with a Dowty bonded seal.
Note: Purge certified analysers are not fitted with scrubbers.
7.5
VOIDS
7.5.1
Cell Assembly
There are cell end bosses at each end of the cell. These may be fitted with two scrubbers. One of
these may be removed to facilitate leak testing and flushing. On instruments where the end
bosses are constantly purged no testing is necessary.
7. 3
On some instruments there is an additional window fitted in the casting insert which divides the
end boss cavities in two. The >cell side= end boss void may be leak tested and flushed via the cell
end boss scrubber ports. No facility is provided for leak testing the >end-box side= void although
this should still be flushed at time of assembly.
7.5.2
Detector Assembly
This is normally fitted with a scrubber and a leak test port. Remove the dowel from the leak test
port and fit a 4mm OD tube to facilitate leak testing. Loosen the scrubber 2 turns and introduce
nitrogen via the leak test port to flush. Tighten the scrubber, remove the 4mm OD tube and refit the
dowel to the leak test port.
Note: Not necessary on purge certified analysers.
7.5.3
Chopper Box
This is fitted with a leak test port in the centre of the lid. Remove the dowel and fit a 4mm OD tube
to facilitate leak testing. Loosen the brass scrubber port 2 turns and flush the box via the tube.
Tighten the scrubber port and refit the dowel pin to the leak test port.
Note: Not necessary on purge certified analysers.
7. 4
SECTION 8: PRINTED CIRCUIT BOARDS

LIST OF CONTENTS
Section
8.1
Page
POWER CONTROL PCB .............................................................................................................8.6
8.1.1 General.............................................................................................................................8.6
8.1.2 Mains Input Voltages .......................................................................................................8.6
8.1.3 Solenoid Valve Driver ......................................................................................................8.7
8.1.4 Source Voltage Control ...................................................................................................8.7
8.1.5 Chopper Box Heater Control...........................................................................................8.8
8.1.6 Motor Control ...................................................................................................................8.9
8.1.7 Pressure Sensor Amplifier...............................................................................................8.9
8.1.8 Cell Temperature Control............................................................................................. 8.10
8.1.9 Diagnostics.................................................................................................................... 8.11
8.1.10 Fault Displays ............................................................................................................... 8.12
8.1.10.1 Source Voltage High/Low............................................................................................. 8.12
8.1.10.2 Sample Flow Failure ..................................................................................................... 8.13
8.1.10.3 Chopper Temp High/Low ............................................................................................. 8.13
8.1.10.4 Cell Temp High/Low ..................................................................................................... 8.13
8.1.10.5 Source Temp High/Low................................................................................................ 8.13
8.1.10.6 Infrared Source Failure................................................................................................. 8.14
8.1.10.7 Chopper Motor out of Lock........................................................................................... 8.14
8.1.10.8 Detector Signal High .................................................................................................... 8.14
8.2
TRANSMITTER PCB ................................................................................................................. 8.15

8.2.1
8.2.2
8.2.3
8.2.4
8.2.5
Three Channel Synchronous Detector ........................................................................ 8.17

Analogue/Digital Multiplexer and I/O (Input/Output).................................................... 8.17
Serial EEPROM ............................................................................................................ 8.18
Autocal Latches ............................................................................................................ 8.18
Switch Settings.............................................................................................................. 8.18
8.3
SENSOR INTERFACE PCB...................................................................................................... 8.19
8.4
OPTION PCB=s .......................................................................................................................... 8.20
8.5
MICROPROCESSOR PCB ....................................................................................................... 8.21

8.5.1
8.5.2
8.5.3
Watchdog Circuitry ....................................................................................................... 8.21

Memory Test ................................................................................................................. 8.22
Diagnostics.................................................................................................................... 8.22
.....continued overleaf
8. 1
LIST OF CONTENTS (continued)

Section
8.6
Page
DISPLAY PCB............................................................................................................................ 8.22
8.6.1
Diagnostics.................................................................................................................... 8.23
8.7
POWER SUPPLY....................................................................................................................... 8.23
8.8
DETECTOR PCB ....................................................................................................................... 8.24

8.8.1 Diagnostics .................................................................................................................... 8.24
8.8.1.1 Detector Setup for 2500 Series Analyser..................................................................... 8.25
8.9
MOTOR CONNECTION PCB.................................................................................................... 8.26
Figure
Page
8.1
2500C PCB Locations...................................................................................................................8.3
8.2
Option Board Layout .....................................................................................................................8.4
8.3
Microprocessor PCB Layout.........................................................................................................8.5
8.4
Diagnostic Waveforms ............................................................................................................... 8.16
8. 2
Note:
Power Supply Part Number 02000925

Optional Output PCB Part number 02000916
Sensor Interface PCB part number 02000934
Figure 8.1 2500C PCB Locations

8. 3
Figure 8.2 Option Board Layouts
8. 4
Figure 8.3 Microprocessor PCB Layout

8. 5
8.1
POWER CONTROL PCB
8.1.1
General
The Power Control PCB (02500/911A) provides power distribution, control signals and
interconnections to most of the analyser's circuitry. The PCB also provides most of the fuse
protection for the analyser. Fuses values and circuitry protection are listed below.
Fuse
Value
F30
F31
F32
F33
F34
F35
F36
F37
F38
1A(T)
2A(F)
2A(F)
1A(T)
2.5A(T)HBC
2.5A(T)HBC
3.15A(T)HBC
1A(T)
800mA(F)
T = anti-surge
F = quick blow
Protection
20V AC supply to Source Power Supply
20V AC supply to Cell Heater Control
20V AC supply to Chopper Box Heater Control
20V AC supply to Solenoid Valve Drivers
230V AC from TB31 to Transformer Primary
115V AC from TB31 to Transformer Primary
AC mains input to mains filter
AC mains input to DC power supply
Source Supply
HBC (or H) = high break capacity
The PCB is located in the source-end assembly. For removal instructions refer to Section 5.
8.1.2
Mains Input Voltages

The incoming mains AC voltages are routed to the primary winding of the mains transformer and
the Power Supply PCB via terminal blocks (TB) TB30, TB31, mains filter (X1) and PL3. Analyser
working voltages are selected at TB31 using wire links. Voltages requirements and their wire links
are as follows:
115V nominal TB31 pin 1(com) to TB31 pin 2
230V nominal TB31 pin 1(com) to TB31 pin 3
Filtered mains voltages are taken via PL3 to the Power Supply PCB fitted to the Transmitter PCB.
The transformer secondary provides operating voltages (wrt 0V) of 110V, 60V, 30V, for the sample
cell heater, operating voltages of 20V for solenoid valve drivers, source power supply and chopper
box heater control.
8. 6
8.1.3
Solenoid Valve Driver

The solenoid valve driver circuitry provides three volt free contacts rated 240V AC/1.0A,
30VDC/1.0A. These are designated SV1, SV2 and SV3.
An auxiliary circuit provides +24VDC for internal solenoid valve driver, maximum power available
is 12W. The out put is routed to TB36-5&6(+24VDC), 0V connection being made to TB36-3&4.
An AC voltage of 20V is input via PL3 and fed, via a 1 amp fuse F33 to full wave bridge rectifier
BR2 for conversion to an unstabilised, smoothed +24V DC.
Solenoid valve driver input voltages and signals are listed below.
Circuit Reference
PL3 pin
PL1 pin
20V AC
0V AC
SV3
SV2
SV1
15
14
-
30
31
32
Valve driver terminals are listed below. Note that these are volt free contacts.
8.1.4
Circuit Reference
TB34 pin
SV1
SV2
SV3
1,2
3,4
5,6
Source Voltage Control - Infrared Analysers

The source voltage control circuitry provides operating voltages and signals for the IR source
assembly.
20V AC is input via PL3 and full wave rectified and smoothed by BR1 and capacitor C1 to +24V
DC providing the operating voltage for the switched mode power supply IC3. The line input is fuse
protected by F30 (1 amp). Further DC regulated DC voltages of +12V and +5V are required which
are provided by on-board regulators, IC18 and IC1.
The IR source assembly voltages are monitored continuously with information being fed back to
on-board control circuitry and via PL1 to the Microprocessor PCB. A green coloured light emitting
diode (LED) D6, monitoring the SOURCE FAIL signal line, will be lit under normal operating
conditions (see paragraph 8.1.9). Test points, TP1 and TP2, are available for external monitoring
of the +/- ve sense lines.
Source voltage control input signals are listed below.
8. 7
Circuit Reference
PL1 pin
PL3 pin
20V AC(from : PS PCB)

0V AC (from : PS PCB)
Sync. pulse
Source fail
27
26
9
8
-
Source voltage control output signals are listed below.
8.1.5
Circuit Reference
PL1 pin
PL4 pin
Source voltage
Source voltage error
-ve supply
-ve sense
+ve sense
+ve supply
7
8
-
1
2
3
4
Chopper Box Heater Control

The chopper box heater control circuitry provides the necessary voltages and signal lines to
maintain the chopper box assembly at a steady temperature. Signals from the chopper box
thermistor are fed via PL2 to a Wheatstone bridge arrangement. Changes in voltage across the
bridge are sensed by differential amplifiers which in turn control 20V AC voltage to the heaters 1
and 2. Test points TP4 and TP5 are provided which enable monitoring of differential amplifier
signal levels.
Input signals are listed below.
8. 8
Circuit Reference
PL1 pin
PL2 pin
0VA
-15VA
+15VA
Chop.box temp.+ve
Chop.box temp.-ve
Sync.pulse
20V AC c/box htr
Chop.box therm.
0V AC c/box htr
Chop.box therm.
13,14
15,16
17,18
1
2
13
18
20
12
11
-
PL3 pin
Signal outputs are listed below.
8.1.6
Circuit Reference
PL1 pin
PL2 pin
Sync.pulse
20V AC switched(c/box htr)
0V AC (c/box htr)
27
-
17,19
15,16
Motor Control
The motor control circuitry maintains the chopper box motor at a constant 11.25 Hz (675 rpm) and
provides visual indications if faults occur.
LEDs D5 and D7, normally lit, will extinguish when motor operation is impaired in any way. D5
monitors the +24VP DC rail and if extinguished, this will indicate the +ve supply to the board is
missing. The +24VP, input via PL1 pins 37 and 38 is used to provide a stabilised +12VP supply
(IC26) for the control circuitry. If D7 is extinguished it will indicate that the motor has stopped.
Motor control input signals are listed below.
Circuit Reference
PL1 pin
PL2 pin
0VP
+24VP
Hall I/P (b)
Hall I/P (c)
Hall I/P (a)
Motor phase (c)
Motor phase (b)
Motor phase (c)
0VD
+5VD
33,34,35,36
37,38
-
3
4
5
6
7
8
9
10
12
14
Motor control output signals are listed below.
8.1.7
Circuit Reference
PL1 pin
Motor current
Motor lock
6
25
Pressure Sensor Amplifier

The pressure sensor amplifier circuitry, when utilised, simply amplifies signals from the pressure
transducer via TB35 pins 1 and 2. the pressure signal is output at PL1 pin 27.
8. 9
8.1.8
Cell Temperature Control

The cell temperature control circuitry receives voltage signals from the cell thermocouple via PL5.
The signals are then amplified, and in conjunction with switch SW2, activate the TRIACs to allow
the correct AC heater voltage to reach the sample cell. The circuitry generates its own +5V
reference voltage, derived from the +15V rail, required for the differential amplifier. A test point TP3
wrt 0V is provided to monitor the CELL TEMP. voltage level.
Cell temperature control input signals are listed below.
Circuit Reference
PL5 pin
T.C. +ve
T.C. -ve
1
2
Cell temperature control output signals are listed below.

Circuit Reference
PL1 pin
TB33 pin
Cell sample temp.

Cell sample temp.S.P.
Cell T.C. fail
Cell heater (A)
Cell heater (B)
9
10
11
-
1
4
Switch settings for SW2 showing the respective cell temperatures are listed below.
8. 10
SW2 Setting ............Cell Temp. EC
SW2 Setting .......... Cell Temp. EC
0 .................................................. 30
8.................................................110
1 .................................................. 40
9.................................................120
2 .................................................. 50
A ................................................130
3 .................................................. 60
B ................................................140
4 .................................................. 70
C ................................................150
5 .................................................. 80
D ................................................160
6 .................................................. 90
E ................................................170
7 ................................................ 100
F.................................................180
8.1.9 Diagnostics
The Power Control PCB has 3 diagnostic LED's, D5, D6 and D7. They should be used to identify
the nature of any fault. All circuits operate fully independently with the exception that any motor
failure will also shut down the source voltage to 0.4V.
+24v
Supply D5
Source
Voltage D6
Motor
Lock D7
Diagnosis
On
On
On
Normal operation
On
Off
Off
PL2 disconnected;
Chopper motor failure;
Motor control failure.
On
On
Off
As above but with source also

disconnected/open circuit
On
Off
On
Source driver failure;

fuses blown (check F30,34,35,38)
Off
Off
Off
No mains power;
fuses blown (Check F36,37);
PL1 Disconnected; PS PCB (+24v)
failure
Off
On
Off
PL1 disconnected; PS (+24v) failure;

Fuse F37 blown and source also open
circuit.
8. 11
8.1.10 Fault Displays

8.1.10.1 Source Voltage High/Low
Check source voltage between TP2 wrt TP1 (earth) and check settings of switches SW3 and SW4.
Note: switch settings have been factory set and must not be altered.
SW3 Settings
Source Voltage (Volts)
Rotary
Switch SW3
position
SW4-1OFF & SW4-2ON
0
1
2
3
4
5
6
7
8
9
A
B
C
D
E
F
0.75
0.80
0.85
0.90
0.95
1.00
1.05
1.10
1.15/0.75
1.20/0.80
1.25/0.85
1.30/0.90
1.35/0.95
1.40/1.00
1.45/1.05
1.50/1.10
SW4-1OFF & SW4-2OFF SW4-1ON & SW4-2OFF

1.5
1.6
1.7
1.8
1.9
2.0
2.1
2.2
2.3/1.5
2.4/1.6
2.5/1.7
2.6/1.8
2.7/1.9
2.8/2.0
2.9/2.1
3.0/2.2
3.0
3.2
3.4
3.6
3.8
4.0
4.2
4.4
4.6/3.0
4.8/3.2
5.0/3.4
5.2/3.6
5.4/3.8
5.6/4.0
5.8/4.2
6.0/4.4
Note: Dual voltages are shown in some cases these are selected by SW4-3.
SW4 Settings
Switch position
3 ON
3 OFF
Function
Disable 2.7V limit
Enable 2.7V limit (switch positions 0 to 7 repeated
For standard long wavelength IR sources the voltage is typically set from 2.0V to 2.2V. For short
wavelength sources in the NIR region (2500 liquid applications, etc.) the Quartz Halogen source is
set to 2.6V. For short wavelength sources in the visible and Soft UV versions it is set to 4.4V.
If the source voltage supplied is not according to the switch settings, and no other diagnostics are
indicated, a control chip failure is diagnosed and the Power Control PCB must be replaced. Note
that a motor failure shuts down the source voltage to 0.4V.
8. 12
8.1.10.2 Sample Flow Failure

Check the sample flow and flow switch operation where fitted. This diagnostic will be triggered by
continuity between TB36/1 and TB36/2.
8.1.10.3 Chopper Temp High/Low
Check chopper box temperature at TP4 using a digital voltmeter (DVM) (0.10V per EC -20 to
+80EC) wrt TP5. Standard chopper box set point is 65EC although steady operation in the range
64-68EC is acceptable. Check ambient temperature and ensure analyser has had sufficient time
to warm up if recently switched on (requires up to 2 hours). Ambient temperature outside the
specified range (refer to instrument specification in appropriate User Manual) may result in these
faults.
8.1.10.4 Cell Temp High/Low
Check cell temperature at TP3 (1mV per EC) wrt TP5, and compare with cell temperature
diagnostic display and the factory setpoint (see specification sheet in the User Manual). Check
ambient temperature and ensure that analyser has sufficient time to warm up if recently switched
on. Determine whether overheating or excessive cooling may be due to the sample stream.
WARNING
TB32/1 supplies 110V AC nominal
Severe shock hazard
If no discontinuity/supply failure is found, a control circuit failure is indicated and the Power Control
PCB must be replaced.
8.1.10.5 Source Temp High/Low
Source temp low would normally occur as a consequence of an infrared source failure fault. The
source unit should be checked for resistance of the element (measured between pins 1 & 4 of the
source pins) and should be replaced if it is greater than 3 ohms, and the instrument recalibrated.
The only circumstances where source temp high or source temp low faults would otherwise arise
would be on 2500 SBTW (triple wavelength) analysers where severe source ageing has occurred
or strong interferences are present on one or both of the reference wavelengths. The latter is the
more likely, and steps should be taken to identify whether process composition changes or other
application problems are the cause, before a change of Power Control PCB is attempted.
8. 13
8.1.10.6 Infrared Source (Driver) Failure

An actual infrared source drive circuit failure will be confirmed by D5 and D7 being on, and D6
being off, on the Power Control PCB. Otherwise, if D7 is off, the fault could be related to the
chopper motor being out of lock since source power is interlocked to motor lock (source drive
reduces to 0.4V). Refer to next section (8.1.10.8).
8.1.10.7 Chopper Motor out of Lock
A chopper motor out of lock fault indicates that the motor is not rotating at the correct speed (which
is 675 revolutions per minute). Under these conditions the circuit may reduce the source voltage to
prevent possible damage to some types of IR filter as there is a risk that these might otherwise
remain stationary in the IR beam. Under these conditions Infrared Source Failure and Detector
Signal Low faults may also be displayed.
Check whether Power Control PCB D7 is off or on.
If D7 is on (motor out of lock) :
Check interconnections to DIN Controller (if fitted)
Change SIB PCB
Change Power Control PCB
If D7 is off (motor out of lock) :
Check whether D5 (+24V supply) is off or on.
If D5 is off,
check PL1 connections are good and check other items as
noted in section 8.1.9
If D5 is on,
check PL2 connections are good;
check and replace chopper motor;
change Power Control PCB
8.1.10.8 Detector Signal High
Excessive detector signal may be due to loss of a liquid sample, loss of a normal background gas
sample which has a high absorbance, or possible loss of an IR filter from the chopper wheel.
Check signals at Transmitter PCB, refer to Section 8.2.
8. 14
8.2
TRANSMITTER PCB
The Transmitter PCB (02500/904A) provides the interface between the Power Control PCB and
most of the other PCBs used by the analyser (see Fig 8.1). It provides three test points and a 0V
reference point along its front edge.
Functions carried out by the Transmitter PCB are three channel synchronous detection, analogue
and digital multiplexing, input/outputs and storage of calibration data in EEPROM devices.
Note: the term transmitter is generic and is merely descriptive of how voltages and signals are
progressed for onward transmission although there is a printer RS232C port routed from the
Microprocessor PCB.
8. 15
Figure 8.4 Diagnostic Waveforms

8. 16
8.2.1 Three Channel Synchronous Detector

The three channel synchronous detector (TCSD) circuitry receives pulses from the detector box,
via connector PL3. The output from the detector is a composite signal comprising a stream of
pulses corresponding to the transmission of energy through the sample at each filter wavelength.
It is changes in the magnitude of these pulses with change in sample composition which enable
measurements to be made. Pulse amplitudes are determined by sampling the pulse stream. For
optimum accuracy, two samples are taken for each pulse; one, just before the pulse (baseline) and
one during the pulse (peak).These samples are fed into a differential amplifier and filter circuit. The
subsequent output represents the pulse height and hence the transmission of the sample at the
wavelength concerned. A standard 2500 has three such circuits (each capturing two samples)
and hence output signals from up to three filters. Using a dual beam oscilloscope and with
reference to Fig.8.4, monitor the signal at TP2 wrt 0V. On the transmitter PCB.
To aid sampling, the periphery of the filter disc assembly is slotted, with the slots being detected by
a photo-interrupter (part of the Motor Connection PCB Fig.5.3 item 35). The three filter disc
assembly has thirteen slots, twelve of which are used to control the six samples, (one to start each
sample, one to end it) and a thirteenth, wider slot, which is detected by a discriminator circuit and
serves to identify the first filter. The pulse stream from the opto-interruptor may be viewed, using
the oscilloscope on TP3 wrt 0V and the output from the discriminator may be viewed on TP1 wrt
0V. The two or three signals, monitored at TP2, feed into two or three inputs of the analogue
multiplexer. The multiplexer has a total of six inputs for transmission signals, and the other three
connect to plug PL5 together with the detector signal pulse stream, the discriminator output and
the timing slot pulse stream. This permits connection of optional additional circuits (on 2510 and
2550 models) to allow up to six filter pulses to be sampled.
8.2.2 Analogue/Digital Multiplexer and I/O (Input/Outputs)
The analogue multiplexer provides sixteen inputs, six of which are used for the incoming filter disc
signals. Remaining inputs are used for sample pressure and temperature signals and various
analogue diagnostics such as source voltage and motor current. The output from the analogue
multiplexer is passed via a variable gain circuit to a current output circuit which has a range of 4 20 mA.
The digital multiplexer has eight inputs and receives digital diagnostic data such as motor lock, cell
thermocouple fail, etc. Output from the digital multiplexer is fed to a CMOS driver and filter circuit.
Both analogue and digital multiplexers are controlled by four common control lines (although only
three are connected to the digital multiplexer) which are fed via resistor and zener diode filters
under the control of the Microprocessor PCB via the SIB PCB and this allows the Microprocessor
PCB to read any digital or analogue signals.
In addition to the four control lines, three further digital lines, buffered in a similar way to the control
lines are provided to control the gain of the analogue output stage, referred to earlier.
8. 17
8.2.3 Serial EEPROM

The non-volatile serial EEPROM, (Electronically Erasable Programmable Read Only Memory)
forming part of the Microprocessor PCB memory, contains factory set information relating to the
calibration, such as calibration data points, span and zero constants, temperature and pressure
compensation factors and filter temperature coefficients. The stored data is unique to each
instrument. An exact backup copy is stored in a second EEPROM fitted to the Transmitter PCB. If
data in the microprocessor EEPROM becomes corrupted, data can be downloaded to the
Microprocessor PCB by using the ASSOCIATE command, available from the keypad.
8.2.4 Autocal Latches
There are four latches on the Transmitter PCB. The control lines are each connected to the input
of one latch. The latches are clocked by a dedicated signal via the SIB PCB. The outputs from the
latches are fed to drivers for solenoid valves, mounted on the Power Control PCB, used by
Autocal. This enables the Microprocessor PCB to energise any combination of valves as required.
If failure or disconnection of the Microprocessor occurs while Autocal is running it could leave
calibration gases permanently connected so an automatic time out is provided. This circuit clears
the latches after 4 seconds if activity on the control line ceases.
8.2.5
Switch Settings
If the Transmitter PCB is replaced ensure that PCB switch SW2 settings are set according to the
analyser model:
For models 2500 / 2520 and 2510 set SW2 1 & 2 to OFF
For model 2550 set SW2 1 & 2 to ON
8. 18
Transmitter input signals:

Circuit Reference
PL1 pin
Chopper box temp.

Pressure
Motor current
Source voltage
Source voltage error
Cell sample voltage
C/S temp. S.P.
Cell T.C. fail
Chopper temp. S.P.
Motor lock
Source fail
Sync.pulse
Flow fail
Solenoid valve driver SV3
1
5
6
7
8
9
10
11
12
25
26
27
28
30
31
32
Transmitter output signals:
8.3
Circuit Reference
PL3 pin
Detector shield
Detector signal
Detector temp.
1,2,15,16
3,4,
10
SENSOR HEAD INTERFACE BOARD (SIB PCB)

The Sensor Head Interface board (SIB) (02000/934) connects to the Transmitter PCB (sockets
SK2 and SK3) via PL1 and PL2. The SIB is powered by +5VD,+/- 15VA and +24VP received from
the PS PCB. The +5VD and +/- 15VA provides circuitry requirements and +24VP is used to
provide +/-15VIA and +/- 15VIB via DC/DC converters for 2 isolated analogue measurement signal
outputs (mA or V) and also to energise 3 relay contact pair outputs (NO or NC). A simplified board
layout is shown in Fig.8.2.
8. 19
Input voltages are listed below.

Circuit Reference
PL1 row b pin
PL2 pin
+5VD
0VD
+15VA
0VA
-15VA
+24VP
0VP
13,14,15,16
1,2,3,4
-
1C
1B
1A
3A,3B,3C
2A,2B,2C
Connections to analogue signal outputs and relays are made at TB24 and TB23 mounted on the
Transmitter PCB.
Analogue signal output connections are listed below.
Circuit Reference
TB24 pin
1.1+
1.11.2+
1.2-
4
3
2
1
Relay output connections are listed below.

Circuit Reference
TB23 pin
1.3+
1.31.4+
1.41.5+
1.5-
1
2
3
4
5
6
In addition the SIB performs A/D conversion, drives control lines and reads the digital output line
from the Transmitter PCB.
8.4
OPTION PCB=s
When the Option PCB (02000/916) is fitted, it is located in sockets SK4 and SK5. Option PCB=s are
depopulated SIB=s. The 02000/916 retains sufficient circuitry to drive 2 analogue and 2 relay
outputs. Board layouts are shown in Fig.8.2.
8. 20
8.5
MICROPROCESSOR PCB
The microprocessor PCB (02000/912) is plugged into socket SK1 of the Transmitter PCB and is
powered by +5VD.
The PCB carries out all of the measurement and diagnostic functions of the analyser. The PCB
contains all the necessary integrated circuits to support operation of the 68HC001 microprocessor,
around which the Microprocessor PCB is based. Components include RAM, ROM (Flash
EEPROM, for firmware storage) FRAM (for non-volatile storage of user settings etc) and the
required microprocessor housekeeping logic such as an address decoder, and data acknowledge
(DTACK) generator.
Three LEDs DS01, DS02 and DS03 that form part of the circuitry are used and provide a visual
indication of the state of some operational aspects of the PCB. DS01 (green) is hardware driven
and indicates that the microprocessor is running. DS02 and DS03 (red) indicate the results of
memory tests.
The PCB, in addition to controlling analyser operation and storing factory set data, drives the
following peripheral functions:
Real time clock and backup power source
Keypad interface circuit
Front panel FAULT and ALARM LED drivers
Bus Interface to Display, SIB and Option PCB=s
RS232 printer port
RS485 digital link port
Keyswitch input
The PCB is not a field serviceable item and if faulty should be replaced with a known working PCB.
If a replacement PCB is to be fitted, ensure that link P002 is not fitted and switch (S001) settings
are identical to the faulty (original) PCB. SW1/S001, contact 1 to ON (all other contacts are OFF)
is used to configure the PCB for printer use via the RS232 port. Refer to the board layout shown
Fig.8.3.
8.5.1 Watchdog Circuitry

Functions of RAM, ROM and FRAM devices are monitored by a watchdog circuit. The watchdog
circuit has the following functions:
1
It ensures that the microprocessor will be prevented from running if the input from the PS
PCB indicates that the supply voltage is too low for safe operation.
It monitors a timer (on the PCB) which must be re-initialised every 500ms, (approx) by the
software to prevent time out when it will generate a momentary hardware reset. This will
ensure that if the software should crash and consequently fail to re-initialise the timer, the
software will be re-started within 500ms.
8. 21
In the event of a hardware fault which stops the microprocessor, the watchdog circuit will
repeatedly pulse the RESET line and cause LED DS01 to flash. See Section 8.5.3.
8.5.2 Memory Test

The memory test is a software check on RAM, ROM and FRAM and is carried out whenever the
microprocessor is reset, eg. on power-up, and after watchdog time out. Initially LEDs DS02 and
DS03 will be lit. If the RAM test is satisfactory DS02 will be extinguished, and if the ROM test is OK,
DS03 will also be extinguished. During normal operation both LEDs will be unlit.
8.5.3 Diagnostics
The conditions of LEDs DS01,DS02 and DS03, shown below, can be used to determine possible
problems related to the Microprocessor PCB.
RUN
DS01
RAM fail
DS02
ROM fail
DS03
Diagnosis
On
Off
Off
Normal operation
Flashing
Flashing
On
On
On
Off
On
Off
Off
On
Off
On
Probably a Microprocessor
PCB fault caused by failure
of all or one of the RAM,
ROM and FRAM devices.
Blank display screen.
Off
On
On
Probably an external
RESET caused by a PS. PCB
fault or low mains voltage.
Loss of the peripheral functions, listed in Section 8.5, without total loss of analyser operation, could
be caused by failure of control circuits on the Microprocessor PCB, and should be checked by
PCB replacement.
8.6
DISPLAY PCB
The Display PCB (02501/903) is connected to the Transmitter PCB PL2 by ribbon cable which
carries power and high speed address and data bus to the PCB. Voltage requirements by the
PCB are +5VD only.
The display, mounted on the reverse side of the PCB, features a 2 x 16 character vacuum
fluorescent display (VFD) module. Each character is made up from a 5 x 7 array of dots. The VFD
module internally generates the required higher working voltage from the 5V supply.
The PCB is directly coupled to the microprocessor bus, and operates by copying bit patterns from
a dedicated RAM out to the display drivers. The characters are multiplexed to reduce the number
of drivers required, and the whole display is scanned approximately every 20ms. The bit patterns
are created in the RAM by the microprocessor, so the software can construct any character that is
8. 22
required, including the subscript numbers used in chemical formulae, which are not normally seen
on dot matrix displays.
The circuit has a master blanking line which when high, blanks the whole display irrespective of
the RAM contents. This is driven from the Microprocessor PCB, and defaults high when the
microprocessor is first powered up, or is reset. The line can only be taken low by the software,
and this is only occurs when the display RAM has been loaded with a valid bit pattern.
8.6.1 Diagnostics
In the event of an erroneous display, the fault may be on the Display PCB or the Microprocessor
PCB, and it can be impossible to tell without substituting PCB's because their functions are so
closely interrelated.
8.7
Fault
Diagnosis
Display characters lit but message garbled
Microprocessor PCB fault
Whole characters and dots from characters

missing
Display PCB fault
Display not lit after initialisation routines
Display module failure; cracked

display glass
POWER SUPPLY
Regulated DC voltages, derived from the AC mains supply, are provided by a switched mode
power supply (02000925) which plugs into socket SK6. Voltages are routed to plug-in PCBs via
on-board connections and to Power Control and Display PCBs via PL1 and PL2 respectively. The
power supply has internal in-line fuse protection and the inrush current is thermally limited. The
mains input to the power supply, which is filtered, can vary between 85V and 265V without
affecting the power supply output. The LINE/LIVE input is protected by a 1A anti-surge fuse F37.
Output voltages are:
+5V (0.2V) at 1A
15V (0.75V) at 200mA
+24V (1.92V) at 1A
8. 23
PS PCB input and output pin connections are listed below.

Mains input:
Circuit Reference
PL4 pin
SK6 pin
Mains (L)
Mains (N)
Mains (E)
2
3
1
28A,32A
26C,30C
20A,22C,24A
Output voltages are listed below.
8.8
Circuit Reference
PL1 pin
PL3 pin
SK6 pin
+5VD
0VD
+15VA
0VA
-15VA
+24VP
0VP
23,24
19,20,21,22
7
8
9
10
11
7
5,6
8,9
13,14
11,12
2A,2B,2C
4A,4B,4C
17,18
13,14
2,15,16
37,38
33,34,35,36
DETECTOR PCB
The pyroelectric detector used on 2500, 2510 and 2550 analysers consists of a lithium tantalate
pyroelectric element, which is sensitive to any changes in incident radiation. The detector used on
a 2520 analyser is a UV photodiode type.
The detector response to the chopped light from the source is a near triangle wave which is AC
coupled into the first stage amplifier (IC1). This is a non inverting amplifier with a band pass gain,
matched to the chopping frequency and a gain which is variable between 48 and 1000 by adjusting
RV1. The setting of RV1 is fundamental to the calibration of the analyser and should NOT be
adjusted in the field.
The amplified signal is fed into a differentiating amplifier (IC2) with a gain of 1. The differential of a
triangle is a square wave and the result is a "squared" up signal.
Changes in the sample absorption result in changes to the square peaks proportional to
1/absorbance.
8.8.1
Diagnostics
Setup varies depending upon analyser type, but should always be performed using a
ZERO sample.
8. 24
8.8.1.1 Detector Setup for 2500 Series Analyser

Use an oscilloscope to observe the detector waveform on TP2 of the 02500/904 Transmitter PCB
using TP4 as the earth. Trigger the oscilloscope from the falling edge of the signal on TP1 of the
same PCB.
Adjust RV1 on the 02500/905 Detector pre-amp PCB (visible through the top of the detector
assembly) so that the largest of the peaks is set to 3V0 0V2
Note: If the noise level on the output of the calibrated analyser is greater than 1% f.s.d. (on ZERO
sample) then it is permissible to set the largest peak to a maximum of approx. 4V6 to improve the
signal to noise ratio.
Peak amplitude should be measured from the flat region of the baseline immediately before the
rising edge of the peak, to the flat region at the top of the peak.
Check that the waveform is steady, and that the value of the DETECTOR SIG R, in DIAGNOSTICS
should be greater than 160000.
Use a D.V.M. and connect the -ve lead to TP1 (0V) on the 02510/901 Adapter PCB and the D.V.M.
+ve lead to TP3 on the same PCB. Adjust RV1 on the 02500/905 Detector pre-amp PCB (visible
through the top of the detector screening box) until the D.V.M. reading (VN2) is 5V 0V1
Connect the D.V.M. +ve lead to TP4 on the 02510/901 Adapter PCB - on the same PCB use SW1
as a coarse adjustment and RV1 as a fine adjustment to obtain a D.V.M. reading (VDiff) of 0V5
0V1
Connect the D.V.M +ve lead to TP5 on the 02510/901 Adapter PCB and check that the D.V.M.
reading (VGas) is within 0V1 of the value of VN2.
Use an oscilloscope to observe the detector waveform on TP2 of the 02500/904 Transmitter PCB,
using TP4 as the earth. Trigger the oscilloscope from the falling edge of the signal on TP1 of the
same PCB.
Up to six peaks will be observed dependant upon the application.
Adjust RV1 on the 02500/905 Detector pre-amp PCB (visible through the top of the detector
assembly) so that the largest peak is optimised at 3V0 0V2.
Peak amplitude should be measured from the flat region of the baseline immediately before the
rising edge of the peak, to the flat region at the top of the peak.
Check that the waveform is steady, and that the value of the DETECTOR SIG R1 in
DIAGNOSTICS should be greater than 160000.
8. 25
8.9
MOTOR CONNECTION PCB

The Motor Connection PCB (02500/906) forms part of the chopper box and provides
interconnections for the chopper motor drive voltages and monitors chopper box temperature, all
under supervision of the Power Control PCB. A thermal fuse mounted on the board will fail if the
chopper box temperature exceeds 95 degrees Celsius. Normal operating temperature is approx.
65EC.
The opto-interrupter (IC1), in conjunction with the filter disc assembly provides the pulse stream
data which is fed to the analogue multiplexer on the Transmitter PCB. The periphery of the filter
disc assembly is slotted, with the slots being detected by the photo-interrupter. The three filter disc
assembly has thirteen slots, twelve of which are used to control the six samples, (one to start each
sample, one to end it) and a thirteenth, wider slot, which is detected by a discriminator circuit and
serves to identify the first filter. Pulse stream data can be monitored with an oscilloscope, at TP3
(wrt 0V) on the Transmitter PCB.
8. 26
SECTION 9: PARTS LISTS

LIST OF CONTENTS
Section
Page
9.1
INTRODUCTION...........................................................................................................................9.3
9.2
PARTS LISTS................................................................................................................................9.3
9.2.1
9.2.2
9.2.3
9.2.4
Source End Assembly .....................................................................................................9.3

Chopper Box ....................................................................................................................9.4
Detector End Assembly...................................................................................................9.5
Detector Box ....................................................................................................................9.7
9. 1
NOTES
9. 2
9.1
INTRODUCTION
This section lists parts numbers and names for use with disassembly of the analyser.
Spares list and recommended spares requirements can be found in the Section 7 of the 2500 User
Manual, including all window and window sealing spares.
Due to the large variation in sample cell types, other cell part numbers are not given here. Please
contact Servomex or their agents with details of cell type if replacement parts are required.
9.2
PARTS LISTS
9.2.1
Source End Assembly

Refer to Fig. 5.1a and 5.1b.
Item No.
Part No.
5
6
8
10
12*
12*
12*
13
14
15*
15*
15*
S2500989
S2500911A
02500502
02500463
S1200921
S1200922
S1200924
02500471
refer to 9.2.2
S2500981
S2500982A
S2500982B
Parts Name and Description

Gas strut kit
Power Control PCB
Cell thermocouple (300mm long sheath)
End boss
Scrubber - H2O Mix.
Scrubber - H2O/CO2 Mix
Scrubber - H2O/CO2/CO Mix
Casting insert
Source
Cell Servicing Kit (includes S2500982A)
Cell Seals Kit - Viton & PTFE seals
Cell Seals Kit - Chemraz seals
*Application dependent, refer to Analyser specification.
9. 3
9.2.2
Chopper Box
Refer to Fig. 5.3.
Item No.
1
2
3
5
6
7
9
10
12
13
14
15
16
17
19
20
21
22
23
24
25
27
28
29
30
31
32
33
34
38
Note:
9. 4
Parts No.
02500466
02520401
02500407
02520402
S2500931A
S2500931B
S2500931C
S2500943A
S2500943B
S2520933
2259-2543
3941-0555
2323-6297
2475-0941
2112-3014
01201414
Consult Servomex
2259-2543
02500410
02520403
S2500986
Consult Servomex
2356-1083
2321-4059
02500451
2323-6266
1723-8010
S2000511
S2000512
2666-2255
S2500906
2323-6398
2536-0329
S2500933A
S2500933B
S2500933C
S2500933D
S2500933E
2323-6297
2323-6273
02520922A
02520406
2259-1780
02510401
02500468

Chopper box, machined
Chopper box, 2520 analyser
Lid, chopper box, machined
Lid, chopper box, 2520 analyser
Source assembly
Zinc selenide
Barium fluoride
Calcium fluoride
Source (Short wave) CaF2
Source (Short wave) Glass
Source Soft UV CaF2
Screw, M4 x 16
Captive screw retainer
>O= ring, Viton
Adaptor, 5mm male x 4 O/D
Dowel, 4 O/D x 28mm long
Mount, filter
Cut-off filter
Screw, M4 x 16
Mounting plate
Mounting plate, 2520 analyser
Motor assembly
Filter wheel assembly
Plug, brass 3" BSPP (if fitted)
Sealing washer 3" BSP (if fitted)
Blanking plug, M25
>O= ring, Viton
Scrubber sachet (if fitted)
H20 Mix.
H20/CO2 Mix.
H2O/CO2/CO Mix.
Resistor, 10 ohm, 15W
Motor Connection PCB assembly
>O= ring, Viton
Thermal Fuse 98C
Lens assembly
Zinc selenide
Barium fluoride
Calcium fluoride
Crown glass
Germanium
>O= ring, Viton
>O= ring, Viton
Front lens assembly, CaF2, 2520 analyser
Source insulator, 2520 analyser
Screw, M3 x 30
Spacer, Motor Connection PCB (2510 & 2520)
Insulator mounting
>O= rings shown above are only available in Seals Kit Part No. S2500975.
Fixings are only available in Fixings Kit Part No. S2500974.
9.2.3
Detector End Assembly

Refer to Fig. 5.2a and 5.2b.
Item No.
Part No.
Part Name and Description
10
16
17
18
19
21
02500463
02501405
02501903
02501998
S2501999
00608333
00608334
02500418
02500449
S2500904A
02500493
02500415
02500416
* See Note 2
02000934
02000916
S2000925
Cell end boss

Display PCB cover
Display PCB
Keypad
Keypad and Display
Transformer (115/230V)
Transformer (100/200V)
Bracket
Transformer cover
Transmitter PCB
Cage Assembly
Side
Side
Cover
Processor PCB
SIB PCB
Option PCB
Power Supply
34
S2510901A
S2510901B
S2550901
Gas Filter Adaptor PCB (2510 x10 Gain)

Gas Filter Adaptor PCB (2510 x40 Gain)
Multicomponent Adaptor PCB (2550)
35
36
00022919
S2501352
Earth Strap Kit

Window
23
26
28
30
31
32
33
* Note:
1) Adaptor PCB item 34 is fitted to 2510 and 2550 analysers only.
2) Order spare Processor PCB or Firmware according to instrument type (refer to table below).
Instrument
Spare Processor PCB
Spare Firmware
02500C
S2500965A
S2550665FA
02510C
S2510965A
S2510665FA
02520C
S2500965A
S2550665FA
02550C
S2500965A
S2550665FA
9. 5
9.2.4
Detector Box
Refer to Fig. 5.4.
Item No.
1/3
Part No.
02500413
02510402, 02510403
02600413
7
8
9
10
11
12
13
14
15
S2501905A
S2501905B
S2501905C
S2600905
2475-0941
2112-3014
S1200921
S1200922
S1200924
2321-4035
2323-6134
02500412
2323-6297
02500933A
02500933B
02500933C
02500933D
02500933E
02500411

Box detector, screening 2500, 2550
2510 analyser
2520 analyser
Detector PCB Assembly :
CaF2 window
KRS - 5 window
CVD-FET /CaF2 /SW
UV Photo diode
Adaptor,5mm male x 4 O/D (if fitted)
Dowel pin 4 O/D x 28mm long (if fitted)
Scrubber Assembly (if fitted)
H2O Mix
H2O/CO2 Mix.
H2O/CO2/CO Mix.
Bonded seal
>O= ring Viton
Block, detector mounting 2500, 2550
>O= ring, Viton
Lens assembly
Zinc selenide
Barium fluoride
Calcium fluoride
Crown glass
Germanium
Boss, detector mounting 2500, 2550
Note that >O= rings shown above are only available in Seals Kit S2500975.
Note: Purge certified analysers do not have adaptor and dowel (items 7 & 8) or scrubber (item 9)
fitted.
9. 6
SECTION 10 : ENGINEERING DRAWINGS
Drawing Number
02501/171
02500/834
02500/835
Description
Power Distribution Circuit Diagram
Cell Assemblies 1 to 64mm Path Lengths
Cell Assemblies 128 to 1000mm Path Lengths
The engineering drawings in this manual are intended for guidance to component location only.
For component part numbers refer to the relevant section of this manual.
Servicing of faulty circuit boards is carried out on a PCB replacement basis.
10. 1
NOTES
10. 2
1701 SOUTH SUTRO TERRACE

CARSON CITY, NV. 89706
TELEPHONE (800) 993-9309
(775) 883-2500
FAX: 775-883-6388
MODEL 3040
SINGLE CHANNEL
SAMPLE COOLER
See us on the WEB at http://www.universalanalyzers.com

e-mail address: sales@universalanalyzers.com
MAN3040 Rev F

TELEPHONE (800) 993-9309
(775) 883-2500
FAX: 775-883-6388
LIMITED WARRANTY
ALL PRODUCTS MANUFACTURED BY UNIVERSAL ANALYZERS INC. ARE
WARRANTED TO BE FREE OF MANUFACTURING DEFECTS FOR A PERIOD OF ONE
YEAR FROM THE DATE OF RECEIPT AT THE CUSTOMERS RECEIVING AREA AND
FOR AN ADDITIONAL PERIOD OF UP TO 90 DAYS IF THE PRODUCT IS PLACED IN
SERVICE AFTER BEING IN STORAGE. THIS WARRANTY COVERS MATERIALS AND
LABOR TO RESTORE ANY PRODUCTS TO ORIGINAL FACTORY SPECIFICATIONS IF
A DEFECT IS FOUND WITHIN THE WARRANTY PERIOD.
THE DEFECTIVE PRODUCT SHOULD BE SENT, FREIGHT PREPAID, TO THE
FACTORY IN CARSON CITY, NEVADA. REPAIRS WILL BE PERFORMED AT THE
FACTORY AND RETURNED, PREPAID, BY THE SAME SHIPPING METHOD USED TO
SEND THE PRODUCT TO THE FACTORY.
THIS WARRANTY DOES NOT APPLY WHERE THE EQUIPMENT HAS SUSTAINED
DAMAGE DUE TO NEGLECT, MODIFICATION, CORROSION, OR OTHER REASON
BEYOND THE SCOPE OF THE NORMAL DEFINITION OF MANUFACTURING
DEFECT.
FURTHER, THIS WARRANTY IS LIMITED TO REPLACING THE DEFECTIVE
COMPONENTS AND RETURNING THE EQUIPMENT MANUFACTURED BY
UNIVERSAL ANALYZERS INC. TO THE CUSTOMER IN WORKING CONDITION. ANY
OTHER CLAIMS ARE OUTSIDE THE SCOPE OF THIS WARRANTY. NO WARRANTIES
ARE MADE AS TO THE SUITABILITY OF THE USE OF THE EQUIPMENT IN ANY
PARTICULAR APPLICATION OR LOCATION. THE SUITABILITY OF THE USE OF THE
EQUIPMENT IS THE RESPONSIBILITY OF THE CUSTOMER AND THE INSTALLING
CONTRACTOR.
Universal Analyzers Inc.

TELEPHONE: (775) 883-2500
CARSON CITY, NV 89706

FAX: (775) 883-6388
UNIVERSAL ANALYZERS MODEL 3040 SAMPLE COOLER

SPECIFICATIONS
SAMPLE FLOW RATE:
0 to 6 L/M (at STP)
MAXIMUM INLET TEMPERATURE:

STAINLESS STEEL HEAT EXCHANGER:
KYNAR/GLASS HEAT EXCHANGER:
700o F. (371o C.)

280o F. (138o C.)
MAXIMUM INLET GAS DEW POINT:
180o F. (82o C.)
MAXIMUM INLET WATER CONCENTRATION:
50%*
MINIMUM AMBIENT TEMPERATURE:
32o F. (0o C.)
MAXIMUM AMBIENT TEMPERATURE:
105o F. (41o C.)*
MAXIMUM COOLING POWER, (SECOND STAGE):
126 BTU'S/Hr. (120 kJ/Hr.)
OUTLET SAMPLE DEW POINT:
41o F. (5o C.), adjustable
MAXIMUM INPUT POWER:
350 WATTS
VOLTAGE:
95-125 VAC, 50/60 Hz or

190-250 VAC, 50/60 Hz
ELECTRICAL CLASSIFICATION:
NEMA 1
Class I, Grps. A, B, C, & D,
Division 2 (FM Approved)
DIMENSIONS:
18" x 7 1/2" x 11", HWD
WEIGHT:
33 LB's., (15 KG)
SOLUBLE GAS REMOVAL RATES:
NO
NO2
SO2
CO
CO2
*at reduced flow rates. See capacity chart.
3040 Manual Rev A
0% LOSS
<10% LOSS
< 2% LOSS
0% LOSS
< 2% LOSS
MODEL 3040 SAMPLE COOLER

OPERATING INSTRUCTIONS
APPLICATION
In order to analyze combustion products or incinerator effluents utilizing a direct
extractive sampling technique, it is important to remove the water vapor without
removing the water soluble fraction(s) from the gas sample. The heat exchangers
(impingers) used in the Universal Analyzers gas sample coolers are designed to minimize
the gas/condensate area and time of contact to reduce to a minimum, the amount of mass
transfer of those water soluble components from the gas phase into the liquid phase. The
result is a dry gas sample which has the same composition on a dry basis before and after
passing through the chiller.
A gas sample is usually taken from a stack with a probe extending into the center of the
stack mounted onto or adjacent to a heated filter. The heated filter is maintained at a
temperature above the dew point of the stack gas, usually 300o to 400o F. in order to
avoid cementing the filtered particulates to the filter medium with condensate. A means
is usually provided to automatically blow the particulates trapped by the filter, back into
the stack on a periodic basis.
The stack gas sample is clean but "wet" after passing through the filter assembly. The
moisture in the gas sample comes from the fuel as a product of combustion, from the
humidity in the air which supports the combustion and from the water content which was
trapped in the fuel. This latter source of water in the sample can be from burning moist
coal, wet garbage, or from water injected into the fire box. Water from all of these
sources will remove the water soluble gasses from the sample stream if allowed to
condense in the sample line prior to the controlled separation within the Universal
Analyzers' heat exchangers in the sample cooler.
In order to maintain the temperature of the gas sample above the dew point as it is
transported to the gas sample cooler, a heat traced sample line is usually employed. The
heat traced sample line can be very short if the gas sample cooler is located close to the
heated stack filter or it could be several hundred feet long if the gas sample cooler is
located in the analyzer shack some distance from the stack.
The Universal Analyzers gas sample cooler contains the special impinger type heat
exchanger(s). These are mounted within heat transfer blocks which are cooled by
thermoelectric elements utilizing the "Peltier Effect" discovered in France over half a
century ago. Where high water contents are encountered, it is efficient to remove the
condensate in two stages, one at the temperature of the air in the vicinity of the
"Precooler" and then by passing the sample into a heat exchanger cooled by the
thermoelectric elements. The precooler can remove water which will condense at the
temperature of the environment. In high water content samples, this could be as much as
80% of the water in the sample.
The thermoelectrically cooled stage is temperature controlled at a factory setting of 5o C.

This temperature can be adjusted with a set point potentiometer easily as described
below.
The gas sample conditioning system should contain additional components to insure that
a clean, dry sample is presented to the analyzer panel for minimum analyzer maintenance.
A sensor should be provided to sense the presence of condensate, should any exist in the
tubing following the chiller. This is the optional WCO (Water Carry-Over) sensor which
can be provided with a Universal Analyzers chiller. A visible coalescing filter which
collects particulates on the outside of the cylindrical filter, surrounded by a transparent
bowl will allow the operator to inspect the condition of the heated stack filter. The WCO
sensor can be provided with the sensing elements in the bottom of the filter bowl to
provide an early warning if the coalescing filter removes liquid from the sample stream.
This combination filter/moisture sensor is called the "WCOF".
The location of the sample pump (usually an oil-less diaphragm pump) within the
sampling system is the subject of much debate. If the pump is located upstream from the
chiller, it should have a heated head to avoid the presence of a two phase mixture which
shortens the life of a diaphragm and causes maintenance problems. It can be shown that
passing the gas sample through the chiller under a slight positive pressure will result in a
lower gas dew point than if the gas were at a slight vacuum. A common location for the
sample pump is in the sample line after the chiller. This allows the sample pump to
handle a cool, dry sample with much reduce maintenance problems. Some design
engineers have taken the approach to use a sample cooler having two chilled heat
exchangers. The pump is placed in the sample line between the two heat exchangers.
The first chilled heat exchanger takes enough of the water vapor from the sample to
protect the pump. The second heat exchanger is under a slight pressure and the dew point
is at it's minimum because it is on the discharge side of the pump. The sample pump
location within the sample system is a matter of choice and good engineering.
The condensate must be removed from the heat exchanger(s) using one of the following
methods:
1. A continuously running peristaltic tubing pump can be used
with the heat exchanger either under pressure or vacuum. This is an easy
solution which lends itself to leak testing because of the positive
displacement nature of the peristaltic pump. It is, however, a device which
requires periodic maintenance to replace the tubing.
2. Condensate can be removed from the heat exchanger using an
eductor with a flow limiter to draw some of the hot, wet sample through
the heat exchanger along with the condensate. This method utilizes the
heat exchanger as a bypass condenser and serves the purpose of reducing
the time lag in the sample line without loading the chiller with the water
vapor in the bypassed sample.
3. A float drain trap can be used to collect the condensate running

out of the bottom of the heat exchanger(s) if the heat exchangers are at a
slight positive pressure with respect to the atmosphere. The float drain
trap functions like a steam trap. The float rises to discharge the
condensate when there is enough to lift the float.
4. A small drain tank can be provided with a dual level,
conductivity type level control to collect the condensate. When the tank if
full, the level controller will start a pump to remove the condensate until it
reaches to the lower electrode. When contact is lost, the pump stops and
the condensate is again allowed to fill the tank. Typically, a peristaltic
pump is used to remove the condensate. The advantage is that the pump
only runs occasionally and bypasses no gas sample. The peristaltic pump
requires less maintenance because it does not run continuously.
Finally, a means of controlling the flow of the sample to the analyzers must be
considered. This can be as simple as providing a flow meter with a flow control needle
valve to pinch off the sample flow causing the sample pump to pump higher on the pump
curve. One option which is used is to provide an adjustable back-pressure regulator
between the inlet and outlet of the sample pump to allow a portion of the gas pumped to
be recirculated back to the inlet if discharge pressure exceeds the back-pressure control
point. Some analyzers have their own sample pump which may be sufficient to supply
the analyzer but insufficient to pull the sample through the chiller, sample line, and
heated stack filter. These can be supplied by piping the sample from the external sample
pump into the run of a tee with a flow meter which registers the flow of excess sample
from the branch of the tee to atmosphere. The internal analyzer sample pump can then
withdraw sample from the opposite run of the tee which is essentially at atmospheric
pressure and unaffected by pressure changes within the sample line due to changes in
filter pressure drop or sample pump efficiency.
DESCRIPTION
The key to the success of the Universal Analyzers Sample Cooler being able to condense
the water from a wet gas sample with a minimal loss of the water soluble gas fraction, is
due to the design of the heat exchanger. Please refer to Drawings P0146 thru P0149. The
separation occurs in a classical impinger which has a highly polished cylindrical surface
cooled to the desired dew point temperature. The hot wet sample is brought to the bottom
of the cylinder through an insulated tube and allowed to rise through a narrow annular
area at a relatively high Reynolds number to insure the entire sample is influenced by the
cold surface. The condensate falls down the cold polished surface in the form of a sheet
(as opposed to droplets or the bubbling of the gas sample through the condensate) which
minimizes the surface area in contact with the gas sample.
The temperature of the cylindrical condensation surface of the heat exchanger is
maintained through intimate contact with an aluminum heat transfer block. In the Model
3040 Sample Cooler, the heat transfer block is cooled by the use of two Thermoelectric
Elements at a controlled temperature. The factory temperature setting is 5o C. The
temperature sensor is an AD592 semiconductor device. The controller is a proportional
controller with a proportional band of about 1o C. The set point is field adjustable by
opening the door on the front of the chiller, moving a jumper (J3) with needle nose pliers,
and adjusting a trim-pot to a new temperature value shown on the display. The jumper
needs to be placed in the original position to, again, indicate the temperature of the heat
transfer block.
The heat which is removed from the gas sample (and that which is created by the
Thermoelectric Elements) is discharged by a heat sink which is cooled with a centrifugal
drum blower. The turbulence and velocity provided by the high static pressure capability
of the blower allows for efficient cooling of the heat sinks. The heat sinks are fabricated
from solid blocks of aluminum which eliminates the epoxy joints in more conventional
heat sink designs which are barriers to heat conduction. The result is a heat removal
system with superior performance under all conditions.
Universal Analyzers Thermoelectric Sample Coolers have a digital display as a front
panel indication of the of the operating temperature, (o C.) of the heat exchangers. In
addition, there are two green LED lamps to indicate the status of the cooler. The
"COOL" lamp lights when the operating temperature is between 0o C and 10o. If the
operating temperature is above or below this range, the light will be out and the alarm
relay will be in the alarm position. The "DRY" lamp indicates that there is no water in
contact with the moisture sensor listed as the "WCO" or "WCOF" options. If the "DRY"
lamp is out, the alarm relay will be in the alarm position.
The alarm relay is a single relay activated by either of the above alarm conditions. The
alarm relay is energized in the "safe" condition and will relax into the de-energized, alarm
position if a fault is detected. If a broken thermocouple occurs, the result will be that the
temperature indication is out of range and the alarm relay will indicate a fault.
A thermal switch is mounted on the heat sink to serve as a safety device to turn off power
to the thermoelectric elements if the heat sink approaches 160o F. This protects the
thermoelectric elements from melting in the event high temperature conditions are
encountered for any reason.
The 3000 Series thermoelectric sample coolers are designed to incorporate a peristaltic
pump for condensate removal within the enclosure to reduce the total volume required for
the system installation. Alternatively, it also has provisions for incorporating an eductor,
air filter, and dual heat sample pump with the second head used for generating the
necessary compressed air for the eductor.
Electrical connections are made to external wiring which will enter conduit fittings on the
bottom of the chiller. Internal conduit tubes direct the wires as they are pushed into the
chiller into the vicinity of the terminal strips.

accessible from the front of the chiller.
All of the terminal strips are easily
If it is desired to connect conduit to the chiller, a conduit coupling can be screwed onto
the 1/2" male conduit threads which extend from the bottom.
"PEM Nuts" are provided on the right hand side to mount accessories such as a sample
pump, visible filter, condensate alarm sensor, and flow meter. These options can be user
or factory installed.
The chiller can be changed from 115 VAC to 230 VAC operation with the movement of a
circuit card on the power supply. Accessories such as the sample pump or peristaltic
pump must be rated for the correct supplied line voltage.
INSTALLATION INSTRUCTIONS
Thermoelectric Sample Coolers should be installed away from heat sources in a well
ventilated area of an instrument rack or enclosure. Completely enclosing any instrument
which consumes as much power as a thermoelectric chiller will cause the temperature of
the interior of an unventilated enclosure to rise to too great a level for the sample cooler
to perform reliably. Where it is necessary for the enclosure to be tightly gasketed, a water
cooled thermoelectric chiller should be used. Contact the factory for recommendations.
Air purging an enclosure does not provide enough ventilation to remove the heat which
will be generated internally by the sample chiller. On the other hand, there are air
conditioners and vortex coolers which can provide the necessary cooling for enclosing
thermoelectric chillers.
The 3000 series sample cooler has a flange on the top and bottom to allow it to be wall
mounted or mounted to rails in an instrument rack. Accessories mounted on the side can
be supported by the mounting flange on the cooler.
A 3/8" tubing fitting is provided at the top of the heat exchanger as the sample inlet. The
dry sample outlet from the cooler is the 1/4" Kynar tubing fitting coming out of the top of
the heat exchanger at an angle. The gas sample should be further conditioned with an
additional filter as a safety measure before it enters the analyzer(s). The WCOF visible
filter which incorporates a safety moisture sensor is designed for this purpose. A similar
filter without the moisture sensor is also available from Universal Analyzers. A separate
moisture sensor, the WCO, can also be provided where the user prefers that form factor.
Contact the factory for drawings.
A sample pump is normally required to pull the sample through the sample cooler and to
force it through the visible filter. The moisture sensor, if not a part of the visible filter
should be located ahead of the visible filter.
There must be a method to remove the condensate from the heat exchanger. Several
methods are discussed above. A drain line from the peristaltic pump, eductor, or drain
pot must be run to sewer, a container, or to the ground outside the instrument enclosure to
avoid collecting water (condensate) on the floor.
If an eductor is utilized to remove the condensate, the outlet tube length should be no
longer than two feet in order to keep too much back pressure from the outlet of the
eductor. The outlet tube can be placed in a larger pipe to channel the condensate to a
drain.
The electrical power, about 3 amps at 115 VAC or 1.5 amps at 230 VAC 50/60 HZ
should be supplied. Installation shall be in accord with the manufacture's instructions and
the National Electrical Code (ANSI/NFPA 70). Tampering and replacement with
nonfactory components may adversely affect the safe use of the system. For the 115
VAC case, a power cord is supplied. It can be replaced with conduit wiring easily. See
the electrical installation Drawing P0093. The alarm relay has two sets of "Form C"
contacts brought out to the center terminal strip, TB2. One set are totally dry contacts.
The other set are MOV protected and designed to interrupt power to the sample pump
when in the alarm condition. When the pump is powered through the connector on the
power supply board, the MOV protected contacts are hot, with line power supplied.
The moisture sensor can be connected to the "Viking" connector mounted on the exterior
of the cabinet below the heat exchangers or, alternatively, connected to TB3 on the power
supply board.
START UP PROCEDURE
Apply power to the sample cooler. The indicated temperature will start to drop
immediately. It should be below the over-temperature alarm point in approximately four
minutes and the "COOL" green LED lamp should light. When the temperature reaches
the control set point, the rate at which the temperature drops will be reduced. The
temperature will stabilize within 1o C. of the control set point.
Start the sample gas flow by turning on the sample pump and adjusting the flow control
valve to the desired flow rate. Water should be observed to be removed from the bottom
of each heat exchanger when steady state conditions are established.
If an eductor is utilized to remove the condensate, a strong flow of air should be felt to be
flowing from the eductor outlet tube. The outlet tube length should be no longer than two
feet. The outlet tube can be placed in a larger pipe to channel the condensate to a drain.
The green "DRY" LED light will be on. If an optional moisture is installed, the light will
go out and the alarm relay de-energized when the sensor detects condensate. A test can
be performed by putting water on the moisture sensor. If the sample pump is powered
through the alarm relay contacts, it will cease running. When the moisture sensor is
wiped dry, the sample pump will start.
Turn on the analyzer(s) and initiate the calibration cycle.
TROUBLE SHOOTING
The presence of water in liquid form after the sample cooler is an indication of a fault in
the system. Reasons for the presence of condensate in the system after the sample cooler
could be one or more of the following:
1. Overloading of the cooling capacity of the cooler due to too
much water vapor in the sample or due to too great a sample flow rate.
2. The condensate removal equipment (peristaltic pump, eductor,
or drain pot) may be faulty. The heat exchanger(s) may be full of
condensate.
3. An air leak may be in the condensate removal system allowing
air to enter and blow the condensate back into the heat exchanger. (This
assumes the heat exchanger is under a slight vacuum.)
4. The temperature of the air passing through the cooler to cool the
heat sink is too high. This could be due to placement of the cooler in a
tightly sealed box.
5. The sample cooler could have failed.
Dimensional drawings, installation drawings, and schematics are included as part of this
manual. If additional information is required, telephone assistance can be obtained by
calling (775) 883-2500 or FAX request to (775) 883-6388.
D
NOTICE
REVISION OF THIS DOCUMENT
MUST BE AUTHORIZED BY
APPROPRIATE APPROVAL AGENCIES
7-1/2"
5-1/2"
FM
WET SAMPLE GAS

INLET
3/8" TUBE FITTING
APPROVED
11-1/4" 11-3/4"
DRY SAMPLE GAS

OUTLET
1/4" TUBE FITTING
HOLES FOR
1/4" BOLTS
(4 TYP)
(BOLTS SUPPLIED
BY OTHERS)
THERMOELECTRICALLY
COOLED STAGE
EX
HA
US
T
AIR
FL
OW
SOLID STATE
RELAY
DISPLAY
CIRCUIT BOARD
HIGH PRESSURE
BLOWER/S
HEAT SINKS
17"
EX
HA
US
T
18"
EX
HA
US
T
EX
HA
US
T
AIR
AIR
FL
OW
FL
OW
FL
OW
5,
46
5,
57
POWER SUPPLY
CIRCUIT BOARD
AIR
3
1/2" CONDUIT PORT
(2 TYP)
OPTIONAL
SINGLE HEAD
PERISTALTIC PUMP
CONDENSATE DRAIN
LINE
USER ACCESSABLE
TERMINAL BLOCKS
B 04/16/98
A 1/25/94
REV
SINGLE IMPINGER
THERMOELECTRIC
SAMPLE COOLER
FONT/PATENT #/NEW HEAD/RELAY EAM TB

LARGE TEXT/PAT PEND ADDED HWM TB
DATE

OUTLINE
PART NO.
FOR
UNIVERSAL ANALYZERS INC.
1701 S. Sutro Terrace

Carson City, Nevada 89706 USA
DRAWING NO
HARVEY MITCHELL
P0082
TED BARBEN
DATE
SCALE
SIZE
12/16/93
1:1
C
DRAWN BY
APVD BY
DWN APVD
DESCRIPTION
REVISIONS
SHEET
1 OF 1
13 5/8"
5 1/2"
3 13/16"
WET GAS
SAMPLE INLET
3/8" TUBING
FITTING
SAMPLE COOLER
DRY SAMPLE GAS

TO ANALYZER
18 13/16"
18"
17"
SINGLE HEAD
ADI MINI
DIA-VAC
PUMP
8
,57
65
5,4
PERISTALTIC
PUMP HEADS
B
5,465,57
WATER
CARRY OVER
SENSOR
CONNECTOR
FLOW METER
VISIBLE FILTER
WITH WATER
CARRY OVER
SENSOR
FRONT VIEW
DESCRIPTION
REV DATE
DWN APVD
REVISIONS
3000 SERIES SAMPLE COOLER

ACCESSORY OUTLINE FOR
SYSTEMS WITH PERISTALTIC PUMP
FOR
INSTRUMENT
PART NO.
NOT ISSUED
ISOMETRIC VIEW

1701 South Sutro Terrace
DRAWN BY
APVD BY
DATE
07/07/1998
DRAWING NO
E. Musselman
T. Barben II
P0294
SCALE
1:1
SIZE
E
SHEET
1 OF 1
24V
ADJ
+ 4
+ 3
+ 2
SOLID STATE RELAY

MODEL Z240D10
+ 1
+3
TB3
W
C
O
RED
BLACK
POWER SUPPLY
BOARD
PELTIER CONNECTIONS
RED
BLACK
RED
BLACK
RED
BLACK
RED
BLACK
RED
1
2
MOISTURE
SENSOR
CONNECTOR
-4
- CAUTION TERMINALS
1,2, & 3 ARE
HOT WHEN
SAMPLE
PUMP IS
INSTALLED
TB2
PELTIER
ELEMENTS
A MOV PROT.
L N.C. 1
2
A
R N.O. 3
M
R
E
L
A
Y
#1
N.C.
DRAIN
5
N.O.
#4
BLOWER
6 AMP FUSE
MODELS
3040
3050
3080
JUMPER CARD
115V
230V
12 AMP FUSE
TB1
P HOT L1
O
W COM L2
E
R
SAMPLE
DRY CIRC.
1
2
3
MODEL
3080
BLOWER
BLACK
BLUE
RED
GREEN
BLACK
#2
WHITE
G
B R
BL LAC EEN
AC K
K
#3
AD592
BL
AC
K
IN
DRA
D
RE
DR
AIN
RE
D
K
AC
BL ACK
BL
THERMAL
SAFETY
SWITCH
MOISTURE SENSOR
CONNECTOR
R
PERISTALTIC
DRAIN PUMP
3
FM
APPROVED
NOTICE
DISPLAY BOARD
2
(JUMPER)
TEMPERATURE
OR
SET POINT
TEMP
SET
10/24/03
REV
DATE
SSR CONNECTIONS TO 1-BLK / 4-RED

DESCRIPTION
REVISIONS
EM
PART NO.
FOR

CALIBRATION ADJUST
(FACTORY SET)
DRAWN BY
DRAWING NO
APVD BY
P0093
HARVEY MITCHELL
TED BARBEN
DATE
SCALE
3/17/94
NONE
TEMPERATURE
SENSOR
MODEL 3040 3050 3080

INTERNAL 115VAC WIRING
DIAGRAM
POWER
SUPPLY
SET POINT
ADJUST
TB
DWN APVD
SIZE
SHEET
1 OF 2
24V
ADJ
+ 4
+ 3
+ 2
SOLID STATE RELAY

MODEL Z240D10
+ 1
+3
TB3
W
C
O
RED
BLACK
POWER SUPPLY
BOARD
PELTIER CONNECTIONS
RED
BLACK
RED
BLACK
RED
BLACK
RED
BLACK
RED
1
2
MOISTURE
SENSOR
CONNECTOR
-4
- CAUTION TERMINALS
1,2, & 3 ARE
HOT WHEN
SAMPLE
PUMP IS
INSTALLED
TB2
PELTIER
ELEMENTS
A MOV PROT.
L N.C. 1
2
A
R N.O. 3
M
R
E
L
A
Y
#1
N.C.
DRAIN
5
N.O.
#4
BLOWER
6 AMP FUSE
MODELS
3040
3050
3080
JUMPER CARD
115V
230V
12 AMP FUSE
TB1
P HOT L1
O
W COM L2
E
R
SAMPLE
DRY CIRC.
1
2
3
MODEL
3080
BLOWER
WHITE
BLUE
BLACK
RED
GREEN
#2
WHITE
G
B R
BL LAC EEN
AC K
K
#3
AD592
BL
AC
K
IN
DRA
D
RE
DR
AIN
RE
D
K
AC
BL ACK
BL
THERMAL
SAFETY
SWITCH
MOISTURE SENSOR
CONNECTOR
R
PERISTALTIC
DRAIN PUMP
3
FM
APPROVED
NOTICE
DISPLAY BOARD
2
(JUMPER)
TEMPERATURE
OR
SET POINT
TEMP
SET
10/24/03
REV
DATE

DESCRIPTION
REVISIONS
EM
PART NO.
FOR

CALIBRATION ADJUST
(FACTORY SET)
HARVEY MITCHELL
APVD BY
TED BARBEN
DATE
SCALE
3/17/94
NONE
DRAWN BY
TEMPERATURE
SENSOR
MODEL 3040 3050 3080

DIAGRAM
POWER
SUPPLY
SET POINT
ADJUST
TB
DWN APVD
DRAWING NO
P0093
SIZE
SHEET
2 OF 2
TO
DISPLAY
BOARD
POWER SUPPLY
BOARD
24V
ADJ
+ 4
+ 3
+ 2
+ 1
TB3
W
C
O
RED
1
2
MOISTURE
SENSOR
CONNECTOR
-CAUTIONTERMINALS
1,2 & 3 ARE
HOT WHEN
SAMPLE
PUMP IS
INSTALLED
TB2
R
E
L
A
Y
DRY CIRC.
N.C.
4
5
N.O.
BLACK
WHITE
GREEN
DRY CIRCUIT
TO ALARM
(CONTACT CLOSES
WHEN IN ALARM)
6 AMP FUSE
SAMPLE
DRAIN
BLOWER
JUMPER CARD
115V
230V
12 AMP FUSE
TB1
P HOT L1
O
W COM L2
E
R
SAMPLE PUMP
A MOV PROT.
L N.C. 1
2
A
R N.O. 3
M
1
2
WATER CARRY OVER

FILTER
L 1(HOT)
L 2(COMMON)
WATER CARRY OVER SENSOR

WITH FLOW THRU ADAPTER
TERMINAL BLOCK
WIRED
A 01/05/00 ADD PAGES 2 & 3 TO DRAWING PACKAGE

REV DATE
DESCRIPTION
EAM JK
DWN APVD
REVISIONS
MOISTURE SENSOR
CONNECTOR
OR
EXTERNAL WIRING DIAGRAM
FOR MODELS 3040 3050 3080
OR
PART NO.
NOT ISSUED
FOR
INSTRUMENT

DRAWING NO
H. MITCHELL
P0094
T. BARBEN II
DATE
SCALE
SIZE
03/17/1994
1:1
D
DRAWN BY
APVD BY
SHEET
1 OF 3
TO
DISPLAY
BOARD
POWER SUPPLY
BOARD
24V
ADJ
+ 4
+ 3
+ 2
+ 1
TB3
W
C
O
RED
1
2
MOISTURE
SENSOR
CONNECTOR
-CAUTIONTERMINALS
1,2 & 3 ARE
HOT WHEN
SAMPLE
PUMP IS
INSTALLED
TB2
A MOV PROT.
L N.C. 1
2
A
R N.O. 3
M
R
E
L
A
Y
DRY CIRC.
N.C.
4
5
N.O.
SAMPLE PUMP
SAMPLE
DRY CIRCUIT TO ALARM

(CONTACT CLOSES
WHEN IN ALARM)
DRAIN
BLOWER
6 AMP FUSE
JUMPER CARD
115V
230V
12 AMP FUSE
TB1
P HOT L1
O
W COM L2
E
R
1
2
HOT
WATER CARRY OVER

FILTER
COMMON

SOLID STATE RELAY

MAX 240VAC 25 AMP
1
240V
TERMINAL BLOCK
WIRED
A 01/05/00 SHOW HIGH CURRENT PUMP & SOLID STATE RELAY EAM JK
REV DATE
DWN APVD
DESCRIPTION
REVISIONS
25A
115 / 230 VAC

3+
4
BLACK
MOISTURE SENSOR
CONNECTOR
HOT (CUSTOMER SUPPLIED VOLTAGE)
OR

FOR 115VAC HIGH CURRENT
SAMPLE PUMP APPLICATIONS
OR
PART NO.
FOR
NOT ISSUED MODELS 3040 3050 3080

DRAWING NO
H. MITCHELL
P0094
T. BARBEN II
DATE
SCALE
SIZE
03/17/1994
1:1
D
DRAWN BY
APVD BY
SHEET
2 OF 3
TO
DISPLAY
BOARD
POWER SUPPLY
BOARD
24V
ADJ
+ 4
+ 3
+ 2
+ 1
TB3
W
C
O
RED
1
2
MOISTURE
SENSOR
CONNECTOR
-CAUTIONTERMINALS
1,2 & 3 ARE
HOT WHEN
SAMPLE
PUMP IS
INSTALLED
TB2
A MOV PROT.
L N.C. 1
2
A
R N.O. 3
M
R
E
L
A
Y
DRY CIRC.
N.C.
4
5
N.O.
SAMPLE PUMP
SAMPLE

(CONTACT CLOSES
WHEN IN ALARM)
DRAIN
BLOWER
6 AMP FUSE
JUMPER CARD
115V
230V
12 AMP FUSE
TB1
P HOT L1
O
W COM L2
E
R
1
2
HOT
COMMON
WATER CARRY OVER

FILTER

SOLID STATE RELAY

MAX 240VAC 25 AMP
1
240V
TERMINAL BLOCK
WIRED
2
25A
115 / 230 VAC

3+
4
BLACK
L1 (CUSTOMER
SUPPLIED
VOLTAGE)
SOLID STATE RELAY

MAX 240VAC 25 AMP
1
240V
MOISTURE SENSOR
CONNECTOR
OR

OR
PART NO.
FOR

2
25A
115 / 230 VAC

3+
4
BLACK
REV DATE
DWN APVD
DESCRIPTION
REVISIONS

L2 (CUSTOMER SUPPLIED VOLTAGE)
DRAWING NO
H. MITCHELL
P0094
T. BARBEN II
DATE
SCALE
SIZE
03/17/1994
1:1
D
DRAWN BY
APVD BY
SHEET
3 OF 3
1/4" NPT
.400
D
.300
1-1/8"
.400
MOUNTING HOLE
FOR 10-32 SCREW
(2 TYP)
FLOW
.950
3"
1/4" NPT
3
1.500
24" CABLE
B 03/10/03 Revised P/N for Item 1 & 2
REV DATE
DESCRIPTION
REVISIONS
PART NO.
6020-0001
PART NO.
5101-0002
5101-0001
5205-0007
FOR
W.C.O.

DRAWING NO
H. MITCHELL
P0006
TED BARBEN II
DATE
SCALE
SIZE
B
10/08/1991
1:1
DRAWN BY
APVD BY
MODEL W.C.O. WATER

CARRY OVER MOISTURE
SENSOR WITH FLOW THRU
ADAPTER
TABLE A
ITEM NAME
1 HOLDER FLOW THRU BODY
2 KYNAR MOISTURE SENSOR ASSY
3 SENSOR LOCK ASSY KIT
RPH JK
DWN APVD
SHEET
1 OF 1
HOLES FOR #10 PANHEAD

MOUNTING SCREWS
(SUPPLIED BY OTHERS)
1/2"
3"
2"
1.65"
EXPLODED FRONT VIEW
3"
2"
2
COMPLETE
FILTER P/N
1"
5/8"
1
1 1/4"
8"
1
FILTER
INLET PORT
1/4" NPT
1
FILTER
OUTLET PORT
1/4" NPT
4980-0039
4980-0058
4980-0005
4980-0009
4980-0059
FILTER PRESSURE DROP RATINGS

ELEMENT
INCHES OF WATER
P/N
5 LPM 10 LPM 20 LPM
SINTERED S.S. 4980-0023
10
14
24
4980-0022
PAPER
8
12
20
4980-0006
TEFLON
4
6
10
4980-0007
CERAMIC
4
6
10
COATED CERAMIC 4980-0018
6
8
12
1 FOR COALESCING (COATED CERAMIC WCOF)

P/N 4980-0059 SAMPLE INLET & OUTLET PORTS
ARE REVERSED.
7
1/8"
08/24/04
REV
DATE
8
7
6
5
2
1
1
1
4
3
2
1
ITEM
MIDDLE
PIN
Revised with New Bowl Design & Ext. Cable

DESCRIPTION
REVISIONS
-
1
1
1
1
QTY DWG NO.
4704-0010
3907-0052
4904-0006
5205-0038
RPH
TB
VIEW "A" - 2x SCALE

VERIFY BEFORE CONNECTING THAT
MIDDLE PIN IS SHORTER THAN
OUTSIDE PIN. IF NOT, CUT MIDDLE PIN
AS SHOWN
10-32X3/8"PH
14" EXT. CABLE
O-RING 2-030
BOWL ASSEMBLY
5110-0012
SEE TABLE
5008-0004
5110-0011
PART NO.
A
LEFT SIDE
RETAINER
FILTER ELEMNT
BRACKET
KYNAR HEAD
DESCRIPTION
FOR
INSTRUMENT

DRAWN BY
DRAWING NO
APVD BY
P0018
HARVEY MITCHELL
TED BARBEN II
DATE
SCALE
04/14/92
1:1
RIGHT SIDE
PART NO.
SEE TABLE
DWN APVD
VISIBLE GAS FILTER WITH MOISTURE SENSOR

(W.C.O.F.)
ITEM #3 TYPE
SIZE
SHEET
1 OF 1
D
2-5/8"
INSULATED SECTION
TOP VIEW
CHILLED SURFACE
0.25" INSIDE DIAMETER
THERMOCOUPLE
(TYPE "K")
(TYPE "J")
(TYPE "T")
"L"
(SEE TABLE)
CONDENSATE DRAIN
3/8" NPT
(FEMALE)
ANNULAR SPACE .060" WIDE

(GAS TO BE DRIED RISES IN THIS SPACE)
SIDE VIEW
DRY GAS OUTLET

1/8" NPT
(FEMALE)
B
SAMPLE GAS INLET
1/4" NPT
(FEMALE)
1). SEE SHEET 2 FOR ASSEMBLY INSTRUCTIONS.
APPROX 316 S.S.

LENGTH EXCHANGER
"L"
P/N
5200-SK50
5"
5200-SJ50
5200-ST50
10"
5200-SK10
5200-SJ10
5200-ST10
HASTELLOY C276
EXCHANGER
P/N
5200-CK50
5200-CJ50
5200-CT50
ALLOY 20
EXCHANGER
P/N
5200-AK50
5200-AJ50
5200-AT50
5200-CK10
5200-CJ10
5200-CT10
5200-AK10
5200-AJ10
5200-AT10
TITANIUM
UNIVERSAL
EXCHANGER ANALYZERS
P/N
SERIES
5200-TK50
400
5200-TJ50
500
5200-TT50
800
5200-TK10
1000
5200-TJ10
1100
5200-TT10
3000
01/23/97
REV
DATE
SHOW NEW DESIGN W/THERMOCOUPLE BRACKET
HEAT EXCHANGER OUTLINE

PART NO.
SEE TABLE

EV MUSSELMAN
HARVEY MITCHELL
DATE
SCALE
12/11/95
1:1
FOR
SEE TABLE
APVD BY
HWM
DWN APVD
METALLIC TEMPERATURE SENSING
DRAWN BY
EAM
DESCRIPTION
REVISIONS
DRAWING NO
P0146
SIZE
SHEET
1 OF 2
EXPLODED METALLIC HEAT EXCHANGER

THERMOCOUPLE
ASSY.
(TYPE "K")
(TYPE "J")
(TYPE "T")
2-021 VITON
O-RING
P/N 4904-0013
(SEE NOTES)
METALLIC
OUTER TUBE ASSEMBLY
S.S. COMPRESSION FITTING

W/TEFLON FERRULES
P/N 4954-0095
1/16" TEFLON
THERMOCOUPLE SLEEVE
METALLIC
INNER TUBE ASSEMBLY
6-32 X 1/2"
PAN HEAD SCREW
"L"
LENGTH
5"
5"
5"
5"
5"
5"
5"
5"
5"
5"
5"
5"
10"
10"
10"
10"
10"
10"
10"
10"
10"
10"
10"
10"
MATERIAL
DESC.
316 S.S.
"
"
ALLOY 20
"
"
HASTELLOY C276
"
"
TITANIUM
316 S.S.
"
"
ALLOY 20
"
"
HASTELLOY C276
"
"
TITANIUM
"
"
COMPLETE ASSY
P/N
5200-SK50
5200-SJ50
5200-ST50
5200-AK50
5200-AJ50
5200-AT50
5200-CK50
5200-CJ50
5200-CT50
5200-TK50
5200-TJ50
5200-TT50
5200-SK10
5200-SJ10
5200-ST10
5200-AK10
5200-AJ10
5200-AT10
5200-CK10
5200-CJ10
5200-CT10
5200-TK10
5200-TJ10
5200-TT10
COMPLETE ASSEMBLY
SPARE PARTS LIST

OUTER TUBE
INNER TUBE
ASSY P/N
ASSY P/N
5201-0015
5201-0012
"
"
5201-0022
"
"
5201-0020
"
"
5201-0024
"
"
5201-0013
"
"
5201-0023
"
"
5201-0021
"
"
5201-0025
"
"
"
"
"
"
"
"
"
"
5201-0028
"
"
5201-0016
"
"
"
"
"
"
"
"
5201-0029
"
"
TYPE "K" THERMOCOUPLE

ASSEMBLY P/N
1150-0011
X
X
"
X
X
"
X
X
1150-0018
X
X
1150-0011
X
X
"
X
X
"
X
X
1150-0018
X
X
TYPE "J" THERMOCOUPLE

ASSEMBLY P/N
X
1150-0012
X
X
"
X
X
"
X
X
1150-0019
X
X
1150-0012
X
X
"
X
X
"
X
X
1150-0019
X
TYPE "T" THERMOCOUPLE

ASSEMBLY P/N
X
X
1150-0013
X
X
"
X
X
"
X
X
1150-0014
X
X
1150-0013
X
X
"
X
X
"
X
X
1150-0014
2). LIGHTLY LUBRICATE O-RING

WITH SILICONE GREASE BEFORE
ASSEMBLY.
INNER TUBE
MATERIAL IDENTIFIER
1). O-RING IS FACTORY INSTALLED

IN METALLIC OUTER TUBE ASSY.
2-56 X 1/2"
PAN HEAD SCREW
NOTES:
"L"
(SEE TABLE)
OUTER TUBE
MATERIAL IDENTIFIER
01/23/97
EAM HWM
REV
DATE
DESCRIPTION
REVISIONS
DWN APVD

HEAT EXCHANGER ASSEMBLY
PART NO.
SEE TABLE
FOR
400 500 800 1000 1100 3000 SERIES

DRAWING NO
EV MUSSELMAN
P0146
HARVEY MITCHELL
DATE
SCALE
SIZE
B
12/11/95
1:1
DRAWN BY
APVD BY
SHEET
2 OF 2
8
B
6
B
5
VITON O-RING
P/N 4904-0013
INSULATED
INNER TUBE
ASSY
OUTER TUBE
ASSY
.305 I.D.
SAMPLE
GAS
OUTLET
C
1/4"
TUBE
PLUG
1/16" NPT
A
TOP VIEW

SAMPLE GAS INLET

3/8" TUBE
SECTION A-A
HEAT
APPROX
LENGTH EXCHANGER OUTER TUBE MATERIAL
P/N
"L"
5"
5200-S050
316 S.S.
5"
5200-T050
TITANIUM
5"
5200-A050
ALLOY 20
5"
5200-C050
HASTELLOY C-276
5"
5200-S05T TEFLON COATED 316 S.S.
10"
5200-S010
316 S.S.
10"
5200-T010
TITANIUM
10"
5200-A010
ALLOY 20
10"
5200-C010
HASTELLOY C-276
10"
CONDENSATE
DRAIN 3/8"NPT
"L"
(SEE TABLE)
UNIVERSAL
ANALYZERS
SERIES
400/500
400/500
400/500
400/500
400/500
800/1000/1100/3000
800/1000/1100/3000
800/1000/1100/3000
800/1000/1100/3000
800/1000/1100/3000
02/09/99
REVISE P/N TABLE FOR TEFLON COATED
REV
DATE
DESCRIPTION
REVISIONS
EAM
RD
DWN APVD
HEAT EXCHANGER METALLIC

NON-TEMPERATURE SENSING
OUTLINE
PART NO.
SEE TABLE
FOR
SEE TABLE

1701 South SutroTerrace
Carson City, Nevada 897
06 USA
SECTION B-B
DRAWN BY
DRAWING NO
APVD BY
P0147
EV MUSSELMAN
H. MITCHELL
DATE
SCALE
12/11/95
NONE
SIZE
SHEET
1 OF 2
VITON O-RING
#2-021
SEE NOTES
D
OUTER TUBE ASSEMBLY METALLIC
INNER TUBE
MATERIAL
IDENTIFIER
"L"
INNER TUBE ASSEMBLY
OUTER TUBE
MATERIAL
IDENTIFIER
HEAT EXCHANGER
SEPERABLE
INNER
APPROX
P/N
TUBE ASSY
"L"
P/N
LENGTH
5"
5200-S050 5201-0015
5"
5200-T050
"
5"
5200-A050
"
5"
5200-C050
"
5"
5200-S05T 5201-0041
10"
5200-S010 5201-0016
10"
5200-T010
"
10"
5200-A010
"
10"
5200-C010
"
10"
5200-S01T 5201-0042
SPARE PARTS LIST

OUTER
VITON O-RING PLUG
TUBE ASSY #2-021 P/N 1/16"NPT
P/N
P/N
5201-0012
4904-0013 4951-0058
5201-0024
"
"
5201-0022
"
"
5201-0020
"
"
5201-0043
"
"
5201-0013
4904-0013 4951-0058
5201-0025
"
"
5201-0023
"
"
5201-0021
"
"
5201-0044
"
"
NOTES:
1). O-RING IS FACTORY INSTALLED IN
METALLIC OUTER TUBE.
2). LIGHTLY LUBRICATE O-RING WITH
SILICONE GREASE BEFORE ASSEMBLY. B
02/09/99
REV
DATE
REVISE TABLE TO INCLUDE TEFLON PARTS EAM

DESCRIPTION
REVISIONS
FOR
INSTRUMENT

6 USA
DRAWN BY
DRAWING NO
APVD BY
P0147
EV MUSSELMAN
H. MITCHELL
DATE
SCALE
12/11/95
NONE
RD
DWN APVD

METALLIC
PART NO.
SEE TABLE
SIZE
SHEET
2 OF 2
CHILLED SURFACE
INSULATED SECTION
THERMOCOUPLE
(TYPE "J")
(TYPE "K")
(TYPE "T")
TOP VIEW

2-5/8"
"L"
(SEE TABLE)
CONDENSATE DRAIN
3/8" NPT
(FEMALE)
SIDE VIEW
DRY GAS OUTLET
1/8" NPT
(FEMALE)
SAMPLE GAS INLET

1/4" NPT
(FEMALE)

GLASS KYNAR
LENGTH HEAT EXCHANGER
ASSEMBLY
"L"
P/N
5"
5200-KK50
5200-KJ50
5200-KT50
10"
5200-KK10
5200-KJ10
5200-KT10
15"
5200-KK15
5200-KJ15
5200-KT15
UNIVERSAL
ANALYZERS
SAMPLE COOLER
MODELS
520
530
540
570
1040
1050
1060
1080
1090
C 10/02/01
REV DATE
Add 15" Heat Exchanger Data To Table

DESCRIPTION
REVISIONS
Glass Kynar Temperature Sensing

Heat Exchanger Outline
PART NO.
SEE TABLE
FOR
SEE TABLE

FGA2
DRAWN BY
APVD BY
DRAWING NO
E. Mussleman
H. Mitchell
DATE
12/11/95
EM
JK
DWN APVD
P0148
SCALE
1:1
SIZE
SHEET
1 OF 2
EXPLODED GLASS KYNAR HEAT EXCHANGER

W/TEFLON FERRULES
P/N 4954-0095
THERMOCOUPLE
ASSY.
(TYPE "K")
(TYPE "J")
(TYPE "T")
1/16" THERMOCOUPLE
TEFLON INSULATOR
#2-120 VITON
O-RING
P/N 4904-0004
(SEE NOTE 2)
6-32 X 1/2"
PAN HEAD SCREW
GLASS TUBE
#2-018 VITON
O-RING
P/N 4904-0003
(SEE NOTE 2)
KYNAR INSULATED
SECTION ASSEMBLY
GLASS KYNAR
HEAT EXCHANGER
ASSEMBLY
LENGTH "L"
P/N
5"
5200-KK50
5200-KJ50
5"
5200-KT50
5"
10"
5200-KK10
10"
5200-KJ10
10"
5200-KT10
15"
5200-KK15
15"
5200-KJ15
15"
5200-KT15
KYNAR DRAIN
FITTING
P/N 5110-2002
(SEE NOTE 1)
KYNAR HEAD
P/N 5201-0017
(SEE NOTE 1)
SPARE PARTS LIST
KYNAR
TYPE "T"
TYPE "K"
TYPE "J"
GLASS
INSULATED SECTION
THERMOCOUPLE THERMOCOUPLE THERMOCOUPLE
TUBE
ASSEMBLY
P/N
P/N
P/N
P/N
P/N
1150-0013
1150-0012
5110-2003
1150-0011
5201-0002
"
"
"
"
"
"
"
"
"
"
5110-2004
5201-0001
"
"
"
"
"
"
"
"
"
"
"
"
"
5110-2006
5201-0078
"
"
"
"
"
"
"
"
"
"
"
"
"
NOTES:
1). O-RINGS ARE FACTORY INSTALLED
IN KYNAR HEAD AND KYNAR DRAIN FITTING.
2). LIGHTLY LUBRICATE O-RINGS
ASSEMBLY.
C
REV
10/02/01
DATE
Add 15" Data To Parts List Table

DESCRIPTION
REVISIONS
EM
JK
DWN APVD
Glass Kynar Temperature Sensing Heat Exchanger

Spare Parts List Exploded Assembly
PART NO.
SEE TABLE
7/8" WRENCH
FLATS

2-56 X 1/2"
PAN HEAD SCREW
FOR
SAMPLE COOLERS
DRAWN BY
COMPLETE GLASS KYNAR

APVD BY
DATE
12/11/95
DRAWING NO
E. Musselman
H. Mitchell
P0148
SCALE
1:1
SIZE
SHEET
2 OF 2

INSULATED SECTION
CHILLED SURFACE
PLUG
1/16" NPT
TOP VIEW
"L"
(SEE TABLE)
CONDENSATE DRAIN
3/8"NPT
SIDE VIEW
DRY GAS OUTLET

1/4" TUBE
B
SAMPLE GAS INLET
3/8" TUBE
LENGTH
"L"
5"
10"
15"
UNIVERSAL
QTY OF
GLASS KYNAR HEAT
ANALYZERS
EXCHANGERS PER
EXCHANGER
SAMPLE
COOLER
SAMPLE COOLER
ASSEMBLY P/N
MODELS
520
1
2
530
5200-K050
2
540
570
4
1040
1
1050
2
5200-K010
1060
2
1080
2
1090
4
FGA2
5200-K015
1
10/02/01
REV
DATE
Add 15" Data To Table
EM
DESCRIPTION
REVISIONS
HEAT EXCHANGER GLASS /

KYNAR NON-TEMPERATURE
SENSING OUTLINE
PART NO.
SEE TABLE
FOR
INSTRUMENT

DRAWING NO
EV MUSSELMAN
P0149
H. MITCHELL
DATE
SCALE
SIZE
C
12/11/95
1:1
DRAWN BY
APVD BY
RD
DWN APVD
SHEET
1 OF 2
PLUG
1/6"NPT
#2-120 VITON
O-RING
(SEE NOTE 2)
GLASS TUBE
#2-018 VITON
O-RING
(SEE NOTE 2)
KYNAR INSULATED
SECTION ASSEMBLY
KYNAR HEAD
(SEE NOTE 1)
KYNAR DRAIN
FITTING
(SEE NOTE 1)
C
GLASS KYNAR
HEAT EXCHANGER
ASSEMBLY
LENGTH "L"
P/N
5"
5200-K050
10"
5200-K010
15"
5200-K015
KYNAR
INSULATED
SECTION ASSY
P/N
5110-2003
5110-2004
5110-2006
SPARE PARTS LIST

KYNAR
GLASS
DRAIN
TUBE
FITTING
P/N
P/N
5201-0002
5110-2002
5201-0001
"
"
5201-0078
#2-120
VITON
O-RING
P/N
4904-0004
"
"
#2-018 VITON
KYNAR HEAD
O-RING
P/N
4904-0003
"
"
1/16" NPT PLUG
P/N
5201-0017
"
"
P/N
4951-0066
"
"
7/8" WRENCH
FLATS

NOTES:
10/02/01
REV
DATE

IN KYNAR HEAD AND KYNAR DRAIN
FITTINGS
EAM
DESCRIPTION
REVISIONS
PART NO.
SEE TABLE
FOR
INSTRUMENT

DRAWING NO
EV MUSSELMAN
P0149
H. MITCHELL
DATE
SCALE
SIZE
C
12/11/95
1:1
DRAWN BY
APVD BY
RD
DWN APVD

SENSING SPARE PART
INSTALLATION

ASSEMBLY.
Add 15" Data to Table
SHEET
2 OF 2
R13
C4
U2
TB1
C8
C14
R43
U6
C17 C21
R22
R37
R38
R40
U5
U4
CR5
J1
C24
R42
R28
R11
R8
R44
CR2
C11
C7
R20
CR9
CR1
C28
U9
R30
C23
C25
W1
R24
R27
C10
C12
C20
C27
U8
C26
R31
R23
C13
R17
R19
R32
U3
CR7
CR8
U1
CR4 CR3
R33
R16
R7
J3
R10
R14
R15
C
J5
C16
C15
C19
U7
C18
R35
C6
R3
R34
C22
R25
CR6
R5
R12
C3
R45
B
NOTES: UNLESS OTHERWISE SPECIFIED.
ITEM
DWG.
SIZE
DWG NO.
REVISIONS
UNLESS OTHERWISE INDICATED:

ANGLES = $$p 2$$a
MACHINED FINISH 300/OR BETTER
CHAMFER ANGLE = $$p 3$$a
CHAMFER LENGTH = $$p .015"
DIMENSIONS ENCLOSED IN A
ARE MORE CRITICAL THAN APPLICABLE
INDUSTRY STANDARDS.
ALL DIMENSIONS $$p .005" UNLESS
OTHERWISE SPECIFIED.
APV SYM DATE
ASSY OR B/M
CHANGE
TB C 1/16
98 REMOVED R10
TB B 5/24
95 REFDES U8 TO U6
TB A 2/13
94
FINISH
PER SPEC.
REQ'D
THIRD ANGLE PROJECTIONS
SUPERSCEDES
DWG.
K2
K1
R9
DIMENSIONS IN INCHES.
J6
B
Package To Prevent Handling
And Stocking Damage
C9
R18
R21
R2
R1
Q1
R36
R39
C5
Q2
R6
C1
R26
C2
R4
PART NO.
NAME
PART NO.
NAME
3600-0012
PARTS LOCATION
FOR
MODEL 3040/50/80 COOLER/DISPLAY

SCALE
FULL
DATE
2/13/94
INTERNATIONAL

SIZE
B
SHEET
DRAWING NO.
E0030
REV.
DWN. CHKD.APVD.ENGR.
MRM
TB TB TB
CONT. ON.
10
NOTICE
G
+VREF
R3
10K
+10V
R6
R7
49.9K
TEMP
SET
2K
27L2
7
U3
5 +
4
6
R9
1K
20T
8
U3
R45
R5
2.49K
1K
1
27L2
CR9
J5
1
C7 +15V
.1
MLC
R8
24.9K
R11
CR2
.47uf, POLYE
R12
C28
.1
MLC
C6
.1uf
MLC
J1
1
TP GND
J1
2
+VREF
SET
R16
10K
10K
-VREF
TEMP
CAL
+15V
R20
10K
J3
R21
J1
4
COM
1K
20T
R17
8.66K
R19
J1
3
J1
5
+15V
R23
4.99K
C12
.1uf
MLC
C10
R24
4.99K
C13
.1uf
MLC
100K
8
U4
1
U4
4 27L2
R27
10K
+10mv/ C
-VREF
R31
10K
1 MEG
3
10K
U5
4 27L2
R37
R35
15K
1K
+15V
DRY
8
U5
7
27L2
11
12
13
14
U6
10
4025
8
2
1
U6
R42
R36
24.9K
Q2
WET/DRY
J5
6
100K
U6
C20
.1uf
MLC
7 4025
J5
3
+10V
C19
.1uf
MLC
CR6
LM385 -2.5
+VREF
(+5V)
-VREF
(+2.5V)
C22
.1uf
MLC
W1
+5V
8 2
C26
15uf
TANT
C15
15uf
TANT
B
REV DATE
CHANGE
06/07
99
REV DATE
1
6
7
15uf
TANT
U9
7660S
4
5
-5V
C27
15uf
TANT
NAME:3000 SERIES LOW TEMP

SCHEMATIC
CONTROLLER/DISPLAY
FOR
PART NO. 3600-0033
UNIVERSAL DATE: 2/12/98

ANALYZERS
C E0061
INC.
RELAY
DRIVE
C25
3). ALL DIODES ARE 1N4148.

2). ALL RESISTORS ARE IN OHMS.
1). ALL RESISTORS ARE 1/4W, 1%, 50ppm/ C.
CR5
R40
499ohm
R39
100K
U7
C18
.1uf
MLC
2N4401
4025
5
4
3
J5
2
1 MEG
CR4
GRN
78L05
R33
2K
R41
2K
COM
J5
5
C17
.1uf
MLC
CR3
GRN
COOL
+15V
+15V
6
+15V
HOT=HIGH
COOL=LOW
DISPLAY
+15V
C16
15uf
TANT
C21
.1uf
MLC
FROZEN=HIGH
OK=LOW
U1
3 1/2
DIGIT
LCD
J5
4
TEST
C14
.01uf
R38
10
+VREF
+15V
R30
R34
10K
+VREF
26
+VREF
+VREF R32
32
TEST
21
16
22
18
19
2
3
4
5
6
7
8
9
10
11
12
13
14
15
17
20
23
24
25
BP
B3
G3
OSC2 E3
B4
OSC1 D1
CREF C1
B1
CREF A1
U2 F1
7136 G1
E1
A/Z
D2
C2
B2
BUFF
A2
F2
INT
E2
D3
F3
IN+
INPOL
REF+
A3
REFC3
TEST G2
1
G
16
12
8
28
38
39
40
1
29
32
9
3
18
19
20
21
22
23
17
14
15
24
25
26
13
10
31
2
30
11
27
Q1
-100mv/ C
+VREF
J6
39
C2
33
.47uf POLYE
C4
29
.47uf POLYE
R13
28
1.74 MEG
C8
27
.15uf POLYP
31
30
+VREF
36
35
R26
37
10K
R43
15K
R1
2N4401
R2
100K
1
38 OSC3
549K
1 MEG
+10V
+VREF
+VREF +VREF
-VREF
C9
.01uf
47pf
R4
27L2
R28
10K
.47uf
POLYE
2
1 MEG
+VREF
0 C=0V
25 C=+.25V
w.r.t. +VREF
.1uf, MLC
R25
R18
TEMP
C11
100K
C24
.1uf
MLC
TEMP
SENSOR
-
R22
4.99K
R15
+10V
APPROVED
P/S
CONTROL
3
R
40
34
24.9
1 MEG
R14
20K
FM
C1
R44
10K
CR1
C3
C5 -5V
.1uf
MLC
+VREF
+5V
TP PS
+10V
+10mv/ C
DELETE C23
CHANGE
SHEET 1 OF
DWN MRM
CHK TB
APV TB
ENG TB
CR17
CR15
R1
C33
R34
R26
T3
C4
C6
L2
RH1
J4
C2
CR6
CR5
CR8
CR7
CR3
CR1
J3
TB1
F1
TB2
K1
CR22
Q5
J6
R42
R43
TB3
C41
R41
R40
C37
C1
J2
RH7
RH6
RH5
C14
U3
CR4
CR2
C17
T2
RH4
U5
U4
C31
C21
R12
R7
R29
R28
R21
R24
C12
F2
R32
C36 C23
R19
R23
C10
C9
C43
C8
U7
R3
J1
C30
R4
R22
Q4
C35
R8
R38
R13
L1
C13
C29
R30
C11
R31
R39
R11
U6
R6
R37
Q3
R10
C19
R14
C39
R15
R36
C38 C40
C15
J5
C3
RH3
RH2
T1
C25
ITEM
DWG NO.
DWG.
SIZE
PART NO.
REVISIONS
APV SYM DATE
ASSY OR B/M
UNLESS OTHERWISE
INDICATED:
.
ANGLES =_+ 2
MACHINED FINISH 300/OR
BETTER
.
CHAMFER ANGLE_= + 3
CHAMFER LENGTH_= + .015"
INDUSTRY STANDARDS.
ALL DIMENSIONS_ +.005" UNLESS
NAME
3000 SERIES POWER SUPPLY

CHANGE
FINISH
PER SPEC.
REQ'D
SUPERSCEDES
DWG.
C5
R20
T4
C20
C22
C26
R27
R5

And Stocking Damage
R2
R25
CR20
CR19
R16
CR13
CR12
C32
R33
R17
C7
CR10
CR9
CR21
Q1
R18
C24
5
Q2
6
CR11
7
U2
PART NO.
NAME
PARTS LOCATION
3600-0011
FOR
MODEL 3040/50/80 POWER SUPPLY

SCALE
FULL
DATE
2/23/94
INTERNATIONAL

SIZE
B
SHEET
DRAWING NO.
E0034
REV.
MRM
CONT. ON.
10
LINE
F1
TB1
4
RH1
L1
12 AMP
250V
NEUT/
LINE 2
C1
.22
250V
R3
422K
C3
4700pf
250V
C5
4700pf
250V
+
AC
CR21
FPIL
60
TB1
115V
230V
5
J4
6
7
RH2
130V
MOV
C4
680
200VDC
0VDC
T1
1
3
1
J1
WHT
1
3
J1
GRN
F2
6 AMP
250V
J1
BLK
DRAIN PUMP
TB2
NC1 1
J2
TB2
2
TB2
NO1 3
TB2
NC2 4
J2
TB2
NO2 6
115V
J4
230V
J4
BLK
J2
115V
J2
CR3
J4
J2
J2
SAMPLE PUMP
5
6
3
RELAY CONTACTS
REQUIRE 24VDC
200mA MAX.
RESISTIVE LOAD
IN CLASS I, GROUP A, B, C, OR D
DIVISION 2 AREAS
J3
J3
BLU
+15V
J3
10K
C37
1000pf
MLC
GRN
3+
240V
3 - 32 VDC
10K
25A
R44
MOISTURE
SENSOR
Q5
2N4401
BLK
PUMP
J2-3
WHT
PUMP
J2-1
GRN
PUMP
SOLID STATE RELAY

(SSR1)
P/N 3152-0002
PUMP CONTROL
3-32VDC CONTROL
25AMP
J6
U7
LM1830N
J5
6
12
DIV 2
SAMPLE PUMP
H
G
5/25
05
4/12
01
9/11
00
13
9
FM
11
C43
15
25V
TANT
ADD SOLID STATE

RELAY & PUMP WIRES E
REVISION PER
D
SHEET 2
ADD GROUP A&B
C
CLASSIFICATION NOTE
CHANGE
WET/DRY
APPROVED

2). ALL CAPACITORS ARE IN MFD.
1). ALL RESISTORS ARE 1/4W, 1%, 50ppm/oC.
SCHEMATIC
FOR
+VREF
NOTICE
REV DATE
10
+VREF
10
TB3
2
J2-2
J5
2
7
5
C41
.1
MLC
TB3
1
RELAY MOUNTED ON PANEL NEXT OT POWER SUPPLY BOARD

(SEE DRAWING P0083)
COM
J3
CR22
1N4148
R43
24.9K
J5
5
14
RED
R40
71.5K
OHMS
R42
+15V
BLK
J3
BLOWER
R41
75
1/2W
J5
4
WHT
J6
CR4
C8
15
25V
TANT
6
12
PL5.0-16
C
RELAY
DRIVE
+15V
U2
C7
470
50VDC
10
+15V
J5
7815
N/C
K1
-160VDC
CR2
CR1
4X 1N4005
GRN
RH6
250V
MOV
RH7
250V
MOV
TB2
ARM2 5
WHT
RH4
250V
MOV
RH5
250V
MOV
ARM1
R2
C6
100K
680
1/2W
200VDC
R1
100K
1/2W
RH3
130V
MOV
GND
TB1
+160VDC
CL30
C2
.22
250V
6/7
99
10/15
96
5/16
94
REV DATE
R40 FROM 20K TO

71.5K OHMS
C19 VALUE CHANGE
RELAY RATINGS
NAME:500
WATT POWER SUPPLY
PART NO.3600-0011

ANALYZERS
C E0024
INC.
SHEET 1 OF
CHANGE
DWNMRM
CHK
APV
ENG
10
G
+15V
2
+VREF
U6
3+
1
R4
1 MEG
C35
F
0VDC
+15VDC
+VREF
+24V
C15
R5
2.15K
+24V R27
ADJ 100
1T
P/S 1
CONTROL
R12
499
R30
Q3
24.9K
R28
24.9K
J5
R29
49.9K
2N4401
.1
50V
MLC
R11
10K
C36
.1
MLC
16
R39
10K
2
R32
24.9K
C9
15
25V
TANT
1
R14
24.9K
C30
15
25V
TANT
C10
15
25V
TANT
C11
.1
MLC
C12
.1
MLC
C13
.1
MLC
1N4148
T2
U3
3525A
50KHz
+15V
11
R21
100
8
2 U4
R24
100
12
CR10
R16
1N4148
24.9
R33
49.9
11T
6
7
C29
8
1
2 U5
5 4
Q1
IRFP451R
CR11A
T3
R20
C32
2200pf
MLC
D.S.
R36
R38
54.9K
C40
.01
MLC
120
5W
C22
470pf
2KV
L2
1+
FEP30DP
8T
R18
D.S.
8T
C24
D.S.
18 uH
35T
3+
CR11B
+24V
FEP30DP
1N4148
6
7
R13
R22
CR17
R25
2.43
1N4148
24.9
R34
49.9
4420
CR19
1N5245
R26
15V
10K
CR20
1N5245
15V
Q2
IRFP451R
1-
2+
2-
C33
2200pf
MLC
C25
4700
35V
3-
4+
C26
4700
35V
4-
-160VDC
NOTICE
B
SCHEMATIC
FOR
H
G
F
5/25
05
4/12
01
9/11
00
REVISION PER
SHEET 1
C35 FROM 1000pf TO
47pf
REVISION PER
SHEET 1
REV DATE
TLC3702
15
TANT
25V
CR15
14T
11T
4). D.S. COMPONENTS R15, R18, R38, AND C24

ARE NOT PRESENT.
o
CR12
1N5245
R17
15V
10K
CR13
1N5245
15V
1
5 4
4420 50V
POLYE
+15V
14
5+
U6
6-
100K
D.S.
C39
CR9
3
APPROVED
20K
C38
0.1
MLC
+160VDC
FM
10
4.99K
C17
0.1
MLC
+VREF
C14
.1
MLC
R37
15
1/2W
R8
13
8
2.49K
4X 1N4148
CR7
CR8
R7
R15
10
Q4
2N4401
50T
CR5
R6
1K
1/2W
47pf
MLC
CR6
15
C19
330pF
100V
MLC
9
C21
C31
2200pf MLC
1
R19
50V
6
POLYE 11.5K
C23
R10
5
34K
R23
1000pf 5.11
100V
7
MLC
R31
1T
1
400VDC
POLYP
+15VDC
TLC3702
T4
C20
CHANGE
E
D
C
6/7
99
10/15
96
5/16
94
REV DATE
R40 FROM 20K TO

71.5K OHMS
C19 VALUE CHANGE
RELAY RATINGS
NAME:
500 WATT POWER SUPPLY
PART NO. 3600-0011

ANALYZERS
C E0024
INC.
SHEET 2 OF
CHANGE
DWNMRM
CHK
APV
ENG
22-3/4"
CARRYING HANDLE
15-1/4"
WET GAS
SAMPLE INLET
DRY SAMPLE GAS
TO ANALYZER
3/8" TUBING
FITTING
SAMPLE COOLER
SAMPLE PUMP HEAD
DOUBLE HEAD
ADI MINI DIA-VAC
PUMP
26-1/2"
FLOW METER
VISIBLE FILTER
WITH WATER
CARRY OVER
SENSOR
COMPRESSED AIR HEAD
8
,57
65
5,4
78
5,465,5
EDUCTOR
B
AIR FILTER
WATER CARRY
OVER SENSOR
CONNECTOR
FOUR LEG STAND
(ONE LEG NOT VISIBLE IN THIS VIEW)
ISOMETRIC VIEW
FRONT VIEW
12-3/8"
04/17/98
ADD MOUNTING FEET/PATENT NUMBER
REV
DATE
DESCRIPTION
REVISIONS
EAM
3000 SERIES PORTABLE SAMPLE COOLER

ACCESSORY OUTLINE FOR SYSTEMS WITH
EDUCTOR
PART NO.
FOR

DRAWN BY
APVD BY
DATE
12/20/93
JK
DWN APVD
DRAWING NO
HARVEY MITCHELL
P0084
TED BARBEN
SCALE
SIZE
D
1:1
SHEET
1 OF 1
22-3/4"
CARRYING HANDLE
13-5/8"
WET GAS
SAMPLE INLET
DRY SAMPLE GAS

TO ANALYZER
3/8" TUBING
FITTING
SAMPLE COOLER
SINGLE HEAD
ADI MINI
DIA-VAC
PUMP
26-1/2"
FLOW METER
VISIBLE FILTER
WITH WATER
CARRY OVER
SENSOR
8
5,465,57
5,4
65
,57
PERISTALTIC
PUMP HEADS
WATER
CARRY OVER
SENSOR
CONNECTOR
FOUR LEG STAND
ISOMETRIC VIEW
FRONT VIEW
12-3/8"
04/23/98
ADD LEG/FEET/NEW HEAD DESIGN/PAT #
REV
DATE
DESCRIPTION
REVISIONS
EAM

ACCESORY OUTLINE FOR SYSTEMS WITH
PERISTALTIC PUMP
PART NO.
FOR

DRAWN BY
APVD BY
DATE
12/20/93
DRAWING NO
HARVEY MITCHELL
P0085
TED BARBEN
SCALE
SIZE
D
1:1
JK
DWN APVD
SHEET
1 OF 1
4
1
D
*
8
7
8
6
5,4
65
,57
7
5
ASSEMBLED FRONT VIEW
(ACCESSORIES NOT SHOWN FOR CLARITY)
VIEW AS SEEN LOOKING AT BACK OF SAMPLE COOLER

BILL OF MATERIALS FOR

LEG MOUNT KIT
P/N 9515-0019
ITEM
1
2
3
4
5
6
7
8
*
*
QTY
2
1
1
2
3
4
3
3
DESCRIPTION
LEG SINGLE
LEG DUAL
PLUG ROUND PLASTIC
PLUG SQUARE PLASTIC
SCREW 1/4" x 1-1/2" S.S.
SCREW #6 x 1-1/4" S.S.
WASHER 1/4" FLAT S.S.
NUT 1/4" S.S.
A 04/28/98 ADD FOOT PADS REVISE BOM TABLE

DESCRIPTION
REV DATE
EAM JK
DWN APVD
REVISIONS
P/N
6006-0001
6006-0002
4919-0007
4919-0006
4704-0047
4704-0048
4710-0001
4711-0006
LEG MOUNTING KIT

INSTALLATION FOR 3000
SERIES SAMPLE COOLERS
PART NO.
9515-0019
FOR
3000 SERIES COOLERS
*NOTE: ITEMS 3 AND 4 ARE FACTORY INSTALLED

DRAWN BY
APVD BY
DATE
02/04/1994
DRAWING NO
H. MITCHELL
T. BARBEN II
P0089
SCALE
NTS
SIZE
E
SHEET
1 OF 1
INSTALLATION:
1). INSTALL ITEMS #1 INTO BOTTOM OF
BOTH HEAT EXCHANGERS.
2). INSTALL ITEMS #2 & #3 INTO ITEMS #1

WITH ITEM #2 IN THE FRONT HEAT
EXCHANGER.
3). INSTALL ITEMS #4 INTO TOP OF LIQUID
DRAINS TYPICAL.
FRONT
4). INSTALL ITEMS #5 ONTO ITEMS #2 & #3.
PARTS TABLE
ITEM#
DESCRIPTION
QTY
P/N
1
1/2" TUBE X 3/8"NPT CONNECTOR 2 4954-0058
2
1/2" 316 S.S. X 5" BENT TUBE
1 9011-0004
3
1/2" 316 S.S. X 3" STRAIGHT TUBE
1 9011-0004
4
5
FLOAT DRAIN VALVE
2 4955-0001
4
3
5
DESCRIPTION
REV DATE
DWN APVD
REVISIONS
FLOAT DRAIN INSTALLATION

LAYOUT
PART NO.
9515-0100
RIGHT SIDE VIEW

DRAWN BY
APVD BY
DRAWING NO
E. Musselman
T. Barben II
DATE
09/15/1999
FOR
3020, 3050, 3080
P0360
SCALE
NTS
SIZE
E
SHEET
1 OF 1
1701 South Sutro Terrace Carson City, NV 89706

Telephone (775) 883-2500 (800) 993-9309
Fax (775) 883-6388
SPARE PARTS RECOMMENDATIONS FOR 3000 SERIES SAMPLE COOLERS

Level A, Consumable Parts (All Models):
9216-0002
Peristaltic Pump Tubing, #15, 5 ft. length
3010-0005
6 amp Slow Blow Fuse for 3000 Series Power Supply
3010-0006
12 amp Fast Acting Fuse for 3000 Series Power Supply
2 Yr Req.
9
2
2
Level B, Basic Parts (3000SS Series):

5200-S010
Heat Exchanger/Impinger 316S.S. 10 Inch
4904-0013
O-Ring, 316S.S. Heat Exchanger Viton 2-021
8010-0001
Paste, Heat Sinking - 0.1 Ounce Container
9515-0040
Ambient Heat Exchanger Conversion Kit
(Converts the Model 3040SS to a Model 3050SS)
2
2
Level B, Basic Parts (3000PV Series):

5200-K010 Heat Exchanger/Impinger Glass/Kynar 10 Inch
5201-0001
Glass Tube, Outer Heat Exchanger Replacement 10 Inch
4904-0003
O-Ring, Glass/Kynar Heat Exchanger Viton 2-018
4904-0004
O-Ring, Glass/Kynar Heat Exchanger Viton 2-120
8010-0001
Paste, Heat Sinking - 0.1 Ounce Container
9515-0041
Ambient Heat Exchanger Conversion Kit
(Converts the Model 3040PV to a Model 3050PV)
1
2
2
2
Level C, Critical Parts (All Models):

3016-0002
Peltier Element, Pair - 15Vdc 8.5 Amp 40mm Sq.
9515-0042
Insulation Kit - Heat Transfer Block (Model 3040 & 3050)
9515-0023
Insulation Kit - Heat Transfer Block (Model 3080)
1150-0017
Temperature Sensor Assembly, AD592
3103-0006
Temperature Limit Switch, 185F
3152-0004
Solid State Relay, 3-32 VDC / 240VAC 10Amp (Blower Motor)
4800-0010
Blower & Motor Squirrel Cage 115/230Vac
1
1
1
Level D, In-Depth Parts (All Models):

3600-0012
Controller Circuit Board
3600-0011
Power Supply Board - 15Vdc 500 Watt
4958-0028
Peristaltic Pump Motor, 115Vac 6RPM
4958-0031
Peristaltic Pump Motor, 230Vac 6RPM
4958-0006
Peristaltic Pump Head, #15
Optional Parts/Accessories:
4958-0025
Sample Pump - 115Vac Mini Dia-Vac Alum/Teflon Single Head
4958-0015
Sample Pump - 230Vac Mini Dia-Vac Alum/Teflon Single Head
4958-0026
Sample Pump - 115Vac Mini Dia-Vac Alum/Teflon Dual Head
4958-0016
Sample Pump - 230Vac Mini Dia-Vac Alum/Teflon Dual Head
9515-0018
Sample Pump Rebuild Kit - Mini Dia-Vac (for Single Head)
9515-0018
Sample Pump Rebuild Kit - Mini Dia-Vac (for Dual Head)
4955-0004
Sample Pressure Control, AirTrol 0-10Psig Adjustable
4955-0091
Sample Pressure Control, Swagelok 316SS 10-225Psig Adjustable
3000 Spare Parts Rev D
3
6
2
2
Optional Parts/Accessories, Continued:

3152-0002
Solid State Relay, 3-32 VDC / 240VAC 25Amp (Sample Pump)
4980-0005
WCOF Assembly - Moisture Sensor/2m Teflon Filter
5205-0006
Bowl, WCOF Filter - Replacement with Cable & O-Ring
4904-0006
O-Ring, WCOF Bowl Viton 2-030
4980-0006* Filter Element - 2m Teflon (WCOF)
6020-0001
WCO Moisture Sensor Assembly w/ Flow Thru Adaptor
5101-0001
WCO Moisture Sensor (for Non-Filtered Flow Thru Style)
9515-0046
Thermocouple Kit, Heat Exchanger - New Jersey Type K
9515-0047
Thermocouple Kit, Heat Exchanger - New Jersey Type J
9515-0048
Thermocouple Kit, Heat Exchanger - New Jersey Type T
9515-0100
Condensate Drain Kit - Automatic (Models 3050 & 3080)
9515-0101
Condensate Drain Kit - Automatic (Models 3040)
9515-0019
Portable Leg Kit (3000 Series)
* Commissioning Spare Part
2 Yr Req.
1
2
6

MOISTURE CONVERSION TABLE
DEW POINT,
DEGREES C.
-100
-50
-20
-10
-5
-4
-3
-2
1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
% WATER BY VOLUME % WATER BY WEIGHT

AT SATURATION
AT SATURATION
0.00000139
0.00000081
0.00388
0.00241
0.102
0.0633
0.256
0.1596
0.396
0.229
0.432
0.268
0.469
0.291
0.510
0.317
0.555
0.345
0.602
0.364
0.649
0.404
0.696
0.433
0.750
0.466
0.803
0.499
0.861
0.535
0.922
0.573
0.988
0.614
1.06
0.658
1.13
0.702
1.21
0.753
1.29
0.802
1.38
0.860
1.48
0.920
1.58
0.980
1.68
1.044
2.31
1.433
3.13
2.004
4.19
2.64
5.55
3.54
7.28
4.67
9.46
6.12
12.2
8.0
15.5
10.3
19.7
13.3
24.4
16.8
30.7
21.7
38.0
27.8
46.7
35.6
57.2
45.7
69.2
58.4
WATER VAPOR
PRESSURE, mm. Hg
0.0000099
0.0295
0.776
1.950
3.014
3.280
3.569
3.880
4.223
4.579
4.937
5.294
5.70
6.10
6.54
7.01
7.51
8.05
8.58
9.15
9.8
10.5
11.2
12.0
12.8
17.5
23.8

TELEPHONE (800) 993-9309
(775) 883-2500
FAX: 775-883-6388
MODEL 3050
SINGLE SAMPLE
DUAL STAGE
SAMPLE COOLER
See us on the WEB at http://www.universalanalyzers.com

e-mail address: sales@universalanalyzers.com
MAN3050 Rev D

TELEPHONE (800) 993-9309
(775) 883-2500
FAX: 775-883-6388
LIMITED WARRANTY
ALL PRODUCTS MANUFACTURED BY UNIVERSAL ANALYZERS INC. ARE
WARRANTED TO BE FREE OF MANUFACTURING DEFECTS FOR A PERIOD OF ONE
YEAR FROM THE DATE OF RECEIPT AT THE CUSTOMERS RECEIVING AREA AND
FOR AN ADDITIONAL PERIOD OF UP TO 90 DAYS IF THE PRODUCT IS PLACED IN
SERVICE AFTER BEING IN STORAGE. THIS WARRANTY COVERS MATERIALS AND
LABOR TO RESTORE ANY PRODUCTS TO ORIGINAL FACTORY SPECIFICATIONS IF
A DEFECT IS FOUND WITHIN THE WARRANTY PERIOD.
THE DEFECTIVE PRODUCT SHOULD BE SENT, FREIGHT PREPAID, TO THE
FACTORY IN CARSON CITY, NEVADA. REPAIRS WILL BE PERFORMED AT THE
FACTORY AND RETURNED, PREPAID, BY THE SAME SHIPPING METHOD USED TO
SEND THE PRODUCT TO THE FACTORY.
THIS WARRANTY DOES NOT APPLY WHERE THE EQUIPMENT HAS SUSTAINED
DAMAGE DUE TO NEGLECT, MODIFICATION, CORROSION, OR OTHER REASON
BEYOND THE SCOPE OF THE NORMAL DEFINITION OF MANUFACTURING
DEFECT.
FURTHER, THIS WARRANTY IS LIMITED TO REPLACING THE DEFECTIVE
COMPONENTS AND RETURNING THE EQUIPMENT MANUFACTURED BY
UNIVERSAL ANALYZERS INC. TO THE CUSTOMER IN WORKING CONDITION. ANY
OTHER CLAIMS ARE OUTSIDE THE SCOPE OF THIS WARRANTY. NO WARRANTIES
ARE MADE AS TO THE SUITABILITY OF THE USE OF THE EQUIPMENT IN ANY
PARTICULAR APPLICATION OR LOCATION. THE SUITABILITY OF THE USE OF THE
EQUIPMENT IS THE RESPONSIBILITY OF THE CUSTOMER AND THE INSTALLING
CONTRACTOR.

TELEPHONE: (775) 883-2500
CARSON CITY, NV 89706

FAX: (775) 883-6388
UNIVERSAL ANALYZERS MODEL 3050 SAMPLE COOLER

SPECIFICATIONS
SAMPLE FLOW RATE:
0 to 8 L/M (at STP)
MAXIMUM INLET TEMPERATURE:

STAINLESS STEEL HEAT EXCHANGER:
KYNAR/GLASS HEAT EXCHANGER:
700o F. (371o C.)

280o F. (138o C.)
MAXIMUM INLET GAS DEW POINT:
194o F. (90o C.)
MAXIMUM INLET WATER CONCENTRATION:
70%*
MINIMUM AMBIENT TEMPERATURE:
32o F. (0o C.)
MAXIMUM AMBIENT TEMPERATURE:
105o F. (41o C.)*
MAXIMUM COOLING POWER, (SECOND STAGE):
126 BTU'S/Hr. (120 kJ/Hr.)
SAMPLE DEW POINT LEAVING FIRST STAGE:
AMBIENT + 10o F. (6o C.)
OUTLET SAMPLE DEW POINT:
41o F. (5o C.), adjustable
MAXIMUM INPUT POWER:
350 WATTS
VOLTAGE:
95-125 VAC, 50/60 Hz or

190-250 VAC, 50/60 Hz
ELECTRICAL CLASSIFICATION:
NEMA 1
Class I, Grps. A, B, C, & D,
Division 2 (FM Approved)
DIMENSIONS:
18" x 7 1/2" x 11", HWD
WEIGHT:
33 LB's., (15 KG)
SOLUBLE GAS REMOVAL RATES:
NO
NO2
SO2
CO
CO2
*at reduced flow rates. See capacity chart.
3050 Text Rev A
0% LOSS
<10% LOSS
< 2% LOSS
0% LOSS
< 2% LOSS

OPERATING INSTRUCTIONS
APPLICATION
In order to analyze combustion products or incinerator effluents utilizing a direct
extractive sampling technique, it is important to remove the water vapor without
removing the water soluble fraction(s) from the gas sample. The heat exchangers
(impingers) used in the Universal Analyzers gas sample coolers are designed to minimize
the gas/condensate area and time of contact to reduce to a minimum, the amount of mass
transfer of those water soluble components from the gas phase into the liquid phase. The
result is a dry gas sample which has the same composition on a dry basis before and after
passing through the chiller.
A gas sample is usually taken from a stack with a probe extending into the center of the
stack mounted onto or adjacent to a heated filter. The heated filter is maintained at a
temperature above the dew point of the stack gas, usually 300o to 400o F. in order to
avoid cementing the filtered particulates to the filter medium with condensate. A means
is usually provided to automatically blow the particulates trapped by the filter, back into
the stack on a periodic basis.
The stack gas sample is clean but "wet" after passing through the filter assembly. The
moisture in the gas sample comes from the fuel as a product of combustion, from the
humidity in the air which supports the combustion and from the water content which was
trapped in the fuel. This latter source of water in the sample can be from burning moist
coal, wet garbage, or from water injected into the fire box. Water from all of these
sources will remove the water soluble gasses from the sample stream if allowed to
condense in the sample line prior to the controlled separation within the Universal
Analyzers' heat exchangers in the sample cooler.
In order to maintain the temperature of the gas sample above the dew point as it is
transported to the gas sample cooler, a heat traced sample line is usually employed. The
heat traced sample line can be very short if the gas sample cooler is located close to the
heated stack filter or it could be several hundred feet long if the gas sample cooler is
located in the analyzer shack some distance from the stack.
The Universal Analyzers gas sample cooler contains the special impinger type heat
exchanger(s). These are mounted within heat transfer blocks which are cooled by
thermoelectric elements utilizing the "Peltier Effect" discovered in France over half a
century ago. Where high water contents are encountered, it is efficient to remove the
condensate in two stages, one at the temperature of the air in the vicinity of the
"Precooler" and then by passing the sample into a heat exchanger cooled by the
thermoelectric elements. The precooler can remove water which will condense at the
temperature of the environment. In high water content samples, this could be as much as
80% of the water in the sample.
The thermoelectrically cooled stage is temperature controlled at a factory setting of 5o C.
This temperature can be adjusted with a set point potentiometer easily as described
below.
The gas sample conditioning system should contain additional components to insure that
a clean, dry sample is presented to the analyzer panel for minimum analyzer maintenance.
A sensor should be provided to sense the presence of condensate, should any exist in the
tubing following the chiller. This is the optional WCO (Water Carry-Over) sensor which
can be provided with a Universal Analyzers chiller. A visible coalescing filter which
collects particulates on the outside of the cylindrical filter, surrounded by a transparent
bowl will allow the operator to inspect the condition of the heated stack filter. The WCO
sensor can be provided with the sensing elements in the bottom of the filter bowl to
provide an early warning if the coalescing filter removes liquid from the sample stream.
This combination filter/moisture sensor is called the "WCOF".
The location of the sample pump (usually an oil-less diaphragm pump) within the
sampling system is the subject of much debate. If the pump is located upstream from the
chiller, it should have a heated head to avoid the presence of a two phase mixture which
shortens the life of a diaphragm and causes maintenance problems. It can be shown that
passing the gas sample through the chiller under a slight positive pressure will result in a
lower gas dew point than if the gas were at a slight vacuum. A common location for the
sample pump is in the sample line after the chiller. This allows the sample pump to
handle a cool, dry sample with much reduce maintenance problems. Some design
engineers have taken the approach to use a sample cooler having two chilled heat
exchangers. The pump is placed in the sample line between the two heat exchangers.
The first chilled heat exchanger takes enough of the water vapor from the sample to
protect the pump. The second heat exchanger is under a slight pressure and the dew point
is at it's minimum because it is on the discharge side of the pump. The sample pump
location within the sample system is a matter of choice and good engineering.
The condensate must be removed from the heat exchanger(s) using one of the following
methods:
1. A continuously running peristaltic tubing pump can be used
with the heat exchanger either under pressure or vacuum. This is an easy
solution which lends itself to leak testing because of the positive
displacement nature of the peristaltic pump. It is, however, a device which
requires periodic maintenance to replace the tubing.
2. Condensate can be removed from the heat exchanger using an
eductor with a flow limiter to draw some of the hot, wet sample through
the heat exchanger along with the condensate. This method utilizes the
heat exchanger as a bypass condenser and serves the purpose of reducing
the time lag in the sample line without loading the chiller with the water
vapor in the bypassed sample.
3. A float drain trap can be used to collect the condensate running
out of the bottom of the heat exchanger(s) if the heat exchangers are at a
slight positive pressure with respect to the atmosphere. The float drain
trap functions like a steam trap. The float rises to discharge the
condensate when there is enough to lift the float.
4. A small drain tank can be provided with a dual level,
conductivity type level control to collect the condensate. When the tank if
full, the level controller will start a pump to remove the condensate until it
reaches to the lower electrode. When contact is lost, the pump stops and
the condensate is again allowed to fill the tank. Typically, a peristaltic
pump is used to remove the condensate. The advantage is that the pump
only runs occasionally and bypasses no gas sample. The peristaltic pump
requires less maintenance because it does not run continuously.
Finally, a means of controlling the flow of the sample to the analyzers must be
considered. This can be as simple as providing a flow meter with a flow control needle
valve to pinch off the sample flow causing the sample pump to pump higher on the pump
curve. One option which is used is to provide an adjustable back-pressure regulator
between the inlet and outlet of the sample pump to allow a portion of the gas pumped to
be recirculated back to the inlet if discharge pressure exceeds the back-pressure control
point. Some analyzers have their own sample pump which may be sufficient to supply
the analyzer but insufficient to pull the sample through the chiller, sample line, and
heated stack filter. These can be supplied by piping the sample from the external sample
pump into the run of a tee with a flow meter which registers the flow of excess sample
from the branch of the tee to atmosphere. The internal analyzer sample pump can then
withdraw sample from the opposite run of the tee which is essentially at atmospheric
pressure and unaffected by pressure changes within the sample line due to changes in
filter pressure drop or sample pump efficiency.
DESCRIPTION
The key to the success of the Universal Analyzers Sample Cooler being able to condense
the water from a wet gas sample with a minimal loss of the water soluble gas fraction, is
due to the design of the heat exchanger. Please refer to Drawings P0146 thru P0149. The
separation occurs in a classical impinger which has a highly polished cylindrical surface
cooled to the desired dew point temperature. The hot wet sample is brought to the bottom
of the cylinder through an insulated tube and allowed to rise through a narrow annular
area at a relatively high Reynolds number to insure the entire sample is influenced by the
cold surface. The condensate falls down the cold polished surface in the form of a sheet
(as opposed to droplets or the bubbling of the gas sample through the condensate) which
minimizes the surface area in contact with the gas sample.
The temperature of the cylindrical condensation surface of the heat exchanger is
maintained through intimate contact with an aluminum heat transfer block. In the Model
3050 Sample Cooler, the first of the heat transfer blocks is cooled by direct contact with
the heat sink cooled by the blower. The temperature of the first of the two heat
exchangers will be about 10o F. above the temperature of the air passing through the heat
sink. (The temperature differential depends on the amount of heat that is being extracted
from the sample, which is a function of the water content of the sample.)
The second of the heat exchangers through which the sample passes is cooled by the use
of Thermoelectric Elements at a controlled temperature. The factory temperature setting
is 5o C. The temperature sensor is an AD592 semiconductor device. The controller is a
proportional controller with a proportional band of about 1o C. The set point is field
adjustable by opening the door on the front of the chiller, moving a jumper (J3) with
needle nose pliers, and adjusting a trim-pot to a new temperature value shown on the
display. The jumper needs to be placed in the original position to, again, indicate the
temperature of the heat transfer block.
The heat which is removed from the gas sample (and that which is created by the
Thermoelectric Elements) is discharged by a heat sink which is cooled with a centrifugal
drum blower. The turbulence and velocity provided by the high static pressure capability
of the blower allows for efficient cooling of the heat sinks. The heat sinks are fabricated
from solid blocks of aluminum which eliminates the epoxy joints in more conventional
heat sink designs which are barriers to heat conduction. The result is a heat removal
system with superior performance under all conditions.
Universal Analyzers Thermoelectric Sample Coolers have a digital display as a front
panel indication of the of the operating temperature, (o C.) of the heat exchangers. In
addition, there are two green LED lamps to indicate the status of the cooler. The
"COOL" lamp lights when the operating temperature is between 0o C and 10o. If the
operating temperature is above or below this range, the light will be out and the alarm
relay will be in the alarm position. The "DRY" lamp indicates that there is no water in
contact with the moisture sensor listed as the "WCO" or "WCOF" options. If the "DRY"
lamp is out, the alarm relay will be in the alarm position.
The alarm relay is a single relay activated by either of the above alarm conditions. The
alarm relay is energized in the "safe" condition and will relax into the de-energized, alarm
position if a fault is detected. If a broken thermocouple occurs, the result will be that the
temperature indication is out of range and the alarm relay will indicate a fault.
A thermal switch is mounted on the heat sink to serve as a safety device to turn off power
to the thermoelectric elements if the heat sink approaches 160o F. This protects the
thermoelectric elements from melting in the event high temperature conditions are
encountered for any reason.
The 3000 Series thermoelectric sample coolers are designed to incorporate a peristaltic
pump for condensate removal within the enclosure to reduce the total volume required for
the system installation. Alternatively, it also has provisions for incorporating an eductor,
air filter, and dual heat sample pump with the second head used for generating the
necessary compressed air for the eductor.
Electrical connections are made to external wiring which will enter conduit fittings on the
bottom of the chiller. Internal conduit tubes direct the wires as they are pushed into the
chiller into the vicinity of the terminal strips. All of the terminal strips are easily
accessible from the front of the chiller.
If it is desired to connect conduit to the chiller, a conduit coupling can be screwed onto
the 1/2" male conduit threads which extend from the bottom.
"PEM Nuts" are provided on the right hand side to mount accessories such as a sample
pump, visible filter, condensate alarm sensor, and flow meter. These options can be user
or factory installed.
The chiller can be changed from 115 VAC to 230 VAC operation with the movement of a
circuit card on the power supply. Accessories such as the sample pump or peristaltic
pump must be rated for the correct supplied line voltage.
INSTALLATION INSTRUCTIONS
Thermoelectric Sample Coolers should be installed away from heat sources in a well
ventilated area of an instrument rack or enclosure. Completely enclosing any instrument
which consumes as much power as a thermoelectric chiller will cause the temperature of
the interior of an unventilated enclosure to rise to too great a level for the sample cooler
to perform reliably. Where it is necessary for the enclosure to be tightly gasketed, a water
cooled thermoelectric chiller should be used. Contact the factory for recommendations.
Air purging an enclosure does not provide enough ventilation to remove the heat which
will be generated internally by the sample chiller. On the other hand, there are air
conditioners and vortex coolers which can provide the necessary cooling for enclosing
thermoelectric chillers.
The 3000 series sample cooler has a flange on the top and bottom to allow it to be wall
mounted or mounted to rails in an instrument rack. Accessories mounted on the side can
be supported by the mounting flange on the cooler.
Sample tubing should be brought to the front, unchilled heat exchanger first. A 3/8"
tubing fitting is provided at the top of the first heat exchanger as the sample inlet. A 1/4"
Teflon transfer tube is provided to carry the sample from the first, ambient temperature
heat exchanger to the second, chilled stage. The dry sample outlet from the cooler is the
1/4" Kynar tubing fitting coming out of the top of the second heat exchanger at an angle.
The gas sample should be further conditioned with an additional filter as a safety measure
before it enters the analyzer(s). The WCOF visible filter which incorporates a safety
moisture sensor is designed for this purpose. A similar filter without the moisture sensor
is also available from Universal Analyzers. A separate moisture sensor, the WCO, can
also be provided where the user prefers that form factor. Contact the factory for
drawings.
A sample pump is normally required to pull the sample through the sample cooler and to
force it through the visible filter. The moisture sensor, if not a part of the visible filter
should be located ahead of the visible filter.
Some have preferred to locate the sample pump in the sample line between the two heat
exchangers. The theory is that the first heat exchanger reduces the water content to the
point that water will not condense in the sample pump. A controlled portion of the
sample can be discharged to atmosphere to reduce the sample lag in the sample line
before the final cooling/dehydration stage. The final cooling stage then only handles the
sample which is required by the analyzer(s). This location of the sample pump also
allows the final stage of cooling to be performed at a slightly higher pressure which is
theoretically more efficient.
There must be a method to remove the condensate from the heat exchanger(s). Several
methods are discussed above. A drain line from the peristaltic pump, eductor, or drain
pot must be run to sewer, a container, or to the ground outside the instrument enclosure to
avoid collecting water (condensate) on the floor.
If an eductor is utilized to remove the condensate, the outlet tube length should be no
longer than two feet in order to keep too much back pressure from the outlet of the
eductor. The outlet tube can be placed in a larger pipe to channel the condensate to a
drain.
The electrical power, about 3 amps at 115 VAC or 1.5 amps at 230 VAC 50/60 HZ
should be supplied. Installation shall be in accord with the manufacture's instructions and
the National Electrical Code (ANSI/NFPA 70). Tampering and replacement with
nonfactory components may adversely affect the safe use of the system. For the 115
VAC case, a power cord is supplied. It can be replaced with conduit wiring easily. See
the electrical installation Drawing P0093. The alarm relay has two sets of "Form C"
contacts brought out to the center terminal strip, TB2. One set are totally dry contacts.
The other set are MOV protected and designed to interrupt power to the sample pump
when in the alarm condition. When the pump is powered through the connector on the
power supply board, the MOV protected contacts are hot, with line power supplied.
The moisture sensor can be connected to the "Viking" connector mounted on the exterior
of the cabinet below the heat exchangers or, alternatively, connected to TB3 on the power
supply board.
START UP PROCEDURE
Apply power to the sample cooler. The indicated temperature will start to drop
immediately. It should be below the over-temperature alarm point in approximately four
minutes and the "COOL" green LED lamp should light. When the temperature reaches
the control set point, the rate at which the temperature drops will be reduced. The
temperature will stabilize within 1o C. of the control set point.
Start the sample gas flow by turning on the sample pump and adjusting the flow control
valve to the desired flow rate. Water should be observed to be removed from the bottom
of each heat exchanger when steady state conditions are established.
If an eductor is utilized to remove the condensate, a strong flow of air should be felt to be
flowing from the eductor outlet tube. The outlet tube length should be no longer than two
feet. The outlet tube can be placed in a larger pipe to channel the condensate to a drain.
The green "DRY" LED light will be on. If an optional moisture is installed, the light will
go out and the alarm relay de-energized when the sensor detects condensate. A test can
be performed by putting water on the moisture sensor. If the sample pump is powered
through the alarm relay contacts, it will cease running. When the moisture sensor is
wiped dry, the sample pump will start.
Turn on the analyzer(s) and initiate the calibration cycle.
TROUBLE SHOOTING
Tampering and replacement with nonfactory components may adversely affect the safe
use of the system.
The presence of water in liquid form after the sample cooler is an indication of a fault in
the system. Reasons for the presence of condensate in the system after the sample cooler
could be one or more of the following:
1. Overloading of the cooling capacity of the cooler due to too
much water vapor in the sample or due to too great a sample flow rate.
2. The condensate removal equipment (peristaltic pump, eductor,
or drain pot) may be faulty. The heat exchanger(s) may be full of
condensate.
3. An air leak may be in the condensate removal system allowing
air to enter and blow the condensate back into the heat exchanger. (This
assumes the heat exchanger is under a slight vacuum.)
4. The temperature of the air passing through the cooler to cool the
heat sink is too high. This could be due to placement of the cooler in a
tightly sealed box.
5. The sample cooler could have failed.
Dimensional drawings, installation drawings, and schematics are included as part of this
manual. If additional information is required, telephone assistance can be obtained by
calling (775) 883-2500 or FAX request to (775) 883-6388.
A
8
NOTICE
8
7-1/2"
5-1/2"
FM
DRY SAMPLE GAS

OUTLET
1/4" TUBE FITTING
APPROVED
11-1/4" 11-3/4"
R
WET SAMPLE GAS

INLET
3/8" TUBE FITTING
HOLES FOR
1/4" BOLTS
(4 TYP)
(BOLTS SUPPLIED
BY OTHERS)
THERMOELECTRICALLY
COOLED STAGE
EX
HA
US
TA
AMBIENT
COOLED STAGE
IR
FL
OW
SOLID STATE
RELAY
DISPLAY
CIRCUIT BOARD
HIGH PRESSURE
BLOWER/S
HEAT SINKS
17"
EX
HA
US
TA
18"
EX
HA
US
TA
EX
HA
US
TA
IR
IR
FL
FL
FL
OW
OW
OW
5,
46
5,
5
78
POWER SUPPLY
CIRCUIT BOARD
IR
3
1/2" CONDUIT PORT
(2 TYP)
OPTIONAL
DUAL HEADED
PERISTALTIC PUMP
CONDENSATE DRAIN
LINES
USER ACCESSABLE
TERMINAL BLOCKS
SINGLE SAMPLE
DUAL STAGE
SAMPLE COOLER
A
04/08/98
Font/Patent#/New Heads/Relay
REV
DATE
DESCRIPTION
REVISIONS
EM
TB
DWN APVD

OUTLINE
PART NO.
FOR

DRAWN BY
DRAWING NO
APVD BY
P0069
HARVEY MITCHELL
TED BARBEN
DATE
SCALE
09/02/93
1:1
SIZE
SHEET
1 OF 1
13 5/8"
5 1/2"
3 13/16"
WET GAS
SAMPLE INLET
3/8" TUBING
FITTING
SAMPLE COOLER
DRY SAMPLE GAS

TO ANALYZER
18 13/16"
18"
17"
SINGLE HEAD
ADI MINI
DIA-VAC
PUMP
8
,57
65
5,4
PERISTALTIC
PUMP HEADS
B
5,465,57
WATER
CARRY OVER
SENSOR
CONNECTOR
FLOW METER
VISIBLE FILTER
WITH WATER
CARRY OVER
SENSOR
FRONT VIEW
DESCRIPTION
REV DATE
DWN APVD
REVISIONS
3000 SERIES SAMPLE COOLER

ACCESSORY OUTLINE FOR
SYSTEMS WITH PERISTALTIC PUMP
FOR
INSTRUMENT
PART NO.
NOT ISSUED
ISOMETRIC VIEW

DRAWN BY
APVD BY
DATE
07/07/1998
DRAWING NO
E. Musselman
T. Barben II
P0294
SCALE
1:1
SIZE
E
SHEET
1 OF 1
24V
ADJ
+ 4
+ 3
+ 2
SOLID STATE RELAY

MODEL Z240D10
+ 1
+3
TB3
W
C
O
RED
BLACK
POWER SUPPLY
BOARD
PELTIER CONNECTIONS
RED
BLACK
RED
BLACK
RED
BLACK
RED
BLACK
RED
1
2
MOISTURE
SENSOR
CONNECTOR
-4
- CAUTION TERMINALS
1,2, & 3 ARE
HOT WHEN
SAMPLE
PUMP IS
INSTALLED
TB2
PELTIER
ELEMENTS
A MOV PROT.
L N.C. 1
2
A
R N.O. 3
M
R
E
L
A
Y
#1
N.C.
DRAIN
5
N.O.
#4
BLOWER
6 AMP FUSE
MODELS
3040
3050
3080
JUMPER CARD
115V
230V
12 AMP FUSE
TB1
P HOT L1
O
W COM L2
E
R
SAMPLE
DRY CIRC.
1
2
3
MODEL
3080
BLOWER
BLACK
BLUE
RED
GREEN
BLACK
#2
WHITE
G
B R
BL LAC EEN
AC K
K
#3
AD592
BL
AC
K
IN
DRA
D
RE
DR
AIN
RE
D
K
AC
BL ACK
BL
THERMAL
SAFETY
SWITCH
MOISTURE SENSOR
CONNECTOR
R
PERISTALTIC
DRAIN PUMP
3
FM
APPROVED
NOTICE
DISPLAY BOARD
2
(JUMPER)
TEMPERATURE
OR
SET POINT
TEMP
SET
10/24/03
REV
DATE

DESCRIPTION
REVISIONS
EM
PART NO.
FOR

CALIBRATION ADJUST
(FACTORY SET)
DRAWN BY
DRAWING NO
APVD BY
P0093
HARVEY MITCHELL
TED BARBEN
DATE
SCALE
3/17/94
NONE
TEMPERATURE
SENSOR
MODEL 3040 3050 3080

DIAGRAM
POWER
SUPPLY
SET POINT
ADJUST
TB
DWN APVD
SIZE
SHEET
1 OF 2
24V
ADJ
+ 4
+ 3
+ 2
SOLID STATE RELAY

MODEL Z240D10
+ 1
+3
TB3
W
C
O
RED
BLACK
POWER SUPPLY
BOARD
PELTIER CONNECTIONS
RED
BLACK
RED
BLACK
RED
BLACK
RED
BLACK
RED
1
2
MOISTURE
SENSOR
CONNECTOR
-4
- CAUTION TERMINALS
1,2, & 3 ARE
HOT WHEN
SAMPLE
PUMP IS
INSTALLED
TB2
PELTIER
ELEMENTS
A MOV PROT.
L N.C. 1
2
A
R N.O. 3
M
R
E
L
A
Y
#1
N.C.
DRAIN
5
N.O.
#4
BLOWER
6 AMP FUSE
MODELS
3040
3050
3080
JUMPER CARD
115V
230V
12 AMP FUSE
TB1
P HOT L1
O
W COM L2
E
R
SAMPLE
DRY CIRC.
1
2
3
MODEL
3080
BLOWER
WHITE
BLUE
BLACK
RED
GREEN
#2
WHITE
G
B R
BL LAC EEN
AC K
K
#3
AD592
BL
AC
K
IN
DRA
D
RE
DR
AIN
RE
D
K
AC
BL ACK
BL
THERMAL
SAFETY
SWITCH
MOISTURE SENSOR
CONNECTOR
R
PERISTALTIC
DRAIN PUMP
3
FM
APPROVED
NOTICE
DISPLAY BOARD
2
(JUMPER)
TEMPERATURE
OR
SET POINT
TEMP
SET
10/24/03
REV
DATE

DESCRIPTION
REVISIONS
EM
PART NO.
FOR

CALIBRATION ADJUST
(FACTORY SET)
HARVEY MITCHELL
APVD BY
TED BARBEN
DATE
SCALE
3/17/94
NONE
DRAWN BY
TEMPERATURE
SENSOR
MODEL 3040 3050 3080

DIAGRAM
POWER
SUPPLY
SET POINT
ADJUST
TB
DWN APVD
DRAWING NO
P0093
SIZE
SHEET
2 OF 2
TO
DISPLAY
BOARD
POWER SUPPLY
BOARD
24V
ADJ
+ 4
+ 3
+ 2
+ 1
TB3
W
C
O
RED
1
2
MOISTURE
SENSOR
CONNECTOR
-CAUTIONTERMINALS
1,2 & 3 ARE
HOT WHEN
SAMPLE
PUMP IS
INSTALLED
TB2
R
E
L
A
Y
DRY CIRC.
N.C.
4
5
N.O.
BLACK
WHITE
GREEN
DRY CIRCUIT
TO ALARM
(CONTACT CLOSES
WHEN IN ALARM)
6 AMP FUSE
SAMPLE
DRAIN
BLOWER
JUMPER CARD
115V
230V
12 AMP FUSE
TB1
P HOT L1
O
W COM L2
E
R
SAMPLE PUMP
A MOV PROT.
L N.C. 1
2
A
R N.O. 3
M
1
2
WATER CARRY OVER

FILTER
L 1(HOT)
L 2(COMMON)

TERMINAL BLOCK
WIRED
A 01/05/00 ADD PAGES 2 & 3 TO DRAWING PACKAGE

REV DATE
DESCRIPTION
EAM JK
DWN APVD
REVISIONS
MOISTURE SENSOR
CONNECTOR
OR
FOR MODELS 3040 3050 3080
OR
PART NO.
NOT ISSUED
FOR
INSTRUMENT

DRAWING NO
H. MITCHELL
P0094
T. BARBEN II
DATE
SCALE
SIZE
03/17/1994
1:1
D
DRAWN BY
APVD BY
SHEET
1 OF 3
TO
DISPLAY
BOARD
POWER SUPPLY
BOARD
24V
ADJ
+ 4
+ 3
+ 2
+ 1
TB3
W
C
O
RED
1
2
MOISTURE
SENSOR
CONNECTOR
-CAUTIONTERMINALS
1,2 & 3 ARE
HOT WHEN
SAMPLE
PUMP IS
INSTALLED
TB2
A MOV PROT.
L N.C. 1
2
A
R N.O. 3
M
R
E
L
A
Y
DRY CIRC.
N.C.
4
5
N.O.
SAMPLE PUMP
SAMPLE

(CONTACT CLOSES
WHEN IN ALARM)
DRAIN
BLOWER
6 AMP FUSE
JUMPER CARD
115V
230V
12 AMP FUSE
TB1
P HOT L1
O
W COM L2
E
R
1
2
HOT
WATER CARRY OVER

FILTER
COMMON

SOLID STATE RELAY

MAX 240VAC 25 AMP
1
240V
TERMINAL BLOCK
WIRED
REV DATE
DWN APVD
DESCRIPTION
REVISIONS
25A
115 / 230 VAC

3+
4
BLACK
MOISTURE SENSOR
CONNECTOR
HOT (CUSTOMER SUPPLIED VOLTAGE)
OR

OR
PART NO.
FOR

DRAWING NO
H. MITCHELL
P0094
T. BARBEN II
DATE
SCALE
SIZE
03/17/1994
1:1
D
DRAWN BY
APVD BY
SHEET
2 OF 3
TO
DISPLAY
BOARD
POWER SUPPLY
BOARD
24V
ADJ
+ 4
+ 3
+ 2
+ 1
TB3
W
C
O
RED
1
2
MOISTURE
SENSOR
CONNECTOR
-CAUTIONTERMINALS
1,2 & 3 ARE
HOT WHEN
SAMPLE
PUMP IS
INSTALLED
TB2
A MOV PROT.
L N.C. 1
2
A
R N.O. 3
M
R
E
L
A
Y
DRY CIRC.
N.C.
4
5
N.O.
SAMPLE PUMP
SAMPLE

(CONTACT CLOSES
WHEN IN ALARM)
DRAIN
BLOWER
6 AMP FUSE
JUMPER CARD
115V
230V
12 AMP FUSE
TB1
P HOT L1
O
W COM L2
E
R
1
2
HOT
COMMON
WATER CARRY OVER

FILTER

SOLID STATE RELAY

MAX 240VAC 25 AMP
1
240V
TERMINAL BLOCK
WIRED
2
25A
115 / 230 VAC

3+
4
BLACK
L1 (CUSTOMER
SUPPLIED
VOLTAGE)
SOLID STATE RELAY

MAX 240VAC 25 AMP
1
240V
MOISTURE SENSOR
CONNECTOR
OR

OR
PART NO.
FOR

2
25A
115 / 230 VAC

3+
4
BLACK
REV DATE
DWN APVD
DESCRIPTION
REVISIONS

L2 (CUSTOMER SUPPLIED VOLTAGE)
DRAWING NO
H. MITCHELL
P0094
T. BARBEN II
DATE
SCALE
SIZE
03/17/1994
1:1
D
DRAWN BY
APVD BY
SHEET
3 OF 3
1/4" NPT
.400
D
.300
1-1/8"
.400
MOUNTING HOLE
FOR 10-32 SCREW
(2 TYP)
FLOW
.950
3"
1/4" NPT
3
1.500
24" CABLE
B 03/10/03 Revised P/N for Item 1 & 2
REV DATE
DESCRIPTION
REVISIONS
PART NO.
6020-0001
PART NO.
5101-0002
5101-0001
5205-0007
FOR
W.C.O.

DRAWING NO
H. MITCHELL
P0006
TED BARBEN II
DATE
SCALE
SIZE
B
10/08/1991
1:1
DRAWN BY
APVD BY
MODEL W.C.O. WATER

CARRY OVER MOISTURE
SENSOR WITH FLOW THRU
ADAPTER
TABLE A
ITEM NAME
1 HOLDER FLOW THRU BODY
2 KYNAR MOISTURE SENSOR ASSY
3 SENSOR LOCK ASSY KIT
RPH JK
DWN APVD
SHEET
1 OF 1
HOLES FOR #10 PANHEAD

MOUNTING SCREWS
(SUPPLIED BY OTHERS)
1/2"
3"
2"
1.65"
EXPLODED FRONT VIEW
3"
2"
2
COMPLETE
FILTER P/N
1"
5/8"
1
1 1/4"
8"
1
FILTER
INLET PORT
1/4" NPT
1
FILTER
OUTLET PORT
1/4" NPT
4980-0039
4980-0058
4980-0005
4980-0009
4980-0059
FILTER PRESSURE DROP RATINGS

ELEMENT
INCHES OF WATER
P/N
5 LPM 10 LPM 20 LPM
SINTERED S.S. 4980-0023
10
14
24
4980-0022
PAPER
8
12
20
4980-0006
TEFLON
4
6
10
4980-0007
CERAMIC
4
6
10
COATED CERAMIC 4980-0018
6
8
12
1 FOR COALESCING (COATED CERAMIC WCOF)

P/N 4980-0059 SAMPLE INLET & OUTLET PORTS
ARE REVERSED.
7
1/8"
08/24/04
REV
DATE
8
7
6
5
2
1
1
1
4
3
2
1
ITEM
MIDDLE
PIN
Revised with New Bowl Design & Ext. Cable

DESCRIPTION
REVISIONS
-
1
1
1
1
QTY DWG NO.
4704-0010
3907-0052
4904-0006
5205-0038
RPH
TB
VIEW "A" - 2x SCALE

VERIFY BEFORE CONNECTING THAT
MIDDLE PIN IS SHORTER THAN
OUTSIDE PIN. IF NOT, CUT MIDDLE PIN
AS SHOWN
10-32X3/8"PH
14" EXT. CABLE
O-RING 2-030
BOWL ASSEMBLY
5110-0012
SEE TABLE
5008-0004
5110-0011
PART NO.
A
LEFT SIDE
RETAINER
FILTER ELEMNT
BRACKET
KYNAR HEAD
DESCRIPTION
FOR
INSTRUMENT

DRAWN BY
DRAWING NO
APVD BY
P0018
HARVEY MITCHELL
TED BARBEN II
DATE
SCALE
04/14/92
1:1
RIGHT SIDE
PART NO.
SEE TABLE
DWN APVD
VISIBLE GAS FILTER WITH MOISTURE SENSOR

(W.C.O.F.)
ITEM #3 TYPE
SIZE
SHEET
1 OF 1
D
2-5/8"
INSULATED SECTION
TOP VIEW
CHILLED SURFACE
THERMOCOUPLE
(TYPE "K")
(TYPE "J")
(TYPE "T")
"L"
(SEE TABLE)
CONDENSATE DRAIN
3/8" NPT
(FEMALE)

SIDE VIEW
DRY GAS OUTLET

1/8" NPT
(FEMALE)
B
SAMPLE GAS INLET
1/4" NPT
(FEMALE)
APPROX 316 S.S.

LENGTH EXCHANGER
"L"
P/N
5200-SK50
5"
5200-SJ50
5200-ST50
10"
5200-SK10
5200-SJ10
5200-ST10
HASTELLOY C276
EXCHANGER
P/N
5200-CK50
5200-CJ50
5200-CT50
ALLOY 20
EXCHANGER
P/N
5200-AK50
5200-AJ50
5200-AT50
5200-CK10
5200-CJ10
5200-CT10
5200-AK10
5200-AJ10
5200-AT10
TITANIUM
UNIVERSAL
EXCHANGER ANALYZERS
P/N
SERIES
5200-TK50
400
5200-TJ50
500
5200-TT50
800
5200-TK10
1000
5200-TJ10
1100
5200-TT10
3000
01/23/97
REV
DATE
HEAT EXCHANGER OUTLINE

PART NO.
SEE TABLE

EV MUSSELMAN
HARVEY MITCHELL
DATE
SCALE
12/11/95
1:1
FOR
SEE TABLE
APVD BY
HWM
DWN APVD
DRAWN BY
EAM
DESCRIPTION
REVISIONS
DRAWING NO
P0146
SIZE
SHEET
1 OF 2
EXPLODED METALLIC HEAT EXCHANGER

THERMOCOUPLE
ASSY.
(TYPE "K")
(TYPE "J")
(TYPE "T")
2-021 VITON
O-RING
P/N 4904-0013
(SEE NOTES)
METALLIC
OUTER TUBE ASSEMBLY

W/TEFLON FERRULES
P/N 4954-0095
1/16" TEFLON
THERMOCOUPLE SLEEVE
METALLIC
INNER TUBE ASSEMBLY
6-32 X 1/2"
PAN HEAD SCREW
"L"
LENGTH
5"
5"
5"
5"
5"
5"
5"
5"
5"
5"
5"
5"
10"
10"
10"
10"
10"
10"
10"
10"
10"
10"
10"
10"
MATERIAL
DESC.
316 S.S.
"
"
ALLOY 20
"
"
HASTELLOY C276
"
"
TITANIUM
316 S.S.
"
"
ALLOY 20
"
"
HASTELLOY C276
"
"
TITANIUM
"
"
COMPLETE ASSY
P/N
5200-SK50
5200-SJ50
5200-ST50
5200-AK50
5200-AJ50
5200-AT50
5200-CK50
5200-CJ50
5200-CT50
5200-TK50
5200-TJ50
5200-TT50
5200-SK10
5200-SJ10
5200-ST10
5200-AK10
5200-AJ10
5200-AT10
5200-CK10
5200-CJ10
5200-CT10
5200-TK10
5200-TJ10
5200-TT10
COMPLETE ASSEMBLY
SPARE PARTS LIST

OUTER TUBE
INNER TUBE
ASSY P/N
ASSY P/N
5201-0015
5201-0012
"
"
5201-0022
"
"
5201-0020
"
"
5201-0024
"
"
5201-0013
"
"
5201-0023
"
"
5201-0021
"
"
5201-0025
"
"
"
"
"
"
"
"
"
"
5201-0028
"
"
5201-0016
"
"
"
"
"
"
"
"
5201-0029
"
"
TYPE "K" THERMOCOUPLE

ASSEMBLY P/N
1150-0011
X
X
"
X
X
"
X
X
1150-0018
X
X
1150-0011
X
X
"
X
X
"
X
X
1150-0018
X
X
TYPE "J" THERMOCOUPLE

ASSEMBLY P/N
X
1150-0012
X
X
"
X
X
"
X
X
1150-0019
X
X
1150-0012
X
X
"
X
X
"
X
X
1150-0019
X
TYPE "T" THERMOCOUPLE

ASSEMBLY P/N
X
X
1150-0013
X
X
"
X
X
"
X
X
1150-0014
X
X
1150-0013
X
X
"
X
X
"
X
X
1150-0014
2). LIGHTLY LUBRICATE O-RING

ASSEMBLY.
INNER TUBE
MATERIAL IDENTIFIER
1). O-RING IS FACTORY INSTALLED

IN METALLIC OUTER TUBE ASSY.
2-56 X 1/2"
PAN HEAD SCREW
NOTES:
"L"
(SEE TABLE)
OUTER TUBE
MATERIAL IDENTIFIER
01/23/97
EAM HWM
REV
DATE
DESCRIPTION
REVISIONS
DWN APVD

PART NO.
SEE TABLE
FOR
400 500 800 1000 1100 3000 SERIES

DRAWING NO
EV MUSSELMAN
P0146
HARVEY MITCHELL
DATE
SCALE
SIZE
B
12/11/95
1:1
DRAWN BY
APVD BY
SHEET
2 OF 2
8
B
6
B
5
VITON O-RING
P/N 4904-0013
INSULATED
INNER TUBE
ASSY
OUTER TUBE
ASSY
.305 I.D.
SAMPLE
GAS
OUTLET
C
1/4"
TUBE
PLUG
1/16" NPT
A
TOP VIEW

SAMPLE GAS INLET

3/8" TUBE
SECTION A-A
HEAT
APPROX
LENGTH EXCHANGER OUTER TUBE MATERIAL
P/N
"L"
5"
5200-S050
316 S.S.
5"
5200-T050
TITANIUM
5"
5200-A050
ALLOY 20
5"
5200-C050
HASTELLOY C-276
5"
10"
5200-S010
316 S.S.
10"
5200-T010
TITANIUM
10"
5200-A010
ALLOY 20
10"
5200-C010
HASTELLOY C-276
10"
CONDENSATE
DRAIN 3/8"NPT
"L"
(SEE TABLE)
UNIVERSAL
ANALYZERS
SERIES
400/500
400/500
400/500
400/500
400/500
800/1000/1100/3000
800/1000/1100/3000
800/1000/1100/3000
800/1000/1100/3000
800/1000/1100/3000
02/09/99
REVISE P/N TABLE FOR TEFLON COATED
REV
DATE
DESCRIPTION
REVISIONS
EAM
RD
DWN APVD
HEAT EXCHANGER METALLIC

OUTLINE
PART NO.
SEE TABLE
FOR
SEE TABLE

06 USA
SECTION B-B
DRAWN BY
DRAWING NO
APVD BY
P0147
EV MUSSELMAN
H. MITCHELL
DATE
SCALE
12/11/95
NONE
SIZE
SHEET
1 OF 2
VITON O-RING
#2-021
SEE NOTES
D
OUTER TUBE ASSEMBLY METALLIC
INNER TUBE
MATERIAL
IDENTIFIER
"L"
INNER TUBE ASSEMBLY
OUTER TUBE
MATERIAL
IDENTIFIER
HEAT EXCHANGER
SEPERABLE
INNER
APPROX
P/N
TUBE ASSY
"L"
P/N
LENGTH
5"
5200-S050 5201-0015
5"
5200-T050
"
5"
5200-A050
"
5"
5200-C050
"
5"
5200-S05T 5201-0041
10"
5200-S010 5201-0016
10"
5200-T010
"
10"
5200-A010
"
10"
5200-C010
"
10"
5200-S01T 5201-0042
SPARE PARTS LIST

OUTER
VITON O-RING PLUG
TUBE ASSY #2-021 P/N 1/16"NPT
P/N
P/N
5201-0012
4904-0013 4951-0058
5201-0024
"
"
5201-0022
"
"
5201-0020
"
"
5201-0043
"
"
5201-0013
4904-0013 4951-0058
5201-0025
"
"
5201-0023
"
"
5201-0021
"
"
5201-0044
"
"
NOTES:
1). O-RING IS FACTORY INSTALLED IN
METALLIC OUTER TUBE.
2). LIGHTLY LUBRICATE O-RING WITH
SILICONE GREASE BEFORE ASSEMBLY. B
02/09/99
REV
DATE
REVISE TABLE TO INCLUDE TEFLON PARTS EAM

DESCRIPTION
REVISIONS
FOR
INSTRUMENT

6 USA
DRAWN BY
DRAWING NO
APVD BY
P0147
EV MUSSELMAN
H. MITCHELL
DATE
SCALE
12/11/95
NONE
RD
DWN APVD

METALLIC
PART NO.
SEE TABLE
SIZE
SHEET
2 OF 2
CHILLED SURFACE
INSULATED SECTION
THERMOCOUPLE
(TYPE "J")
(TYPE "K")
(TYPE "T")
TOP VIEW

2-5/8"
"L"
(SEE TABLE)
CONDENSATE DRAIN
3/8" NPT
(FEMALE)
SIDE VIEW
DRY GAS OUTLET
1/8" NPT
(FEMALE)
SAMPLE GAS INLET

1/4" NPT
(FEMALE)

GLASS KYNAR
LENGTH HEAT EXCHANGER
ASSEMBLY
"L"
P/N
5"
5200-KK50
5200-KJ50
5200-KT50
10"
5200-KK10
5200-KJ10
5200-KT10
15"
5200-KK15
5200-KJ15
5200-KT15
UNIVERSAL
ANALYZERS
SAMPLE COOLER
MODELS
520
530
540
570
1040
1050
1060
1080
1090
C 10/02/01
REV DATE
Add 15" Heat Exchanger Data To Table

DESCRIPTION
REVISIONS
Glass Kynar Temperature Sensing

Heat Exchanger Outline
PART NO.
SEE TABLE
FOR
SEE TABLE

FGA2
DRAWN BY
APVD BY
DRAWING NO
E. Mussleman
H. Mitchell
DATE
12/11/95
EM
JK
DWN APVD
P0148
SCALE
1:1
SIZE
SHEET
1 OF 2

W/TEFLON FERRULES
P/N 4954-0095
THERMOCOUPLE
ASSY.
(TYPE "K")
(TYPE "J")
(TYPE "T")
1/16" THERMOCOUPLE
TEFLON INSULATOR
#2-120 VITON
O-RING
P/N 4904-0004
(SEE NOTE 2)
6-32 X 1/2"
PAN HEAD SCREW
GLASS TUBE
#2-018 VITON
O-RING
P/N 4904-0003
(SEE NOTE 2)
KYNAR INSULATED
SECTION ASSEMBLY
GLASS KYNAR
HEAT EXCHANGER
ASSEMBLY
LENGTH "L"
P/N
5"
5200-KK50
5200-KJ50
5"
5200-KT50
5"
10"
5200-KK10
10"
5200-KJ10
10"
5200-KT10
15"
5200-KK15
15"
5200-KJ15
15"
5200-KT15
KYNAR DRAIN
FITTING
P/N 5110-2002
(SEE NOTE 1)
KYNAR HEAD
P/N 5201-0017
(SEE NOTE 1)
SPARE PARTS LIST
KYNAR
TYPE "T"
TYPE "K"
TYPE "J"
GLASS
INSULATED SECTION
THERMOCOUPLE THERMOCOUPLE THERMOCOUPLE
TUBE
ASSEMBLY
P/N
P/N
P/N
P/N
P/N
1150-0013
1150-0012
5110-2003
1150-0011
5201-0002
"
"
"
"
"
"
"
"
"
"
5110-2004
5201-0001
"
"
"
"
"
"
"
"
"
"
"
"
"
5110-2006
5201-0078
"
"
"
"
"
"
"
"
"
"
"
"
"
NOTES:
IN KYNAR HEAD AND KYNAR DRAIN FITTING.
ASSEMBLY.
C
REV
10/02/01
DATE
Add 15" Data To Parts List Table

DESCRIPTION
REVISIONS
EM
JK
DWN APVD
Glass Kynar Temperature Sensing Heat Exchanger

Spare Parts List Exploded Assembly
PART NO.
SEE TABLE
7/8" WRENCH
FLATS

2-56 X 1/2"
PAN HEAD SCREW
FOR
SAMPLE COOLERS
DRAWN BY

APVD BY
DATE
12/11/95
DRAWING NO
E. Musselman
H. Mitchell
P0148
SCALE
1:1
SIZE
SHEET
2 OF 2

INSULATED SECTION
CHILLED SURFACE
PLUG
1/16" NPT
TOP VIEW
"L"
(SEE TABLE)
CONDENSATE DRAIN
3/8"NPT
SIDE VIEW
DRY GAS OUTLET

1/4" TUBE
B
SAMPLE GAS INLET
3/8" TUBE
LENGTH
"L"
5"
10"
15"
UNIVERSAL
QTY OF
GLASS KYNAR HEAT
ANALYZERS
EXCHANGERS PER
EXCHANGER
SAMPLE
COOLER
SAMPLE COOLER
ASSEMBLY P/N
MODELS
520
1
2
530
5200-K050
2
540
570
4
1040
1
1050
2
5200-K010
1060
2
1080
2
1090
4
FGA2
5200-K015
1
10/02/01
REV
DATE
Add 15" Data To Table
EM
DESCRIPTION
REVISIONS

SENSING OUTLINE
PART NO.
SEE TABLE
FOR
INSTRUMENT

DRAWING NO
EV MUSSELMAN
P0149
H. MITCHELL
DATE
SCALE
SIZE
C
12/11/95
1:1
DRAWN BY
APVD BY
RD
DWN APVD
SHEET
1 OF 2
PLUG
1/6"NPT
#2-120 VITON
O-RING
(SEE NOTE 2)
GLASS TUBE
#2-018 VITON
O-RING
(SEE NOTE 2)
KYNAR INSULATED
SECTION ASSEMBLY
KYNAR HEAD
(SEE NOTE 1)
KYNAR DRAIN
FITTING
(SEE NOTE 1)
C
GLASS KYNAR
HEAT EXCHANGER
ASSEMBLY
LENGTH "L"
P/N
5"
5200-K050
10"
5200-K010
15"
5200-K015
KYNAR
INSULATED
SECTION ASSY
P/N
5110-2003
5110-2004
5110-2006
SPARE PARTS LIST

KYNAR
GLASS
DRAIN
TUBE
FITTING
P/N
P/N
5201-0002
5110-2002
5201-0001
"
"
5201-0078
#2-120
VITON
O-RING
P/N
4904-0004
"
"
#2-018 VITON
KYNAR HEAD
O-RING
P/N
4904-0003
"
"
1/16" NPT PLUG
P/N
5201-0017
"
"
P/N
4951-0066
"
"
7/8" WRENCH
FLATS

NOTES:
10/02/01
REV
DATE

IN KYNAR HEAD AND KYNAR DRAIN
FITTINGS
EAM
DESCRIPTION
REVISIONS
PART NO.
SEE TABLE
FOR
INSTRUMENT

DRAWING NO
EV MUSSELMAN
P0149
H. MITCHELL
DATE
SCALE
SIZE
C
12/11/95
1:1
DRAWN BY
APVD BY
RD
DWN APVD

SENSING SPARE PART
INSTALLATION

ASSEMBLY.
Add 15" Data to Table
SHEET
2 OF 2
R13
C4
U2
TB1
C8
C14
R43
U6
C17 C21
R22
R37
R38
R40
U5
U4
CR5
J1
C24
R42
R28
R11
R8
R44
CR2
C11
C7
R20
CR9
CR1
C28
U9
R30
C23
C25
W1
R24
R27
C10
C12
C20
C27
U8
C26
R31
R23
C13
R17
R19
R32
U3
CR7
CR8
U1
CR4 CR3
R33
R16
R7
J3
R10
R14
R15
C
J5
C16
C15
C19
U7
C18
R35
C6
R3
R34
C22
R25
CR6
R5
R12
C3
R45
B
ITEM
DWG.
SIZE
DWG NO.
REVISIONS
UNLESS OTHERWISE INDICATED:

ANGLES = $$p 2$$a
MACHINED FINISH 300/OR BETTER
CHAMFER ANGLE = $$p 3$$a
CHAMFER LENGTH = $$p .015"
INDUSTRY STANDARDS.
ALL DIMENSIONS $$p .005" UNLESS
APV SYM DATE
ASSY OR B/M
CHANGE
TB C 1/16
98 REMOVED R10
TB B 5/24
95 REFDES U8 TO U6
TB A 2/13
94
FINISH
PER SPEC.
REQ'D
SUPERSCEDES
DWG.
K2
K1
R9
J6
B
And Stocking Damage
C9
R18
R21
R2
R1
Q1
R36
R39
C5
Q2
R6
C1
R26
C2
R4
PART NO.
NAME
PART NO.
NAME
3600-0012
PARTS LOCATION
FOR
MODEL 3040/50/80 COOLER/DISPLAY

SCALE
FULL
DATE
2/13/94
INTERNATIONAL

SIZE
B
SHEET
DRAWING NO.
E0030
REV.
MRM
TB TB TB
CONT. ON.
10
NOTICE
G
+VREF
R3
10K
+10V
R6
R7
49.9K
TEMP
SET
2K
27L2
7
U3
5 +
4
6
R9
1K
20T
8
U3
R45
R5
2.49K
1K
1
27L2
CR9
J5
1
C7 +15V
.1
MLC
R8
24.9K
R11
CR2
.47uf, POLYE
R12
C28
.1
MLC
C6
.1uf
MLC
J1
1
TP GND
J1
2
+VREF
SET
R16
10K
10K
-VREF
TEMP
CAL
+15V
R20
10K
J3
R21
J1
4
COM
1K
20T
R17
8.66K
R19
J1
3
J1
5
+15V
R23
4.99K
C12
.1uf
MLC
C10
R24
4.99K
C13
.1uf
MLC
100K
8
U4
1
U4
4 27L2
R27
10K
+10mv/ C
-VREF
R31
10K
1 MEG
3
10K
U5
4 27L2
R37
R35
15K
1K
+15V
DRY
8
U5
7
27L2
11
12
13
14
U6
10
4025
8
2
1
U6
R42
R36
24.9K
Q2
WET/DRY
J5
6
100K
U6
C20
.1uf
MLC
7 4025
J5
3
+10V
C19
.1uf
MLC
CR6
LM385 -2.5
+VREF
(+5V)
-VREF
(+2.5V)
C22
.1uf
MLC
W1
+5V
8 2
C26
15uf
TANT
C15
15uf
TANT
B
REV DATE
CHANGE
06/07
99
REV DATE
1
6
7
15uf
TANT
U9
7660S
4
5
-5V
C27
15uf
TANT
NAME:3000 SERIES LOW TEMP

SCHEMATIC
CONTROLLER/DISPLAY
FOR
PART NO. 3600-0033

ANALYZERS
C E0061
INC.
RELAY
DRIVE
C25
3). ALL DIODES ARE 1N4148.

CR5
R40
499ohm
R39
100K
U7
C18
.1uf
MLC
2N4401
4025
5
4
3
J5
2
1 MEG
CR4
GRN
78L05
R33
2K
R41
2K
COM
J5
5
C17
.1uf
MLC
CR3
GRN
COOL
+15V
+15V
6
+15V
HOT=HIGH
COOL=LOW
DISPLAY
+15V
C16
15uf
TANT
C21
.1uf
MLC
FROZEN=HIGH
OK=LOW
U1
3 1/2
DIGIT
LCD
J5
4
TEST
C14
.01uf
R38
10
+VREF
+15V
R30
R34
10K
+VREF
26
+VREF
+VREF R32
32
TEST
21
16
22
18
19
2
3
4
5
6
7
8
9
10
11
12
13
14
15
17
20
23
24
25
BP
B3
G3
OSC2 E3
B4
OSC1 D1
CREF C1
B1
CREF A1
U2 F1
7136 G1
E1
A/Z
D2
C2
B2
BUFF
A2
F2
INT
E2
D3
F3
IN+
INPOL
REF+
A3
REFC3
TEST G2
1
G
16
12
8
28
38
39
40
1
29
32
9
3
18
19
20
21
22
23
17
14
15
24
25
26
13
10
31
2
30
11
27
Q1
-100mv/ C
+VREF
J6
39
C2
33
.47uf POLYE
C4
29
.47uf POLYE
R13
28
1.74 MEG
C8
27
.15uf POLYP
31
30
+VREF
36
35
R26
37
10K
R43
15K
R1
2N4401
R2
100K
1
38 OSC3
549K
1 MEG
+10V
+VREF
+VREF +VREF
-VREF
C9
.01uf
47pf
R4
27L2
R28
10K
.47uf
POLYE
2
1 MEG
+VREF
0 C=0V
25 C=+.25V
w.r.t. +VREF
.1uf, MLC
R25
R18
TEMP
C11
100K
C24
.1uf
MLC
TEMP
SENSOR
-
R22
4.99K
R15
+10V
APPROVED
P/S
CONTROL
3
R
40
34
24.9
1 MEG
R14
20K
FM
C1
R44
10K
CR1
C3
C5 -5V
.1uf
MLC
+VREF
+5V
TP PS
+10V
+10mv/ C
DELETE C23
CHANGE
SHEET 1 OF
DWN MRM
CHK TB
APV TB
ENG TB
CR17
CR15
R1
C33
R34
R26
T3
C4
C6
L2
RH1
J4
C2
CR6
CR5
CR8
CR7
CR3
CR1
J3
TB1
F1
TB2
K1
CR22
Q5
J6
R42
R43
TB3
C41
R41
R40
C37
C1
J2
RH7
RH6
RH5
C14
U3
CR4
CR2
C17
T2
RH4
U5
U4
C31
C21
R12
R7
R29
R28
R21
R24
C12
F2
R32
C36 C23
R19
R23
C10
C9
C43
C8
U7
R3
J1
C30
R4
R22
Q4
C35
R8
R38
R13
L1
C13
C29
R30
C11
R31
R39
R11
U6
R6
R37
Q3
R10
C19
R14
C39
R15
R36
C38 C40
C15
J5
C3
RH3
RH2
T1
C25
ITEM
DWG NO.
DWG.
SIZE
PART NO.
REVISIONS
APV SYM DATE
ASSY OR B/M
UNLESS OTHERWISE
INDICATED:
.
ANGLES =_+ 2
MACHINED FINISH 300/OR
BETTER
.
CHAMFER ANGLE_= + 3
CHAMFER LENGTH_= + .015"
INDUSTRY STANDARDS.
ALL DIMENSIONS_ +.005" UNLESS
NAME
3000 SERIES POWER SUPPLY

CHANGE
FINISH
PER SPEC.
REQ'D
SUPERSCEDES
DWG.
C5
R20
T4
C20
C22
C26
R27
R5

And Stocking Damage
R2
R25
CR20
CR19
R16
CR13
CR12
C32
R33
R17
C7
CR10
CR9
CR21
Q1
R18
C24
5
Q2
6
CR11
7
U2
PART NO.
NAME
PARTS LOCATION
3600-0011
FOR
MODEL 3040/50/80 POWER SUPPLY

SCALE
FULL
DATE
2/23/94
INTERNATIONAL

SIZE
B
SHEET
DRAWING NO.
E0034
REV.
MRM
CONT. ON.
10
APPROVED
LINE
F1
NEUT/
LINE 2
RH1
L1
12 AMP
250V
R3
422K
C1
.22
250V
C3
4700pf
250V
C5
4700pf
250V
CL30
C2
.22
250V
TB1
115V
230V
GND
T1
1
3
J1
WHT
1
3
J1
GRN
F2
6 AMP
250V
2
2
J1
BLK
DRAIN PUMP
TB2
NC1 1
J2
J2
TB2
2
TB2
NO1 3
TB2
NC2 4
J2
J2
J2
TB2
NO2 6
115V
230V
RH3
130V
MOV
115V
CR3
J4
CR4
JUMPER
J2
4
5
6
3
RELAY CONTACTS
REQUIRE 24VDC
200mA MAX.
RESISTIVE LOAD
IN CLASS I, GROUP A, B, C, OR D
DIVISION 2 AREAS
J3
J3
J3
J3
J3
BLU
+15V
J5
4
+15V
J5
5
COM
+VREF
J5
2
+VREF
12
J5
6
WET/DRY
1
C37
1000pf
MLC
GRN
BLOWER
CR22
1N4148
MOISTURE
SENSOR
7
5
J6
U7
LM1830N
C41
.1
MLC
1
13
9
2
C43
15
25V
TANT
11
SCHEMATIC
FOR
E
10
4/12
01
9/11
00
REV DATE
REVISION PER
D
SHEET 2
ADD GROUP A&B
C
CLASSIFICATION NOTE
10
TB3
2
Q5
2N4401
14
RED
TB3
1

1). ALL RESISTORS ARE 1/4W, 1%, 50ppm/oC.
BLK
J6
-160VDC
WHT
R40
71.5K
OHMS
R43
24.9K
C8
15
25V
TANT
6
12
PL5.0-16
JUMPER
SAMPLE PUMP
10K
0VDC
+15V
U2
C7
470
50VDC
10
N/C
R42
7815
4X 1N4005
R41
75
1/2W
3
CR2
CR1
J4
3
GRN
K1
J5
C4
680
200VDC
J4
2
BLK
RH6
250V
MOV
RH7
250V
MOV
TB2
ARM2 5
RELAY
DRIVE
CR21
FPIL
60
+160VDC
R1
100K
1/2W
R2
C6
100K
680
1/2W
200VDC
+15V
AC
WHT
RH4
250V
MOV
RH5
250V
MOV
ARM1
RH2
130V
MOV
TB1
5
J4
6
7
NOTICE
FM
TB1
CHANGE
6/7
99
10/15
96
5/16
94
REV DATE
R40 FROM 20K TO

71.5K OHMS
C19 VALUE CHANGE
RELAY RATINGS
CHANGE
NAME:500
WATT POWER SUPPLY
PART NO.3600-0011

ANALYZERS
C E0024
INC.
SHEET 1 OF
DWNMRM
CHK
APV
ENG
10
1
G
G
+15V
2
+VREF
1
R4
1 MEG
C35
F
+15VDC
+VREF
+24V
C15
R5
2.15K
+24V R27
ADJ 100
1T
P/S 1
CONTROL
R12
499
R30
Q3
24.9K
R28
24.9K
J5
R29
49.9K
2N4401
.1
50V
MLC
R11
10K
C36
.1
MLC
+15VDC
16
R39
10K
2
R32
24.9K
C9
15
25V
TANT
C30
15
25V
TANT
C10
15
25V
TANT
C12
.1
MLC
4.99K
C17
0.1
MLC
20K
C38
0.1
MLC
C13
.1
MLC
+VREF
C14
.1
MLC
1N4148
T2
U3
3525A
50KHz
+15V
11
R21
100
R24
100
12
8
2 U4
CR10
R16
1N4148
24.9
R33
49.9
6
7
C29
CR12
1N5245
R17
15V
10K
CR13
1N5245
15V
Q1
IRFP451R
8
1
2 U5
5 4
R20
120
5W
C22
R36
R38
54.9K
C40
.01
MLC
470pf
2KV
L2
1+
FEP30DP
8T
R18
D.S.
8T
C24
D.S.
18 uH
35T
3+
CR11B
+24V
R22
CR17
R25
2.43
1N4148
24.9
R34
49.9
4420
CR19
1N5245
R26
15V
10K
CR20
1N5245
15V
Q2
IRFP451R
1-
C33
2200pf
MLC
2+
3-
4+
2C25
4700
35V
4-
C26
4700
35V
-160VDC
NOTICE
B
SCHEMATIC
FOR
E
G
F
D.S.
FEP30DP
1N4148
6
7
CR11A
T3
C32
2200pf
MLC
CR15
14T
R13
1
5 4
4420 50V
POLYE
11T
4). D.S. COMPONENTS R15, R18, R38, AND C24

ARE NOT PRESENT.
o
TLC3702
15
TANT
25V
11T
+15V
14
5+
U6
6-
100K
D.S.
C39
CR9
3
FM
R37
15
1/2W
+160VDC
APPROVED
C11
.1
MLC
1
R14
24.9K
10
4X 1N4148
CR7
CR8
R8
13
8
2.49K
50T
R7
R15
10
Q4
2N4401
1T
CR5
R6
1K
1/2W
47pf
MLC
CR6
15
C19
330pF
100V
MLC
9
C21
C31
2200pf MLC
1
R19
6
50V
POLYE 11.5K
C23
R10
5
34K
R23
1000pf 5.11
100V
7
MLC
R31
C20
1
400VDC
POLYP
TLC3702
T4
0VDC
U6
3+
4/12
01
9/11
00
REV DATE
C35 FROM 1000pf TO

47pf
REVISION PER
SHEET 1
CHANGE
D
C
6/7
99
10/15
96
5/16
94
REV DATE
R40 FROM 20K TO

71.5K OHMS
C19 VALUE CHANGE
RELAY RATINGS
CHANGE
NAME:
500 WATT POWER SUPPLY
PART NO. 3600-0011

ANALYZERS
C E0024
INC.
SHEET 2 OF
DWNMRM
CHK
APV
ENG
22-3/4"
CARRYING HANDLE
15-1/4"
WET GAS
SAMPLE INLET
DRY SAMPLE GAS
TO ANALYZER
3/8" TUBING
FITTING
SAMPLE COOLER
SAMPLE PUMP HEAD
DOUBLE HEAD
ADI MINI DIA-VAC
PUMP
26-1/2"
FLOW METER
VISIBLE FILTER
WITH WATER
CARRY OVER
SENSOR
COMPRESSED AIR HEAD
8
,57
65
5,4
78
5,465,5
EDUCTOR
B
AIR FILTER
WATER CARRY
OVER SENSOR
CONNECTOR
FOUR LEG STAND
ISOMETRIC VIEW
FRONT VIEW
12-3/8"
04/17/98
ADD MOUNTING FEET/PATENT NUMBER
REV
DATE
DESCRIPTION
REVISIONS
EAM

ACCESSORY OUTLINE FOR SYSTEMS WITH
EDUCTOR
PART NO.
FOR

DRAWN BY
APVD BY
DATE
12/20/93
JK
DWN APVD
DRAWING NO
HARVEY MITCHELL
P0084
TED BARBEN
SCALE
SIZE
D
1:1
SHEET
1 OF 1
22-3/4"
CARRYING HANDLE
13-5/8"
WET GAS
SAMPLE INLET
DRY SAMPLE GAS

TO ANALYZER
3/8" TUBING
FITTING
SAMPLE COOLER
SINGLE HEAD
ADI MINI
DIA-VAC
PUMP
26-1/2"
FLOW METER
VISIBLE FILTER
WITH WATER
CARRY OVER
SENSOR
8
5,465,57
5,4
65
,57
PERISTALTIC
PUMP HEADS
WATER
CARRY OVER
SENSOR
CONNECTOR
FOUR LEG STAND
ISOMETRIC VIEW
FRONT VIEW
12-3/8"
04/23/98
ADD LEG/FEET/NEW HEAD DESIGN/PAT #
REV
DATE
DESCRIPTION
REVISIONS
EAM

ACCESORY OUTLINE FOR SYSTEMS WITH
PERISTALTIC PUMP
PART NO.
FOR

DRAWN BY
APVD BY
DATE
12/20/93
DRAWING NO
HARVEY MITCHELL
P0085
TED BARBEN
SCALE
SIZE
D
1:1
JK
DWN APVD
SHEET
1 OF 1
4
1
D
*
8
7
8
6
5,4
65
,57
7
5
ASSEMBLED FRONT VIEW
VIEW AS SEEN LOOKING AT BACK OF SAMPLE COOLER

BILL OF MATERIALS FOR

LEG MOUNT KIT
P/N 9515-0019
ITEM
1
2
3
4
5
6
7
8
*
*
QTY
2
1
1
2
3
4
3
3
DESCRIPTION
LEG SINGLE
LEG DUAL
PLUG ROUND PLASTIC
PLUG SQUARE PLASTIC
SCREW 1/4" x 1-1/2" S.S.
SCREW #6 x 1-1/4" S.S.
WASHER 1/4" FLAT S.S.
NUT 1/4" S.S.
A 04/28/98 ADD FOOT PADS REVISE BOM TABLE

DESCRIPTION
REV DATE
EAM JK
DWN APVD
REVISIONS
P/N
6006-0001
6006-0002
4919-0007
4919-0006
4704-0047
4704-0048
4710-0001
4711-0006
LEG MOUNTING KIT

INSTALLATION FOR 3000
SERIES SAMPLE COOLERS
PART NO.
9515-0019
FOR
3000 SERIES COOLERS
*NOTE: ITEMS 3 AND 4 ARE FACTORY INSTALLED

DRAWN BY
APVD BY
DATE
02/04/1994
DRAWING NO
H. MITCHELL
T. BARBEN II
P0089
SCALE
NTS
SIZE
E
SHEET
1 OF 1
INSTALLATION:
1). INSTALL ITEMS #1 INTO BOTTOM OF
BOTH HEAT EXCHANGERS.
2). INSTALL ITEMS #2 & #3 INTO ITEMS #1

WITH ITEM #2 IN THE FRONT HEAT
EXCHANGER.
3). INSTALL ITEMS #4 INTO TOP OF LIQUID
DRAINS TYPICAL.
FRONT
4). INSTALL ITEMS #5 ONTO ITEMS #2 & #3.
PARTS TABLE
ITEM#
DESCRIPTION
QTY
P/N
1
2
1/2" 316 S.S. X 5" BENT TUBE
1 9011-0004
3
1/2" 316 S.S. X 3" STRAIGHT TUBE
1 9011-0004
4
5
FLOAT DRAIN VALVE
2 4955-0001
4
3
5
DESCRIPTION
REV DATE
DWN APVD
REVISIONS
FLOAT DRAIN INSTALLATION

LAYOUT
PART NO.
9515-0100
RIGHT SIDE VIEW

DRAWN BY
APVD BY
DRAWING NO
E. Musselman
T. Barben II
DATE
09/15/1999
FOR
3020, 3050, 3080
P0360
SCALE
NTS
SIZE
E
SHEET
1 OF 1

MOISTURE CONVERSION TABLE
DEW POINT,
DEGREES C.
-100
-50
-20
-10
-5
-4
-3
-2
1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
% WATER BY VOLUME % WATER BY WEIGHT

AT SATURATION
AT SATURATION
0.00000139
0.00000081
0.00388
0.00241
0.102
0.0633
0.256
0.1596
0.396
0.229
0.432
0.268
0.469
0.291
0.510
0.317
0.555
0.345
0.602
0.364
0.649
0.404
0.696
0.433
0.750
0.466
0.803
0.499
0.861
0.535
0.922
0.573
0.988
0.614
1.06
0.658
1.13
0.702
1.21
0.753
1.29
0.802
1.38
0.860
1.48
0.920
1.58
0.980
1.68
1.044
2.31
1.433
3.13
2.004
4.19
2.64
5.55
3.54
7.28
4.67
9.46
6.12
12.2
8.0
15.5
10.3
19.7
13.3
24.4
16.8
30.7
21.7
38.0
27.8
46.7
35.6
57.2
45.7
69.2
58.4
WATER VAPOR
PRESSURE, mm. Hg
0.0000099
0.0295
0.776
1.950
3.014
3.280
3.569
3.880
4.223
4.579
4.937
5.294
5.70
6.10
6.54
7.01
7.51
8.05
8.58
9.15
9.8
10.5
11.2
12.0
12.8
17.5
23.8
RECOMMENDED SPARE & CONSUMABLE PARTS LIST

AIT-A18 REV 2
EQUIPMENT TAG NO:

VENDOR NAME:
________SERVOMEX_____________
AUTHORIZED SIGNATURE:______________________Date:__________
PART DESCRIPTION
REF. DWG.
OR PART
STREAM 1 PROCESS GAS
EQUIPMENT DESCRIPTION:
TYPE OR MODEL
NUMBER
15036-3843A-M-IN72
MIDREX PURCHASE ORDER:
MFG.
NAME
RECOMMENDED
APPROX.
Delivery
SPARES QUANTITY
UNIT
Time
WEIGHT
2
(Wks) START
CAPITAL
(Kg.)
UP
YEARS
SINTERED METAL FILTER ELEMENT
203495
050-11-20M
BALSTON
0.9
MICROFIBER FILTER ELEMENT
203497
050-11-BQ
BALSTON
0.4
PRESSURE GAUGE
205388
25.500-60-PSI/BAR1/4-LM
NOSHOK
0.8
SOLENOID VALVE
206201
EV8314G301-24VDC
ASCO
0.9
FLOW SWITCH
203427
FS6204CV-1MXSPECIAL
AUTOFLOW
0.8
FLOWMETER 5LPM
024A0037
VFA-21-SSV
DWYER
0.9
FLOWMETER 3.8LPM
203564
KING
1.36
FLOWMETER 42LPM
205421
KING
1.36
PRESSURE GAUGE
205457
NOSHOK
0.8
74C-123G081323810
74C-234G041323810
25.510-30-PSI/BAR1/4-CBM
10 REGULATOR, 0-15 PSIG
025A0003
960-175-203
BELLOFRAM
1.3
11 INLINE FILTER ELEMENT
205973
SS-8F-K4-2
SWAGELOK
0.4
12 PERISTALTIC PUMP TUBING 5 FT
200598
9216-0002
UNIVERSAL ANALYZERS
0.3
13 CHILLER 12 AMP FUSE
200591
3010-0006
UNIVERSAL ANALYZERS
0.2
200590
3010-0005
UNIVERSAL ANALYZERS
0.2
15 O-RING HEAT EXCHANGER
204355
4904-0013
UNIVERSAL ANALYZERS
0.1
16 FILTER ELEMENT WCOF
200587
4980-0006
UNIVERSAL ANALYZERS
0.5
17
FORM 177 REV. C
Page 1 of 2
1
1

AIT-A18 REV 2
EQUIPMENT TAG NO:

VENDOR NAME:
________SERVOMEX_____________
PART DESCRIPTION
REF. DWG.
OR PART
TYPE OR MODEL
NUMBER
15036-3843A-M-IN72
MFG.
NAME
RECOMMENDED
APPROX.
Delivery
SPARES QUANTITY
UNIT
Time
WEIGHT
2
(Wks) START
CAPITAL
(Kg.)
UP
YEARS
18
19 FUSE KIT
2500996
SERVOMEX
20 DETECTOR SCRUBBER
S1210939
SERVOMEX
21 CHOPPER BOX SCRUBBER
S2000512
SERVOMEX
22 O-RINGS
S2500982A
SERVOMEX
23
24
25
26
27
28
29
30
31
32
33
34
FORM 177 REV. C
Page 2 of 2
0.4
0.1

AIT-A33.1 REV 1
EQUIPMENT TAG NO:

VENDOR NAME:
________SERVOMEX_____________
PART DESCRIPTION
REF. DWG.
OR PART
STREAM 2.1 BUSTLE GAS
TYPE OR MODEL
NUMBER
15036-3843A-M-IN72
MFG.
NAME
RECOMMENDED
APPROX.
Delivery
SPARES QUANTITY
UNIT
Time
WEIGHT
2
(Wks) START
CAPITAL
(Kg.)
UP
YEARS
203495
050-11-20M
BALSTON
0.9
203497
050-11-BQ
BALSTON
0.4
PRESSURE GAUGE
205388
25.500-60-PSI/BAR1/4-LM
NOSHOK
0.8
SOLENOID VALVE
206201
EV8314G301-24VDC
ASCO
0.9
FLOW SWITCH
203427
FS6204CV-1MXSPECIAL
AUTOFLOW
0.8
FLOWMETER 5LPM
024A0037
VFA-21-SSV
DWYER
0.9
FLOWMETER 3.8LPM
203564
KING
1.36
FLOWMETER 19LPM
204644
KING
1.36
PRESSURE GAUGE
205457
NOSHOK
0.8
74C-123G081323810
74C-214G021423810
25.510-30-PSI/BAR1/4-CBM
025A0003
960-175-203
BELLOFRAM
1.3
205973
SS-8F-K4-2
SWAGELOK
0.4
200598
9216-0002
UNIVERSAL ANALYZERS
0.3
200591
3010-0006
UNIVERSAL ANALYZERS
0.2
200590
3010-0005
UNIVERSAL ANALYZERS
0.2
204355
4904-0013
UNIVERSAL ANALYZERS
0.1
200587
4980-0006
UNIVERSAL ANALYZERS
0.5
17
FORM 177 REV. C
Page 1 of 2
1
1

AIT-A33.1 REV 1
EQUIPMENT TAG NO:

VENDOR NAME:
________SERVOMEX_____________
PART DESCRIPTION
REF. DWG.
OR PART
STREAM 2.1 BUSTLE GAS
TYPE OR MODEL
NUMBER
15036-3843A-M-IN72
MFG.
NAME
RECOMMENDED
APPROX.
Delivery
SPARES QUANTITY
UNIT
Time
WEIGHT
2
(Wks) START
CAPITAL
(Kg.)
UP
YEARS
18
19 FUSE KIT
2500996
SERVOMEX
S1200922
SERVOMEX
S2000511
SERVOMEX
22 O-RINGS
S2500982A
SERVOMEX
23
24
25
26
27
28
29
30
31
32
33
34
FORM 177 REV. C
Page 2 of 2
0.4
0.1

AIT-A37 REV 2
EQUIPMENT TAG NO:

VENDOR NAME:
________SERVOMEX_____________
PART DESCRIPTION
REF. DWG.
OR PART
STREAM 3 COOLING GAS
TYPE OR MODEL
NUMBER
15036-3843A-M-IN72
MFG.
NAME
RECOMMENDED
APPROX.
Delivery
SPARES QUANTITY
UNIT
Time
WEIGHT
2
(Wks) START
CAPITAL
(Kg.)
UP
YEARS
203495
050-11-20M
BALSTON
0.9
203497
050-11-BQ
BALSTON
0.4
PRESSURE GAUGE
205388
25.500-60-PSI/BAR1/4-LM
NOSHOK
0.8
SOLENOID VALVE
206201
EV8314G301-24VDC
ASCO
0.9
FLOW SWITCH
203427
FS6204CV-1MXSPECIAL
AUTOFLOW
0.8
FLOWMETER 5LPM
024A0037
VFA-21-SSV
DWYER
0.9
FLOWMETER 3.8LPM
203564
KING
1.36
FLOWMETER 42LPM
205421
KING
1.36
PRESSURE GAUGE
205457
NOSHOK
0.8
74C-123G081323810
74C-234G041323810
25.510-30-PSI/BAR1/4-CBM
025A0003
960-175-203
BELLOFRAM
1.3
205973
SS-8F-K4-2
SWAGELOK
0.4
200598
9216-0002
UNIVERSAL ANALYZERS
0.3
200591
3010-0006
UNIVERSAL ANALYZERS
0.2
200590
3010-0005
UNIVERSAL ANALYZERS
0.2
204355
4904-0013
UNIVERSAL ANALYZERS
0.1
200587
4980-0006
UNIVERSAL ANALYZERS
0.5
17
FORM 177 REV. C
Page 1 of 2
1
1

AIT-A37 REV 2
EQUIPMENT TAG NO:

VENDOR NAME:
________SERVOMEX_____________
PART DESCRIPTION
REF. DWG.
OR PART
STREAM 3 COOLING GAS
TYPE OR MODEL
NUMBER
15036-3843A-M-IN72
MFG.
NAME
RECOMMENDED
APPROX.
Delivery
SPARES QUANTITY
UNIT
Time
WEIGHT
2
(Wks) START
CAPITAL
(Kg.)
UP
YEARS
18
19 FUSE KIT
2500996
SERVOMEX
S1200922
SERVOMEX
S2000511
SERVOMEX
22 O-RINGS
S2500982A
SERVOMEX
23
24
25
26
27
28
29
30
31
32
33
34
FORM 177 REV. C
Page 2 of 2
0.4
0.1

AIT-A75 REV 2
EQUIPMENT TAG NO:

VENDOR NAME:
________SERVOMEX_____________
PART DESCRIPTION
REF. DWG.
OR PART
TYPE OR MODEL
NUMBER
15036-3843A-M-IN72
MFG.
NAME
RECOMMENDED
APPROX.
Delivery
SPARES QUANTITY
UNIT
Time
WEIGHT
2
(Wks) START
CAPITAL
(Kg.)
UP
YEARS
203495
050-11-20M
BALSTON
0.9
203497
050-11-BQ
BALSTON
0.4
PRESSURE GAUGE
205388
NOSHOK
0.8
FLOWMETER 42 LPM
205458
KING
1.36
FLOWMETER 400CCM
205459
KING
1.36
PRESSURE GAUGE
205388
NOSHOK
0.8
INLINE FILTER ELEMENT
205973
SS-8F-K4-2
SWAGELOK
0.4
HEATER
205390
400/100 T3 JB TS40
INTERTEC
2.2
PERISTALTIC PUMP TUBING 5 FT
200598
9216-0002
UNIVERSAL ANALYZERS
0.3
200591
3010-0006
UNIVERSAL ANALYZERS
0.2
200590
3010-0005
UNIVERSAL ANALYZERS
0.2
204355
4904-0013
UNIVERSAL ANALYZERS
0.1
200587
4980-0006
UNIVERSAL ANALYZERS
0.5
25.500-60-PSI/BAR1/4-LM
74C-234G031325810
74C-103G041425710
25.500-60-PSI/BAR1/4-LM
14
15
16
17
FORM 177 REV. C
Page 1 of 2
1
1

AIT-A75 REV 2
EQUIPMENT TAG NO:

VENDOR NAME:
________SERVOMEX_____________
PART DESCRIPTION
REF. DWG.
OR PART
TYPE OR MODEL
NUMBER
MFG.
18
19
FORM 177 REV. C
Page 2 of 2
NAME

15036-3843A-M-IN72
RECOMMENDED
APPROX.
Delivery
SPARES QUANTITY
UNIT
Time
WEIGHT
2
(Wks) START
CAPITAL
(Kg.)
UP
YEARS

AIT-D18.1 & AIT- D19 REV 2
EQUIPMENT TAG NO:

VENDOR NAME:
________SERVOMEX_____________
PART DESCRIPTION
REF. DWG.
OR PART
STREAM 8.1 SEAL GAS
TYPE OR MODEL
NUMBER
15036-3843A-M-IN72
MFG.
NAME
RECOMMENDED
APPROX.
Delivery
SPARES QUANTITY
UNIT
Time
WEIGHT
2
(Wks) START
CAPITAL
(Kg.)
UP
YEARS
203495
050-11-20M
BALSTON
0.9
203497
050-11-BQ
BALSTON
0.4
PRESSURE GAUGE
205388
25.500-60-PSI/BAR1/4-LM
NOSHOK
0.8
SOLENOID VALVE
206201
EV8314G301-24VDC
ASCO
0.9
FLOW SWITCH
203427
FS6204CV-1MXSPECIAL
AUTOFLOW
0.8
FLOWMETER 5LPM
024A0037
VFA-21-SSV
DWYER
0.9
FLOWMETER 3.8LPM
203564
KING
1.36
FLOWMETER 13LPM
205419
KING
1.36
PRESSURE GAUGE
205457
NOSHOK
0.8
74C-123G081323810
74C-214G021323810
25.510-30-PSI/BAR1/4-CBM
025A0003
960-175-203
BELLOFRAM
1.3
205973
SS-8F-K4-2
SWAGELOK
0.4
200598
9216-0002
UNIVERSAL ANALYZERS
0.3
200591
3010-0006
UNIVERSAL ANALYZERS
0.2
200590
3010-0005
UNIVERSAL ANALYZERS
0.2
204355
4904-0013
UNIVERSAL ANALYZERS
0.1
200587
4980-0006
UNIVERSAL ANALYZERS
0.5
17 FLOWMETER 400CCM
202178
74C-103G041423710
KING
1.36
FORM 177 REV. C
Page 1 of 2
1
1
2
1

AIT-D18.1 & AIT- D19 REV 2
EQUIPMENT TAG NO:

VENDOR NAME:
________SERVOMEX_____________
PART DESCRIPTION
REF. DWG.
OR PART
STREAM 8.1 SEAL GAS
TYPE OR MODEL
NUMBER
15036-3843A-M-IN72
MFG.
NAME
RECOMMENDED
APPROX.
Delivery
SPARES QUANTITY
UNIT
Time
WEIGHT
2
(Wks) START
CAPITAL
(Kg.)
UP
YEARS
18
19 FUSE KIT
2500996
SERVOMEX
S1210939
SERVOMEX
S2000512
SERVOMEX
22 O-RINGS
S2500982A
SERVOMEX
0.1
23 FUSE KIT
204629
SERVOMEX
0.4
24 RESTRICTOR KIT
S1910980
SERVOMEX
25
26
27
28
29
30
31
32
33
34
FORM 177 REV. C
Page 2 of 2
0.4
1
1

AIT-H26 REV 2
EQUIPMENT TAG NO:

VENDOR NAME:
________SERVOMEX_____________
PART DESCRIPTION
REF. DWG.
OR PART
STREAM 9 DUST COLLECTOR
TYPE OR MODEL
NUMBER
15036-3843A-M-IN72
MFG.
NAME
RECOMMENDED
APPROX.
Delivery
SPARES QUANTITY
UNIT
Time
WEIGHT
2
(Wks) START
CAPITAL
(Kg.)
UP
YEARS
203495
050-11-20M
BALSTON
0.9
203497
050-11-BQ
BALSTON
0.4
PRESSURE GAUGE
205387
25.500-30/15PSI/BAR-1/4-LM
NOSHOK
0.8
SOLENOID VALVE
206201
EV8314G301-24VDC
ASCO
0.9
FLOW SWITCH
203427
FS6204CV-1MXSPECIAL
AUTOFLOW
0.8
FLOWMETER 5LPM
024A0037
VFA-21-SSV
DWYER
0.9
FLOWMETER 3.8LPM
203564
KING
1.36
FLOWMETER 42LPM
205421
KING
1.36
PRESSURE GAUGE
205457
NOSHOK
0.8
74C-123G081323810
74C-234G041323810
25.510-30-PSI/BAR1/4-CBM
025A0003
960-175-203
BELLOFRAM
1.3
205973
SS-8F-K4-2
SWAGELOK
0.4
200598
9216-0002
UNIVERSAL ANALYZERS
0.3
200591
3010-0006
UNIVERSAL ANALYZERS
0.2
200590
3010-0005
UNIVERSAL ANALYZERS
0.2
204355
4904-0013
UNIVERSAL ANALYZERS
0.1
200587
4980-0006
UNIVERSAL ANALYZERS
0.5
17
FORM 177 REV. C
Page 1 of 2
1
1

AIT-H26 REV 2
EQUIPMENT TAG NO:

VENDOR NAME:
________SERVOMEX_____________
PART DESCRIPTION
REF. DWG.
OR PART
STREAM 9 DUST COLLECTOR
TYPE OR MODEL
NUMBER
15036-3843A-M-IN72
MFG.
NAME
RECOMMENDED
APPROX.
Delivery
SPARES QUANTITY
UNIT
Time
WEIGHT
2
(Wks) START
CAPITAL
(Kg.)
UP
YEARS
18
19 FUSE KIT
2500996
SERVOMEX
S1210939
SERVOMEX
S2000512
SERVOMEX
22 O-RINGS
S2500982A
SERVOMEX
23
24
25
26
27
28
29
30
31
32
33
34
FORM 177 REV. C
Page 2 of 2
0.4
0.1

MASS SPEC REV 2
EQUIPMENT TAG NO:

VENDOR NAME:
________SERVOMEX_____________
PART DESCRIPTION
REF. DWG.
OR PART
STREAM 2.2, 4, 8.2, 10.1-10.7
TYPE OR MODEL
NUMBER
15036-3843A-M-IN72
MFG.
NAME
RECOMMENDED
APPROX.
Delivery
SPARES QUANTITY
UNIT
Time
WEIGHT
2
(Wks) START
CAPITAL
(Kg.)
UP
YEARS
203495
050-11-20M
BALSTON
0.9
10
203497
050-11-BQ
BALSTON
0.4
10
PRESSURE GAUGE
205388
NOSHOK
0.8
FLOWMETER 19 LPM
204644
KING
1.36
FLOWMETER 400CCM
202178
KING
1.36
PRESSURE GAUGE
205388
NOSHOK
0.8
INLINE FILTER ELEMENT
205973
SS-8F-K4-2
SWAGELOK
0.4
SOLENOID VAVLE
206201
EV8314G301-24VDC
ASCO
PERISTALTIC PUMP TUBING 5 FT
200598
9216-0002
UNIVERSAL ANALYZERS
0.3
200591
3010-0006
UNIVERSAL ANALYZERS
0.2
200590
3010-0005
UNIVERSAL ANALYZERS
0.2
204355
4904-0013
UNIVERSAL ANALYZERS
0.1
200587
4980-0006
UNIVERSAL ANALYZERS
0.5
14 FLOWMETER
205421
74C-234G041323810
KING
1.36
25.500-60-PSI/BAR1/4-LM
74C-214G021423810
74C-103G041423710
25.500-60-PSI/BAR1/4-LM
15
16
17
FORM 177 REV. C
Page 1 of 1
2
4
4
2
4
4
Subject:
Project:
Location:
Order #
Date:
Calibration Fluid Calculations

Midrex
Angul, India
631032096
3/2/2011
t
Vc
Terminology
= cylinder life expectancy (days) (per single cylinder)
= cylinder volume (liters) (1)
Pf
= max filing pressure of cylinder (Bar g)
Pd
= delivery pressure of sample (Bar g)
Qc
= sample flow rate (per calibration) (liters/day)(2)
Q1
= sample leak rate (liters/day)
Calculations
Calibration
Checks/day
Frequency
Volume
required
per
Calibration
Check (3)
10
Liters/Day
Vc(Pf-Pd)
t=
Pd(Qc-Q1)
Vc =
43.8
Pf =
103
Pd =
Qc =
10
Q1 =
0.05
t=
222.30151
Days
7.4100503 Months
Note1 :
Note2 :
Note3 :
Assuming 9 in Diameter X 56 Inch Tall Cylinder for

volume calculations
Assuming 1 calibration check/day required
5 LPM flow to sample probe @ 120
seconds/calibration check per day
Air Dimensions Incorporated

1371 West Newport Center Drive, Suite # 101
Deerfield Beach, FL, 33442
800.423.6464 / 954.428.7333 ph , 954.360.0987 fax
info@airdimensions.com www.airdimensions.com
Standard DIA-VAC
MAINTENANCE AND DISASSEMBLY INSTRUCTIONS

A. General Operations Characteristics
1. The Dia-Vac normally runs at 130 to 150 degrees F. It is not an indication of trouble if the
outer surfaces of the Dia-Vac Pump or motor are hot to the touch.
2. To check pumping efficiency, employ suitably damped gauges connected so as to dead-end
either pressure or vacuum.
NOTE: Check each separately, One or the other port must be open during this test. Use 0-60 PSI
pressure gauge and 0-30 inch hg. vacuum gauge, (or mercury manometer.)
Minimum pressure should be 40 PSIG for the .222 eccentric
Minimum vacuum should be 22 inches hg. For the .222 eccentric
3. The Dia-Vac normally runs quietly, especially when both pressure and vacuum ports are
connected into a closed system. An obvious knock or rattle could indicate a problem. Check
through "Disassembly and Inspection Procedures" with particular attention to the tightness of all
screw fasteners.
4. All bolts and screws except A19005 and A19006 should have one drop of Loctite Removable 242 (or equivalent) on threads before tightening.
B. Maintenance Procedures
1. Motor oiling
No oiling or other lubrication addition is necessary at all with the Dia-Vac pumps. Please note
the Air driven GAST motor does require SAE 10 oil lubrication for proper operation.
2. Diaphragm Replacement (See also Maintenance Procedure Below)
a.) Standard EPDM (part 4002 or complete repair kit 11009).
b.) Teflon coated EPDM (part 4001 or complete repair kit 11005).
c.) Viton (part 4003 or kit complete repair kit 11007).
d.) Teflon/Viton (part 4009 or kit 1 complete repair kit 11006)
e.) All-Teflon (part 4009 or kit complete repair kit 11011)
The degree of usage and condition of operating temperatures or pressure will determine the rate
of replacement of part or parts. For heavy loads (25-75 PSI) and constant operation the diaphragm should be inspected at least every six months.
(0707)
"We Pass Your Gas"
For lighter loads (0-15 PSI or up to maximum vacuum) the diaphragm may operate successfully
for a year or more. The corrosive content of the gas media being pumped can effect the recommended inspection and replacement cycle of the diaphragm.
*Diaphragms require close precision tolerance, therefore only ADI diaphragms should be
used as replacements.
C. Disassembly of Head Section and Service Diaphragm
1. Remove head section by unscrewing the four large bolts. A flat-bladed screw driver may be
needed to gently pry the head free of the service diaphragm. **If you have Teflon coating on
the heads use caution not to scratch the surface.
2. The valve body can then be removed by unscrewing the two smaller screws (also accessible
on the top of the head section). This part may be freed by gently tapping on these two screws
after they have been loosened about three or four turns. When the valve body is removed, check
all internal surfaces for any accumulation of dirt. The two valve discs can be wiped clean and
replaced as long as they appear unaffected by usage. The valve gasket can be easily removed and
should be inspected. As a matter of good practice, the valve discs and valve gasket should be
replaced during any routine maintenance check of the head section. A once a year routine procedure is recommended.
3. The service diaphragm is secured by the single screw in its center. Remove this screw with a
5/32" Allen wrench. The diaphragm and its clamping plate should be easily lifted off. Some
slight adherence to the metal may occur if the diaphragm has been in use for a long period. Before inserting the diaphragm cap screw (19007) apply a small amount of Teflon paste or a Teflon Washer seal (23001), (do not use Teflon tape), then tighten the cap screw.
NOTE: When replacing the service diaphragm, be sure the four projecting studs of the base casting are properly located in the four outer holes provided in the diaphragm before the part is
clamped in place. Be sure the diaphragm plate is firmly replaced with its center screw.
D. Disassembly of the Connecting Rod
1. Remove head section and service diaphragm as described in (C) above.
2. Remove the front plate from the face of the base casting by removing the four retaining
screws.
3. Using a hex socket wrench, remove the hex head bolt on the connecting rod top surface. This
will release the connecting rod cap (3001) which may then be lifted off.
4. The connecting rod assembly on single head units, including the counterweight, is held in
place by the counterweight screw. This can be loosened by a 3/16" Allen wrench. The connecting rod assembly may then be slid off the motor shaft. On the dual and quad head units the assembly is held in place by the set screw. This can be loosened by a 1/8" Allen wrench and the
assembly may then be slid off the motor shaft.
(0707)
"We Pass Your Gas"
E. Replacement of the Connecting Rod

1. Replace the connecting rod assembly on the motor shaft, taking care to align set screw or
counterweight screw as squarely as possible on the flat of the motor shaft.
2. Replace the connecting rod cap and connecting rod bolt. Tighten this assembly firmly with the
hex socket wrench.
3. Put a new Service Diaphragm in place taking care to locate it over the four projecting studs on
the top face of the base casting.
F. Related Torque Values

1. Head bolts - 110 inch pounds.
2. Valve body screws and Diaphragm plate screws - 70 inch pounds.
3. Connecting rod bolt - 150 inch pounds.
G. Motor Wiring
1. Please refer to wiring diagram located on motor.
H. Motor Amperage
1. Please refer to data label located on motor for running amperage. Startup amps are 3-4 times
the stated running amps on the motor.
Teflon is a Registered Trademarks of E.I. Du Pont
Loctite is a Registered Trademark of Henkel Technologies Inc.
Dia-Vac is a Registered Trademark of Air Dimensions Inc.
GAST is a Registered Trademark of GAST Mfg. Inc.
Viton is a Registered Trademark of E.I. Du Pont

(0707)
"We Pass Your Gas"
MICRO FLOW SWITCH

Adjustable Gas Series - Range 30 sccm to 20 slpm
FS6200 Series Micro Flow Switch

Available with 1/8 and 1/4 NPT Connections
316L Stainless Steel Construction
Hazardous Location Service

CSA Certified
Class I, Div 1&2
Groups A, B, C, D
Class II, Div 1&2
Groups E, F, G
Class III
Cenelec Certified
EExdII CT3
Class I, Zone I, IIC
CE Compliant
Fully Field Adjustable
Operates in Any Orientation
Operating Temperature
-40F to +220F
(-40C to +105C)
Operating Pressure
3000 psig (207 bar)
316 Stainless Steel construction
Shock and Vibration Resistant
Contamination Resistant
1/8 & 1/4 NPT Connections
FS6200 Series
Micro Flow Switch
available with 1/8 and
1/4 NPT Connections
The FS6200 Series Micro Flow Switch is designed to precisely detect increasing or
decreasing flow rate of gases in critical processes. Typical applications include process analyzer
sample conditioning systems, critical purge monitors, excess flow safety, and oxygen and speciality gas systems. The linear, high resolution adjustment allows for precise settings. The miniature compact construction is ideal for high density system packaging.
revised 11-02
FS6200 Series
MICRO FLOW SWITCH

SPECIFICATIONS
Switch Assembly - SPDT UL 61760
100 VDC, 120 VAC max.
3 Watts resistive max. continuous
0.25 Amp. max. continuous
3.30 VA max. - 100 VDC
2.46 VA max. - 120 VAC
0.20 Ohm max contact resistance
Adjustable Flow Rate Setpoint*
-1 30 sccm to 10 slpm N2
-3 1 slpm to 20 slpm N2
Fluid Media: Gases including
corrosives
Pressure: 3000 psig max. (207 bar) IN
Operating Temperature:
-40F to 220F (-40C to 105C)
Leakage: 1x10-7 cc/sec He max.
Set Point Accuracy: 1%
Response Time: 10 milliseconds max.
Deactuation (reset): less than 12% of
actuation set point
Internal Filter: 40 micron
Materials:
Body and wetted parts: 316 St Stl
Spring: Inconel X
Seals: As specified
Weight: .45 lbs (205 gms)
22 Gauge Lead Wires

x 96 inches long
(244cm)
1/2-14 NPT
Conduit
Connecton
1.66
(42.2mm)
OUT
Flow Rate
Adjustment
1.37
(34.8mm)
Part Number Example:
N.O.
N.C.
Black
White
Blue
Increasing Flow
FS6202 C V - 1 M
Basic Series:
FS6202 - 1/8 NPT
FS6204 - 1/4 NPT
Optional Mounting Bracket
Material:
C = 316 Stainless Steel
Adjustable Flow Range*

-1 30 sccm to 10 slpm
-3 1 slpm to 20 slpm
Seal Material:
V = Viton
B = Buna - N
E = Ethylene Propylene
K = Kalrez
1.50
(38.1mm)
ELECTRICAL SCHEMATIC
COM
ORDERING INFORMATION
Mounting
Bracket
* Adjustable Flow Rate Set Point @ 5 psig (0.34 bar)
Products Co.
15915 So. San Pedro St., Gardena, CA 90248
Ph. (310) 515-2866
Copyright 2002 Autoflow Products Co. Kalrez and Viton are registered trademarks of E.I. du Pont. All rights reserved
FEATURES
Excellent regulation, stability and repeatability

Corrosion-resistant construction (no brass
components, T-51FR & T-51AFR)
NACE Constructed (T-51FRCT Corrosive Tec)
Low droop
Low cost
Small package size
Panel, bracket or pipe mounting
Fluorocarbon pintle seat (T-51FR, T-51AFR & T-51FRCT)
Auto drain option (T-51AFR)
DESCRIPTION
PRECISION CONTROL DEVICE
From
industry
to industry,
Marsh Belloframs
Type 51 Series of Regulators offer a
low-cost, high performance option
for a wide range of applications.
OPTIONS
1
2
3
The Bellofram Type 51 Precision Air Regulator series offers

a high-performance regulator in a compact, low cost package. It operates in output pressure ranges up to 100 psig /
6.9 BAR (120 psig / 8.3 BAR in T-51FR Corrosive Tec), with
a maximum supply pressure of 250 psi (17.3 BAR).
Materials of construction for standard T-51 Series
Regulators (Non-Corrosive Tec): Die-cast aluminum for the
body and dripwell; glass-reinforced thermoplastic polyester
for the bonnet; acetal resin for the internals; BUNA-N for
the diaphragm, gaskets and O-ring, fluorocarbon for the
pintle seat, and aluminum for the drain valve (plated steel
handle).
Materials of construction for Corrosive Tec T-51FRCT:
Aluminum alloy bonnet, body, and filter bowl, 316
stainless steel internals, Inconel alloy range spring, nitrile
diaphragm (fluorocarbon optional), 316 stainless steel
valve assembly, and painted with an epoxy finish. All
metallic parts for this unit conform to NACE material
requirements #MR-01-75 Class III.
These regulators are available standard (T-51R) or as
filter-regulators (T-51FR & T-51FRCT) and are even
available with an automatic drain, for automated flushing
out of contaminants, (T-51 AFR). These versatile regulators
provide excellent regulation for a wide range of applications, including pneumatic instruments, controllers,
chucks, and actuators. They can be through-panel
mounted with the supplied mounting nut, bracket-mounted
with the optional bracket or, due to their light weight,
mounted by their ports. The Corrosive Tec is supplied with
a tapped bonnet vent, to allow for the capture of exhaust air.
= option is available
Fluorocarbon Pintle
Non-Relieving
Knob
Sq. head Adj. Screw
4 5 Micron Filter
5 Epoxy Coating
6 Tapped Vent
Coalescing filter
7 Mounting Bracket
8 Pressure Gauge
9 Tamper - Resistant Cover
Panel Nut Mount
10 Soft Relief Seat
Low Bleed
11 Fluorocarbon Diaphragm
s = option is standard
TYPE 51AFR TYPE 51FRCT
TYPE 51R
TYPE 51FR
s
s
TYPE 51R
Regulator
Filter Regulator
Auto Filter Regulator
TYPE 51AFR
TYPE 51FRCT
250 psig (17.3 BAR)
250 psig (17.3 BAR)
250 psig (17.3 BAR)
250 psig (17.3 BAR)
Output Pressure Range
0-30 psig (0-2.1 BAR)

0-60 psig (0-4.1 BAR)
0-100 psig (0-6.9 BAR)
0-30 psig (0-2.1 BAR)

0-60 psig (0-4.1 BAR)
0-100 psig (0-6.9 BAR)
0-30 psig (0-2.1 BAR)

0-60 psig (0-4.1 BAR)
0-100 psig (0-6.9 BAR)
0-30 psig (0-2.1 BAR)

0-60 psig (0-4.1 BAR)
0-120 psig (0-8.3 BAR)
Supply Pressure Sensitivity
0.20 psig (0.01 BAR )

output change
0.45 psig (0.03 BAR)

output change
0.45 psig (0.03 BAR)

output change
0.45 psig (0.03 BAR)

output change
Sensitivity
1 (2.5 cm) of water
1 (2.5 cm) of water
1 (2.5 cm) of water
1 (2.5 cm) of water
Repeatability
Flow @ 100 psig (6.9 BAR) Supply
0.1 psig (0.01 BAR)

15 SCFM
(425 LPM)
0.1 SCFM
(2.8 LPM)
0.1 psig (0.01 BAR)

20 SCFM
(566 LPM)
0.1 SCFM
(2.8 LPM)
0.1 psig (0.01 BAR)

20 SCFM
(566 LPM)
0.1 SCFM
(2.8 LPM)
0.1 psig (0.01 BAR)

20 SCFM
(566 LPM)
0.1 SCFM
(2.8 LPM)
0 to 125F (-18 to 52 C)
0 to 125F (-18 to 52C)
0 to 125F (-18 to 52 C)
0 to 180F (-18 to 82C)
Maximum Supply Pressure
20 psig (1.4 BAR) outlet
Exhaust Capacity
@ 5 psig (0.4 BAR) above setpoint
Temperature Limits
Air Consumption
Port Size
Materials of
Construction
Corrosive Tec
6 SCFH (2.84 LPM) Maximum 6 SCFH (2.84 LPM) Maximum 6 SCFH (2.84 LPM) Maximum 6 SCFH (2.84 LPM) Maximum
/4 NPT
Aluminum, plated steel,

brass, acetal resin,
Buna-N /polyester,
music wire
/4 NPT

acetal resin,
Buna-N / polyester,
music wire, Fluorocarbon
/4 NPT

acetal resin,
Buna-N / polyester,
music wire, Fluorocarbon
/4 NPT
Aluminum, Stainless Steel,

Inconel, Buna-N / polyester,
Fluorocarbon, acetal,
polyphenylene sulfide
For T-51FR, T-51AFR & T-51R
T-51 SPECIFICATIONS & DIMENSIONS
@ 25 psig / 170 kPa change in supply
TYPE 51FR
ORDERING
INFORMATION
PART NUMBER:
TYPE-51 GENERAL PURPOSE REGULATORS
Part
TYPE
Number
960-222-000
51R
960-223-000
960-224-000
960-175-000
51FR
960-176-000
960-177-000
960-284-000
51AFR
960-285-000
960-286-000
960-303-000
51 FRCT 960-304-000
960-305-000
OPTION ORDERING MATRIX:
Add three digits from table below to end of part number.

OPTION
1 2 3 4 5 6 7
Control Range
psig BAR
0-30 0-2.1
0-60 0-4.1
0-100 0-6.9
0-30 0-2.1
0-60 0-4.1
0-100 0-6.9
0-30 0-2.1
0-60 0-4.1
0-100 0-6.9
0-30 0-2.1
0-60 0-4.1
0-120 0-8.3
REGULATOR
OPTIONS &
ACCESSORIES
9 10 11
Fluorocarbon
Pintle
Non-Relieving
Knob
5 Micron Filter
004 054 064 074 084 094 104 114
Epoxy Coating
005 065 075 085 095 105 115
Coalescing Filter
(T-51AFR only)
Mounting Bracket
Pressure Gauge
Tamper-Resistant Cover
001 021 031 041 051 061 071 081 091 101 111
002 032 042 052 062 072 082 092
003 043 053 063 073 083
112
103 113
006 076 086 096 106 116

007 087 097 107 117
008 098 108 118
009 109 119
Panel mounting Nut

NON RELIEVING
10 Soft Relief Seat
010 110
Used in applications where it is desirLow Bleed
able to relieve pressure downstream
11 Fluorocarbon
011
and not at the regulator. Non-relievDiaphragm
ing regulators should not be used for
low or no flow applications.
TAMPER PROOF COVER
PRESSURE GAUGE
KNOB
Dual scale (psi/kPa) 2 (50mm) A 316 stainless steel hexagonal cover
Replaces the standard square head gauges. Ranges include 0-60 psi (0- placed over the adjusting screw and
adjusting screw. (except T-51FRCT) 4.1 BAR),0-100 psi (0-6.9 BAR) and threaded onto the bonnet of the regu0-120 psi (0-8.3 BAR). When speci- lator with a wrench, prevents ordinary
5 MICRON FILTER
Replaces the 40 micron filter for fied with regulator, the correct range hand adjustments. Supplied with an
O-ring that is designed to seal the
more complete air filtration. (Except will be supplied.
adjusting screws threads in captured
FLUOROCARBON ELASTOMERS
T-51R)
Diaphragm, as well as gaskets and bleed applications. (T-51FRCT Only)
EPOXY FINISH
LOW BLEED DIAPHRAGM
An epoxy paint applied to the body O-rings, are made with a special
and dripwell of the regulator exterior elastomer to prevent deterioration (Soft Relief Seat): Used in applicasurfaces to provide increased from elements in the air supply, such tions where it is desirable to minimize
corrosion resistance. (Standard for as flame retardant synthetic lubri- the standard bleed rate of the
cants normally destructive to the regulator while maintaining the ability
T-51FRCT)
to relieve excess pressure at the
standard BUNA-N material.
MOUNTING BRACKET
regulator. Bleed rate is reduced from
Plated steel bracket for side mountless than 6 SCFH (2.8 LPM) to less
ing. (316 SS for T-51FRCT)
than 0.1 SCFH (0.05 LPM).
COALESCING FILTER
(T-51FRCT only)
Replaces the 40 micron filter for
both moisture and particulate filtration. (T-51AFR only)
USA
State Route 2, Box 305
Newell, WV 26050
800- 727-5646 or (304)387-1200
FAX (304) 387-4417
info@marshbellofram.com
EUROPE
9 Castle Park, Queens Drive
Nottingham NG2 1AH, UK
Tel +44 (0) 115 993 3300
Fax +44 (0) 115 993 3301
bellofram@aol.com
IMPORTANT NOTICE
Our recommendations, if any, for the use of this product are based on
tests believed to be reliable. The greatest care is exercised in the selection of our raw materials and in our manufacturer, no guarantee or warranty, express or implied is made as to such use or effects incidental to
such use, handling or possession or the results to be obtained, whether in
accordance with the directions or claimed so to be. The manufacturer
expressly disclaims responsibility therefor. Furthermore, nothing contained herein shall be construed as a recommendation to use any product
in conflict with existing laws and/or patents covering any material use.
SALES & APPLICATIONS

(800)727-5646 fax:(304) 387-4417
w w w. m a r s h b e l l o f r a m . c o m
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JOB: CRMAIN06-0428-6 Name: 5C-428
5C
100:
DATE: JAN 19 2006
Time: 5:25:03 PM Operator: GK COLOR: CMYK
Dimensions Pg. 430

Factory sealed enclosures are installed in a
rigid metallic conduit system for surface
mounting adjacent to or remote from
equipment being controlled and are used:
to prevent arcing of enclosed device from
causing ignition of a specific hazardous
atmosphere or atmospheres external to the
enclosure
in industrial areas such as chemical plants,
oil and gas refineries, paint and varnish
manufacturing plants, gasoline bulk loading
terminals, grain elevators, grain processing
industries, coal processing or handling areas,
or metal handling or finishing areas where
atmosphere may contain hazardous gases
and/or dust
in non-hazardous areas where sturdy,
durable enclosures are required
in conjunction with magnetic starters or
contactors for remote control of motors
Manual motor starting switch enclosures are
used:
for manual starting of small ac or dc motors
to provide manual starting and stopping
and, in the case of units with heaters, motor
running protection
Features:
Factory sealed devices have many distinct
advantages:
reduce installation problems
eliminate external seals
lower installation costs
improve safety
are used with general purpose snap and
pushbutton type switches
standard neoprene covers for front
operated pushbuttons. Prevents
accumulation of dirt and entrance of water
around operating shafts
mounting lugs and taper tapped hubs with
integral bushings
large machine screws for fastening covers
to bodies
lockout provisions on front operated push
button (marked STOP and OFF) and
selector switch covers
lockout hole for padlock having 14 hasp is
provided when used with covers for front
lever and side rocker type operation
close tolerances in machining of wide,
mating flanges and journalled shafts and
bearings for front button operation, produces
flametightness of enclosure joints
on enclosures with front lever and side
rocker type operating handles, threaded type
shafts and bushings are used to ensure
flametightness
dead end (EFS or EDS) or through feed
(EFSC or EDSC) hubs 12 to 1 sizes
Shafts stainless steel

Shaft bushings stainless steel
Rocker handle and pushbutton guards
type 6/6 nylon
Sealing enclosures copper-free aluminum
Standard Finishes:
Feraloy iron alloy electrogalvanized and
aluminum acrylic paint
Copper-free aluminum natural
Type 6/6 nylon black
Stainless steel natural
NEC/CEC:
Class I, Division 1 & 2, Groups B*,C,D
Class II, Division 1, Groups E,F,G
Class II, Division 2, Groups F,G
Class III
NEMA/EEMAC: 3,7B*CD,9EFG
UL Standard: 894, 698
CSA Standard: C22.2 No. 30
Options:
The following special options are available
from the factory by adding suffix to Cat. No.
Suffix to be
Added to
Cat. #
Description
Emergency Stop button (momentary) front operated red mushroom button . . . . . . . . . . S111
Lockout provision on front operated pushbutton cover (standard on buttons
marked OFF and STOP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S153
For 24 VDC operation on pilot lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S300
Three-position selector switches with modified operation:
Momentary contact clockwise operation, spring return to center, maintained
contact counter-clockwise operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S634
Momentary contact counter-clockwise operation, spring return to center,
maintained contact clockwise operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S635
Bodies and covers (single and two gang units) copper-free aluminum. . . . . . . . . . . . . . . . . . . SA
Where indicated in the catalog listings, EDS units suitable for Class I, Division 1,
Group B usage can be supplied, add suffix - GB, EFS units are suitable for Class I, Division 1,
Group B as standard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GB
Maintained contact mushroom head with lockout and guard. Maximum one per cover
and cannot be used with a pilot light with a transformer or another standard pushbutton.. . S769
EDS bodies and factory sealed cover and device sub-assemblies are available for field
assembly (see pages 394 to 396).
Bodies Feraloy iron alloy; copper-free

aluminum.
Front operated pushbutton and pilot light
covers Feraloy iron alloy
Side operated type pushbutton covers
copper-free aluminum
STIBOINFO((CRH:66008com:5C:428))
CH0 0 5 C- 0
Explosionproof
Dust-Ignitionproof
Raintight
Wet Locations
Certifications and
Compliances:
Suffix S769
Standard Materials:
428
Typedriver Name: TS name csm no.: 100
Cl. I, Div. 1 & 2, Groups B*,C,D

Cl. II, Div. 1, Groups E,F,G
Cl. II, Div. 2, Groups F,G
Cl. III
NEMA 3,7B*CD,9EFG
EFS and EDS Factory Sealed

Control Devices and Manual
Motor Starting Switches
Application:
TCP: 15001
US: 1-866-764-5454
* See Options: suffix GB
CAN: 1-800-265-0502
Copyright 2006 Cooper Crouse-Hinds
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JOB: CRMAIN06-0439-3 Name: 5C-439
DATE: JAN 19 2006
Time: 5:25:16 PM Operator: RB
EDS Factory Sealed General Use

Snap Switches
Dimensions Pg. 430
EDSC2129
COLOR: CMYK
TCP: 15001

Cl. III
NEMA 3,7B*CD,9EFG
Explosionproof
Dust-Ignitionproof
Raintight
Wet Locations
5C
EDS2229
General Use Snap Switch Front Operated

Single Gang
277VAC
20
20
20
20
Dead End
Cat. #
EDS2129
EDS218
EDS2130
EDS2140
20
20
20
20
EDS3129
EDS318
EDS3130
EDS3140
EDSC3129
EDSC318
EDSC3130
EDSC3140
Amperes
Hub
Size
34
34
34
34
Style
1-pole
2-pole
3-way
4-way
120VAC
20
20
20
20
1
1
1
1
1-pole
2-pole
3-way
4-way
20
20
20
20
Two Gang
Through
Feed
Cat. #
EDSC2129
EDSC218
EDSC2130
EDSC2140
Dead End
Cat. #
EDS2229
EDS2230
EDS3229
EDS328
EDS3230
EDS3240
Through
Feed
Cat. #
EDSC2229
EDSC228
EDSC2230
EDSC2240
EDSC3229
EDSC328
EDSC3230
EDSC3240
ON-OFF standard marking for 1-pole and 2-pole units.

Combinations of switches can be furnished.
AC rated switches are tested for resistive, inductive and tungsten filament loads up to the
full current rating and for motor loads up to 80% of the ampere rating.
* Class I, Group B: All units on this page can be modified for Class I, Group B usage. Add
suffix GB to the Cat. No. Seals must be installed within 112 of each conduit opening in
Division 1. In Canada, for Group B applications consult factory.
US: 1-866-764-5454
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439
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with General Use Snap Switches

Front Operated
EDS and EFD enclosures are installed in a

rigid metallic conduit system for surface
mounting adjacent to or remote from
equipment being controlled and are used:
to prevent arcing of enclosed switch from
causing ignition of a specific hazardous
atmosphere or atmospheres external to the
enclosure
in industrial areas such as chemical plants,
oil and gas refineries, paint and varnish
manufacturing plants, gasoline bulk loading
terminals, grain elevators, grain processing
industries, coal processing or handling areas,
or metal handling or finishing areas where
atmosphere may contain hazardous gases
and/or dust
in non-hazardous areas where sturdy,
durable enclosures are required
Features:
Small and compact in design.
Used with snap switches.
Mounting lugs and taper tapped hubs with
integral bushings.
Large machine screws for fastening covers
to bodies.
Lockout hole for padlock having 14 hasp is
provided.
Threaded type shafts and bushings are
used to insure flametightness.
Standard Materials:
Bodies and covers Feraloy iron alloy
Shafts stainless steel
Shaft bushings stainless steel
Standard Finishes:
TCP: 15001
Cl. I, Div. 1 & 2, Groups B*C,D

Cl. III
NEMA 3,7B*CD,9EFG,12
EDS and EFD Enclosures
Application:
COLOR: CMYK
Explosionproof
Dust-Ignitionproof
Raintight
Wet Locations
Certifications and
Compliances:
NEC/CEC: Class I, Div. 1 & 2, Groups
B*,C,D
Class II, Div. 1, Groups E,F,G
Class II, Div. 2, Groups F,G
Class III
NEMA/EEMAC: 3,7B*CD,9EFG,12
UL Standard: 894
CSA Standard: C22.2 No. 30
EDS Enclosed
Snap Switch
Options:
Suffix to be
Added to Encl.
Cat. #
Description
Two or three gang bodies can be supplied with
combinations of devices listed for one gang enclosures . . . . Refer to modular listing, section 4C
Class I Group B, NEMA 7B see listing pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GB
Flush wall mounting cover with 12 overhang single gang only
dull black instrument finish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S173
Complies with U.L. snap switch test requirements as follows:
Type of Test
Overload
Non-Inductive Endurance
Inductive Endurance
Tungsten Filament Lamp Endurance
Temperature Rise
Dielectric Withstand
AC-Rated (only) Switch

Rated Amp. +380%
Power Factor .40-.50
100 cycles, 6-10 cycles per minute
10,000 cycles, 18-24 cycles per minute at
rated current .98 min. P.F.
10,000 cycles, 18-24 cycles per minute
.75-.80 P.F.
10,000 cycles, 6-10 cycles per minute at
rated current and 120 volts
Not to exceed 30C
1500 volts
Feraloy iron alloy electrogalvanized and

aluminum acrylic paint
Stainless steel natural
Dimensions (in inches)

Hub
Size
34
1
Dimensions are approximate, not for construction purposes.

* See suffix GB.
556
STIBOINFO((CRH:66008com:2A:556))
CH0 0 2 A - 4
US: 1-866-764-5454
CAN: 1-800-265-0502
Dim.
h
Dim.
l
78
1316
1516
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JOB: CRMAIN06-0557-6 Name: 2A-557
DATE: JAN 19 2006
EDS and EFD Enclosures

with General Use Snap Switches Front
Operated Single Gang and Two Gang
Amperes
Through
Feed
Cat. #
Style
120VAC
277VAC
34
1-pole
2-pole
3-pole
3-way
4-way
20
20
20
20
20
20
20
20
EDS2129
EDS218
EDS2123
EDS2130
EDS2140
EDSC2129
EDSC218
EDSC2123
EDSC2130
EDSC2140
1
1
1
1
1
1-pole
2-pole
3-pole
3-way
4-way
20
20
20
20
20
20
20
20
EDS3129
EDS318
EDS3123
EDS3130
EDS3140
EDSC3129
EDSC318
EDSC3123
EDSC3130
EDSC3140
1
1
1
1-pole
2-pole
3-way
30
30
30
30
30
30
EFD3591
EFD3593
EFD3594
EFDC3591
EFDC3593
EFDC3594
34
34
Explosionproof
Dust-Ignitionproof
Raintight
Wet Locations
2A
Two Gang
Dead End
Cat. #
34
Through feed
Single Gang
34
TCP: 15001

Cl. III
NEMA 3,7B*CD,9EFG,12
Dead end
Hub
Size
COLOR: CMYK
Dead End
Cat. #
EDS2229
EDS2230
EDS3229
EDS328
EDS3230
EDS3240
EFD3691
EFD3694
Through
Feed
Cat. #
EDSC2229
EDSC228
EDSC2223
EDSC2230
EDSC2240
EDSC3229
EDSC328
EDSC3223
EDSC3230
EDSC3240
EFDC3691
EFDC3693
EFDC3694
*Class I, Group B:
All units listed on this page can be modified
for Class I, Group B usage. Add suffix GB to
the Cat. No.. Example: EDS2129-GB. Seals
must be installed within 112 of each conduit
opening for Group B usage.
See table on page 556 for AC-rated switch information.

ON-OFF standard marking for 1-pole and 2-pole units
15A, 125 VAC; 10A, 250 VAC
Combinations of switches can be furnished.
US: 1-866-764-5454
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CH0 0 2 A - 5
CAN: 1-800-265-0502
557
Zoom: 100
p148
8/17/07
10:15 AM
Page 1
Series
VFA
&
VFB
Visi-Float
Flowmeters
Used to Indicate or Manually Control Air or Water Flow
MODEL VFA AND VFB

L
Flow
E
D
N
M
I
FULL OPEN
The VisiFloat flowmeter bodies are cut and precision machined from solid, clear acrylic plastic blocks. This construction
not only produces a handsome finished product, but permits
complete visual inspection. As a result, the Visi-Float flowmeters are especially popular for medical and laboratory equipment applications.
DIMENSION-IN INCHES
A
B
C
D
E
F
I
K
L
M
N
Scales are easy to read The front scale location and white
background provides excellent visibility. The direct reading
scales are hot stamped into the plastic and will not wear off.
Midrange calibration is established with a master flowmeter.
Accuracy is 5% of full scale for VFA models, 3% for VFB.
Scales average 2" long on the VFA models, 4" long on VFB.
Durable and attractive construction The machined
acrylic bodies of the VisiFloat flowmeters are practically unbreakable. Fabrication is backed by over 60 years of experience
in acrylic instrument machining. The tapered bore is precision
machined to a smooth surface that provides perfect visibility of
the indicating float. The VFA and VFB models are available
with either brass or stainless steel inlet and outlet connections
and are tapped for 1/8 NPT thread. VFB models 85 and 86
have either 1/4 back or 3/8 end connections. All standard
models employ BunaN O rings for leak proof operation and
are available with either back or end connections for horizontal
or vertical piping. Precision metering valves in brass or stainless steel are available for most VFA and VFB models.
148
VISIT OUR WEBSITES:
www.dwyer-inst.com
Model VFA
4
3 (18 female NPT)
158 (10-32 Thread)
1
2
1316
114
2116 (BV or SSV)
4332
1
3
4 (EC)
3
32 (EC)
Model VFB
612
512 (18 female NPT)
312 (10-32 thread)
1
2
112
114
2116 (BV or SSV)
61932
138
3
4 (EC)
3
32 (EC)
Easy installation All VisiFloat flowmeters have metal

mounting inserts on rear for panel mounting. They can also be
supported directly by system piping.
www.dwyer-inst.co.uk
www.dwyer-inst.com.au
p149
8/17/07
10:16 AM
Page 1
Special Multi-Column Visi-Float Flowmeters

Perfect for OEM applications, Visi-Float flowmeters can be custom made with up to 10 columns in a single block of acrylic plastic. Available with or without valves. Consult factory for more
information.
SPECIFICATIONS
Service: Compatible gases & liquids.
Wetted Materials:
Body: Acrylic plastic.
O-ring: Buna-N (Fluoroelastomer available).
Metal Parts: Brass standard, stainless steel optional.
Float: Stainless steel, black glass, aluminum, K Monel
depending on range.
Flow
Temperature & Pressure Limits:

Without Valve: 100 psig (6.9 bar) @ 150F (65C);
150 psig (10 bar) @ 100F (38C).
With Valve: 100 psig (6.9 bar) @ 120F (48C).
OEM Specials Special flowmeter designs can be supplied to meet a
wide range of requirements and specific applications. These include:
on-off plunger and push-to-test valves, special gas or fluid calibration,
special ranges, scales, name brand or other identification. Pointer flags
can be furnished for instant visual reference. For specific information,
please supply an outline of your requirements.
Accuracy: VFA = 5% of full scale; VFB= 3% of full scale.

Process Connection: 1/8 female NPT. VFB ranges 85 and 86
have 1/4 NPT back connections or 3/8 NPT end connections.
These ranges not available with brass valves.
Scale Length: VFA 2 typical length; VFB 4 typical length.
Mounting Orientation: Mount in vertical position.
Weight: VFA: 4.0-4.8 oz (.11-.14 kg). VFB: 7.2-8.8 oz (.20-.25 kg).
How To Order
SeriesRange No.ValveOption
Example: VFA-9-BV
Series VFA with 20-200 SCFH Air Range & Brass Valve
VFB SERIES
VFA SERIES
Model
VFA-X
VFA-X-SS
VFA-X-BV
VFA-X-SSV
VFA-X-EC
VFA-X-EC-SS
Description
Standard VFA
VFA with Stainless Metal Wetted Parts
VFA with Brass Valve
VFA with Stainless Steel Valve
VFA with End Connections
VFA with End Connections and Stainless
Steel Metal Wetted Parts
Options & Accessories

-PF, Red ABS Plastic Pointer Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-VIT, Fluoroelastomer O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RKA, Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POPULAR RANGES
Model
VFB-X
VFB-X-SS
VFB-X-BV
VFB-X-SSV
VFB-X-EC
VFB-X-EC-SS
Description
Standard VFB
VFB with Stainless Metal Wetted Parts
VFB with Brass Valve
VFB with Stainless Steel Valve
VFB with End Connections
VFB with End Connections and Stainless
Steel Metal Wetted Parts
Options & Accessories

-PF, Red ABS Plastic Pointer Flag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
-VIT, Fluoroelastomer O-rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RK-VFB, Pressure Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POPULAR RANGES
Model VFB 4" Scale
Model VFA 2" Scale

Range
No.
1
2
3
4
5
6
7
8
9
32
33
34
Range
SCFH Air
.1-1
.2-2
.6-5
1-10
2-20
4-30
5-50
10-100
20-200
CC Water
per min.
6-50
10-100
20-200
CALL TO ORDER:
Range
No.
21
22
23
24
25
26
27
Range
LPM Air
.06-0.5
.15-1
.6-5
1-10
3-25
6-50
10-100
41
42
43
44
Gal. Water
per hour
.6-5
2-10
3-20
8-40
U.S. Phone 219 879-8000
Range
No.
50
91+
51+
52
53+
54+
55+
Range
SCFH Air
.3-3
1-10
2-20
4-40
10-100
10-150
20-200
SCFM Air
.3-3
CC/Min. Air
100-1000
Range
No.
65
66
67
68
69
LPM Air
.2-4
1-10
1-20
3-30
4-40
CC/Min. Water
82
2-30
GPH Water
80+
90
.5-12
83+
1-20
84
60
6-40
81
6-60
GPM Water
85*
.2-2
86*
.6-5
+
For dual range models in English and Metric add D to end of Range No.
* Ranges 85 and 86 consult factory. Not available with brass valve.
U.K. Phone (+44) (0)1494-461707
Asia Pacific Phone 61 2 4272-2055
149
membrane separator
Model 130
Quick Study
The Series 100 Genie Membrane Separators
remove 100% of entrained liquid and particulate in gas samples, which

preserves sample integrity; also, these models only allow gas sample to
flow to analyzers, which protects against liquid damage. The original
Genie Series 100 models are available in several body styles with different
membrane types to accommodate a wide variety of applications. The
Genie Supreme Series 100 models accommodate the same applications,
yet they offer an improved housing design for easy maintenance and the
innovative Liquid Block Technology that prevents liquid from being
forced across the membrane should sample line pressure conditions
become upset.
The Model 130 protects gas systems and related components
Applications
Analyzer protection against liquids in

gas sample conditioning systems
On-line and portable analyzers

GCs, Mass Specs, O2, H2S,

Moisture, and others
Spot, composite, or continuous gas
sampling in any process industry
including natural gas, petrochemical,
and oil refining
where the flow requirement is higher than the Genie Model 101 can
accommodate, higher than 720 cc/min. for the Type 5 membrane and
2,500 cc/min. for the Hi-Flow Backed membrane. It offers a 2 diameter
membrane, which is ideal for removing continuous liquid slugs from
gas samples; it is also perfect for protecting components such as online analyzers, gas chromatographs, or mass spectrometers. Additional
information such as Application Notes is available.
Technical Specifications
Maximum allowable working pressure
Maximum recommended
supply pressure
Maximum temperature
Stainless Steel
Polypropylene
Kynar
500 psig
50 psig
50 psig
Lowest possible pressure consistent with application*

*Must not exceed Pressure rating listed above
185 F (85 C) for Type 5 & BTU membrane

212 F (100 C) for Hi-Flow/Hi-Flow Backed membrane*
*Applies to Polypropylene & Kynar housing
302 F (150 C) for Hi-Flow/Hi-Flow Backed membrane*
Benefits

Superior analyzer protection

Helps preserve sample integrity
Reduces analyzer maintenance
Improves analyzer reliability
Features

*Applies to Stainless Steel housing
Maximum recommended
membrane flow rate
5,130 cc/min for Type 5 & BTU membrane*

18,000 cc/min for Hi-Flow/Hi-Flow Backed membrane*
(For higher flow rates contact the factory)
*Maximum flow results in approximately 2 psi membrane

differential pressure
Port sizes
Inlet, Outlet, & Bypass: 1/4 female NPT
Internal volume
Inlet: 2.60 cubic inches

Outlet: 0.30 cubic inches
Wetted materials
Machined parts : 316 stainless steel / NACE compliant

All other metal parts: stainless steel / NACE compliant
O-ring: Viton (other materials available upon request)
Membrane: Inert
Genie Membrane Technology

Low internal volume
Simple design
Optional G.U.T.S. seal
Genie, Genie Membrane TechnologyTM, Genie Membrane Separators,TM are trademarks or registered
trademarks of A+ Corporation, LLC. All other referenced trademarks are the property of their respective owners.
Model Numbering & Additional Part Numbers

Your model number is determined by your specific needs. Choose options below.
Sealing material
0 = Viton
Membrane type
2 = Hi-Flow
Material of construction
SS = Stainless Steel
Mounting bracket accessory
Part # 130-509-SS (sold separately)
How to build the model number:
130
1 = Kalrez
(other materials available upon request)
T = G.U.T.S.
5 = Type 5
6 = BTU
7 = Hi-Flow Backed
PP = Polypropylene
K = Kynar
How to build the replacement membrane kit number:
130
Sealing material
Membrane type
Sealing material
Membrane type
Dimensions
Front View
Top View
2.14
OPTIONAL MOUNTING BRACKET
3.74
1.20
3.09
PORT B
PORT C
1.88
3.20
1.16
2.79
1.40
PORT A
0.95
PORT B
0.54
1.20
Local Distributor:
Manufacturer
A+ Corporation, LLC
41041 Black Bayou Rd.
Gonzales, LA 70737
Call for expert product application assistance:

Phone: (225)-644-5255 Website: www.geniefilters.com
Fax: (225)-644-3975 E-mail: sales@geniefilters.com
2005 A+ Corporation, LLC. All rights reserved.

SCC-130-PS_0206
PR-1 Series
Adjustable Pressure Reducing Regulator
The PR-1 Series is a versatile specialty pressure reducing control regulator
designed to fulfill a wide range of needs in instrumentation sample systems
and other applications such as semiconductor processing gases. The many
features of the PR-1 make it ideal for a wide range of applications controlling
pressures at low to moderate flows in gas or liquid service. 316L material
is used to facilitate welded connections. Stainless steel caps and adjusting
screws prevent atmospheric corrosion and maintain appearance.
Enhanced internal body surface finish of better than 25 Ra plus
electropolishing allows easier cleaning and potentially less particle
contamination in the flow stream.
Five different seat materials, three alternate orifice sizes and seven
pressure control ranges with stainless diaphragms offer the user a wide
spectrum of capabilities for pressure control with inlet pressures up to
6000 psig and standard operating temperatures up to 500 F (260 C).
Features & Specifications

Gas or liquid service
Stainless steel (316L), Inconel,
Teflon and Tefzel (or optimal main
seat material choice) only in flow
stream
Electropolished 316L body with better
than 25 Ra diaphragm cavity surface
finish
Stainless steel cap with SS adjusting
screw
Adjustable outlet pressure ranges of

010, 025, 050, 0100, 0250,
0500 and 0750 psig
Operating temperatures of -40 F
(-40 C) up to +500 F (+260 C)
20 micron filters
Bubble tight shutoff under most
conditions
Cv flow coefficients 0.025, 0.06, 0.20
and 0.50 (0.06 std.)
Inlet pressures of up to 6000 psi
Options
Wetted materials of construction:
Monel, Hastelloy and Titanium
Special diaphragm assembly for water

service
Diaphragm attached poppet
SS inlet pressure gauges
Special fittings
SS outlet pressure gauges
Diaphragm assist spring for vacuum

purging
Base mounting brackets

Captured vent
Panel mount (1 3/8 mounting hole)

Self-relieving
Relief valves
2301 Wardlow Circle

Corona, CA 92880
tel 909.270.6200
fax 909.270.6201
www.goreg.com
sales@goreg.com
PR-1 Series
Adjustable Pressure Reducing Regulator
How to Order
See page 3 for standard configurations. For additional configurations, consult the factory.
See page 4 for port locations.
Maximum Temperature & Operating Inlet Pressures

Seat Material
Tefzel
High Density Teflon
PCTFE (formerly Kel-F-81)
Polyimide
Polyimide
PEEK
PEEK
Maximum
Temperature*
150 F (66C)
150 F (66 C)
175 F (80 C)
500 F (260 C)
175 F (80 C)
500 F (260 C)
175 F (80 C)
@
@
@
@
@
@
@
@
Maximum Operating
Inlet Pressure
3600 psig (24.82 MPa)
3600 psig (24.82 MPa)
6000 psig (41.37 MPa)
3600 psig (24.82 MPa)
6000 psig (41.37 MPa)
3600 psig (24.82 MPa)
6000 psig (41.37 MPa)
* Temperatures in excess of 175 F (80 C) require a metal knob or the tamper proof option.
Tefzel and Teflon are registered trademarks of Dupont Corporation.
Outline and Mounting Dimensions
For flow curve charts, go to www.goreg.com.
Page
PR-1 Series - Pressure Reducing Regulator

Material of Body
1
4
6
SS 316L
Monel
Hastelloy C
Port Configuration (see page 4)

STANDARD BODY "A" (ONE INLET PORT AND ONE OUTLET PORT)
Process port types (gauge port type, if specified)

0
1
4
1/8" FNPT (1/8" FNPT Gauge Ports)

1/4" FNPT (1/4" FNPT Gauge Ports), Standard
3/8" FNPT (1/4" FNPT Gauge Ports)
Surface Finish of Diaphragm Cavity

1
<25 Ra, Standard
Seat Material
A
B
C
H
I
Q
Tefzel
CF Teflon
Polyimide, High Temp. Service (Metal Knob Std.)
PCTFE (formerly Kel-F 81)
High Density Teflon
PEEK
Flow Coefficient (Cv)
Cv
3
5
C
H
0.06, Standard
0.2
0.025
0.5
Outlet Range
C
D
E
G
I
J
W
0 - 10 Psig
0 - 25 Psig
0 - 50 Psig
0 - 100 Psig
0 - 250 Psig
0 - 500 Psig
0 - 750 Psig
Diaphragm Type
1
2
3
4
Standard Diaphragm
Diaphragm Attached Poppet (DAP)
Self Relieving
Vacuum Assist Spring, Standard Diaphragm
Diaphragm Facing / Backing Material

1
6
8
0
J
Teflon / S.S.
Tefzel Ring / S.S.
Teflon / Inconel
Teflon / Hastelloy C
Tefzel Ring / Inconel
Cap Assembly
1
4
5
8
H
Standard, S.S.
Panel Mount, S.S.
Captured Vent, Aluminum
Tamper Proof, S.S.
1/4" NPT Dome Loaded, S.S.
Cap
Assembly
Diaphragm
Material
Diaphragm
Type
Outlet
Range
Flow (Cv)
Seat
Material
Cavity
Finish
Port Style
Port
Config.
Material
P R 1 -
page 3
PORT LOCATIONS (SINGLE STAGE PRESSURE REGULATOR)

OUT
270
OUT
IN OUT
180
IN OUT
IN
90
OUT
IN
OUT
OUT
IN
OUT
OUT
IN OUT
IN
IN
IN
OUT
IN
OUT
OUT
IN
OUT
IN
OUT
IN
IN
OUT
IN
OUT
IN
1/8 NPT
OUT
OUT
OUT
IN
OUT
OUT
IN
OUT
IN
IN
L
OUT
OUT
IN
IN
OUT
OUT
OUT
IN
IN
OUT
IN
OUT
IN
LOCATION OF PORTS FROM

TOP VIEW
4
IN
w w w .in te r te c - in s t.c o m
VARITHERM
1
. . . e n c lo s u re s o lu tio n s
ELECTRIC HEATER
Application
Heating of enclosures and protective cabinets in

hazardous areas for
Freeze protection
Protection against condensation and for
Temperature maintenance
Special Features
Vertical or horizontal installation is possible

High heat transfer capabilities due to the design of
the black anodized aluminium ribbed fins
Fins can be machined or removed for mounting
purposes if necessary
Resettable temperature limiter supplied as standard
Bi-standard: Can be used for conduit installation as
well as for installation according to CENELEC
standards
Description
The VARITHERM is part of a versatile, explosion-proof

heating system. The heater uses fins to heat the air by
convection.
A thermostat limiter for constant surface temperature
and a resettable temperature limiter that disconnects
the heater from the power supply in case of external
heating or technical failure are incorporated in the
heater body. After correcting the cause of the failure
and allowing the heater to cool down, the heater can be
switched on again by resetting the red button with the
reset tool provided.
The effective heating capacity depends on the internal

temperature of the protective housing and the
orientation (vertical or horizontal) of the heater.
Particulary when the required enclosure temperatures
exceed >10C, it has to be taken into consideration that
the heat output can be reduced by the switching
behaviour of the internal thermostat. When a vertical
orientation is used, the heating power is approximately
25% less.
Please contact our engineering department for an exact
calculation of the heat requirement and selection of the
heater.
Cl. 1, Div. 1, Gr. A,B,C,D +
Type of protection
EEx ed IIC T4 / T3
Certificate of conformity
CSA NRTL/C File LR 43764

PTB No. Ex-97.D.1090
Protection degree
NEMA 4X , IP 68
Nominal voltage
120 V AC
Connection cable
EWKF 3x1,0mm 0,29(7,4mm)
Connection cable for ..AM
EWKF 5x1,0mm 0,35(8,8mm)
Length of connection cable
39 (1 meter)
Length, Width
8,7 x 8,4 (220mm x 213mm)
Seawater-proof black anodized

aluminium
6
Type
Nom.
Output
Height
in./mm
Heat Output
Technical Data
Design
200/60
300/80 400/100 500/60
600/80 700/100
200 W
300 W
600 W
2.4/ 60
3.1/ 80 3.9/ 100 2.4/ 60
300 W
500 W
IN S T R U M E N T A T IO N
3.1/ 80 3.9/ 100
Other designs upon request.

Model Number Code:
VARITHERM 400/80 T4R (Standard)
VARITHERM 400/80 T4R AM 3M MB (s.Options)
Options
AM
Alarm opens at <40F (5C)
3M
Connection cable 10 (3 meters) long
120V
Nominal voltage 240V AC
MB
Stainless steel mounting bracket
Hd121-6c.doc
IN T E R T E C
700 W
page 1/ 2
L T D .
P .O . B o x 2 3 0 6 0 , M ilt o n - O n t a r io L 9 T 5 B 4
T e l: ( 9 0 5 ) 8 7 5 - 4 7 2 7
F a x (9 0 5 ) 8 7 5 -4 7 2 9
w w w .in te r te c - in s t.c o m
VARITHERM
8
. . . e n c lo s u re s o lu tio n s
ELECTRIC HEATER
9.3
Wiring Diagram
L
N
PE
e.g. in series with
other alarms
6A
For CENELEC installation is a electronic temperature

controller available. See data sheet TC..Ex EN (HD251)
in the English catalog section.
10
Junction Box
TC...Ex, Electronic Temp.Regulator for

CENELEC installation
Installation of the VARITHERM
When the heater is installed, please make sure that the

label and button of the resettable temperature limiter
remain accessible.
ye/gn
bn
bl
ye/gn
>
>
bk
bk
10.1
<
Using the Zinc Plated Mounting

Brackets
>
Option: KR..Ex,
TC ...Ex, ELPR
Varitherm
Option: AM
bl=blue bn=brown ye/gn=yellow/green
Installation of Thermostats and

Temperature Regulators
9.1
TS, Thermostat (Installation with

conduit)
The assembly of the TS thermostat, heater, and

junction box is shown on following pages.
9.2
KR..Ex EN, Thermostat (CENELEC

installation)
Thermal feedback, necessary for good control, can be

achieved by mounting the KR .. directly to the heater.
The cylindrical spacers are supplied with the KR

thermostat. The mounting bracket can also be installed
vertically, and the difference in thickness can be
compensated by using two washers.
The INTERTEC universal mounting brackets, which are

supplied with the heater, allow versatile installation in
horizontal or vertical position.
10.2
Using the Stainless Steel Mounting

Bracket
The mounting bracket provides easy installation e.g. to

a mounting plate or to the INTERTEC mounting-system
(C-rails) of the protective cabinets and enclosures.
It can also be ordered optionally by using the
designation MB.
Hd121-6c.doc
IN T E R T E C
IN S T R U M E N T A T IO N
page 2/ 2
L T D .
P .O . B o x 2 3 0 6 0 , M ilt o n - O n t a r io L 9 T 5 B 4
T e l: ( 9 0 5 ) 8 7 5 - 4 7 2 7
F a x (9 0 5 ) 8 7 5 -4 7 2 9
NOSHOK 500 Series All Stainless Steel Liquid Pressure Gauge Model 500 2 1/2 Inch Di... Page 1 of 2
Address: 1010 West Bagley Road

Berea, OH 44017
Phone: 440-243-0888
Fax: 440-243-3472
E-mail: noshok@noshok.com
500 Series All Stainless Steel Liquid Pressure Gauge

Model 500 - 2 1/2 Inch Dial Size
ORDERING INFORMATION
For Regularly Stocked Items
(Contact Us for additional gauge offerings)
Size and Model
25-500
2 Inch Dial Size - Model 500
NPT Connection Size
1/4" NPT
316 SS Bottom Connection
Single Scale Dial Units
Single Scale Options:
psi
Outer Scale Options:
psi
Inner Scale Options:
kPa
Outer Scale Options:
Inner Scale Options:
psi
Dual Scale Dial Units

bar
kg/cm
Ammonia Scale
Dial Units1
The Ammonia Dial is regularly Stocked in Ranges Indicated with (1) Below
Pressure Ranges
30" Vac 30 inHg Vacuum to 0 inHg
200 0 to 200 psi
30-0-15 -30 inHg to 0 inHg to 15 psi2
300 0 to 300 psi
30-0-30 -30 inHg to 0 inHg to 30 psi
400 0 to 400 psi
600 0 to 600 psi
1,000 0 to 1,000 psi
30-0-160 -30 inHg to 0 inHg to 160 psi1 2
1,500 0 to 1,500 psi
http://www.noshok.com/pg/500series/model500/order_info2.html
9/25/2007
NOSHOK 500 Series All Stainless Steel Liquid Pressure Gauge Model 500 2 1/2 Inch Di... Page 2 of 2

12
30-0-300 -30 inHg to 0 inHg to 300 psi
2,000 0 to 2,000 psi

3,000 0 to 3,000 psi
15 0 to 15 psi
5,000 0 to 5,000 psi
30 0 to 30 psi
6,000 0 to 6,000 psi2
60 0 to 60 psi
10,000 0 to 10,000 psi
100 0 to 100 psi
15,000 0 to 15,000 psi2
160 0 to 160 psi

1
2
Options
Accessories
This Range is Also Available in the Ammonia F/psi Scale from stock
This Range is Not Regularly Stocked in the kg/cm Inner Scale Option
10-32 UNF 2B Connection
Threaded Brass Orifices
1/4" NPT x 1/4" BSP Brass Adapter
Maximum Indicating Pointer
Sealing Gasket for BSP Adapter
Set Pointer
-40 Service Liquid Fill
Certificate of Conformance
Halocarbon Liquid Fill
Certified Calibration
Silicone Liquid Fill
Cleaning for Oxygen Services
Press Fit Brass Orifices
Rubber Case Protector
Cintered Press-Fit Brass Orifices
Silicone Dampened Movements
Piston Type Pressure Snubbers
Pigtail Steam Syphons
Diaphragm Seals
Print this Page

Go Back
http://www.noshok.com/pg/500series/model500/order_info2.html
9/25/2007
www.swagelok.com
I n s t r u m e n t B a l l Va l v e s
40 Series
On-off, switching, and crossover flow paths
Working pressures up to 3000 psig (206 bar)
Temperatures from 50 to 150F (10 to 65C)
Low-temperature service option from 65 to 150F (53 to 65C)
1/16 to 3/4 in. and 3 to 12 mm end connections
Virtually no dead space
40 Series Ball Valves
Features
Directional handle
indicates position
of orifice.
Capsule seat packing

does not require system
pressure to make a seal
allows bidirectional flow
has virtually no dead space
is easily cleaned and purged
is available in optional materials
for system compatibility.
Top-loaded design
allows adjustment with
the valve in-line.
Panel nut
secures valve to
panel or actuator.
End connections
include gaugeable
Swagelok tube fittings and
a variety of others.
One-piece body
eliminates multiple
seal points.
Stainless steel and alloy 400

Swagelok tube fittings are gaugeable.
One-piece ball stem

ensures alignment of
ball and orifice.
Materials of Construction
1
Valve Body Materials

Stainless Steel
Component
41, 42, 44,

45 series
43 series
Handle
Set screw
Packing bolt
Upper gland
4
5
6
9
8
9
7
10
11
12
4
5
6
7
8
9a
10a
11a
12a
Brass
Alloy 400
Material Grade/ASTM Specification

Nylon with brass insert
S17400 SS/A564
316 SS powdered metal or
316 SS/A276 and A479
316 SS/A240
Brass CDA 360/B16

41, 42, 45 series
brass 260/B36;
43, 44 series
316 SS/A240
PTFE/D1710
Brass CDA 360/B16
PTFE/D1710
Brass CDA 360/B16
Alloy 405/B164
Alloy 400/B127
Bushing
Lower gland
316 SS powdered metal
Alloy 400/B164
Upper packing
Ball stem
316 SS/A276 and A479
Alloy 405/B164
Side rings
Fluorocarbon-coated
Fluorocarbon-coated 316 SS
Fluorocarbon-coated
brass powdered metal alloy 400 powdered metal
powdered metal/B783
Side discs
Lower packing
PTFE/D1710
Panel nut
Brass CDA 360/B16
Body
316 SS/A276 and A479
Brass CDA 360/B16
Alloy 400/B164
Lubricant
41, 42, 43 seriessilicone-based; 44, 45 seriessilicone- and fluorinated-based
Wetted components listed in italics.

Molybdenum disulfide with hydrocarbon binder coating.
4-way, 5-way, 6-way, and 7-way valves contain stainless steel stem, rings, and discs.
Bodies with VCO end connections have fluorocarbon FKM O-rings.
For valves assembled without lubrication, see Options, page 8.
Important Information about Packed Valves
Testing
Packing adjustment may be required
Valves that have not been cycled for
during the valves service life.

Warning: Failure to periodically
inspect and maintain valve packing
may result in leakage. Service
instructions are shipped with each 40
series ball valve.
Swagelok ball valves are designed to
be used in a fully open or fully closed
position.
a period of time may have a higher

initial actuation torque.
43 series ball valves require an
adapter to adjust the packing bolt.
Ordering number: MS-WK-43
For all other 40 series ball valves,
packing adjustments can be made
with standard wrenches.
Every 40 series ball valve is adjusted

for factory testing at 1000 psig (69 bar)
with nitrogen or at its maximum rated
pressure if less than 1000 psig (69 bar).
Seat tests have a maximum allowable
leak rate of 0.1 std cm3/min.
Flow Data at 70F (20C)
On-Off (2-Way) Valves
Pressure Drop to Atmosphere (p), psi

10
StraightPattern
Valve
AnglePattern
Valve
On
Off
On
Pressure-Temperature
Ratings
Pressure ratings for valves with
Swagelok tube fitting ends may be
lower. See Swagelok Tubing Data.
Ordering Information
and Dimensions
Valve Series
41, 42, 41-A, 42-A, 43-A
43
End Connections
Fractional
Swagelok
tube fittings
Size
0.3
0.7
1.0
11
0.6
1.4
2.0
0.50
5.6
15
27
1.6
3.5
5.0
0.60
6.8
18
32
1.9
4.2
6.0
0.90
10
27
48
2.8
6.4
9.0
1.2
14
36
64
3.8
8.5
12
1.5
17
45
80
4.7
1.6
18
48
85
5.0
2.4
27
72
120
7.6
17
24
2.6
29
78
140
8.2
18
26
Pressure
Rating
psig (bar)
2500 (172)
3000 (206)
3.0
34
90
160
9.5
21
30
6.0
68
180
320
19
42
60
6.3
71
6.4
72
20
45
2500 (172)
1500 (103)
12
130
38
85
Off
-43S4
2.4 0.90
0.44
2.58 1.29 (32.8) 1.29 (11.2)
(32.8)
1.5 0.90
64
120
-44S6
3.05 1.52 (38.6) 1.43

6.0 2.00 0.281 7.1 (77.5)
(36.3)
12 4.60
3.92 1.96 (49.8) 1.74
0.406 10.3 (99.6)
(44.2)
6.4 3.80
2.01
0.97
0.2 0.15 0.093 2.4 (51.1) 1.01 (25.7) (24.6)
0.28
1.12
1/4 19/32 1.36
(7.1)
(28.4)
(6.4) (15.1) (34.5) (14.7)
0.38
1.53 3/16 25/32 1.56
(9.7)
(38.9)
0.56 (14.2)
(50.8)
0.69 (17.5)
0.34
2.21 1.10 (27.9) 1.07 (8.6)
0.6 0.35 0.125 3.2 (56.1)
(27.2)
2.39 1.20 (30.5) 1.17
2.4 0.90
(60.7)
(29.7) 0.44
0.187 4.8
2.46 1.23 (31.2) 1.20 (11.2)
1.5 0.90
(62.5)
(30.5)
2.00
1.00 (25.4)
2.06
1.03 (26.2)
(9.5) 1 1/2 2.43 1.50

(38.1) (61.7) (38.1)
1/4 19/32 1.36
(6.4) (15.1) (34.5) (14.7)
0.38
1.53 3/16 25/32 1.56
(9.7)
(38.9)
1 1/8 2.07
2.00
(50.8)
3.00
(76.2)
1.12
1/4 19/32 1.36
(6.4) (15.1) (34.5) (14.7)
(7.1)
0.44
0.38
1.53 3/16 25/32 1.56
(11.2)
(9.7)
(38.9)
0.56 (14.2)
(50.8)
-45F8
0.38
1.53 3/16 25/32 1.56
(9.7)
(38.9)
0.38
1.53 3/16 25/32 1.56
(9.7)
(38.9)
0.69 (17.5)
Male NPT
1/4
-43M4
Male NPT/
Swagelok
tube fitting
1/4
-43M4-S4
2.20 1.00 1.20 1.03 0.44

1.6 0.75 0.187 4.8 (55.9)
(25.4) (30.5) (26.2) (11.2)
1/4
-43F4RT
0.9
3/8
-44F6RT
2.6
2.06 1.03 (26.2)

0.187 4.8 (52.3)
2.50 1.25 (31.8)
0.281 7.1 (63.5)
3.12 1.56 (39.6)

0.406 10.3 (79.2)
-45F8RT
6.3
-42VCO4
1.75 0.88 (22.4)

0.6 0.35 0.125 3.2 (44.4)
1.53 3/16 25/32 1.56
0.56 (14.2)
(50.8)
0.69 (17.5)
3.00
1.12
1.88 0.94 (23.9)

2.4 0.90 0.187 4.8 (47.8)
2.12 1.06 (26.9)
0.6 0.35 0.125 3.2 (53.8)
1.09 0.44
0.38
(9.7)
-44VCR8
2.06 1.03 (26.2)

2.4 0.90 0.187 4.8 (52.3)
2.88 1.44 (36.6)
6.0 0.281 7.1 (73.2)
(27.7) (11.2)
-45VCR8
12
3.12 1.56 (39.6)

0.406 10.3 (79.2)
(76.2)
0.78
(4.8) (19.8) (39.6) (19.8)
(38.9)
2.00
0.78
(4.8) (19.8) (39.6) (19.8)
(9.7)
(9.7)
1/2
(38.1) (61.7) (38.1)
0.38
0.38
-43VCR4
1 1/8 2.07 1.12

3/8 (28.6) (52.6) (28.4)
1 1/2 2.43 1.50
0.44
0.94 0.44
-42VCR4
3.00
(76.2)
0.78
(9.5)
(11.2)
(23.9) (11.2)
1/4
Male VCR
fittings
2.00
0.58
(4.8) (19.8) (39.6) (19.8)
1/2
1.56 (39.6)
1.12
(28.4)
(8.6)
3/8
(79.2)
0.78
3/8 (28.6) (52.6) (28.4)

(9.5) 1 1/2 2.43 1.50
(38.1) (61.7) (38.1)
3.0 1.70
2.50
0.281 7.1 (63.5)
2.6 1.50
6.3 3.50 0.406 10.3 3.12
1.25 (31.8)
0.58
(4.8) (19.8) (39.6) (19.8)
-44F4
-44F6
(52.3)
1.12
(28.6) (52.6) (28.4)
1.12
1.2 0.70
(50.8)
3.00
(76.2)
3/8
(28.4)
-43F2
(41.1)
1 1/8 2.07
2.00
(7.1)
-42F2
-43VCO4
0.78
0.28
3.07 1.53 (38.9) 1.43 0.56 (14.2)

6.0 2.00 0.281 7.1 (78.0)
(36.9)
3.92 1.96 (49.8) 1.74 0.69 (17.5)
12 4.60 0.406 10.3 (99.6)
(44.2)
0.34 0.28
0.5 0.30 0.125 3.2 1.62
0.81 (20.6)
1/4
0.58
(4.8) (19.8) (39.6) (19.8)
0.9 0.75
1/4
(65.5)
2.00 1.00 (25.4) 1.03 0.44

1.2 0.75 0.187 4.8 (50.8)
(26.2) (11.2)
VCO fittings
63
-43F4
1/2
Dimensions shown with Swagelok

tube fitting nuts finger-tight.
2.36 1.18 (30.0) 1.17

(29.7)
(59.9)
-43S6
1/8
Angle-Pattern Valves
Add -A to the ordering number
of a valve with the C
dimension listed.
Example: SS-43S4-A
-42S4
12 mm -45S12MM
Female ISO
tapered
640
16
Dimensions, in. (mm)
(42.7)
0.187 4.8
360
2.21 1.10 (27.9) 1.07

0.6 0.35 0.125 3.2 (56.1)
(27.2)
10 mm -44S10MM
Female
NPT
340
15
11
For angle-pattern valve flow data, see Flow Data, page 4.
A
B
B1
0.052 1.3 1.68 0.84 (21.3)
0.187 4.8
Water Flow, U.S. gal/min
330
190
2.01 1.01 (25.7) 0.97 0.34

0.2 0.15 0.093 2.4 (51.1)
(24.6) (8.6)
6 mm
Metric
-43S6MM
Swagelok
tube fittings 8 mm -43S8MM
1/8 in. (3.2 mm) minimum panel

thickness.
5.3
6.0
-41S2
-42S6MM
B1
3.0
2.3
1/8
-45S8
-45S12
100
1.1
0.1
1/4
50
0.20
Orifice
Cv
Cv Angle in. mm
10
0.10
-41S1
3 mm -41S3MM
E
B
Basic
Ordering
Number
100
Air Flow, std ft3/min
1/16
1/2
3/4
G
max panel
thickness J
(10 to 65)
3/8
H
panel
hole
50 to 150
44, 45
44-A, 45-A
Inlet/Outlet
Add SS for 316 stainless

steel, B for brass, or M for
alloy 400 to the basic ordering
number.
Example: SS-43S4
Dimensions are for reference
only and are subject to
change.
Temperature
Rating
F (C)
50
Cv
0.78
(4.8) (19.8) (39.6) (19.8)
1 1/8 2.07
1.12
3/8 (28.6) (52.6) (28.4)

(9.5) 1 1/2 2.43 1.50
(38.1) (61.7) (38.1)
19/32 1.36
(28.4) 3/16 (15.1) (34.5) 0.78

1.53 (4.8) 25/32 1.56 (19.8)
(19.8) (39.6)
(38.9)
1.12
19/32 1.36
(28.4) 3/16 (15.1) (34.5) 0.78

1.53 (4.8) 25/32 1.56 (19.8)
(38.9)
(19.8) (39.6)
2.00
0.56 (14.2)
(50.8)
0.69 (17.5)
(76.2)
3.00
1 1/8 2.07
3/8 (28.6) (52.6) 1.50
(9.5) 1 1/2 2.43 (38.1)
(38.1) (61.7)
Switching (3-Way, 5-Way, and 7-Way) Valves
3-Way Valve
5-Way Valve
Features
7-Way Valve
Unique, top-loaded capsule packing allows reliable
switching.
Flow can be switched from a single inlet to multiple outlets
or from multiple inlets to a common outlet.
3-way valve has a center-off position.
5- and 7-way 43 series valves have a spring-loaded detent
for exact port positioning.
Detent handle components:
Handle: nylon with brass insert
Set screw: S17400 stainless steel
Pins, detent plate: nickel-plated steel
Springs: steel/ASTM A228
Pressure-Temperature Ratings
Valve Series
41X, 42X, 43X
44X, 45X
43Z
45Z
43Z6
Flow Pattern
Temperature
Rating
F (C)
3-way
50 to 150
5-way
7-way
(10 to 65)
Pressure
Rating
psig (bar)
2500 (172)
1500 (103)
2500 (172)
1500 (103)
500 (34.4)
Pressure ratings for valves with Swagelok tube fitting ends

may be lower. See Swagelok Tubing Data.
Pressure Drop to Atmosphere (p) psi

10
50
100
Cv
10
50
100
2-Way Angle Pattern and 3-Way Valves

0.08
0.9
2.4
4.3
0.3
0.6
0.8
0.15
1.7
4.5
8.0
0.4
1.0
1.5
0.30
3.4
9.0
16
0.9
2.1
3.0
0.35
4.0
10
19
1.1
2.4
3.5
0.75
8.5
22
40
2.3
5.3
7.5
0.80
9.0
24
42
2.5
5.6
8.0
0.90
10
27
48
2.8
6.3
9.0
1.5
17
45
80
4.7
11
15
1.7
19
51
90
5.3
12
17
2.0
22
60
100
6.3
14
20
3.5
39
100
180
11
25
35
3.8
43
110
200
12
27
38
4.6
52
140
240
15
33
46
0.07
0.8
2.1
3.7
0.2
0.5
0.7
3.5
39
100
180
11
25
35
0.05
0.6
1.5
2.6
0.1
0.3
0.5
0.07
0.8
2.1
3.7
0.2
0.5
0.7
5-Way Valves
7-Way Valves
Ordering Information and Dimensions

Add SS for 316 stainless steel, B for brass, or M for alloy 400 to the basic ordering number.
Example: SS-43XS4
Dimensions are for reference only and are subject to change.
3-Way Valve
5-Way Valve
7-Way Valve
G max panel
thickness
H
panel
hole
F
G
max panel
thickness J
H
panel
hole
G
max panel
thickness J
H
panel
hole
1/8 in. (3.2 mm) minimum panel thickness.

End Connections
Inlet/Outlet
Size
Basic
Ordering
Number
Orifice
Cv
in.
mm
0.34 (8.6)
1.13 (28.7)
1/4 (6.4)
19/32 (15.0) 1.36 (34.5)
0.58 (14.7)
3/16 (4.8)
25/32 (19.8) 1.56 (39.6)
0.78 (19.8)
1 1/8 (28.7)
2.07 (52.6)
1.12 (28.4)
1 1/2 (38.1) 2.43 (61.7)
1.50 (38.1)
3-Way Valves
Fractional
Swagelok
tube fittings
1/16
-41XS1
0.08
0.052
1.3
1.68 (42.7)
0.84 (21.3)
1/8
-41XS2
0.15
0.093
2.4
2.01 (51.1)
1.01 (25.7)
0.97 (24.6)
-42XS4
0.35
0.125
3.2
2.21 (56.1)
1.10 (27.9)
1.07 (27.2)
1/4
-43XS4
0.90
0.187
4.8
2.39 (60.7)
1.20 (30.5)
1.17 (29.7)
0.44 (11.2)
1.53 (38.9)
3/8
-44XS6
2.0
0.281
7.1
2.89 (73.4)
1.45 (36.8)
1.43 (36.3)
0.56 (14.2)
2.00 (50.8)
1/2
-45XS8
4.6
3/4
-45XS12
3.8
-41XS3MM
-42XS6MM
3 mm
Metric
Swagelok
tube fittings
6 mm
Male NPT/
Swagelok
tube fittings
Female ISO
tapered
Male VCR
fittings
0.406
10.3
3.48 (88.4)
1.74 (44.2)
0.15
0.093
2.4
2.01 (51.1)
1.01 (25.7)
0.97 (24.6)
0.35
0.125
3.2
2.21 (56.1)
1.10 (27.9)
1.07 (27.2)
0.187
4.8
2.39 (60.7)
1.20 (30.5)
1.17 (29.7)
2.46 (62.5)
1.23 (31.2)
1.20 (30.5)
1.45 (36.8)
1.43 (36.3)
3.00 (76.2)
0.34 (8.6)
1.13 (28.7)
1/4 (6.4)
19/32 (15.0) 1.36 (34.5)
0.58 (14.7)
0.44 (11.2)
1.53 (38.9)
3/16 (4.8)
25/32 (19.8) 1.56 (39.6)
0.78 (19.8)
1 1/8 (28.7)
-43XS6MM
0.90
-43XS8MM
0.80
10 mm
-44XS10MM
2.0
0.281
7.1
2.89 (73.4)
0.56 (14.2)
2.00 (50.8)
12 mm
-45XS12MM
4.6
0.406
10.3
3.48 (88.4)
1.74 (44.2)
0.69 (17.5)
3.00 (76.2)
-42XF2
0.30
0.125
3.2
1.63 (41.4)
0.81 (20.6)
0.34 (8.6)
1.13 (28.7)
-43XF4
0.75
0.187
4.8
2.06 (52.3)
1.03 (26.2)
0.44 (11.2)
1.53 (38.9)
-44XF4
1.7
3/8
-44XF6
0.281
7.1
2.50 (63.5)
1.25 (31.8)
0.56 (14.2)
2.00 (50.8)
1.5
1/2
-45XF8
3.5
0.406
10.3
3.13 (79.5)
1.56 (39.6)
0.69 (17.5)
3.00 (76.2)
1/4
-43XS4-S4-M4
0.80
0.187
4.8
2.40 (61.0)
0.44 (11.2)
1.53 (38.9)
1/4
-43XF4RT
0.75
0.187
4.8
2.06 (52.3)
1.03 (26.2)
0.44 (11.2)
1.53 (38.9)
3/8
-44XF6RT
1.5
0.281
7.1
2.50 (63.5)
1.25 (31.8)
0.56 (14.2)
2.00 (50.8)
1/2
-45XF8RT
3.5
0.406
10.3
3.13 (79.5)
1.56 (39.6)
0.69 (17.5)
3.00 (76.2)
-42XVCR4
0.35
0.125
3.2
-43XVCR4
0.90
0.187
4.8
1/4
1/4
2.13 (54.1)
1.20 (30.5)
1.06 (26.9)
1.03 (26.2)
1.09 (27.7)
3/8 (9.7)
0.69 (17.5)
8 mm
1/8
Female NPT
0.81 (20.6)
0.44 (11.2)
1.13 (28.7)
1.53 (38.9)
2.07 (52.6)
1.12 (28.4)
1 1/2 (38.1) 2.43 (61.7)
1.50 (38.1)
1/4 (6.4)
19/32 (15.0) 1.36 (34.5)
0.58 (14.7)
3/16 (4.8)
25/32 (19.8) 1.56 (39.6)
0.78 (19.8)
1 1/8 (28.7)
2.07 (52.6)
1.12 (28.4)
1 1/2 (38.1) 2.43 (61.7)
1.50 (38.1)
3/16 (4.8)
25/32 (19.8) 1.56 (39.6)
0.78 (19.8)
3/16 (4.8)
25/32 (19.8) 1.56 (39.6)
0.78 (19.8)
1 1/8 (28.7)
2.07 (52.6)
1.12 (28.4)
1 1/2 (38.1) 2.43 (61.7)
1.50 (38.1)
3/8 (9.7)
3/8 (9.7)
3/8 (9.7)
3/16 (4.8)
19/32 (15.0) 1.36 (34.5)

25/32 (19.8) 1.56 (39.6)
0.78 (19.8)
5-Way Valves
Female
Swagelok
tube fittings
Female NPT
1/8
-43ZFS2
0.07
0.062
1/8
-43ZF2
0.07
1/2
-45ZF8-ND
3.5
1.6
1.94 (49.3)
0.062
1.6
1.55 (39.4)
0.406
10.3
3.13 (79.5)
0.97 (24.6)
0.78 (19.8)
0.88 (22.4)
1.56 (39.6)
0.44 (11.2)
1.53 (38.9)
5/32 (4.1)
29/32 (23.1) 1.69 (42.9)
0.44 (11.2)
1.53 (38.9)
5/32 (4.1)
29/32 (23.1) 1.69 (42.9)
0.69 (17.5)
3.00 (76.2)
3/8 (9.7)
1 1/2 (38.1) 2.43 (61.7)
0.44 (11.2)
1.53 (38.9)
5/32 (4.1)
29/32 (23.1) 1.69 (42.9)
7-Way Valves
Female
Swagelok
tube fittings
1/16
-43Z6FS1
0.05
0.052
1.3
1/8
-43Z6FS2
0.07
0.062
1.6
1.94 (49.3)
0.97 (24.6)
Dimensions shown with Swagelok tube fitting nuts finger-tight.

Cross-port flow may occur during switching. If cross-port flow is unacceptable, specify a 0.049 in. ball orifice. Example: SS-43ZF2-049
Cross-port flow may occur during switching. If cross-port flow is unacceptable, specify a 0.093 in. ball orifice. Example: SS-45ZF8-ND-093
Crossover (4-Way and 6-Way) Valves

4-Way Valve
6-Way Valve
Features
Capsule packing allows crossover of two or three streams.
Pressure Drop to Atmosphere (p), psi
Machined stops provide positive port positioning.
10
Stop plate material: aluminum/ASTM B209 or B211.
50
100
10
Cv
50
100
4-Way Valves
Valve
Series
43Y6
45Y6
43Y6
Flow
Pattern
Temperature
Rating
F (C)
4-way
50 to 150
(10 to 65)
6-way
0.06
0.7
1.8
3.2
0.08
0.9
2.4
4.2
1.6
18
48
85
Working
Pressure
psig (bar)
2500 (172)
0.06
0.7
1.8
3.2
1500 (103)
0.08
0.9
2.4
4.2
0.2
5.0
0.4
0.6
0.5
0.8
11
16
0.4
0.6
0.5
0.8
6-Way Valves
0.2
1500 (34.4)

Dimensions are for reference only and
are subject to change.
Add SS for 316 stainless steel, B for
brass, or M for alloy 400 to the basic
ordering number.
Example: SS-43YF2
End Connection
Type
1/16
Female
Swagelok
tube fitting 1/8
G
max panel
thickness J
Orifice
Cv
in.
mm
-43YFS1
0.06 0.052
1.3
-43YFS2
0.08 0.062
1.55
0.78
(39.4)
(19.8)
0.44
0.44
1.53
3/16
29/32
1.68
1.95
0.98
(11.2)
(11.2)
(38.9)
(4.8)
(23.1)
(42.7)
(49.5)
(24.9)
-43YF2
1/2
-45YF8
1.6
0.281
7.1
Female
1/16
Swagelok
tube fitting 1/8
-43Y6FS1
0.06 0.052
1.3
-43Y6FS2
0.08 0.062
1.6
1.55
0.78
0.44
0.44
1.53
3/16
29/32
1.69
(39.4)
(19.8)
(11.2)
(11.2)
(38.9)
(4.8)
(23.1)
(42.9)
3.13
1.56
0.69
0.69
3.00
3/8
1 1/2
2.43
(79.5)
(39.6)
(17.5)
(17.5)
(76.2)
(9.7)
(38.1)
(61.7)
6-Way Valves
1.95
0.97
0.44
0.44
1.53
3/16
29/32
1.68
(49.5)
(24.6)
(11.2)
(11.2)
(38.9)
(4.8)
(23.1)
(42.7)
D
Cross-port flow may occur during switching. If cross-port flow is unacceptable, specify a 0.049 in. ball
orifice. Example: SS-43YFS2-049
Cross-port flow may occur during switching. If cross-port flow is unacceptable, specify a 0.093 in. ball
orifice. Example: SS-45YF8-093
E
B
A
6-Way Valve
F
G
max panel
thickness J
H
panel
hole
D
E
B
1/8 in. (3.2 mm) minimum panel thickness.
1.6
1/8
Female
NPT
H
panel
hole
Basic
Ordering
Number
4-Way Valves
4-Way Valve
F
Size

O (S)
N (D)
Pneumatic Actuators
Rack and pinion actuators are compact,
lightweight, easy to mount and can
operate with standard shop air. For
technical data, including actuator types,
materials of construction, and pressuretemperature ratings, see the Swagelok
Rack and Pinion Pneumatic Actuators
catalog.
M
K
F
H
1/8 in.
NPT
1/8 in.
NPT
B
Q
A
4 mounting
holes 0.34
(8.6) dia
S = spring return
D = double acting
Dimensions
Valve Series
Actuator
Model
41, 41-A, 41X,

42, 42-A, 42X
43, 43-A,
43X, 43Y
-131
-151
-133
-153
2.30
(58.4)
4.13
2.00 2.31 4.07 2.32 1.75 0.75 0.81 0.44 2.16 1.56 5.89 7.86
(104) 0.48 (50.8) (58.7) (103) (58.9) (44.5) (19.1) (20.6) (11.2) (54.9) (39.6) (150) (200) 2.56
(65.0)
4.25 (12.2) 2.19
(108)
(55.6)
Typical Ordering Number
SS-43S4 - 31D
Actuation Modes
-131
(90)
-151
(180)
-133
(90)
-153
(180)
-31
-51
-33
-53
3.72
Factory-Assembled Actuators
Dual
(94.5)
Ordering Information
Single
1.75 3.04 1.73 1.31 0.60 0.52 0.31 1.46 1.25 4.09 4.91 1.80
2.91 0.34 2.00 (44.5) (77.2) (43.9) (33.3) (15.2) (13.2) (7.9) (37.1) (31.8) (104) (125) (45.7)
Required pressures based on valve performance using

pressurized air or nitrogen.
Valve
Series
(71.4)
Actuator Pressure at Maximum System Pressure
Actuator Actuator
Model Designator
(73.9) (8.6) (50.8)
45, 45-A,
45X, 45Y
Double Acting
2.81
43, 43-A,
43X, 43Y
44, 44-A, 44X
Spring Return
Single
Dual
Valve Ordering Number
Minimum Actuator Pressure, psig (bar)
41, 41-A,
42, 42-A
20 (1.4)
35 (2.5)
60 (4.2)
43, 43-A, 43Y
50 (3.5)
80 (5.6)
80 (5.6)
41X, 42X
20 (1.4)
35 (2.5)
60 (4.2)
70 (4.9)
70 (4.9)
For dual-mounted assemblies

(two valves mounted to one
actuator), add DM to the
ordering number.
Example: SS-43S4-31DDM
Actuator Designator
Determine valve series,
then select actuator
model (see Actuator
Pressure table).
43X
50 (3.5)
80 (5.6)
70 (4.9)
43, 43-A, 43Y
20 (1.4)
35 (2.5)
65 (4.5)
75 (5.2)
Actuators for Field Assembly
44, 44-A
25 (1.8)
50 (3.5)
70 (4.9)
90 (6.3)
Typical Ordering Number
45, 45-A, 45Y
60 (4.2)
100 (6.9)
90 (6.3)
43X
20 (1.4)
35 (2.5)
65 (4.5)
70 (4.9)
44X
25 (1.8)
50 (3.5)
70 (4.9)
80 (5.6)
45X
60 (4.2)
100 (6.9)
85 (5.9)
Actuation Mode
D = double acting
C = spring return,
normally closed
O = spring return,
normally open
S = spring return,
3- and 4-way valves
MS-131-DA
Actuator Model
Determine valve series,
then select actuator model
(see Actuator Pressure table).
Actuation Mode
DA = double acting
SR = spring return
Other Actuator Options

For Field Assembly or Factory Assembly
Electric Actuators
For information on electric actuators, see the Electric

Actuators catalog.
Solenoid Valves
attach to the actuator to create an electropneumatically
actuated ball valve assembly.
Limit Switches
indicate actuator position by means of an electrical signal.
They meet a variety of NEMA ratings such as NEMA 4
(weatherproof) and NEMA 7 (explosion proof). For more
information, see the Limit Switches catalog.
Position Indicators
provide visual status of a valve.
ISO 5211-Compliant Actuator Mounting Bracket Kits
For information, see the Actuated Ball Valve Selection Guide.
Mounting Bracket Kits

Valve Series
41, 41-A,
42, 42-A
Actuator Model
41X, 42X
-151
43, 43-A
-131
43X
-151
43, 43-A
-133
43X
-153
43Y
44, 44-A
-131
-131
-133
44X
-153
45, 45-A
-133
45X
-153
45Y
-133
Ordering Number
MS-MB-41
MS-MB-43
MS-MB-43-133
MS-MB-43Y
MS-MB-43Y-133
MS-MB-44
MS-MB-45
MS-MB-45Y
42 series valves with

VCO or VCR end
connections mounted to
an actuator are only
available factory
assembled.
44 series valves with
VCR end connections
require kit
MS-MB-44-VCR.
Options
Handles
Vented Valves
Factory-Assembled Nylon
Black is standard. For other colors,
add a handle color designator to
the valve ordering number.
Example: SS-43S4-BL
Handle Color
Black
Designator
-BK
Blue
-BL
Green
-GR
Orange
-OG
Red
-RD
Yellow
-YW
316 Stainless Steel Bar

Add -SH to the valve ordering number.
Example: SS-43S4-SH
2-Way, Straight-Pattern Valves

When the valve is closed, the downstream port vents to
atmosphere through a vent hole in the side of the valve body.
2-Way, Angle-Pattern and 3-Way Valves

When the valve is closed, the bottom port vents to atmosphere
through a vent hole in the side of the valve body.
To order, insert V into the valve ordering number.
Example: SS-43VS4
Pressure rating for vented valves is 500 psig (34.4 bar).
Valves Assembled Without Lubrication
Nylon Oval (2- and 3-Way)
40 series ball valves assembled without lubricant are cleaned

and packaged in accordance with Special Cleaning and
Packaging (SC-11) and are adjusted for factory testing at
200 psig (13.7 bar). Valves have a pressure rating of 200 psig
(13.7 bar). Brass valves are assembled with stainless steel
rings, discs, and stem. To order, add -1466 to the valve
ordering number.
Example: SS-43S4-1466
Add -K to the valve ordering number.

Example: SS-43S4-K
Low-Temperature Service
Aluminum Bar
Add -BKB to the valve ordering number.
Example: SS-43S4-BKB
Nylon oval handles are available factory assembled only.
Handle Kits
include handle and set screw.
Aluminum
Nylon Directional Stainless Steel
Bar Handle
Bar Handle
Handle Basic
Ordering Number Ordering Number Ordering Number
41, 41-A, 41X, 42, 42-A, 42X
BZ-5K-42
SS-5K-42B
A-5S-42B-BK
Valve
Series
Live-loaded packing option extends the temperature range to

65 to 150F (53 to 65C).
For more information, see the Live-Loaded 40 Series Ball
Valves for Low-Temperature Service catalog.
Oxygen Service
For more information about hazards and risks of oxygenenriched systems, see the Oxygen System Safety technical
report.
43, 43-A, 43X, 43Y
BZ-5K-43
SS-5K-43B
A-5S-43B-BK
43Z
BZ-5K-43Z
A-5S-43ZB-BK
Sour Gas Service
44, 44-A, 44X
BZ-5K-44
SS-5K-44B
A-5S-44B-BK
45, 45-A, 45X, 45Y
BZ-5K-45
SS-5K-45B
A-5S-45B-BK
40 series ball valves with female pipe ends are available for
sour gas service. Materials for wetted valve components are
selected in accordance with NACE Standard MR0175 for
sulfide stress cracking resistant materials. Stem, rings, and
discs are alloy 400. To order, add -SG to the valve ordering
number.
Example: SS-43F4-SG
For a complete ordering number, add a handle color designator to the basic
ordering number. Example: BZ-5K-42-BK
Directional Name Plates

Directional name plates indicate the direction of flow.
A matte surface accepts ink or labels. To order, add -WN1
(blank nameplate) or -WN2 (marked nameplate) to the valve
ordering number.
Example: SS-43S4-WN1
Optional Flow Paths
Safe Product Selection

When selecting a product, the total system design must
be considered to ensure safe, trouble-free performance.
Function, material compatibility, adequate ratings,
proper installation, operation, and maintenance are the
responsibilities of the system designer and user.
Caution: Do not mix or interchange parts with those of
other manufacturers.
40 series ball valves are available with a variety of flow paths

to accommodate many special applications.
For more information, see the 40 Series Ball Valve Flow Path
Options selection guide.
Swagelok, VCR, VCOTM Swagelok Company

2001, 2002 Swagelok Company
Printed in U.S.A., MI
December 2002, R6
MS-01-60
Filters 1
www.swagelok.com
Filters
F W, F, a n d T F S e r i e s
Remove system particulate contaminants
Gas and liquid service
1/8 to 1/2 in. and 3 to 12 mm end connections
Stainless steel and brass materials
Filters
Features
All-Welded In-line Filters (FW Series)
All-welded construction provides reliable fluid containment.
Full-penetration weld between body

and element prevents bypass flow
In-line filters are for use where space is limited.

Filter is easily cleaned by backflushing.
Sintered element is available in 0.5 m nominal pore size;
pleated mesh elements are available in 2, 7, and 15 m

nominal pore sizes.
End connections include Swagelok tube fittings, NPT, and
Pleated element shown;

sintered element available
male VCR face seal fittings.
In-line Filters (F Series)

In-line filters are for use where space is limited.
Replaceable sintered elements are available in 0.5, 2, 7, 15,
60, and 90 m nominal pore sizes; replaceable strainer

elements are available in 40, 140, 230, and 440 m nominal
pore sizes.
End connections include Swagelok tube fittings, NPT, tube
Sintered element shown;

strainer element available
adapter, and male VCR face seal fittings.
Tee-Type Filters (TF Series)

Filter element can be replaced without
removing body from system.

Replaceable sintered elements are available in
0.5, 2, 7, 15, 60, and 90 m nominal pore sizes;

replaceable strainer elements are available in 40, 140, 230,
and 440 m nominal pore sizes.
End connections include Swagelok tube fittings, NPT, and
tube socket or tube butt weld ends.
Sintered element
shown; strainer
element available
Bypass port available;

see page 8
Filter Elements
F and TF Series
FW Series
Sintered
Sintered
Pleated Mesh
Strainer
Magnified 13
Traps particles as small as
0.5 m in diameter
316L SS construction
Retainer
screen
Pleated
mesh
element
Retainer
screen
Offers larger filtration area

Stainless steel construction
Traps fine particles in a
dense matrix
316 SS construction
Magnified 2
Removes larger particles
316 SS construction
Filters
For more information about ratings, see the Swagelok Valve Pressure-Temperature
Ratings technical bulletin.
Ratings are based on standard materials of construction. Ratings for TF series filters
with PCTFE gaskets are limited to 200F and 3000 psig (93C and 206 bar). See
page 8.
Series
FW, TF
2F, 4F
Material
6F, 8F
316 SS
Temperature, F (C)
TF
Brass
Working Pressure, psig (bar)
20 (28) to 100
200
300
400
(37)
(93)
(148)
(204)
6000
5160
4660
4280
(413)
(355)
(321)
(294)
3000
2580
2330
2140
(206)
(177)
(160)
(147)
2500
2150
1940
1780
(172)
(148)
(133)
(122)
1000 (68.9)
780 (53.7)
680 (46.8)
500
600
650
700
(260)
(315)
(343)
(371)
3980
3760
3700
2600
(274)
(259)
(254)
(248)
1990
1880
1845
1800
(137)
(129)
(127)
(124)
1660
1560
1540
1500
(114)
(107)
(106)
(103)
750
800
850
900
(398)
(426)
(454)
(482)
3520
3460
3380
3280
(242)
(238)
(232)
(225)
1760
1725
1690
1640
(121)
(118)
(116)
(112)
1460
1440
1410
1360
(100)
(99.2)
(97.1)
(93.7)
2000 (137)
1730 (119)
1470 (101)
Differential Pressure Ratings

Maximum Differential Pressure
psi (bar)
Series
Sintered
Element
Strainer
Element
Pleated
Element
FW
600 (41.3)
100 (6.8)
F, TF
1000 (68.9)
Materials of Construction
Filtration Area
Filter Body Materials

Brass
Component
316 SS
Series Material Grade/ASTM Specification
Series
Sintered
Element
in.2 (mm2)
Strainer
Element
in.2 (mm2)
Pleated
Element
in.2 (mm2)
FW
0.44 (283)
2.25 (1450)
Bonnet nut
TF
Brass/B16
316 SS/A479
2F
0.55 (350)
Bonnet
TF
Brass/B16
316 SS/A479
4F, 2TF, 4TF
1.3 (830)
1.0 (640)
Retainer screens (2)
FW
316 SS
6F, 8F, 6TF, 8TF
2.0 (1280)
1.7 (1090)
0.5 m size
316L SS
FW
2 m size
304 SS
Element
7 and 15 m
size316 SS
F, TF
Sintered316 SS
Strainer316 SS with silver solder
Spring
F, TF
302 SS
Gasket
F, TF
Aluminum/B209
Silver-plated
316 SS/A240
Brass/B16
316 SS/A479
Body
All
Retaining ring
TF
PH 15-7 Mo SS
Lubricant
Silicone based
Wetted components listed in italics.

FW series filters not available in brass.
Filters

FW Series
End Connections
Type
Swagelok tube
fitting,
male VCR fitting
Size
Inlet Pressure, psig (bar)
Nominal
Element
Pore Size
m
5 (0.34)
0.5
0.04 (1.1)
1/4 in.,
6 mm
2, 7, 15
Female NPT
1/4 in.
2, 7, 15
Male NPT, male to

female NPT
1/4 in.
2, 7, 15
10 (0.68)
Pressure Drop, psi (bar)
15 (1.0)
10 (0.68)
Air Flow, std ft3/min (std L/min)
5.6 (150)
0.06 (1.7)
10
0.12 (3.4)
14
(280)
50 (3.4)
(390)
0.01 (0.03)
0.04 (0.15)
0.12 (0.45)
1.7
5.5 (20)
8.3 (31)
(6.4)
4.5 (17)
14
(52)
18
(68)
3.5 (13)
11
(41)
14
(52)
Outlet is discharged to atmosphere.
F Series
Nominal
Element
Pore Size
m

5 (0.34)
10 (0.68)
15 (1.0)
10 (0.68)
Air Flow, std ft3/min (std L/min)
50 (3.4)
100 (6.8)
Water Flow, U.S. gal/min (L/min)
2F Series
0.5
0.04 (1.1)
0.06 (1.7)
0.12 (3.4)
0.01 (0.03)
0.04 (0.15)
0.12 (0.45)
0.20 (5.6)
0.40 (11)
0.60 (17)
0.08 (0.30)
0.24 (0.91)
0.40 (1.5)
0.50 (14)
0.90 (25)
1.2 (34)
0.10 (0.37)
0.30 (1.1)
0.48 (1.8)
15
0.80 (22)
1.3 (36)
1.5 (42)
0.12 (0.45)
0.36 (1.3)
0.58 (2.1)
60
1.7 (48)
2.2 (62)
2.4 (68)
0.15 (0.56)
0.50 (1.8)
0.70 (2.6)
90
1.8 (51)
2.2 (62)
2.6 (73)
0.20 (0.75)
0.50 (1.8)
0.60 (2.2)
4F Series
0.5
0.12 (3.4)
0.26 (7.3)
0.48 (13)
0.04 (0.15)
0.17 (0.64)
0.29 (1.0)
0.60 (17)
1.4 (39)
2.3 (65)
0.24 (0.90)
0.86 (3.2)
1.3
(4.9)
1.4 (39)
2.9 (82)
4.7 (130)
0.40 (1.5)
1.3
(4.9)
2.0
(7.5)
15
1.2 (34)
2.9 (82)
4.7 (130)
0.50 (1.8)
1.3
(4.9)
2.1
(7.9)
60
3.1 (87)
5.9 (160)
8.5 (240)
0.90 (3.4)
3.3 (12)
4.6 (17)
90
4.1 (110)
7.5 (210)
40, 140, 230, 440
4.7 (130)
8.8 (250)
10
(280)
1.2
(4.5)
4.2 (15)
6.1 (23)
12
(340)
1.7
(6.4)
5.6 (21)
7.8 (29)
6F and 8F Series
0.5
0.36 (10)
0.86 (24)
1.6 (45)
0.09 (0.34)
0.40 (1.5)
0.76 (2.8)
1.4 (39)
2.8 (79)
4.0 (110)
0.26 (0.98)
1.1
(4.1)
1.6
3.5 (13)
(6.0)
1.8 (51)
4.2 (119)
6.8 (190)
0.64 (2.4)
2.2
(8.3)
15
1.8 (51)
4.9 (130)
7.9 (220)
0.84 (3.1)
2.6
(9.8)
60
5.1 (140)
10
(280)
15
(420)
2.0
(7.5)
6.7 (25)
10
(37)
90
6.1 (170)
11
(310)
16
(450)
2.3
(8.7)
7.6 (28)
11
(41)
40, 140, 230, 440
7.2 (200)
14
(390)
20
(560)
4.8 (18)
19
(71)
100 (6.8)
15
(56)
4.1 (15)
Filters
TF Series
Nominal
Element
Pore Size
m

5 (0.34)
10 (0.68)
Air Flow, std
15 (1.0)
10 (0.68)
ft3/min (std L/min)
50 (3.4)
100 (6.8)
2TF Series
0.5
0.04 (1.1)
0.06 (1.7)
0.12 (3.4)
0.04 (0.15)
0.17 (0.64)
0.29 (1.0)
0.20 (5.6)
0.40 (11)
0.60 (17)
0.08 (0.30)
0.24 (0.90)
0.40 (1.5)
0.50 (14)
0.90 (25)
1.2 (34)
0.10 (0.37)
0.30 (1.1)
0.48 (1.8)
15
0.80 (22)
1.3 (36)
1.5 (42)
0.12 (0.45)
0.36 (1.3)
0.58 (2.1)
60
1.7 (48)
2.2 (62)
2.4 (68)
0.15 (0.56)
0.50 (1.8)
0.70 (2.6)
90
1.8 (51)
2.2 (62)
2.6 (73)
0.20 (0.75)
0.50 (1.8)
0.60 (2.2)
40, 140, 230, 440
1.8 (51)
2.3 (65)
2.6 (73)
0.20 (0.75)
0.50 (1.8)
0.60 (2.2)
4TF Series
0.5
0.12 (3.4)
0.26 (7.3)
0.48 (13)
0.04 (0.15)
0.17 (0.64)
0.29 (1.0)
0.60 (17)
1.4 (39)
2.3 (65)
0.24 (0.90)
0.86 (3.2)
1.3
(4.9)
1.4 (39)
2.9 (82)
4.7 (130)
0.40 (1.5)
1.3
(4.9)
2.0
(7.5)
15
1.2 (34)
2.9 (82)
4.7 (130)
0.50 (1.8)
1.3
(4.9)
2.1
(7.9)
60
3.1 (87)
5.9 (160)
8.5 (240)
0.80 (3.0)
2.7 (10)
3.9 (14)
90
4.1 (110)
7.5 (210)
40, 140, 230, 440
4.7 (130)
8.8 (250)
10
(280)
1.1
(4.1)
3.4 (12)
4.9 (18)
12
(340)
1.2
(4.5)
4.2 (15)
5.6 (21)
6TF and 8TF Series

0.5
0.36 (10)
0.86 (24)
1.6 (45)
0.09 (0.34)
0.40 (1.5)
0.76 (2.8)
1.4 (39)
2.8 (79)
4.0 (110)
0.26 (0.98)
1.1
(4.1)
1.6
(6.0)
1.8 (51)
4.2 (119)
6.8 (190)
0.64 (2.4)
2.2
(8.3)
3.5 (13)
15
1.8 (51)
4.9 (130)
7.9 (220)
0.84 (3.1)
2.6
(9.8)
4.1 (15)
60
5.1 (140)
10
(280)
15
(420)
1.50 (5.6)
4.8 (18)
6.7 (25)
90
6.1 (170)
11
(310)
16
(450)
1.70 (6.4)
5.5 (20)
7.6 (28)
40, 140, 230, 440
7.2 (200)
14
(390)
20
(560)
2.40 (9.0)
7.2 (27)
10
(37)
Testing
Cleaning and Packaging
Every Swagelok filter is factory tested with nitrogen at

1000 psig (69 bar) to a requirement of no detectable leakage
with a liquid leak detector.
Every Swagelok filter with VCR end connections is specially

cleaned and packaged in accordance with Swagelok
Specification SC-11.
Filters with other end connections are cleaned and packaged
in accordance with Swagelok Specification SC-10; special
cleaning and packaging in accordance with Specification
SC-11 is available as an option.
Filters

Dimensions are for reference only and are subject to change.
FW Series
1 in. (25.4 mm) flat
Add an element designator to the basic

ordering number.
F Series and TF Series

Stainless Steel Filters
Add an element designator to the basic
ordering number.
Example: SS-4FWS-05
Example: SS-2F-2
Brass Filters
Replace SS with B in the ordering
number.
FW Series
Example: B-2F-2
Size
Nominal
Element
Pore Size
m
1/4 in.
0.5
1/4 in.
2, 7, 15
End Connections
Type
Swagelok
tube fitting
6 mm
0.5
6 mm
2, 7, 15
Female NPT
1/4 in.
Male NPT
1/4 in.
Male to
female NPT
1/4 in.
Male VCR
fitting

Orifice
SS-4FWSSS-4FWSS-6FWS-MM-
A
2.09 (53.1)
0.187 (4.75)
SS-6FW-MM-
2, 7, 15
1/4 in.
1/4 in.
Basic Ordering
Number
2.15 (54.6)
2.13 (54.1)
2.15 (54.6)
Filters with VCR fitting end connections

are not available in brass.
F and TF Series Elements

Elements remove 95 % of particles
larger than the nominal pore size.
Nominal Pore Size
Pore Size Range Element Element
m
m
Type Designator
SS-4FW4-
0.453 (11.5)
1.57 (39.9)
SS-4FW2-
0.281 (7.14)
1.89 (48.0)
SS-4FW5-
0.281 (7.14)
1.72 (43.7)
1 to 4
1.95 (49.5)
5 to 10
2.04 (51.8)
15
11 to 25
0.5
0.5
SS-4FWS-VCR-
2, 7, 15
SS-4FW-VCR-
0.187 (4.75)
40
0.5 to 2
60
50 to 75
90
75 to 100
FW Series Elements
140
Elements remove 95 % of particles

larger than the nominal pore size.
230
440
Nominal Pore Size

Pore Size Range Element Element
m
m
Type Designator
0.5
0.5 to 2
15
Sintered
05
2
Pleated
7
15
05
Sintered
2
7
15
Strainer
Sintered
40
60
90
140
Strainer
Not available for 2F series.
230
440
Filters
F Series
End Connections
Swagelok
tube fitting
Female NPT
Size
B flat

Series
Orifice
1/8 in.
SS-2F-
2F
0.094 (2.39)
2.35 (59.7)
9/16 (14.3)
1/4 in.
SS-4F-
4F
0.187 (4.75)
2.95 (74.9)
3/4 (19.0)
3/8 in.
SS-6F-
6F
0.281 (7.14)
3.21 (81.5)
1/2 in.
SS-8F-
8F
0.406 (10.3)
3.49 (88.6)
3 mm
SS-3F-MM-
2F
0.094 (2.39)
2.38 (60.5)
6 mm
SS-6F-MM-
4F
0.187 (4.75)
2.96 (75.2)
3/4 (19.0)
1/8 in.
SS-2F4-
2F
0.094 (2.39)
2.16 (54.9)
9/16 (14.3)
1 (25.4)
9/16 (14.3)
1/4 in.
SS-4F4-
4F
Male NPT
1/4 in.
SS-4F2-
4F
Male VCR
fitting
1/4 in.
SS-4F-VCR-
4F
1/8 in.
SS-2F-T7-
2F
0.094 (2.39)
2.29 (58.2)
9/16 (14.3)
1/4 in.
SS-4F-T7-
4F
0.187 (4.75)
2.91 (73.9)
3/4 (19.0)
Swagelok tube
fitting to tube
adapter
SWAGELOK
Type
Basic
Ordering
Number
2.87 (72.9)
0.187 (4.75)
2.69 (68.3)
3/4 (19.0)
2.82 (71.6)
TF Series
A
B
3/8 in. butt

weld dia
2 mounting holes,
M5 0.8-6H threads,
0.25 (6.4) deep
1/4 in. socket

weld dia
45
C
D
E
F flat
Bolt circle:
1.00 (25.4) for
2TF, 4TF;
1.13 (28.7) for
6TF, 8TF
Tube socket and tube butt

weld end connections
End Connections
Type
Swagelok
tube fitting
Female NPT
Male NPT
Tube socket
weld and tube
butt weld
Size
Basic
Ordering
Number

Series
Orifice
1/8 in.
SS-2TF-
2TF
0.094 (2.39)
2.27 (57.7)
1.07 (27.2)
1/4 in.
SS-4TF-
4TF
0.174 (4.41)
2.47 (62.7)
1.06 (26.9)
3/8 in.
SS-6TF-
6TF
0.213 (5.41)
2.84 (72.1)
1.32 (33.5)
1/2 in.
SS-8TF-
8TF
0.250 (6.35)
3.04 (77.2)
1.31 (33.3)
6 mm
SS-6TF-MM-
4TF
0.172 (4.36)
2.46 (62.5)
1.06 (26.9)
8 mm
SS-8TF-MM-
6TF
0.213 (5.41)
2.84 (72.1)
1.38 (35.1)
2.86 (72.6)
1.32 (33.5)
3.04 (77.2)
1.31 (33.3)
10 mm SS-10TF-MM-
8TF
12 mm SS-12TF-MM-
8TF
1/8 in.
SS-2TF4-
2TF
1/4 in.
SS-4TF4-
4TF
1/4 in.
SS-4TF2-
4TF
3/8 in.
SS-6TF2-
6TF
1/2 in.
SS-8TF2-
8TF
1/4 and
SS-4TF-TW3/8 in.
Top
4TF
0.250 (6.35)
0.174 (4.41)
0.174 (4.41)
0.250 (6.35)
0.174 (4.41)
Dimensions shown with Swagelok nuts finger-tight.

Mounting holes not available with 1/4 in. female NPT end connections.
2.00 (50.8)
2.13 (54.1)
2.13 (54.1)
2.38 (60.5)
2.75 (69.9)
1.68 (42.7)
1.00 (25.4)
0.38 (9.7)
1.87 (47.5)
1 (25.4)
1.13 (28.7)
0.46 (11.7)
2.20 (55.9)
1 1/8 (28.6)
1.00 (25.4)
0.38 (9.7)
1.87 (47.5)
1 (25.4)
1.13 (28.7)
0.46 (11.7)
2.20 (55.9)
1 1/8 (28.6)
1.00 (25.4)
1.00 (25.4)
0.38 (9.7)
1.87 (47.5)
1.00 (25.4)
1.00 (25.4)
0.38 (9.7)
1.87 (47.5)
1.25 (31.8)
1.13 (28.7)
0.46 (11.7)
2.20 (55.9)
1 1/8 (28.6)
1.00 (25.4)
1.00 (25.4)
0.38 (9.7)
1.87 (47.5)
1 (25.4)
1 (25.4)
Options and Accessories

All Filters
F Series
Special Cleaning and Packaging
Special Alloys
To order SC-11 cleaning and packaging, if it is not standard,

add -SC11 to the filter ordering number. Filters with VCR end
connections are specially cleaned and packaged in accordance
with Swagelok Specification SC-11 as standard.
Filters of alloy C-276 are available in some sizes. Contact your

independent Swagelok sales and service representative for
more information.
Example: SS-4FWS-05-SC11
TF Series
Bypass Port
F and TF Series
Element Kits
Kits include element
and instructions.
Filter Series
Basic Kit
Ordering Number
2F
SS-2F-K4-
Select a basic kit

ordering number
and add an element
designator.
4F, 2TF, 4TF
SS-4F-K4-
6F, 8F, 6TF, 8TF
SS-8F-K4-
Example:
SS-2F-K4-05
Nominal
Pore Pore Size
Size
Range Element Element
m
m
Type
Designator
0.5
0.5 to 2
05
1 to 4
5 to 10
15
11 to 25
40
Sintered
Strainer
50 to 75
Filter
Series
2TF,
4TF
Example:
SS-2TF-F1-05
6TF,
8TF
7
15
60
The bypass
port at the filter
bottom enables
sampling or
purging. To
order, insert a
designator into
the filter
ordering
number.
90
75 to 100
140
230
440
40
Sintered
Designator
1/8 in. Swagelok

tube fitting
-F1
1/8 in. female

NPT
-F2
1/4 in. Swagelok

tube fitting
-F3
1/4 in. tube weld
-F8
1/8 in. female

NPT
-F4
1/4 in. Swagelok

tube fitting
-F5
3/8 in. Swagelok

tube fitting
-F6
1/2 in. Swagelok

tube fitting
-F7
Overall
Height
in. (mm)
2.36
(59.9)
2.09
(53.1)
2.82
(71.6)
2.21
(56.1)
2.46
(62.5)
3.14
(79.8)
3.20
(81.3)
3.42
(86.9)
60
90
140
Strainer
Bypass Port
End
Connection
Filters Without Elements
230
TF series filters can be ordered without elements. Add LE to

the basic ordering number.
440
Example: SS-2TF-LE
Not available for 2F series.
Gasket Kits
Kits include gasket and
instructions. To order a stainless
steel gasket kit, select a kit
ordering number. For other
gasket materials, replace SS with
A for aluminum or KF for PCTFE
(TF series only).
Filter
Series
Kit Ordering
Number
2F
SS-2F-K3
4F
SS-4F-K3
6F, 8F
SS-8F-K3
2TF, 4TF
SS-4TF-K2
6TF, 8TF
SS-8TF-K2
Example: A-2F-K3
Safe Product Selection

When selecting a product, the total system design must
be considered to ensure safe, trouble-free performance.
Function, material compatibility, adequate ratings,
proper installation, operation, and maintenance are the
responsibilities of the system designer and user.
Caution: Do not mix or interchange parts with those of
other manufacturers.
Swagelok, VCRTM Swagelok Company

PH 15-7 MoTM AK Steel Corp.
1998, 2000, 2002 Swagelok Company
Printed in U.S.A., MI
July 2002, R3
MS-01-92

In-72 Gas Analyzer System

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LONG TERM STORAGE INSTRUCTIONS

The analyzer system itself is intended to be installed

Servomex 2500 Series

WARNING, CAUTIONS AND NOTES

WARNINGS: Hazards which will result in personal injury or death.

CAUTIONS: Hazards which will result in equipment or property damage.

NOTES: Alert the user to pertinent facts and conditions.

LETHAL VOLTAGES: THE ELECTRICAL POWER USED IN THIS

BEFORE CARRYING OUT MAINTENANCE OR REPAIR THE EQUIPMENT

IF FOR ANY REASON THE POWER SUPPLY CANNOT BE

SECTION 4 INSTALLATION GAS CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . 4.1

SECTION 8 CE MARKING AND OTHER SAFETY APPROVALS . . . . . . . . . . . . 8.1

2500 Overall View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

Analogue Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8

This manual contains information regarding installation and hardware configuration of

To take commissioning to the point where the analyser is

Use the Quickstart manual for:

How to set up the clock, passwords, alarm levels, analogue

How to use the manual and automatic calibration/checking

How to review configuration and set-up information.

2500 Overall View

Options and Accessories

CAUTION, HOT SURFACE

Heated Sample Cell Electrical

Heated Sample Cell Steam

Optional Output Cards

Sample Pressure Compensation

Sample Temperature Compensation

A type 'K' thermocouple in stainless steel sheath is supplied, and a continuous

Unpacking and Inspection

0.5 to 1.5mm2 (20 to 16 AWG)

0.5 to 2.5mm2 (20 to 14 AWG)

Cables should be suitable for temperatures of at least 75C.

The installer must be satisfied that the 2500 analyser installation

If the equipment is used in a manner not specified by the manufacturer

Sensible positioning and an accurate and secure installation will minimise

2500 Positioning Restrictions

2500 Mounting Details

Instructions Specific to Hazardous Area Installations

The following instructions apply to equipment covered by certificate numbers: Sira

The equipment may be located where flammable gases and vapours of

The equipment has not been assessed as a safety-related device (as

Installation of this equipment shall be carried out by suitably trained

Repair of this equipment shall be carried out by the manufacturer or in

If the equipment is likely to come into contact with aggressive substances,

e.g. acid liquids or gases that may attack metals,

e.g. regular checks as part of the routine

ATEX Label Information

EU1 T5 (Unheated Cell)

EU1 T4 (Heated Cell)

Lethal voltage: mains AC power supplies are potentially lethal. The

The installer must be satisfied that the 2500 analyser installation

CAUTION, ELECTRIC SHOCK HAZARD

CAUTION, CONSULT MANUAL

Electrical Power Connections

WARNING (EU1 VERSION)

Isolate the mains AC supply at source.

Remove filter unit cover.

Fit suitable cable gland to the mains filter unit.

Insert cable through gland and secure.

The mains AC supply is connected internally to TB30. The voltage selection is

Connect the 2 external earthing studs to earth/ground. The RF earth provided

When installed in hazardous locations, appropriate wiring practice must be used

2500 AC Power and Valve Connections (Purged Filter)