xendos 2500 Series

Infrared Analyser

Installation Manual

This Installation Manual applies to all variants of the

xendos 2500, 2510, 2520 and 2550 Infrared Analysers
(up to Product Serial Number 2999)

Ref:02500/005B/5
Order as part 02500 005B
 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.

WARNINGS

! 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 Xendos 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.

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 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 (not EUR) . . . . . . . . . . . . . . . . . 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

SECTION 3 INSTALLATION - ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

3.1 Electrical Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

3.2 Signal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6

3.2.1 Analogue Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3.2.2 Analogue Output Link Selections on Sensor Interface Board (SIB)
PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
3.2.3 Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3.2.4 Relay Output Link Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9

3.3 Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10

3.3.1 Range Change Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
3.3.2 Autocalibration Initiation Input . . . . . . . . . . . . . . . . . . . . . . . . . 3.11

ii
 3.3.3 Password Keyswitch Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
3.3.4 Sample Flow Sensor Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
3.3.5 Solenoid Valve Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
3.3.6 Externally Powered Solenoid Valve Connections . . . . . . . . . . 3.13
3.3.7 Internally Powered Solenoid Valve Connections . . . . . . . . . . . 3.14

3.4 Digital Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15

3.4.1 RS-232 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15

3.5 Pressure Transducer Connections - (If Supplied) . . . . . . . . . . . . . . . . 3.21

3.5.1 GEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
3.5.2 EUR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
3.5.3 UK2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
3.5.4 FM2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22

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

4.1 Purge Connections (EUR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10

iii
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 Xendos 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 Design Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.1.5 Performance Characteristics (each component) . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
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
7.1.14 480 Purge Controller (2500 EUR Only) . . . . . . . . . . . . . . . . . . . . 7.5
7.1.15 485 Purge Controller (2500 EUR Only) . . . . . . . . . . . . . . . . . . . . 7.5
7.1.16 Alternative Purge Controller (2500 EUR Only) . . . . . . . . . . . . . . 7.5

SECTION 8 SAFETY APPROVALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1

8.1 02500 Series Analysers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1

iv
 LIST OF FIGURES

Figure 1.1 2500 Overall View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

Figure 1.2 2500 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Figure 2.1 2500 Positioning Restrictions . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
Figure 2.2 2500 Mounting Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
Figure 3.1 a 2500 AC Power and Valve Connection (Purged Filter) . . . . . . . . 3.3
Figure 3.1 b 2500 AC Power and Valve Connections (Non-Purged Filter) . . 3.4
Figure 3.2 2500 Series Terminal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Figure 3.3 SIB and Optional Output PCB’s . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Figure 3.4 Autocalibration Valve Configuration . . . . . . . . . . . . . . . . . . . . . 3.15
Figure 3.5 UK2 Pressure Transducer Assembly . . . . . . . . . . . . . . . . . . . . 3.22
Figure 3.6 FM2 Pressure Transducer Connection . . . . . . . . . . . . . . . . . . . 3.23
Figure 4.1 Purge Connection Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Figure 4.2 Cell End Boss Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
Figure 5.1 General Cell Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6

LIST OF TABLES

Table 3.1 Analogue Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7

Table 3.2 Relay Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Table 3.3 External Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 3.10
Table 3.4 Externally Powered Solenoid Valve Connections . . . . . . . . . . 3.13
Table 3.5 Internally Powered Solenoid Valve Connections . . . . . . . . . . . 3.14
Table 3.6 Serial Data Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
Table 3.7 Fault Number Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
Table 3.8 ASCII Characters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
Table 3.9 RS232 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20
Table 3.10 GEN Pressure Transducer Connections . . . . . . . . . . . . . . . . . 3.21
Table 3.11 EUR Pressure Transducer Connections . . . . . . . . . . . . . . . . . 3.21
Table 3.12 UK2 Pressure Transducer Connections . . . . . . . . . . . . . . . . . 3.21
Table 3.13 FM2 Pressure Transducer Connection . . . . . . . . . . . . . . . . . . 3.23
Table 5.1 Diagnostic Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
Table 5.2 General Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
Table 5.3 Serious Fault Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
Table 6.1 General Spares List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
Table 6.2 Sample Cell Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
Table 6.3 Source Unit Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Table 6.4 Detector Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
Table 6.5 Window Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Table 6.6 Scrubber Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
Table 6.7 Recommended Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5

v
Table 7.1 General Environmental Specifications . . . . . . . . . . . . . . . . . . . . 7.1
Table 7.2 Performance Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
Table 7.3 Sampling Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Table 7.4 Sample and Ambient Influence . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
Table 7.5 Serial Output Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
Table 8.1 02500 Safety Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1

vi
SECTION 1 INTRODUCTION

1.1 Introduction

This manual contains information regarding installation and hardware configuration of

the Servomex Xendos 2500 Series analysers (2500, 2510 ,2520, 2550 in GEN, UK2
FM2, EUR and HTV variants).

GEN - General Purpose/Safe area use.

HTV - High Temperature Variant.
UK2 - Certified for UK/European Zone 2 areas.
FM2 - Certified for US Class 1 Div. 2 areas.
EUR - Certified for UK/European Zone 1 areas.

Note that the UK2, EUR 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 02500/003B. This details software configuration and operation
of the analyser. An alternative Quickstart manual is supplied with the 2510 analysers,
reference part number 02510/003B. Extra copies of either may be ordered from
Servomex.

Some variants are supplied with a Safety Certificate Manual, reference part number
02500/008B which details the hazardous area approvals and declarations applicable.

Details of the hardware and instructions for servicing, by qualified personnel only, are
presented in the Xendos 2500 Service Manual. This may be ordered from Servomex,
reference part number 02500/002A.

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.

1.1
Review How to review configuration and set-up information.

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 Fig 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

1.2
Note that the UK2, EUR and FM2 versions can also be used when flammable samples
are to be monitored in otherwise safe areas (see Safety Certificate Manual).

WARNING

The EUR versions are intended for use with a suitably certified Purge Control
System (PCS). Do not install a EUR 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.

1.4.1 Heated Sample Cell - Electrical (not EUR)

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 Zone 2/Div. II hazardous areas.
The normal temperature setting for common gas applications is 600C, although it may
be supplied set to any temperature from 30 - 1800C for HTV variants or from 30 - 130oC
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 1000C. This allows cell heating in hazardous areas up to Zone 1/Div. I
classification, and is normally used with the EUR 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 02000/906A 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 supplied, plumbed into one sample cell connection,
and a continuous pressure measurement (over the range of the standard transducer,
0 -170 kPa, 0 - 25 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.

The GEN and UK2 versions are detailed in section 3.5.

The FM2 version is only available as a special option.

1.5
The EUR versions for Zone 1 installations includes a Zener barrier inside the 2500
source end. The transducer is certified EEx ia IIC T4 and has a 316SS body with
Hastelloy diaphragm. It is suitable for all samples except oxygen service. Details can
be found in section 3.5.

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 200oC (-58 to
392oF). 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 are available with the 2500 and it
will have been supplied configured with one particular option to make the customer-
specified measurements. Full details of the application configuration (i.e. optical
materials, operating wavelengths, cell pathlength, wetted materials etc.) will be found
on the Product Specification document in the front of this manual.

1.6
SECTION 2 INSTALLATION - GENERAL

2.1 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: do not clean display or keypad with a dry cloth.

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.

After the initial visual inspection carry out the following checks. Beware gas strut
action of the hinged covers.

2.1
! Check that the serial number of the 2500 (located inside source end)
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, and Plastic plugs.

2.3 Electrical Connections

WARNING

! The 2500 Series analysers do not have their own power isolating
switches and therefore it is NECESSARY to ensure that the mains supply
is fitted with a local isolating switch and an appropriate fuse.

! It is ESSENTIAL that the unit is independently earthed/grounded using

a clean earth.

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, ie. nominal
100/115VAC or nominal 200/230VAC. 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.

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 (EUR 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.

! 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.

UK2 versions must be protected against the entry of solid particles or liquids by a
suitable cover or enclosure where necessary.

FM2 versions 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.

EUR versions must be used with either a Servomex 485 or 480 purge controller, or
another suitable Purge Control System which must meet the necessary pressurisation
requirements, and is supplied with the necessary pressurisation and control
components.

2.3
 WARNING

EUR Zone 1 versions must be used with either the Servomex 485 or 480 Purge
Controller, 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 or 480 PCS, installation information
is provided in a separate manual 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 90o 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
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.

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.

WARNING (EUR VERSION)

AC Power for Zone 1 (EUR) 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. The power cable into this unit does not
need to be screened.

Refer to Fig. 3.1 a) or b) for illustration.

To connect the 2500 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.

3.1
6. The mains AC supply is connected internally to TB30. The voltage selection is
made by wire link on TB31 as illustrated in fig.3.1 a) or 3.1 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

If cables are to be installed in a harsh or potentially explosive environment, they must

be protected from mechanical stress and interference.

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

3.5
3.2 Signal Connections

NOTE

The signal cables must have a braided overall screen or armour. The screen must
be terminated at the point of entry to the case. This may be by using a gland which
makes a connection between the cable screen and the case, or alternatively by using
an earth tag under the gland securing nut, taking care to ensure that the screen is
kept as short as possible, and that a good electrical connection is achieved between
the tag and the case. In some instances, an earth stud is provided adjacent to the
gland holes. This may be used in place of the earth tag. Beware of ground/earth
loops if the screens are also connected at the user end.

3.2.1 Analogue Outputs

Each analogue output is supplied set for current output and may be configured by the

Figure 3.3 SIB and Optional Output PCB’s

3.6
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, and
the screen to the adjacent earth stud.

WARNING (EUR VERSION)

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.
Alternatively, the user must provide Zener Barrier isolation in the safe area.

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 Terminal Connections
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 Fig 3.2.

3.7
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 Fig
3.3 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 Current: Link 10 - OPEN

Voltage: Link 10 - CLOSED (solder link)
Analogue o/p No.2 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

3.8
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
230VAC/0.5A or 30VDC/0.5A. 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 23-6
Relay 5* 2.4 TB 22-7 and TB 23-7

*option PCB

Terminal locations are as illustrated in Fig 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 Fig.3.3 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
resoldering the wire links as listed below.

3.9
 WARNING

Setting the relays to Normally Open 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 NO/NC 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 NC Link 3 - A

NO Link 3 - B

Relay o/p No. 2 NC Link 4 - A

NO Link 4 - B

Relay o/p No. 3 NC Link 5 - A

NO Link 5 - B

3.3 Control Connections

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 Range Change TB26 - 1
02500904 or 02500904A TB25 - 3
Transmitter PCB Autocalibration Initialise TB26 - 2
02500904 or 02500904A TB25 - 3
Transmitter PCB Password Keyswitch TB26 - 3
02500904 or 02500904A TB25 - 3
Power Control PCB Flow Failure TB36 - 1
02500911 or 02500911A TB36 - 2

3.10
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

3.11
 WARNING

If the Keyswitch is left "ON" (contacts closed), access is continuously available

to all 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 Fig 3.1.

2500 Power Control PCB 02500911 or 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.

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 3.4. Two or three valves may be used and each valve is powered via the
2500 Power Control PCB relays as illustrated, and all should be sited conveniently close
to the 2500. The valves are selected for operation by the 2500 as shown in Table 3.4.
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 Fig 3.1.

The Autocalibration relays are rated at 230VAC/0.5A, 30VDC/0.5A. An external power

source may be used, or the internal 24VDC/12VA power source may be used. Take
care to ensure that the 12VA rating is not exceeded.

WARNING

If installation is in a hazardous area, use suitable certified solenoid valves.

3.12
 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 condensation is risked in the sample cell if it is not hot, and nitrogen must be
used to flush the cell while it is warming up;

! 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)
Span/Zero Cal/Sample Sample/Inert
Valve SV1 Valve SV2 Valve SV3
TB34 - 1 TB34 - 3 TB34 - 5
TB34 - 2 TB34 - 4 TB34 - 6
Cell or Chopper Box either either OFF(Inert)
Under Temperature
NORMAL STATE OFF(Zero) OFF(Sample) ON(Sample)
Zero Sample Required OFF(Zero) ON(Cal.) ON(Sample)
Span Sample Required ON(Span) ON(Cal.) ON(Sample)

3.13
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 24VDC/12VA rating is not exceeded.

Table 3.5 Internally Powered Solenoid Valve Connections

Valve State (ON=Current Flow Through
Solenoid)
Span/Zero Cal/Sample Sample/Inert
Valve SV1 Valve SV2 Valve SV3
TB34 - 1 (-) TB34 - 3 (-) TB34 - 5 (-)
TB36 - 6 (+) TB36 - 5 (+) TB36 - 5 (+)
Cell or Chopper Box either either OFF(Inert)
Under Temperature
NORMAL STATE OFF(Zero) OFF(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.

3.14
 Figure 3.4 Autocalibration Valve Configuration

3.4 Digital Connections

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:

3.15
 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 1 byte Number of components fitted (range 1..3)
components;
<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 Max 5 bytes Concentration for component 1 as defined
concentration; for measure display.
component 1 units; Max 3 bytes Units defined for component 1.
component 1 alarm 4 bytes One byte for each alarm. Set to alarm
status; number (1,2,3 or 4) when alarm is raised,
<space> when alarm not raised
component 1 1 byte Indicates Autocalibration phase.
Autocalibration status; or 0 = Not in Autocalibration
15 bytes 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 which represent
the zero before calibration and the zero
after calibration respectively.
4 = In span cal
5 = span corrected. This is then followed by
two additional values, which are separated
by commas, each 6 bytes which represent
the span before calibration and the span
after calibration respectively.
6 = In post flush
<CR><LF> 2 bytes Carriage return and Line Feed characters
(ASCII codes 13 and 10 respectively).
Note: The data for components 2 and 3 will only be present on a 2550 instrument.
component 2 formula; Max 6 bytes Chemical formula defined for component 2.
(if fitted)
component 2 Max 5 bytes Concentration for component 2 as defined
concentration; for measure display. (if fitted)
component 2 units; Max 3 bytes Units defined for component 2. (if fitted)
component 2 alarm 4 bytes One byte for each alarm. Set to alarm
status; number (1,2,3 or 4) when alarm is raised,
<space> when alarm not raised. (if fitted)

3.16
component 2 1 byte Indicates Autocalibration phase.
Autocalibration status; or 15 bytes 0 = Not in Autocalibration l
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 which represent
the zero before calibration and the zero
after calibration respectively.
4 = In span cal
5 = span corrected. This is then followed by
two additional values, which are separated
by commas, each 6 bytes which represent
the span before calibration and the span
after calibration respectively.
6 = In post flush
<CR><LF> 2 bytes Carriage return and Line Feed characters
(ASCII codes 13 and 10 respectively).
component 3 formula; Max 6 bytes Chemical formula defined for component 3.
(if fitted)
component 3 Max 5 bytes Concentration for component 3 as defined
concentration; for measure display. (if fitted)
component 3 units; Max 3 bytes Units defined for component 3. (if fitted)
component 3 alarm 4 bytes One byte for each alarm. Set to alarm
status; number (1,2,3 or 4) when alarm is raised,
<space> when alarm not raised. (if fitted)
component 3 1 byte Indicates Autocalibration phase.
Autocalibration status; or 0 = Not in Autocalibration
15 bytes 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 which represent
the zero before calibration and the zero
after calibration respectively.
4 = In span cal
5 = span corrected. This is then followed by
two additional values, which are separated
by commas, each 6 bytes which represent
the span before calibration and the span
after calibration respectively.
6 = In post flush
<CR><LF> 2 bytes Carriage return and Line Feed characters
(ASCII codes 13 and 10 respectively).
Note: End of 2550 specific data
fault status; 1 byte Set to ‘F’ when fault is active, <space>
when no fault active

3.17
 fault numbers; List of fault numbers of active faults,
separated by ‘,’. Fault numbers are defined
in table 3.7.
<CR><LF> 2 bytes Carriage return and Line Feed characters
(ASCII codes 13 and 10 respectively).
chopper Max 4 bytes Chopper temperature as displayed in
temperature;ºC; diagnostic display.
Compensation Max 4 bytes Compensation (detector) temperature as
temperature;ºC; displayed in diagnostic display.
cell/sample Max 5 bytes Cell/sample temperature as displayed in
temperature;ºC; diagnostic display.
source voltage;V; Max 5 bytes Source voltage as displayed in diagnostic
display.
Intensity 1;Intensity 2; Max 6*6 Intensity channel values – diagnostic
Intensity 3;Intensity 4; bytes values representing up to six input
Intensity 5;Intensity 6; positions used for measure and reference
signals.
<CR><LF> 2 bytes Carriage return and Line Feed characters
(ASCII codes 13 and 10 respectively).
checksum; 4 bytes ASCII representation of 16 bit checksum
(modulo 65536), calculated by adding all
data preceding the checksum together.
<CR><LF> 2 bytes Carriage return and Line Feed characters
(ASCII codes 13 and 10 respectively).
<CR><LF> 2 bytes Carriage return and Line Feed characters
(ASCII codes 13 and 10 respectively).

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>

3.18
 Table 3.7 Fault Number Reference

Fault Number Display Message

1 OPTICAL BENCH POWER FAILURE
2 SOURCE VOLTAGE HIGH
3 SOURCE VOLTAGE LOW
4 INFRARED SOURCE FAILURE
5 CHOPPER MOTOR OUT OF LOCK
6 SAMPLE FLOW FAILURE
7 CHOPPER TEMP HIGH
8 CHOPPER TEMP LOW
9 CHOPPER TEMP SENSOR FAILURE
10 CELL TEMP HIGH
11 CELL TEMP LOW
12 CELL TEMP SENSOR FAILURE
13 SAMPLE TEMP SENSOR FAILURE
14 PRESSURE SENSOR FAILURE
15 BAD REFERENCE VOLTAGE
16 COMPENSATION T SENSOR FAILURE
17 DETECTOR SIGNAL HIGH
18 DETECTOR SIGNAL LOW
19 Reserved
20 Reserved
21 Reserved
22 AUTO CAL BAD PREFLUSH
23 ZERO OUT OF TOLERANCE
24 SPAN OUT OF TOLERANCE
25 Reserved
26 Reserved
27 Reserved
28 Reserved
29 Reserved
30 PASSWORD VIOLATION
31 SYSTEM CLOCK INOPERATIVE
32 SYSTEM ADC INOPERATIVE
33 DEFAULT SYSTEM DATA CORRUPTION
34 CALIBRATION DATA CORRUPTION
35 UTILITY DATA CORRUPTION
36 ALARM/RELAY DATA CORRUPTION
37 ANALOGUE ASSIGN DATA CORRUPTION

3.19
 38 BAD SPAN SPAN IGNORED

Some characters defined by the Xendos 2500 are non-standard characters, ie. 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 0 0
129 1 1
130 2 2
131 3 3
132 4 4
133 5 5
134 6 6
135 7 7
136 8 8
137 9 9
138 ? <space>
139 ? <space>
140 <space>
141 ?? <space>
142 º <space>
143 £ <space>

Table 3.9 RS232 Connections

2500 Terminals Connector External RS232 Terminals
0V (Ref.)(0VR) TB2 - 7 Signal GND/0V
Clear to Send (CTS) TB2 - 9 Data Terminal Ready(DTR)
Transmit (Tx) TB2 - 1 Receive (Rx)

3.20
 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. Various cabling configurations are used depending upon the analyser
type selected.

3.5.1 GEN

The pressure transducer is supplied pre-wired to the analyser. The cabling is connected
to PCB 02500911 TB35 as shown in table 3.10.

Table 3.10 GEN Pressure Transducer Connections

PCB 02500911 or 02500911A Interconnecting Cable Pressure Transducer
TB35 - 5 Black - Identified ‘1' Terminal 1 (+)
TB35 - 1 Black - Identified ‘2' Terminal 2 (-)

3.5.2 EUR

The pressure transducer cabling is terminated to the source end right hand side (RHS)
of the analyser, and is supplied pre-wired to an internally mounted 4-20mA isolation
barrier. The cabling to the barrier is shown in table 3.11 below.

Table 3.11 EUR Pressure Transducer Connections

Isolation Barrier Interconnecting Cable Pressure Transducer
Blue Terminal 5 (+) Black - Identified ‘1' Terminal 1 (+)
Blue Terminal 6 (-) Black - Identified ‘2' Terminal 2 (-)

3.5.3 UK2

The pressure transducer is supplied pre-wired to the analyser. The cabling is connected
to PCB 02500911 TB35 as shown in table 3.12.

Table 3.12 UK2 Pressure Transducer Connections

PCB 02500911 or 02500911A Interconnecting Cable Pressure Transducer
TB35 - 5 Black - Identified ‘1' Terminal 1 (+)
TB35 - 1 Black - Identified ‘2' Terminal 2 (-)

3.21
 Figure 3.5 UK2 Pressure Transducer Assembly

The general layout of the pressure transducer option is illustrated in figure 3.5.

3.5.4 FM2

Pressure transducers for these applications are supplied as a special option.

The pressure transducer must be isolated from the analyser, and be cabled to a
suitably certified explosion proof or flameproof enclosure containing a certified mains
powered isolation barrier. Suitable screened cabling should be fitted, as illustrated in
figure 3.6.

For analyser and pressure transducer wiring information, refer to table 3.13 below

3.22
 Table 3.13 FM2 Pressure Transducer Connection

PCB 02500911 or 02500911A Pressure Transducer

TB35 - 1 (Signal +) Terminal 1 (+)
TB35 - 2 (Signal -) Terminal 2 (-)

NOTE

If the transducer cable is shortened, ensure that the braided screen is re-terminated
to the cable gland in order to maintain EMC integrity.

Figure 3.6 FM2 Pressure Transducer Connection

3.23
 NOTES

3.24
SECTION 4 INSTALLATION - GAS CONNECTIONS

4.1 Purge Connections (EUR)

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

WARNING (EUR VERSION)

Where appropriate, the user must refer to the detailed instructions provided
in the manual supplied with the Servomex 485 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 March 1977.

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 (138 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.

WARNING
Exceeding the maximum purge pressure of 2 psi(138 mBar) may damage the
instrument keypad and invalidate the certified protection.

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 carbon dioxide
and 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

The problem 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
flowmeter. The source pressure of the nitrogen should be at least 1.5 times the
sample pressure.
(1)
Dry means a dewpoint 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 Fig 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 EUR Versions).

4. Apply steam to any steam-heated cells fitted.

4.6
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.

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 setpoint 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.

4.7
 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.

4.8
SECTION 5 FAULT DIAGNOSIS AND CELL MAINTENANCE

5.1 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
02500/002A.

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 oC Chopper box temperature

o
COMPENSATION C Detector temperature
o
CELL TEMP C Cell temperature (if enabled)
o
SAMPLE TEMP C Sample Temperature *

[Measurement 1] ABS au Absolute absorbance units (M1)

[Measurement 2] ABS au Absolute absorbance units (M2) *

[Measurement 3] ABS au Absolute absorbance units (M3) *

SAMPLE PRESSURE (units) Sample pressure *

SOURCE VOLTS V Source voltage

MOTOR DRIVE % Motor drive power and set point

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 Description/comments

Entry
SOURCE VOLTAGE SOURCE HIGH Possible Power Control PCB fault
HIGH

SOURCE VOLTAGE SOURCE LOW Possible Power Control PCB fault

LOW

SAMPLE FLOW FLOW FAIL User Sample Flow Alarm active

FAILURE

CHOPPER TEMP HIGH CH TEMP Ambient temp. too high/control

HIGH problem

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

problem

CHOPPER TEMP CH TEMP FAIL Chopper sensor

SENSOR FAILURE failed/disconnected/outside range.

CELL TEMP HIGH CELL T HIGH Possible Power Control PCB fault

CELL TEMP LOW CELL T LOW Possible Power Control PCB fault

CELL TEMP SENSOR CELL T FAIL Cell sensor

FAILURE failed/disconnected/outside range

SAMPLE TEMP SAMPLE T Sample sensor

SENSOR FAILURE FAIL failed/disconnected/outside range

PRESSURE SENSOR NO Sample sensor

FAILURE PRESSURE failed/disconnected/outside range

BAD REFERENCE REF VOLT Possible Transmitter PCB fault

VOLTAGE FAIL

DETECTOR SIGNAL DET SIG LO Probable cell contamination - clean

LOW cell

COMPENSATION T COMP T FAIL Detector sensor

SENSOR FAILURE failed/disconnected

5.3
 ZERO OUT OF ZERO OUT Failed Autocalibration - bad zero
TOLERANCE TOL sample - use One Cycle or Manual
Zero

SPAN OUT OF SPAN OUT Failed Autocalibration - bad span

TOLERANCE TOL sample - use One Cycle or Manual
Span

AUTOCAL BAD BAD Failed Autocalibration - bad

PREFLUSH PREFLUSH preflush - use One Cycle

PASSWORD BAD 3 consecutive Password failures

VIOLATION PASSWORD

SYSTEM CLOCK BAD CLOCK Reset time or replace Clock chip

INOPERATIVE

DEFAULT SYSTEM BAD SYS Factory calibration corrupt - use

DATA CORRUPTION DATA Associate

SYSTEM ADC BAD ADC Possible SIB PCB fault

INOPERATIVE

CALIBRATION DATA BAD CAL User calibration corrupt - repeat

CORRUPTION DATA calibration

UTILITY DATA BAD UTI DATA Utility file corrupt - renew all entries
CORRUPTION

ALARM/RELAY DATA BAD RLY Alarms/Relays file corrupt-renew

CORRUPTION DATA all entries

ANALOGUE ASSIGN BAD ANL Analogue output file corrupt-renew

DATA CORRUPTION DATA all entries

BAD SPAN BAD SPAN Coarse span adjustment limit

SPAN IGNORED 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 Description/comments

Entry
INFRARED SOURCE SOURCE FAIL Source failure
FAILURE
CHOPPER MOTOR OUT OF LOCK Motor or timing failure
OUT OF LOCK
DETECTOR SIGNAL DET SIG HI Possible loss of IR filter, loss of
HIGH 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
 WARNINGS

! 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 leave the 2 steel boss plugs supplied with the cell key to stop up the open ends
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).

5.7
 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.

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 02500979). 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

5.8
squarely and remove it. Finally remove the PTFE gasket. Dismantle the other end
of the cell in a similar manner.

On later analysers, the ‘O’ ring spacer is threaded internally. The Special Tools Kit
Servomex p/n 02500979 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.

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 (Servomex p/n 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 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 4.3.

Reset zero if necessary on a true zero sample.

5.9
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.

5.10
SECTION 6 SPARES LISTS

6.1 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.

6.1.1 General

Table 6.1 General Spares List

Description Part Number
Power Supply PCB (GEN, UK2, EUR, FM2, HTV) S2000925
Display / Keypad Assembly (See Notes Below) S2501999
Sensor Interface PCB 02000934
Option PCB 02000916
Keypad (GEN, HTV, UK2, FM2) 02000981
Purgeable Keypad (EUR) 02000985
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, 100/200 volts S2500978A
Transformer, 115/230 volts S2500978B

6.1
 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 02500996
Multicomponent 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
Microprocessor PCB (2510 only, Fitted with firmware S2510965
02510665F)
Microprocessor PCB (2500, 2520, 2550 Fitted with S2500965
firmware 02550665F)

Note: 1) Display / Keypad Assembly S2501999 replaces Display PCB

S2000903.
2) To replace the Display PCB on instruments fitted with revised Display /
Keypad Assembly S2501999 use replacement part S2501903.

6.1.2 Sample Cell Spares

Table 6.2 Sample Cell Spares

Description Part Number
Thermocouple (use with 02500901 only) 02500501
Thermocouple (300mm Sheath) 02500502
Cell Servicing Kit S2500981
Cell Seals Kit (Viton + PTFE) S2500982A
Cell Seals Kit (Chemraz) S2500982B
PTFE Tape 1835-3026
Hand Aspirator 2387-0514

6.2
6.1.3 Source Units

(Refer to Final Specification Sheet)

Table 6.3 Source Unit Spares

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

6.1.4 Detector Units

(Refer to Final Specification Sheet)

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

(Refer to Final Specification Sheet)

Table 6.5 Window Spares

Description Part Number
CaF2 S2500980A
BaF2 S2500980B
ZnSe S2500980C
IR Quartz S2500980D
Glass S2500980E
Germanium S2500980F
Sapphire S2500980G

6.1.6 Scrubbers

(Refer to Final Specification Sheet)

Table 6.6 Scrubber Spares

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

6.4
6.2 Recommended Spares

Quantity for 2 years.

Table 6.7 Recommended Spares

Item Part Number 1-3 Analysers 4-9 Analysers
Fuse Kit 02500996 2 4
Cell Servicing Kit S2500981 2 4
PTFE Tape 1835-3026 1 1
Chopper Motor S2500986 1 1
Cell sealing Kit Refer to application 2 5
Hand Aspirator 2387-0514 1 1
Windows Refer to application 2 4
Chopper Box Scrubber Refer to application 2 4
Detector & Cell Boss Refer to application 2 4
Scrubber
Source Refer to application 1 2
Detector Refer to application 0 1
Microprocessor PCB Refer to application 0 1
Sensor Interface PCB 02000934 0 1
Power Supply PCB S2000925 0 1
(GEN, UK2, EUR, FM2,
HTV)

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
 NOTES

6.6
SECTION 7 INSTRUMENT SPECIFICATIONS

7.1 Generic Xendos 2500 Series Performance

7.1.1 Environmental Specifications

Table 7.1 General Environmental Specifications

Operating Temperature GEN/EUR 0-55oC (32-131oF)
UK2/FM2/HTV 0- 50oC(32-122oF)
Operating Humidity 0-95% RH, non-condensing
Storage Temperature -40oC(-104oF) to +70oC (158oF)
Storage Humidity 0-95% RH, non-condensing.
Installation Category II Over-voltage impulse to withstand up to
Pollution Degree II 2500V in accordance with IEC664
Rate of Ambient Temperature Change Less than ±25oC/h, (±45oF/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

100VA without optional cell heater
300VA with optional cell heater

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
Frequency

7.1
7.1.4 Design Standards

All 2500 Series Analysers are CE marked and comply with the European Community
“Electromagnetic Compatibility Directive” 89/336/EEC by the application of the
following standards:

EN50081-1: Emissions; Light Industrial Environment

EN50082-2: Immunity; Industrial Environment

All 2500 Series analysers comply with the European Community “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 IEC1010)

Safety requirements for electrical equipment for measurement, control,

and laboratory use - general requirements;
and are rated in accordance with:

IEC664 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.

The UK2 and EUR variants comply with the transitional arrangements of the
European Community “ATEX Directive” 94/9/EC.

7.1.5 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 min (electronic only,
excludes sampling)
Obscuration Less than ±3% fsd zero error for 50% broad
band 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.

7.2
7.1.6 Sample Specification

Table 7.3 Sampling Specification

Sample Temperature 0-180oC/32-356oF (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 Output may change up to ±1.6% fsd for a ±1% change in
Stability 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 Output may change up to ±0.3% fsd for gases for a ±1oC
Stability change in sample temperature. With optional empirical
sample temperature compensation, effect is reduced to
±1% fsd or less for a 20o C 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 Less than 1% fsd zero drift due to rate of ambient
Influence temperature change of 25oC/hr (45oF/hr) over a
maximum of 25oC (45oF) change.

7.1.8 Solenoid Valve Relays

3 x Solenoid valve relays with volt free contacts rated 230VAC/0.5A, 30VDC/0.5A.

1 x 24VDC/12VA auxiliary supply for solenoid valves

7.1.9 Analogue Outputs

2 x mA outputs, plus 3 x relay outputs.

Optionally additional 2 x mA, plus 2 x relay outputs.

7.3
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 230VAC/0.5A, 30VDC/0.5A.

7.1.10 Serial Output

Single ASCII data logging output port (RS232).

Table 7.5 Serial Output Specification

Baud Rate 2400
Parity Even
Stop Bits 1
Data Bits 8
Handshake Hardware

7.1.11 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
7.1.14 480 Purge Controller (2500 EUR Only)

Requires maximum of 40 l/min clean dry Nitrogen or clean dry Air at 4-7 barg,
depending on application.

7.1.15 485 Purge Controller (2500 EUR Only)

Requires maximum of 40 l/min clean dry Nitrogen or clean dry Air at 3-7 barg,
depending on application.

7.1.16 Alternative Purge Controller (2500 EUR Only)

Minimum flow rate = 10 SLPM for 16 minutes.

Minimum overpressure = 0.5 mBar.
Maximum overpressure = 138 mBar.

Refer to Certification Manual (Certificate EEx 92C1034X) for definitive requirements

and operational parameters.

7.5
 NOTES

7.6
SECTION 8 SAFETY APPROVALS

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
UK2, FM2 and EUR 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.

8.1 02500 Series Analysers

Table 8.1 02500 Safety Approvals

Variant Certification
GEN/HTV Only suitable for installation in a non-hazardous area.
UK2 The 02500 Series UK2 version is certified to BS4683 Part 3
and BS6941, and is suitable for use in Zone 2 areas. The
analyser is marked Ex N IIC T3 for cell temperatures up to
130°C and Ex N IIC T4 for cell temperatures up to 80°C.

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.
FM2 The 02500 Series FM2 version is approved for operation in US
Class 1 Div. II locations, without safety purging.

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.
EUR The 02500 Series EUR version is CENELEC certified to Type
'p' standard and is suitable for use in European and UK Zone
1 areas. The analyser is marked EEx p II T5.

8.1
 NOTES

8.2