PROCESS ANALYSERS

SERVOTOUGH SpectraExact
(2500 series)
Process Gas Analysers

Installation Manual

Part Number: 02500005C

Revision: 2
Language: UK English
This page intentionally blank
 WARNING, CAUTIONS AND NOTES
This publication includes WARNINGS, CAUTIONS and NOTES which provide,
where appropriate, information relating to the following:
• WARNINGS: Hazards which will result in personal injury or death.
• CAUTIONS: Hazards which will result in equipment or property damage.
• NOTES: Alert the user to pertinent facts and conditions.

WARNING
• LETHAL VOLTAGES: THE ELECTRICAL POWER USED IN THIS
EQUIPMENT IS AT A VOLTAGE HIGH ENOUGH TO ENDANGER LIFE.
• BEFORE CARRYING OUT MAINTENANCE OR REPAIR THE EQUIPMENT
MUST BE DISCONNECTED FROM THE ELECTRICAL SUPPLY. TESTS
MUST BE MADE TO ENSURE THAT DISCONNECTION IS COMPLETE.
• IF FOR ANY REASON THE POWER SUPPLY CANNOT BE
DISCONNECTED, FUNCTIONAL TESTING, MAINTENANCE AND REPAIR
OF THE ELECTRICAL UNITS IS ONLY TO BE UNDERTAKEN AS A LAST
RESORT AND MUST BE CARRIED OUT BY PERSONS FULLY AWARE
OF THE DANGER INVOLVED.

NOTE
This instruction manual for the 2500 Series range of analysers covers installation,
routine maintenance and fault diagnosis procedures, and it should be thoroughly
read and retained by the personnel responsible.

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ii
 Table of Contents
SECTION 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.2 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
1.3 Basic Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.4 Options and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.4.1 Heated Sample Cell – Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
1.4.2 Heated Sample Cell – Steam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.4.3 Optional Output Cards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.4.4 Compensation Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
1.4.5 Application Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6

SECTION 2 INSTALLATION – GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.2 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.2.1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.2.2 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.2.3 Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
2.3 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
2.4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.4.1 Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2.4.2 Mounting Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
2.5 Instructions Specific to Hazardous Area Installations . . . . . . . . . . . . . . . . . . . 2.7
2.6 ATEX Label Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8

SECTION 3 INSTALLATION – ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1

3.1 Electrical Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1
3.2 Signal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
3.2.1 Analogue Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
3.2.2 Analogue Output Link Selections on Sensor Interface
Board (SIB) PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
3.2.3 Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
3.2.4 Relay Output Link Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
3.3 Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11
3.3.1 Range Change Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12
3.3.2 Autocalibration Initiation Input . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12
3.3.3 Password Keyswitch Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12
3.3.4 Sample Flow Sensor Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
3.3.5 Solenoid Valve Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13
3.3.6 Externally Powered Solenoid Valve Connections . . . . . . . . . . . . .3.14
3.3.7 Internally Powered Solenoid Valve Connections . . . . . . . . . . . . . . 3.15
3.4 Digital Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16
3.4.1 RS-232 Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
3.5 Pressure Transducer Connections – (If Supplied) . . . . . . . . . . . . . . . . . . . . . 3.23

iii
SECTION 4 INSTALLATION GAS CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1 Purge Connections (EU1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.1.1 General Purge Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
4.2 End Boss Purge Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.2.2 End Boss Scrubbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
4.2.3 End Boss Vents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
4.2.4 End Boss Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
4.3 Steam Heated Cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.4 Process Stream Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.4.1 Basic Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.4.2 High Integrity Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
4.5 Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6

SECTION 5 FAULT DIAGNOSIS AND CELL MAINTENANCE . . . . . . . . . . . . . . 5.1

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.2 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1
5.3 General Fault Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
5.4 Serious Fault (Shutdown) Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
5.5 Cell Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
5.6 Routine Leak Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9

SECTION 6 SPARES LISTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1

6.1 Spares List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
6.1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1
6.1.2 Sample Cell Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
6.1.3 Source Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.1.4 Detector Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
6.1.5 Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.1.6 Scrubbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
6.2 Recommended Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5

SECTION 7 INSTRUMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1

7.1 Generic 2500 Series Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.1.1 Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.1.2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.1.3 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.1
7.1.4 Performance Characteristics (each component) . . . . . . . . . . . . . . . 7.2
7.1.5 Performance Characteristics – EMC . . . . . . . . . . . . . . . . . . . . . . . . 7.2
7.1.6 Sample Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
7.1.7 Sample and Ambient Performance . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
7.1.8 Solenoid Valve Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
7.1.9 Analogue Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.1.10 Serial Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.1.11 Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.1.12 Ingress Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.1.13 Optical Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
7.1.14 485 Purge Controller (2500 EU1 Only) . . . . . . . . . . . . . . . . . . . . . . 7.5
7.1.15 Alternative Purge Controller (2500 EU1 Only) . . . . . . . . . . . . . . . . 7.5

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SECTION 8 CE MARKING AND OTHER SAFETY APPROVALS . . . . . . . . . . . . 8.1
8.1 EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.2 Low Voltage Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.3 Pressure Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
8.4 ATEX Directive and other non-European Hazardous Area approvals . . . . . . . 8.2

v
 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 3.1a 2500 AC Power and Valve Connections (Purged Filter) . . . . . . . . . . . 3.3
Figure 3.1b 2500 AC Power and Valve Connections (Non-Purged Filter) . . . . . . . 3.4
Figure 3.2 2500 Series Terminal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5
Figure 3.3 Signal Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
Figure 3.4 SIB and Optional Output PCB's . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
Figure 3.5 Autocalibration Valve Configuration . . . . . . . . . . . . . . . . . . . . . . . . . .3.16
Figure 3.6 Typical Pressure Transducer Assembly . . . . . . . . . . . . . . . . . . . . . . . 3.24
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
Table 3.2 Relay Output Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
Table 3.3 External Control Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
Table 3.4 Externally Powered Solenoid Valve Connections . . . . . . . . . . . . . . 3.14
Table 3.5 Internally Powered Solenoid Valve Connections . . . . . . . . . . . . . .3.15
Table 3.6 Serial Data Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17
Table 3.7 Fault Number Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
Table 3.8 ASCII Characters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22
Table 3.9 RS232 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22
Table 3.10 Pressure Transducer Connections . . . . . . . . . . . . . . . . . . . . . . . . . 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
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2

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SECTION 1 INTRODUCTION

1.1 Introduction

This manual contains information regarding installation and hardware configuration of

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

Use the Quickstart manual for:

Configuration How to set up the clock, passwords, alarm levels, analogue
outputs, relays and other parameters.
Calibration How to use the manual and automatic calibration/checking
facilities.
Review How to review configuration and set-up information.

1.1
1.2 General Description

The Servomex 2500 Series is a single beam, multi wavelength process analyser
suitable for monitoring up to three components in a gas sample stream (2550). It is
supplied configured to the customer's precise analytical requirements for a stated
analysis in a specific background stream.
The general layout of the 2500 Series is shown in Figure 1.1. It has been designed for
modern industrial environments with the emphasis on rugged construction, reliable
performance, simple operation and easy servicing. The analyser is controlled using an
on-board microprocessor, which gives flexibility to the user, enabling him/her to
configure the operation of the 2500 to suit the particular process environment. The
2500 is operated via a very simple control panel, which is mounted on the analyser
itself.
The gas or liquid sample to be analysed must be passed continuously through the
analyser's sample cell. The 2500 is designed for continuous 24 hour/day operation and
should not normally be switched off. Versions of the 2500 analyser are suitable for use
in safe and hazardous areas. They are also designed to I.P. 65. (without electrical cell
heater, I.P. 50 with cell heater).

Figure 1.1 2500 Overall View

Note that the EU1, EU2 and FM2 versions can also be used when flammable samples
are to be monitored in otherwise safe areas (see Safety Certificate Manual).

1.2
 WARNING

The EU1 versions are intended for use with a suitably certified Purge Control
System (PCS). Do not install a EU1 version in a hazardous area without a
purge controller.

The analyser's software is menu driven and has been designed to be as intuitive as
possible, enabling the user to fully operate and control the 2500 with the minimum of
familiarisation.

NOTE
Full technical specifications for 2500 Series Analysers are presented in section 7 of this
manual.

1.3 Basic Construction

The basic construction of the 2500 is shown in Figure 1.2. It comprises 2 cast end
assemblies (with hinged opening/removable covers), connected by a rigid mounting
beam, or chassis. The sample cell is mounted between the 2 end assemblies and is
removable for cleaning. This configuration results in a single optical axis, i.e. straight
through beam design, with no alignment adjustments necessary. The source end (right
side) contains the soft U.V. or infrared source, which generates a broad beam of
energy across the appropriate spectrum. This is mounted on the chopper box
assembly, which contains the interference filters, mounted on a rotating chopper wheel.
These filters select the appropriate wavelengths for the analysis for which the 2500 is
configured. In most applications, there is one measurement wavelength and one
reference wavelength for each measured component.
The infrared or visible beam, alternating in wavelength, is then focused through the
sample cell, where energy at the measurement wavelength is selectively absorbed by
the components being analysed. The remaining energy falls on the detector in the
detector end.
The sample cell is a simple thick metal construction (316 stainless steel as standard)
fitted with optical windows (each 6 mm thick) to allow passage of the beam. It is
supported between the 2 ends of the 2500 by short cylindrical bosses, which may be
scrubbed or purged, depending on application. The whole cell assembly is easily
removed by loosening the two bosses and lifting it away, as described in Section 5.

1.3
 Figure 1.2 2500 Construction
The detector end (left side) contains the detector assembly and also the main
electronic circuit boards. The display and control panel is also mounted in the hinged
lid of this end.

1.4 Options and Accessories

The 2500 supplied may have been fitted with customer specified options and/or
accessories. The full list of available items with brief descriptions is given here.

WARNING

The surface temperature of heated cells can reach or exceed 100°C

The following symbol is used on the heated cell:

CAUTION, HOT SURFACE

1.4.1 Heated Sample Cell – Electrical

Where fitted, this is powered and controlled by the 2500 itself and is suitable for gas
samples. It may be used in both general purpose and some hazardous areas. The
normal temperature setting for common gas applications is 60°C, although it may be
supplied set to any temperature from 30 – 180°C for HTV variants or from 30 – 130°C
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 100°C. This allows cell heating in hazardous areas up to Zone 1/Div. I
classification, and is normally used with the EU1 version only.

1.4.3 Optional Output Cards

As standard, all 2500 Analysers have 2 analogue mA (current) outputs and 3 relay
contact pairs. The analogue outputs are user configured as described in the Quickstart
manual. The relay contacts are user-assigned to any combination of concentration
alarms, Fault alarm, or calibration in progress, as similarly described in the Quickstart
manual. These standard outputs originate from the Sensor Interface Board (SIB PCB)
of the 2500.
An additional output PCB is available as option:
The 02000/916 PCB provides an extra 2 x (mA) plus 2 x (relay) outputs
This additional output PCB can be fitted into the normally vacant slot 2 in the 2500.
These extra outputs are configured along with the standard outputs in the usual way
(See Quickstart manual).

NOTE
Any or all of these analogue outputs may be configured as a voltage output by hardware
link selection, as an alternative to current output.

1.4.4 Compensation Options

The output of any infrared analyser is affected by changes in sample pressure and
sample temperature, unless compensation is applied. Alternatively, these parameters
can be kept constant by a suitable sample conditioning system. Ambient (barometric)
pressure will also affect sample pressure in the analyser if a gas sample is being simply
vented to atmosphere. The following compensation options may be fitted to a 2500.

• Sample Pressure Compensation

A solid state pressure transducer is fitted and plumbed into one sample cell connection.
A continuous pressure measurement over the range of the standard transducer, 0 -345
kPa (0 – 50 psia), is made by the 2500. During calibration in the factory, an empirical
sample pressure/span concentration relationship is determined and stored in memory
to calibrate the compensation. Suitable for gas sample measurements only.
This option is detailed in Section 3.5

1.5
.

WARNING

Standard transducers are not suitable for oxygen service.

• Sample Temperature Compensation

A type 'K' thermocouple in stainless steel sheath is supplied, and a continuous
temperature measurement is made by the 2500 over the range -50 to 200°C (-58 to
392°F). During calibration in the factory, an empirical sample temperature/span
concentration relationship is determined and stored in memory to calibrate the
compensation. Suitable for gas or liquid samples, and for safe and hazardous area
installations. Not available with heated cell.

1.4.5 Application Options

A range of standard and special application options is available with the 2500 and it will
have been supplied configured with one particular option to make the customer-
specified measurements. Full details of the application configuration (i.e. optical
materials, operating wavelengths, cell path length, wetted materials etc.) will be found
on the Product Specification document in the front of this manual.

1.6
SECTION 2 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: Clean display and keypad using a clean cloth moistened
with water.

2.2.3 Unpacking and Inspection

WARNING

2500 analysers weigh at least 25 kg (55 lb) and care must be taken when
handling. Use 2 people if necessary and only lift using the yellow handles
provided, not the sample cell.

Lift in the approved manner and remove the 2500 analyser from its packing and inspect
for any damage incurred during transit. If any damage has occurred inform Servomex
or their agents immediately. Retain packing, in case it is required to return the analyser
to the supplier.

2.1
After the initial visual inspection, carry out the following checks. Beware gas strut
action of the hinged covers.
• Check that the serial number of the 2500 (located inside source end and also
marked on the external rating label) corresponds to the serial number given in
the Manufacturing Data Sheet found at the front of this manual.
• Check that the specification sheet details are in order and agree with the
purchase requirements. Pay particular attention to the Manufacturing Data
Sheet supplied, and any Special Instrument Process Sheets attached.
• Check that the accessories are present and undamaged. Standard 2500
accessories provided are: Fuse kit, Allen key, Plastic plugs (refer to section
2.4.2) and Ferrites (refer to section 3.2).

2.3 Electrical Connections

CAUTION

Specific voltage rating information is given on the label located on the outside of the
2500 Analyser and copied within the enclosure. Ensure that the analyser is correctly
configured for the supply voltage.
The 2500 Analyser has no integral switch for disconnecting the electrical supply.
The installer must include a means of isolating the electrical power by means of a
switch or circuit breaker located close to the 2500 Analyser. It must be marked as
the disconnecting device for the analyser and be easily accessible
The electrical supply to the 2500 Analyser MUST be protected by a suitable fuse or
over current protection device rated at no greater than 6 Amps.

Where the main electrical supply is not referenced to ground, an isolating transformer
must be fitted and its secondary winding suitably earthed. The following mains power
cable requirements must be met:
• Three core cable with Line/Live (L), Neutral (N), Earth/Ground (E) conductors.
• The cable voltage rating should conform to the supply voltage. The type of
cable used should conform to current local regulations, and be suitable for the
installation environment. For use in areas exposed to weather or mechanical
stress, armoured or sheathed cable is recommended.
• All electrical cables enter the body of the 2500 Analyser via user-supplied cable
glands. These cable glands must be air tight and/or suitably approved if the
units are to be purged and/or mounted in hazardous areas.
• The electrical supply connection terminals are suitable the following cable:
Flexible conductors – 0.5 to 1.5mm2 (20 to 16 AWG)
Solid conductors – 0.5 to 2.5mm2 (20 to 14 AWG)

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

2.2
2.4 Installation

WARNINGS

• The 2500 Series analysers are not suitable for use in hazardous areas
unless the correct certification labels have been affixed by Servomex
and a suitable purge control system is installed (EU1 versions).
• The installer must be satisfied that the 2500 analyser installation
conforms to the relevant safety requirements, national electrical code
and any other local regulations, and that the installation is safe for any
extremes of conditions which may be experienced in the operating
environment of the analyser.
• If the equipment is used in a manner not specified by the manufacturer
the protection provided by the equipment might be impaired.
• Many process samples, gas streams and test samples are toxic,
asphyxiant, corrosive, flammable or a combination of some or all of
these. It is the responsibility of the installer to ensure that adequate
precautions are taken during installation of the 2500 analyser,
connection of samples, and during any other checks or tests. All
sample line connections must be checked for no leaks.

2.4.1 Positioning
Sensible positioning and an accurate and secure installation will minimise
maintenance, instrument breakdowns and will provide reliable service.
The location should be reasonably vibration free, subject to minimal fluctuations in
ambient temperature and provide reasonable access to the instrument and the
availability of any required services.
If the 2500 is to be mounted outside it must be suitably protected from all extremes of
climatic conditions by a suitable insulated enclosure, paying particular attention to the
ambient temperature range and the rate of temperature change specifications.
EU2 versions must be protected against the entry of solid particles or liquids by a
suitable cover or enclosure where necessary.
EU1 versions must be used with either a Servomex 485 Purge Control Unit with the
associated Servomex 486 Relay Unit, or another suitable Purge Control System, which
must meet the necessary pressurisation requirements, and is supplied with the
necessary pressurisation and control components.
FM2 versions fitted with electically heated sample cells must be installed in locations
which provide adequate protection against the entry of solid foreign bodies and liquids
capable of impairing safety.

2.3
 WARNING

EU1 Zone 1 versions must be used with either the Servomex 485 Purge
Control Unit with the associated Servomex 486 Relay Unit, or a third-party
purge controller, which meets the necessary pressurisation and certification
requirements as detailed in the Safety Certificate Manual.

If the 2500 has been supplied with a Servomex 485 Purge Unit with the associated
Servomex 486 Relay Unit, installation information is provided in a separate manual
part no. 00485001C, supplied with the analyser system.
If a gas sample conditioning system is to be connected it must be designed to provide
a filtered, clean, non-condensing sample for the analyser with no risk of a possible
carry- over of condensate into the sample cell.
If a liquid sample conditioning system is to be connected it must be designed to provide
a filtered, single-phase sample for the analyser.

2.4.2 Mounting Details

The following paragraphs provide mounting information for the 2500 Analyser. Use the
yellow lifting handles to manoeuvre the 2500 into position, using two people where
necessary.
The analyser may be mounted vertically or horizontally, ideally at chest height for best
visibility and ease of access, but with some restrictions (refer to Fig 2.1).

CAUTION

• For Liquids the analyser should be mounted horizontally with the cell
inlet port at the bottom.
• For Gases the analyser should be mounted horizontally with the cell
inlet port on top, especially if there is risk of particulates or
condensates in the sample.
• The 2500 may be mounted vertically for gas samples, provided the cell
outlet is at the bottom. This is only suitable if there is no risk of
particulates or condensates in the gas sample.

2.4
When mounting the analyser ensure that the panel or brackets employed are adequate
to take the weight and there is a minimum clearance above the casing of 500mm (20")
to provide space to open the end covers.
Fig 2.2 provides mounting details and a table of mounting hole spacings for the various
cell lengths. Be sure to identify the correct hole spacing.
When the 2500 is to be vertically mounted the display may be rotated 90° to bring it into
a legible position. This is done by removing the internal metal cover and ribbon cable
clamp, and removing the retaining bracket. The display unit can then be withdrawn a
little and rotated. Reassemble the disturbed components in reverse order, carefully
folding the ribbon cable to prevent any stress on it.

Figure 2.1 2500 Positioning Restrictions

2.5
 Figure 2.2 2500 Mounting Details

Once mounted, the two yellow lifting handles and their spacers MUST be removed by
unscrewing the securing screws. Press the black pop-in plugs supplied into the vacant
screw holes and retain the handles for possible future use.

2.6
2.5 Instructions Specific to Hazardous Area Installations

(Reference European ATEX Directive 94/9/EC, Annex ll, 1.0.6.)

The following instructions apply to equipment covered by certificate numbers: Sira
02ATEX1395X and Sira 03ATEX2236X

2.5.1 The equipment may be located where flammable gases and vapours of
groups llA, llB and llC may be present. The equipment is only certified for use
in ambient temperatures in the range -20°C to +55°C for type 'p' approval and
-5°C to +55 °C for type 'n' approval, and should not be used outside these
ranges.
(Note performance specification is 0°C to +55°C)

2.5.2 The equipment has not been assessed as a safety-related device (as
referred to by Directive 94/9/EC, Annex ll, clause 1.5).

2.5.3 Installation of this equipment shall be carried out by suitably trained

personnel in accordance with the applicable code of practice (EN 60079-14
within Europe).

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

accordance with the applicable code of practice (IEC 60079-19).

2.5.5 If the equipment is likely to come into contact with aggressive substances,
then it is the responsibility of the user to take suitable precautions that prevent
it from being adversely affected, thus ensuring that the type of protection is
not compromised.

Aggressive substances e.g. acid liquids or gases that may attack metals,
or solvents that may affect polymeric materials.
Suitable Precautions e.g. regular checks as part of the routine
inspections or establishing from the material's
data sheet that it is resistant to specific
chemicals.

2.7
2.6 ATEX Label Information

2.6.1 EU1 T5 (Unheated Cell)

2.6.2 EU1 T4 (Heated Cell)

2.8
2.6.3 EU2 T3

2.6.4 EU2 T4

2.9
2.10
SECTION 3 INSTALLATION – ELECTRICAL

WARNINGS

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

installer must ensure that the power supply has been isolated before
commencing installation.
• The installer must be satisfied that the 2500 analyser installation
conforms to the relevant safety requirements, national electrical code
and any other local regulations, and that the installation is safe for any
extremes of conditions which may be experienced in the operating
environment of the analyser.

WARNING

The following symbols are used on the warning label fitted on the inside of the
Source End Enclosure Cover.

CAUTION, ELECTRIC SHOCK HAZARD

CAUTION, CONSULT MANUAL

3.1 Electrical Power Connections

For convenience the gas struts may be removed during installation by carefully levering
them off. Ensure that the cable used is suited to the installation environment, and is the
correct rating. Ensure that the fuse is suited to current rating of the analyser and that
all glands and cable connections are secured firmly.
The mains power connection to this instrument is made via an electrical filter unit
attached to the outside of the case. The power cable into this unit does not need to be
screened.

3.1
 WARNING (EU1 VERSION)

AC Power for Zone 1 (EU1) versions may only be connected via a suitably
certified Purge Control System. Refer to the PCS manual for details. The
mains power connection to the instrument is made via the purged electrical
filter unit attached to the outside of the case.
Refer to Figure 3.1 a) or b) for illustration.
To connect the 2500 analyser to the mains supply:
1. Isolate the mains AC supply at source.
2. Remove filter unit cover.
3. Fit suitable cable gland to the mains filter unit.
4. Insert cable through gland and secure.
5. Wire to terminals.
6. The mains AC supply is connected internally to TB30. The voltage selection is
made by wire link on TB31 as illustrated in Figure 3.1 a) or b).
7. Connect the 2 external earthing studs to earth/ground. The RF earth provided
must be locally earthed using as suitable solid conductor connected to a local
physical earth to ensure optimum RFI protection. The external system earth must
be connected to the mounting panel / cubicle / frame / local Intrinsically Safe
earth, as appropriate.

DO NOT APPLY POWER YET.

NOTE

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

(e.g. within Europe installation must be in accordance with IEC 60079-14)

3.2
Figure 3.1a 2500 AC Power and Valve Connections (Purged Filter)

3.3
 Figure 3.1b 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

All signal cables must have a braided overall screen or armour. The screen must be
terminated at the point of entry to the case. This will be by using a gland, which
makes a connection between the cable screen and the case. Beware of ground/
earth loops if the screens are also connected at the user end.
Where two cables are passed through a single entry, a metal gland specifically
intended for two separate cables shall be used.
To minimise the effects of interference from the RF fields, a Steward type 28B0562-
200 or equivalent ferrite sleeve (Servomex Part No. 2824-0017) shall be placed
over each mA output cable pair. Refer to Figure 3.3.

Figure 3.3 Signal Cable Connections

3.6
3.2.1 Analogue Outputs

Figure 3.4 SIB and Optional Output PCB's

Each analogue output is supplied set for current output and may be configured by the
user to be 0-20mA or 4-20mA, and be assigned a particular range of operation, in
software. This is described in the Quickstart manual. In addition, a "Range 2" setting
for each analogue output can also be configured in software. Maximum impedance is
1k ohm for current output. If desired, each analogue output may be changed to voltage
output of either 0-10V or 2-10V, minimum impedance 1M ohms. This is done by
soldering links into position "LINK 10" and "LINK 11" on the relevant SIB (Sensor
Interface Board) PCB or Option PCB for the first and second analogue output
respectively. See Section 3.2.2. In every case, fit a suitable gland, insert, secure and
strip a suitable cable pair before connecting the cores to the appropriate terminals.

3.7
 WARNING (EU1 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.

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 Figure 3.2.

3.8
3.2.2 Analogue Output Link Selections on Sensor Interface Board (SIB) PCB
After connecting up the required analogue outputs, the user should make the following
hardware link selections on the SIB PCB and (where fitted) Option PCB(s). Refer to
Figure 3.3.4 for general schematic of both these types of PCB. Carefully remove the
PCB for link selection and be sure to replace it in the correct slot and in the correct
orientation.

• Current/Voltage
Each output may be individually selected as current (0/4-20mA) or voltage
(0/2-10V). Factory setting is CURRENT.
Analogue o/p No.1 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

3.9
3.2.3 Relay Outputs

NOTE

Each relay output is supplied set for NC (i.e. Normally Closed under "Safe"
condition) operation, and may be assigned to a particular alarm or signalling
function in software. This is described in the Quickstart manual.

User selection of NC or NO operation is described in Section 3.2.4. As with the

analogue outputs, each relay has its own software identity relating to the slot in which
the PCB, on which it is physically located, resides. The following tables show the
physical locations for connections to the relay outputs. All relay outputs are rated
240VAC/1.0A or 30VDC/1.0A. In each case, fit suitable glands and cable and connect
to the relevant terminals. Select the correct procedure according to the architecture.

Table 3.2 – Relay Output Connections

Output Software ID Terminal Connections
Relay 1 1.3 TB 23-1 and TB 23-2
Relay 2 1.4 TB 23-3 and TB 23-4
Relay 3 1.5 TB 23-5 and TB 23-6
Relay 4* 2.3 TB 22-5 and TB 22-6
Relay 5* 2.4 TB 22-7 and TB 23-7

*option PCB
Terminal locations are as illustrated in Figure 3.2.

3.2.4 Relay Output Link Selection

After connecting up the required relay output, the NC/NO selections may be altered on
the SIB PCB and (where fitted) output Option PCB(s). Refer to Figure 3.4 for general
schematic and carefully remove and replace the PCB as before, if a change is to be
made.
Normally Closed/Normally Open (NC/NO)
The factory setting of all relay output wire links is soldered in the NC position. This
means that the contacts will open to signal an alarm. The contacts will also be open if
there is no power applied to the 2500, i.e. they are fail-safe. If, however, it is required
to change to NO operation (i.e. close to signal an alarm) this can be done by cutting
and reordering the wire links as listed below.

3.10
 WARNING

Setting the relays to Normally Open (N.O.) operation will mean that there is no
fail-safe action since any loss of cable continuity will prevent an alarm being
signalled.

NOTE

Regardless of N.O./ N.C. setting, the relays will always be in "alarm" state wherever
there is no power applied to the 2500, or when they are unassigned.

Relay o/p No. 1 N.C. Link 3 – A N.O. Link 3 – B

Relay o/p No. 2 N.C. Link 4 – A N.O. Link 4 – B
Relay o/p No. 3 N.C. Link 5 – A N.O. Link 5 – B

3.3 Control Connections

NOTE

All control cables must have a braided overall screen or armour. The screen must be
terminated at the point of entry to the case. This will be by using a gland, which
makes a connection between the cable screen and the case. Beware of ground/earth
loops if the screens are also connected at the user end.
Where two cables are passed through a single entry, a metal gland specifically
intended for two separate cables shall be used.

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
02500904A TB25 – 3
Transmitter PCB Autocalibration Initialise TB26 – 2
02500904A TB25 – 3
Transmitter PCB Password Keyswitch TB26 – 3
02500904A TB25 – 3
Power Control PCB Flow Failure TB36 – 1
02500911A TB36 – 2

3.11
3.3.1 Range Change Input
Every analogue output can be independently scaled in software to represent some or
all of the calibrated range of the instrument, as described in the Quickstart manual.
However, under some process conditions (e.g. plant start-up) it may be desirable to
have different output ranges on demand. When the Range Change Input is used all
analogue outputs will change to their user-designated "Range 2" settings. Note that
"Range 2" settings can be identical to "Range 1" settings if desired.

NOTE

"Range 2" is selected as long as contacts remain closed.

Range 2 settings selected by Contact closure between:

TB26 – 1 and TB25 – 3

3.3.2 Autocalibration Initiation Input

Autocalibration/Autocheck may be triggered by the user from the control panel or by
using the 2500's own real time clock system. Alternatively, it may be triggered at will
using a manual remote switch or by a host device, closing a contact.
Autocalibration initialised by contact closure between:
TB26 – 2 and TB25 – 3

NOTE

• Contacts must be closed for at least 2 seconds but no more than 59 seconds.
• Remote initiation starts the "one cycle" routine using all the user-set
parameters. It will not repeat unless contact closure is made again.
• User is advised to set the Autocalibration period in software to zero
(i.e. internal timer disabled) when using remote Autocalibration initiation,
to prevent duplication of Autocalibrations.

3.3.3 Password Keyswitch Input

As an alternative to the use of passwords via the control panel, a simple Keyswitch can
be connected which enables access to both Operator and Supervisor levels without
password demands. The user must first set SW1/8 to ON on the Microprocessor PCB,
to enable this feature. See the Quickstart Manual for more details.
Keyswitch setting selected by Contact closure between: TB26 – 3 and TB25 – 3

3.12
.

WARNING

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

available to all normally protected areas of the software.

3.3.4 Sample Flow Sensor Input

If the sampling system supplying the process sample to the 2500 is fitted with a loss of
flow sensor, this can be connected to the 2500 to enable the "loss of sample flow"
diagnostic to operate, which in turn triggers the analyser's Fault alarm. See Figure 3.1.

2500 Power Control PCB 02500911A

Loss of flow diagnostic triggered by contact closure between: TB36 – 1 and TB36 – 2.

NOTE

In common with all fault diagnostics this alarm will only be cleared by restoration of
flow/opening of contacts.

WARNING

Where the 2500 analyser is in a hazardous area, suitable protection concepts

must be used to connect the loss of flow sensor to the 2500 analyser.

3.3.5 Solenoid Valve Drives

Autocalibration routines are provided as standard on the 2500, and if they are to be
used, suitable 3-way solenoid valves can be plumbed into the sampling system as
shown in Fig 3.5. Two or three valves may be used and all should be located
conveniently close to the 2500. Each valve is switched via the 2500 Power Control PCB
relays as illustrated. The valves are selected for operation by the 2500 as shown in
Table 3.4 and Table 3.5. Connect the valves to the appropriate terminals using suitable
screened cables and glands, and attach screens to the nearest earth stud with the
minimum length of screen. See Figure 3.1.
The Autocalibration relay contacts are rated at 240VAC/1.0A, 30VDC/1.0A. The
contacts are fitted with an R-C snubber (100R + 47nF) to provide transient protection
when used with AC solenoids. 220/240Vac solenoid valves with a power rating less
than about 6VA are not recommended because the 'leakage' current through the
snubber may prevent low power solenoids from de-energising correctly.
Solenoid valves may use an external power source, or the internal 24VDC/12VA power
source may be used. When using the internal power source, ensure that the 12VA
rating is not exceeded. DC solenoid valves must have built-in suppression diodes fitted
across the coil to protect the relay contacts.

3.13
 WARNING

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

NOTE

Valve (SV3) reverts to OFF in Shutdown (Serious Fault) condition. The use of the
optional 3rd "Sample/Inert valve will prevent sample entering the 2500 sample cell
while the cell or chopper box under temperature diagnostic is activated, i.e. heated
cell is not fully warmed up. This can be used whether or not Autocalibration is used
and will be appropriate in some applications: e.g.
• if there is a possibility of condensation forming in the sample cell during warm
up, then nitrogen or another purge gas must be used to flush the cell during
it's warming up period.
• if a hazardous sample is being monitored, the cell should be purged in the
event of a serious fault.

3.3.6 Externally Powered Solenoid Valve Connections

Connect via solenoid valve relays as detailed. Ensure that the relay rating is not
exceeded.

Table 3.4 – Externally Powered Solenoid Valve Connections

Valve State (ON=Current Flow Through
Solenoid)
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 OFF (Zero) ON(Sample) ON(Sample)
Zero Sample Required OFF (Zero) ON(Cal.) ON(Sample)
Span Sample Required ON(Span) ON(Cal.) ON(Sample)

3.14
3.3.7 Internally Powered Solenoid Valve Connections
Connect to solenoid valve relays SV1, SV2 and SV3 as detailed below. Take care to
ensure that internal 12VA (total) rating of the 24VDC supply is not exceeded.

Table 3.5 – Internally Powered Solenoid Valve Connections

Valve State (ON=Current Flow Through
Solenoid)
Span/Zero 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 OFF (Zero) ON(Sample) ON(Sample)
Zero Sample Required OFF (Zero) ON(Cal.) ON(Sample)
Span Sample Required ON(Span) ON(Cal.) ON(Sample)

NOTE

To ensure internally powered solenoid valve function, fit links between:

TB34 – 2 and TB36 – 4

TB34 – 4 and TB36 – 3
TB34 – 6 and TB36 – 3

CAUTION

TB36 terminals 5 and 6 (+24V) are always live and should not be grounded.

3.15
 Figure 3.5 Autocalibration Valve Configuration

3.4 Digital Connections

NOTE
All digital cables must have a braided overall screen or armour. The screen must be
terminated at the point of entry to the case. This will be by using a gland, which
makes a connection between the cable screen and the case. Beware of ground/earth
loops if the screens are also connected at the user end.
Where two cables are passed through a single entry, a metal gland specifically
intended for two separate cables shall be used.

Digital connections in RS/EIA-232 format are provided for attaching a local portable
printer to receive set-up information directly down loaded from the 2500, or to report
measurement and analyser status information to a DCS or datalogger.

3.4.1 RS-232 Connection

See the Quickstart manual for configuration of the RS-232 port and operation of this
function. See Figure 3.2 and Table 3.9 for connections. The format of the serial data
stream is as follows:

3.16
 Table 3.6 – Serial Data Format
Item Size Description
<CR> 1 byte Carriage return character (ASCII code 13).
date; 8 bytes dd/mm/yy or mm/dd/yy depending on user
settings.
time; 8 bytes hh:mm:ss
number of 1 byte 1 byte Number of components fitted
components (range 1-3)
<CR><LF> 2 bytes Carriage return and Line Feed characters
(ASCII codes 13 and 10 respectively).
component 1 formula; Max 6 bytes Chemical formula defined for component 1.
component 1 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 or Indicates Autocalibration phase.
Autocalibration 15 bytes 0 = Not in Autocalibration
status; 1 = In span preflush
2 = In zero cal
3 = zero corrected. This is then followed by
two additional values, which are separated
by commas, each 6 bytes that represent the
zero before calibration and the zero after
calibration respectively.
4 = In span cal
5 = span corrected. This is then followed by
two additional values, which are separated
by commas, each 6 bytes that 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)

3.17
 Table 3.6 – Serial Data Format
component 2 Max5 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)
component 2 1 byte or Indicates Autocalibration phase.
Autocalibration 15 bytes 0 = Not in Autocalibration l
status; 1 = In span preflush
2 = In zero cal
3 = zero corrected. This is then followed by
two additional values, which are separated
by commas, each 6 bytes that represent the
zero before calibration and the zero after
calibration respectively.
4 = In span cal
5 = span corrected. This is then followed by
two additional values, which are separated
by commas, each 6 bytes that 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)

3.18
 Table 3.6 – Serial Data Format
component 3 1 byte or Indicates Autocalibration phase.
Autocalibration 15 bytes 0 = Not in Autocalibration
status; 1 = In span preflush
2 = In zero cal
3 = zero corrected. This is then followed by
two additional values, which are separated
by commas, each 6 bytes that represent the
zero before calibration and the zero after
calibration respectively.
4 = In span cal
5 = span corrected. This is then followed by
two additional values, which are separated
by commas, each 6 bytes that 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
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 values
Intensity 3;Intensity 4; bytes representing up to six input positions used
Intensity 5;Intensity 6; for measure and reference signals.
<CR><LF> 2 bytes Carriage return and Line Feed characters
(ASCII codes 13 and 10 respectively).

3.19
 Table 3.6 – Serial Data Format
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>

3.20
 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
38 BAD SPAN SPAN IGNORED

3.21
Some characters defined by the 2500 are non-standard characters, i.e. not part of the
ASCII character set. These either occupy the ASCII codes above 127 or redefine an
ASCII code as another character. When these characters are used, for example in the
component formula, they will be substituted with a valid ASCII character prior to output
on the RS232. The non-standard characters and their substitute values are as follows:

Table 3.8 – ASCII Characters

ASCII Code Character Substitute Character
126 ? <space>
127 ? <space>
128 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 ° <space>
143 £ <space>

Table 3.9 – RS232 Connections

2500 Terminals Connector External RS232 Terminals
0V (Ref.)(0VR) TB20 – 1 Signal GND/0V
Clear to Send (CTS) TB20 – 3 Data Terminal Ready (DTR)
Transmit (Tx) TB20 – 4 Receive (Rx)

3.22
 WARNING
Do not use an uncertified dcs, datalogger or printer in a hazardous area.

3.5 Pressure Transducer Connections – (If Supplied)

The pressure transducer cabling is terminated to the source end right hand side (RHS)
of the analyser.

The pressure transducer is supplied pre-wired to the analyser. The cabling is

connected to PCB 02500911A TB35 as shown in Table 3.10
.

Table 3.10 – Pressure Transducer Connections

PCB 02500911A Interconnecting Cable Pressure Transducer
TB35 – 5 (signal +) Identified '1' Terminal 1 (+)
TB35 – 1 (signal -) Identified '2' Terminal 2 (-)

The general layout of the pressure transducer option is illustrated in Figure 3.6.

3.23
 Figure 3.6 Typical Pressure Transducer Assembly

3.24
SECTION 4 INSTALLATION GAS CONNECTIONS

4.1 Purge Connections (EU1)

The next phase of the installation is to connect up any safety purge system required for
safe operation in a hazardous area.

4.1.1 General Purge Connections

WARNING (EU1 VERSION)

Where appropriate, the user must refer to the detailed instructions provided
in the manual supplied with the Servomex 485/486 purge units or other Purge
Control System, and use them in conjunction with the following instructions.

Figure 4.1 Purge Connection Schematic

4.1
The general schematic for a hazardous area purge system is shown in Figure 4.1.

WARNINGS (FIGURE 4.1)

1. If this component is mounted in a hazardous area it should be protected

by one of the norms listed in EN 50014.
2. Cable glands used in EEx 'd' apparatus shall be approved Ex 'd'
components, which maintain the degree of protection necessary.
3. All cable glands for use in electrical cable entries shall be of a type, which
seals and clamps the cable.

NOTES (FIGURE 4.1)

1. The PCS shall include an automatic device, which operates when the
overpressure falls below the minimum prescribed value. This device operates
in turn a pressure switch, which can be used for alarm and/or isolation
purposes.
2. Where the PCS is used to protect the 2500 bench unit only, the protective gas
supply shall be connected from the PCS to the 2500. The minimum level of
overpressure shall be monitored at or close to the outlet aperture of the 2500.
The maximum level of overpressure shall be monitored at or close to the inlet
and the PCS shall incorporate a limiting device to ensure that the maximum
overpressure specified in normal service (80 mBar) is not exceeded.
3. A protective device shall be fitted to the purge exhaust aperture to prevent
sparks or incandescent particles from being ejected from the pressurised
enclosure.
4. The PCS shall require to be put through a purge cycle after a pressure loss
before power can be restored to the instrument.
5. The PCS shall contain a pressure sensing element which is factory set, to a
level not less than the specified minimum (50 Pa, 0.5 Mb) and shall measure
pressure at the point in the system where the lowest pressure occurs.
6. The PCS shall supply a flow rate of protective gas, not less than 10 SLPM, and
shall incorporate an automatic device to monitor flow during the purge time
specified below.
7. The PCS shall maintain the minimum specified overpressure during the purge
phase and afterwards.
8. The PCS shall incorporate a purge timer, which shall be set to not less than
16 minutes. The purge timer shall be set to zero if either the minimum
overpressure or minimum purge flow is not maintained.
9. The PCS shall incorporate a device to ensure that power is not connected to
the apparatus being protected until the specified purge time has elapsed.

4.2
4.2 End Boss Purge Connection

Depending on application, fittings for 1/8" o.d. tube may be provided to purge the end
bosses on either side of the sample cell and these should now be connected. Refer to
the following application notes and Figure 4.2 where necessary.

4.2.1 Introduction
The 2500 measuring cell is mounted on two short tubes or "end bosses" which
preserve the integrity of the optical system, while providing thermal isolation. The
measuring cell and the analyser enclosure are both independently sealed using
windows or lenses and elastomeric seals. The end bosses form the interface between
the two, and the implications of a cell window leak must be considered when
flammable, corrosive or toxic gases are measured.
Under ideal circumstances, the gas in the end bosses should be totally transparent to
the wavelengths of infrared energy used for the measurement. However, simply filling
the bosses with nitrogen and sealing them is not always satisfactory, because the
elastomeric seals are permeable and atmospheric gases such as carbon dioxide or
water vapour can leak in. Specifically, a problem will arise when the gas being
measured is also carbon dioxide or water vapour, or when the measurement is cross
sensitive to either of those gases: the effect of a gradual ingress of the atmospheric
gases will be seen as drift in the measurement. A further problem arises with low-level
measurements of carbon monoxide. In this case it is out-gassing of carbon monoxide
from the seals themselves which can cause drift.

4.2.2 End Boss Scrubbers

Problems, relating to cross interference within the end bosses, can usually be resolved
by fitting chemical "scrubbers" to the end bosses. These are small metal housings
packed with a chemically active material, which absorbs or reacts with the problem gas.
A number of materials are available which absorb water vapour (molecular sieve),
carbon dioxide (soda lime) and carbon monoxide (Hopcalite).
When a 2500 is specified, a suitable scrubber material is stipulated for the end bosses,
where necessary, and the analyser will be delivered with these scrubbers fitted.

NOTE
If the analyser is dismantled for any reason, the scrubbers must not be left exposed
to normal atmosphere for more than a few minutes or they will be exhausted.
Similarly, after long-term use they may need to be replaced, and this must always
be with the correct type.

4.3
4.2.3 End Boss Vents
When a flammable, severely corrosive or toxic gas or liquid is present in the
sample cell, either as the sample or a background gas, additional issues arise.
The construction of the cell window seal is such that any leak of the seal or failure of
the window will result in the sample gas entering the end boss, but not being released
to the surrounding atmosphere or directly into the analyser enclosure. This is a
deliberate safety feature of the design. However it is necessary that steps are taken to
deal with the leak so that no permanent hazard arises, and permanent sealing of the
end bosses and the use of scrubbers is not generally acceptable. Instead, the end
bosses will be supplied with adaptors for connecting vent or purge lines.
If the measurement is not affected by atmospheric gases, then a single vent connection
of at least 4mm I.D. should be made to each end boss, which will vent to atmosphere
in a safe location where release of the sample will not cause a hazard. If the sample
pressure exceeds 50kPa (7 psig), the vent should be 8mm I.D., and the sample cell
outlet connection should be fitted with a non return valve, and the sample cell inlet
connection should be fitted with a restrictor which will limit the total flow to less than
10 litres/min in the event of total window failure.

4.2.4 End Boss Purge

If the measurement is affected by atmospheric gases, then in addition to the vent
described above, the second connection to each end boss should be connected to a
supply of dry (1) nitrogen (2) regulated to a flow of 100ml/min using a suitable flow
meter. Ensure that the end boss purge is always vented to atmospheric pressure and
the pressure within the end boss dead volume space does not exceed 2.5psig.

Suitable precautions should be made to ensure that, in the unlikely event of a

catastrophic failure of the cell window /sealing, sample gas is prevented from
contaminating the purge gas supply.
(1)
Dry means a dew point of below -30 deg C.
(2)
Dry CO2-free air may also be used in most applications except low-level CO2.

Hazardous Area Certification – flammable samples, additional note

The analysers are certified for use in either Zone 2 / Div II or Zone 1. In all cases this
certification does not permit the analyser (or any part of its enclosure) to be exposed to
a permanently flammable atmosphere. Sealing the end-bosses with scrubbers when
measuring a flammable sample would mean that should there be a cell window leak,
the part of the enclosure that the end boss seals against would become exposed to a
permanently flammable atmosphere. Venting or purging the end bosses resolves this
issue.

4.4
 NOTE
Vent lines, if required, should be connected to end boss bottom tappings. Purge gas
should be connected to top tappings when required. When not required, top tappings
should be plugged.
IF FITTED, COMMENCE END BOSS PURGE FROM THIS POINT ONWARDS.

WARNING
Where the sample is corrosive or toxic, the vent lines from the end bosses
must take away any potential leakage to a safe disposal point.

Figure 4.2 Cell End Boss Connection

4.5
4.3 Steam Heated Cell

Some 2500's are fitted with steam heated cells, and at this stage suitable low pressure
steam, typically at 14-21kPa, 2-3 psig venting to atmosphere after the cell, should be
connected ready for use, but do not pass steam into the heating coil yet. Fittings for
1/8" o.d. tube are normally provided.

4.4 Process Stream Connection

4.4.1 Basic Operation

The process stream connections to and from the 2500 sample cell inlet and outlet
should now be made. The inlet and outlet are 1/4" o.d. stubs. Connections will normally
be from a local sample conditioning system. Ensure that any pressure compensation
transducer is correctly fitted. Ensure that all connections are made securely with the
correct compression fittings, of suitable materials. Gas samples should enter the cell
from above. (Refer to Figure 2.1).
Do NOT pass process samples into the 2500 yet.

4.4.2 High Integrity Operation

This is the recommended mode of operation and where appropriate, the process
sample can be routed via the "Sample/Inert" solenoid valve, controlled by the 2500,
which will only permit sample to enter the sample cell when it is fully warmed up and
no serious faults are present. See Section 3.3.5.
Do NOT pass process samples into the 2500 yet.

WARNING
In either case for toxic/flammable samples ensure that the sample inlet line
has a suitable restrictor inserted to limit sample flow in case of catastrophic
failure of sample tubing/cell connections.

4.5 Power-Up

1. Confirm that all electrical and plumbing connections have been correctly made as
described in the preceding sections.
2. Ensure purge gas is applied to the Purge Controller (Where Fitted).
3. Apply power to the 2500 (via the Purge Control System for EU1 Versions).
4. Apply steam to any steam-heated cells fitted.
5. The 2500 will show the start-up and Identity display as follows:
– Self-checks (Fault and Alarm LEDs tested)
– System O.K.
– Analyser identity/Software revision number.
– Serial number and order number.
– Calibration (measurand, range, units).
– Commence measurement.

4.6
6. The normal measurement display will then appear and the 2500 will be
operational.

NOTES
• The measurement will not be valid at this point since process sample is not
yet flowing.
• If a heated cell is fitted, it will not yet be up to temperature and the intermittent
"warming up" message will be displayed. Depending on set point and/or
environment this may take several hours to reach temperature and the
message to cease.
• The 2500 chopper box will also take up to 2 hours to reach specified
temperature and the "warming up" message will also be displayed until this is
accomplished.

WARNING
Check for no leaks of sample at full operating pressure and temperature
before proceeding. This is especially important for toxic/flammable samples.

While the analyser is warming up, the software configuration to suit the user's particular
requirements may now be accomplished. Proceed to the Quickstart Manual for details
of configuration. Note that during the warming up period, all outputs and alarms are live
and fully operational. All diagnostics are also operational, EXCEPT cell temperature
and chopper box temperature. These last two diagnostics only become operational
once the temperature set points have been reached or after 2 hours (for chopper box)
or 10 hours (for cell) have elapsed from power-up.
At this point process sample may be turned on and allowed to flow through the
2500 sampling system.

NOTE
Where the 3rd (sample/inert) solenoid valve is in use (see Section 3.3.5) the inert
medium will automatically be supplied to the analyser until the cell reaches correct
temperature.

4.7
4.8
SECTION 5 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
02500/002C.

5.2 Diagnostics

The diagnostics listed in Table 5.1 can be interrogated via the DIAGNOSTICS function
in DISPLAY menu. See Quickstart Manual.

5.1
 Table 5.1 – Diagnostic Displays
Display Description
CHOPPER TEMP °C Chopper box temperature
COMPENSATION °C Detector temperature
CELL TEMP °C Cell temperature (if enabled)
SAMPLE TEMP °C Sample Temperature *
[Measurement 1] ABS au Absolute absorbance units (M1)
[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 HIGH Ambient temp. too high/control
problem
CHOPPER TEMP LOW CH TEMP LOW Ambient temp. too low/control
problem
CHOPPER TEMP CH TEMP FAIL Chopper sensor failed/
SENSOR FAILURE 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 failed/disconnected/
FAILURE outside range
SAMPLE TEMP SAMPLE T FAIL Sample sensor failed/disconnected/
SENSOR FAILURE outside range
PRESSURE SENSOR NO PRESSURE Sample sensor failed/disconnected/
FAILURE outside range
BAD REFERENCE REF OLT FAIL Possible Transmitter PCB fault
VOLTAGE
DETECTOR SIGNAL DET SIG LO Probable cell contamination – clean
LOW cell
COMPENSATION T COMP T FAIL Detector sensor failed/disconnected
SENSOR FAILURE
ZERO OUT OF ZERO OUT TOL Failed Autocalibration – bad zero
TOLERANCE sample – use One Cycle or Manual
Zero

5.3
 Table 5.2 – General Fault Messages
SPAN OUT OF SPAN OUT TOL Failed Autocalibration – bad span
TOLERANCE sample – use One Cycle or Manual
Span
AUTOCAL BAD BAD PREFLUSH Failed Autocalibration – bad
PREFLUSH preflush – use One Cycle
PASSWORD BAD PASSWORD 3 consecutive Password failures
VIOLATION
SYSTEM CLOCK BAD CLOCK Reset time or replace Clock chip
INOPERATIVE
DEFAULT SYSTEM BAD SYS DATA Factory calibration corrupt – use
DATA CORRUPTION Associate
SYSTEM ADC BAD ADC Possible SIB PCB fault
INOPERATIVE
CALIBRATION DATA BAD CAL DATA User calibration corrupt – repeat
CORRUPTION calibration
UTILITY DATA BAD UTI DATA Utility file corrupt – renew all entries
CORRUPTION
ALARM/RELAY DATA BAD RLY DATA Alarms/Relays file corrupt-renew all
CORRUPTION entries
ANALOGUE ASSIGN BAD ANL DATA Analogue output file corrupt-renew
DATA CORRUPTION all entries
BAD SPAN SPAN BAD SPAN Coarse span adjustment limit
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
 WARNING
• Lethal voltages: mains AC power supplies are potentially lethal. The
maintainer must ensure that all mains power supplies are disconnected
from the supply before maintenance work is started.
• Purge the measuring cell and associated pipework with an inert gas
before work is started.
• It is the users responsibility to ensure that work is carried out in an
adequately ventilated space – taking due account of risks associated
with release of flammable or toxic samples. Attention is also drawn to
the risks associated with the release of asphyxiants.

To remove the cell assembly from the 2500 proceed as follows:

Flush the cell thoroughly with Nitrogen and disconnect the process connections. Where
fitted, remove cell heater connection plug from the socket at the source end and allow
sufficient time for it to cool (this may take some hours). Remove any purge connections
from the end bosses if fitted. Slacken 3 x M6 socket screws securing the cell bosses at
either end of the sample cell.
Carefully disconnect the cell thermocouple from the cell body. Support the cell
assembly and pull the bosses inward from the ends of the 2500 sufficient to enable the
cell to be removed and taken to a workshop for maintenance. If necessary, slacken the
screws holding the source end casting onto the mounting chassis to permit easy
removal.

CAUTION
Do not pull or strain heater connection leads at any stage.

If the scrubbers (if fitted) are not to be removed, leave the bosses on the analyser and
blank the open ends of the bosses using the 2 blanking plugs (02500460), supplied
with the Special Tools Kit S2500979, to preserve the existing scrubbers. Otherwise
take the entire cell and boss assembly to a workshop.
Working on a clean bench in a suitable environment, dismantle the cell. Pull the end
bosses off the cell body. Note that these items are one-piece stainless steel. If the
bosses are fitted with absorbent scrubbers, these should be removed and replaced
(A variety of types may be fitted – see spares list for appropriate part numbers).

WARNING
Special materials are used for the windows. Some of these are toxic
(i.e. germanium, barium fluoride, zinc selenide, etc.) these substances must
be handled in accordance with the relevant local standards.

5.7
The windows are usually ground from optical grade single crystal material and as such
may be EXTREMELY EXPENSIVE. The windows may have special anti-reflective
coatings and they may easily be damaged by brittle fracture. The standard material
chosen by Servomex is Calcium Fluoride. This material is non-toxic and reasonably
robust. However, some applications may require materials such as Germanium,
Barium Fluoride, Zinc Selenide, etc. which are toxic and must be handled with extreme
care. See the Manufacturing Data Sheet at the front of this manual for details of the
windows fitted.
Windows should be kept optically clean, i.e. free from dirt, scratches, grime, grease,
fingerprints etc. When handling windows it is recommended that cotton gloves or finger
cots be worn.

WARNING – ZINC SELENIDE

If windows of zinc selenide are fitted and have been damaged by acidic attack
(e.g. acidic condensate or organic acids have entered the cell) it will be likely
that some of the zinc selenide will be reduced to selenium metal. This is
highly toxic and on no account should attacked zinc selenide material be
handled with bare fingers. Such material should be bagged and disposed of
according to local regulations.

Cleaning of the cell windows should be carried out using cotton buds or lens tissue,
detergent and/or a suitable solvent such as Isopropanol. Avoid abrasive cleaning
compounds, as these will damage the optical surface.

WARNING
The use of some solvents (iso-propyl alcohol, alcohol etc.) constitutes a
hazard. These substances must be handled in accordance with the relevant
local standards.

To remove the cell windows proceed as follows:

Ensure that the end bosses have been removed from the cell body. Starting at one end
first, unscrew and remove one locking ring with a cell key (supplied in Special Tools Kit
Servomex p/n S2500979). Remove the 5 wavy washers, spacer, and 'O' ring being
careful not to damage them or the window. To remove the window, seal the outlet and
with the cell in a vertical position, connect a hand operated aspirator (Servomex p/n
2387-0514) to the inlet. Apply a gentle pressure to lift the window up squarely and
remove it. Finally remove the PTFE gasket. Dismantle the other end of the cell in a
similar manner.
The 'O' ring spacer is threaded internally. The Special Tools Kit Servomex p/n
S2500979 contains an extractor, which screws into the spacer to aid removal.
The windows may now be carefully cleaned. The cell body may also be cleaned as
necessary.

5.8
Ensure all items are thoroughly clean and dry before reassembly, which is the reverse
procedure but with the following points noted:
• The windows should be 'floated' into place squarely using a hand aspirator or
equivalent, reversing the removal procedure.
• Use new 'O' rings and other cell sealing kit items making sure that all dust, hairs
etc, are rigorously excluded from them. Ensure the window surfaces are also
free from solvent residues or finger grease.
• The locking ring has a coated thread to prevent seizure – PTFE tape is not
required. The locking ring should be tightened down in stages, pausing for a
moment between stages until the metal faces of the cell body and locking ring
meet when fully tightened, with no gap between them. Where Teflon 'O' rings
are being used, this will require significant torque, with longer pauses. DO NOT
use the cell inlet/outlet stubs as levers.
After re-assembly, perform a leak check on the cell using a manometer before installing
it in the 2500. Do not submerge the cell or fill it with water.
Re-installation of the complete cell assembly onto the 2500 is the reverse of the
dismantling process with the added requirement that, unless fitted with a purge, the end
bosses should be briefly flushed with clean dry nitrogen after the cell has been
mounted and then new absorbent scrubbers should be quickly screwed into them. Be
sure to fully tighten the screws holding the source end casting onto the mounting
chassis if they have been slackened.
Finally, connect up the cell thermocouple to the cell body, reconnect the cell heater
plug (where fitted) and connect up any purge connections and the process
connections. Return the analyser to service as described in Section 4.5.
Reset zero if necessary on a true zero sample.

5.6 Routine Leak Checks

WARNING
It is the users responsibility to keep all sample connections to the 2500
sample cell, purge connections (if fitted) to the end bosses and steam coil
connections completely free from leaks. All plumbing connections should
therefore be regularly inspected for signs of leakage and urgent corrective
action taken if any are found. This is especially important for process
samples, which are flammable, toxic, liquid, or any combination of these.

5.9
5.10
SECTION 6 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.

NOTE
For ATEX versions EU1 and EU2 only those boards listed may be used as spares

6.1.1 General

Table 6.1 – General Spares List

Description Part Number
Power Supply S2000925
Display PCB 02501903
Display/Keypad Assembly S2501999
Keypad Assembly 02501998
Sensor Interface PCB 02000934
Option PCB 02000916
Transmitter PCB S2500904A
Motor Connection PCB S2500906
Power Control PCB S2500911A
Interconnecting Ribbon Cable Assembly 1-256mm path S2500928A
Interconnecting Ribbon Cable Assembly 512mm path S2500928B
Interconnecting Ribbon Cable Assembly 1000mm path S2500928C
Display Ribbon Cable Assembly S2500929
Interconnecting Cableform 1-256mm path S2500944A
Interconnecting Cableform 512mm path S2500944B
Interconnecting Cableform 1000mm path S2500944C
Fixings Kit (All fasteners) S2500974
Seals Kit (All Seals excluding Cell Seals) S2500975
Chopper Box Insulation S2500977
Transformer, 115/230 volts 00608333
Transformer, 100/200 volts 00608334

6.1
 Table 6.1 – General Spares List
Special Tools Kit S2500979
Enclosure Earth Studs S2500984
Pressure Transducer S2500985
Chopper Motor S2500986
Chopper Box Seals Kit S2500988
Gas Strut Kit S2500989
Motor Connection PCB S2500906
Fuse Kit 02501996
Multi component Adaptor PCB (2550 only) S2550901
10 x Gas Filter Correlation Adaptor PCB (2510 only) S2510901A
40 x Gas Filter Correlation Adaptor PCB (2510 only) S2510901B
Processor PCB + Firmware (2510 only) S2510965A
Processor PCB + Firmware (2500, 2520, 2550) S2500965A
Thermal Fuse (98°C) 2536-0329

6.1.2 Sample Cell Spares

Table 6.2 – Sample Cell Spares

Description Part Number
Thermocouple (300mm Sheath) 02500502
Cell Servicing Kit S2500981
Cell Seals Kit (Viton + PTFE) S2500982A
Cell Seals Kit (Chemraz) S2500982B
Special Tools Kit S2500979
PTFE Tape 1835-3026
Hand Aspirator 2387-0514

6.2
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 02501996 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 S2000925 0 1

NOTE
Scrubbers should be used as soon as received, or otherwise they must be stored in
their original unopened packaging in an airtight container, or preferably in a
desiccator. Scrubbers should be used on a "first in, first out" basis.

6.5
6.6
SECTION 7 INSTRUMENT SPECIFICATIONS

7.1 Generic 2500 Series Performance

7.1.1 Environmental Specifications

Table 7.1 – General Environmental Specifications

Operating Temperature GEN, EU1, EU2, FM2, HTV 0-55°C (32-131°F)
Operating Humidity 0-95% RH, non-condensing
Storage Temperature -40°C(-104°F) to +70°C (158°F)
Storage Humidity 0-95% RH, non-condensing
Altitude Up to 3000 M
Installation Category II Over-voltage impulse to withstand up to 2500V
Pollution Degree II in accordance with IEC 60664-1
Rate of Ambient Temperature Less than ±25°C/h, (±45°F/h) Change
Change
Warm-up Time Typically 2-10h, depending on application and
environment

7.1.2 Dimensions
Length: Max 1618mm, (63.7") min 615mm (24.2")
Height: 241mm (9.5")(allow 500 mm (20")
to open end covers)
Width: 248mm (9.8")
Weight: from 25 kg (55 lb)

7.1.3 Power Supply

115/230V AC ±15%, 50/60Hz or 100/200V AC ±15%, 50/60Hz.
120 VA without optional electrically heated cell.
300 VA with optional electrically heated cell.

Power Supply
Voltage Effects: Less than ±1% fsd for ±15% change.
Power Supply
Frequency Effects: Less than ± 1% fsd for 47 to 53 Hz or 57 to 63 Hz.

7.1
7.1.4 Performance Characteristics (each component)

Table 7.2 – Performance Characteristics

Intrinsic Error* Less than ±1% fsd
Repeatability ±0.5% fsd
Output Fluctuation (Noise) Less than 1% fsd (peak-peak) at minimum T90†

Linearity Error Typically less than ±1% fsd

Short Term Zero Drift: Less than ±1% fsd per week
Response Time (T90) User adjustable from 11s minimum (electronic
only, excludes sampling)
Obscuration Less than ±3% fsd zero error for 50% broadband
obscuration of cell windows
Influence Errors Dependant on application (see specification
details)

* error when used under reference conditions.

†
2510 HCL measurement less than 2% fsd (peak-peak) at minimum T90.

7.1.5 Performance Characteristics – EMC

Configuration of equipment:
Fitted with an unscreened power cable. Also included were two separate mA
output cables, each individually screened. Each signal pair was fitted with
ferrite bead (Servomex part No. 2824-0017). The screens and drain wires were
terminated at the glands.
Results:
Met the requirements of EN 61326, Table 4, Class B (Equipment for use in
domestic establishments) in respect of conducted and radiated emissions.
Met the requirements of EN 61326, Table A1 (Equipment for use in industrial
establishments) in respect of electrostatic discharges, fast transients/bursts,
surges, conducted RF disturbances, voltage dips and interrupts.
An additional error of 3% FS over the intrinsic error given in Table 7.2 may be
observed at some frequencies under the influence of radiated RF fields
specified for industrial environments.
Connection of additional or other signal/control cables and pressure
compensation could lead to a deterioration in performance at some RF
frequencies.

7.2
7.1.6 Sample Specification

Table 7.3 – Sampling Specification

Sample Temperature 0-180°C/32-356°F (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 ±1°C
Stability change in sample temperature. With optional empirical
sample temperature compensation, effect is reduced to
±1% fsd or less for a 20°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 25°C/hr (45°F/hr) over a
maximum of 25°C (45°F) change.

7.1.8 Solenoid Valve Relays

3 x Solenoid valve relays with volt free contacts rated 240VAC/1.0A, 30VDC/1.0A.
1 x 24VDC/12VA auxiliary supply for solenoid valves

7.3
7.1.9 Analogue Outputs
2 x mA outputs, plus 3 x relay outputs. Optionally additional 2 x mA, plus 2 x relay
outputs.
All analogue mA outputs are assignable and selected as 0-20mA or 4-20mA (max.
impedance 1KOhm) or alternatively 0-10V or 2-10V (min. impedance 1MOhm).
Dual ranges on every Analogue output. Optional additional mA outputs should be
specified for 3 component analysers.
All relay outputs are assignable contact pairs selected by links as NC or NO, and are
rated 240VAC/1.0A, 30VDC/1.0A.

7.1.10 Serial Output

Single ASCII data logging output port (RS232).

Table 7.5 – Serial Output Specification

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
7.1.14 485 Purge Controller (2500 EU1 Only)
Requires maximum of 40 l/min clean dry Nitrogen or clean dry Air at 3-7 barg,
depending on application.

7.1.15 Alternative Purge Controller (2500 EU1 Only)

Minimum flow rate = 10 SLPM for 11 minutes.

Minimum overpressure = 0.5 mBar.
Maximum overpressure = 80 mBar.

Refer to Certification Manual (Certificate SIRA 02ATEX1395X) for definitive

requirements and operational parameters.

7.5
7.6
SECTION 8 CE MARKING AND OTHER SAFETY APPROVALS

All 2500, 2510 and 2550 Analysers are CE marked and comply with all appropriate
European Community Directives.

8.1 EMC Directive

Electromagnetic Compatibility Directive 89/336/EEC (as amended by 92/31/EEC and

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

8.2 Low Voltage Directive

NOTE
Assessment under the Low Voltage Directive is not required for CE marking if the
equipment is approved under the ATEX Directive for use in potentially explosive
atmospheres

Low Voltage Directive 73/23/EEC and the CE Marking Directive 93/68/EEC by the
application of the following standards:
EN 61010-1 (equivalent to IEC 61010-1)
Safety requirements for electrical equipment for measurement, control and
laboratory use – general requirements:
2500, 2510 and 2550 Analysers are rated in accordance with:
IEC 60664 for Installation Category II, which is characterised as being local level (i.e.
not distribution level), appliances and portable equipment with over-voltage impulse
withstand up to 2500V.

8.3 Pressure Directive

All the relevant design aspects of the 2500 series analysers have been assessed in
respect of the requirements of the Pressure Equipment Directive (97/23/EC). These
products are excluded from the scope of this directive when installed and operated
within their published specifications.

8.1
8.4 ATEX Directive and other non-European Hazardous Area approvals

ATEX Directive 94/9/EEC

NOTE
Depending on the variant ordered an additional Safety Certificate Manual may be
supplied. This contains all the relevant safety certificates and declarations for the
EU1, EU2 and FM2 variants.

WARNING
The installer and/or the user of the analyser must be satisfied that the
installation complies with any "Special Conditions for Safe Use" or
"Schedules of Limitations" contained in the Certificates included in the
separate certification manual.

Table 8.1 – 02500 Safety Approvals

Variant Certification
GEN/HTV Only suitable for installation in a non-hazardous area.
The 2500, 2510 and 2550 EU1 version is ATEX CAT 2
equipment certified to Type 'p' standard EN 50016 and is
EU1
suitable for use in European and UK Zone 1 areas. The
analyser is marked EEx p ia [ia] IIC.
The EU2 version is ATEX CAT 3 equipment certified to
Type 'n' standard EN 50021, and is suitable for use in
Zone 2 areas. The analyser is marked
EEx nCL IIC T3 for cell temperatures up to 130°C and
EU2 EEx nCL 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.
The 02500 Series FM2 version is approved for operation
in US Class 1 Div. II location, without safety purging.

FM2 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.

8.2