Analizador de Co, Co2 y O2 en Linea Innovantis Tech. #6017380 Nov 13

INSTRUMENTS INC.
ENDA-4000 System
for
Innovantis Technologies
C/O Venezpress
NETWORK #6017380
S.O. #250548
HORIBA INSTRUMENTS INCORPORATED

9755 RESEARCH DRIVE
IRVINE, CALIFORNIA 92618-4626
TELEPHONE 949-250-4811 / 800-446-7422
FAX NUMBER 949-250-0924
CONTENTS: Network No.: 6017380
Innovantis Technologies C/O Venezpress
SECTION 1 OPERATION MANUAL FOR HORIBA ENDA-4000

Version 2.0, Published March 1998, Revised May 2005
SECTION 2 STANDARD MANUFACTURERS MANUALS

Baldwin Classic Thermo-Electric Coolers Model M115
Baldwin Classic Thermo-Electric Coolers Model M225
Horiba Instruments COM-1D Converter Specifications
Crydom Solid State Relay
Dekoron Unitherm Installation Instructions
Newport i32 Temperature & Process Controller
Peter Paul Solenoid Valves
SECTION 3 HORIBA PARTS LIST 256894-1
SECTION 4 ENDA-4000 RECOMMENDED SPARE PARTS LIST
SECTION 5 QUALITY ASSURANCE CHECK-OUT LIST & CERTIFICATE
SECTION 6 HORIBA DRAWINGS
201160 Probe Assembly Diagram (2 pages)

587770 Heated Line Diagram (3 pages)
592225 ENDA-4240 Outline Diagram (1 page)
592226 ENDA-4240 Flow Diagram (1 page)
592227 ENDA-4240 Wiring Diagram (3 pages)
Page 1
Instruction Manual
For
ENDA-4000
Version: 2.0
Date: 5/18/05
Horiba Manual No.: 93130-1

Revised March 1998, January 1999, December 2002, May 2004 and May 2004,
May 2005

17671 Armstrong Avenue
Irvine, CA 92614
Telephone: (949) 250-4811, Fax: (949) 250-0924
Operation Manual
HORIBA ENDA 4000
Version 2.0
May 2005
HORIBA INSTRUMENTS
HORIBA ENDA-4000 Operation Manual
Version 1.8, October 1997. Revised December 2002, May 2004, May 2005
Document Number: 092569
Copyright 1995, 1996, 1997 HORIBA INSTRUMENTS, Inc.
All Rights Reserved.
Printed in USA.
Notice
Specifications in this Operation Manual and for the product it describes are subject to
change without notice by Horiba Instruments, Inc.
Trademarks
Centronics is a trademark of Centronics Inc.
ENDA-4000 and XS are trademarks of Horiba Instruments, Inc.
Hewlett-Packard and HP are trademarks of Hewlett Packard Company.
IBM is a registered trademark of International Business Machines Corporation.
LapLink is a registered trademark of Traveling Software, Inc.
Snoop is a registered trademark of the Scott Specialty Gases division of Scott

Environmental Technology, Inc.
Teflon and Viton are registered trademarks of E.I. Dupont de Nemours & Co., Inc.
All other trademarks are the property of their respective owners.

Irvine, CA 92614
Telephone: (949) 250-4811 Facsimile: (949) 250-0924
Preface
Horiba Recycling Policy

Horiba Instruments (Horiba) is committed to protecting the environment by minimizing
the impact of all internal operations and the services and products we provide. In
addition to compliance with all relevant regulatory requirements regarding the
environment, it is our goal to ensure the reasonable on-going improvement of our
performance relative to the environment. As a result, Horiba encourages the recycling of
any of our equipment that is no longer in service. Should your Horiba equipment become
obsolete or out-of-service, please contact your local Horiba facility or dial 800-4-HORIBA
for instructions on returning this equipment for proper recycling or disposal.
Thank you for helping Horiba to protect our environment.
How to Use This Manual

Instructions for Beginning Users
This manual has been arranged so that each chapter builds upon the information
provided in previous chapters. Because of this structure, the best way to derive the
greatest benefit from this manual is to read it through from the beginning.
Instructions for Advanced Users

Information regarding installation, set up, and running a system verification check is
provided in Chapter 8, Installation and Chapter 9, System Verification Checks.
This manual is designed to be useful to personnel at various levels of experience. Users

who have extensive experience in emissions monitoring and want to proceed directly to
operating the instrument can refer to Chapter 4, XS Analyzer and Chapter 5, Operation.
How This Manual is Organized
This manual is organized as follows:
Chapter 1, Introduction to the ENDA-4000, describes the physical components of the

ENDA-4000, their basic functions, and provides an overview of operation.
Chapter 2, ENDA-4000 Hardware Description, presents an in-depth study of all

instrument hardware.
Chapter 3, Theory of Operation, describes how the various elements of the ENDA-
4000 work together.
Horiba Instruments i
ENDA-4000 Manual Preface
Chapter 4, XS Analyzer, provides detailed procedures for performing all setup and
operating functions of the analyzer.
Chapter 5, Operation, explains everyday operation of the ENDA-4000.
Chapter 6, Maintenance, provides details on scheduled and as-needed maintenance.
Chapter 7, Troubleshooting and Service, explains various options for solving

problems and includes a table of symptoms and suggested remedies.
Chapter 8, Installation, provides an outline of how to initially install and set up the
ENDA-4000.
Chapter 9, System Verification Checks, explains how to verify that the ENDA-4000
has been correctly installed and set up.
The appendices contain drawings and specifications that relate to your specific ENDA-
4000 configuration.
ii Horiba Instruments
Preface ENDA-4000 Manual
Warnings and Cautions
READ AND UNDERSTAND THESE IMPORTANT SAFETY

INSTRUCTIONS BEFORE OPERATING THIS EQUIPMENT:
DANGER: The ENDA-4000 enclosure contains electrically energized components.

Physical contact with energized components can be lethal. Always disconnect all power
to the ENDA-4000 before servicing electrical components.
WARNING: To avoid risk of electric shock and fire, all AC power and ground wiring to
the equipment must be installed, tested, and inspected only by licensed electricians or
other qualified personnel.
WARNING: The operating switches do not shut off power to components inside the
power distribution enclosure. You must turn OFF main switches controlling power to the
equipment before performing service.
1 WARNING: This equipment uses un-odorized compressed gases that are toxic
and/or flammable. Gas piping to the ENDA-4000 must be installed, tested, and
inspected only by qualified personnel.
1WARNING: The ENDA-4000 must be connected to a leak-tight ventilation line that

safely discharges waste gases outside of the building.
WARNING: Sample lines entering the ENDA-4000 contain high-temperature toxic gases
that may be very hot (190C / 374F). Hot sample lines present a risk of burns if
accidentally touched. Hot sample lines may also melt nearby electrical insulation and
create a short-circuit or electric shock hazard. Hot sample lines must be properly routed
and insulated to reduce risks to personnel and equipment. Sample line piping to the
equipment must be installed, tested, and inspected only by qualified personnel.
IMPORTANT: The ENDA-4000 weighs many hundreds of pounds (kgs) and may be
unevenly balanced and top-heavy. To avoid injuries or damage when moving the
equipment, do not tilt the cabinet more than 10 degrees from upright.
Horiba Instruments iii

IMPORTANT: During operation the ENDA-4000 traps condensate from the stack gas
sample line. Your local sanitation code may not permit you to discharge this waste into a
sanitary sewer. In such cases, you must connect the trap drain line to an approved
waste collection system.
IMPORTANT: Do not let large amounts of span gas escape while you are searching for
leaks. If necessary, disconnect the span gas line and pressurize it with compressed air
or nitrogen to perform leak tests.
IMPORTANT: Only qualified personnel should perform ENDA-4000 calibration,

troubleshooting and repairs. Observe all safety warnings and use the required safety
equipment when performing troubleshooting and repairs.
IMPORTANT: The ENDA-4000 should be operated only by trained and qualified

personnel. Always follow safety warnings.
iv Horiba Instruments
Glossary
AC Alternating current
Analyzer Device for measuring emission products
Atmosphere Air pressure at sea level
Blowback Function that forces air through the sample probe
Button Control switch that reacts to the users touch to perform an action
Calibration Function that permits adjustment of analyzer readings by comparison
with known gas concentrations
Calibration gas Gas of known concentration used to calibrate an analyzer
cfm Cubic feet per minute
CO Carbon monoxide
CO2 Carbon dioxide
CPU Central processing unit
Data display Area of screen where data values are displayed
DC Direct current
Diluent A neutral gas used to reduce concentration of the subject gas
Download Function that permits loading a new version of software into memory
Drift Movement in measured values due to temperature, etc.
ENDA-4000 Integrated sample-collection and analyzer instrument that measures
concentrations of emissions
FS Full-scale
HII HORIBA Instruments Inc.
I/O Input/output
In W.C. Inches water column
In Hg Inches mercury
inst. Instrument
2
kg/cm Kilograms per centimeters squared
l Liter; a metric unit of volume equal to approximately 1 quart
Horiba Instruments v
lpm Liters per minute

MPA Magneto-pneumatic analyzer
N2 Nitrogen gas
NDIR Non-dispersive infrared [analysis]
NOX Oxides of nitrogen (NO and NO2)
O2 Oxygen gas
ppm Parts per million
psi Pounds per square inch
psig Pounds per square inch (gauge)
Range Band of measured values supported by an analyzer
Sample gas Gas from the sample source, used to take test measurements
Sample line Tubing from the sample source to the ENDA-E4000
SO2 Sulfur dioxide
Span Calibration gas concentration or the value that is used to verify the
response of an analyzer.
Span gas Gas used to perform a span check
stp Standard temperature and pressure (20C, 760 mm Hg)
Volt Measure of electrical potential
vi Horiba Instruments
Contents
Preface ................................................................................................ i
Horiba Recycling Policy .................................................................................................................i
How to Use This Manual................................................................................................................i
Warnings and Cautions................................................................................................................ iii
Glossary ........................................................................................................................................v
Contents...................................................................................................................................... vii
1.0 Introduction .............................................................................. 1-1

1.1 Description of the Product.............................................................................................. 1-1
1.2 Overview of Operation ................................................................................................... 1-1
1.2.1 Sample Probe and Primary Filter Assembly ........................................................... 1-1
1.2.2 Sample Line ............................................................................................................ 1-2
1.2.3 Sample Conditioning Equipment ............................................................................ 1-3
1.2.4 XS Instrument ......................................................................................................... 1-3
1.2.5 Microprocessor Control........................................................................................... 1-3
1.3 Specifications ................................................................................................................. 1-4
2.0 ENDA-4000 Hardware Description .......................................... 2-1

2.1 Overview ........................................................................................................................ 2-1
2.2 Electrical Hardware ........................................................................................................ 2-1
2.2.1 AC Supply Wiring.................................................................................................... 2-1
2.2.2 208 VAC or 220 VAC Options ................................................................................ 2-2
2.2.3 Low Voltage Power Supply..................................................................................... 2-2
2.2.4 Power Distribution and Control ............................................................................... 2-2
2.2.4.1. Power Distribution............................................................................................ 2-2
2.2.4.2. Circuit Breaker ................................................................................................. 2-2
2.2.4.3. Fuses ............................................................................................................... 2-3
2.2.5 Front Panel Switches .............................................................................................. 2-3
2.2.6 Front Panel Temperature Controller ....................................................................... 2-4
2.2.7 Interior Switches ..................................................................................................... 2-4
2.3 Interfaces to External Devices ....................................................................................... 2-4
2.3.1 Digital Inputs ........................................................................................................... 2-7
2.3.2 Digital Outputs ........................................................................................................ 2-8
2.4 Mechanical Hardware .................................................................................................... 2-9
2.4.1 Sampling Point........................................................................................................ 2-9
2.4.1.1. Sample Probe and Mounting Flange ............................................................... 2-9
2.4.1.2. Primary Filter (F1).......................................................................................... 2-10
2.4.1.3. Sample Probe Blowback Option.................................................................... 2-10
2.4.1.4. Primary Filter Heater ..................................................................................... 2-10
2.4.1.5. Sample Line................................................................................................... 2-10
2.4.1.6. Peristaltic Drain Pump (Option) ..................................................................... 2-11
2.4.1.7. Sample Line Heater ....................................................................................... 2-11
2.4.2 Sample Conditioning Equipment .......................................................................... 2-12
2.4.2.1. NH3 Scrubber (Option)................................................................................... 2-12
2.4.2.2. HCl Scrubber (Option) ................................................................................... 2-12
2.4.2.3. HF Scrubber (Option) .................................................................................... 2-12
2.4.2.4. Cl2 Scrubber (Option) .................................................................................... 2-12
2.4.2.5. Water Separator (WS1) ................................................................................. 2-12
2.4.2.6. Pre-Cooler (Option) ....................................................................................... 2-13
2.4.2.7. Overflow Trap (TR2) ...................................................................................... 2-13
Horiba Instruments vii

2.4.2.8. Mist Catcher (MC1)........................................................................................ 2-13

2.4.2.9. High-Capacity Mist Catcher (Option)............................................................. 2-13
2.4.2.10. NOX Converter (COM1-D) ............................................................................. 2-13
2.4.2.11. High-Capacity NOX Converter (Option)......................................................... 2-14
2.4.2.12. Secondary Filters (F2 and F3) ...................................................................... 2-14
2.4.2.13. Needle Valve (NV-1) ..................................................................................... 2-14
2.4.2.14. Sample Pump (P1) ........................................................................................ 2-14
2.4.2.15. Constant Pressure Trap (TR1)...................................................................... 2-14
2.4.2.16. Solenoid Valves (SVx)................................................................................... 2-15
2.4.2.17. Thermoelectric Cooler (TEC) ........................................................................ 2-15
2.4.2.18. Sample Flow Meter (FM-1A) ......................................................................... 2-15
2.4.3 Reference Gas Conditioning Equipment .............................................................. 2-16
2.4.3.1. Humidifier Bath (HB1).................................................................................... 2-16
2.4.3.2. CO Purifier (PUR) .......................................................................................... 2-16
2.4.3.3. Reference Gas Scrubber (SCR-1)................................................................. 2-16
2.4.3.4. Reference Gas Filter (FA-1) .......................................................................... 2-16
2.4.3.5. Needle Valves (NV-1, NV-2, NV-3) ............................................................... 2-17
2.4.3.6. Reference Gas Pump (P2) ............................................................................ 2-17
2.4.3.7. Buffer Tank (BT1) .......................................................................................... 2-17
2.4.3.8. Desiccant Gas Drier (SG).............................................................................. 2-17
2.5 Instrument .................................................................................................................... 2-18
2.6 Chassis......................................................................................................................... 2-20
2.6.1 Cabinet.................................................................................................................. 2-20
2.6.2 Access Panels and Doors..................................................................................... 2-20
2.6.3 Ventilation Fan ...................................................................................................... 2-20
2.6.4 Air Conditioner (Option) ........................................................................................ 2-20
3.0 Theory of Operation................................................................. 3-1

3.1 Sample Collection .......................................................................................................... 3-1
3.2 Sample Conditioning ...................................................................................................... 3-1
3.3 Cross-Modulation NDIR Analysis................................................................................... 3-2
3.4 Chemiluminescent Measurement of NOX (Option) ........................................................ 3-5
3.5 Magneto-Pneumatic Measurement of Oxygen .............................................................. 3-6
3.6 Reference Gas Conditioning.......................................................................................... 3-7
3.7 Analyzer Calibration ....................................................................................................... 3-8
3.8 Flow Diagram ................................................................................................................. 3-8
4.0 XS Analyzer ............................................................................. 4-1

4.1 Overview ........................................................................................................................ 4-1
4.2 Analyzer Controls........................................................................................................... 4-1
4.2.1 Operator Controls ................................................................................................... 4-2
4.2.2 Setup Controls ........................................................................................................ 4-3
4.3 Analyzer Displays and Indicators................................................................................... 4-4
4.3.1 Alphanumeric Displays ........................................................................................... 4-4
4.3.2 Indicators ................................................................................................................ 4-4
4.4 Instrument Operations.................................................................................................... 4-7
4.4.1 Span Gas Set.......................................................................................................... 4-7
4.4.2 Set System Time and Date..................................................................................... 4-9
4.4.3 Automatic Instrument Calibration.......................................................................... 4-10
4.4.4 Automatic Instrument Calibration Start ................................................................. 4-11
4.4.5 Automatic Instrument Calibration Interval............................................................. 4-13
4.4.6 Purge (Blowback) Setup ....................................................................................... 4-14
4.4.7 Purge Start (optional)............................................................................................ 4-14
4.4.8 Purge Interval (optional) ....................................................................................... 4-17
4.5 Calibration Setup.......................................................................................................... 4-19
viii Horiba Instruments

4.5.1 Blowback Setup In-Blow Time ........................................................................... 4-19

4.5.2 Sample Delay Time............................................................................................... 4-20
4.5.3 NOX Calibration Range......................................................................................... 4-21
4.5.4 SO2 Calibration Range.......................................................................................... 4-21
4.5.5 CO Calibration Range........................................................................................... 4-22
4.5.6 CO2 Calibration Range ......................................................................................... 4-22
4.5.7 O2 Calibration Range ............................................................................................ 4-23
4.5.8 MAT O2 Set Value................................................................................................. 4-23
4.5.9 Calibration Duration .............................................................................................. 4-23
4.6 Calibration .................................................................................................................... 4-24
4.6.1 Automatic Calibration............................................................................................ 4-24
4.6.2 Manual Calibration ................................................................................................ 4-24
4.7 Alarms and Cautions.................................................................................................... 4-25
4.7.1 Displaying Alarm Codes........................................................................................ 4-26
4.7.2 Interpreting Alarm Codes...................................................................................... 4-28
4.7.3 Interpreting Caution Codes................................................................................... 4-29
4.7.4 Clearing Alarms .................................................................................................... 4-30
5.0 Operation ................................................................................. 5-1

5.1 Overview ........................................................................................................................ 5-1
5.2 Start-Up .......................................................................................................................... 5-1
5.3 Daily Operation .............................................................................................................. 5-3
5.4 Instrument Shut-Off........................................................................................................ 5-4
5.4.1 Extended Idle Period............................................................................................... 5-5
6.0 Maintenance ............................................................................ 6-1

6.1 Overview ........................................................................................................................ 6-1
6.2 Scheduled Maintenance................................................................................................. 6-1
6.3 Unscheduled Maintenance............................................................................................. 6-4
7.0 Troubleshooting and Service ................................................... 7-1

7.1 Overview ........................................................................................................................ 7-1
7.2 Required Safety Equipment, Tools, and Materials ........................................................ 7-1
7.3 Symptoms and Remedies .............................................................................................. 7-2
7.3.1 Alarm and Caution Codes....................................................................................... 7-2
7.3.2 Alarm Conditions NOX.......................................................................................... 7-4
7.3.3 Alarm Conditions SO2 .......................................................................................... 7-5
7.3.4 Alarm Conditions CO ........................................................................................... 7-6
7.3.5 Alarm Conditions CO2 .......................................................................................... 7-7
7.3.6 Alarm Conditions O2 ............................................................................................ 7-8
7.3.7 Alarm Conditions Control Program ...................................................................... 7-9
7.3.8 Miscellaneous Problems....................................................................................... 7-10
7.4 Factory Service ............................................................................................................ 7-12
7.5 Service Policies............................................................................................................ 7-14
7.6 Warranties.................................................................................................................... 7-15
8.0 Installation................................................................................ 8-1

8.1 Overview ........................................................................................................................ 8-1
8.2 Site Preparation ............................................................................................................. 8-1
8.2.1 Room ...................................................................................................................... 8-1
8.2.2 Operating Environment ........................................................................................... 8-3
8.2.3 Required Access Clearances ................................................................................. 8-4
8.2.4 Electrical ................................................................................................................. 8-5
8.2.5 AC Power Wiring..................................................................................................... 8-6
Horiba Instruments ix
8.2.6 Signal and Control Wiring ....................................................................................... 8-6

8.2.7 ENDA-4000 Ventilation ........................................................................................... 8-7
8.2.8 Room Ventilation..................................................................................................... 8-7
8.2.9 Waste Water Drain.................................................................................................. 8-8
8.2.10 Gas Piping .............................................................................................................. 8-8
8.2.11 Sample Line Piping ................................................................................................. 8-9
8.3 Receiving ..................................................................................................................... 8-10
8.3.1 Unpacking ............................................................................................................. 8-11
8.3.2 Receiving Inspection............................................................................................. 8-12
8.3.3 Repacking for Return Shipment............................................................................ 8-13
8.4 Mechanical Installation................................................................................................. 8-13
8.4.1 Required Safety Equipment, Tools, and Parts ..................................................... 8-13
8.4.2 Transporting the ENDA-4000 to the Site .............................................................. 8-13
8.4.3 Orientation and Location....................................................................................... 8-14
8.4.4 Installation of Anchor Bolts ................................................................................... 8-14
8.4.5 Attachment to Anchor Bolts .................................................................................. 8-15
8.5 Plumbing Installation .................................................................................................... 8-16
8.5.1 Bulkhead Connection Panel ................................................................................. 8-17
8.5.2 Ventilation Connection .......................................................................................... 8-17
8.5.3 Drain Connection .................................................................................................. 8-18
8.5.4 Sample Probe and Flange .................................................................................... 8-19
8.5.5 Primary Filter......................................................................................................... 8-22
8.5.6 Heated Sample Line Assembly............................................................................. 8-23
8.5.7 Blowback Air Piping (Optional) ............................................................................. 8-25
8.6 Electrical Installation .................................................................................................... 8-26
8.6.1 AC Power Connection........................................................................................... 8-26
8.6.2 Primary Filter Power Connection .......................................................................... 8-28
8.6.3 Sample Line Heater Power Connection................................................................ 8-29
8.6.4 Signal and Control Cable Connection................................................................... 8-30
8.6.4.1. Analog Output Cables to Chart Recorder...................................................... 8-30
8.7 Subassembly Setup ..................................................................................................... 8-31
8.7.1 Overflow Trap ....................................................................................................... 8-31
8.8 Installation Checks ....................................................................................................... 8-32
8.9 Post-Installation Inspection .......................................................................................... 8-33
8.9.1 Inspection Checklist .............................................................................................. 8-34
9.0 System Verification Checks ..................................................... 9-1

9.1 Overview ........................................................................................................................ 9-1
9.2 Preparation..................................................................................................................... 9-1
9.3 Verification Checks ........................................................................................................ 9-2
10.0 Analyzer Parts List................................................................. 10-1

10.1 CMA-600 Analyzer ................................................................................................... 10-1
10.2 NOX, SO2, and CO2 IR Bench................................................................................... 10-4
10.3 CO Bench ................................................................................................................. 10-7
10.4 O2 Bench ................................................................................................................ 10-10
10.5 Solenoid Valve Block.............................................................................................. 10-12
10.6 Pressure Trap, Humidifier, and Silica Gel ENDA-4000.......................................... 10-14
10.7 I/O Analog Outputs PCBs ENDA-4000 .................................................................. 10-16
10.8 Overflow Trap and Buffer Tanks ENDA-4000 ........................................................ 10-18
10.9 Water Separator ENDA-4000................................................................................. 10-20
10.10 EC600 Bench ......................................................................................................... 10-22
x Horiba Instruments
Tables
Table 2-1: Switches and Functions .............................................................................................. 2-4
Table 2-2: Analog Output Terminal Block TB4 Pin-Outs and Assignments ................................. 2-5
Table 2-3: Analog Output Terminal Block TB5 Pin-Outs and Assignments ................................. 2-6
Table 2-4: Digital Input Terminal Block TB6 Pin-Outs and Assignments ..................................... 2-7
Table 2-5: Digital Output Terminal Block TB7 Pin-Outs and Assignments .................................. 2-8
Table 2-6: Digital Output Terminal Block TB8 Pin-Outs and Assignments .................................. 2-9
Table 2-7: XS Instrument Rear Panel Elements ........................................................................ 2-19
Table 2-8: ENDA-4000 Cabinet Dimensions and Required Clearances.................................... 2-22
Table 4-1: Alarm Codes.............................................................................................................. 4-28
Table 4-2: Caution Codes........................................................................................................... 4-29
Table 6-1: Daily and Weekly Scheduled Maintenance Tasks ...................................................... 6-1
Table 6-2: Quarterly and Annual Scheduled Maintenance Tasks................................................ 6-2
Table 6-3: Two Year and Five year Scheduled Maintenance Tasks............................................ 6-3
Table 6-4: Unscheduled Maintenance Tasks ............................................................................... 6-4
Table 7-1: Alarm Codes................................................................................................................ 7-2
Table 7-2: Caution Codes............................................................................................................. 7-3
Table 7-3: Symptoms and Suggested Remedies for NOX Related Alarms.................................. 7-4
Table 7-4: Symptoms and Suggested Remedies for SO2 Related Alarms .................................. 7-5
Table 7-5: Symptoms and Suggested Remedies for CO Related Alarms ................................... 7-6
Table 7-6: Symptoms and Suggested Remedies for CO2 Related Alarms .................................. 7-7
Table 7-7: Symptoms and Suggested Remedies for O2 Related Alarms..................................... 7-8
Table 7-8: Symptoms and Suggested Remedies for Control Program ........................................ 7-9
Table 7-9: Symptoms and Suggested Remedies for ENDA-E4000........................................... 7-10
Table 8-1: ENDA-E4000 Cabinet Dimensions and Required Clearances ................................... 8-5
Table 8-2: Signal and Control Wiring Guidelines ......................................................................... 8-7
Horiba Instruments xi
Figures
Figure 1-1: ENDA-4000 Simplified Schematic ............................................................................. 1-2
Figure 2-1: Switch Panel .............................................................................................................. 2-3
Figure 2-2: XS Instrument Front Panel....................................................................................... 2-18
Figure 2-3: XS Instrument Rear Panel ....................................................................................... 2-18
Figure 2-4: ENDA-4000 Cabinet................................................................................................. 2-21
Figure 3-1: NDIR Analyzer Schematic ......................................................................................... 3-3
Figure 3-2: CLA NOX Analyzer Schematic ................................................................................... 3-5
Figure 3-3: MPA Analyzer Schematic........................................................................................... 3-6
Figure 3-4: ENDA-4000 Flow Diagram (Typical).......................................................................... 3-9
Figure 4-1: XS Analyzer in Operation........................................................................................... 4-1
Figure 4-2: Front Panel Operation Controls ................................................................................. 4-2
Figure 4-3: Setup Controls (Behind Panel Door).......................................................................... 4-3
Figure 4-4: Concentration Display ................................................................................................ 4-4
Figure 4-5: Range Display............................................................................................................ 4-4
Figure 4-6: XS Analyzer Indicators............................................................................................... 4-5
Figure 4-7: Example CO Span Gas Selected............................................................................ 4-8
Figure 4-8: Analyzer Clock Display 2:35 P.M. (example)............................................................. 4-9
Figure 4-9: AIC Start After 1 Day at 13:00 Hours (example)...................................................... 4-11
Figure 4-10: AIC Interval of 12 Hours (example)........................................................................ 4-13
Figure 4-11: Purge Start After 2 Days at 18:00 (example)......................................................... 4-15
Figure 4-12: Purge Interval (Blowback) Every 10 Hours (example)........................................... 4-17
Figure 4-13: Setup Buttons......................................................................................................... 4-19
Figure 4-14: Setup Control Buttons ............................................................................................ 4-26
Figure 4-15: Alarm Check Mode................................................................................................. 4-27
Figure 5-1: Constant Pressure Trap Bubble Flow ........................................................................ 5-2
Figure 8-1: ENDA-4000 Required Clearances ............................................................................. 8-4
Figure 8-2: Anchor Bolt Installation Details ................................................................................ 8-15
Figure 8-3: Bulkhead Connection Panel..................................................................................... 8-17
Figure 8-4: Sample Gas Temperature to Offtank Flange Length Relation................................. 8-20
Figure 8-5: Flange and Probe Mounting Details......................................................................... 8-21
Figure 8-6: Primary Filter Connections....................................................................................... 8-22
Figure 8-7: Sample Line Configuration....................................................................................... 8-24
Figure 8-8: Sample Line Heater Details ..................................................................................... 8-29
Figure 10-1: ENDA-600 Exploded View ..................................................................................... 10-3
Figure 10-2: NOX, SO2, and CO2 IR Bench Exploded View ....................................................... 10-6
Figure 10-3: CO Bench Exploded View...................................................................................... 10-9
Figure 10-4: O2 Bench Exploded View ..................................................................................... 10-11
Figure 10-5: Solenoid Valve Block Exploded View .................................................................. 10-13
Figure 10-6: Pressure Trap, Humidifier, and Silica Gel Exploded View................................... 10-15
Figure 10-7: I/O Analog Outputs PCBs Exploded View ........................................................... 10-17
Figure 10-8: Overflow Trap and Buffer Tanks Exploded View ................................................. 10-19
Figure 10-9: Water Separator Exploded View.......................................................................... 10-21
Figure 10-10: EC600 Bench Exploded View ............................................................................ 10-23
xii Horiba Instruments

1.0 Introduction
1.1 Description of the Product
The ENDA-4000 stack gas analysis system has been designed to continuously measure
the concentrations of oxides of nitrogen, sulfur dioxide, carbon monoxide, carbon
dioxide, and oxygen in stack gas emissions. The ENDA-4000 uses Horibas non-
dispersive infrared analysis method for NOX, SO2, CO and CO2 measurements and the
magnetopneumatic analysis method for O2 measurements. The analyzers are designed
to automatically compensate for the interference caused by CO2 and H2O in the sample
gas.
1.2 Overview of Operation

A standard configuration of the ENDA-4000 incorporates a sample probe and primary
filter assembly, a sample line, and an analyzer. A very simplified schematic of the
product is presented in Figure 11 (on the next page) and discussed in the paragraphs
that follow.
1.2.1 Sample Probe and Primary Filter Assembly
The sample probe and primary filter assembly is installed directly in the stack. The
primary filter removes most of the dust in the stack gas sample. To prevent
condensation of moisture inside the filter, a built-in electric heater heats the primary filter.
The primary filter may be ordered from the factory to accept customer-supplied
compressed air that is used for probe blowback.
The primary filter assembly also provides upstream connections for introduction of
calibration and zero gas. This assures that analyzer calibration gases flow through the
same out-of-stack components, as does the sample gas.
Horiba Instruments 1-1

ENDA-4000 Manual Chapter 1: Introduction
1.2.2 Sample Line
After passing through the heated primary filter, the sample gas passes along a sample
line, (provided by the customer, or optionally available from Horiba), to the sample
conditioning subsystem. Depending upon the temperature of stack gas and outside air
temperatures, the sample line may be insulated and/ or heated to prevent condensation
of moisture. As the sample moves from the primary filter to the sample handler, it is
allowed to cool to near ambient temperature. When the sample gas enters the sample
handler subsystem, its temperature must be near ambient.
SAMPLE LINE
Pri.
Sample Filter
Probe Sample
Inlet SAMPLE CONDITIONING XE ANALYZER
Water
Filter
Separator
Sample Thermo-
Pump electric
Cooler
Sample
Outlet
Constant
Pressure Analyzer
Condensed Water Trap
Humidifier
Ref Gas Bath
Filter
Pump
Calib.
Gases
Air Water
Inlet Sample Flow
Drain
Condensed Water Flow
Reference Gas
Figure 1-1: ENDA-4000 Simplified Schematic
1-2 Horiba Instruments

Chapter 1: Introduction ENDA-4000 Manual
1.2.3 Sample Conditioning Equipment
The sample enters the sample handler and flows through a water separator that extracts
condensate from the sample. The sample passes through an anhydrous sulfuric acid
(SO3) mist catcher and a secondary filter, where sulfuric acid mist and remaining
particulates are removed. A sample pump sends the sample, now at ambient
temperature, through a thermoelectric cooler where it is cooled to 5C and all remaining
water vapor condenses and is trapped. The sample is sent to a constant pressure trap
and the pressure-controlled sample stream from the trap is fed to the analyzer.
Condensed water from the water separator and the thermoelectric cooler is collected
and used to automatically replenish the level of the water in the constant pressure trap
and the humidifier bath (used to humidify the reference gas). Excess condensed water is
routed to a drain connection on the cabinet.
1.2.4 XS Instrument
The sample flows into the XS instrument where it is divided and sent to the various
configured detectors. The detector modules can measure the concentrations of NOX,
SO2, CO, and CO2. The MPA detector measures the concentrations of O2.
Following measurement, the sample gas leaves the XS instrument and is routed to a
bulkhead outlet connector.
1.2.5 Microprocessor Control
Sample collection and management, and instrument calibration and measurements are
all directly controlled by a microprocessor inside the XS instrument. The microprocessor
coordinates all functions of the ENDA-4000.

1.3 Specifications
Analysis:
Measured components: Nitrogen oxides (NOX)
Sulfur dioxide (SO2)
Carbon monoxide (CO)
Carbon dioxide (CO2)
Oxygen (O2)
Measurement ranges: NOX: 100 5000 ppm
SO2: 100 5000 ppm
CO: 100 5000 ppm
CO2: 5 20% volume
O2: 5 25% volume
Repeating accuracy: 0.5% of full-scale value
Zero drift: 1.0% of full-scale value per week
( 5C ambient temperature changes)
Span drift: 2.0% of full-scale value per week
( 5C ambient temperature changes)
Linearity: 1.0% of full-scale value for each component and range
Analysis methods: NDIR: Non-dispersive infrared absorbtiometry (standard
for all components except O2)
MPA: Magneto-pneumatic analysis (O2 component only)
Response speed: 60 seconds max. at system inlet (T90)
(240 sec. max. for the SO2 measurement only).
Interference compensation: NOX: H2O, CO2 (standard)
SO2: H2O (standard), CH4 (optional)
CO: CO2 (standard)
Total interference: 2.0 % of full-scale value (except SO2)
Composition limits: NO: 1000 ppm max.
NO2: 1/10 NO or less
SO2: 5000 ppm max.

SO3: 1/10 SO2 or less
CO: 1000 ppm max.

CO2: 5 15 vol %
O2: 0.2 to 15 vol %
H2O: 4 to 20 vol %
NH3: must be removed by optional scrubber

Sampling:
Sample temperature at 482F (250C) max.
primary filter:
Sample gas flow rate: 2.5 to 4.0 lpm.
Sample pressure: Atmospheric pressure 4 in. W.C.
Allowable dust: 0.1 g/Nm3 (0.04 grains/dscf) or less
Sample backpressure: None
Exhaust backpressure: None
Pressure control method: Constant-pressure trap
Sampling method: Dehumidified sampling at 5C using passive water
separator and thermoelectric cooler
Sample inlet tube: Teflon tube 3/8 in. O.D.
Materials exposed to sample Stainless steel 316, Teflon, polypropylene fluororubber,
gas: PVC, glass, and Kynar
Effluent from sample Condensed water from stack gas sample (< 0.1 lpm)
handling:
Calibration:
Calibration methods: Automatic or manually selected.
Interval: Automatic calibration interval configurable from 1 to 9
day cycle
Zero gas: Nitrogen (N2)
Span gas: Gas cylinder for measured component
Carrier gas for O2 Conditioned ambient air
measurement:

Signals:
Display: Digital readout of concentration
Isolated output: 4 to 20 mA,
0 to 1 VDC
Status signals: Analyzer malfunction; calibration error, power off range
identification; calibration in progress; blowback in
progress (optional)
Contact capacity: 250 VAC or 120 VAC @1A in resistive load
Electrical:
Input voltage: 115 VAC (standard)
208 VAC (optional heated lines)
220 VAC (optional heated lines)
Frequency: 60 Hz (standard)
50 Hz (optional)
Power consumption: 700 VA (approx.)
Sample line heater: 1.5 kVA typical; 4.0 kVA max.
Primary filter heater: 100 VA
Supply requirement: Isolated, ripple-free supply for computer
(conditioned line recommended)

Environment:
Ambient temperature: +5 to 40C (standard)
15 to 40C (option)
5 to 50C (option)
Temperature change: 5C per hour max.
Vibration: 0.03 G max. at 100 Hz
Cabinet options: NEMA-12 (indoor installation standard)
NEMA-4 (outdoor installation, not exposed to direct
sunlight)
NEMA-4X (outdoor installation, special)
Physical:
Dimensions: 75 in (H), 25 in. (W), 32 in. (D)
(190.5 cm (H), 63.5 cm (W), 81.3 cm (D))
Weight: 660 lbs. (300 kg.)
Cabinet: Doors at front and rear
Color: 26360 semi-gloss gray (per FED-STD-595B)
Options: Shelter-mounted option; transportable option

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2.0 ENDA-4000 Hardware
Description
2.1 Overview
This chapter describes all of the hardware elements that make up the ENDA-4000 and
provides specifications when necessary. This chapter begins by describing the electrical
hardware, including power supply and distribution. The mechanical hardware subsection
describes the internal plumbing including the gas-handling equipment. The instrument
subsection provides a basic description of all standard and optional instrument features.
The chassis subsection describes features used in the chassis and cabinet of the ENDA-
4000.
The ENDA-4000 may be factory ordered with combinations of multiple options. The
temperature, pressure, and specific contents of stack gases will dictate which options
are required for best performance. This chapter includes descriptions of standard
equipment and commonly ordered options.
2.2 Electrical Hardware

The following sections describe the electrical hardware requirements of the ENDA-4000.
2.2.1 AC Supply Wiring
The ENDA-4000 is designed for permanent connection to an unshared 115 VAC, 5060
Hz circuit rated for 15 amps. The system is designed to be connected by three-
conductor wiring of the appropriate gauge from a customer-supplied junction box. The
power supply cable originates at a wall or ceiling-mounted junction box and passes
through a 3/4-inch rigid conduit hub near the top right side of the cabinet. Once inside
the cabinet, the wiring connects directly to the junction box circuit breakers.
ENDA-4000 systems equipped with the optional heated sample line require a 20-amp
circuit. Systems equipped with an optional air conditioner require a separate 15-amp
circuit for the air conditioner. Details about power requirements for your configuration
can be found in the appendix of this Operation Manual.

ENDA-4000 Manual Chapter 2: ENDA-4000 Hardware Description
Power for the 100-watt primary filter heater and the optional sample line heater is
supplied from the junction box. A two-conductor cable, of adequate gauge to supply a
100 watt load at the required distance, plugs into the junction box, passes through an
insulated grommet pass-through on the cabinet, passes through conduit and connects to
terminals inside the primary filter assembly. The sample line heater is permanently wired
to the sample line circuit breaker in the junction box. Messenger wires in the heated
sample line may carry power for the primary filter if local code and area classification
permit.
2.2.2 208 VAC or 220 VAC Options
The standard ENDA-4000 is designed for connection to a 115 VAC circuit. For
installations where only 208 VAC or 220 VAC circuits are available, Horiba offers
factory-installed options that permit connection to these higher voltage circuits.
2.2.3 Low Voltage Power Supply
The low-voltage power supply is a step-down transformer and rectifier that provides
unregulated 24-volt DC power for valve solenoids, relays, indicators, etc.
2.2.4 Power Distribution and Control
WARNING: The power distribution network contains energized components. Physical

contact with energized components can be lethal. Always disconnect all power to the
ENDA-4000 before performing service on electrical components.
2.2.4.1. Power Distribution
The ENDA-4000 is equipped with an AC voltage distribution network that consists of

switches, circuit breakers, fuses, and power distribution wiring.
IMPORTANT: The bottom four outlets on the back of the junction box are wired to
supply 100 VAC and must not be used as convenience outlets.
2.2.4.2. Circuit Breaker
The ENDA-4000 is equipped with a 15-amp circuit breaker mounted on the left of the
power distribution terminal board.

Chapter 2: ENDA-4000 Hardware Description ENDA-4000 Manual
2.2.4.3. Fuses
The factory attaches an identifying label for each fuse-protected subsystem inside the
cabinet. The label identifies the protected device and the fuse capacity.
A replaceable fuse mounted on the rear of the instrument case protects the instrument.
The fuse rating is printed next to the fuse holder. A separate set of labeled fuses
protects loads within the sample conditioning system. A complete set of spare fuses may
be obtained from Horiba or from your electrical parts supplier.
2.2.5 Front Panel Switches
The left side of the control panel contains a row of switches that control power to the
instrument, sample handling system, and microprocessor controller. These switches are
illustrated in Figure 21 and explained in the table that follows.
Figure 2-1: Switch Panel

Table 2-1: Switches and Functions
SWITCH LABEL SWITCH FUNCTION

INSTRUMENT/AUXILIARY Controls power to the instrument and sample
handling equipment (except sample pump).
HEATED LINE Controls power to the optional sample line heater.
HVAC Controls power to ventilation fan or optional air
conditioner.
HEATED PRIMARY FILTER Controls power to the primary filter heater.
PUMP Controls power to the sample pumps.
2.2.6 Front Panel Temperature Controller
The right side of the control panel (see Figure 21) contains temperature controller and
indicator display for the heated sample line. Details about the operation of the
temperature controller may be found in the Appendix of this Operation Manual.
2.2.7 Interior Switches
In addition to the switches mounted on the front panel, a power switch for the XS
instrument may be found on the rear of the instrument case.
2.3 Interfaces to External Devices

The ENDA-4000 supports 10 isolated analog output channels providing one output for
each raw measurement, one output for each diluent-corrected value, plus options for
integrated values. Analog outputs are hardware configurable for 0 1 VDC, 0 16 mA,
or 4 20 mA.
All analog output signals terminate at terminal board EN-TML-01. The terminal board
has two terminal blocks for connection to cable pairs to external analog devices. Horiba
recommends using three-conductor shielded cables to connect analog outputs to
external devices.
Terminal block TB4 (top) has 20 terminal screws. Terminal block TB5 (bottom) has 30
terminal screws. Terminal block pin-outs and typical analog output channel assignments
(in parentheses) are described in Tables 22 and 23 on the following pages.

Table 2-2: Analog Output Terminal Block TB4 Pin-Outs and Assignments
TB4 TB4
Pin Pin
DESCRIPTION DESCRIPTION
No. No.
0 Channel 1 voltage output [+] 10 Channel 1 voltage output []
(NOX raw) (NOX raw)
1 Channel 1 current output [+] 11 Channel 1 current output []
(NOX raw) (NOX raw)
(SO2 raw) (SO2 raw)
3 Channel 2 current output [+] 13 Channel 2 voltage output []
(SO2 raw) (SO2 raw)
(CO raw) (CO raw)
(CO raw) (CO raw)
(CO2 raw) (CO2 raw)
(CO2 raw) (CO2 raw)
(O2 raw) (O2 raw)
(O2 raw) (O2 raw)

Table 2-3: Analog Output Terminal Block TB5 Pin-Outs and Assignments
TB5 TB5
Pin Pin
DESCRIPTION DESCRIPTION
No. No.
(NOX corrected) (NOX corrected)
(NOX corrected) (NOX corrected)
(SO2 corrected) (SO2 corrected)
(SO2 corrected) (SO2 corrected)
(CO corrected) (CO corrected)
(CO corrected) (CO corrected)
(CO2 corrected) (CO2 corrected)
(CO2 corrected) (CO2 corrected)
8 Channel 10 voltage output 23 Channel 10 voltage output []
[+] (O2 corrected) (O2 corrected)
(O2 corrected) (O2 corrected)
10 External O2 input [+] 25 External O2 input []
11 Ground 26 Ground
12 Reserved 27 Reserved
14 Not used 29 Not used

2.3.1 Digital Inputs
The ENDA-4000 supports 15 digital input channels that accept contact inputs from
external control devices.
All digital input signals terminate at terminal board EN-RR-01. The terminal board has
one terminal block for connection to cables from external devices. Horiba recommends
using two-conductor cables to connect digital inputs from external devices.
Terminal block TB6 (top left) has 20 terminal screws. Terminal block pin-outs and input
channel assignments are described in Table 24.
Table 2-4: Digital Input Terminal Block TB6 Pin-Outs and Assignments
TB6
TB6
Pin
DESCRIPTION Pin No. DESCRIPTION
No.
0 NOX range 1 10 Calibration
1 SO2 range 1 11 Purge start
2 CO range 1 12 Integration reset
3 CO2 range 1 13 Hold
4 O2 range 1 14 Reserved
5 O2 set value 15 Reserved
6 Hold 16 Reserved
7 Output zero 17 Output span
8 Common 18 Common

2.3.2 Digital Outputs
The ENDA-4000 supports 11 isolated digital output channels that provide signals to
external monitoring devices. Digital outputs are dry-contact type, rated for 1 A, 250 VAC
or 125 VDC resistive load.
All digital output signals terminate at terminal board EN-RR-01. The terminal board has
two terminal blocks, TB7 and TB8, for connection to cable pairs to external devices.
Horiba recommends using two-conductor cables to connect digital outputs to external
devices.
Terminal block TB7 (bottom left) has 30 terminal screws. Terminal block TB8 (top right)
has 30 terminal screws. Terminal block pin-outs and output channel assignments are
described in Tables 25 and 26.
Table 2-5: Digital Output Terminal Block TB7 Pin-Outs and Assignments
TB7
Pin DESCRIPTION
Nos.
01 Alarm
23 Power failure
45 NOX calibration failure
67 SO2 calibration failure
89 CO calibration failure
10 11 CO2 calibration failure
12 13 O2 calibration failure
14 15 Reserved
16 17 Calibrating
18 19 Purging
20 21 Reserved
22 23 Reserved
24 25 Reserved
26 27 Caution
28 29 Holding

Table 2-6: Digital Output Terminal Block TB8 Pin-Outs and Assignments
TB8 TB8
Pin DESCRIPTION Pin DESCRIPTION
No. No.
0 Reserved Blowback 10 Reserved
1 Reserved Blowback 11 CO Common
2 Reserved Blowback 12 CO range 2
3 Reserved Blowback 13 CO range 1
4 O2 Common 14 SO2 Common
5 O2 range 2 15 SO2 range 2
6 O2 range 1 16 SO2 range 1
7 CO2 Common 17 NOX Common
8 CO2 range 2 18 NOX range 2
9 CO2 range 1 19 NOX range 1
2.4 Mechanical Hardware

ENDA-4000 mechanical hardware is described in the subsections that follow.
2.4.1 Sampling Point
The following describes hardware components located at the sampling point.
2.4.1.1. Sample Probe and Mounting Flange
A schedule 40, 316 stainless steel pipe with a 3/4 in. diameter is standard. Optional
lengths and materials are available. The pipe penetrates the stack wall to a point within
the interior of the stack. The length of the pipe penetration into the stack is determined
by the geometry of the stack. The sample probe must be located in a region of the stack
that is subject to representative conditions for mixing and flow. The primary filter
(attached to the end of the mounting flange) can tolerate ambient temperatures up to
482 F. If the temperature of the outer stack wall exceeds this value, the flange must be
lengthened to assure that the primary filter doe not overheat.

The exterior end of the pipe is threaded to a standard 150 lb., 2-in. ASA RF stainless
steel pipe flange. A spacer for introduction of calibration gas is attached to the flange,
and the primary filter assembly is attached to the spacer. A gas-tight, high-temperature
gasket is fitted between the mating surfaces.
Ambient temperature and water vapor content factors may require that the exposed
exterior of the flange be insulated and/or enclosed by an electrically heated jacket to
prevent condensation of water vapor inside the sample probe.
2.4.1.2. Primary Filter (F1)
The primary filter removes dust and foreign matter from the sample gas. The filter
element consists of a cylindrical bellows made of stainless steel and quartz wool. The
filter has a filtration capability of 2.
In applications where the stack gas contains large amounts of dust, Horiba offers an
optional blowback feature that permits a jet of compressed air to periodically blow
accumulated dust out of the primary filter and back into the stack through the sample
probe.
2.4.1.3. Sample Probe Blowback Option
The standard sample probe and primary filter is designed for applications where the
amount of dust in the stack gas does not exceed 0.1 g/m3. For applications where the
dust content of the stack gas lies between 0.1 g/m3 and 1 g/m3, Horiba offers an optional
primary filter assembly that is equipped with a ball-valve and a compressed air input
fitting.
When equipped with the blowback option, customer-supplied compressed air can blow
accumulated dust back through the primary filter and sample probe and into the stack.
The blowback operation is performed automatically under system control.
2.4.1.4. Primary Filter Heater
The primary filter is heated by a 100-watt, self-limiting electric heating element that is
built-into the filter assembly. This heater maintains the filter at approximately 250 F.
Power to the primary filter heater is supplied by an outlet on the rear of the power
distribution junction box. A switch on the front panel controls the heater.
2.4.1.5. Sample Line
The sample line is an un-spliced length of Teflon tubing with an inner diameter of .25 in.
and an outer diameter of .375 in. Ambient temperature and water vapor content factors
typically require that the sample line be enclosed by an electrically heated jacket to
prevent condensation of water vapor inside the sample line.

Sample lines longer than 200 ft. will require that the ENDA-4000 be factory-equipped
with the peristaltic drain pump option.
2.4.1.6. Peristaltic Drain Pump (Option)
The standard sample-handling configuration is designed for applications where the

pressure of the stack gas, at the sample probe inlet, is between 0.0 in. W.C.
(atmospheric pressure) and 5.0 in. W.C. (0.18 psi).
For applications with elevated stack gas pressure (0.18 psi to 10.0 psi), or where the
sample probe encounters a vacuum (0.1 in. W.C. to 140 in. W.C.), Horiba offers an
optional peristaltic drain pump in place of trap T2.
2.4.1.7. Sample Line Heater
Most installation conditions require that the length of the sample line be electrically
heated to prevent condensation of water vapor inside the sample line. In such cases,
Horiba provides an electric heater sleeve, insulation, and a protective cover that
maintains the sample line above the dew point. The sample line heater is rated at 13
watts per foot (45 W per meter) and when properly installed and insulated, will keep the
sample from cooling below 248 F (120 C).
Power to the sample line heater is supplied by wiring from the temperature
controller/indicator. A switch on the front panel of the instrument controls the heater. The
temperature controller provides set-point and control logic, driving the heater through a
solid-state relay. The temperature controller accepts thermocouple or RTD inputs (a J-
type thermocouple is standard).
Under most installation conditions, the last 3 feet of the sample line are left unheated
and un-insulated. This permits radiant cooling to reduce the temperature of the sample
gas to near the ambient before the gas is admitted to the water separator.

2.4.2 Sample Conditioning Equipment
The following describes the hardware components that make up the sample conditioning
system.
2.4.2.1. NH3 Scrubber (Option)
Anhydrous ammonia (NH3) reacts with sulfur dioxide (SO2) in the stack gas in a way that
interferes with accurate measurement of SO2 concentrations by the SO2 analyzer. The
ENDA-4000 is designed for applications where the amount of NH3 in the stack gas does
not exceed 10 ppm. For NH3 concentrations between 10 ppm and 100 ppm (and water
vapor less than 20 vol%), Horiba offers an optional NH3 scrubber that removes NH3 from
the sample gas before interfering reactions with SO2 can occur.
2.4.2.2. HCl Scrubber (Option)
If hydrochloric acid (HCl) is present in the stack gas, it may damage sample-handling
components of the ENDA-4000. For applications where HCl is present in the stack gas,
Horiba offers an optional HCl scrubber that removes HCl from the sample before it is
admitted to the instrument.
2.4.2.3. HF Scrubber (Option)
If hydrofluoric acid (HF) is present in the stack gas, it will damage the optical
measurement cells and other components of the instrument. For applications where HF
is present in the stack gas, Horiba offers an optional HF scrubber that removes HF from
the sample before it is admitted to the instrument.
2.4.2.4. Cl2 Scrubber (Option)
If chlorine gas (Cl2) is present in the stack gas, it will damage sample-handling
components of the ENDA-4000. For applications where Cl2 is present in the stack gas,
Horiba offers an optional Cl2 scrubber that removes Cl2 from the sample before it is
admitted to the instrument.
2.4.2.5. Water Separator (WS1)
The water separator removes condensed water from the sample gas up to the dew point
at the ambient temperature. The condensed water is collected and routed to the overflow
trap, the constant pressure trap, and the reference gas humidifier bath. Excess water is
discharged through the wastewater discharge drain.
For applications where the stack gas contains large amounts of water vapor, Horiba
offers an optional pre-cooler in place of the water separator.

2.4.2.6. Pre-Cooler (Option)
The water separator is designed for an application where the amount of water vapor
does not exceed 20 vol% and the ambient temperature in the ENDA-4000 cabinet never
exceeds 40 C. When either the volume percentage of water vapor or the ambient
temperature exceeds these limits, Horiba offers an optional pre-cooler. The pre-cooler
allows operation with samples containing up to 40 vol% water content.
2.4.2.7. Overflow Trap (TR2)
The overflow trap provides a reservoir for condensed water supplied by the water
separator. The overflow trap prevents excess water from backing-up into sample lines or
entering the instrument.
The overflow trap will allow the sample pumps to draw up to 18 in. W.C. vacuum before
a vacuum release mechanism opens.
2.4.2.8. Mist Catcher (MC1)
The sulfuric acid mist catcher is a reservoir that collects anhydrous sulfuric acid (SO3)
mist before it can damage downstream sample conditioning equipment or the
instrument. The mist catcher requires periodic replacement by the operator.
For applications where an elevated amount of sulfuric acid is found in the stack gas, an
optional high-capacity mist catcher is available.
2.4.2.9. High-Capacity Mist Catcher (Option)
The standard sulfuric acid mist catcher is designed for applications where the amount of
anhydrous sulfuric acid (SO3) in the stack gas is between 20 ppm and 100 ppm. For SO3
concentrations between 100 ppm and 500 ppm, Horiba offers an optional high-capacity
sulfuric acid mist catcher.
2.4.2.10. NOX Converter (COM1-D)
ENDA-4000 configurations that do not measure NOX will not contain a NOX converter.
The NOX converter is a vertically mounted insulated cylinder that contains a catalytic
matrix that converts the nitrogen dioxide (NO2) component of sample gas to nitric oxide
(NO). The converter is heated by a surrounding heating mantle and the entire assembly
is encased in thermal insulation to maintain the catalyst temperature and reduce heat
losses to the surrounding air.
For applications where the stack gas contains large concentrations of NO2, Horiba offers
an optional high-capacity NOX converter.

2.4.2.11. High-Capacity NOX Converter (Option)
The standard NOX converter is designed for applications where the amount of nitrogen
dioxide (NO2) in the stack gas does not exceed 6 ppm. For NO2 concentrations between
6 ppm and 25 ppm, Horiba offers an optional high-capacity NOX converter. The high-
capacity NOX converter contains an enlarged catalytic matrix that converts the nitrogen
dioxide (NO2) component of sample gas to nitric oxide (NO).
2.4.2.12. Secondary Filters (F2 and F3)
A secondary filters remove ultra-fine particulate matter from the sample and reference
gas streams. F2 filters the sample stream and F3 filters the reference gas stream. The
filter element is a replaceable 16 mm diameter borosilicate glass cylinder with a
fluorocarbon binder that catches dust as fine as 0.1 on its surface. The secondary
filters require periodic replacement by the operator.
2.4.2.13. Needle Valve (NV-1)
A manually adjustable needle valve is provided to permit fine adjustment of the flow rate
of the sample gas. The needle valve is adjusted to produce a slow, steady stream of
bubbles in the constant pressure trap, resulting in a flow through the instrument of about
0.5 lpm.
2.4.2.14. Sample Pump (P1)
A Viton diaphragm pump is used to draw sample gas through the sample line and
sample conditioning equipment and discharge the conditioned gas through the
instrument. The pump provides a continuous flow rate of between 4 and 5 lpm.
For applications where the stack gas, at the sample probe, is significantly higher or lower
than atmospheric pressure, Horiba offers an optional bypass and peristaltic sample
pump.
2.4.2.15. Constant Pressure Trap (TR1)
The constant pressure trap acts as a precision backpressure regulator to finely regulate
the flow rates of sample gas and reference gas through the instrument by constantly
bubbling a small amount of gas through water in the trap. Needle valves NV1 and NV2
control the rate at which the gas bubbles through the constant pressure trap. The trap is
made of transparent polycarbonate plastic to facilitate viewing of the bubble streams
when the operator adjusts flow-rate needle valves.

Water for the constant pressure trap is supplied by the water separator and
thermoelectric cooler condensate. Excess water is discharged from the trap through an
overflow tube and is routed to the reference gas humidifier bath.
In applications where the stack gas contains very little water vapor, the constant
pressure trap may not be supplied with sufficient water from the water separator and
must be periodically refilled with water by the operator.
2.4.2.16. Solenoid Valves (SVx)
Solenoid valves route sample and reference gas through the instrument as required. The
solenoid valves are powered by the low-voltage power supply (PS-1) and are activated
by signals from the instrument.
2.4.2.17. Thermoelectric Cooler (TEC)
The thermoelectric cooler uses an impinger to remove remaining water vapor from the
sample gas by cooling the gas from the ambient temperature to approximately 5 C. A
low flow of gas through the cooler drain port sweeps moisture through the impinger.
Condensate from the thermoelectric cooler is routed to the constant pressure trap.
The impinger is made of 316 stainless steel or Kynar, depending upon the application.
The thermoelectric cooler is a solid-state device with no moving parts or circulating

refrigerant gases. The unit is equipped with a built-in miniature fan that operates
continuously to cool the hot heat exchange surface.
For applications where the stack gas contains large amounts of water vapor, Horiba
offers an optional pre-cooler in place of the water separator.
2.4.2.18. Sample Flow Meter (FM-1A)
A sample flow meter is mounted on the front panel of the instrument. This meter
provides a visible indication of the sample flow rate through the instrument. The flow rate
is set by pressure in the constant pressure trap (TR1). If the trap is full of water and is
bubbling, the sample flow meter will indicate maximum flow. If the trap is not functioning,
the flow meter will indicate zero flow.

2.4.3 Reference Gas Conditioning Equipment
The following hardware components make up the reference gas conditioning subsystem.
2.4.3.1. Humidifier Bath (HB1)
The reference gas humidifier bath is used to humidify the reference gas, at ambient
temperature, before submitting the gas to a controlled drying step. This function reduces
measurement errors by assuring that sample gas and reference gas are both at the
same dewpoint before they are supplied to the instrument.
The overflow drain from the constant pressure trap supplies the humidifier bath water.
Excess water in the humidifier bath is discharged through an overflow tube and is routed
to the wastewater discharge drain.
In applications where the stack gas contains very little water vapor, the humidifier may
not be supplied with sufficient water from the water separator. In this case, the operator
must periodically refill HB1 with water through the constant pressure trap (TR1).
2.4.3.2. CO Purifier (PUR)
When the ENDA-4000 is factory-configured to measure carbon monoxide (CO), the

ambient air used as a reference gas must be free of trace amounts of interfering CO.
Horiba installs a reference gas CO purifier that uses an electrically-heated catalyst to
convert CO in the ambient air to CO2. The purified air may then be used as a reference
gas for the CO analyzer.
ENDA-4000 configurations that do not measure CO will not be equipped with a CO

purifier.
2.4.3.3. Reference Gas Scrubber (SCR-1)
For ENDA-4000 systems configured without a carbon monoxide analyzer, a reference

air scrubber, made of activated charcoal in a reservoir, is installed to scrub interferent
gases from the reference gas stream.
2.4.3.4. Reference Gas Filter (FA-1)
Filter FA-1 uses a replaceable mesh screen to remove dust from the gas stream before
the gas is admitted to the instrument. ENDA-4000 configurations that do not measure
oxygen concentrations will not be equipped with filter FA-1.

2.4.3.5. Needle Valves (NV-1, NV-2, NV-3)
Needle valve NV1 is used to finely regulate the flow rate of sample gas by adjusting the
stream of bubbles in the constant pressure trap, resulting in a sample gas flow through
the instrument of about 0.5 lpm.
Needle valve NV2 regulates the flow rate of reference gas through the constant pressure
trap, resulting in a reference gas flow through the instrument of about 0.5 lpm.
Needle valve NV3 regulates the flow rate of reference gas to the oxygen analyzer.
2.4.3.6. Reference Gas Pump (P2)
The reference gas pump is identical to sample pump P1.
2.4.3.7. Buffer Tank (BT1)
A buffer tank is used to prevent pump pulsations in the reference gas stream before the
reference gas is admitted to the oxygen analyzer. ENDA-4000 configurations that do not
measure oxygen concentrations will not be equipped with this buffer tank.
2.4.3.8. Desiccant Gas Drier (SG)
The silica gel gas drier is used to remove water, under controlled conditions, from the
ambient air that will be used as a reference gas for the oxygen analyzer. The silica gel
gas drier requires periodic replacement by the operator.
ENDA-4000 configurations that do not measure oxygen concentrations will not be

equipped with a silica gel gas drier.

2.5 Instrument
The ENDA-4000 XS instrument is a collection of analyzer modules that are custom-
ordered to provide accurate measurement of the stack gas components and
concentration ranges of interest. The most basic ENDA-4000 configuration may include
only a single analyzer module, (for example a NOX analyzer), that would measure only
one component of the stack gas. A fully equipped ENDA-4000 configuration would
include five analyzer modules that are capable of measuring ppm concentrations of NOX,
SO2, and CO, and volume percentage concentrations of CO2, and O2.
The front panel of the instrument features a display and control buttons. The front panel
is illustrated in Figure 22 and the rear panel is illustrated in Figure 23.
Figure 2-2: XS Instrument Front Panel
8
1 3 4
2 5 6 10 11 12 14 13
Figure 2-3: XS Instrument Rear Panel

Table 2-7: XS Instrument Rear Panel Elements
ITEM
DESCRIPTION
No.
1 CFA analyzer exhaust (1/8 in. ISO 7/1 threaded)
2 MPA analyzer exhaust (1/8 in. ISO 7/1 threaded)
3 Bypass outlet (1/8 in. ISO 7/1 threaded)
4 Sample inlet (1/8 in. ISO 7/1 threaded)
5 Reference gas inlet (1/8 in. ISO 7/1 threaded)
6 OPE gas (air) inlet (1/8 in. ISO 7/1 threaded)
7 Power switch
8 Fuse holder (for replaceable cartridge fuse)
9 Recessed socket (mates with three-conductor power cord)
10 24 VDC power input receptacle
11 Solenoid valve connector (to 40-pin, female)
12 Option connector (50-pin, female)
13 Analog signal connector (30-pin, female)
14 Horiba service test connector
Note: Connectors 1 through 6 are factory-fitted with polypropylene tube connectors that
will accept 6 mm O.D. x 4 mm I.D., and 0.125 in. O.D. x 0.1875 in. I.D. Teflon tubing.

2.6 Chassis
The following describes items commonly found with the equipment housing.
2.6.1 Cabinet
The ENDA-4000 is contained inside a single-bay rack-mount cabinet. The cabinet is

illustrated on the following page in Figure 24. The dimensions and required clearances
of the cabinet are described in Table 28 following the illustration.
2.6.2 Access Panels and Doors
The ENDA-4000 cabinet is equipped with front and rear doors. Hinges attach the front
and rear doors. To remove a door, unbolt the door from the hinge.
To preserve a stable thermal environment around the sample conditioning equipment

and instrument, the cabinet doors should be kept closed when the ENDA-4000 is
operating.
2.6.3 Ventilation Fan
A low-speed fan that draws room air into the enclosure through ventilation holes cools
the standard NEMA-12 type enclosure and a disposable filter mounted on the lower half
of the rear door.
ENDA-4000 systems supplied in a NEMA-4 type cabinet do not include a ventilation fan.
2.6.4 Air Conditioner (Option)
For high-temperature operating environments, Horiba offers an optional air conditioning

subsystem that forces cooled air through the cabinet when the ambient temperature
exceeds 40C.
ENDA-4000 systems supplied in a NEMA-4 cabinet are equipped with the air conditioner
in place of the ventilation fan.

Figure 2-4: ENDA-4000 Cabinet

Table 2-8: ENDA-4000 Cabinet Dimensions and Required Clearances
DIMENSION UNITS (metric)

Height 75 in. (190.5 cm)
Width (without air conditioner) 25 in. (63.5 cm)
Width (with air conditioner) 33.5 in. (85.1 cm)
Depth 32 in. (81.3 cm)
Front Clearance 36 in. (91.5 cm)
Right Side Clearance 31.5 in. (80.0 cm)
Rear Clearance 28 in. (71.1 cm)
Top Clearance 6 in. (15.2 cm)
Weight 660 lb. (300 kg)

3.0 Theory of Operation
3.1 Sample Collection
Powered by a continuously operating, corrosion-resistant (Viton) diaphragm pump, a
stream of sample gas is extracted from the stack through a stainless steel sample probe.
The probe penetrates the stack wall at a location where the stack gas flow and
temperature are stable. The probe delivers the sample gas stream to an electrically
heated primary filter assembly which extracts dust particles larger than 2 from the
sample. The primary filter is heated to prevent water vapor condensation in the filter
assembly.
When high-dust content is expected, the primary filter may be ordered from the factory
with a blowback option, which allows connection to a dry compressed air source. Under
ENDA-4000 program control a solenoid valve and motor-driven ball valve assembly may
be periodically opened to blow accumulated dust particles out of the filter and probe and
back into the stack.
The filtered sample gas stream passes downward, through the sample line to the sample
inlet of the ENDA-4000 instrument. Depending upon the water vapor content of the
sample, the ambient temperature, and expected cold-season temperatures, the sample
line may be insulated or even electrically heated to control the temperature of the
sample gas before it enters the ENDA-4000 sample inlet. The objective is to use radiant
cooling to reduce the temperature of the sample gas from the stack temperature down
to near the ambient temperature just prior to admitting the sample to the system.
Under some operating circumstances, the dew point of the sample gas may be higher
than the ambient air temperature, resulting in water vapor condensing near the bottom of
the sample line. In such cases, the sample line must slope into the water separator
where the condensed water can drain.
If the sample line becomes blocked or its flow is severely restricted during operation, a
vacuum switch senses excessive sample line vacuum and the control program indicates
an alarm.
3.2 Sample Conditioning

The ambient-temperature sample enters the ENDA-4000 sample inlet and is routed to
the water separator. This element separates water from the sample gas stream up to the
dew point at ambient temperature. The collected water is sent to the overflow trap, the
constant pressure trap, and the reference gas humidifier. Excess water is discharged
from the instrument through the condensate discharge line.
The sample is next routed through the mist catcher. The mist catcher traps any sulfuric
acid mist present in the sample.

ENDA-4000 Manual Chapter 3: Theory of Operation
If the ENDA-4000 is configured to measure NOX emissions, the sample is next routed to
an electrically heated catalytic converter that converts NO2 in the sample gas to NO.
The sample gas is then passed through a secondary filter that eliminates ultra-fine dust
particles from the sample gas stream. After leaving the filter, the sample passes through
a manually adjustable Teflon needle valve that is used to regulate the flow rate of the
sample and assure that the sample is supplied to the analyzer at the correct flow rate.
The sample gas stream then passes through a Viton diaphragm pump and is discharged
through a thermoelectric cooler. The cooler reduces the temperature of the sample from
the ambient to approximately +5 C. This has the effect of condensing additional water
vapor from the sample gas stream (the sample will still contain about 5000 ppm H2O).
The condensate is collected and routed to the constant pressure trap.
The cooled and dried sample gas stream is next admitted to the analyzer where it is
passes through another filter and is sent to the NDIR subsystem. If the instrument is
configured for oxygen analysis, the sample is divided into two streams for admission to
the NDIR analyzer and the optional MPA oxygen analyzer. Each analyzer is equipped
with a flowmeter that indicates the rate at which sample gas is flowing through the
analyzer. The cross-flow design requires very-low sample gas flow rates: typically 0.5
lpm of sample and reference gas.
Following processing by the analyzer(s), the sample gas stream is routed to the sample
outlet, where it must be carried away by customer-supplied piping and discharged safely
outside the building.
3.3 Cross-Modulation NDIR Analysis

The ENDA-4000 uses the non-dispersive infrared absorbtiometry (NDIR) method to
measure the NOX, CO, CO2, and SO2 components of the sample gas. A twin-detector
(five-sensors) NDIR subsystem is used to measure NOX, CO2 and SO2. A single-detector
subsystem, on a separate optical path, measures CO. (Oxygen measurement is
performed by an MPA subsystem, described later in this chapter.) No optical alignment
of the detectors is required.
A schematic illustration of the NDIR analyzer is shown in Figure 31.

Chapter 3: Theory of Operation ENDA-4000 Manual
MAIN
NOX Detector
1
Light Beam Beam
Source Splitter Splitter Subtraction Subtraction
Measured
Measurement Value of
Cell NOx
2 1
CO2 COMP
Sensor
COMP MAIN
SO2 Detector
Subtraction
Measured
Value of
SO2
CO2 Signal
Reference Gas
(zero gas)
MAIN
CO
Detector
Sample Gas
Subtraction
Light
Source Measured
Measurement value of CO
Cell
COMP
Figure 3-1: NDIR Analyzer Schematic
To measure NOX, CO2 and SO2, the sample gas and the reference (zero) gas are
alternately routed to the measurement cell by continuous switching of the solenoid
valves. The flow rates for both gases have been adjusted to be equal. At the
measurement cell, infrared light from the IR source passes through the measurement
cell and enters a detector.

The NOX, CO2 and SO2 components of the sample gas absorb infrared light; the zero
gas does not. Infrared light generated from the infrared source passes through the
measurement cell and enters a detector containing the gas to be measured. When the
reference gas is sent to the measurement cell, more infrared light reaches the detector;
when the sample gas is sent to the measurement cell, less infrared light reaches the
detector. Thus, the infrared light intensity reaching the detector is modulated. The
degree of this modulation is directly related to the concentration of sample gas in the
measurement cell. The frequency of the signal is related to the flow rate; the amplitude is
related to the concentration. The flow rate is precisely controlled and must remain
constant during measurement.
Each detector contains a movable membrane that detects pressure changes in the
optical cell. If there is a difference in absorbed energy between the reference gas and
the sample gas, a pressure change occurs within the optical cell and is detected. This
difference is amplified and output as an electrical signal.
No membrane displacement occurs when the concentration of the measured gas does
not change during a cycle (i.e. the sample gas concentration is the same as the
reference gas concentration). Therefore, when the same gas is sent to both the sample
and reference lines, the detector produces a zero output with essentially no drift.
Variations in infrared source intensity and/or accumulations of deposits on the
measurement cell windows affect the sample and reference measurements to the same
degree and thus produce no zero drift.
A beam-splitter is used to divide the infrared source output between the NOX and SO2
detectors. The CO detector is located in an independent optical system.
The NOX and SO2 detectors are arranged with two optical cells in series to sense
measured components and interference components. This arrangement provides a
method of reducing the effect of interference gases present in the sample gas stream.
The main detector senses both measured components and interference components.
The compensation detector senses interference components only.
H2O and CO2 are the chief interferents in the NDIR measurement of NOX. The ENDA-
4000 minimizes the effects of these interferents by using a compensating detector for
H2O and by using the CO2 detector. The output from the CO2 detector is used to correct
the NOX signal for interference caused by the presence of CO2. This correction is made
in real-time by the analyzer electronics. For analyzers configured to measure SO2, a
compensating detector for H2O is provided. This arrangement ensures stable signals
with minimal levels of interference.

3.4 Chemiluminescent Measurement of NOX

(Option)
The ENDA-E4000 can be optionally configured to measure NOX using the
Chemiluminescent NOX Analyzer (CLA) method of analysis (Figure 3-2). The CLA NOX
measurement is not cross-modulated. In some CLA NOX configurations the ENDA-
E4000 will require two 19-inch rack-mounted analyzer enclosures.
The chemiluminescent NOX measurement is based on the chemical reaction that occurs
between the analyte NO and internally generated ozone (O3). Under certain conditions,
the reaction between these two chemicals results in light being emitted. This
chemiluminescent reaction extends from the red to the infrared spectrum. Under certain
conditions, the light can be measured and its intensity will be proportional to the
concentration of NO present.
Figure 3-2: CLA NOX Analyzer Schematic
NO2 will not participate in the chemiluminescent reaction. A NO2-to-NO converter is

installed in the sample system upstream of the CLA NOX detector. The ENDA-4000 CLA
NOX detector operates at atmospheric pressure and uses a solid-state light detector for
superior temperature stability. The CLA NOX measurement is less subject to interfering
components than the NDIR measurement. This allows the CLA NOX to have lower
detection limits.
A sample of NO is introduced into a tee upstream of the detector. The other side of the
tee supplies a flow of clean, dry air at 10 times the sample flowrate. This dilutes the
sample minimizing CO2 interference and lowering the concentration of O3 necessary to
create the chemiluminescent reaction. An internal ozone generator uses the same dry
air to supply high concentrations of ozone. The diluted sample and O3 are mixed
together in a chamber in front of the solid-state light detector. The detector will measure
the light from the chemiluminescent reaction. The reacted sample flows out of the
detector and into a deozonator to scrub the remaining O3 before it is exhausted out of
the ENDA-4000 system.

3.5 Magneto-Pneumatic Measurement of

Oxygen
The ENDA-4000 uses the magneto-pneumatic analysis (MPA) method to measure the
concentration of oxygen in the sample gas. A schematic illustration of the MPA analyzer
is shown in Figure 32.
Sample Gas
Outlet Magnet
Magnetic
Field Cell
Detector
Reference Sample Gas

Air Inlet Inlet
Figure 3-3: MPA Analyzer Schematic
Oxygen behaves as a paramagnetic gas in the presence of an uneven magnetic field.

When an uneven magnetic field is applied to a paramagnetic gas, the gas is attracted
towards the strongest region of the field, raising the pressure in that region. A sample
gas containing a large volume of oxygen will move vigorously in the presence of a strong
oscillating magnetic field. A sample containing a relatively small volume of oxygen will
move relatively less and a sample containing no oxygen will not change pressure in a
magnetic field.
The MPA analyzer excites an electromagnet to create pressure changes in the

measurement cell. A capacitor microphone detects the pressure changes and converts
them to an electronic signal. The output of the detector is linear with the concentration of
oxygen.

The MPA analyzer uses purified dried ambient air as a reference gas. Ambient air
contains 20.9 percent oxygen by volume and sample gas ordinarily contains less
oxygen. Thus when the signal from the reference gas (20.9% O2) is compared to the
signal from the oxygen-depleted sample gas, the sample gas will produce an attenuated
signal that is proportional to the volume of O2 present. A sample gas containing no
paramagnetic gas (e.g. no oxygen) will produce a detector signal of zero.
3.6 Reference Gas Conditioning

The ENDA-4000 uses purified ambient air as a reference gas source for the NDIR and
MPA analyzers. A separate continuously operating diaphragm pump powers the
reference gas conditioning subsystem. Ambient air is collected from the room and
passed through a scrubber and a particulate filter to eliminate dust from the reference
gas stream. If the ENDA-4000 is configured to perform oxygen measurements, the
reference gas stream is divided into two streams.
NDIR Reference Gas Stream

The NDIR reference gas stream first passes through an ultra-fine particulate filter (FA1).
After leaving the filter, the gas flows through a gas humidifier (supplied with water by
condensate from the sample gas water separator). If the analyzer is configured for low-
concentration carbon monoxide measurements (in the 500 ppm range), the humidified
stream is passed through a hydrocarbon scrubber and an electrically-heated catalytic
purifier element that converts trace CO in the ambient air into CO2, thereby reducing the
amount of contaminating CO in the reference gas to a sub-parts-per-million level. If the
analyzer is not configured for low-concentration carbon monoxide measurements, the
stream is passed through a hydrocarbon scrubber only.
Next the NDIR reference gas stream flows through a second filter and through a
manually-adjustable needle valve which is used to regulate the flow rate of the reference
gas stream and assure that it is supplied to the analyzer at the correct flow rate. The flow
rate of reference gas through the analyzer is typically 0.5 lpm.
The reference gas stream then passes through a separate diaphragm pump and is
discharged via a separate path through the thermoelectric cooler. The cooler reduces
the temperature of the reference gas stream from the ambient to approximately +5 C.
This has the effect of condensing all water vapor from the gas.
The cooled and dried reference gas stream is admitted to the reference inlet of the NDIR
analyzer where solenoid valves control its entry into the measurement cells. Following
processing by the analyzer, the reference gas stream is discharged from the analyzer
into the waste stream.

MPA Reference Gas Stream

The MPA reference gas stream passes through the reference gas pump and is routed
through a desiccant where water vapor is removed from the gas. An attached buffer tank
stabilizes the flow of gas by reducing the effect of pump pulsations on the flow. The
reference gas stream passes through an ultra-fine dust filter and then is admitted to the
reference inlet of the MPA (oxygen) analyzer, where it passes through the cell at a 12
ml/min. flow rate. The MPA reference gas is then discharged from the analyzer into the
waste stream.
3.7 Analyzer Calibration

Zero and span gas cylinders, used to calibrate the analyzers, are connected through
flow regulators to a group of solenoid valves that discharge into a manifold. The manifold
supplies a pressurized line that carries the calibration gases to an inlet connector on the
primary filter, next to the sample probe. A check-valve in the primary filter prevents
calibration gas backflow into the stack. During calibration, the zero and span gases are
filtered, cooled, and dried by the same apparatus that conditions the sample gas. This
design routes calibration gas through all out-of-stack components and filters. This
method assures that analyzer calibration and measurement functions are performed
under identical supply conditions and reduces variability and errors in measurement.
3.8 Flow Diagram

A flow diagram of a typically configured ENDA-4000 system is illustrated in Figure 34.

Figure 3-4: ENDA-4000 Flow Diagram (Typical)


4.0 XS Analyzer
4.1 Overview
This chapter provides descriptions of the XS analyzer controls and indicators and
provides detailed procedures and examples for setup and operation of the analyzer.
The XS analyzer front panel, as it would appear during normal operation, is illustrated in
Figure 41. The example shows that the analyzer is in measurement mode and no
alarms are active. The gas indicator shows that the oxides of nitrogen (NOX)
measurement is currently displayed. The measurement range for NOX is 0 100 ppm
and the currently measured concentration of NOX in the sample gas is 60.0 ppm.
Figure 4-1: XS Analyzer in Operation
4.2 Analyzer Controls

The analyzer is controlled by two sets of labeled pushbuttons. The operator controls are
arranged as a row of eight buttons along the bottom of the front panel (see Figure 42).
The setup controls are arranged as two rows of three buttons behind a screw-attached
panel on the front of the analyzer cabinet (refer to Figure 43).

ENDA-4000 Manual Chapter 4: XS Analyzer
4.2.1 Operator Controls
Figure 4-2: Front Panel Operation Controls
The front panel control buttons are used to perform the typical daily activities associated
with the analyzer. These buttons and their functions are described, from left to right, as
follows:
SELECT Selects a measured gas (NOX, SO2, CO, CO2, O2.) for
concentration display or for span setting.
Right Arrow Selects a digit displayed on the concentration or range

display.
Up Arrow Increases the value of the selected digit.
RANGE Changes the measurable range.
FUNCTION Selects an analyzer function (span gas set, time, AIC start,
AIC interval, purge start, purge interval, or measurement
mode).
GAS MODE Allows manual selection of a calibration gas.
CAL Performs a calibration using the selected calibration gas.
AIC Starts (and aborts) the automatic instrument calibration

process.

Chapter 4: XS Analyzer ENDA-4000 Manual
4.2.2 Setup Controls
Figure 4-3: Setup Controls (Behind Panel Door).
The setup controls are used to perform infrequently needed functions such as calibration
set-up and alarm display. The operator must unscrew and open the panel at the center
of the analyzer cabinet to expose these buttons. These buttons and their functions are
described, from top left to bottom right, as follows:
PURGE Performs a probe and primary filter blowback.
INT Reserved for use by Horiba service.
SET UP Allows selection of each of ten set-up functions.
RES 1 Selects and exits check alarm mode.
RES 2 Clears an active alarm or caution.
RES 3 Reserved for use by Horiba service.

4.3 Analyzer Displays and Indicators

The front panel of the XS analyzer features two methods of displaying information. Two
segmented electroluminescent displays (concentration and range) are used to show
alphanumeric data, values, prompts, and messages. Twenty-seven illuminated
indicators provide a variety of status information. These displays and indicators are
explained in the text that follows.
4.3.1 Alphanumeric Displays
The analyzer features two alphanumeric displays: one is used primarily to display
concentration values and the other is used primarily to display range values. The
concentration display is about 50% larger than the range display. Both can display up to
four characters plus a decimal point.
The concentration display is illustrated in Figure 44. This illustration shows the display
with all character segments illuminated.
Figure 4-4: Concentration Display
The range display is illustrated in Figure 45. This illustration shows the display with a
typical set of character segments illuminated.
Figure 4-5: Range Display
4.3.2 Indicators
The analyzer also uses twenty-seven backlit labeled indicators to provide status and
fault information. Figure 46 shows the analyzer front panel as if all 27 indicators were
illuminated (in normal operation, all indicators would never be illuminated at the same
time). The name and function of each indicator is explained in the text that follows.
NOTE: For the purposes of illustration, a five-gas analyzer is shown. Your XS analyzer
may be configured for fewer than five gases, in which case some of the examples may
not apply to your system.

Figure 4-6: XS Analyzer Indicators
The indicators are grouped roughly into seven columns. Beginning at the far right edge
of the panel, the first column indicates the measured gas that is selected for display:
NOX Indicates that oxides of nitrogen (NOX) is the currently-selected measured gas.
SO2 Indicates that sulfur dioxide (SO2) is the currently selected measured gas.
CO Indicates that carbon monoxide (CO) is the currently selected measured gas.
CO2 Indicates that carbon dioxide (CO2) is the currently selected measured gas.
O2 Indicates that oxygen (O2) is the currently selected measured gas.
The second column is associated with analyzer status:
MAT Indicates that the displayed value is being corrected to an O2.concentration.
EXT Indicates that the measurable range is controlled by an external input.

The third column is located immediately to the right of the concentration display. The two
indicators show the appropriate units notation for the value displayed on the
concentration display:
vol % Indicates that the displayed concentration is expressed as a volume

percentage (vol %).
ppm Indicates that the displayed concentration is expressed in parts per million
(ppm).
The fourth column is associated with operator-selectable functions:
SPAN GAS SET Indicates that span gas concentration entry function is active.
TIME Indicates that the time entry function is active.
AIC START Indicates that the automatic instrument calibration (AIC) start time
entry function is active.
AIC INTERVAL Indicates that the automatic instrument calibration (AIC) interval entry
function is active.
PURGE START Indicates that the purge start time entry function is active.
PURGE INTERVAL Indicates that the purge interval entry function is active.
The fifth column is associated with measurement and calibration selections:
MEAS Indicates that the analyzer is in measurement mode.
NOX Indicates that the NOX analyzer has been selected for calibration.
SO2 Indicates that the SO2 analyzer has been selected for calibration.
CO Indicates that the CO analyzer has been selected for calibration.
CO2 Indicates that the CO2 analyzer has been selected for calibration.
O2 Indicates that the O2 analyzer has been selected for calibration.

The sixth column provides additional calibration status information:
ZERO Indicates that the associated zero calibration gas has been selected.
SPAN Indicates that the associated span calibration gas has been selected.
DELAY Indicates that the analyzer has switched from calibration gas to sample
gas and is waiting for the concentration measurements to stabilize.
The seventh (rightmost) column provides status and alarm information:
PURGE Indicates that a probe and primary filter blowback (purge) is in progress.
The purge function is a factory-configured option.
ALARM Indicates that an alarm condition exists.
CAUTION Indicates that a caution condition exists.
4.4 Instrument Operations

This subsection provides detailed, step-by-step procedures for operating the ENDA-
4000 system. Each operator-controlled function is explained and illustrated with
examples.
4.4.1 Span Gas Set
The ENDA-4000 analyzer requires accurate entry of span gas concentrations for all
ranges of each measured gas. To display and/or set span gas concentrations, perform
the following steps:
1. Make certain that the analyzer is in measurement (MEAS) mode before proceeding.
2. Press the FUNCTION button once. The front panel displays and indicators will
change as follows:
The MEAS indicator will be extinguished and the SPAN GAS SET indicator will be
illuminated.
The indicator for the currently selected span gas will be illuminated.
The concentration display will show the currently specified concentration of the
selected span gas.
The range display will show the currently selected range for the span gas.

Figure 47 shows the front panel when the analyzer is in span gas set mode. The
selected span gas is carbon monoxide (CO), the current span concentration is 100 ppm,
and the selected span range is 0 100 ppm.
Figure 4-7: Example CO Span Gas Selected
3. Press the SELECT button repeatedly to select the span gas to be set. Each time
the SELECT button is pressed, the indicator for the next available span gas is
illuminated. When the associated indicator is illuminated, the span gas has been
selected.
4. If your analyzer was factory-configured for two ranges for the selected span gas,
press the RANGE button to toggle between the two ranges. When the range
display shows the correct value, the range has been selected.
5. If the selected span concentration is correct, no further action is required Press the
FUNCTION button to return to measurement mode.
6. If the span concentration is incorrect, press the right arrow button. The leftmost
digit on the display will begin to blink.
7. To change the value of the blinking digit press the up arrow button. The digit will be
incremented by one each time the button is pressed. When the value reaches 9,
pressing the up arrow button causes the value to rollover to 0.
8. When the first digit is correct, press the right arrow button once. The second digit
on the display will begin to blink.
9. Press the up arrow button to increment the displayed value. The second digit can
be set to 0 through 9.

10. When the second digit is correct, press the right arrow button once. The third digit
11. Press the up arrow button to increment the displayed value. The third digit can be
set to 0 through 9.
12. When the third digit is correct, press the right arrow button once. The rightmost
13. Press the up arrow button to increment the displayed value. The fourth digit can be
set to 0 through 9.
14. When all four displayed digits are correct, span concentration entry for the selected
gas and range is complete.
15. To display and/or set the span gas concentration(s) for additional gas(es) repeat
steps 2 through 15.
16. When all span gas entries are complete, press the FUNCTION button to return to
measurement mode.
4.4.2 Set System Time and Date
The ENDA-4000 analyzer uses an internal clock to control the timing of automatic
operations. The time may be displayed and/or reset by the operator. The analyzer uses
24-hour time notation (e.g. 1:00 p.m. is 13:00). To display and reset the time of day,
perform the following steps:
1. Make certain that the analyzer is in measurement (MEAS) mode before

proceeding.
2. Press the FUNCTION button twice until the TIME indicator is illuminated.
3. The analyzer responds by displaying the current clock setting on the four-digit
concentration display. The reading will be formatted in 24-hour notation. See
Figure 48.
Figure 4-8: Analyzer Clock Display 2:35 P.M. (example)
4. If the reading is correct, no further action is required. Press the FUNCTION button
until the display returns to measurement mode.

5. If the reading is incorrect, press the right arrow button. The leftmost digit on the
display will begin to blink.
incremented by one each time the button is pressed. The leftmost digit can only be
set to 0, 1, or 2. When the display reaches 2, pressing the up arrow button causes
the value to rollover to 0.
incremented by one each time the button is pressed. When the display reaches 9,
pressing the up arrow button causes the value to rollover to 0. The second digit
can be set to 0 through 9.
set to 0 through 9.
11. When the third digit is correct, press the right arrow button once. The rightmost
set to 0 through 9.
13. When all four displayed digits are correct, press the right arrow button once. The
decimal point on the display will begin to blink.
14. Time entry is now complete. Press the FUNCTION button five times to return to
measurement mode.
4.4.3 Automatic Instrument Calibration
The Automatic Instrument Calibration (AIC) function automatically performs zero and
span calibrations for all measured gases. The analyzer clock controls the AIC function.
The user must specify the time interval between automatic calibrations (AIC Interval) and
the time at which the AIC interval cycle shall begin (AIC Start). These two AIC setup
procedures are described in the text that follows.

4.4.4 Automatic Instrument Calibration Start
The automatic instrument calibration start is a day offset (from today) and a time of day
value when the automatic calibration cycle should begin.
1. Make certain that the analyzer is in measurement (MEAS) mode before proceeding.
2. Press the FUNCTION button three times. The front panel displays and indicators will
change as follows:
The MEAS indicator will be extinguished and the AIC START indicator will be
illuminated.
The concentration display will show the number of days that will elapse before the
AIC cycle begins. A zero indicates that the calibration will occur when the indicated
time is reached. A 1 indicates that the calibration will occur at the indicated time
tomorrow.
The range display will show the currently selected hour of the specified day when the
AIC cycle will begin.
Figure 49 shows the front panel when the analyzer is in AIC start mode. The AIC cycle
is set to begin after 1 day at 13:00 hours (1:00 p.m.). Thus the first automatic calibration
will occur tomorrow at 1:00 p.m.
Figure 4-9: AIC Start After 1 Day at 13:00 Hours (example)

3. If the AIC start time is correct, no further action is required. Press the FUNCTION
button to return to measurement mode.
4. To change AIC start time press the right arrow button. Observe the concentration
display. The digit to the left of the day label will begin to blink.
5. Select a day value, between 0 and 9, when the automatic instrument calibration
cycle should begin. Select 0 to choose today; select 1 to choose a one-day
delay, etc. The longest delay that may be entered is 9 days.
incremented by one each time the button is pressed. The day digit can only be
set to 0 through 9. When the display reaches 9, pressing the up arrow button
causes the value to rollover to 0.
7. When the desired day value is displayed, press the right arrow button once.
Observe the range display. The first digit on the display will begin to blink.
8. Select a time of day, (24-hour notation) between 00 and 23, when the AIC cycle
should begin. If you selected 0 days in step 6, (i.e. you wish to start the AIC cycle
today), you must choose a starting time that is after the current time today. For
example, if you wish to start the AIC cycle today and it is now 9:00 a.m., you must
select a start hour that is after 9:00 a.m. (i.e. 10 or above). The analyzer will not
allow you to set an invalid hour: only 00 through 23 are valid.
9. To change the value of the first blinking digit press the up arrow button. The digit
will be incremented by one each time the button is pressed. The first hour digit can
only be set to 0, 1, or 2. When the display reaches 2, pressing the up arrow button
11. Press the up arrow button to increment the displayed value. If the first digit has
been set to 0, 1 or 2, the second digit can be set to 0 through 9.
12. When both displayed digits are correct, AIC start entry is complete. Press the
FUNCTION to return to measurement mode.
NOTE: Both AIC start time and AIC interval must be correctly entered for the automatic
instrument calibration feature to operate properly.

4.4.5 Automatic Instrument Calibration Interval
The automatic instrument calibration interval is the amount of time that must elapse
between calibrations. The user may select from ten available settings: 12 hours, 1 day, 2
days, 3 days, . . . up to a maximum of 9 days.

proceeding.
2. Press the FUNCTION button four times. The front panel displays and indicators will
change as follows:
The MEAS indicator will be extinguished and the AIC INTERVAL indicator will be
illuminated.
The concentration display will show the currently selected number of days between
automatic calibrations.
The range display will show zero (0) or twelve (12). Twelve indicates automatic
calibration will be performed every 12 hours.
Figure 410 shows the front panel when the analyzer is in AIC interval mode. The
current AIC interval is set at 12 hours, which means that the analyzer will perform two
automatic calibrations each day.
Figure 4-10: AIC Interval of 12 Hours (example)

3. If the AIC interval is correct, no further action is required. Press the FUNCTION
4. To change AIC interval, press the up arrow button. Observe the concentration and
range displays. The digit to the left of the day label and the two digits in the range
5. Each time the up arrow button is pressed, the displays will show the next allowed
interval value. When 9 day, 00 hour is displayed, pressing the up arrow button
causes the value to roll over to 0 day, 00 hour.
IMPORTANT: If your analyzer is configured for automatic calibration control by an

external host computer or other device, you must set the AIC interval to 0 day, 00 hour.
6. When the correct interval value is selected, AIC interval entry is complete. Press
the FUNCTION button to return to measurement mode.
NOTE: Both AIC start time and AIC interval must be correctly entered for the automatic
instrument calibration feature to operate properly.
4.4.6 Purge (Blowback) Setup
The purge function automatically performs a primary filter and probe blowback operation.
The analyzer clock controls the blowback functions. The user must specify the time
interval between blowbacks (Purge Interval) and the time at which the blowback interval
cycle shall begin (Purge Start). These two setup procedures are described in the text
that follows.
The purge functions only apply to ENDA-4000 systems that have been factory-equipped
with the automatic probe and filter blowback option. On systems not equipped with this
option, the purge functions are not connected.
4.4.7 Purge Start (optional)
The purge start is a day offset (from today) and a time of day value when the automatic
blowback cycle should begin.

proceeding.
2. Press the FUNCTION button five times. The front panel displays and indicators will
change as follows:
The MEAS indicator will be extinguished and the PURGE START indicator will be
illuminated.

The concentration display will show the currently specified number of days that will
elapse before the blowback cycle begins.
The range display will show the currently selected hour of the specified day when the
blowback cycle will begin.
Figure 411 shows the front panel when the analyzer is in purge start mode. The
blowback cycle is set to begin after 2 days at 18:00 hours (6:00 p.m.). Thus the first
blowback will occur the day after tomorrow at 6:00 p.m.
Figure 4-11: Purge Start After 2 Days at 18:00 (example)
3. If the purge start time is correct, no further action is required. Press the FUNCTION
4. To change purge start time press the right arrow button. Observe the concentration
display. The digit to the left of the day label will begin to blink.
5. Select a day value, between 0 and 9, when the automatic blowback cycle should
begin. Select 0 to choose today; select 1 to choose a one-day delay, etc. The
longest delay that may be entered is 9 days. This value is usually set to zero (0)
to immediately start a blowback cycle when the start time is reached.
incremented by one each time the button is pressed. The day digit can only be
set to 0 through 9. When the display reaches 9, pressing the up arrow button
7. When the desired day value is displayed, press the right arrow button once.
Observe the range display. The first digit on the display will begin to blink.

8. Select a time of day, (24-hour notation) between 00:00 and 23:59, when the
blowback cycle should begin. If you selected 0 days in step 6, (i.e. you wish to start
the blowback cycle today), you must choose a starting time that is after the current
time today. For example, if you wish to start the blowback cycle today and it is now
9:00 a.m., you must select a start hour that is after 9:00 a.m. (i.e. 10 or above). If
you chose a time that is before 9:00 a.m., the blowback will not start until the next
day at the selected start time.
9. To change the value of the first blinking digit press the up arrow button. The digit
will be incremented by one each time the button is pressed. The first hour digit can
only be set to 0, 1, or 2. When the display reaches 2, pressing the up arrow button
11. Press the up arrow button to increment the displayed value. If the first digit was set
to 0, 1, or 2, the second digit can be set to 0 through 9.
set to 0 through 5.
14. When the third digit is correct, press the right arrow button once. The fourth (last)
set to 0 through 9.
16. When all four displayed digits are correct, purge start entry is complete. Press the
FUNCTION to return to measurement mode.
NOTE: Both purge start time and purge interval must be correctly entered for the
automatic blowback feature to operate properly.

4.4.8 Purge Interval (optional)
The purge interval is the amount of time that must elapse between blowbacks. The user
may set the interval between 1 and 99 hours.
The purge interval should be adjusted according to the particulate load in the sample
gas. If particulate loading is unknown, start with a conservative interval. Over the next
few days, Increase the interval until the high sample vacuum/loss of sample flow alarm
occurs. When a loss of sample flow alarm occurs, perform a manual blowback and set
the purge interval to an interval slightly shorter than the setting last used.

proceeding.
2. Press the FUNCTION button repeatedly until the front panel displays and
indicators change as follows:
The MEAS indicator will be extinguished and the PURGE INTERVAL indicator will be
illuminated.
The range display will show the currently selected number of hours between
blowbacks.
Figure 412 shows the front panel when the analyzer is in purge interval mode. The
current purge interval is set at 10 hours, which means that the analyzer will perform a
blowback every ten hours.
Figure 4-12: Purge Interval (Blowback) Every 10 Hours (example)

3. If the purge interval is correct, no further action is required. Press the FUNCTION
IMPORTANT: If your analyzer is configured for automatic blowback control by an

external device, you must set the purge interval to 00.
4. To change purge interval, press the right arrow button. The leftmost digit on the
incremented by one each time the button is pressed. The leftmost digit can be set
to 0 through 9. When the display reaches 9, pressing the up arrow button causes
the value to rollover to 0.
incremented by one each time the button is pressed. When the display reaches 9,
pressing the up arrow button causes the value to rollover to 0. The second digit
can be set to 0 through 9.
8. When the second digit is correct, purge interval entry is complete. Press the
FUNCTION button to return to measurement mode.
NOTE: Both purge start time and purge interval must be correctly entered for the
automatic blowback feature to operate properly.

4.5 Calibration Setup

The calibration setup functions are initially performed by the factory and are usually not
changed by the operator in the field. Should it become necessary to change one or more
of the calibration setup values, the procedure for changing these values is described in
the text that follows.
All calibration setup functions are invoked by pressing the SET UP button located behind
the center panel. To open the panel, remove the screws. Inside the open panel are six
labeled pushbuttons (see Figure 413). The SET UP button is located near the upper
right corner of the panel opening.
NOTE: The SET UP button will not function whenever the analyzer is in calibration
mode, a purge is in progress, or a function is being selected.
Figure 4-13: Setup Buttons
4.5.1 Blowback Setup In-Blow Time
The in-blow purge step rotates the ball valve to shut off the sample line and connect the
compressed air line to the primary filter outlet. To set the in-blow purge duration, perform
the following:

proceeding.

2. Press the SET UP button once. The analyzer responds by displaying iblo in the
range display and the current setting of the in-blow purge interval in the
concentration display. The interval is expressed in minutes. The factory setting of
the in-blow purge interval is 1 minute.
3. Press the right arrow button. The leftmost digit of the concentration display will
begin to blink.
4. Press the up arrow button to increment the value of the blinking digit.
5. When the value of the blinking digit is correct, press the right arrow button. The
next digit will begin to blink.
6. Repeat steps 3 through 5 until all displayed digits are correct.
7. Press the SET UP button nine times to exit setup mode and return to measurement
mode.
4.5.2 Sample Delay Time
The blowback sequence uses the same sample delay as the calibration sequence. To
set the sample delay time duration, perform the following:

proceeding.
2. Press the SET UP button three times. The analyzer responds by displaying dely
in the range display and the current setting of the sample delay time interval in the
concentration display. The interval is expressed in minutes.
3. Press the right arrow button. The leftmost digit of the concentration display will
begin to blink.
4. Press the up arrow button to increment the value of the blinking digit.
5. When the value of the blinking digit is correct, press the right arrow button. The
next digit will begin to blink.
6. Repeat steps 3 through 5 until all displayed digits are correct.
7. Press the SET UP button repeatedly until you exit setup mode and return to
measurement mode.

4.5.3 NOX Calibration Range
To set the NOX calibration range, perform the following:

proceeding.
2. Press the SET UP button four times. The analyzer responds by displaying CAL 1
in the range display and the current calibration range value in the concentration
display. The range is expressed in ppm.
3. Press the up arrow button to set the full-scale range to high or low.
measurement mode.
4.5.4 SO2 Calibration Range
To set the SO2 calibration range, perform the following:

proceeding.
2. Press the SET UP button five times. The analyzer responds by displaying CAL 2
measurement mode.

4.5.5 CO Calibration Range
To set the CO calibration range, perform the following:

proceeding.
2. Press the SET UP button six times. The analyzer responds by displaying CAL 3
measurement mode.
4.5.6 CO2 Calibration Range
To set the CO2 calibration range, perform the following:

proceeding.
2. Press the SET UP button seven times. The analyzer responds by displaying CAL
4 in the range display and the current calibration range value in the concentration
measurement mode.

4.5.7 O2 Calibration Range
To set the O2 calibration range, perform the following:

proceeding.
2. Press the SET UP button eight times. The analyzer responds by displaying CAL 5
measurement mode.
4.5.8 MAT O2 Set Value
To enter the MAT O2 set value, perform the following:

proceeding.
2. Press the SET UP button ten times. The analyzer responds by displaying o2 in
the range display and the current O2 (set) value in the concentration display.
3. Press the up arrow button to increment the value of the O2 set value. (This
selection may only be made if two set values have been configured for your
analyzer.)
4.Press the SET UP button once to exit setup mode and return to measurement mode.
4.5.9 Calibration Duration
Each step in the calibration sequence has a factory-set duration of 3 minutes (15
minutes for SO2 zero and span). For some installations, the duration of each step may
have to be increased if a stable response is not reached within 2 minutes. The duration
is selectable from 1 30 minutes. Consult the Horiba Service Department for
instructions on changing the duration.
NOTE: The required durations can be empirically determined by performing a manual

calibration (see Manual Calibration, step 4).

4.6 Calibration
The XS analyzer is designed to perform all recalibration activities automatically under
microprocessor and system clock control. This automatic instrument calibration (AIC)
feature reduces the operator workload to a practical minimum. In situations where a
manual recalibration is required, the analyzer provides a convenient means for
performing manual calibration. Automatic calibration and manual calibration procedures
are described in the text that follows.
4.6.1 Automatic Calibration
To start an automatic calibration, perform the following steps:

proceeding.
2. Press the AIC button. The analyzer will respond by entering calibration mode.
The MEAS indicator will be extinguished.
3. To abort an automatic calibration, press the AIC button again. The calibration
process will be immediately aborted.
4. The calibration process will proceed automatically until it is finished. When

calibration terminates, either at the normal end of the process, or because the
AIC button was used to abort, the analyzer will ordinarily return to measurement
mode. No further user input is required.
If the automatic calibration was started during a purge, or an external purge start
command was received during automatic calibration, or the purge interval has expired
during calibration, the analyzer will return to purge mode.
4.6.2 Manual Calibration
To perform a manual calibration of one or all of the analyzer modules, perform the
following steps:

proceeding.
2. Select the calibration gas by repeatedly pressing the GAS MODE button. Each
time the GAS MODE button is pressed, the next available calibration gas is
selected. For example, a five-gas analyzer allows selection of ten calibration gases
in the following order:

1. NOX zero 6. NOX span

2. SO2 zero 7. SO2 span
3. CO zero 8. CO span
4. CO2 zero 9. CO2 span
5. O2 zero 10. O2 span
When O2 span is selected and the GAS MODE button is pressed, the sample gas is
selected and the DELAY indicator will be illuminated (see step 7).
3. When the indicator for the desired calibration gas is illuminated and the ZERO or
SPAN indicator is also illuminated, calibration can begin.
4. Wait for the value shown on the concentration display to stabilize around the
concentration of the selected calibration gas. When the reading is stable, press the
CAL button. (This step may also be used to determine the calibration step
duration.)
5. The system responds by adjusting the analyzer module signal to match the
calibration gas value. The LED indicator next to the CAL button will be illuminated
for about two seconds as calibration takes place.
6. Repeat steps 2 through 5 for each desired calibration.
7. When all calibrations are complete, press the GAS MODE button repeatedly until
the DELAY indicator is illuminated. Sample gas is now flowing through the
analyzer.
8. Wait for the value shown on the concentration display to stabilize around the
concentration of the sample gas. When the reading is stable, press the GAS
MODE button again to return to measurement mode.
4.7 Alarms and Cautions

The XS analyzer constantly monitors its performance. When the analyzer approaches
the limit of the zero or span calibration range, a caution condition occurs and the
CAUTION indicator on the front panel is illuminated. When a zero or span calibration
fails, or a hardware problem is detected, an alarm condition occurs and the ALARM
indicator on the front panel is illuminated. Caution and alarm conditions also generate
outputs at the external contacts to notify an attached host computer or other device that
a problem has been encountered.
When an alarm or caution condition occurs, the operator must first display the
associated alarm or caution code(s). Tables 41 and 42 provide information about the
codes. When corrective action has remedied the problem, the operator must manually
clear the alarm or caution condition. When all alarms and cautions have been cleared,
the alarm and/or caution outputs at the external contacts will automatically reset.

4.7.1 Displaying Alarm Codes
To display the alarm or caution code on the concentration display, perform the following
steps.

proceeding.
2. Open the panel cover near the center of the analyzer front panel. There are six
labeled pushbuttons behind the cover (see Figure 414.).
Figure 4-14: Setup Control Buttons
3. Locate the RES1 button. It may be found near the lower left corner of the panel
opening.
4. Press the RES1 button once. The analyzer will respond by switching to check
alarm mode. The front panel displays and indicators will change as follows:
The MEAS indicator will be extinguished and the PURGE INTERVAL indicator will be
illuminated.
The ALARM and/or CAUTION indicator(s) will be illuminated and blinking.
If the alarm pertains to a specific measured gas, the indicator for the gas will be
illuminated and blinking.
The concentration display will show the first alarm or caution code.

Figure 415 shows the front panel when the analyzer is in check alarm mode. In the
figure, the concentration display shows alarm code A01 and the NOX and ALARM
indicators are blinking.
Figure 4-15: Alarm Check Mode
5. Refer to Tables 41 and 42 to interpret the code displayed on the concentration

display. Codes that begin with the letter A indicate an alarm condition. Codes that
begin with the letter C indicate a caution condition.
6. Press the up arrow button to display additional codes, if any. Each time the up
arrow button is pressed, the next active alarm or caution code will be displayed. If
no other alarms are active, pressing the up arrow button will have no effect.

4.7.2 Interpreting Alarm Codes
Table 41 provides descriptive information about each alarm code.
Table 4-1: Alarm Codes
ALARM
ALARM CONDITION FRONT PANEL INDICATORS
CODE
A01 NOX zero calibration failed ALARM displayed, NOX blinks
A02 SO2 zero calibration failed ALARM displayed, SO2 blinks
A03 CO zero calibration failed ALARM displayed, CO blinks
A04 CO2 zero calibration failed ALARM displayed, CO2 blinks
A05 O2 zero calibration failed ALARM displayed, O2 blinks
A06 NOX span calibration failed ALARM displayed, NOX blinks
A07 SO2 span calibration failed ALARM displayed, SO2 blinks
A08 CO span calibration failed ALARM displayed, CO blinks
A09 CO2 span calibration failed ALARM displayed, CO2 blinks
A10 O2 span calibration failed ALARM displayed, O2 blinks
A11 Faulty RAM memory ALARM displayed
CPU Faulty CPU ALARM displayed, range display
shows Err

4.7.3 Interpreting Caution Codes
Table 42 provides descriptive information about each caution code.
Table 4-2: Caution Codes
CAUTION FRONT PANEL

ALARM CONDITION
CODE INDICATORS
C01 Approaching NOX zero CAUTION displayed, NOX
calibration range limit blinks
C02 Approaching SO2 zero CAUTION displayed, SO2
C03 Approaching CO zero CAUTION displayed, CO
C04 Approaching CO2 zero CAUTION displayed, CO2
C05 Approaching O2 zero calibration CAUTION displayed, O2 blinks
range limit
C06 Approaching NOX span CAUTION displayed, NOX
C07 Approaching SO2 span CAUTION displayed, SO2
C08 Approaching CO span CAUTION displayed, CO
C09 Approaching CO2 span CAUTION displayed, CO2
C10 Approaching O2 span CAUTION displayed, O2 blinks
calibration range limit

4.7.4 Clearing Alarms
To clear an active alarm or caution, perform the following:
1. First, remedy the condition that caused the alarm or caution condition.
2. When the cause has been located and remedied, press the up arrow button until
the desired alarm or caution code appears in the concentration display.
3. In the recessed area behind the open cover panel, locate and press the RES2
button.
4. The selected alarm or caution will be cleared. Repeat steps 1 through 3 for all
active alarms or cautions.
5. When all active alarms and/or cautions have been cleared, the contact outputs for
alarm and caution will automatically reset.
6. Press the RES1 button to exit the alarm check mode. Replace the center panel
door and secure the screws.

5.0 Operation
5.1 Overview
This chapter describes how to start the ENDA-4000 after an extended idle period and
how to perform an orderly shutoff of the instrument prior to performing unscheduled
maintenance or repair.
When performing the tasks listed in this chapter always follow safety instructions.
5.2 Start-Up
To start the ENDA-4000 after an extended idle period, perform the following steps:
1. At the span gas bottles, turn all gas bottle regulators to the OFF position.
2. Open all bottle valves and adjust each regulator to the specified pressure. Refer to
the system drawings and specifications for supply pressure specifications.
3. If equipped with the sample probe blowback option, manually turn on the supply of
blowback compressed air. Inspect the regulator to assure that the output pressure
is within specifications.
4. At the system cabinet front panel, make certain that all switches are in the OFF
position.
5. Inspect the water level in the constant pressure trap and the reference gas
humidifier bath. The water level should be at or above the minimum level indicator
for each reservoir.
6. If necessary, remove the rubber cap on the constant pressure trap TR1 and
carefully pour clean water into the reservoir until excess water flows out of the
wastewater drain.
7. Turn on the master switch or circuit breaker that controls power to the ENDA-4000.
8. Turn on circuit breakers CB1, CB2, and CB3 (if present), inside the junction box.
9. At the front panel turn on the INSTRUMENT/AUXILIARY switch. The instrument

responds by starting the ventilation fan. The display screen will be illuminated and
the control program will begin to load automatically.
10. Turn on the HEATED PRIMARY FILTER switch. If your installation includes a
heated sample line, turn on the HEATED LINE switch.

ENDA-4000 Manual Chapter 5: Operation
11. Allow the heaters to reach operating temperature before proceeding. Wait one hour
before performing the following steps.
12. When the heated components have reached operating temperature, turn on the
PUMP switch. The instrument responds by starting the sample pump and
reference gas pump.
13. Wait 10 minutes for the temperature of the sample conditioning equipment to
stabilize.
14. Locate and observe the constant pressure trap inside the cabinet. Steady streams
of bubbles should issue from the bottom of the two (or three) trap tubes and the
one (or two) thermoelectric cooler drain connections.
15. Adjust the stream of bubbles for the sample gas by adjusting needle valve NV-1.
Balance the flow for reference and sample gas by closing NV-1 and NV-2 until a
steady stream of bubbles is formed and one or two bubbles per second emerge
from the thermoelectric cooler drain connections. Refer to Figure 51 for proper
bubble flow.
Proper Excessive Insufficient
Figure 5-1: Constant Pressure Trap Bubble Flow
16. Adjust the stream of bubbles for the reference gas by adjusting needle valve NV-2.
Refer to Figure 51 for proper bubble flow.
17. If your ENDA-4000 is configured with an oxygen analyzer, adjust the stream of
bubbles for the OPE gas by adjusting needle valve NV-3. Opening NV-3 releases
more air to the vent and decreases the bubble flow. Close NV-3 to increase the
bubble rate. Refer to Figure 51 for proper bubble flow.

Chapter 5: Operation ENDA-4000 Manual
18. Locate and observe the analyzer flowmeter(s) on the front of the analyzer panel.
19. Assure that the sample flow meter shows a flow of about 1.0 lpm.
20. If your instrument is configured with an oxygen analyzer module, assure that the O2
sample flowmeter shows a flow of about 30 ml/min.
21. Wait 3 hours for the temperature of the ENDA-4000 to stabilize before performing
the following steps.
22. When the heated components have reached operating temperature perform an
automatic instrument calibration (AIC). Autocal can be started manually by
pressing the AIC button. Refer to Chapter 4 for details.
23. The analyzer responds by automatically recalibrating all configured analyzer

modules. This process is fully automatic and requires no user input. Automatic
recalibration requires 20 40 minutes, depending on the analyzer configuration
and the length of the sample line.
24. When automatic calibration has been completed, inspect the front panel to assure
that no alarm conditions are active. If one or more alarms are active, take remedial
steps before proceeding.
25. If no alarm conditions are active at the end of an automatic calibration, place the
analyzer in measurement mode to begin continuous measurement of stack gas
components.
5.3 Daily Operation

During normal daily operation perform the following steps.
1. At the beginning of each shift, observe the analyzer front panel and assure that no
alarms are active. If an alarm condition exists, perform the appropriate remedial
action without delay.
2. At the beginning of each shift, observe the flowmeter(s) on the front panel of the
instrument. Assure that the sample flowmeter shows a flow of about 1.0 lpm and, if
so equipped, the oxygen sample flow shows a flow of about 30 ml/min.
3. Once each day, open the cabinet and inspect the water levels in the overflow trap,
the constant pressure trap, and the reference gas humidifier. If the levels are below
the indicated minima, refill the overflow trap with clean tap water until normal
operating levels are restored.
4. Once each day, if the ENDA-4000 is attached to a chart recorder or data printer,
check the paper supply to the attached recording device.

5. Periodically visually inspect the sample line, primary heater, and the drain and
waste gas lines to assure that they are undamaged and in good order.
5.4 Instrument Shut-Off

To shut off the ENDA-4000 for an extended duration perform the following steps:
1. Turn off the PUMP switch. The instrument responds by stopping the sample pump
and reference gas pump.
2. Turn off the HEATED PRIMARY FILTER switch. If your installation includes a
heated sample line, turn off the HEATED LINE switch.
3. Turn off the INSTRUMENT/AUXILIARY switch. The instrument responds by

stopping the ventilation fan. The front panel will go dark.
4. Turn off circuit breakers CB1, CB2, and CB3 (if present), in the junction box.
5. Turn off the master switch or circuit breaker that controls power to the ENDA-4000.
6. Allow at least 1 hour for the internal components to cool before performing
maintenance.
IMPORTANT: The ENDA-4000 has heated internal components that can cause burns if
touched. Maintenance of ENDA-4000 components should only be performed by qualified
personnel.

Chapter 5: Operation ENDA-4000 Manual
5.4.1 Extended Idle Period
If the instrument is to be idled for a long period (more than 72 hours), perform the
following additional steps:
1. Manually drain the overflow trap, constant pressure trap, and reference gas
humidifier reservoirs.
2. Manually shut off all cylinder valves from all calibration gas cylinders to the
calibration gas manifold.
3. If equipped with the sample probe blowback option, manually shut off the supply of
blowback compressed air.
4. Purge the system with clean, dry air or nitrogen for 10 minutes.
5. Cap or plug any tube connectors that have been disconnected.
6. Use the start-up procedure described earlier in this chapter to restart the ENDA-
4000 after an extended idle period.


6.0 Maintenance
6.1 Overview
Some subassemblies and parts of the ENDA-4000 are subject to wear and tear and will
require periodic maintenance. These items have been divided into two categories:
scheduled maintenance tasks and unscheduled maintenance tasks.
Scheduled maintenance tasks should be performed at least as frequently as

recommended in this chapter. If your ENDA-4000 is subject to extreme or unusual
conditions during use, you may be required to perform these tasks more frequently than
the schedule recommends.
The frequency of unscheduled maintenance tasks depends upon the your specific usage
conditions. Most of these tasks are performed when a maintenance item exhibits signs
of imminent failure or actually fails.
6.2 Scheduled Maintenance

Table 61 lists frequent scheduled maintenance tasks for the ENDA-4000.
Table 6-1: Daily and Weekly Scheduled Maintenance Tasks
ITEM FREQUENCY MAINTENANCE TASK

Constant pressure trap, Daily Check water level. Refill reservoirs if
humidifier bath, and necessary.
overflow trap.
Water discharge drain. Daily Check flow. Clear blockages.
Sample flow meter. Daily Check flow. Adjust if necessary.
Sample line heater Daily Check operation and temperature.
Secondary filters Weekly Inspect for clogging. Replace if
required.
Span gas Weekly Check pressure. Replace cylinder
when pressure drops below 300 psig.
Air conditioner or fan filter Monthly Inspect for clogging and clean.
Mist separator Monthly Inspect. Replace mist separator when
discolored (white).
Primary filter Monthly Inspect for clogging. Replace if
required. Check packing for proper
sealing. Clean O-ring; apply silicone
grease.

ENDA-4000 Manual Chapter 6: Maintenance
Table 62 lists quarterly and annual maintenance tasks for the ENDA-4000.
Table 6-2: Quarterly and Annual Scheduled Maintenance Tasks

Condensate drain 90 days Inspect operation of drain.
Sample probe 90 days Inspect for clogging and clean if
required.
Thermoelectric cooler 90 days Remove, clean, and replace fan filter.
Check operating temperature.
Optional sample gas Annually Replace scrubber. Perform leak check.
scrubbers.
Fluororubber, Annually Inspect and replace if deterioration or
polypropylene, PVC, leakage is found. Perform leak check.
toalone, and Teflon
joints.
Sample pump Annually Replace pump diaphragms.
diaphragms
O-ring gaskets. Annually Replace. Perform leak check.

Chapter 6: Maintenance ENDA-4000 Manual
Table 63 lists scheduled maintenance tasks that must be performed every two years
and every five years.
Table 6-3: Two Year and Five year Scheduled Maintenance Tasks

Primary filter heater. 2 years Inspect and check temperature.
Replace if deteriorated.
Sample line heater. 2 years Inspect and check temperature.
Replace sample line if deteriorated.
Fluororubber joints. 2 years Replace. Perform leak check.
Toalone joints. 2 years Replace. Perform leak check.
Cabinet ventilation fan. 2 years Inspect operation. Replace if noisy or
deteriorated.
Primary filter heater. 5 years Replace. Check temperature of new
unit.
Water separator. 5 years Inspect. Replace if deteriorated.
Perform leak check.
Sample pump. 5 years Replace. Perform leak check.
Reference gas pump. 5 years Replace. Perform leak check.
Solenoid valves. 5 years Replace. Perform leak check.
Thermoelectric cooler. 5 years Replace. Perform leak check. Check
temperature of new unit.
Polypropylene joints. 5 years Replace. Perform leak check.
Teflon joints. 5 years Replace. Perform leak check.
Cabinet ventilation fan. 5 years Replace.
Fluorescent lamp unit. 5 years Inspect socket and switch. Replace if
deteriorated.
Terminal board 5 years Inspect. Replace if corroded or worn.
sockets.
Wiring and terminal 5 years Inspect. Replace if deteriorated.
connectors.
Switches. 5 Years Inspect. Replace if deteriorated.
Low-voltage power 5 years Inspect and test. Replace if
supply. performance cannot be adjusted to
meet specification.

ENDA-4000 Manual Chapter 6: Maintenance
6.3 Unscheduled Maintenance

Horiba recommends that you keep a set of designated spare parts on hand to perform
unscheduled maintenance. Your Horiba representative can advise you about
recommended parts and quantities.
Table 64 lists unscheduled maintenance tasks and their criteria.
Table 6-4: Unscheduled Maintenance Tasks
ITEM CRITERIA MAINTENANCE TASK

Sample When sample flow Remove filter bowl, remove clogged
conditioning falls below element, replace with new filter element,
filter element. minimum. replace bowl and inspect for leakage.
Primary filter When clogged or Replace filter element. Perform leak check.
element. deteriorated.
Solenoid valves. When leaking. Replace valve diaphragm. Perform leak
check.
Solenoid valves. When actuator Remove and clean actuator. Reinstall and
vibrates or chatters. test. Replace if problem persists. Perform
leak check.
Needle valves. When leaking or Replace. Perform leak check.
clogged.
Flow meter. When clogged or Replace. Perform leak check.
leaking.
Calibration gas When leaking, Replace. Perform leak check.
cylinder noisy, or when
pressure gauge is
regulators. inaccurate.
Fluorescent When failure Replace.
lamp tube. occurs.
Sample pump When noisy or Remove failed diaphragm, replace with
diaphragm. when failure occurs. new. Reassemble and test. Perform leak
check.
Sample line. When sample flow Disconnect sample line from instrument
is restricted. and clean with approved solvent.
Reassemble and perform leak check.
Sample probe. When clogged, Replace. Perform leak check.
corroded, or
leaking.

7.0 Troubleshooting and Service
7.1 Overview
IMPORTANT: Only qualified personnel should perform ENDA-4000 troubleshooting and
repairs. Observe all safety warnings and use the required safety equipment when
performing troubleshooting and repairs.
This chapter provides information about performing troubleshooting and service for the
ENDA-4000. Tables of symptoms, probable causes, and suggested remedies have been
provided to assist troubleshooting by qualified users. Only Horiba-trained service
personnel should perform some test and repair tasks. If you encounter a problem that is
not listed in this chapter, contact the Horiba service department for assistance.
The last half of this chapter explains how to contact the Horiba service department and
provides details about service policies and warranties.
7.2 Required Safety Equipment, Tools, and

Materials
The following safety equipment, tools, and materials are required to perform diagnostic
and troubleshooting tasks.
The following safety equipment, tools, and materials are required to perform diagnostic
and troubleshooting tasks.
Required Safety Equipment:

Safety glasses Work gloves
Required Tools:
Small straight-blade screwdriver Small Phillips-head screwdriver
Adjustable wrench Thermometer
Volt-Ohmmeter (VOM) Inspection lamp or flashlight
Required Materials:
Teflon tape Leak-indicating fluid
Compressed clean air Wiring diagrams
Plumbing diagrams

ENDA-4000 Manual Chapter 7: Troubleshooting and Service
7.3 Symptoms and Remedies

The tables on the following pages provide a list of symptoms, probable causes, and
suggested remedies for a variety of ENDA-4000 faults. If you encounter a problem that
is not listed in these tables, contact the Horiba service department for assistance.
7.3.1 Alarm and Caution Codes
Table 71 lists all alarm codes and Table 72 lists all caution codes in numeric order.
The tables indicate the alarm or caution condition and direct the reader to more detailed
information.
Table 7-1: Alarm Codes
ALARM FOR DETAILS,

ALARM CONDITION
CODE REFER TO TABLE
A01 Zero calibration for NOX failed. See Table 73.
A02 Zero calibration for SO2 failed. See Table 74.
A03 Zero calibration for CO failed. See Table 75.
A04 Zero calibration for CO2 failed. See Table 76.
A05 Zero calibration for O2 failed. See Table 77.
A06 Span calibration for NOX failed. See Table 73.
A07 Span calibration for SO2 failed. See Table 74.
A08 Span calibration for CO failed. See Table 75.
A09 Span calibration for CO2 failed. See Table 76.
A10 Span calibration for O2 failed. See Table 77.
A11 RAM Failure. See Table 78.

Chapter 7: Troubleshooting and Service ENDA-4000 Manual
Table 7-2: Caution Codes
CAUTION FOR DETAILS,

ALARM CONDITION
CODE REFER TO TABLE
C01 Approaching Zero Calibration See Table 73.
Range Limit for NOX.
Range Limit for SO2.
Range Limit for CO.
Range Limit for CO2.
Range Limit for O2.
C06 Approaching Span Calibration See Table 73.
Range Limit for NOX.
Range Limit for SO2.
Range Limit for CO.
Range Limit for CO2.
Range Limit for O2.

7.3.2 Alarm Conditions NOX
Table 7-3: Symptoms and Suggested Remedies for NOX Related Alarms
ALARM ALARM
PROBABLE CAUSE SUGGESTED REMEDY
CODE CONDITION
A01 Zero 1. Calibration gas 1. Check pressure at
calibration for cylinder is empty. regulator; if empty, replace
NOX failed. 2. Constant pressure trap cylinder.
is improperly adjusted. 2. Adjust proper bubble rate
3. Restricted gas flow. for constant pressure trap.
4. Cooler temperature 3. Check flowmeters FM1A &
problem. FM2A.
4. Check operation of thermo-
electric cooler.
A06 Span Incorrect calibration range Assure that span gas
calibration for selected or incorrect span concentration is 80 95% of
NOX failed. gas used. selected calibration range.
C01 Approaching 1. Cumulative zero drift 1. Contact HII service for
Zero requires analyzer analyzer recalibration.
Calibration recalibration. 2. Check setting of zero limit.
Range Limit 2. Range limit value
for NOX. improperly set.
C06 Approaching 1. Cumulative span drift 1. Contact HII service for
Span requires analyzer analyzer recalibration.
Calibration recalibration. 2. Check setting of span limit.
for NOX. improperly set.

7.3.3 Alarm Conditions SO2
Table 7-4: Symptoms and Suggested Remedies for SO2 Related Alarms
ALARM ALARM
CODE CONDITION
calibration cylinder is empty. regulator; if empty, replace
for SO2 2. Constant pressure trap cylinder.
failed. is improperly adjusted. 2. Adjust proper bubble rate
problem. FM2A.
electric cooler.
calibration selected or incorrect span concentration is 80 95% of
for SO2 gas used. selected calibration range.
failed.
for SO2. improperly set.
for SO2. improperly set.

7.3.4 Alarm Conditions CO
Table 7-5: Symptoms and Suggested Remedies for CO Related Alarms
ALARM ALARM
CODE CONDITION
for CO failed. 2. Constant pressure trap cylinder.
problem. FM2A.
electric cooler.
for CO failed. gas used. selected calibration range.
for CO. improperly set.
for CO. improperly set.

7.3.5 Alarm Conditions CO2
Table 7-6: Symptoms and Suggested Remedies for CO2 Related Alarms
ALARM ALARM
CODE CONDITION
for CO2 2. Constant pressure trap cylinder.
failed. is improperly adjusted. 2. Adjust proper bubble rate
problem. FM2A.
electric cooler.
for CO2 gas used. selected calibration range.
failed.
for CO2. improperly set.
for CO2. improperly set.

7.3.6 Alarm Conditions O2
Table 7-7: Symptoms and Suggested Remedies for O2 Related Alarms
ALARM ALARM
CODE CONDITION
calibration for cylinder is empty. regulator; if empty, replace
O2 failed. 2. Constant pressure trap cylinder.
problem. FM2A.
5. Air leak on vacuum 4. Check operation of thermo-
side of sample pump. electric cooler.
5. Check for leaks.
A10 Span 1. Incorrect calibration 1. Assure that span gas
calibration for range selected or concentration is 80 95%
O2 failed. incorrect span gas of selected calibration
used. range.
2. Air leak on vacuum 2. Check for leaks.
side of sample pump.
for O2. improperly set.
for O2. improperly set.

7.3.7 Alarm Conditions Control Program
Table 7-8: Symptoms and Suggested Remedies for Control Program
ALARM ALARM
CODE CONDITION
A11 RAM A failure has occurred in the Contact Horiba service.
Failure. analyzer memory.
none CPU A failure has occurred in the Contact Horiba service.
Failure. analyzer microprocessor.

7.3.8 Miscellaneous Problems
Table 7-9: Symptoms and Suggested Remedies for ENDA-E4000
SYMPTOM PROBABLE CAUSE SUGGESTED REMEDY

Analyzers Temperature changes in 1. Make certain that the room is
experience room. not subjected to wide variations
excessive drift. in temperature.
2. Isolate equipment from drafts
and exposure to direct sunlight.
Analyzer response Sample residue in analyzer 1. Purge analyzer with dry air and
too slow. sample cell. recalibrate.
2. If performance poor after
extended purging, recalibrate
affected analyzer.
Low sample flow. 1. Obstructed filter media. 1. Replace filter media in sample
2. Leak in sample line. line.
3. Pump diaphragm 2. Plug end of sample line and
failure. perform leak check on sample
line.
4. Exhaust blocked or
restricted. 3. Check flow through sample
pump. Insufficient flow may
require replacement of pump
diaphragm.
4. Assure that sample exhaust line
from analyzer is unobstructed.
No sample flow. Sample line problem. 1. Check for blocked probe.
Perform blowback, if equipped
with blowback option.
2. Check filter media in sample
line.
3. Check for proper sample pump
operation.
4. Check for opening or
obstruction in primary filter or
sample line.
5. Check tubing connections at
analyzer.

Continued
SYMPTOM PROBABLE CAUSE SUGGESTED REMEDY

Whistling or hissing Leak in sample handling 1. Perform leak check on sample
noise during subsystem. line.
operation. 2. Inspect all filters and traps.
Leak in exhaust line. Check exhaust line for leaks.
Whistling or hissing Leak in span or zero gas Inspect and leak-check all span and
noise during connections. zero gas connections.
calibration
Valve body chatter Solenoid worn or valve Perform diagnostics and inspection
or buzzing noise. loose in seat. recommended by valve supplier.
Replace valve if required.

7.4 Factory Service

Customer Support Line:
The Horiba Irvine, California office has established a Customer Support Line that is
available from 8:00 a.m. to 5:00 p.m. (Pacific time), Monday through Friday. The
Customer Support Line telephone numbers are:
(800) 446-7422 or (949) 250-4811
You may call these numbers to obtain assistance with any hardware or software problem
and get answers to questions about Horiba equipment. You may also use these
numbers to request a service call or to order emergency spare parts.
After hours, you may call the customer support line to leave a message on the Service
Department voice-mail system. Horiba will return voice-mail calls on the morning of the
next business day.
Horiba will respond to all telephone requests for service within twenty-four (24) hours
after receipt of a call (during normal business hours, 8:00 a.m. - 5:00 p.m., Monday
through Friday).
Preparing to Call the Customer Support Line:

To help Horiba's Customer Support Line staff best serve you, please be ready to provide
the following information:
The name and model number of the equipment experiencing the problem
A description of the symptoms or the cause (if known)
A list of error messages or fault indicators
Supporting documentation such as printed reports, calibration records, etc.
You may avoid delays by having a purchase order number ready when you call for
service. If you are ordering parts, please use the Horiba part numbers provided in the
appendix of this document.
Purchase Orders:
The Service Department manager will provide an estimate of service charges in advance
of performing any services, based upon a verbal description of the problem or
symptoms. However, service work, including instrument checkout or disassembly to
confirm the existence of a problem will not be performed until a completed purchase
order or customer billing authorization has been received by Horiba's Service
Department.

Customers should be aware that estimates of service costs are difficult to develop until
the work is completed and, therefore, actual service charges may exceed the estimate.
The customer will be advised in advance if, in the course of servicing an instrument,
Horiba determines that the actual cost will exceed the estimate by more than ten (10)
percent.
Returning Equipment to Horiba for Repair:

Before returning equipment to Horiba for repair or warranty service, contact the Service
Department, or call the Customer Support Line to obtain a Service Return Authorization
(SRA) number. An SRA number is required for all items returned to Horiba for service.
When preparing the item for shipment to Horiba, please mark the SRA number clearly
on the outside of the shipping container.
Service Locations:
Service facilities and factory service representatives are located at the following U.S.
offices:
California
Horiba Instruments, Inc.
Irvine, CA 92614
Telephone: (949) 250-4811 or (800) 446-7422
FAX: (949) 250-0924
TELEX: 4772-0213
Arkansas
125 Ammons Street
Waldron, AR 72958
Telephone: (501) 637-4008
FAX: (504) 637-2692
Louisiana
2369 Ray Weiland Dr.
Baker, LA 70714
Telephone: (225) 774-1120
FAX: (225) 774-1128
Maryland
8218 Elkwood Court
Pasadena, MD 21122
Telephone: (410) 360-6874
FAX: (410) 360-6875

Pennsylvania
5 Beaver Lane
Brier Crest Wood
Blakeslee, PA 18610
Phone: (570) 646-9381
For addresses and contact numbers for our overseas offices, please contact one of the
U.S. offices listed above. Service rates and policies for Horiba offices outside the United
States conform to local customs and may differ from those described herein.
7.5 Service Policies

Telephone Service Advice:
Service advice and guidance will be given free of charge over the telephone whenever
possible. However, if in the opinion of the Horiba Service Manager, the time required for
this service is excessive (usually more than ten [10] minutes during any single day), the
customer will be invoiced for the labor cost of this telephone service at Horiba's standard
rate.
Installation:
Installation and operational training are not included with any item purchased at
commercial list prices or net government prices. Complete installation assistance and
instruction in the theory, operation, calibration, preventative maintenance, and general
maintenance are optionally available at either the Horiba Irvine California office, Horiba
regional offices, or at the purchaser's facility. Routine installation assistance and training
courses will be provided by a factory-trained Horiba service representative at quoted
standard service rates. Special installation contracts, yearly service and maintenance
contracts, and training classes for large groups are available to meet any customer
requirements. Proposals and price estimates for special services may be obtained by
contacting the Horiba Service Manager in Ann Arbor, Michigan. The user may elect to
have the Horiba Service Representative visit his facility; however, the user will be
invoiced for travel time and expenses for this optional elected service.
Replacement Parts:
Large inventories of repair parts required to support Horiba analyzers are maintained at
the California and Michigan offices. Minimal emergency stocks are maintained at other
offices. A sufficient quantity of essential parts required to complete any emergency
repair will normally be available at any location within 24 hours. Standard deliveries will
be quoted for quantities of spare parts which a user elects to purchase and hold in stock.
Please call the Horiba Service Department for current pricing.

Freight Charges:
All inbound and return the customer must pay freight charges for instruments. Horiba will
not accept any collect shipments unless prior approval has been obtained from the local
Horiba Service Representative. Horiba will normally return repaired instruments freight-
collect, but will, upon request, prepay the freight charges and add the actual charges to
the customer's invoice.
Minimum Charge:
Horiba will invoice the customer for a minimum of one (1) hour of service labor on all
service work performed to cover the costs of shipping and receiving, handling, and
administrative functions.
Service Hours:
Standard service labor and travel time rates apply from 8:00 a.m. to 5:00 p.m., Monday
through Friday. After 5:00 p.m. and all day Saturday, the service and travel time will be
billed at one and one-half (1.5) times the standard rate, and all day Sunday and on
national holidays at two (2) times the standard rate.
Service Rates:
Please contact the Horiba Service Department for current information and service rates.
7.6 Warranties
Limited Warranty and Remedy for Manufactured Products Other Than CPU
Hardware:
(1) Horiba Instruments, Inc. ("Horiba") warrants to the original purchaser that the
manufactured products identified on the sales agreements and invoices ("Manufactured
Products") shall be free from defects in materials and workmanship for a period of one
(1) year from the date of shipment to the original purchaser. This warranty applies to all
parts and materials provided during the warranty period in connection with the remedy
outlined below. This limited warranty does not apply to Manufactured Products that have
been used in any manner not specified by Horiba or the original manufacturer; or have
not been installed, serviced, or repaired by Horiba-authorized personnel; or have been
the subject of accident, disaster, or abuse.

(2) If the Manufactured Products fail to meet this limited warranty, then the Customer
shall so notify Horiba in writing as to the defects claimed by the Customer, and shall
cooperate with Horiba in Horiba's evaluation of such alleged defects. Horiba's sole
obligation, and the Customer's sole remedy, is Horiba's repair or replacement of parts
determined by Horiba to be defective so as to cause the Manufactured Products to fail to
meet Horiba specifications. At Horiba's option and direction, (i) the defective parts shall
be returned by the Customer to Horiba, transportation charges prepaid, or (ii) Horiba
shall make an on-site visit to the Customer's location, invoicing travel time at standard
rates and travel and living expenses at cost. Horiba shall bear the cost of all parts and
labor necessary for such replacement or repair during the warranty period. Upon
completion of warranty repairs at a Horiba Service Center, the equipment will be
returned to the customer, freight collect.
Limited Warranty and Remedy for CPU Hardware:

(1) Horiba warrants to the original purchaser that the CPU hardware purchased in
connection with the Manufactured Products shall be free from defects in materials and
workmanship for a period of ninety (90) days from the date of shipment to the original
purchaser. This warranty applies to all parts and materials provided during the warranty
period in connection with the remedy outlined below. This limited warranty does not
apply to CPU hardware that has been used in any manner not specified by Horiba or the
original manufacturer; or has not been installed, serviced, or repaired by Horiba-
authorized personnel; or has been the subject of accident, disaster, or abuse.
(2) If the CPU hardware fails to meet this limited warranty, then the Customer shall so
notify Horiba in writing as to the defects claimed by the Customer, and shall cooperate
with Horiba in Horiba's repair or replacement of parts determined by Horiba to be
defective so as to cause the CPU hardware to fail to meet Horiba specifications. At
Horiba's option and direction, (i) the defective parts shall be returned by the Customer to
Horiba, transportation charges prepaid, or (ii) Horiba shall make an on-site visit to the
Customer's location, invoicing travel time at standard rates and travel and living
expenses at cost. Horiba shall bear the cost of all parts and labor necessary for such
replacement or repair. Upon completion of warranty repairs at a Horiba Service Center,
the equipment will be returned to the customer, freight collect.
Limited Warranty for Software:

(1) Horiba warrants to the original purchaser that the application computer programs
identified in the related sales agreements and invoices ("Software") shall conform to
Horiba's standard specifications set forth in its documentation for a period of one (1) year
from the date of shipment to the original purchaser. Horiba does not warrant that the
functions contained in the software will meet the Customer's requirements, or will
operate in the variations that may be selected for use by the Customer, or that the
Software will be error-free. This warranty applies only to Software used in accordance
with Horiba instructions and not modified in any way other than by Horiba-authorized
personnel.

(2) Service with respect to any given program error will be provided upon Customer's
written notice to Horiba as to how the Software fails to meet specifications. Horiba shall
use its best efforts to (i) correct the error and forward a corrected version of the Software
to the Customer, or (ii) provide an alternative method to circumvent the error, or (iii)
correct the error in subsequent Software releases. If Horiba makes an on-site visit, the
Customer shall be invoiced for travel time at standard rates and travel and living
expenses at cost.
Horiba Service Warranty:

(1) After the expiration of the warranty periods set forth above, the Customer may
request that Horiba provide certain repair or replacement services on the Manufactured
Products or CPU hardware. Horiba warrants that the labor provided in connection with
such services shall be performed in a workmanlike manner by qualified personnel, and
that the materials installed in connection with the service shall be free from defects for a
period of ninety (90) days from the date the service was completed.
(2) If Horiba provides service on Manufactured Products or CPU hardware after the
original warranty period but within ninety (90) days of Horiba's previous repair or
replacement of the same equipment, Horiba shall bear all costs for labor and materials
associated with such service and the Customer shall be invoiced for travel time at
standard rates and travel and living expenses at cost.
(3) If Horiba provides service on Manufactured Products or CPU hardware after the
original warranty period and after the expiration of any applicable ninety (90) day service
warranty period set forth in subsection (2) above, then the Customer shall bear all costs
for labor, materials, and travel time and living expenses for on-site repairs and
replacement parts to be invoiced in accordance with prevailing service rates.
(4) This warranty applies only to Manufactured Products or CPU hardware provided by
Horiba that are used in a manner specified by Horiba or the original manufacturer, and is
limited to the work performed and materials provided.
THESE LIMITED WARRANTIES ARE IN LIEU OF, AND THE CUSTOMER WAIVES,
ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WITHOUT
LIMITATION, ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE. THE REMEDIES SET FORTH ABOVE ARE EXCLUSIVE.
Limitation of Liability for Damages:

Horiba shall not be liable for the Customer's incidental, consequential, or special
damages, or for lost profits or business interruption losses, in connection with the
operation of the Manufactured Products, CPU hardware, or Software. In no event shall
Horiba be liable to the customer, under any theory of recovery, for an amount in excess
of the fees paid in connection with this agreement. Any claims relating to this
Agreement. Any claims relating to this Agreement shall be brought within one year after
the occurrence of the event giving rise to the cause of action.


8.0 Installation
8.1 Overview
This chapter provides instructions on site preparation, unpacking, inspection, installation,
and checkout of the ENDA-4000. The site preparation subsection describes the physical
and environmental requirements of the ENDA-4000 and provides guidelines for selecting
and preparing a location to install the system. The receiving and installation subsections
describe how to unpack, inspect, and install the equipment. The post-installation
inspection subsection provides a procedure and checklist for assuring that all installation
steps have been correctly performed.
Your local building and fire codes will govern the manner in which some site preparation
and installation tasks are performed. If you have questions about whether your
installation conforms to local building codes, Horiba recommends that you consult your
local building inspector or a licensed engineer or contractor.
8.2 Site Preparation

The following subsections provide guidelines on site preparation required for placement
of the CEMS equipment.
8.2.1 Room
Location: To obtain the best results, the ENDA-4000 should be installed in a location
that is free from vibration. Avoid choosing a location that is subject to heavy foot traffic
and slamming doors or near equipment that imparts vibrations to the floor or walls such
as large compressors, pumps, etc. Avoid choosing a site that will experience extreme
variations in temperature or will allow direct sunlight to fall upon the instrument. The
ideal location is one that is located below, and close to, the sample point.
Size: The ENDA-4000 requires operating and service clearances on three sides and
above the cabinet. In addition, space allowances must be made for power and signal
cable conduits, the sample and waste gas lines, and the wastewater drain. Cabinet
dimensions and clearances are provided in Table 81, later in this subsection.
Doors: The ENDA-4000 cabinet will fit through a standard 36-inch wide industrial interior
door. Because the instrument is intended for use only by qualified users, Horiba
recommends that the equipment be protected from unauthorized access by locked
doors.

ENDA-4000 Manual Chapter 8: Installation
Floor: The instrument must be installed on a level floor capable of supporting the weight
of the equipment and the operators. If you intend to use a floor covering under the
equipment, avoid combustible materials, industrial carpeting, or materials that will permit
generation of electrostatic charges. A noncombustible laboratory floor covering will
reduce the possibility of contamination and eliminate electrostatic charges. A sealed
concrete floor is recommended. The ENDA-4000 is designed to be permanently
attached to four anchor bolts installed in the floor.
If local building and waste disposal codes permit, a recessed floor sink may be installed
to accommodate periodic discharge of the condensate trap water. Because of the
possibility of accidental discharge or spillage of trap water, Horiba does not recommend
the use of power receptacles recessed into the floor.
Elevation: The ENDA-4000 contains internal sparking parts that must not be exposed to
flammable vapors.
Walls:
The sample line, waste gas discharge line, signal cables, power conduits, and ventilation
ducts may penetrate the walls of the room. Horiba recommends the use of wall-mounted
power receptacles and bulkhead gas connectors.
Ceiling: The sample line, signal cables, and power conduits may penetrate the ceiling.
The waste gas discharge line must not be routed upward through the ceiling. Acoustic
sound reduction treatment is not required.
Illumination: Normal workroom lighting is recommended. Room lighting must be bright

enough to clearly view the controls and indicators but not so bright as to interfere with
viewing the screen. The ENDA-4000 should be oriented so that direct sunlight never falls
upon the screen or the analyzer.
Fire Protection. Horiba recommends that the room be equipped with an automatic fire
extinguishment system. Because the ENDA-4000 contains sensitive electronic
equipment, a halogen or CO2 system should be used. If possible, avoid using a
pressurized water sprinkler system or dry chemical extinguishers. The room should be
equipped with a portable CO2 or halogen fire extinguisher that meets local fire code
requirements.
To protect against the risk of fire or explosion, the ENDA-4000 must not be operated in
the vicinity of flammable gases or volatile liquid fuels.
Lightning Protection: Power and signal lines that connect to the ENDA-4000 should be
protected by approved lightning arrestors. Horiba also recommends the use of AC power
surge suppressors of the proper rating to protect sensitive electronic components. If
local codes permit, the waste gas discharge line to the building exterior should be made
of nonconductive materials. If metal piping is required by code, an approved lightning
protection system must be used and, if permitted, an insulated adapter should connect
the metal waste gas line to the ENDA-4000 waste gas discharge connector.

Chapter 8: Installation ENDA-4000 Manual
In addition, the primary filter assembly, heater, and optional sample line heater should
be protected by approved lightning arrestors. Consult a qualified electrician for
information about local code-compliant lightning protection.
8.2.2 Operating Environment
Temperature: The ENDA-4000 will operate reliably within the +5 40 C (23 104 F)
temperature range encountered in industrial buildings. Areas subject to extremes of
temperatures or rapid temperature changes (10 C [18 F] in 24 hours) must be
avoided. Horiba recommends that the room be equipped with an accurate thermometer.
Because the ENDA-4000 generates heat during operation, the equipment room may
require a supply of cooled air. The exact heat load from the equipment may be derived
from kVA figures supplied in the specifications.
The optional cold-environment instrument will operate within a -15 40 C (5 104 F)

temperature range. The optional hot-environment instrument will operate within a +5
50 C (23 122 F) temperature range.
Humidity: The ENDA-4000, in a NEMA-12 type cabinet, will operate reliably within 0
90 percent relative humidity (non-condensing).
Altitude: The ENDA-4000 will operate reliably at altitudes from sea level to 7500 feet (0
2286 m).
Barometric Pressure: The ENDA-4000 will operate reliably within the range of 950
1050 millibars (28 31 mm Hg).
Ambient Air Quality: The ENDA-4000 must be installed in an area free of air
contaminated by fuel vapors, stack gases, corrosive gases, span gases, chemicals,
dust, or other pollution. Horiba offers an optional environmentally controlled sealed
shelter for applications where the ambient air is contaminated.
Vibration: Avoid locating the ENDA-4000 in areas with elevated noise levels and areas
that experience severe transient noises.
Noise Emission: The ENDA-4000 generates sounds from the operation of valves,
relays, pumps and fans. The noise level is about the same as that generated by office
machinery and should not disturb adjacent work areas.

8.2.3 Required Access Clearances
Unobstructed access to the front and rear of the ENDA-4000 cabinet must be provided.
In addition, during installation, maintenance, and service operations, unobstructed
access must be available at the sides and top of the cabinet.
ENDA-4000 cabinet outlines and clearances are illustrated in Figure 81. Clearance
dimensions are listed in Table 81.
Figure 8-1: ENDA-4000 Required Clearances

Table 8-1: ENDA-E4000 Cabinet Dimensions and Required Clearances
DIMENSION UNITS (metric)

Height 75 in. (190.5 cm)
Width (without air conditioner) 25 in. (63.5 cm)
Width (with air conditioner) 33.5 in. (85.1 cm)
Depth 32 in. (81.3 cm)
Front Clearance 36 in. (91.5 cm)
Right Side Clearance 31.5 in. (80.0 cm)
Rear Clearance 28 in. (71.1 cm)
Top Clearance 6 in. (15.2 cm)
Weight 660 lb. (300 kg)
8.2.4 Electrical
In general, the ENDA-4000 made for use in North America is configured to use 120
VAC, 60 Hz power. Specific amperage requirements will vary, depending upon the
options ordered. The ENDA-4000 may also be factory-configured to operate on single-
phase or polyphase circuits at 208 VAC, 240 VAC, and/or 50 Hz.
The specifications describe the exact voltage, frequency, amperage, and kVA
requirements of your ENDA-4000 configuration. These factors will control the types of
wiring, circuit breakers, switches, and receptacles that must be used to supply AC power
to the equipment.
The instrument requires a source of "clean" electrical power that is free of noise,
transients, and surges. Ordinarily this requirement can be met by connecting the ENDA-
4000 to a dedicated circuit that originates at the building's main panel. In cases where
severe noise is present throughout your building, you may be required to install a line
filter or power-conditioner between the ENDA-4000 and the power line.

8.2.5 AC Power Wiring
Horiba recommends that the circuit serving the ENDA-4000 be routed through a main
shutoff switch mounted in the equipment room. Your local electrical code will dictate
specific requirements for the wiring, circuit breaker, and switch.
The power line serving the ENDA-4000 must not be shared with electrical equipment
that may generate line noise or voltage transients.
The ENDA-4000 is supplied from the factory with a conduit attachment point and
terminal attachment board. Refer to the specifications for detailed information about the
amperage and wiring requirements for receptacles or conduit-jacketed wiring to serve
the instrument.
In areas where lightning protection is recommended or required, Horiba recommends

that a lightning arrestor and/or surge suppressor be installed on all circuits serving the
equipment.
8.2.6 Signal and Control Wiring
Your ENDA-4000 may be configured to connect to external peripheral devices such as

chart recorders, data acquisition systems, etc. Signal cables must be shielded and must
conform to the end-to-end lengths imposed by the interface specifications. Signal wiring
guidelines are summarized in Table 82.
In areas where lightning protection is recommended or required, Horiba recommends

that a lightning arrestor be installed on all wiring that connects to circuits outside the
building.

Table 8-2: Signal and Control Wiring Guidelines
CABLE TYPE SHIELDING MAX CABLE

CIRCUIT TYPE
AND GAUGE REQUIRED? LENGTH
Analog Output 2-conductor Required 100 ft. (30 m)
22 AWG
8.2.7 ENDA-4000 Ventilation
IMPORTANT: The ENDA-4000 uses toxic gases. The ENDA-4000 must be connected to
a leak-tight ventilation line that safely discharges waste gases outside of the building.
The ENDA-4000 is equipped with a waste gas collection system that terminates in a
coupler that must be connected to an unobstructed leak-tight ventilation line that safely
discharges the waste gases to a point outside the building. The waste discharge line
must flow continuously downhill to prevent condensed water backflow. The discharge
point must be at atmospheric pressure and be free of fluctuations or backpressure. The
ENDA-4000 ventilation system is driven by the sample and reference gas pumps that
operate continuously when the equipment is in use.
The instrument provides a connector that attaches to a customer-supplied

1/2 in. NPT PVC ventilation line. If a pipe run greater than 20 ft. is required, pipe of a
larger diameter must be used.
If local building codes require that metal ducting be used to carry waste gases out of the
building, lightning protection may be required. Consult a qualified electrician for
information about code-compliant lightning protection.
The end of the waste gas line should be equipped with a rain-deflecting cap and/or a
trap that prevents water (rain or snow) from entering the line. To assure that no
backflow can occur, the ENDA-4000 ventilation line must not be shared with other
ventilation stacks in the building.
8.2.8 Room Ventilation
The ENDA-4000 generates heat during operation. You must provide adequate
ventilation for the comfort of the operators and the safety of the equipment. Room
ventilation or air conditioning systems should be designed to accommodate the
combined heat load of the operators, the ENDA-4000, heat-generating optional
equipment, heat radiated from sample lines, and heat radiated by adjacent equipment.
Refer to the specifications for information about the heat load of the ENDA-4000 and its
optional equipment. To assure reliable operation of the equipment, your ventilation or air
conditioning system must be carefully controlled to avoid producing rapid and/or extreme
variations in room temperature.

8.2.9 Waste Water Drain
IMPORTANT: During operation the ENDA-4000 collects condensate from the sample
line. Surplus condensate is discharged through a drain line. Your local sanitation code
may not permit you to discharge this wastewater into a sanitary sewer. In such cases,
you must connect the drain line to an approved waste collection system.
The ENDA-4000 requires a plumbing connection that permits the equipment to

discharge surplus condensate. This wastewater may be discharged into a floor sink
connected to the sanitary sewer. Where sanitation codes prohibit discharge of industrial
waste into the sewer, the drain line must be connected by unobstructed tubing to a
customer-supplied waste collection and storage system.
8.2.10 Gas Piping
WARNING: The ENDA-4000 uses compressed gases that are toxic and/or flammable.
Gas piping to the equipment must be installed, tested, and inspected only by qualified
personnel.
Ordinarily span gas cylinders are connected to individual pressure regulators and shutoff
valves. Short lengths of stainless steel or Teflon tubing are used to connect the
regulator discharge connectors to the cabinet bulkhead panel. The ENDA-4000 is
equipped with a bank of solenoid valves that operate under program control to select
and flow calibration gases through the calibration gas supply line. Typically, the
calibration gas supply line is attached to a connector on the primary filter assembly. This
design assures that span gases follow the same route (and are subjected to the same
conditions) as sample gas.
A typical five-analyzer ENDA-4000 will use five span gas cylinders and a zero gas
cylinder. A fully equipped ENDA-4000, configured for multiple analyzer ranges may use
additional cylinders.
A primary filter configured with the sample probe blowback option requires a permanent
connection to a customer-supplied compressed air source capable of delivering 6 8
scfm at 40 100 psi.
NOTE: Compressed air used for sample probe blowback must be dry and free of oil and
other contaminants.

8.2.11 Sample Line Piping
WARNING: The sample line contains high-temperature toxic gases. Sample line piping
to the ENDA-4000 must be installed, tested, and inspected only by qualified personnel.
A sample line connects the sample probe and primary filter to the sample conditioning
equipment. Depending upon ambient and stack gas temperature conditions, the sample
line may be electrically heated and wrapped in insulation.
The sample probe and primary filter must be installed at a point that is higher than the
sample line inlet connection to the instrument. This arrangement prevents condensed
moisture in the sample line from flowing back into the primary filter and clogging it. The
sample line must be kept as short as possible to reduce water condensation inside the
sample line and to reduce the response time of the analyzer. The sample line is routed
from the primary filter discharge connector to the sample input connector on the ENDA-
4000.
WARNING: The sample line may be very hot (150 C / 302 F) and present a risk of
burns if accidentally touched. The hot sample line may also melt nearby electrical
insulation and create a short-circuit or electric shock hazard. The sample line must be
properly routed and insulated to reduce risks to personnel and equipment.
When a heated sample line is used, the line must be insulated and installed with care to
avoid conducting heat into equipment or fittings that are not designed for high
temperatures.
If the system cannot be located so that the sample probe will be higher than the sample
system inlet, the sample line should be run so that there are no low spots which could
form water traps. The line may be run continuously up to a high point, then sloped
continuously downward to the ENDA-4000. In this fashion, any condensed water will
either run back into the process or down into the water separator (WS1).

8.3 Receiving
This subsection explains how to receive, unpack, and inspect the ENDA-4000. The
instrument cabinet is heavy and requires care to move safely. Please read and
understand all instructions and warnings before performing these tasks. Always use the
recommended safety equipment.
Shipping Containers
IMPORTANT: When crated for shipping, the ENDA-4000 weighs many hundreds of
pounds (kgs) and may be unevenly balanced and top-heavy. To avoid injuries or
damage when using a forklift truck or pallet-jack to move crated equipment, keep the
shipping container upright at all times.
Delivery Inspection
Inspect the shipping containers upon arrival at your facility. If the containers or contents
appear to be damaged, you must contact the carrier without delay and file a damage
claim. If shipping damage occurred, the carrier may wish to have a claims agent present
when the equipment is unpacked and inspected. You must also notify your Horiba
representative and advise that the equipment was damaged during shipment.
Preparation for Unpacking

If the shipping containers were received in good order, you may unpack the equipment.
You may wish to unpack and inspect the equipment on your receiving dock before
moving it to its permanent location, or you may wish to transport the equipment to the
installation site and unpack it there. When moving a crated unit, keep the shipping
container upright at all times.
Regardless of the location chosen for uncrating, you must position the ENDA-4000 so
that there is adequate working space on all four sides and above the crate. Make certain
that you have assembled the required tools, materials, and safety equipment before
beginning work.
Required Safety Equipment, Tools, and Materials

Steel-toe shoes Safety ladder (optional)
Required Tools:
18-in. pry bar or nail-puller Claw hammer
Box knife Pair of large scissors
Phillips-head screwdriver Straight-blade screwdriver
Strap cutter Pen or pencil
Inspection flashlight or lamp
Required Materials:
A copy of the packing list A copy of the purchase order

8.3.1 Unpacking
1. Remove all packing lists or other documents attached to the shipping containers.
2. Examine the shipping documents to make certain that they agree with your copy of
the order. If there is a discrepancy between the order and the items or quantity
shipped, contact your Horiba representative without delay.
3. Begin by opening the smaller shipping containers and inspecting their contents.
When using a box knife or scissors, take care not to damage the contents of the box.
4. Using the required safety equipment and tools, begin uncrating the ENDA-4000
cabinet by cutting the metal and/or nylon straps that surround the shipping container.
5. Remove any screws, nails, or staples that attach the topmost piece to the rest of the
shipping container. Watch out for sharp objects protruding from the packing
materials.
6. Carefully remove the top of the shipping and set it aside in a safe place. You may
need to use a ladder to reach the topmost areas of the container. Observe all safety
precautions when standing on and using ladders. Lift the packing material straight up
and off, taking care to avoid damaging the electrical fittings that may be found near
the top of the cabinet. Take care to avoid scratching the cabinet finish.
7. Carefully remove each of the side panels of the shipping container and set them
aside in a safe place. Watch out for sharp nails and/or screws protruding from the
packing materials. Take care to avoid scratching the cabinet finish when using
scissors or knives.
8. Remove the polyethylene sheeting that surrounds the cabinet. If possible, remove
this material by unwrapping the equipment by hand, rather than cutting this material
with scissors or knives.
9. Remove spacers, packing inserts, protective coverings, plastic bags, and other
shipping materials from the outside of the ENDA-4000. Do not use knives or scissors
to perform this task.
10. Carefully collect and dispose of the packing materials. Remove any protruding nails
and/or screws before discarding the crate material. Many of the packing materials
used by Horiba are suitable for recycling and need not contribute to landfills.
11. The ENDA-4000 and its associated components are now ready for receiving
inspection.

8.3.2 Receiving Inspection
1. Inspect the unpacked components for evidence of shipping damage. Compare the
quantity and labeling of each component to the shipping documents and/or purchase
order. If there is a discrepancy between the order and the items or quantity received,
contact your Horiba representative.
2. Inspect all four sides of the ENDA-4000 cabinet exterior for evidence of shipping
damage. The metal panels and doors should be un-dented and unscratched and
they should be properly aligned with the frame of the cabinet.
3. Inspect the top of the ENDA-4000 cabinet exterior for evidence of shipping damage.
The metal panel should be un-dented and unscratched and it should be properly
aligned with the frame below. Inspect the bulkhead panel and electrical fittings for
damage.
4. Open the front door of the cabinet and inspect the front surface of the equipment. All
flow meters, knobs, shafts, and switches should appear undamaged and properly
aligned. No broken glass or plastic should be found. No loose metal or plastic parts
should be present.
5. Open the rear door and use an inspection lamp to examine the rear surface and
interior of the cabinet. The interior apparatus should appear undamaged and
properly aligned. No broken glass or plastic should be found. No loose metal or
plastic parts should be present.
NOTE: It is normal to encounter unconnected cables inside the cabinet before the
ENDA-4000 has been installed.
6. If no damage to the ENDA-4000 or its components was discovered during

inspection, the equipment is ready to be moved to its permanent location and
installed.
7. If you discovered hidden damage during inspection, contact the shipper and Horiba
without delay. The shipper will furnish instructions on how to document the
discovered damage. Horiba will arrange to promptly ship replacement parts and
coordinate a site visit from a service technician.

8.3.3 Repacking for Return Shipment
Detailed repacking instructions are beyond the scope of this document. If it becomes
necessary to repack parts of the ENDA-4000 for return shipment to Horiba, contact your
Horiba representative for detailed instructions.
8.4 Mechanical Installation

This subsection explains how to move, orient, and mount the ENDA-4000 cabinet. The
ENDA-4000 cabinet is heavy and requires care to move safely. Please read and
understand all instructions and warnings before performing these tasks. Always use the
8.4.1 Required Safety Equipment, Tools, and Parts
The following safety equipment, tools, and parts are required to perform mechanical
installation tasks.

Steel-toe shoes
Required Tools:
Measuring tape Bubble level
Power drill and 5/16-in. bit Adjustable wrench
Marking pen or scribe
Required Parts:
(4) 5/16-in. anchor bolts 2-in. wide steel shim material
(4) 5/16-in. lock washers and nuts
8.4.2 Transporting the ENDA-4000 to the Site
If you have not already done so, move the ENDA-4000 and its associated equipment to
its permanent location. Use a forklift or pallet jack with sufficient lifting capacity to safely
carry 440 lb. (200 kg).
IMPORTANT: The ENDA-4000 weighs many hundreds of pounds (kgs) and may be
unevenly balanced and top-heavy. To avoid injuries or damage when moving a ENDA-
E4000, do not tilt the cabinet keep the cabinet upright at all times.

8.4.3 Orientation and Location
1. Orient the cabinet so that it is positioned with the necessary clearances from walls,
ceiling, and surrounding equipment and is facing the desired direction.
2. Use a measuring tape to verify that the necessary clearances have been observed.
Refer to Table 81 for required clearances.
3. If a floor sink has been provided, align the cabinet to permit wastewater discharge
line to be routed directly to the sink. Also make certain that the cabinet is aligned to
permit connection of the ENDA-4000 waste gas coupler to the waste gas stack.
4. The ENDA-4000 must be precisely level to operate reliably. Once the cabinet has
been moved into place and clearances have been checked, place a bubble level on
the top of the cabinet, along the wide axis of the cabinet and observe the position of
the bubble. Turn the bubble level 90 and place it on top of the cabinet, along the
deep axis of the cabinet, and observe the position of the bubble.
5. If the cabinet is not level, you must insert shims to raise the lower end(s). Correcting
an out-of-level plane usually involves installing shims in pairs. However, in some
cases of uneven floors, inserting a single shim will restore level conditions along both
planes at once. Use the bubble level to check your progress after each adjustment.
IMPORTANT: The cabinet must be supported at all four corners.
8.4.4 Installation of Anchor Bolts
IMPORTANT: The ENDA 4000 must be securely fastened to the floor with four anchor
bolts. Failure to properly secure the equipment as described can create an operating
hazard and may void the product warranty.
1. When the cabinet has been moved into its permanent position, re-measure all
cabinet clearances before proceeding.
2. If all clearances are within the limits shown in Table 81, use a marking pen or scribe
to mark floor with the location of the four anchor holes at the bottom of the cabinet.
Mark the center-points of each anchor hole.
3. Inspect the floor and the surrounding area to assure that holes drilled in the
marked locations will not penetrate underlying pipes, conduits, or structures.
4. Carefully move the ENDA-4000 cabinet away from the marked floor. Allow enough
space to permit drilling of the floor and setting of anchor bolts.

5. Use a power drill or hammer-drill and a 5/16-in. bit to bore four holes into the floor
where marked. Each hole must penetrate the floor to a minimum depth of 5 inches
(127 mm).
6. Install four anchor expansion bolts in the four holes using the procedure
recommended by the manufacturer. Refer to Figure 82 for anchor bolt mounting
details.
Figure 8-2: Anchor Bolt Installation Details
8.4.5 Attachment to Anchor Bolts
1. Carefully move the ENDA-4000 cabinet so that its four frame-bottom mounting holes
are aligned with the anchor bolt studs. Take care not to damage exposed threads on
the studs.
2. If necessary, replace the shims that were installed in Orientation and Location step 5.
3. Thread a lock washer over each threaded stud and attach the nut. Tighten all four
nuts securely.
4. Place the bubble level on the top of the cabinet, along the wide axis of the cabinet,
and observe the position of the bubble. Turn the bubble level 90 and place it on top
of the cabinet, along the deep axis of the cabinet, and observe the position of the
bubble.
5. If the cabinet is not level, loosen the nuts on the four anchor bolts and install shims
until the cabinet is level along both axes.

6. Retighten the anchor nuts and recheck the installation with the bubble level. If the
cabinet is level and is resting on all four corners, the mechanical installation of the
cabinet is complete.
8.5 Plumbing Installation

This subsection describes the materials required and procedures used to install the
ENDA-4000 sample probe, primary filter, sample line, waste gas ventilation line,
calibration gas supply line, and waste water drain. Please read and understand all
instructions and warnings before performing these installation tasks. Always use the

The following safety equipment, tools, and materials are required to perform plumbing
installation tasks.

Steel-toe shoes
Required Tools:
Adjustable wrench Safety ladder (optional)
Tubing cutter Tape measure
Required Materials:
Teflon tubing (.25-in. [6 mm] I.D. / .375-in. [8 mm] O.D.)
Teflon or stainless steel tubing (.25-in. [6 mm] O.D., 0.035 in. wall
1/2 in. PVC pipe
Permanent labels for gas lines
Teflon tape or paste thread sealant
Leak-indicating fluid
Tubing insulation and weatherproof covering
Pressure-test assembly (regulator, gauge, valve & tubing)
Compressed clean air (100 psi)
Required Parts:
Schedule-40, 3/4-in. stainless steel 316 pipe (probe)
2-in. ASA 150 lb. stainless-steel pipe flange
Flange gasket and mounting fasteners
Sample line electric heater and thermostat (optional)

8.5.1 Bulkhead Connection Panel
Most plumbing connections to the ENDA-4000 are made at the bulkhead connection
panel, located near the top rear of the instrument cabinet. Figure 83 illustrates the
panel.
Power 220 VAC Signal Wiring Cal Gas Instrument Sample

Blowback
to Probe Air Inlet
3/8" T 1/4" T 3/8" T 3/8" T

3/4" NPTF 3/4" NPTF
Power 115 VAC Probe Wiring Zero NO SO2 CO CO2 O2
Gas Span Span Span Span Span
3/4" NPTF 3/4" Watertight 1/4" T
Figure 8-3: Bulkhead Connection Panel
8.5.2 Ventilation Connection
IMPORTANT: The ENDA-4000 uses toxic gases. The instrument must be connected to
a leak-tight ventilation line that safely discharges waste gases outside of the building. To
protect the equipment from lightning discharge, the ventilation line must not form a
conductive path between the instrument and ground.
1. Locate a suitable waste gas discharge point, on the building roof or wall, where
waste gas can be safely discharged outside the building. The discharge point must
be below the ENDA-4000 to prevent condensate backflow. The discharge point must
vent to atmospheric pressure and not be subject to pressure fluctuations or
backpressure.
2. Locate the waste gas discharge connector near the bottom right of the ENDA-4000
cabinet. The connector is labeled SAMPLE OUTLET.
3. Determine and measure an appropriate route for the waste gas discharge line to
connect the two points. The discharge line must be kept as short as possible.
4. Using 1/2 in. PVC pipe and your measurements, fabricate a connection between the
instrument waste gas discharge connector and the discharge point.

5. If pieces must be joined, use a non-combustible sealing compound to secure joints.

Do not use duct-tape to seal joints. Run the pipe with a downward slope to a safe
ventilation point outside the building that is at atmospheric pressure.
6. Attach the waste gas line to the threaded discharge connector on the ENDA-4000.
7. Connect the far end of the waste gas line to the discharge point. Make certain that
the discharge point is protected against lightning and entry of water.
8. Inspect the finished waste gas line and connections for leaks or irregularities. If none
are found, the ventilation connection is complete.
8.5.3 Drain Connection
NOTE: The wastewater discharge line must drain freely, by gravity, to a location at
atmospheric pressure and no backpressure.
1. Before connecting the wastewater discharge line, test the drain or waste collection
system to make certain that flow is unobstructed.
2. Locate the wastewater discharge line connector on the right side of the ENDA-4000.
The connector is labeled DRAIN OUT.
3. Measure the distance between the drain discharge coupler and the floor sink or
waste connection. Cut or fabricate length of PVC piping to connect the drain coupler
to the waste discharge point. Use compressed air to blow all cuttings or chips out of
the finished tubing before connecting it.
4. Connect the PVC pipe to the coupler. Route the pipe safely to the discharge point
and secure it to the floor sink or attach it to a coupler on the waste collection system.
5. Inspect the finished drain line and connections for leaks or irregularities. If none are
found, the drain connection is complete.

8.5.4 Sample Probe and Flange
Selecting the Probe Location:

The sample probe is a stainless steel pipe that penetrates the smoke stack at a point
where a representative sample of stack gas can be obtained. When choosing a
location for the probe, the following requirements apply:
The probe should be mounted higher than the sample inlet of the ENDA-4000, or the
sample line from the probe must slope up, and then down. The sample line must
have no low spots that could form water traps. Any condensed water must be made
to either run back into the process or down into the water separator.
The probe should sample from a region of the stack that is free of turbulence,
irregular gas flow, or air penetration. Choose a location where no sudden changes to
stack gas velocity or pressure will occur. (Refer to regulatory requirements [e.g.
40CFR60] for details.)
The length of the outside portion of the sample probe flange may be adjusted to
produce radiant cooling of the sample gas. Horiba recommends that the sample
enter the primary filter at a temperature between 100 C and 250 C (212 F
482F).
When sample gas temperature is between 100 C and 250 C (212 F 482 F), and
the moisture content is 20 vol% or less, the sample probe flange should be jacketed
with insulating material and protected with a weatherproof covering.
When sample gas temperature is 482 F (250 C) or higher, the flanged pipe must
be made longer to provide radiant cooling of the sample to the 100 C 250 C
(212 F 482 F) range. Refer to Figure 84 to determine the recommended flange
length for various sample temperatures.
When sample gas temperature is below 100 C (212 F), the sample probe flange
must be electrically heated and insulated to prevent condensation. The temperature
at the primary filter must always be maintained above the dew point.
Horiba recommends that the sample line be heated. When the moisture content is
above 20 vol%, the sample line must be heated and maintained above the dew point.
The sample line from the probe and primary filter to the ENDA-4000 should be kept
as short as possible and must be trap-free.

Figure 8-4: Sample Gas Temperature to Offtank Flange Length Relation
Installing the Probe and Flange:
IMPORTANT: Do not open the stack wall or perform sample probe installation tasks
when the stack is in use. Allow the stack to thoroughly cool before performing these
installation steps.
1. Determine the appropriate location for the sample probe flange, taking into account
the requirements discussed in the preceding subsection.
2. For applications with greater than 20 vol% water and/or entrained droplets, the
flange must be mounted at a 5 degree downward angle. Refer to Figure 85 for
details about flange mounting.

Figure 8-5: Flange and Probe Mounting Details
3. Measure the stack wall at the planned point of penetration. Accurately measure the
flange pipe diameter.
4. Using the measurements as a guide, bore or cut an opening through the stack wall
that will accommodate the flange.
5. Use compressed air to blow chips and debris out of the opening.
6. Insert the flange in the opening and slid it into place until the flange end is flush with
the interior wall of the stack.
7. Weld or otherwise seal the external portion of the flange to the stack. A leak-tight
joint must be made before and after thermal expansion.
8. Use compressed air to blow dust and debris out of the flange interior.
9. Insert the sample probe of the primary filter assembly into the flange.

8.5.5 Primary Filter
Figure 86 illustrates the primary filter and its connections.
Figure 8-6: Primary Filter Connections
1. Position the probe pipe so that the bevel is on the bottom or perpendicular to the
direction of stack flow.
2. Attach the primary filter assembly to the flange using the supplied gasket. Secure the
primary filter by threading four bolts through the flange mounting holes and attaching
a lock-washer and nut to each. Use an adjustable wrench to carefully tighten the
nuts. Do not over tighten.

3. Open the door on the primary filter assembly in preparation for sample line and
power cable installation.
8.5.6 Heated Sample Line Assembly
WARNING: During operation this sample line contains high-temperature toxic gases.
Sample line piping to the ENDA-4000 must be installed, tested, and inspected only by
qualified personnel.
The ENDA-4000 heated sample line assembly connects the sample stream to the
instrument and connects calibration gases from the instrument to the primary filter inlet.
Ordinarily an un-spliced length of 3/8 in. Teflon tubing connects the primary filter to the
ENDA-4000, and an un-spliced length of 1/4 in. Teflon tubing connects the calibration
gas outlet on the ENDA-4000 cabinet to the calibration inlet on the primary filter. The
entire assembly (except for the primary filter) is jacketed by an electric heater and
wrapped in insulation.
WARNING: The sample line and primary filter may be very hot (482 F / 250 C) and
present a risk of burns if accidentally touched. A hot sample line may melt nearby
electrical insulation and create a short-circuit or electric shock hazard. The hot sample
line must be properly routed and insulated to reduce risks to personnel and equipment.
1. Refer to Figure 87 for details about allowable sample line configurations. Locate the
sample line discharge connector on the primary filter and the sample line inlet on the
ENDA-4000. The sample line inlet is labeled SAMPLE INLET. Determine and
measure an appropriate route for a sample line to connect these two points. The
end-to-end length of the standard sample line should not exceed 200 ft. Use of a
longer sample line requires factory-installed optional equipment.
To help prevent condensation, the sample line should be installed using a steep
vertical gradient of 1:5 or greater (i.e. the line drops 1 vertical unit for every 5
horizontal units).

Figure 8-7: Sample Line Configuration
2. Cut and trim the tubing to the appropriate length. Use compressed air to blow all
cuttings or chips out of the finished tubing before connecting it.
IMPORTANT: To prevent air leaks, the sample line must be made from a single tube. Do
not splice or join tubes between the primary filter and the sample inlet.
3. Insert the sample line through the heat-shrink boot. Connect the sample line tube to
the sample line discharge connector on the primary filter. Refer to Figure 86. Use
care to produce a leak-tight connection. Route the tubing safely to the top rear of
the probe enclosure.
4. Insert the calibration gas supply line (typically in the heated sample line bundle)
through the heat-shrink boot. Connect the calibration gas tube to the calibration gas
inlet connector on the primary filter. Use care to produce a leak-tight connection.
Route the tubing safely to the top rear of the probe enclosure.
5. When routing the connecting tubing, remember that this line will be carrying high-
temperature gases. Use care to avoid placing the tubing in contact with materials
that may melt or burn. Allow around the line. Provide a minimum of 1 in. (2.5 cm)
clearance between the sample line and other piping or conduits.
6. Connect the sample line tube to the sample inlet inside the cabinet. Use care to
produce a leak-tight connection.
7. Connect the calibration line tube to the calibration outlet inside the cabinet. Use
care to produce a leak-tight connection.

8. Inspect the finished connections and assembly for leaks, damage, or irregularities.
Correct any problems before proceeding.
9. Wrap all but the bottom 3-ft. (1 m) of the newly installed sample line assembly with
suitable thermal insulation. Do not use combustible material for this purpose.
10. Wrap the insulated length of the sample line with a weatherproof protective
covering.
11. Secure the insulated sample line using clamps and brackets.
12. Heat the heat-shrink boot with a heat gun to seal the heated line. Take care not to
melt the heated line.
13. Inspect the finished insulated line for slack, gaps, damage, or irregularities. If none
are found, the sample line piping connections are complete.
8.5.7 Blowback Air Piping (Optional)
If your ENDA-4000 was factory configured with the sample probe blowback option, you
must connect your compressed air source to the inlet fitting on the primary filter. An
optional heated line bundle with a blowback tube is available for this purpose.
IMPORTANT: Compressed air used for blowback purposes must be thoroughly dried
and free of oil or other contaminants. Horiba recommends installing an instrument-grade
drier/filter upstream of the blowback supply line.
1. Connect one end of the blowback tube to the compressed air supply shutoff valve.
Use care to produce a leak-tight connection.
2. Make certain that the shutoff valve is closed firmly. Connect the leak test assembly
to the open end of the tube and pressurize the line to 30 psig. Close the test
assembly valve and note the pressure reading. Wait three minutes. If the pressure
has remained stable during this period, the tubing is acceptable. If a pressure drop
is noted after three minutes, the tubing, fittings, or shutoff valve is leaking. Find and
correct the source of the leak before proceeding.
3. Disconnect the leak-test assembly from the tubing.
4. Pass the tube end through the heat-shrink boot on the primary filter cover and
connect the open end of the tube to the blowback inlet connector. Use care to
produce a leak-tight connection.
5. Secure the blowback air supply line using clamps and brackets.

6. Inspect the finished connecting line and couplers for damage or irregularities. If
none are found, the blowback air supply connections are complete.
8.6 Electrical Installation

This subsection describes the materials required and procedures used to connect the
ENDA-4000 to AC power and signal and control circuits. Please read and understand all
instructions and warnings before performing these installation tasks. Always use the
Required Safety Equipment, Tools, and Materials:

The following safety equipment, tools, and materials are required to perform electrical
installation tasks.

Steel-toe shoes
Required Tools:
Polarity & ground fault indicator Small straight-blade screwdriver
Volt-Ohmmeter (VOM) Small Phillips-head screwdriver
Required Materials:
Wire nuts Interface cables (optional)
Permanent labels for cables
8.6.1 AC Power Connection
Prior to installation, the room containing the ENDA-4000 must be pre-wired for AC
service to the equipment. The specifications provide details about voltage and current
requirements of your ENDA-4000 configuration.
the ENDA-4000 must be installed, tested, and inspected only by licensed electricians or
Refer to the electrical drawings in the appendix for details about power and signal
connection details for your ENDA-4000. Read and understand this figure and the
electrical drawings that accompany the ENDA 4000 before performing electrical
installation tasks.
1. Locate the conduit that will serve the ENDA-4000. Make certain that it has been
wired to supply the required voltage and current. Attach a permanent label to the
conduit that indicates the maximum amperage rating for the circuit.

2. Make certain that the main switch and/or circuit breaker that serves the conduit
wiring is turned OFF before proceeding.
3. Use an ohmmeter to test the resistance between the ground wire of the circuit and
true ground. For safe operation, a resistance of zero ohms is required. If problems
are revealed, find and correct the problem before proceeding to step 4.
4. With the facility main switch and/or circuit breaker turned ON, carefully use a
voltmeter, set to the appropriate AC voltage setting, to measure the voltage
between the hot and neutral wires of the circuit. The polarity of the wires must be
correct and the indicated voltage and variances must correspond to the voltages
and tolerances specified in the specifications for your ENDA-4000 configuration. If
problems are revealed, find and correct the problem before proceeding to step 5.
5. Connect a voltmeter to the circuit and trip the associated circuit breaker, then reset
the breaker. Make certain that power to the circuit is interrupted and restored.
6. Connect a voltmeter to the circuit and turn the associated main switch OFF, then
ON. Make certain that power to the circuit is interrupted and restored.
7. Turn the main switch and/or circuit breaker that serves the conduit wiring OFF
before proceeding.
8. Locate the AC conduit attachment point inside the junction box in the ENDA-4000
cabinet. Each conduit coupler will be labeled to identify the associated circuit.
9. Remove the cover from the supply circuit junction box. Remove the wire nuts from
each lead and set them aside.
10. Firmly attach the conduit to the coupler on the ENDA-4000 cabinet. Pull three wires
(hot, neutral, and ground) from the junction box through the conduit and into the
ENDA-4000 cabinet.
11. Connect the three-wire set to the circuit breakers inside the junction box. Use
approved wire-nuts and observe correct polarity.
12. Connect the three-wire set inside the ENDA-4000 cabinet circuit breaker CB1.
Connect the hot lead to the terminal labeled H. Connect the neutral lead to the
terminal labeled N. Connect the ground lead to the ground bus GND.
13. Secure the wires at the conduit fitting when connection is completed.
14. Inspect the completed wiring for irregularities. If none are found, replace the cover
on the supply junction box and secure it.

8.6.2 Primary Filter Power Connection
The electric heater in the primary filter assembly is powered by a cable that originates at
the ENDA-4000 junction box.
the ENDA-E4000 must be installed, tested, and inspected only by licensed electricians
or other qualified personnel.
1. Make certain that the main switch and/or circuit breaker that serves the ENDA-4000
2. Fabricate and install a code-compliant conduit from the primary filter heater to the
conduit attachment point on the ENDA-4000 cabinet. Refer to the electrical
drawings in the appendix for locations.
3. Pull three wires through the conduit from the ENDA-4000 cabinet to the primary
filter.
4. Pass the wires through the protective cover of the primary filter and attach the hot
and neutral leads to the labeled terminals TS2 1 & 2 inside the primary filter
assembly. Attach the ground lead to the ground terminal. Use approved wire-nuts
and observe correct polarity.
5. Close the door of the primary filter assembly.
6. Connect the three-wire set inside the ENDA-4000 cabinet to the three-prong plug
supplied with the cabinet. Connect the hot lead to the gold terminal; connect the
neutral lead to the silver terminal; connect the ground lead to the green terminal.
7. Plug the finished plug into receptacle PLG-10 on the rear of the junction box.
9. Inspect the completed wiring for irregularities. If none are found, the primary filter
wiring task is complete.

8.6.3 Sample Line Heater Power Connection
the ENDA-4000 must be installed, tested, and inspected only by licensed electricians or
A cable that originates at the ENDA-E4000 terminal board powers the sample line
electric heater. Figure 88 illustrates sample line heater details.
Figure 8-8: Sample Line Heater Details
1. Make certain that the main switch and/or circuit breaker that serves the ENDA-4000
2. Fabricate and install a code-compliant conduit from the ENDA-4000 cabinet to the
lead attachment point for the sample line heater. Provide a weatherproof junction box
at the heater end of the conduit.
3. Pull three wires through the conduit from the ENDA-4000 cabinet to the junction box.
4. Attach the three wires to the heater leads inside the junction box. Use approved wire-
nuts and observe correct polarity.

5. Replace and secure the junction box cover.
6. Connect the three-wire set inside the ENDA-4000 cabinet to the 20-amp circuit
breaker CB2. Connect the L1, L2 and ground leads to the circuit breaker.
8. Inspect the completed wiring for irregularities. If none are found, the sample line
heater wiring task is complete.
8.6.4 Signal and Control Cable Connection
The following procedures describe how to connect various optional signal and control
cables to the ENDA-4000. If your configuration does not support one or more of these
connections, you may disregard the associated installation procedure.
8.6.4.1. Analog Output Cables to Chart Recorder
If your ENDA-4000 is configured to support an attached multi-channel chart recorder,

you may connect the analog output cables to the recorder by performing the following
steps:
1. Make certain that the ENDA-4000 and the chart recorder is located within the
specified distance limits. Refer to Table 83 for details about distance limits.
2. Attach the analog signal input leads for each channel to the chart recorder. Follow
the instructions provided by the manufacturer of the recorder.
3. Attach a label to each analog cable that indicates the assigned channel number.
4. Safely route the analog signal cables from the recorder to the rear of the ENDA-4000
cabinet. Push the cable ends through the cable pass-through in the cabinet and
carefully route the cables to the rear of the logic enclosure. Make certain that the
cables are not resting on heated or energized components within the cabinet. You
may wish to use plastic cable ties to secure the cables to frame or cross-members.
5. Refer to the electrical drawings that accompany the ENDA-4000. Locate terminals
TB4 and TB5 on board EN-TML. Attach the leads for each channel to the indicated
terminals. Refer to Tables 23 and 24 in Chapter 2 for pin-outs. Use a small
screwdriver to tighten the terminal screws.
6. Inspect each cable for loose connections or irregularities. If none are found, the
analog output cable installation is complete.

8.7 Subassembly Setup

This subsection describes how to setup ENDA-4000 subassemblies. Disregard setup
instructions for options not configured for your ENDA-4000. Sensitive and fragile parts
are used in ENDA-4000 subassemblies. Please read and understand all instructions and
warnings before performing these installation tasks. Always use the recommended
safety equipment.

The following safety equipment, tools, and materials are required to perform
subassembly setup tasks.

Safety glasses
Required Tools:
Inspection lamp or flashlight
Required Materials:
3 quarts (3 liters) clean water
8.7.1 Overflow Trap
1. Locate the condensate overflow trap. Refer to the diagrams furnished in Chapter 2
Hardware Description.
2. Carefully remove the protective cover from the top of the overflow trap.
3. Carefully fill the condensate overflow trap with clean water until surplus water is seen
flowing out of the wastewater drain line. By introducing water into the overflow trap,
the constant pressure trap and the reference gas humidifier bath, downstream of the
overflow trap, will both be filled to operating level. Excess water will be discharged
through the drain line.

8.8 Installation Checks

This subsection describes how to turn on power and perform basic checks of the
electrical subsystems of the ENDA-4000. No safety equipment, tools, or materials are
required. Please read and understand all instructions and warnings before performing
these tasks.
IMPORTANT: Do not perform a power-on check before all preceding installation tasks
have been successfully completed. The ENDA-4000 must be correctly installed, wired,
and plumbed before it is energized.
1. Inspect the power cables and conduits attached to the ENDA-4000 and related
equipment.
2. Make certain that all switches on the front of the ENDA-4000 power distribution panel
are set to the OFF position.
3. Turn ON all facility circuit breakers that control power to the lines that serve the
ENDA-4000.
4. Turn ON all wall-mounted main switches that that control power to the lines that
serve the ENDA-4000.
5. Locate the main switch (labeled INSTRUMENT/AUXILIARY) on the front of the

power distribution panel and turn it ON. The orange neon indicator inside the switch
will glow, indicating the presence of power. The cabinet ventilation blower will start
and the display screen will be illuminated. All display labels will light briefly, then the
normal display will appear.
6. Locate the heated primary filter circuit switch (labeled HEATED PRIMARY FILTER)
and turn it ON. The orange neon indicator inside the switch will glow, indicating the
presence of power.
7. Locate the pump circuit switch (labeled PUMP) and turn it ON. The orange neon
indicator inside the switch will glow, indicating the presence of power. The sample
pump and reference gas pumps will start.
8. If your ENDA-4000 is equipped with a heated sample line, locate the heated sample
line circuit switch (labeled HEATED LINE) and turn it ON. The orange neon
indicator inside the switch will glow, indicating the presence of power.
9. If no problems were encountered during the power-on check, the ENDA-4000 is

ready for the post-installation inspection.

8.9 Post-Installation Inspection

The post-installation inspection is a formal procedure for reexamining all installation
steps to assure that they have been performed correctly. Use the inspection checklist to
review each installation step and mark the result in the box provided. When the post-
installation inspection is complete, your ENDA-4000 is ready for the system verification
check described in the following chapter.

The following safety equipment and materials are required to perform post-installation
check tasks.

Safety glasses
Required Materials:
Inspection checklist

8.9.1 Inspection Checklist
REMARKS OR
INSTALLED
CORRECTIVE
INSTALLATION ITEM CORRECTLY?
ACTION
(YES / NO)
REQUIRED
Equipment room door is lockable and
meets local building and fire codes.
Equipment room contains a portable
CO2 fire extinguisher.
Equipment room has automatic fire (Option)
detection system.
Equipment room has non-water (Option)
automatic fire extinguishment system.
Cabinet is located in draft-free,
vibration-free, dust-free room.
Cabinet is not in direct sunlight or in
cooling drafts.
Cabinet is level on both axes and
secured to four anchor bolts.
Correct clearances were observed for
four sides and top of cabinet.
Ventilation coupler is connected to
leak-tight waste gas discharge line.
Ventilation line is unshared with other
vents and exhausts to outside bldg.
Ventilation line is unobstructed and
protected from water entry.
Ventilation line is protected from
lightning.
Wastewater drain line is plumbed to
working drain or waste collection
system.
Span gas line from span gas manifold
has passed leak test.
Sample line has passed leak test.
Compressed dry air is connected to (Option)
blowback inlet by leak-tight tubing.

REMARKS OR
INSTALLED
CORRECTIVE
INSTALLATION ITEM CORRECTLY?
ACTION
(YES / NO)
REQUIRED
All gas lines were checked for leaks
during and after installation.
Sample line is connected correctly
and was inspected for leaks.
Heated sample line is insulated and (Option)
isolated from contact with
combustibles.
Building circuit breakers and switches
are installed correctly and tested.
AC power wiring is of correct voltage
and amperage.
AC power wiring observes correct
polarity and ground.
Circuit ground has zero ohm
resistance to true ground.
AC power conduits are labeled to
show capacity.
Overflow trap is filled with water to the
correct level.
Constant-pressure trap is filled with
water to the correct level.
Reference gas humidifier bath is filled (Option)
with water to the correct level.
Power-on check performed without
encountering problems.


9.0 System Verification Checks
9.1 Overview
This chapter provides a detailed step-by-step procedure for verifying that an installed
ENDA-4000 is operating within specifications and is ready for performing
measurements. The procedure consists of an ordered list of tasks and a description of
the expected result. These system verification checks should be performed following the
installation a ENDA-4000 and after major maintenance or repairs have been completed.
IMPORTANT: The ENDA-4000 should be operated only by trained and qualified

personnel. Always follow safety warnings.
Required Safety Equipment and Materials

The following safety equipment and materials are required to perform system verification
check tasks.

Safety glasses
Required Materials:
Procedure checklist
Accurate contact thermometer (250C / 482F)
9.2 Preparation
Before performing any system verification checks, make certain that the ENDA-4000 has
been installed as described in Chapter 8. The following items should be rechecked
before proceeding:
1. All span gas supply lines and the ventilation line are properly connected and have
been thoroughly tested for leaks.
2. The wiring, circuit breakers, and shutoff switches to the equipment are installed
properly and are working.
3. The traps and bath are filled to the proper level with water.
4. All span gases and service gases have been connected in the bottle room.
5. Span gas shutoff valves are turned ON, supply lines are pressurized, and regulators
are set to the proper pressure.

ENDA-4000 Manual Chapter 9: System Verification Checks
9.3 Verification Checks

Perform the following check tasks in the indicated order:
1. Turn on the The power indicator should be illuminated

INSTRUMENT/AUXILIARY and the front panel displays and indicators
switch. should be illuminated.
2. Turn on the HEATED The power indicator should be illuminated.
PRIMARY FILTER switch.
3. Turn on the HEATED LINE The power indicator should be illuminated.
switch (if so equipped).
4. Allow the equipment to warm
up for 20 minutes before
performing steps 5 and 6.
5. Use a contact thermometer to The temperature should be between 100 C
measure the temperature of and 250 C (212F 482F).
the primary filter.
6. Use a contact thermometer to The temperature should be above 120C
measure the temperature of (248F).
the sample line.
7. Turn on the PUMP switch. The power indicator should be illuminated.
The sample pump and the reference gas
pump should start.
8. Open the cabinet and inspect Two bubble streams should issue from the
the constant pressure trap. bottom of the dip tubes. Refer to Figure 51
in Chapter 5 for specifications.
9. Adjust needle valve NV-1 for The sample gas bubble stream should
the correct sample gas bubble respond to changes in the setting of the
stream. needle valve.
10. Adjust needle valve NV-2 for The reference gas bubble stream should
the correct reference gas respond to changes in the setting of the
bubble stream. needle valve.
11. Observe the main sample The flowmeter should indicate gas flow of
flowmeter FM-1A. 1.0 lpm.
12. Observe oxygen sample flow- The flowmeter should indicate gas flow of
meter FM-4a, if so equipped. 30 ml/min.
Otherwise skip to step 13.
13. Set the correct time of day The analyzer should accept the new
into the analyzer clock. Refer entries.
to Chapter 4 for instructions.

Chapter 9: System Verification Checks ENDA-4000 Manual
14. Wait 3 hours for the No alarm conditions should occur during
temperature of the instrument warm-up.
to stabilize before performing
the following steps.
15. Press the Automatic The analyzer should begin an automatic
Instrument Calibration (AIC) calibration sequence.
button.
16. Wait 40 minutes for the No alarm conditions should occur during
automatic calibration to be calibration.
completed.
17. Recheck the settings of The bubble streams from the dip tubes
needle valves NV-1 and NV-2. should be as shown in Figure 51.
18. Recheck flowmeters FM-1A The flow rates should be as indicated in
and FM-4A (if equipped). steps 11 and 12.
19. Observe the concentration The display should show valid
display and the component concentration data for the indicated
indicator. component gas.
20. Verification checks are now
complete.

ENDA-4000 Manual Chapter 9: System Verification Checks

10.0 Analyzer Parts List
10.1 CMA-600 Analyzer
REF HII P/N QTY DESCRIPTION HOR P/N

1 1 Plate H568424-01
2 1 Front case H369961-01
3 384987 2 Mounting bracket H510863-01
4 1 Key sheet H370426-01
5 1 Display mounting hardware H230692-01
6 1 PCB, EN-PNL-05 U801154800
7 320280 18 Stay, P-523-14 F022017700
8 1 PCB, AP-MPU-02 U801155700
9 385162 2 Fan, D09T-24PH F021894500
10 2 Plate, fan H569523-01
11 1 PCB, EN-ADA-01 U801380500
12 1-4 PCB, EN-AMP-01, (IR), discontinued U801155800
use part no.
13 16 Spacer, KGLS-3S F022275900
14 1 Mounting hardware H369960-01
15 1 Power supply U801437800
16 1 Switching power supply, EWS50-5 E012910500
17 320030 5 Filter, cover H511212-01
18 1 Cover H230688-01
19 13 Wire band, WS-1 F022830500
20 1 Guides, PCB
21 1 Chassis H240245-01
22 1 Switching power supply, EWS150-15 E012910400
23 1 PCB, EN-PIO-01 U801156200
24 1 PCB, EN-AMP-01, (MPA), U801155900
discontinued use part no.
25 1 PCB, EN-RPL-01 U801154900
26 1 Frame, rear H369959-01
27 360262 1 Ground terminal E010570800
28 1
29 1 Noise filter, FN285-6106, 250, 6A E012858900
30 1 Noise filter, FN2080-3-06
31 1
32 1 Solenoid assembly
33 310495 1 Bench unit, O2, MPA
34 310500 1 Bench unit, NOX/CO2, NDIR

ENDA-4000 Manual Chapter 10: Analyzer Parts List

310514 1 Bench unit, NOX/SO2/CO2, NDIR
310515 1 Bench unit, CO2, NDIR
310516 1 Bench unit, SO2, NDIR
310517 1 Bench unit, SO2/CO2, NDIR
310493 1 Bench unit, NOX, CLD
35 310497 1 Bench unit, CO, NDIR
1 Kit, bench unit CO% range, NDIR
36 303043 4 Joint L G8014770
37 384818 4 Hose clip H511428-08
38 350222 1 Tubing, Teflon F020092000
39 1 F020074600
40 303033 4 Hose clip
41 1 Flow tube, tapered, 10 x 100 ml F020173300
42 1 H520282-01
43 1
44 380172 1 Joint, 3-way H568364-01
45 1
46 303042 1 Flow tube, tapered, 0.2 x 2 lpm H520283-01
47 1 Flow meter case H570797-01
48 303019 1 Tube, Tygon, 5 x 9 F021529600
49 303001 1 Scrubber, ESU-050A U801149600
50 384381 1 L-fitting H473812-05
51 384378 1 Pipe clip H456665-05
52 320254 1 Hose band F021463100
53 303020 1 Tube, Teflon, 1 x 3 F020287400
54 G8812663 1 PCB, EN-SVC-01 U801266300
55 1 SVD cable H583470-01
56 1-4 PCB, PG-AMP-03 (IR) U801439800
57 G8815086 1 PCB, PG-AMP-02 (MPA) U801508600
58 1 EEPROM, phase 2, ver. 1.10 U801396700
59 253858-1 1 Signal cable, 50 pin, EM-RR-01
60 253859-1 1 Signal cable, 30 pin, EM-TML-01
61 253860-1 1 Option cable, 40 pin, EM-TRL-01

Chapter 10: Analyzer Parts List ENDA-4000 Manual
Figure 10-1: ENDA-600 Exploded View

10.2 NOX, SO2, and CO2 IR Bench

1 1 Fin, heat radiation U801160800
2 1 Light source, HHL-AGR-100-1 U801160100
3 3 Holder, light source H568950-01
4 4 Mirror plug H570786-01
5 1 Solid filter, LPF-01001 U801176700
6 G8815549 1 Mirror block assembly, CO2 U801159400
7 1 Plate, mirror block H568874-01
8 1 Gas cell U801156900
9 2 Packing H568887-02
10 2 Cell holder H230570-01
11 2 Packing H568054-01
12 1 Cell assembly H568086-01
13 2 Washer, insulation E012982600
14 1 Plate H568875-01
15 1 Mirror block assembly, NOx, SO2 U801154400
16 352119 1 Solid filter, SO2 U800330000
17 350222 1 Tube, Teflon, 2 x 3 F020074600
18 384378 4 Pipe clip H456665-05
19 384381 3 L-fitting H473812-05
20 320254 4 Hose bands F021463100
21 1 Thermistor, PXA-64 E013128100
23
24 3 Wire band, WS-1 F022830500
25 1 Base, bench H569519-01
26 355034 1 Retainer plate H507897-01
27 1 Short cell, CO2 U801154500
28 1 Spacer cell U801159200
29 1 Sensor assembly, PYR-01, CO2 U800907300
30 303085 1 Detector, AS5, SO2 U800670000
31 355020 2 Insulation plate H521141-01
32 355023 2 Insulation sheet 3 H520186-01
33 355021 2 Insulation sheet 2 H520187-01
34 4 Insulation seat H593189-01
35 2 Heater, EY0013A0-R F022836200


36 1 O-ring H580691-01
37 303084 1 Detector, AS5, NO U800669900
38 1
39 320116 4 Stand, Pre-amp H514230-01
40 303082 2 PCB, PRE-02, NO, CO, SO2 U800658900
41 320113 2 Case, Pre-amp H514685-01
42 1
43 352126 8 Stay, M3 H443993-01
44 1
45 1 Cover H369884-01
46 355039 3 Edge saddle F021485900
47 303021 1 O-ring, NOK S14 F021469500
48 1 O-ring, NOK S-7 F020645700
49 351013 1 O-ring, NOK S28 F020349100
50 2 Retainer plate H581103-01
51 4 Insulation sheet H581415-01
52 1 Packing, neoprene H443963-01
53 2 SF packing H570798-01
54 4 Sleeve insulation E012366300
55 1 Ring H517678-01
56 385903 1 Cell packing H506772-01
57 2

Figure 10-2: NOX, SO2, and CO2 IR Bench Exploded View

10.3 CO Bench

1 1 Fin, heat radiation H250352-01
2 1 Light source, HHL-AGR-100-1 U801160100
3 2 Holder, light source H568950-01
4 1 Block, tapered U801159300
5 1 Packing H568887-02
7 2 Packing H568054-01
8 1 Cell assembly H568086-01
9 355034 1 Retainer, cell H507897-01
10 1 Plate H569518-01
12 1
14 385310 1 Optical window H421238-03
15 1 Packing, window H550755-01
16 352116 1 Solid filter, CO U800432700
17 303083 1 Detector, AS5, CO U80658800
18 572261-1 1 Base-2, bench H569517-01
1 Base, % CO, 3mm
19 1 Cover H369886-01
572256-1 1 Cover, % CO, 3mm
20 355039 3 Edge saddle F021485900
21 2 Wire band F022830500
22 1
23 320254 1 Hose band F021463100
24 384381 2 L-fitting H473812-05
25 384378 2 Pipe clip H456665-05
26 350222 1 Tube, Teflon, 2 x 3 F020074600
27 355020 1 Insulation plate H521141-01
28 2 Insulation seat H593189-01
29 355023 1 Insulation Sheet, 3 H520186-01
30 1
31 1
32 1 Heater, EY0013A0-R F022836200
33
34 355025 2 Bushing, B-1 3K E010612300


35 320116 2 Stand, pre-amp H514230-01
36 303082 2 PCB, PRE-02, CO U800658900
37 352126 4 Stay, M3 H443993-01
38 320113 2 Case, Pre-amp H514685-01
39 1 Plate, retainer H581103-01
40 2 Insulation sheet H581415-01
41 2 Sleeve insulation E012366300

Figure 10-3: CO Bench Exploded View

10.4 O2 Bench

1 374371 1 Excitation coil H460496-05
2 374372 1 Pole B H460440-01
4 1 MPA Cell-2 H366037-01
5 1 Cell spacer H557061-01
6 1 Packing H557308-01
7 1 MPA Cell-1 H366036-01
8 303090 1 Detector, MPA U801066000
9 320113 1 Case, Pre-amp H514685-01
10 352126 2 Stay, M3 H443993-01
11 320115 1 PCB, PRE-01, O2 U800601800
12 320116 1 Stand, Pre-amp H514230-01
13 2 Capillary, SA-171-QJ U801156400
14 1
15 303047 2 Packing, capillary H518091-01
16 352134 7 O-ring, P4 F02006440
17 383983 3 Fitting, 8.5 2.8 - 24L H454994-05
18 384381 1 L-fitting H473812-05
19 320254 3 Hose band F021463100
20 384378 3 Pipe clip H456665-05
21 1 Pattern block, MPA H370204-01
22 383522 1 Hose clip F020113200
23 1 Cell assembly, MPA U801434800

Figure 10-4: O2 Bench Exploded View

10.5 Solenoid Valve Block

1 1 Pattern block, SV H230732-01
2 300005 2 Capillary, SA-102-QJ U800638600
3 1
4 385442 1 Capillary, SA-201-QJ U800641700
5 2 Capillary, SA-060-KJ U801214000
6 303047 5 Packing, capillary H518091-01
7 2 Solenoid valve, MV-14-1, 24Vdc U800860000
8 1
9 385132 2 O-ring, P3 F020058200
10 380033 2 Packing sheet, SV F021358100
11 320254 8 Hose band F021463100
12 384381 3 L-fitting H473812-05
13 384378 6 Pipe clip H456665-05
14 383983 3 Fitting H454994-05
15 1 Inlet block H569526-01
16 6 Union, half F022709600
17 1
18 320050 4 Filter, P8 H516549-02
19 2 Hose end H502410-02
20 383522 2 Hose clip F020113200
21 2 O-ring H020005100
22 1 Cap H443969-02

Figure 10-5: Solenoid Valve Block Exploded View

10.6 Pressure Trap, Humidifier, and Silica Gel

ENDA-4000

1 602144-6 2 Hose clip
2 1 Pressure trap H230887-01
3 383522 2 Hose clip F020113200
4 303019 1 Tubing, Tygon, 5 x 9 F021529600
5 100696 1 Tubing, Tygon, 3/8 x 9/16
Cap, new style H4436969-01
6 602144-1 4 Hose clip
7 100152 1 Tubing, Teflon, 1/4
Cap w/o CLA
8 100699 1 Tubing, Tygon, 1/2 x 11/16
9 1 Bracket, silica gel
10 361382 1 Silica gel, 500 gram bottle F020902900
11 602144-14 2 Hose clip
12 383983 2 Fitting H454994-01
13 601244-4 1 Hose clip
14 100036 1 Tubing, Teflon, 1/8
15 100698 1 Tubing, Tygon, 5/16 x 1/2
303221 1 Cap, new style
16 100700 1 Tubing, Tygon, 3/16 x 3/8
17 1 Bubbler H569262-01
18 303043 1 Elbow
19 361226 1 Filter Element F021565700
20 1
21 1 Cap H0451271003
22 1
23 1 Bracket
24 1
25 381623 1 Hose clip F020173200
26 303223 1 Blind cap H443969-04
27 1 Silica gel complete assembly U801339600
28 1 Bubbler assembly w/ bracket U801264300
29 1 Pressure trap assembly U801261900
30 602144-2 4 Hose clip

Figure 10-6: Pressure Trap, Humidifier, and Silica Gel Exploded View

10.7 I/O Analog Outputs PCBs ENDA-4000

1 1
2 1
3 1 PCB, EN-TML-01 U801201100
4 1 PCB, EN-RR-01 U801201200
5 1
6 1
7 253859-1 1 Cable, PS-D30CM-100X-1D E011739200
8 253860-01 1 Cable, PS-D40CM-80X-1D E011740600
9 253858-1 1 Cable, PS-D50CM2-100X-1D E011742200

Figure 10-7: I/O Analog Outputs PCBs Exploded View

10.8 Overflow Trap and Buffer Tanks ENDA-4000

1 1 Overflow tank complete assembly U801261800
2 1 Buffer tank complete assembly U801264400
3 1
4 1
5 1
6 1
7 1
8 1 Hose clip
9 100696 1 Tubing, Tygon, 3/8 x 9/16
10 1 Bracket
11 1 Trap, overflow H563916-03
12 1 Hose clip
13 100699 1 Tubing, Tygon, 1/2 x 11/16
14 1 Tank, buffer U800797800
15 1
16 1 Plate H569277-01
17 320009 8 Hose clip F020207700
18 4 Joint, rubber H434654-02
19 350222 1 Tubing, Teflon, 2.0 x 3.0 F020074600
20 303019 1 Tubing, Tygon, 5.0 x 9.0 F021529600
21 100152 1 Tubing, Teflon, 1/4 x 1/8
22 100700 1 Tubing, Tygon 3/16 x 3/8

Figure 10-8: Overflow Trap and Buffer Tanks Exploded View

10.9 Water Separator ENDA-4000

1 1 Drain separator complete assembly U801261700
2 1 DS bracket H570969-01
3 1 Plate, fitting H560777-01
4 1 Water separator H570237-01
5 1 Cover H560778-01
6 385162 1 Fan, D09T-24PH F021894500
7 320042 1 Guard, fan F021281300
8 1 Rubber joint H559227-01
9 1 Rubber joint H534574-01
10 3 Hose clip
11 3 Hose clip
12 2 Grommet F020039200
13 1
14 100699 1 Tubing, Tygon, 1/2 x 11/16
15 1
16 1
17 1
18 100150 1 Tubing, Teflon, 3/8 x 1/4
19 100152 1 Tubing, Teflon, 1/4 x 1/8
20 1
21 100700 1 Tubing, Tygon, 3/16 x 3/8

Figure 10-9: Water Separator Exploded View

10.10 EC600 Bench

1 1 Case, Pre-amp H514685-01
2 1 Detector Unit U801235800
3 H058371101 1 Plate, Detector H583711-01
4 1 Reactor U801101900
5 G8811319 1 W O-ring H0566868001
6 1 Plate, CLA base H583710-01
7 1 O3 generator H371887-01
8 1 Plate, O3 H583300-01
9 G8813690 1 EN-CLP-02 Assembly, PCB and U801369000
bracket
10 2 Cover, capillary H583700-01
11 1 Solenoid valve U801156700
12 385439 1 Capillary, SA-701-Q U800647800
13 1 Block, pattern, CLA H381844-01
14 380169 1 O-ring F020058100
15 310454 1 O-ring F020553800
16 385440 1 Capillary, SA-700-QJ U800647600

Figure 10-10: EC600 Bench Exploded View


INSTRUCTION MANUAL
CLASSIC THERMO-ELECTRIC COOLERS

Model M115
Baldwin, Inc. Tel: 775-850-1800

895 E. Patriot Blvd., Suite 107 Tel: 888-234-7366 (toll free US)
Reno, NV 89511 USA Fax: 775-850-1818
www.baldwinUSA.com Email: info@baldwinUSA.com
TABLE OF CONTENTS
A: Specifications................................................................................................................ 3
B: Limited Warranty........................................................................................................... 4
C: Principle of Operation ................................................................................................... 5
D: Installation .................................................................................................................... 8
E: Start-up Procedure ....................................................................................................... 9
F: LED Indicators ............................................................................................................ 10
G: I/O Terminal Block Description................................................................................... 11
H: Test & Adjustment Procedures................................................................................... 12
I: Description of Options.................................................................................................. 15
J: New Jersey Thermocouple Option............................................................................ 16
K: Troubleshooting .......................................................................................................... 17
L: Spare Parts .................................................................................................................19
Appendix A: Classic Model M115 ................................................................................... 20
Appendix B: Sample Conditioning System...................................................................... 21
Table of Contents 2
A: SPECIFICATIONS
Physical Description
Single Channel System

1 x 5 Heat Exchanger
1 Active (cooled to 4C) Heat Exchanger
LCD temperature display (optional)
Operating Specifications
Sample Gas Flow Range 1-2 LPM

2.1-4.3 SCFH
Inlet Dew Point at Rated Flow 140F @ 20% H2O, 2 LPM
60C
Maximum Cooling Rate 56 BTU/Hr
59kJ/Hr
Dimensions 11.2 x 7.25 x 11.2 in. HWD
28.5 x 14.4 x 28.5 cm
Weight 15 lbs
6.8 kg
Maximum Inlet Sample 392F (200C) SS, Durinert, Glass
Temperature Impingers
280F (138C) Kynar Impinger
Maximum Inlet Pressure 45 psig
3 bar / 2250 mmHg
Maximum Heat Exchanger <+1 in. H2O
Pressure Drop
Ambient Temperature Range 33-104F

0.6-40 C

Outlet Sample Gas Dew Point 41 F

5C
Inlet Tubing Connection 3/8 in. FPT
Outlet Tubing Connection in. FPT
Drain Tubing Connection 3/8 in. FPT
Voltage 90-240 VAC
50/60 Hz
Thermoelectric Elements 40 mm
Power Supply 100W
Cooling Down Time Less than 3 minutes
Section A: Specifications 3
B: LIMITED WARRANTY
BALDWIN, INC.
LIMITED WARRANTY
Baldwin, Inc., hereafter referred to as Baldwin, warrants to the original purchaser that the material
and workmanship of its supplied products shall be free of defects and will be manufactured with
materials of construction chosen to provide maximum service life against corrosion. This expressed
warranty is for a period of 18 months from date of installation by others, or 24 months from shipment
from Baldwin, Inc., Reno, Nevada; whichever occurs first. If any part is returned by the purchaser, at
his expense, to Baldwin and in the sole judgment of Baldwin, that part has failed due to material or
workmanship, Baldwin will replace that part with a new and like part at no cost to the purchaser and
the return shipping costs will be paid for by Baldwin.
In the case of OEM purchases, Baldwin expects the OEM to act as a first echelon service
organization. This entails all customer contact, removal, shipment, and replacement of the defective
product at the expense of the OEM. Baldwin will honor costs only to the extent listed in paragraph
one above.
For major sub-assemblies not manufactured by Baldwin but supplied by a vendor, Baldwin limits its
warranty liability to written warranty extended by the vendor. Under no circumstances will Baldwin
give an unlimited warranty to parts or assemblies subject by the application to gas or solids corrosion
or excessive mechanical wear due to high temperature operation. Baldwin does not warranty
consumable items such as filter elements, diaphragm pump internal parts (diaphragms, check valves,
disks, etc), electrical fuses, thermal control elements, thermal heating elements, "O" Rings, seals, Air
Dryer elements.
Baldwin cannot warranty against operator error resulting in damaged components or operator
deficiencies resulting in gross System failure or catastrophic cessation of operation.
All warranty repairs will be conducted at Baldwin's facility in Reno, Nevada; and on parts returned by
the purchaser at his shipping expense. There will be no charge for labor or materials for warranty
repair and/or replacement at Baldwin's facility. If the warranty repair is undertaken in the field at the
request of the purchaser and the part or assembly is judged to have failed due to defects in material
and/or workmanship, then the labor and portal to portal transportation cost will be chargeable to the
purchaser at the current rates in effect at the time of the warranty repair. The replacement part will be
at no charge for a Baldwin manufactured component, and at the limited warranty replacement policy
noted above for any vendor supplied parts or assemblies.
The repair or replacement of defective components shall constitute the sole remedy of the purchaser
and the sole liability of Baldwin, Inc. There shall be no responsibility by Baldwin for loss of time of
operation, consequential damages, fines or citations due to system down time, or the expense of
replacing said components at the job site by personnel other than a Baldwin employee, or hired
service representative.
This warranty is invalidated if the purchaser fails to pay for Baldwin products and sub-systems on a
timely basis outside of Baldwin's Net Terms, or if the purchaser fails to maintain the components of
the products to proper specifications. Proof of periodic maintenance requirements are demonstrated
satisfactorily with daily Operator Check Sheets filled out from start up date to date of component
failure.
Any unauthorized modifications to Baldwin products or components within a vendor-supplied system

shall also invalidate this warranty.
Section B: Limited Warranty 4

C: PRINCIPLE OF OPERATION
Thank you for purchasing a Baldwin Classic Series Thermo-Electric Cooler. Our
Classic M115 features a unique slim design leaving additional space to install or
access other sample conditioning system components. A unique drop-down door on
this model provides easy access to electronic boards and the power supply. All
electronic boards (control, relay, and display) are mounted on the door for easy
access.
The process of sampling combustion product stack gas or exhaust from internal
combustion engines requires a method to remove the moisture from the sample,
without removing the gas components of interest. The Baldwin Classic Thermo-
Electric Cooler is an ideal way to decrease the dew point of combustion gases to a
repeatable, stable, constant low dewpoint. The Baldwin cooler prevents water
condensation in sample pre-filters, sample pumps, and gas analyzers. For gas
analyzers where water vapor is an interferent, a stable, repeatable dewpoint
becomes a part of the gas analyzer performance specification. Baldwin coolers
provide this constant low water concentration, resulting in an accurate component
gas measurement.
All Baldwin coolers use thermo-electric elements (Peltiers) to cool the sample gas to
the desired dew point temperature. A Classic Thermo-Electric Cooler is best
illustrated as a small heat pump
with no moving parts. The
Peltiers operate on direct
current and may be used for
heating or cooling by reversing
the direction of current flow.
This is achieved by moving
heat from one side of the
module to the other with current
flow and the laws of
thermodynamics. A typical
single stage Peltier (Figure 1)
consists of two ceramic plates
with p- and n-type
semiconductor material
(bismuth telluride) between the
plates. The elements of Figure 1: Thermo-electric element (Peltier)
semiconductor material are
connected electrically in series and thermally in parallel.
When a positive DC voltage is applied to the n-type thermo-electric element,

electrons pass from the p- to the n-type thermo-electric element and the cold side
temperature will decrease as heat is absorbed. The heat absorption (cooling) is
Section C: Principle of Operation 5

proportional to the current and the number of thermo-electric couples. This heat is
transferred to the hot side of the Peltier element where it is dissipated into the heat
sink and surrounding environment.
Baldwin Classic Thermo-Electric Coolers remove the moisture from the sample gas
by cooling the gas as it passes through a laminar impinger (heat exchanger). A
diagram showing the gas flow path through an impinger is shown in the Appendix.
The heat exchanger, made of 316L stainless steel, Durinert (a corrosion-resistant
inert coating over 316L stainless steel), PVDF (Kynar), or glass, is mounted within a
thermally insulated heat transfer block bored to receive the heat exchanger without a
mechanical lock. This assembly allows the easy removal of any heat exchanger
simply by slipping it out of the cooling block by hand. The heat transfer block cools
the heat exchanger through the heat pumping action of the peltier element. The
heat transfer block is on the cold side of the thermo-electric element and the heat
sink is on the hot side of the thermo-electric element. The heat from the heat
transfer block is pumped to the heat sink where it is then dissipated into the air by
the heat sink fan. See Figure 2. The desired temperature is maintained by a closed
loop control system, which is implemented through an analog proportional controller.
The controller uses a type K thermocouple in the heat transfer block located very
close to the cold side of the peltier element as the input sensor.
Figure 2: Heat Exchanger, Impinger and Heat Sink Assembly
The sample gas is passed to the Classic Thermo-Electric Cooler via the heated filter
sample probe and heated sample line. The Classic Thermo-Electric Cooler lowers
the sample dew point to 5o C (41F). As the gas cools and the moisture vapor

condenses, the condensate exits the heat exchanger through the bottom drain
connection. Particulate matter which passes through the sample cooler is removed
by an optional Baldwin pre-filter, located downstream from the cooler along with an
optional water slip sensor. The conditioned sample gas can then be directed to the
gas analyzers.

D: INSTALLATION
The Model M115 should be installed away from heat sources in a well ventilated
area of an instrument rack or enclosure. REMEMBER, the Model M115 can only
control to 71F. DIFFERENTIAL from ambient temperature. Thus, at an output
temperature control of 41F., the maximum ambient temperature is 104F., above
which cooling control is lost. When this differential is exceeded, the controller will go
full-on, with the cooling capacity floating in relation to the ambient temperature
above 104F. No damage will occur to the cooler, however, the output dew point will
also float in relation to the ambient temperature. The more stable the ambient
temperature environment around the Model M115, the better the output dew point
stability.
Sample tubing connections to the Model M115 depend on the heat exchanger
material of construction. A cooler with a stainless steel heat exchanger uses a
stainless steel inlet fitting. The outlet is Kynar standard compression type tube
fitting with Teflon ferrules. A PVDF (Kynar) heat exchanger uses Kynar standard
compression type tube fittings with Teflon ferrules. Baldwin cannot warrantee
against damage to the Peltier element or heat exchanger if our supplied Kynar tube
fittings are not used.
The inlet and outlet tubing of all metal or Kynar heat exchangers is 1/4" NPT; the
user should always use the compression type fittings provided for that purpose by
the factory. The inlet of the Channel 1 heat exchanger uses a 3/8 tube x MNPT,
tube connector fitting to mate with most standard 3/8 sample lines.
The condensate drain connection is a Kynar elbow, 3/8 MNPT x 1/4 barbed tube
fitting. An automatic condensate drain, Baldwin Model 3KPB-001 Peristaltic Pump,
dual head, is recommended for water removal. This pump uses size 17 tubing.
CAUTION: Do no reduce the size of the condensate tubing since doing so restricts
water flow resulting in water slip (moisture carryover) in the sample.
CAUTION: If using a stainless steel sample line, place 2 inches of TEFLON tubing
in between the exchanger inlet fitting and the heated line. This prevents the sample
cooler from heat sinking the incoming heated line, which adds undue load to the
cooler.
Section D: Installation 8
E: START-UP PROCEDURE
Plug in the power cord to a properly grounded main circuit. The Ready Green LED
will come on within 3 minutes, indicating the relay temperature (10C) has been
achieved. After approximately 3 minutes, the set point of +5C. (41F) is achieved.
The SLIP Green LED should also be on if a Water Slip Sensor is connected to the
internal relay board. The sample gas flow may be started immediately after the SLIP
Green LED comes on.
The Model M115 is virtually maintenance free. However, in the event of electrical
problems, refer to the troubleshooting guide in this manual. All voltages can be read
at the PCB terminal strip. Any deviations from the correct voltages indicate a
problem.
Section E: Start-up Procedure 9

F: LED INDICATORS
The Model M115 has two green and one red LED operating indicators. These
indicators are arranged vertically on the front of the cooler. The bottom green LED
indicates the READY operating temperature status, normally set for 10C (50F).
After the set-point temperature is reached, the sample pump may be turned on by
other devices. When the impinger temperature is below 10C (50F) the ready LED
will be on. Above this temperature, the ready LED will be off. The middle green
LED (applicable when the alarm relay option is installed) is ON when there is NO
water carry over and OFF when there IS water carry over. The red LED at the top is
the thermocouple failure indicator. When this occurs, the red LED stays illuminated.
The M115 cooler has an analog voltage output found on the bottom left side of the
cooler marked ANALOG OUT. This output is factory standard at 0-2.5 VDC = 0-
25C.
Section F: LED Indicators 10

G: I/O TERMINAL BLOCK DESCRIPTION
The I/O terminal blocks are found on the bottom panel of the cooler:
TB1 TB1 is the standard analog output (low voltage DC output) for all Classic
Series Thermo-Electric Coolers. Model M115 has one active 5 heat exchanger.
Only Channel 1 references apply to this model. Channel 1 is always active and
channel 2 will be active if so equipped. The output is 0vdc to 2.5vdc for a
temperature range of 0C to 25C.
C Terminal 1 is earth ground. This terminal should be used to ground the shield of the
shielded twisted pair cable that is used to connect the analog output to a receiving
instrument.
C Terminal 2 is the signal return.
C Terminal 3 is the channel 1 output.
TB2 TB2 is the I/O terminal block (low level DC voltage or current or no voltage
contact) used for all installed options, such as the alarm relay/water slip option or
auxiliary analog output option.
shielded twisted pair cable that is used to connect the analog output board of the
auxiliary analog output to a receiving instrument.
C Terminal 2 is the signal return for the auxiliary analog voltage output.
C Terminal 3 is the auxiliary analog voltage output.
C Terminal 4 is the negative side of the auxiliary analog 4-20mA output.
C Terminal 5 is the positive side of the auxiliary analog 4-20mA output.
C Terminals 6 & 7 are the dry contact form A relay output used for computer sense for
the alarm relay/water slip option.
C Terminals 8 & 9 are the water slip sensor input used for water carry over sense for the
alarm relay/water slip option.
twisted pair cable that is used to connect the water slip sensor to terminals 8 & 9.
TB3 TB3 is the switched AC terminal block (line AC voltage output) used for
sample pump control when the alarm relay/water slip option is installed.
C Terminal 1 is the AC LINE voltage.
C Terminal 2 is the AC NEUTRAL.
C Terminal 3 is the EARTH GROUND.
TB4 Note: The description for TB4 is the same as for TB2. TB4 is used for
Channel 2's I/O (not applicable to Model M115).
channel 2's switched AC (not applicable to Model M115).
Section G: I/O Terminal Block Description 11

H: TEST & ADJUSTMENT PROCEDURES
NOTE: All test and adjustment procedures have been performed at the factory.
Therefore, no adjustment should be necessary.
A. Main Control board
(1) WARNING: Before connecting power to the cooler, be aware of the

HAZARDOUS LIVE VOLTAGE on the control board. Disconnect power from the
cooler before opening the swing-down "L-door". Note: The auxiliary output board
must be removed if the cooler is so equipped. Remove the thermocouples from TB1
and TB2. The thermocouple generator should not be connected to either of the
thermocouple inputs at this time. Connect power to the cooler. After 10 to 20
seconds, the red LED(s) (thermocouple failure indicators) should be on.
(2) Connect the thermocouple generator to the Channel 1 thermocouple input, (TB1
terminal), inserting the yellow wire into the terminal marked Y and the red wire into
the terminal marked R. Turn on the generator. The red LED should turn off.
Connect a voltmeter between the ground test point, TP7 and TP1, the red lead to
TP1 and the black lead to TP7. Set the thermocouple generator to 0C. Set the
voltmeter to 20vdc range.
(3) Adjust POT1 (the zero pot) to obtain a 0vdc reading on the voltmeter.
(4) Set the thermocouple generator to 10C.
(5) Adjust POT3 (the span pot) to obtain a 1.0vdc reading on the voltmeter.
(6) Move the positive lead (red lead) of the voltmeter to TP5.
(7) Adjust POT8 (the ready pot) to obtain a 1.0vdc reading on the voltmeter.
(9) Adjust POT5 (the set pot) to obtain a 0.5vdc reading on the voltmeter.
(10) Set the thermocouple generator to 11C. The bottom green LED should be off.
(11) Set the thermocouple generator to 8C. The bottom green LED should be on.
Section H: Test & Adjustment Procedures 12

B. Display Board

cooler before opening the swing-down "L-door". Remove display cover from the
front of the swing-down "L-door". Connect a voltmeter between the ground test
point, TP7 on the main control board and TP1 on the display board, the red lead to
TP1 and the black lead to TP7.
(2) Connect power to the cooler and allow the temperature of the cooler to stabilize
around 5C.
(3) Adjust POT1 on the display board so the display corresponds to the voltmeter
reading. That is, if the voltmeter reads 0.5vdc, adjust the pot so that the display
reads 0.5.
C. Auxiliary Analog Output Board

cooler before opening the swing-down "L-door". Remove the thermocouples from
TB5 and TB6 on the auxiliary analog output board. The thermocouple generator
should not be connected to either of the thermocouple inputs at this time. Connect
power to the cooler. After 10 to 20 seconds, the red LED(s) (thermocouple failure
indicator) on the auxiliary analog output board should be on.
(2) Connect the thermocouple generator to the Channel 1 thermocouple input (TB5
the terminal marked R. Turn on the generator. The red LED (CR5) should turn off.
Set the thermocouple generator to 0C.
For Voltage Output

(3) If the auxiliary analog output board is set for voltage output, set the voltmeter to
20vdc range. Connect the voltmeter to TB2 (the channel 1 voltage output terminal),
the black lead to the negative (-) terminal and the red lead to the positive (+)
terminal.
(6) Adjust POT1 (the span pot) to obtain a full scale voltage reading on the
voltmeter. This value will depend on the gain that was specified for the cooler at the
time of manufacture. Available gains are 0-1.0vdc, 0-2.5vdc, 0-10.0vdc for a 0C-
25C temperature range.

For Current Output
(3a) If the auxiliary analog output board is set up for current output, set the ammeter
to 200ma range. Connect the ammeter to TB1 (the channel 1 current output
terminal), the black lead to the negative (-) terminal and the red lead to the positive
(+) terminal.
(4a) Adjust POT4 (the zero pot) to obtain a 4mA reading on the ammeter.
(5a) Set the thermocouple generator to 25C.
(6a) Adjust POT1 (the span pot) to obtain a 20mA reading on the ammeter.

I: DESCRIPTION OF OPTIONS
Baldwin Classic Series Thermo-Electric Coolers have three available options: (1)
temperature display; (2) alarm relay/water slip, and (3) auxiliary analog output.
Classic Series Coolers may be equipped with any one or all of the options. All
external I/O connections for these options are available through the terminal blocks
on the bottom of the cooler.
1. Display Option
The display option is a secondary board that is mounted on the main control board.
This board has a three-digit LCD display that displays the temperature (in degrees
C) of the active channel(s). If the cooler has two active channels, there will be a
toggle switch installed to select Channel 1 or 2.
2. Alarm Relay/Water Slip Option

The alarm relay/water slip option is a secondary board that is mounted on the main
control board. This board has two inputs and three outputs per channel. The first
input, which comes from the main control board, is the ready input. The second
input, which comes from the water slip sensor, is the water slip input. The first
output, which is fed back to the main control board, controls the ready and water slip
LED(s). The second output is a 1/4 amp SPST form A dry contact relay. This relay
is used for computer sensing and is NOT intended for the controlling of electrical
loads. The third output is a 6-amp DPST form C dry contact relay. This relay can be
used for sample pump or other heavier electrical load control. This relay output
terminal is normally wired for a 120vac sample pump (ground, neutral, and line). If
there is water carry over (water slip LED), computer sense and load control relays
will be turned off. If the temperature of the cooler rises above 10C (50F), the ready
LED, computer sense and load control relays will be turned off. This means that the
relays operate in a fail-safe manner.
Note: If the alarm relay/water slip option is not installed, the SLIP LED(s) on the
front of the cooler will be off.
3. Auxiliary Analog Output Option

The auxiliary analog output option is a secondary board that is mounted on the main
control board. This board has one input and two outputs per channel. The input is
for a K type thermocouple. The first output is an analog voltage output that can be
configured for either 0vdc to 2.5vdc or 0vdc to 10vdc for a 0C (32F) to 25C (77F)
temperature range. The second output is a 4-20 mA for the same temperature
range. The K type thermocouple is normally a 1/32-inch diameter hypodermic type
thermocouple that is installed in a special impinger so the actual sample dew point
temperature can be measured.
Note: This option is sometimes referred to as the New Jersey thermocouple outlet
temperature option.
Section I: Description of Options 15

J: NEW JERSEY THERMOCOUPLE OPTION
Some air quality management districts (e.g., those in New Jersey and Southern
California) require temperature measurement of the gas stream at the outlet of the
last heat exchanger on the cooler. Baldwin offers a 1/32-inch diameter hypodermic-
style type K thermocouple that can be inserted into a special heat exchanger (i.e., it
has a small port for insertion of the thermocouple) so the actual sample dew point
temperature can be measured. This is sometimes referred to as the New Jersey
thermocouple outlet temperature option.
The Model M115 has one 5 heat exchanger which can be upgraded to include the
New Jersey thermocouple option. This heat exchanger will have a New Jersey
thermocouple to sense the temperature inside the heat exchanger (upgrade option:
4C-NJ/K-5). In the part number, the NJ identifies the upgrade for a NJ type
thermocouple. The K identifies the thermocouple itself as a type K thermocouple.
The -5 is the height of the heat exchanger.
In addition, Baldwin offers an optional temperature transmitter board for signal or

voltage temperature output. This board has one input and two outputs per channel.
The input is for the type K thermocouple. The first output is an analog voltage output
that can be configured for either 0-2.5vdc or 0-10vdc for a 0C (32F) to 25C (77F)
temperature range. The second output is a 4-20mA for the same temperature
range. The M115 utilizes a single-channel NJ thermocouple transmitter board
(3CCB-012).
Model M115 New Jersey Thermocouple Option

Part No. Description
4C-NJ/K-5 Heat exchanger upgrade to include NJ thermocouple port
3CXS-002 Heat exchanger, 5 SS w/ NJ thermocouple port
3CXD-002 Heat exchanger, 5 Durinert w/ NJ thermocouple port
3CXK-002 Heat exchanger, 5 Kynar w/ NJ thermocouple port
3CCB-012 Temperature transmitter board, single stream
3KTC-001 Thermocouple, Type K, replacement kit
Section J: New Jersey Thermocouple Option 16

K: TROUBLESHOOTING
Symptom Check Action

No LED(s) and no fan. AC power input. Ensure that AC power is
connected.
No LED(s) and fan on. AC input fuse on control board. Replace fuse as necessary.
DC output fuse on control board. Replace fuse as necessary.
VC on control board. Replace control board.
LED(s) on and no fan. AC input fuse on power supply. Replace fuse as necessary.
+12vdc TB4 on control board. Replace power supply.
Impinger remains at Peltier current draw. Should be Replace Peltier element.

ambient temperature. above 6 amps.
Thermocouple failure LED is Thermocouple connection TB1, 2. Ensure proper connection.
on. Replace thermocouple.
Impinger frozen and cooler Thermocouple placement in heat Ensure proper placement.
indicates ambient exchanger block. Replace control board.
temperature.
Impinger does not reach set System loading. Ensure system loading is not
temperature, but is below exceeding cooler capacity.
ready temperature. Calibration and set temperature Adjust as necessary.
adjustment.
Impinger temperature cycles Peltier connections on control Ensure a firm connection on
up and down. board. flag connectors on control
board. Ensure system loading
is not exceeding cooler
capacity.
Ready LED does not come on Ready temperature adjustment. Adjust as necessary.
when impinger is below 7C.
Water carryover in system. Impinger temperature. Should be Ensure system loading is not
below 6C. exceeding cooler capacity.
Slip LED does not come on Water carryover in system. Ensure system loading is not
(alarm relay/water slip option exceeding cooler capacity.
installed). Water slip sensor connections. Ensure that all water slip sensor
connections are made.
Clean tip of sensor.
Replace alarm relay/water slip
board.
Pump does not start. Ready Pump electrical connections. Ensure proper connections.
and slip LED(s) are on (alarm Replace board.
relay/water slip option
installed).
Section K: Troubleshooting 17
For further service assistance, contact:
Baldwin, Inc.
895 East Patriot Blvd., Suite 107
Reno, NV 89511
Tel: 888-234-7366 (toll free U.S.)
Tel: 775-850-1800
Fax: 775-850-1818
Email: tech@baldwinUSA.com
or your local representative
L: SPARE PARTS
Classic Model M115

3CCB-016 Alarm Board: Single Channel
2FAN-004 Fan: Muffin, 4 x 1 , 12 VDC
3CXD-001 Heat Exchanger: 5" Durinert
3CXG-005 Heat Exchanger: 5" Glass, threaded w/ fittings
3CXK-001 Heat Exchanger: 5" Kynar
3CXS-001 Heat Exchanger: 5" Stainless Steel
3CCB-017 LCD Temperature Display Board: Single Channel
3KPE-004* Peltier Element Kit, 40 mm
1PSD-013* Power Supply: 100 W, 12 VDC
3TCB-001* Temperature Control Board: Single Channel
1TTC-003 Thermocouple, Temperature, Control, Type K 36
* Recommended Spares
Sample Conditioning Systems w/ Model M115 Classic Thermo-Electric Cooler
Model C
3KFA-001 Filter Assembly, Sample in-line, 2-micron
3FHG-001 Filter Bowl, Glass
3FEC-002** Filter Element: Ceramic, 2-micron
3KPB-001 Peristaltic Pump: Single, Kit, 115V Complete w/ Enclosure
2PBM-003 Peristaltic Pump: Head Only, Standard
2PBM-001 Peristaltic Pump: Motor Only, 115V AC 60 Hz
2PBT-002PK* Peristaltic Pump: Tubing, Norprene, Size 17 (10 feet)
3KPA-001* Sample Pump: Assembly, Single Head w/ Check Valve, 115V
2PAS-008 Sample Pump: Single Head, Mini-Dia-Vac, 115V (bare)
2PAM-001* Sample Pump: Repair Kit, Single
3CWS-001 Water Slip Sensor (Hastelloy/SS Pins)
3KCW-002 Water Slip Sensor (SS Pins) w/ Holder Assembly
* Recommended Spares **Consumables
Section L: Spare Parts 19

APPENDIX A: CLASSIC MODEL M115
20
MODULAR SERIES
Model M115
Single Channel System

1 x 5 Heat Exchangers
1 Active (cooled to 4C) Heat Exchanger
LED Temperature display (LCD Optional)

2.1-4.3 SCFH
Inlet Dew Point at Rated Flow 140F @ 20% H2O. 2 LPM
60C
59kJ/Hr
28.5 x 18.4 x 28.5 cm
Weight 15 lbs
6.8 kg
Maximum Inlet Sample 392F (200C) SS, Glass Impingers
Temperature 280F (138C) Kynar Impinger
3 bar / 2250 mmHg
Pressure Drop
Ambient Temperature Range 33-104F
0.6-40C
Outlet Sample Gas Dew Point 41F
5C
Inlet Tubing Connection in. FPT
Drain Tubing Connection in. FPT
Voltage 110 (220 optional) VAC
50/60 Hz
Power Supply 100W

Reno, NV 89511 USA Fax: 775-850-1818
www.baldwinUSA.com Email: info@baldwinUSA.com v4.01
Modular Series Thermo-Electric Coolers
Control Board
Display Board
Auxiliary Analog Output Board
1 2 3 4 5 6
TP9
Header for Relay Alarm Board AC_LINE
1
U6 100uH
RN4C AC_NEUTRAL
P3 6 5 1 8 TP8 F1 L1
C29 NC +V VCC .1uf X type 250vac
1M + 2 7 PWR1 F2 TB15
1
1 CHN2_READY +CAP OSC VCC
3 6 1
2 TC_2_OK 15uf GND LV 1 amp C45 C44 C47
C28 VCC 4 5 + + 5 1
3 VCC -CAP Vout VEE +OUT ACL 2 amp 250vdc
D3 C40 C43 2 2
4 TEMP_2 VCC ACN
1
ICL7660 D7 68uf 68uf 4 3 TB10
5 CHN1_READY SA5.0
+ -OUT ACG
.1uf 15uf .1uf
6 TC_1_OK WATER_SLIP2 RN3D 1
1
7 WATER_SLIP2
3
GREEN 4.7K 5V_AC/DC
8 WATER_SLIP1
TP7
4 RN2B 3 5 U7A
D 2 GREEN D
5
10K C32
4 470 D6
.001uf LM339 U8A
8 7 RN5D 8
A4
2
C35 C33 6 12
A3 Y4
12
4 14
RN2A .1uf .1uf A2 Y3 CHN2_READY
C4 15uf VCC 2 16 TB13
TC2_SENSE A1 Y2 TC_2_OK
+
10K 18
FOR ZERO / SPAN ADJ. Y1 AC_LINE 1
1 5 6
G
Channel 2 R6 TP6 470
.1uf 4.7K TP2 MC74HC240A RED TB11
1
1 RN5C
TB2 D2
1 RN4D CHAN 1 AC OUTPUT 1
3 C6 7 8
RED TC2_SENSE
U2 20K POT7 1M 2
2 1 14
+IN -IN VCC VCC VCC
1
YEL 2 13
+C -ALM READY TEMP. R25 U9A Q5
1 100 3 12
+T +ALM VCC RN3C 10K
R4 4 11 1 OPTO3
COM V+ VCC CHN_1_CONTROL_OUT TC_1_OK
4
5 10 4.7K 2 12 5 RN6C 61 6 R27 3 MAC8D
-T COMP R23 CHN1_READY
6 9 3 U5A 13 220 200
-C Vo RN2D U7B 100K
7 8 1 8 7 7 2 4
1
V- FB R17 AC_NEUTRAL
2 1 Q3 MC74HC11
4
10K C38 CHN_2_CONTROL_OUT MOC3023
AD595AQ 24.9K LF347N 6 2N3904
.001uf LM339 TB14
11
6
C12
VEE C42 C39 AC_LINE 1
C48
VCC RN2C
10K .1uf .1uf VCC
.1uf C21 TB12
.1uf .1uf
CHAN 2 AC OUTPUT 1
JP2
NOTE 1 R13 100K R29 1 2
5
TC_1_OK 1 2
2
200K 200K 3 4
POT4 TC_2_OK 3 4 VCC
Header for Current Transmitter Board JP1 5 6
U5B R20 CHN1_READY 5 6 R26 U9B Q6
C17 6 1 2 7 8
VCC 1 2 CLK_1 CHN2_READY 7 8 10K
.1uf SPAN 7 1M 3 4 9 10 3 OPTO4
3 4 CLK_2 CHN_1_CONTROL_OUT 9 10 RN6D R28 MAC8D
POT2 5 11 12 4 6 7 81 6 3
C2 C1 R14 R15 LF347N 1 CHN_2_CONTROL_OUT 11 12 R24
+ 5 220 200
15uf .1uf ZERO TP4 NOTE 3 100K 2 4
1
C 100K 2K AC_NEUTRAL C
20K NOTE 2 Q4 MC74HC11
20K 2N3904 MOC3023
VEE POT6
P1
VCC
C46
3 VEE
SET TEMP. TB6
2 VCC VCC
1 .1uf +12vdc 1
3 RN4B 4 CHAN 1 DC OUTPUT
1M VCC TB8
C7 + D4 TEMP_1 1
1
15uf C8
.1uf
WATER_SLIP1 RN3A Q1
GREEN 4.7K
1 RN1A 2 11 U7D +12vdc MPT50N06V

13 GREEN
2
10K C31
10 470 D5
.001uf LM339 U8B R21 TB16
17 3 RN5B 4 2K
A4 +12vdc 1
3
C30 C34 15 3
A3 Y4 OPTO1
13 5 U10A 1 5 CHAN 1 DC OUTPUT
RN1B .1uf .1uf A2 Y3 CHN1_READY VCC
C3 15uf VCC 11 7 1 TB17
TC1_SENSE A1 Y2 TC_1_OK TC_1_OK RN6B
+
10K 9 3 3 42 4
Y1 1
FOR ZERO / SPAN ADJ. 19 1 2 2 220
G CHN_1_CONTROL_OUT MOC8113
.1uf 4.7K TP1 MC74HC240A RED Q7
4
1 MM74C08
TB1 RN5A
1 D1
3 C5 1 RN4A 2
RED TC1_SENSE MPT50N06V
U1 20K POT8 1M C49
2 1 14 +12vdc
+IN -IN VCC VCC VCC
1
YEL 2 13
+C -ALM READY TEMP. .1uf
1 100 3 12 TB7
+T +ALM RN3B
R3 4 11 R22
COM V+ VCC 4.7K +12vdc 1
5 10 2K
-T COMP CHAN 2 DC OUTPUT
6 9 12 U5D OPTO2
-C Vo RN1C U7C U10B
7 8 14 5 6 9 JP3 1 5 TB9
B V- FB R16 VCC B
13 14 1 2 4
3
10K C37 CHN_1_CONTROL_OUT TC_1_OK 1 2 1
AD595AQ LF347N 8 3 4 6 1 RN6A 22 4
24.9K TC_2_OK 3 4
.001uf LM339 5 6 5 220
CHN_1_CONTROL_OUT 5 6
7
C11 7 8 MOC8113 Q2
C36 C41 CHN_2_CONTROL_OUT 7 8
VCC MM74C08
RN1D
.1uf C20 10K .1uf .1uf NOTE 2 MPT50N06V
.1uf
NOTE 1 R12 100K R30 TB18
8
200K 200K +12vdc 1
POT3 TB5
C16 2 CHAN 2 DC OUTPUT
VCC SPAN R19 +12vdc
.1uf U5C 9 TB19
CLK_1 +12vdc power input
POT1 8 1M 1
R11 R10 1
10
1
ZERO 100K 2K LF347N
20K TP3 Q8
VEE
20K POT5
MPT50N06V
VCC
TB4 D8
SET TEMP. 2
+12vdc
U3B fan power output 1 1N4006
6 NOTE 1: R12 & R13 are installed when the controller board is used for cooling.
C14 .1uf U4A C15 7 D9 R12 & R13 are removed and jumper wires are installed when the controller board is used for heating.
3 5 R9 5 1N4006
CON OUT CLK_1 C19 C22 TEMP_1 C10 NOTE 2: For JP3, jumper pins 1 &2 and pins 5 & 6 for channel 1 control.
6 1 200K + R7
TRG DIS 1uf 15uf .1uf .1uf For JP3, jumper pins 3 & 4 and pins 7 & 8 for channel 2 control.
2 LM358A 100K
THRES For JP2, jumper pins 1 &2, pins 5 & 6, and pins 9 & 10 for channel 1 control.
4 P2
C13 RST For JP2, jumper pins 3 & 4, pins 7 & 8, and pins 11 & 12 for channel 2 control.
NOTE 4 1 TEMP_2
.01uf VCC LM556C
2
3 VEE NOTE 3: if both channels are used for either cooling or heating, then jumper pins 1 & 2.
4 VCC VEE
NOTE 5 if one channel is used for cooling and the other channel is used for heating, jumper pins 3 & 4.
5
4
200 TB3
6 TEMP_1 U3A R8 NOTE 4: if the channel is used for cooling, C13 or C24 is a .01uf monoceramic cap.
A 3 A
2
TEMP1 output if the channel is used for heating, C13 or C24 is a 3.3uf monoceramic cap.
C27 + 1 2
C23 .1uf U4B C25 15uf C26 3
TEMP2 output NOTE 5: if both the channels are used for the same function,
R18 .1uf TEMP_2 C9
200 R2
that is cooling or heating, only CLK_1 is used for both channels.
11 9 R1 1
CON OUT CLK_2 .1uf GND Refer to NOTE 3
8 13 200K LM358A 100K
TRG DIS 1uf
12
8
THRES
10 Header for Display Board
C24 RST VCC
NOTE 4 Title
.01uf C18 LM556C M-class Cooler Control Board
.1uf
Size Number Revision
VCC NOTE: PCB PN 1CBT-001 REV B
C
PN 3TCB-001 REV C
Date: 14-Sep-2001 Sheet of

File: C:\DRAWIN~1\..\3TCB001C.SCH Drawn By:
1 2 3 4 5 6
1 2 3 4 5 6
TB3
VCC 1
D3 D2 2
5
RELAY1
D1 1 3
D 4 D
Chn2 Pump Relay
1N916 3
TB2
1 1 RN2A 2 VCC
2
1M VCC TB1
2 2
VCC
8
6
5
R4 1
Water Slip 2 2K Q8
7
5
3
1
1 RN1A 2 2
VCC 2N7000
100K 7 Chn2 Computer Sense
2
4
C5 3 RELAY2
--
1 RN1B 3 .001uf LM311
VCC
3
100K U1 JP2
VCC Q4
4
1
1 2
3 4
C3 C4 RN2B NOTE 1
.1uf .1uf 1M 2N7000
R5
1
3
CHN2_READY
470
4
Q5
VCC
Q9 TC_2_OK
C 2N7000 2N7000 C
P1 R2
WATER_SLIP2
1 CHN2_READY Q6
2.2M
2 TC_2_OK
3 VCC
4 2N7000
C2 +
5 CHN1_READY
6 TC_1_OK
3
1
7 WATER_SLIP2 1uf
8 WATER_SLIP1
TB6
4 3
2 1
NOTE 1 VCC 1
JP3
D6 D5 2
4
2
5
RELAY4
D4 1 3
4
Chn1 Pump Relay
1N916 3
TB5
1 5 RN2C 6 VCC
2
B 1M VCC TB4 B
2 2
VCC
8
6
5
3
1
R3 1
Water Slip 1 2K Q7
7
5
3
1
1 RN1C 4 2
VCC 2N7000
4 3
2 1
C6 3 JP1 RELAY3
+
--
1 RN1D 5 .001uf LM311

VCC
7
U2 Q1
4
2
100K
VCC
4
1
C8 C7 RN2D NOTE 1
.1uf .1uf 1M CHN1_READY
R6 2N7000
470
Q2
8
VCC
Q10 TC_1_OK
2N7000 2N7000
WATER_SLIP1 R1
Q3
2.2M
Note: PCB PN 1CBC-009
A NOTE 1: For single sample streams only, if separate water slip and temperature alarms are required, 2N7000 A
jumper pins 1 & 2 on JP1, JP2 and JP3. C1 +
For dual sample streams, jumper pins 3 & 4 on JP1, JP2 and JP3. Title
1uf M-class Relay Board
B
Assy. PN 3CCB-016 REV C

File: C:\DRAWIN~1\..\3CCB016C.SCH Drawn By:
1 2 3 4 5 6
APPENDIX B: SAMPLE CONDITIONING SYSTEM
21
CHART OF VOLUME PERCENT WATER CONCENTRATIONS
AT SATURATION FOR VARIOUS TEMPERATURES
AT STANDARD PRESSURE (ATMOSPHERIC PRESSURE)
DEGREES C DEGREES F VOLUME % DEGREES C DEGREES F VOLUME %
+100 + 212 100.00 +2 + 36 0.696
+ 90 + 194 69.20 +1 + 34 0.649
+ 80 + 176 46.70 0 + 32 0.602
+ 75 + 167 38.70 -1 + 30 0.555
+ 70 + 158 30.70 -2 + 28 0.510
+ 65 + 149 25.20 -3 + 27 0.469
+ 60 + 140 19.70 -4 + 25 0.431
+ 55 + 131 15.50 -5 + 23 0.396
+ 50 + 122 12.20 -6 + 21 0.363
+ 45 + 113 9.45 -7 + 19 0.333
+ 40 + 104 7.25 -8 + 18 0.305
+ 35 + 95 5.55 -9 + 16 0.281
+ 30 + 86 4.19 - 10 + 14 0.256
+ 29 + 84 3.95 - 11 + 12 0.234
+ 28 + 82 3.73 - 12 + 10 0.214
+ 27 + 81 3.62 - 13 +9 0.196
+ 26 + 79 3.32 - 14 +7 0.179
+ 25 + 77 3.13 - 15 +5 0.163
+ 24 + 75 2.94 - 16 +3 0.148
+ 23 + 73 2.77 - 17 +1 0.135
+ 22 + 72 2.61 - 18 0 0.123
+ 21 + 70 2.46 - 19 -2 0.112
+ 20 + 68 3.31 - 20 -4 0.102
+ 19 + 66 2.17 - 22 -8 0.084
+ 18 + 64 2.04 - 24 - 11 0.069
+ 17 + 63 1.91 - 26 - 15 0.057
+ 16 + 61 1.79 - 28 - 18 0.046
+ 15 + 59 1.68 - 30 - 22 0.038
+ 14 + 57 1.58 - 32 - 26 0.031
+ 13 + 55 1.48 - 34 - 30 0.025
+ 12 + 54 1.38 - 36 - 34 0.019
+ 11 + 52 1.29 - 38 - 37 0.016
+ 10 + 50 1.21 - 40 - 40 0.013
+9 + 48 1.13 - 42 - 44 0.011
+8 + 46 1.06 - 44 - 47 0.008
+7 + 45 0.988 - 46 - 51 0.006
+6 + 43 0.922 - 48 - 54 0.005
+5 + 41 0.861 - 50 - 58 0.004
+4 + 39 0.803 - 52 - 62 0.003
+3 + 37 0.751 - 54 - 65 0.002
MOISTURE CONVERSION TABLE
VAPOR PRESSURE
DEWPOINT PPM on VOLUME RELATIVE
(WATER/ICE in PPM on WEIGHT
BASIS at 760 mm HUMIDITY
EQUALIBRIUM) BASIS in AIR
F C of Hg PRESSURE at 70 F
mm MERCURY
-110 -166 .0000010 .00132 .0000053 .00082
-108 -162 .0000018 .00237 .0000096 .0015
-106 -159 .0000028 .00368 .000015 .0023
-104 -155 .0000043 .00566 .000023 .0035
-102 -152 .0000065 .00855 .000035 .0053
-100 -148 .0000099 .0130 .000053 .0081
-98 -144 .000015 .0197 .000080 .012
-96 -141 .000022 .0289 .00012 .018
-94 -137 .000033 .0434 .00018 .027
-92 -134 .000048 .0632 .00026 .039
-90 -130 .00007 .0921 .00037 .057
-88 -126 .00010 .132 .00054 .082
-86 -123 .00014 .184 .00075 .11
-84 -119 .00020 .263 .00107 .16
-82 -116 .00029 .382 .00155 .24
-80 -112 .00040 .562 .00214 .33
-78 -108 .00056 .737 .00300 .46
-76 -105 .00077 1.01 .00410 .83
-74 -101 .00105 1.38 .00559 .86
-72 -98 .00143 1.88 .00762 1.17
-70 -94 .00194 2.55 .0104 1.58
-68 -90 .00261 3.43 .0140 2.13
-66 -87 .00349 4.59 .0187 2.84
-64 -83 .00464 6.11 .0248 3.79
-62 -80 .00614 8.08 .0328 5.01
-60 -76 .00808 10.6 .0430 6.59
-58 -72 .0106 13.9 .0565 8.63
-56 -69 .0138 18.2 .0735 11.3
-54 -65 .0178 23.4 .0948 14.5
-52 -62 .0230 30.3 .123 18.8
-50 -58 .0295 38.8 .157 24.1
-48 -54 .0378 49.7 .202 30.9
-46 -51 .0481 63.3 .257 39.3
-44 -47 .0609 80.0 .325 49.7
-42 -44 .0768 101 .410 62.7
-40 -40 .0966 127 .516 78.9
-38 -36 .1209 159 .644 98.6
-36 -33 .1507 198 .804 122.9
-34 -29 .1873 246 1.00 152
-32 -26 .2318 305 1.24 189
-30 -22 .2859 376 1.52 234
-28 -18 .351 462 1.88 287
-26 -15 .430 566 2.30 351
-24 -11 .526 692 2.81 430
-22 -8 .640 842 3.41 523
-20 -4 .776 1020 4.13 633
-18 0 .939 1240 5.00 770
-16 +3 1.132 1490 6.03 925
-14 +7 1.361 1790 7.25 1110
-12 +10 1.632 2150 8.69 1335
-10 +14 1.950 2570 10.4 1596
-8 +18 2.326 3060 12.4 1900
-6 +21 2.765 3640 14.7 2260
-4 +25 3.280 4230 17.5 2680
-2 +28 3.880 5100 20.7 3170
0 +32 4.579 6020 24.4 3640
+2 +36 5.294 6970 28.2 4330
+4 +39 6.101 8030 32.5 4990
+6 +43 7.013 9230 37.4 5730
+8 +46 8.045 10590 42.9 6580
+10 +50 9.029 12120 49.1 7530
+12 +54 10.52 13840 56.1 8600
+14 +57 11.99 15780 63.9 9800
+16 +61 13.63 17930 72.6 11140
+18 +64 15.48 20370 82.5 12650
+20 +68 17.54 23080 93.5 14330
+22 +71 19.827 26088 16699
+24 +75 33.377 29443 18847
+26 +79 25.209 33169 21232
+28 +8
INSTRUCTION MANUAL
CLASSIC THERMO-ELECTRIC COOLERS

Model M225
Version 4.07

Reno, NV 89511 USA Fax: 775-850-1818
www.baldwinUSA.com Email: info@baldwinUSA.com
TABLE OF CONTENTS
A: Specifications................................................................................................................ 3
B: Limited Warranty........................................................................................................... 4
C: Principle of Operation ................................................................................................... 5
D: Installation .................................................................................................................... 8
E: Start-up Procedure ....................................................................................................... 9
F: LED Indicators ............................................................................................................ 10
G: I/O Terminal Block Description................................................................................... 11
H: Test & Adjustment Procedures................................................................................... 12
I: Description of Options.................................................................................................. 15
J: New Jersey Thermocouple Option............................................................................ 16
K: Troubleshooting .......................................................................................................... 17
L: Spare Parts .................................................................................................................19
Appendix A: Classic Model M225 ................................................................................... 21
Appendix B: Sample Conditioning System...................................................................... 22
Table of Contents 2
A: SPECIFICATIONS
Single (Series) / Dual (Parallel) Channel System

2 x 5 Heat Exchangers connected in series or parallel
2 Active (cooled to 4C) Heat Exchangers
LCD temperature display (optional)

6.5-10.8 SCFH
Inlet Dew Point at Rated 140F @ 20% H2O, 5 LPM
Flow 60C
118kJ/Hr
28.5 x 18.4 x 28.5 cm
Weight 17 lbs
7.7 kg
Maximum Inlet Sample 392F (200C) SS, Glass
Temperature Impingers
280F (138C) Kynar Impinger
3 bar / 2250 mmHg
Pressure Drop
Ambient Temperature 33-104F
Range 0.56-40C
Outlet Sample Gas Dew 41F
Point 5C
Inlet Tubing Connection in. FPT
Drain Tubing Connection in. FPT
Voltage 110 (220 optional) VAC
50/60 Hz
Power Supply 250W
Section A: Specifications 3
B: LIMITED WARRANTY
BALDWIN, INC.
LIMITED WARRANTY
Baldwin, Inc., hereafter referred to as Baldwin, warrants to the original purchaser that the material
and workmanship of its supplied products shall be free of defects and will be manufactured with
materials of construction chosen to provide maximum service life against corrosion. This expressed
warranty is for a period of 18 months from date of installation by others, or 24 months from shipment
from Baldwin, Inc., Reno, Nevada; whichever occurs first. If any part is returned by the purchaser, at
his expense, to Baldwin and in the sole judgment of Baldwin, that part has failed due to material or
workmanship, Baldwin will replace that part with a new and like part at no cost to the purchaser and
the return shipping costs will be paid for by Baldwin.
In the case of OEM purchases, Baldwin expects the OEM to act as a first echelon service
organization. This entails all customer contact, removal, shipment, and replacement of the defective
product at the expense of the OEM. Baldwin will honor costs only to the extent listed in paragraph
one above.
For major sub-assemblies not manufactured by Baldwin but supplied by a vendor, Baldwin limits its
warranty liability to written warranty extended by the vendor. Under no circumstances will Baldwin
give an unlimited warranty to parts or assemblies subject by the application to gas or solids corrosion
or excessive mechanical wear due to high temperature operation. Baldwin does not warranty
consumable items such as filter elements, diaphragm pump internal parts (diaphragms, check valves,
disks, etc), electrical fuses, thermal control elements, thermal heating elements, "O" Rings, seals, Air
Dryer elements.
Baldwin cannot warranty against operator error resulting in damaged components or operator
deficiencies resulting in gross System failure or catastrophic cessation of operation.
All warranty repairs will be conducted at Baldwin's facility in Reno, Nevada; and on parts returned by
the purchaser at his shipping expense. There will be no charge for labor or materials for warranty
repair and/or replacement at Baldwin's facility. If the warranty repair is undertaken in the field at the
request of the purchaser and the part or assembly is judged to have failed due to defects in material
and/or workmanship, then the labor and portal to portal transportation cost will be chargeable to the
purchaser at the current rates in effect at the time of the warranty repair. The replacement part will be
at no charge for a Baldwin manufactured component, and at the limited warranty replacement policy
noted above for any vendor supplied parts or assemblies.
The repair or replacement of defective components shall constitute the sole remedy of the purchaser
and the sole liability of Baldwin, Inc. There shall be no responsibility by Baldwin for loss of time of
operation, consequential damages, fines or citations due to system down time, or the expense of
replacing said components at the job site by personnel other than a Baldwin employee, or hired
service representative.
This warranty is invalidated if the purchaser fails to pay for Baldwin products and sub-systems on a
timely basis outside of Baldwin's Net Terms, or if the purchaser fails to maintain the components of
the products to proper specifications. Proof of periodic maintenance requirements are demonstrated
satisfactorily with daily Operator Check Sheets filled out from start up date to date of component
failure.
Any unauthorized modifications to Baldwin products or components within a vendor-supplied system

shall also invalidate this warranty.
Section B: Limited Warranty 4

C: PRINCIPLE OF OPERATION
Thank you for purchasing a Baldwin Classic Series Thermo-Electric Cooler. Our
Classic Model M225 features a unique slim design leaving additional space to install
or access other sample conditioning system components. A unique drop-down door
on the M225 provides easy access to electronic boards and the power supply. The
electronic control board is mounted on the door for easy access.
The process of sampling combustion product stack gas or exhaust from internal
combustion engines requires a method to remove the moisture from the sample,
without removing the gas components of interest. The Baldwin Classic Thermo-
Electric Cooler is an ideal way to decrease the dew point of combustion gases to a
repeatable, stable, constant low dewpoint. The Baldwin cooler prevents water
condensation in sample pre-filters, sample pumps, and gas analyzers. For gas
analyzers where water vapor is an interferent, a stable, repeatable dewpoint
becomes a part of the gas analyzer performance specification. Baldwin coolers
provide this constant low water concentration, resulting in an accurate component
gas measurement.
All Baldwin coolers use thermo-electric elements (Peltiers) to cool the sample gas to
the desired dew point temperature. A Classic Thermo-Electric Cooler is best
illustrated as a small heat pump
with no moving parts. The
Peltiers operate on direct
current and may be used for
heating or cooling by reversing
the direction of current flow.
This is achieved by moving
heat from one side of the
module to the other with current
flow and the laws of
thermodynamics. A typical
single stage Peltier (Figure 1)
consists of two ceramic plates
with p- and n-type
semiconductor material
(bismuth telluride) between the
plates. The elements of Figure 1: Thermo-electric element (Peltier)
semiconductor material are
connected electrically in series and thermally in parallel.
When a positive DC voltage is applied to the n-type thermo-electric element,

electrons pass from the p- to the n-type thermo-electric element and the cold side
temperature will decrease as heat is absorbed. The heat absorption (cooling) is
proportional to the current and the number of thermo-electric elements. This heat is

transferred to the hot side of the Peltier element where it is dissipated into the heat
sink and surrounding environment.
Baldwin Classic Thermo-Electric Coolers remove the moisture from the sample gas
by cooling the gas as it passes through a laminar impinger (heat exchanger). A
diagram showing the gas flow path through an impinger is shown in the Appendix.
The heat exchanger, made of 316L stainless steel, Durinert (a corrosion-resistant
inert coating over 316L stainless steel), PVDF (Kynar), or glass, is mounted within a
thermally insulated heat transfer block bored to receive the heat exchanger without a
mechanical lock. This assembly allows the easy removal of any heat exchanger
simply by slipping it out of the cooling block by hand. The heat transfer block cools
the heat exchanger through the heat pumping action of the peltier element. The
heat transfer block is on the cold side of the thermo-electric element and the heat
sink is on the hot side of the thermo-electric element. The heat from the heat
transfer block is pumped to the heat sink where it is then dissipated into the air by
the heat sink fan. See Figure 2. The desired temperature is maintained by a closed
loop control system, which is implemented through an analog proportional controller.
The controller uses a type K thermocouple in the heat transfer block located very
close to the cold side of the peltier element as the input sensor.
Figure 2: Heat Exchanger, Impinger and Heat Sink Assembly
The sample gas is passed to the Classic Thermo-Electric Cooler via the heated filter
sample probe and heated sample line. The Classic Thermo-Electric Cooler lowers
the sample dew point to 5o C (41F). As the gas cools and the moisture vapor
condenses, the condensate exits the heat exchanger through the bottom drain

connection. Particulate matter passing through the sample cooler is removed by an
optional Baldwin pre-filter, located downstream from the cooler along with an
optional water slip sensor. The conditioned sample gas can then be directed to the
gas analyzers.

D: INSTALLATION
The Model M225 should be installed away from heat sources in a well ventilated
area of an instrument rack or enclosure. The more stable the ambient temperature
environment around the Model M225, the better the output dew point stability.
Sample tubing connections to the Model M225 depend on the heat exchanger
material of construction. A cooler with a stainless steel heat exchanger uses a
stainless steel inlet fitting. The outlet is Kynar standard compression type tube
fitting with Teflon ferrules. A PVDF (Kynar) heat exchanger uses Kynar standard
compression type tube fittings with Teflon ferrules. Baldwin cannot warrantee
against damage to the Peltier element or heat exchanger if our supplied Kynar tube
fittings are not used.
The inlet and outlet tubing for all metal or Kynar heat exchangers is 1/4" NPT; the
user should always use the compression type fittings provided for that purpose by
the factory. The inlet of the Channel 1 heat exchanger uses a 3/8 tube x MNPT
fitting to mate with most standard 3/8 sample lines.
The condensate drain connection is a Kynar elbow (or straight), 3/8 MNPT x 1/4
barbed tube fitting. An automatic condensate drain, Baldwin Model 3KPB-003
Peristaltic Pump, dual head, is recommended for water removal. This pump uses
size 17 tubing.
CAUTION: Do no reduce the size of the condensate tubing since doing so restricts
water flow resulting in water slip (moisture carryover) in the sample.
CAUTION: If using a stainless steel sample line, place 2 inches of Teflon tubing in
between the exchanger inlet fitting and the heated line. This prevents the sample
cooler from heat sinking the incoming heated line, which adds undue load to the
cooler.
Section D: Installation 8
E: START-UP PROCEDURE
Plug in the power cord to a properly grounded main circuit. The Ready Green LED
will come on within 3 minutes, indicating the relay temperature (10C) has been
achieved. After approximately 3 minutes, the set point of +5C. (41F) is achieved.
The sample gas flow may be started immediately after the READY Green LED
comes on.
The Model M225 is virtually maintenance free. However, in the event of electrical
problems, refer to the troubleshooting guide in this manual. All voltages can be read
at the PCB terminal strip. Any deviations from the correct voltages indicate a
problem.
Section E: Start-up Procedure 9

F: LED INDICATORS
The Model M225 has four green and two red LED operating indicators. These
indicators are arranged vertically on the front of the cooler with the right side
corresponding to CH1 and the left to CH2. The bottom green LEDs indicate the
READY operating temperature status, normally set for 10C (50F). After the set-
point temperature is reached, the sample pump may be turned on by other devices.
When the impinger temperature is below 10C (50F) the ready LEDs will be on.
Above this temperature, the ready LEDs will be off. The middle green LEDs
(applicable when the alarm relay option is installed) are ON when there is NO water
carry over and OFF when there IS water carry over. The red LEDs at the top are
the thermocouple failure indicators. When this occurs, the red LED stays illuminated.
The M225 cooler has an analog voltage output. This output is factory standard at 0-
2.5 VDC = 0-25C. The connector for this output is located on the bottom of the
cooler. It is labeled Analog Out (TB1).
Section F: LED Indicators 10

G: I/O TERMINAL BLOCK DESCRIPTION
The I/O terminal blocks are found on the bottom panel of the cooler:
TB1 TB1 is the standard analog output (low voltage DC output) for all Classic
Series Thermo-Electric Coolers. Model M225 has two active 5 heat exchangers.
The output is 0vdc to 2.5vdc for a temperature range of 0C to 25C.
shielded twisted pair cable that is used to connect the analog output to a receiving
instrument.
C Terminal 2 is the signal return.
TB2 TB2 is the I/O terminal block (low level DC voltage or current or no voltage
contact) used for all installed options, such as the alarm relay/water slip option or
auxiliary analog output option.
shielded twisted pair cable that is used to connect the analog output board of the
auxiliary analog output to a receiving instrument.
C Terminal 2 is the signal return for the auxiliary analog voltage output.
C Terminal 3 is the auxiliary analog voltage output.
C Terminal 4 is the negative side of the auxiliary analog 4-20mA output.
C Terminal 5 is the positive side of the auxiliary analog 4-20mA output.
C Terminals 6 & 7 are the dry contact form A relay output used for computer sense for
the alarm relay/water slip option.
C Terminals 8 & 9 are the water slip sensor input for the alarm relay / water slip
(moisture carryover) option.
twisted pair cable that is used to connect the water slip sensor to terminals 8 & 9.
TB3 TB3 is the switched AC terminal block (line AC voltage output) used for
sample pump control when the alarm relay/water slip option is installed.
C Terminal 1 is the AC LINE voltage.
C Terminal 2 is the AC NEUTRAL.
C Terminal 3 is the EARTH GROUND.
Channel 2's I/O.
Channel 2's switched AC.
Section G: I/O Terminal Block Description 11

H: TEST & ADJUSTMENT PROCEDURES
NOTE: All test and adjustment procedures have been performed at the factory.
Therefore, no adjustment should be necessary.
A. Main Control board

cooler before opening the swing-down "L-door". Note: The auxiliary output board
must be removed if the cooler is so equipped. Remove the thermocouples from TB1
and TB2. The thermocouple generator should not be connected to either of the
thermocouple inputs at this time. Connect power to the cooler. After 10 to 20
seconds, the red LED(s) (thermocouple failure indicators) should be on.
(2) Connect the thermocouple generator to the Channel 1 thermocouple input, (TB1
the terminal marked R. Turn on the generator. The red LED should turn off.
Connect a voltmeter between the ground test point, TP7 and TP1, the red lead to
TP1 and the black lead to TP7. Set the thermocouple generator to 0C. Set the
voltmeter to 20vdc range.
(5) Adjust POT3 (the span pot) to obtain a 1.0vdc reading on the voltmeter.
(7) Adjust POT8 (the ready pot) to obtain a 1.0vdc reading on the voltmeter.
(9) Adjust POT5 (the set pot) to obtain a 0.5vdc reading on the voltmeter.
(10) Set the thermocouple generator to 11C. The bottom green LED should be off.
(11) Set the thermocouple generator to 8C. The bottom green LED should be on.

B. Display Board (not standard on the Model M225)

cooler before opening the swing-down "L-door". Remove display cover from the
front of the swing-down "L-door". Connect a voltmeter between the ground test
point, TP7 on the main control board and TP1 on the display board, the red lead to
TP1 and the black lead to TP7.
(2) Connect power to the cooler and allow the temperature of the cooler to stabilize
around 5C.
(3) Adjust POT1 on the display board so the display corresponds to the voltmeter
reading. That is, if the voltmeter reads 0.5vdc, adjust the pot so that the display
reads 0.5.
C. Auxiliary Analog Output Board (not standard on the model M225)

cooler before opening the swing-down "L-door". Remove the thermocouples from
TB5 and TB6 on the auxiliary analog output board. The thermocouple generator
should not be connected to either of the thermocouple inputs at this time. Connect
power to the cooler. After 10 to 20 seconds, the red LED(s) (thermocouple failure
indicator) on the auxiliary analog output board should be on.
(2) Connect the thermocouple generator to the Channel 1 thermocouple input (TB5
the terminal marked R. Turn on the generator. The red LED (CR5) should turn off.
Set the thermocouple generator to 0C.
For Voltage Output

(3) If the auxiliary analog output board is set for voltage output, set the voltmeter to
20vdc range. Connect the voltmeter to TB2 (the channel 1 voltage output terminal),
the black lead to the negative (-) terminal and the red lead to the positive (+)
terminal.
(6) Adjust POT1 (the span pot) to obtain a full scale voltage reading on the
voltmeter. This value will depend on the gain that was specified for the cooler at the
time of manufacture. Available gains are 0-1.0vdc, 0-2.5vdc, 0-10.0vdc for a 0C-
25C temperature range.

For Current Output
(3a) If the auxiliary analog output board is set up for current output, set the ammeter
to 200ma range. Connect the ammeter to TB1 (the channel 1 current output
terminal), the black lead to the negative (-) terminal and the red lead to the positive
(+) terminal.
(4a) Adjust POT4 (the zero pot) to obtain a 4mA reading on the ammeter.
(5a) Set the thermocouple generator to 25C.
(6a) Adjust POT1 (the span pot) to obtain a 20mA reading on the ammeter.

I: DESCRIPTION OF OPTIONS
Baldwin Classic Series Thermo-Electric Coolers have three available options: (1)
temperature display; (2) alarm relay/water slip, and (3) auxiliary analog output.
Classic Series Coolers may be equipped with any one or all of the options. All
external I/O connections for these options are available through the terminal blocks
on the bottom of the cooler.
1. Display Option
The display option is a secondary board that is mounted on the main control board.
This board has a three-digit LCD display that displays the temperature (in degrees
C) of the active channel(s). If the cooler has two active channels, there will be a
toggle switch installed to select Channel 1 or 2.
2. Alarm Relay/Water Slip Option

The alarm relay/water slip option is a secondary board that is mounted on the main
control board. This board has two inputs and three outputs per channel. The first
input, which comes from the main control board, is the ready input. The second
input, which comes from the water slip sensor, is the water slip input. The first
output, which is fed back to the main control board, controls the ready and water slip
LED(s). The second output is a 1/4 amp SPST form A dry contact relay. This relay
is used for computer sensing and is NOT intended for the controlling of electrical
loads. The third output is a 6-amp DPST form C dry contact relay. This relay can be
used for sample pump or other heavier electrical load control. This relay output
terminal is normally wired for a 120vac sample pump (ground, neutral, and line). If
there is water carry over (water slip LED), computer sense and load control relays
will be turned off. If the temperature of the cooler rises above 10C (50F), the ready
LED, computer sense and load control relays will be turned off. This means that the
relays operate in a fail-safe manner.
Note: If the alarm relay/water slip option is not installed, the SLIP LED(s) on the
front of the cooler will be off.
3. Auxiliary Analog Output Option

The auxiliary analog output option is a secondary board that is mounted on the main
control board. This board has one input and two outputs per channel. The input is
for a K type thermocouple. The first output is an analog voltage output that can be
configured for either 0vdc to 2.5vdc or 0vdc to 10vdc for a 0C (32F) to 25C (77F)
temperature range. The second output is a 4-20 mA for the same temperature
range. The K type thermocouple is normally a 1/32-inch diameter hypodermic type
thermocouple that is installed in a special impinger so the actual sample dew point
temperature can be measured.
Note: This option is sometimes referred to as the New Jersey thermocouple outlet
temperature option.
Section I: Description of Options 15

J: NEW JERSEY THERMOCOUPLE OPTION
Some air quality management districts (e.g., those in New Jersey and Southern
California) require temperature measurement of the gas stream at the outlet of the
last heat exchanger on the cooler. Baldwin offers a 1/32-inch diameter hypodermic-
style type K thermocouple that can be inserted into a special heat exchanger (i.e., it
has a small port for insertion of the thermocouple) so the actual sample dew point
temperature can be measured. This is sometimes referred to as the New Jersey
thermocouple outlet temperature option.
The second 5 heat exchanger on the M225 can be upgraded to include the New
Jersey thermocouple option. This heat exchanger will have a New Jersey
thermocouple to sense the temperature inside the heat exchanger (upgrade option:
4C-NJ/K-5). In the part number, the NJ identifies the upgrade for a NJ type
thermocouple. The K identifies the thermocouple itself as a type K thermocouple.
The -5 is the height of the heat exchangers.
In addition, Baldwin offers an optional temperature transmitter board for signal or

voltage temperature output. This board has one input and two outputs per channel.
The input is for the type K thermocouple. The first output is an analog voltage output
that can be configured for either 0-2.5vdc or 0-10vdc for a 0C (32F) to 25C (77F)
temperature range. The second output is a 4-20mA for the same temperature
range. The M225 utilizes a single-channel NJ thermocouple transmitter board
(3CCB-012).
Model M225 New Jersey Thermocouple Option

4C-NJ/K-5 Heat exchanger upgrade to include NJ thermocouple port
3CXS-002 Heat exchanger, 5 SS w/ NJ thermocouple port
3CXD-002 Heat exchanger, 5 Durinert w/ NJ thermocouple port
3CXK-002 Heat exchanger, 5 Kynar w/ NJ thermocouple port
3CCB-012 Temperature transmitter board, single stream
3KTC-001 Thermocouple, Type K, replacement kit
Section J: New Jersey Thermocouple Option 16

K: TROUBLESHOOTING
Symptom Check Action

No LED(s) and no fan. AC power input. Ensure that AC power is
connected.
No LED(s) and fan on. AC input fuse on control board. Replace fuse as necessary.
DC output fuse on control board. Replace fuse as necessary.
VC on control board. Replace control board.
LED(s) on and no fan. AC input fuse on power supply. Replace fuse as necessary.
+12vdc TB4 on control board. Replace power supply.
Impinger remains at Peltier current draw. Should be Replace Peltier element.

ambient temperature. above 6 amps.
Thermocouple failure LED is Thermocouple connection TB1, 2. Ensure proper connection.
on. Replace thermocouple.
Impinger frozen and cooler Thermocouple placement in heat Ensure proper placement.
indicates ambient exchanger block. Replace control board.
temperature.
Impinger does not reach set System loading. Ensure system loading is not
temperature, but is below exceeding cooler capacity.
ready temperature. Calibration and set temperature Adjust as necessary.
adjustment.
Impinger temperature cycles Peltier connections on control Ensure a firm connection on
up and down. board. flag connectors on control
board. Ensure system loading
is not exceeding cooler
capacity.
Ready LED does not come on Ready temperature adjustment. Adjust as necessary.
when impinger is below 7C.
Water carryover in system. Impinger temperature. Should be Ensure system loading is not
below 6C. exceeding cooler capacity.
Slip LED does not come on Water carryover in system. Ensure system loading is not
(alarm relay/water slip option exceeding cooler capacity.
installed). Water slip sensor connections. Ensure that all water slip sensor
connections are made.
Clean tip of sensor.
Replace alarm relay/water slip
board.
Pump does not start. Ready Pump electrical connections. Ensure proper connections.
and slip LED(s) are on (alarm Replace board.
relay/water slip option
installed).
For further service assistance, contact:
Baldwin, Inc.
895 East Patriot Blvd., Suite 107
Reno, NV 89511
Tel: 888-234-7366 (toll free U.S.)
Tel: 775-850-1800
Fax: 775-850-1818
Email: tech@baldwinUSA.com
or your local representative
L: SPARE PARTS
Classic Model M225

2FAN-004 Fan: Muffin, 4 x 1 , 12 VDC
3CXD-001 Heat Exchanger: 5" Durinert
3CXG-005 Heat Exchanger: 5" Glass, threaded w/ fittings
3CXK-001 Heat Exchanger: 5" Kynar
3CXS-001 Heat Exchanger: 5" Stainless Steel
3KPE-004* Peltier Element Kit, 40 mm
1PSD-027* Power Supply: 240 W, 15 VDC
3TCB-002* Temperature Control Board: Dual Channel
1TTC-003 Thermocouple, Temperature, Control, Type K 36
* Recommended Spares
Sample Conditioning Systems w/ Model M225 Classic Thermo-Electric Cooler
Model C1 (Model 4S-M225-9AC1, 4S-M225-9DC1)

3KPB-003 Peristaltic Pump: Dual, Kit, 115V Complete w/ Enclosure
3KPA-001* Sample Pump: Assembly, Single Head w/ Check Valve, 115V
2PAS-008 Sample Pump: Single Head, Mini-Dia-Vac, 115V (bare)
2PAM-001* Sample Pump: Repair Kit, Single
Model CD (Models 4S-M225-9ACD, 4S-M225-9DCD)

3FEC-002* Filter Element: Ceramic, 2-micron
3KPA-002* Sample Pump: Assembly, Dual Head w/ Check Valve, 115V
2PAD-006 Sample Pump: Dual Head, Mini-Dia-Vac, 115V (bare)
2PAM-002* Sample Pump: Repair Kit, Dual

Model CD2 (Models 4S-M225-9ACD2, 4S-M225-9DCD2)
2PBT-002PK Peristaltic Pump: Tubing, Norprene, Size 17 (10 feet)
3KPA-002* Sample Pump: Assembly, Dual Head w/ Check Valve, 115V
2PAD-006 Sample Pump: Dual Head, Mini-Dia-Vac, 115V (bare)
2PAM-002* Sample Pump: Repair Kit, Dual

APPENDIX A: CLASSIC MODEL M225
21
Control Board
1 2 3 4 5 6
TP9
Header for Relay Alarm Board AC_LINE
1
U6 100uH
RN4C AC_NEUTRAL
P3 6 5 1 8 TP8 F1 L1
C29 NC +V VCC .1uf X type 250vac
1M + 2 7 PWR1 F2 TB15
1
1 CHN2_READY +CAP OSC VCC
3 6 1
2 TC_2_OK 15uf GND LV 1 amp C45 C44 C47
C28 VCC 4 5 + + 5 1
3 VCC -CAP Vout VEE +OUT ACL 2 amp 250vdc
D3 C40 C43 2 2
4 TEMP_2 VCC ACN
1
ICL7660 D7 68uf 68uf 4 3 TB10
5 CHN1_READY SA5.0
+ -OUT ACG
.1uf 15uf .1uf
6 TC_1_OK WATER_SLIP2 RN3D 1
1
7 WATER_SLIP2
3
GREEN 4.7K 5V_AC/DC
8 WATER_SLIP1
TP7
4 RN2B 3 5 U7A
D 2 GREEN D
5
10K C32
4 470 D6
.001uf LM339 U8A
8 7 RN5D 8
A4
2
C35 C33 6 12
A3 Y4
12
4 14
RN2A .1uf .1uf A2 Y3 CHN2_READY
C4 15uf VCC 2 16 TB13
TC2_SENSE A1 Y2 TC_2_OK
+
10K 18
FOR ZERO / SPAN ADJ. Y1 AC_LINE 1
1 5 6
G
.1uf 4.7K TP2 MC74HC240A RED TB11
1
1 RN5C
TB2 D2
1 RN4D CHAN 1 AC OUTPUT 1
3 C6 7 8
RED TC2_SENSE
U2 20K POT7 1M 2
2 1 14
+IN -IN VCC VCC VCC
1
YEL 2 13
+C -ALM READY TEMP. R25 U9A Q5
1 100 3 12
+T +ALM VCC RN3C 10K
R4 4 11 1 OPTO3
COM V+ VCC CHN_1_CONTROL_OUT TC_1_OK
4
5 10 4.7K 2 12 5 RN6C 61 6 R27 3 MAC8D
-T COMP R23 CHN1_READY
6 9 3 U5A 13 220 200
-C Vo RN2D U7B 100K
7 8 1 8 7 7 2 4
1
V- FB R17 AC_NEUTRAL
2 1 Q3 MC74HC11
4
10K C38 CHN_2_CONTROL_OUT MOC3023
AD595AQ 24.9K LF347N 6 2N3904
.001uf LM339 TB14
11
6
C12
VEE C42 C39 AC_LINE 1
C48
VCC RN2C
10K .1uf .1uf VCC
.1uf C21 TB12
.1uf .1uf
CHAN 2 AC OUTPUT 1
JP2
NOTE 1 R13 100K R29 1 2
5
TC_1_OK 1 2
2
200K 200K 3 4
POT4 TC_2_OK 3 4 VCC
Header for Current Transmitter Board JP1 5 6
U5B R20 CHN1_READY 5 6 R26 U9B Q6
C17 6 1 2 7 8
VCC 1 2 CLK_1 CHN2_READY 7 8 10K
.1uf SPAN 7 1M 3 4 9 10 3 OPTO4
3 4 CLK_2 CHN_1_CONTROL_OUT 9 10 RN6D R28 MAC8D
POT2 5 11 12 4 6 7 81 6 3
C2 C1 R14 R15 LF347N 1 CHN_2_CONTROL_OUT 11 12 R24
+ 5 220 200
15uf .1uf ZERO TP4 NOTE 3 100K 2 4
1
C 100K 2K AC_NEUTRAL C
20K NOTE 2 Q4 MC74HC11
20K 2N3904 MOC3023
VEE POT6
P1
VCC
C46
3 VEE
SET TEMP. TB6
2 VCC VCC
1 .1uf +12vdc 1
3 RN4B 4 CHAN 1 DC OUTPUT
1M VCC TB8
C7 + D4 TEMP_1 1
1
15uf C8
.1uf
WATER_SLIP1 RN3A Q1
GREEN 4.7K
1 RN1A 2 11 U7D +12vdc MPT50N06V

13 GREEN
2
10K C31
10 470 D5
.001uf LM339 U8B R21 TB16
17 3 RN5B 4 2K
A4 +12vdc 1
3
C30 C34 15 3
A3 Y4 OPTO1
13 5 U10A 1 5 CHAN 1 DC OUTPUT
RN1B .1uf .1uf A2 Y3 CHN1_READY VCC
C3 15uf VCC 11 7 1 TB17
TC1_SENSE A1 Y2 TC_1_OK TC_1_OK RN6B
+
10K 9 3 3 42 4
Y1 1
FOR ZERO / SPAN ADJ. 19 1 2 2 220
G CHN_1_CONTROL_OUT MOC8113
.1uf 4.7K TP1 MC74HC240A RED Q7
4
1 MM74C08
TB1 RN5A
1 D1
3 C5 1 RN4A 2
RED TC1_SENSE MPT50N06V
U1 20K POT8 1M C49
2 1 14 +12vdc
+IN -IN VCC VCC VCC
1
YEL 2 13
+C -ALM READY TEMP. .1uf
1 100 3 12 TB7
+T +ALM RN3B
R3 4 11 R22
COM V+ VCC 4.7K +12vdc 1
5 10 2K
-T COMP CHAN 2 DC OUTPUT
6 9 12 U5D OPTO2
-C Vo RN1C U7C U10B
7 8 14 5 6 9 JP3 1 5 TB9
B V- FB R16 VCC B
13 14 1 2 4
3
10K C37 CHN_1_CONTROL_OUT TC_1_OK 1 2 1
AD595AQ LF347N 8 3 4 6 1 RN6A 22 4
24.9K TC_2_OK 3 4
.001uf LM339 5 6 5 220
CHN_1_CONTROL_OUT 5 6
7
C11 7 8 MOC8113 Q2
C36 C41 CHN_2_CONTROL_OUT 7 8
VCC MM74C08
RN1D
.1uf C20 10K .1uf .1uf NOTE 2 MPT50N06V
.1uf
NOTE 1 R12 100K R30 TB18
8
200K 200K +12vdc 1
POT3 TB5
C16 2 CHAN 2 DC OUTPUT
VCC SPAN R19 +12vdc
.1uf U5C 9 TB19
CLK_1 +12vdc power input
POT1 8 1M 1
R11 R10 1
10
1
ZERO 100K 2K LF347N
20K TP3 Q8
VEE
20K POT5
MPT50N06V
VCC
TB4 D8
SET TEMP. 2
+12vdc
U3B fan power output 1 1N4006
6 NOTE 1: R12 & R13 are installed when the controller board is used for cooling.
C14 .1uf U4A C15 7 D9 R12 & R13 are removed and jumper wires are installed when the controller board is used for heating.
3 5 R9 5 1N4006
CON OUT CLK_1 C19 C22 TEMP_1 C10 NOTE 2: For JP3, jumper pins 1 &2 and pins 5 & 6 for channel 1 control.
6 1 200K + R7
TRG DIS 1uf 15uf .1uf .1uf For JP3, jumper pins 3 & 4 and pins 7 & 8 for channel 2 control.
2 LM358A 100K
THRES For JP2, jumper pins 1 &2, pins 5 & 6, and pins 9 & 10 for channel 1 control.
4 P2
C13 RST For JP2, jumper pins 3 & 4, pins 7 & 8, and pins 11 & 12 for channel 2 control.
NOTE 4 1 TEMP_2
.01uf VCC LM556C
2
3 VEE NOTE 3: if both channels are used for either cooling or heating, then jumper pins 1 & 2.
4 VCC VEE
NOTE 5 if one channel is used for cooling and the other channel is used for heating, jumper pins 3 & 4.
5
4
200 TB3
6 TEMP_1 U3A R8 NOTE 4: if the channel is used for cooling, C13 or C24 is a .01uf monoceramic cap.
A 3 A
2
TEMP1 output if the channel is used for heating, C13 or C24 is a 3.3uf monoceramic cap.
C27 + 1 2
C23 .1uf U4B C25 15uf C26 3
TEMP2 output NOTE 5: if both the channels are used for the same function,
R18 .1uf TEMP_2 C9
200 R2
that is cooling or heating, only CLK_1 is used for both channels.
11 9 R1 1
CON OUT CLK_2 .1uf GND Refer to NOTE 3
8 13 200K LM358A 100K
TRG DIS 1uf
12
8
THRES
10 Header for Display Board
C24 RST VCC
NOTE 4 Title
.01uf C18 LM556C M-class Cooler Control Board
.1uf
VCC NOTE: PCB PN 1CBT-001 REV B
C
PN 3TCB-001 REV C

File: C:\DRAWIN~1\..\3TCB001C.SCH Drawn By:
1 2 3 4 5 6
1 2 3 4 5 6
TB3
VCC 1
D3 D2 2
5
RELAY1
D1 1 3
D 4 D
Chn2 Pump Relay
1N916 3
TB2
1 1 RN2A 2 VCC
2
1M VCC TB1
2 2
VCC
8
6
5
R4 1
Water Slip 2 2K Q8
7
5
3
1
1 RN1A 2 2
VCC 2N7000
2
4
C5 3 RELAY2
--
1 RN1B 3 .001uf LM311
VCC
3
100K U1 JP2
VCC Q4
4
1
1 2
3 4
C3 C4 RN2B NOTE 1
.1uf .1uf 1M 2N7000
R5
1
3
CHN2_READY
470
4
Q5
VCC
Q9 TC_2_OK
C 2N7000 2N7000 C
P1 R2
WATER_SLIP2
1 CHN2_READY Q6
2.2M
2 TC_2_OK
3 VCC
4 2N7000
C2 +
5 CHN1_READY
6 TC_1_OK
3
1
7 WATER_SLIP2 1uf
8 WATER_SLIP1
TB6
4 3
2 1
NOTE 1 VCC 1
JP3
D6 D5 2
4
2
5
RELAY4
D4 1 3
4
Chn1 Pump Relay
1N916 3
TB5
1 5 RN2C 6 VCC
2
B 1M VCC TB4 B
2 2
VCC
8
6
5
3
1
R3 1
Water Slip 1 2K Q7
7
5
3
1
1 RN1C 4 2
VCC 2N7000
4 3
2 1
C6 3 JP1 RELAY3
+
--
1 RN1D 5 .001uf LM311

VCC
7
U2 Q1
4
2
100K
VCC
4
1
C8 C7 RN2D NOTE 1
.1uf .1uf 1M CHN1_READY
R6 2N7000
470
Q2
8
VCC
Q10 TC_1_OK
2N7000 2N7000
WATER_SLIP1 R1
Q3
2.2M
Note: PCB PN 1CBC-009
A NOTE 1: For single sample streams only, if separate water slip and temperature alarms are required, 2N7000 A
jumper pins 1 & 2 on JP1, JP2 and JP3. C1 +
For dual sample streams, jumper pins 3 & 4 on JP1, JP2 and JP3. Title
1uf M-class Relay Board
B
Assy. PN 3CCB-016 REV C

File: C:\DRAWIN~1\..\3CCB016C.SCH Drawn By:
1 2 3 4 5 6
APPENDIX B: SAMPLE CONDITIONING SYSTEM
22
AIR DIMENSIONS INCORPORATED
1371 West Newport Center Dr., Suite 101, Deerfield Beach, FL 33442 - Phone 954-428-7333 or 800-423-6464 Fax 954-360-0987
http://www.airdimensions.com e-mail address -Info@AirDimensions.com
MINI DIA-VAC
MAINTENANCE AND DISASSEMBLY INSTRUCTIONS
A. General Operations Characteristics

1. Normal motor coil temperatures may be 160 - 180 degrees F. Winding insulation is Class B.
Please note the two fans are different, so before removing the fans, note which side they belong on.
2. To check pumping efficiency, employ suitably damped gauges connected so as to dead-end either
pressure or vacuum.
NOTE: Check each separately, One or the other port must be open during this test.
Use 0-60 PSI pressure gauge and 0-30 inch hg. vacuum gauge, (or mercury manometer).
Maximum pressure should be at least 33 PSIG for the .160 eccentric.
Maximum vacuum should be 21 inches Hg when using the .160 eccentric.
3. Match electrical power to motor
4. Do not start pump and motor with load of pressure or vacuum on pump head.
5. Pumps are intended for gaseous operation, eliminate liquids entering pump.
6. Nominal running amps for Mini Dia-Vac at 115/230 volts are 1.7/0.8
B. Maintenance Procedures
1. Motor oiling - No oiling or other lubrication addition is necessary at all. All bearings are pre-
lubricated and shielded from external contamination.
2. Diaphragm Replacement (also see Maintenance Procedure Below):

a. Standard EPDM (part 4302 or kit 11309) - Operating life can be five years or more under
conditions of light pressure or vacuum loads and infrequent operation. Over 20 PSI and constant
operation may require 3 month diaphragm inspection procedure. High ambient conditions over 100
degrees F may also decrease diaphragm life.
b. Teflon coated EPDM (part 4301 or kit 11305) - Satisfactory operation can be attained for periods
of 12 months or more under conditions of light pressure of vacuum loads.
c. Viton/Nomex (part 4303 or kit 11307) - same as b above.
Where critical processes may involve the pumping of corrosive or toxic gas media, it is
recommended that a monthly check of the diaphragm be part of a scheduled maintenance procedure.
Air Dimensions Inc. will supply recommendations on the choice of diaphragm material and or pump
head construction on request.
*Diaphragms require close precision tolerance, therefore only ADI diaphragms should be used as
replacements.
C. Disassembly of Head Section and Service Diaphragm

1. Remove head section by unscrewing the four large bolts. A flat-bladed screw driver may be
needed to gently pry the head free of the service diaphragm. **If you have Teflon coating on the
heads use caution not to scratch the surface.
2. The valve body can then be removed by unscrewing the two smaller screws (also accessible on
the top of the head section). This part may be freed by gently tapping on these two screws after they
have been loosened about three or four turns. When the valve body is removed, check all internal
surfaces for any accumulation of dirt. The two valve discs can be wiped clean and replaced as long
as they appear unaffected by usage. The valve gasket can be easily removed and should be
inspected. As a matter of good practice, the valve discs and valve gasket should be replaced during
any routine maintenance check of the head section. A once a year routine procedure is
recommended.
3. The service diaphragm is secured by the single screw in its center. Remove this screw with a
5/32" Allen wrench. The diaphragm and its clamping plate should be easily lifted off. Some slight
adherence to the metal may occur if the diaphragm has been in use for a long period.
4. When replacing the service diaphragm, a Teflon washer (part# 23001) should be inserted under
the head of the diaphragm cap screw. This is added insurance against small gas leaks through screw
heads and may be essential in vacuum applications where outside air contamination cannot be
tolerated. After tightening the screw, the excess Teflon should be trimmed away.
NOTE: When replacing the service diaphragm, be sure the four projecting studs of the base casting
are properly located in the four outer holes provided in the diaphragm before the part is clamped in
place. Be sure the diaphragm plate is firmly replaced with its center screw.
D. Disassembly and Replacement of the Connecting Rod

1. Remove head section and service diaphragm as described in (C) above. When this is done and the
front screen has been removed, the connecting rod assembly may be taken out (refer to exploded
view drawing). Gently pry up and remove the connecting rod cap (part# 3301) which is held in place
by the diaphragm screw.
2. Loosen but do not remove the counterweight screw. This is accessible from the top of the pump
base casting and will require a 5/32" hex allen wrench. The connecting rod eccentric assembly,
including counterweight and fan, will then slide of the motor shaft.
3. When replacing the eccentric assembly, be careful to align the flat section on the motor shaft with
the counterweight screw. The eccentric assembly should be aligned so the fan is on the outer side
from the motor. Slide this assembly as far onto the motor shaft as it will go before tightening the
counterweight screw onto the flat of the motor.
NOTE: After prolonged use, the eccentric assembly may freeze up on the motor shaft. A wheel
puller may be needed to free the part. When replacing the eccentric assembly, the motor shaft should
be lightly coated with a graphite or MDS based lubricant.
E. Related Torque Values
1. Head bolts - 110 inch pounds.
2. Valve body screws and Diaphragm plate screws - 70 inch pounds
Dia-Vac is a Registered Trademark of Air Dimensions Inc.
1. Single Pump Head Loading
Note: Use only MASTERFLEX Precision Tubing with MASTERFLEX

Pumps to insure optimum performance. Use of other tubing may void
applicable warranties.
Contents: One pump head, one 15 in (38 cm) length of silicone tubing,
one mounting hardware package, manual and tubing loading key.
Supplied tubing loading key required for assembly.
a) Separate the end bells (the pump head halves). Hold the end bell
containing the rotor as shown with the tubing retainer grooves
facing down.
b) Place tubing in the right groove and against the first two rollers.
Hold tubing with thumb. Near groove, insert smaller prong of
loading key between the top of the rotor and tubing. Push key in
as far as possible.
c) Push down and turn key counterclockwise (ccw) completely

around the rotor. The key will push the tubing uniformly into the
end bell assembly. Hold the second end of tubing. Remove key.
d) Position the other end bell on top and press the end bells together.
Be careful not to pinch the tubing. If end bells do not snap tightly
together, reload tubing. If necessary, turn key in slot on rotor shaft
to adjust tubing (as in Step e).
e) With key in slot on rotor shaft, turn key to align tang on rotor
shaft with slot in motor drive shaft. Point tubing retainer grooves
up. Shift the pump head slightly till it snaps on the alignment pins
(if present). Secure with four provided screws. Tighten with
fingers only.
Set contains four #8-32 screws, four washers, and four wingnuts.
Number of heads Cold- rolled steel Stainless steel
To be mounted Order number Order number
1 MN-07013-02 MN-07013-04
2 MN-07013-03 MN-07013-05
3 MN-07013-03 MN-07013-08
4 MN-07013-07 MN-07013-09
2. Multi-Channel Mounting
Flat bladed screwdriver required for mounting.
Tubing loading key required for mounting.
Note: Other special mounting hardware for multi-channel pumping.

See 3. Replacement Parts and Accessories.
a) Load the pump heads with tubing.
b) Install the four correct length-mounting screws in drive.
c) Slide the first pump head into the mounting screws.

4. Specifications
d) Place key in slot on mounting shaft. Twist to align tang on rotor Thin wall* Thick wall*
shaft with slot in motor drive shaft. Shift the pump housing Maximum continuous
around till it drops over the alignment pins (if present). discharge pressure-psi(bar): 20(1.4) 25(1.7)
Maximum intermittent
e) Repeat for each additional pump head, aligning pump head tang discharge pressure-psi(bar): 35(2.4) 40(2.7)
with slot on previously mounted pump head. Maximum vacuum: 660(510)m Hg 26(20)in Hg
Maximum suction lift: 8.8(6.7)m H2O 29(22)ft H2O
f) Slide the four flat washers onto screws and secure with the four Number of rollers: 3
wingnuts. Tighten with fingers only. Occlusion: Standard fixed
Maximum pump speed (rpm): 600
g) A support bracket is supplied with 3 and 4 channel mounting Nominal torque load: 6.5 kg-cm(90 oz-in)
hardware for additional support. Mount over bottom two screws. Housing materials: Polycarbonate (PC) all models, or Polyphenylene
Inert one of the three different adjustments screws depending sulfide (PPS) all models except 07035
upon drive height. Roller/rotor materials: Cold rolled Stl (CRS) or Stainless Stl (SS)
Operating temperature: 0 to 40 (32 to 104F)
3. Replacement Parts and Accessories *Thin wall: tubing 13, 14, 16, 17, 18 Thick wall: tubing 15, 24, 35
With tubing 17 & 18
A. End Bells (order two end bells for a complete head assembly). Use in this temperature range for continuous duty operation with no
Pump Head # PC Order number Pump Head # PC Order decrease in performance or product life. Pump heads will work outside
number this range with some possible reductions in performance or product
07013-00, -20 MN-07013-81 - - life.
07013-10, -21 MN-07013-91 07013-50, -52 MN-07013-92
07014-00, -20 MN-07014-81 - - 5. Warranty and Return Items
07014-10, -21 MN-07014-91 07014-50, -52 MN-07014-92
07015-00, -20 MN-07015-81 - -
07015-10, -21 MN-07015-91 07015-50, -52 MN-07015-92 Warranty
07016-00, -20 MN-07016-81 - -
Use only MASTERFLEX Precision Tubing with MASTERFLEX Pumps
07016-10, -21 MN-07016-91 07016-50, -52 MN-07016-92 to insure optimum performance. Use of other tubing may void
07017-00, -20 MN-07017-81 - -
applicable warranties.
07017-10, -21 MN-07017-91 07017-50, -52 MN-07017-92
07018-00, -20 - The manufacturer warrants this product to be free from any significant
MN-07018-81 -
07018-10, -21 MN-07018-91 07018-50, -52 MN-07018-92 deviations from published specifications. If repair or adjustment is
necessary within the warranty period, the problem will be corrected at
07024-00, -20 MN-07024-81 - -
no charge if it is not due to misuse or abuse on your part, as determined
07024-10, -21 MN-07024-91 07024-50, -52 MN-07024-92
by the manufacturer. Repair costs outside the warranty period, or those
07035-02, -20 MN-07035-81 - -
resulting from product misuse or abuse, may be invoiced to you.
07035-12, -21 MN-07035-91 - -
The warranty period for this product is noted on the Warranty Card.
B. Rotor assemblies
Pump Head number Pump Head suffix Order number Product Return
-00 MN-07013-75 To limit charges and delays, contact the seller or manufacturer for
07013, 07014, 07016 -10, -50 MN-07013-76
07018 -20 MN-07013-80 authorization and shipping instructions before returning the product,
-21, -52 MN-07013-95 either within or outside the warranty period. When returning the
-00, -02 MN-07013-75 product, please state the reason for the return. For your protection, pack
-10, -50, -12 MN-07013-76
07015, 07024, 07035
-20 MN-07013-80 the product carefully and insure it against possible damage or loss. Any
-21, -52 MN-07013-90 damages resulting from improper packaging are your responsibility.
C. MN-07021-04 Thrust washers. Pack of 10.

Technical Assistance
D. MN-07013-90 Tubing loading key.
If you have any questions about the use of this product, contact the
E. Mounting hardware for standard pump heads.
manufacturer or authorized dealer.
CHART OF VOLUME PERCENT WATER CONCENTRATIONS
AT SATURATION FOR VARIOUS TEMPERATURES
AT STANDARD PRESSURE (ATMOSPHERIC PRESSURE)
DEGREES C DEGREES F VOLUME % DEGREES C DEGREES F VOLUME %
+100 + 212 100.00 +2 + 36 0.696
+ 90 + 194 69.20 +1 + 34 0.649
+ 80 + 176 46.70 0 + 32 0.602
+ 75 + 167 38.70 -1 + 30 0.555
+ 70 + 158 30.70 -2 + 28 0.510
+ 65 + 149 25.20 -3 + 27 0.469
+ 60 + 140 19.70 -4 + 25 0.431
+ 55 + 131 15.50 -5 + 23 0.396
+ 50 + 122 12.20 -6 + 21 0.363
+ 45 + 113 9.45 -7 + 19 0.333
+ 40 + 104 7.25 -8 + 18 0.305
+ 35 + 95 5.55 -9 + 16 0.281
+ 30 + 86 4.19 - 10 + 14 0.256
+ 29 + 84 3.95 - 11 + 12 0.234
+ 28 + 82 3.73 - 12 + 10 0.214
+ 27 + 81 3.62 - 13 +9 0.196
+ 26 + 79 3.32 - 14 +7 0.179
+ 25 + 77 3.13 - 15 +5 0.163
+ 24 + 75 2.94 - 16 +3 0.148
+ 23 + 73 2.77 - 17 +1 0.135
+ 22 + 72 2.61 - 18 0 0.123
+ 21 + 70 2.46 - 19 -2 0.112
+ 20 + 68 3.31 - 20 -4 0.102
+ 19 + 66 2.17 - 22 -8 0.084
+ 18 + 64 2.04 - 24 - 11 0.069
+ 17 + 63 1.91 - 26 - 15 0.057
+ 16 + 61 1.79 - 28 - 18 0.046
+ 15 + 59 1.68 - 30 - 22 0.038
+ 14 + 57 1.58 - 32 - 26 0.031
+ 13 + 55 1.48 - 34 - 30 0.025
+ 12 + 54 1.38 - 36 - 34 0.019
+ 11 + 52 1.29 - 38 - 37 0.016
+ 10 + 50 1.21 - 40 - 40 0.013
+9 + 48 1.13 - 42 - 44 0.011
+8 + 46 1.06 - 44 - 47 0.008
+7 + 45 0.988 - 46 - 51 0.006
+6 + 43 0.922 - 48 - 54 0.005
+5 + 41 0.861 - 50 - 58 0.004
+4 + 39 0.803 - 52 - 62 0.003
+3 + 37 0.751 - 54 - 65 0.002
MOISTURE CONVERSION TABLE
VAPOR PRESSURE
DEWPOINT PPM on VOLUME RELATIVE
(WATER/ICE in PPM on WEIGHT
BASIS at 760 mm HUMIDITY
EQUALIBRIUM) BASIS in AIR
F C of Hg PRESSURE at 70 F
mm MERCURY
-110 -166 .0000010 .00132 .0000053 .00082
-108 -162 .0000018 .00237 .0000096 .0015
-106 -159 .0000028 .00368 .000015 .0023
-104 -155 .0000043 .00566 .000023 .0035
-102 -152 .0000065 .00855 .000035 .0053
-100 -148 .0000099 .0130 .000053 .0081
-98 -144 .000015 .0197 .000080 .012
-96 -141 .000022 .0289 .00012 .018
-94 -137 .000033 .0434 .00018 .027
-92 -134 .000048 .0632 .00026 .039
-90 -130 .00007 .0921 .00037 .057
-88 -126 .00010 .132 .00054 .082
-86 -123 .00014 .184 .00075 .11
-84 -119 .00020 .263 .00107 .16
-82 -116 .00029 .382 .00155 .24
-80 -112 .00040 .562 .00214 .33
-78 -108 .00056 .737 .00300 .46
-76 -105 .00077 1.01 .00410 .83
-74 -101 .00105 1.38 .00559 .86
-72 -98 .00143 1.88 .00762 1.17
-70 -94 .00194 2.55 .0104 1.58
-68 -90 .00261 3.43 .0140 2.13
-66 -87 .00349 4.59 .0187 2.84
-64 -83 .00464 6.11 .0248 3.79
-62 -80 .00614 8.08 .0328 5.01
-60 -76 .00808 10.6 .0430 6.59
-58 -72 .0106 13.9 .0565 8.63
-56 -69 .0138 18.2 .0735 11.3
-54 -65 .0178 23.4 .0948 14.5
-52 -62 .0230 30.3 .123 18.8
-50 -58 .0295 38.8 .157 24.1
-48 -54 .0378 49.7 .202 30.9
-46 -51 .0481 63.3 .257 39.3
-44 -47 .0609 80.0 .325 49.7
-42 -44 .0768 101 .410 62.7
-40 -40 .0966 127 .516 78.9
-38 -36 .1209 159 .644 98.6
-36 -33 .1507 198 .804 122.9
-34 -29 .1873 246 1.00 152
-32 -26 .2318 305 1.24 189
-30 -22 .2859 376 1.52 234
-28 -18 .351 462 1.88 287
-26 -15 .430 566 2.30 351
-24 -11 .526 692 2.81 430
-22 -8 .640 842 3.41 523
-20 -4 .776 1020 4.13 633
-18 0 .939 1240 5.00 770
-16 +3 1.132 1490 6.03 925
-14 +7 1.361 1790 7.25 1110
-12 +10 1.632 2150 8.69 1335
-10 +14 1.950 2570 10.4 1596
-8 +18 2.326 3060 12.4 1900
-6 +21 2.765 3640 14.7 2260
-4 +25 3.280 4230 17.5 2680
-2 +28 3.880 5100 20.7 3170
0 +32 4.579 6020 24.4 3640
+2 +36 5.294 6970 28.2 4330
+4 +39 6.101 8030 32.5 4990
+6 +43 7.013 9230 37.4 5730
+8 +46 8.045 10590 42.9 6580
+10 +50 9.029 12120 49.1 7530
+12 +54 10.52 13840 56.1 8600
+14 +57 11.99 15780 63.9 9800
+16 +61 13.63 17930 72.6 11140
+18 +64 15.48 20370 82.5 12650
+20 +68 17.54 23080 93.5 14330
+22 +71 19.827 26088 16699
+24 +75 33.377 29443 18847
+26 +79 25.209 33169 21232
+28 +8
17671 Armstrong Avenue, Irvine, CA 92614
Phone: 1 (800) 446-7422; FAX: (949) 250-0924
In California Phone (949) 250-4811
November 11, 2010
Subject: COM-1D NOX Converter Specifications
Item Horiba Part Number

NOX Converter Assembly (COM-1D) ....................................................201002-1
NOX Converter Catalyst Tube (4 grams)............................................... 253767-14
NOX Converter Catalyst (Bulk 25g/bottle)................................................3842601
Use the following when monitoring NOx & SO2:

NOX Converter Assembly (COM-1DS) w/SO2 Pre-Cond Tube2 ............201002-2
NOX Converter Catalyst Tube (4 grams) w/SO2 Pre-Cond Tube2 ..........200930-1
Catalyst Type: Molybdate Carbon Spheres
Catalyst Temperature: Approximately 190C
Catalyst Quantity: 4 grams
Sample Gas Conditions:

Dust <0.1 g/m3
Water Non-condensing at converter inlet
NH3 Less than 10 ppm
Flowrate 750 cc/min (maximum)
Converter efficiency: > 90%
Maximum NO2 Conc: 100 ppm at 90% efficiency
Catalyst Lifetime3: 4 g Catalyst; Converts 24 ppm NO2 continuously for one year
A World Ahead in Analyzer Technology

COM-1Dspec (Rev D) Page 1 of 2
November 11, 2010
Electrical:
Power: 60W, 120 VAC, 50/60 Hz
Heater: (2) 30 W Cartridge heaters
Sensor: Platinum RTD
Control: Integrated PID controller w/solid state relay. Set-point at 210C
with <1C Hysteresis.
Physical:
Dimensions: Approx 8.75 L x 3.5 diameter cylinder
Orientation: Mount vertically with flow into top.
Catalyst tube: O.D. Ti tube. Can be repacked by user.
Connections: Viton boots with clamps. Accepts or 6 mm O.D. tube.
Notes:
1. Part number 384265 has been discontinued. Use part number 384260.
2. SO2 Pre-Conditioning. The Molybdenum catalyst will absorb SO2. When measuring NOX
and SO2, the catalyst must be pre-conditioned with a high concentration of SO2. Pre-
conditioned catalyst is not available in bulk quantity.
3. Catalyst Lifetime. The Molybdenum catalyst is consumed by the NO2 to NO conversion
reaction(s). The lifetime of the catalyst depends on several factors such as, NO2
concentration, flowrate and O2 concentration. The specified lifetime is calculated with a
20% safety margin. It is possible to convert higher concentrations of NO2 continuously with
a reduced catalyst lifetime. The lifetime is approximately reduced linearly with increased
NO2 concentrations.
4. The high capacity 4 gram NOX converter catalyst tube (p/n 253767-2) has been discontinued.
Horiba Instruments has upgraded the standard NOX converter catalyst tube (p/n 253767-1)
from 2 grams to 4 grams.
A World Ahead in Analyzer Technology

COM-1Dspec (Rev D) Page 2 of 2
DEKORON/UNITHERM
Page 1 of 13
A Division of Customer Support
Approval Signatures Issued by: Tim Edge
Prepared by:
Approved by General Manager Approved by Procedure Number Rev.

Tony Peet Chick Jakacki WI-IS Installation
Installation Instructions Electric Trace Bundles and Probe Support Original Effective Date
Bundles for CEM Application
1.0 Purpose
This bulletin provides the Field Engineer and the craft people with information for the proper
installation of Unitherm Electrically Traced products. These recommendations have been proven by
years of actual experience. They are put forth as suggestions and do not preclude the use of other
methods and good field construction practices
1 This bulletin provides a general discussion on:
Handling and Storage
Planning and Preparation
Product Installation
2 Topics such as:
Methods of Installation
Methods of Bending and Straightening
Hanging and Support Instructions
Electrical Connection Kits
are discussed in detail with the use of step-by-step instructions, illustrations, and diagrams. Various
charts are included to cover product specifications, recommended support centers, and minimum
bend radii, to guide in all phases of planning and installation.
2.0 Handling and Storage

All Unitherm Traced products are shipped on non-returnable wooden reels, which take minimum
space and provide maximum product protection. The standard reel for analyzer bundles has a 54"
flange, is 36" wide, with a 40" drum, weighing 160 pounds. Other reel sizes may be used,
depending upon coil lengths.
Each length is sealed at the ends to prevent entry of moisture or foreign material. However, if reels
are to be stored out of doors at the jobsite, a weatherproof covering (e.g., polyethylene film, canvas,
etc.) should be used.
3.0 Planning and Preperation

The methods recommended for installing Unitherm Traced products are based upon accepted
practices presently used by Instrument Engineers, Electricians and Pipe Fitters. Planning and
preparation are essential to proper installation.
Initial planning and system layout is recommended to take total advantage of the installation cost
savings. Preliminary planning should encompass such things as: determination of run lengths,
position and angle of probe connection, accessible routing of the Analyzer line, existing support
structures and their location, entry into the analyzer house and the possibility of external tracing
requirements beyond the bundle. It is important to review the section on hanging and supports
while planning the run to make the best use of existing supports.
DEKORON/UNITHERM Page 2 of 13

Procedure Number Rev.
WI-IS Installation
3.0 Planning and Preperation (Contd)

Check with DEKORON/UNITHERM Customer Service for information on the size, weight, support
distance, and minimum bend radius of the bundle being installed.
4.0 Length Determination

Bundle length is determined by the routing distance between sample point and instrument.
However, some allowance for extra length should be made. Minimum additional length requirement
for each connection point, such as splice, termination and input power kit, should be 12 inches.
Allowances must also be made for routing inside probe enclosures and the analyzer housing.
5.0 Routing
The initial consideration in establishing the best route is to install instruments and adjacent supports
which will allow the traced line to run straight for 12" to 18" before being connected to any
instruments, sample points, orifice plates, etc. This will simplify the job of connecting after the
bundle is secured.
Wide bearing
clamps
TYPICAL
BUNDLE
Existing Pipe Run
FIG 1
Routing should be chosen to take advantage of existing cable trays, beams, columns, etc. Provide
long radius sweeping bends whenever possible. Long radius bends allow the bundle to work at its
maximum efficiency and also provide a place where the bundle can expand and contract due to
ambient and tube temperature changes. Tighter bends can be made, as explained below. Take
care to insure that all bends are greater than the minimum bend radius. Support the bundle from 6
to 10 inches either side of the bend with wide bearing clamps (see fig. 1). The routing should not
position the product in an area where the ambient will reach above 120F (49C), such as near a
boiler, reactor, heat exchanger, or against a hot chimney wall; unless the bundle is designed
specifically to handle high ambient temperatures. If the bundle is routed within an enclosed cable
tray or conduit, this maximum temperature may be reduced. Contact Unitherm Customer Service
for information on the limitations of your bundle.
Horizontal runs should be sloped to assist drainage of any condensate or particulate matter that
may collect in the tube. Unitherm suggests a slope of 3/4 inch per foot of horizontal run. In systems
where there is high gas velocity, this slope could be decreased.
Multiple bundle routing, where more than one bundle is run in parallel, should allow at least 1" space
between bundles. Bundles may be stacked if insulating spacers, no less than 1" thick, are used.
Unitherm Customer Service has information on acceptable stacking hardware.

WI-IS Installation
6.0 Methods of Installation

The Unitherm products range from semi-rigid Traced bundles to extremely flexible Heated Hoses.
These products cannot be treated like power cables. The maximum pulling tension on most
Unitherm analyzer bundles is less than 50 pounds, so they cannot be simply attached to a draw
cable and pulled into place.
Installation generally begins at the probe end. If the probe is elevated, position the reel at the base
of the stack, if possible directly below the line where the bundle will be secured. A draw cable can
be fitted with split pulling grips (see Figs 2 and 3). These grips are attached to the bundle a
intervals of 35 feet maximum. The cable and bundle are then pulled up to the level of the probe.
Draw cable
Pulling grip, spaced at

intervals no greater than
35 feet. Spacing is closer for
bundles with multiple heated tubes
or multiple messenger wires.
Analyzer or Probe Support Bundle
Raising bundle up stack

(FIG 2)
NOTE: the cable grip is not a recommended method for securing the bundle to the stack.
Other methods must be employed. If the vertical run is offset around the stack from the probe
location, the installer should pull sufficient bundle up the stack to make the offset. The bundle is
secured on the vertical run before routing the bundle around the stack. Do not attach pulling blocks
at the top of the vertical run and pull the bundle from the probe location. The force applied at the
pulling block is sufficient to damage the internal components even though there may be no apparent
damage to the jacket.
Route the bundle from the vertical run to the probe. Again, allow extra bundle for routing into and
connecting to the probe.
PULLING Plain Grips: Kellems K100P orReliable 824
GRIP Split Grips: Kellems UB125-A or Reliable 1863
Begin securing the bundle within 18 inches of the probe,
OVERALL KELLEMS STANDARD using clamps and installation accessories detailed the
BUNDLE OD SUPPORT GRIP following sections. Never use wire or cable ties to secure
1.50"
1.75"
TO
TO
1.75"
2.00"
P/N O22-03-007
P/N 022-03-008
Unitherm Analyzer bundles. Follow the bundle back from
2.00" TO 2.50" P/N 022-03-009 the probe, securing the bundle at the recommended
2.50" TO 2.99" P/N 022-03-010
3.00" TO 3.49" P/N 022-03-011
support locations. Unitherm bundles are generally
3.50" TO 3.99" P/N 022-03-012 supported every 6 feet on a horizontal run and every 15
feet on a vertical run.
(FIG 3)
Once the bundle is secured at the base of the stack, it can then be routed along exiting structures or
in cable trays to the analyzer house. At this point, the draw cable and cable grips can be removed
and used on another bundle. Again, the bundle should be laid in, not pulled.
On reaching the analyzer house, sufficient bundle should be pulled off the reel to route into the
analyzer house and to the analyzer cabinet. Contact Unitherm Customer Service for
recommendations on bulkhead fittings and entry seals for this application.

WI-IS Installation
7.0 Methods of Bending

Bending the Unitherm traced products can be accomplished by various means, depending upon the
product type and size. In any case, no bend should exceed the minimum bend radius. Exceeding
the bend radius can result in damage to the bundle jacket, core tubes, and heater (see Figure 4).
Since most analyzer bundles are constructed using fluoropolymer tubing, they can be bent by hand.
If the metal tubes or a number of messenger wires in the core, other methods may be needed. A
thin wall conduit or MCM cable bender can be used with the smaller O.D. tube bundles. Other
types of benders can also be used for all products if care is taken to prevent flattening of the tube(s)
or damaging or misplacing the heating element. (A small amount of wrinkling in the jacket is normal
and does not indicate bundle failure or loss of bundle properties.
A stationary mandrel may also be used for bending.
The mandrel, such as a cable reel flange, should have a
diameter of twice the minimum bend radius of the
particular product. If the mandrel is smaller than twice
the minimum bend radius, the complete bend cannot be
made in one operation. Several large curvature bends
OK NO
must be made throughout the entire bend area so as
(FIG 4) not to exceed the minimum bend radius. The installer
should also use this procedure when hand bending.
8.0 Uncoiling Methods

A free-wheeling payoff stand should always be used when uncoiling analyzer bundles. Back tension
should only be enough to keep the reel from overrunning the pull. Tension should always be
minimal.

WI-IS Installation
9.0 Hanging and Supports

Unitherm traced products should be supported securely according to the support center dimensions
shown in the Unitherm catalog. In addition to these dimensions, the product should be securely
supported within 18 to 24 inches of any connection kit. Suggested support methods are listed
below.
9.1 Angle Iron
Angle Iron, sized to the closest 1/2" to the nominal bundle O.D., can be used effectively to support
long vertical or horizontal single bundle runs. The Unitherm traced product is secured to the angle
iron with either plastic or metal strap ties (Figure 6). As always, strap ties should have wide bearing
area and should not be so tight that they deform the jacket of the analyzer bundle more than 1/8
inch. Horizontal runs should have the angle iron over the Unitherm traced product to prevent
containment of water, ice and snow.
TRACED BUNDLE
PIPE STRAPS
ANGLE IRON
(FIG 6)
9.2 Channel Iron
Channel Iron can be used in the same manner as angle iron, but can accept multiple bundles if
sizing is made to allow bundle separation. Strap ties may also be used here.
9.3 Cable Tray
CABLE TRAY INSTALLATION
1"
1"
1"
WIDE BEARING
PIPE STRAPS
STRUT CLAMP IN TRAY
Figure 7
Standard industrial grade cable trays are best suited for multiple product runs. The product should
be anchored to the tray to maintain clearance between the bundles. Securing each bundle to the
tray within 6" to 10" of either side of a bend is recommended. The minimum spacing rule of 1 inch
should apply on straight runs and bends (see Figure 7). Cable tray bends should be sized to the
next standard size above the minimum bending radius of the bundle.

9.4 Pipe or Tube Supports

Unitherm recommends individual supporting hardware that has large supporting surface areas and
cannot be over tightened to the point where the support can crush the product and damage the core
tube or heating element (see Figure 8).
CHANNEL TYPE STRUT
1"
1"
OVERHEAD SUPPORT
HORIZONTAL OR
VERTICAL WALL SUPPORT
Figure 8
Strut clamps are sized according to the bundle diameter and the location of the clamp. Clamps
used on horizontal runs are sized to the nearest standard size greater than the bundle diameter.
This allows the bundle to expand and contract through the clamp. Clamps used on vertical runs are
sized to the nearest standard size less than the bundle diameter. This provides a secure anchor for
the vertical run. Smooth radius bends at each end of the vertical run are recommended.
Do not use wires or thin ties to tie

bundles together or to attach bundles
to hangers. These deform the jacket
and insulation, reducing bundle
efficiency and life.
Figure 9.
Suggested Hanger Types Types of use

Double Bolt Hangers Support and anchor
Band Hangers Support
Split Steel Hanger Support and anchor
F & M Hanger Support and anchor
Short Clip Hanger Support and anchor
Sliding Guide Support Support and anchor
Refrigeration Clevis Hanger Support
Copper Tubing Adjustable Ring Hanger Support
Auto Grip Insul-Speed Hanger Support

10.0 Terminal Expansion

The construction of the Unitherm traced products inherently allow for movement caused by thermal
expansion and contraction. The minimum bend radius is large enough to absorb tube movement
due to expansion. If there are no bends in a run using a single metal process tube product, some
method, such as an expansion loop, should be used to take up the movement.
11.0 Electrical Connections

The following section deals with terminating and connecting Unitherm heated analyzer bundles to
electrical power. If the bundle is factory sealed and terminated (common with Unitherm Heated
Hose products), follow the instructions on the label attached to the power lead wires. The power
lead wires are the two white and one green wire exiting from the power sleeve at the power end of
the bundle.
The 2252, 2256, 2262, and

2266 products use a
parallel resistance heating
JACKET element with bus wires.
FIBROUS GLASS
THERMAL INSULATION These wires can be
BRAID HEATING connected directly to the
ELEMENT
power supply wires after
separation. These bus
wires must not be
PROCESS
TUBE connected together on the
termination end and must
HEAT REFLECTION be electrically isolated from
FOIL WRAP
one another.
Figure 10 - TYPICAL ELECTRIC TRACED BUNDLE
12.0 Connection Kits

Electrical connection kits are offered for each product, which provide an electrical enclosure and
weather tight connection. Figure 11 shows a Unitherm P/N 1548-10000 Electrical Connection Kit.
This kit contains all the components necessary to make: 1- input power connection; -or- 1- input
power splice connection; -or- 1- splice connection; -and- 2- termination connections.

12.0 Connection Kits (Contd)

12.1 Power Connection Procedure
This information provided with each 1548-10000 connection kit.
1. Strip 8" of jacket and thermal insulation
from product end, carefully exposing the
process tube(s) and heating element.
CONNECTION KIT 1548-10000
2. Place the metal bracket (9) on the bundle
5 3 2 jacket, 1/2" from the end of the bared
section and tighten cable ties.
4 3. Attach connection box (6) to bracket with

1 one weather tight connector.
1b 3
2
4. Feed the heater through the connector
1a 6
7 cap (1a), two (2) metal washers (2), and
the silicone grommet with the slotted hole
8 (3). Insert the grommet into the connector
1 9 body (1c) and tighten the cap.
5. Thread power leads (not furnished)
through the connection box opening and
attach to heater leads using insulated
ITEM NO. DESCRIPTION QUANITY crimp connectors (10g or 10h) supplied in
1 CONNECTOR 2 kit. See heater stripping instructions
2 METAL WASHER 2 following. Insulate connections with high
3 GROMMET 2
1
temperature tape (10e).
4 3/4 LOCKNUT
5 3/4 PIPE PLUG 1
6 CONNECTION BOX 1 6. Attach gasket (7) and cover (8). Insert
7 CONNECTION BOX GASKET1 plug (5) into open end of box. Attach
8 CONNECTION BOX COVER 1
9 MOUNTING BRACKET 1 caution sticker (10b) to box.
10 HARDWARE PACKAGE 1
a) END BOOT 7. Push thermal insulation inside the end of
b) CAUTION LABEL
c) SILICONE TUBING
the bundle jacket approximately 1/4" and
d) SILICONE SEALANT fill void with RTV sealant (10d).
e) HI-TEMP TAPE
f) CABLE TIE
g) 10-12 GA. BUTT CONNECTOR
8. All electrical components and connections
h) 14-16 GA. BUTT CONNECTOR must follow the National Electric Code and
all Local Codes.
Figure 10
13.0 Heater Insulation stripping Instructions

13.1 CPD Heater
The Constant Power Density (CPD) heating element used in Unitherm 2252 and 2262 Series
bundles is constructed of two parallel, stranded, nickel plated copper bus wires with spiral wound
zones of high resistance heating wire. Alternating bus contact at fixed intervals form a chain of
parallel zones equal resistance producing constant power output in each zone. These circuits, or
zones, can be found by feeling for a small lump on the edge of the heater. (see Figure 12)
Since the heating zone must be connected to both bus wires to operate, the wire past the last bus
connection to the end of the heater will be cold. Care must be taken or the first one to two feet of
the bundle will have no heat.

13.0 Heater Insulation stripping Instructions (Contd)
13.1 CPD Heater
THIS SECTION WILL BE 1. Cut heater 2-1/2
UNHEATED AFTER CUT inches from the last grid
connection.
METALLIC OUTER 2. Push back the tinned
GRID INSULATED copper braid 4 inches
BRAD JACKET
CONNECTION CONDUCTORS from the end of the
heating element.
Secure temporarily with
BUS
tape.
WIRES 3. Slit the heater down
the center 3/4 inches fro
the end. Score around
1/2" the outer jacket 3/4
inches from the end.
3/4" 4. Remove the outer
jacket and small
2-1/2"
Figure 12 diameter heater wire,
4" exposing both insulated
conductors.
5. Split the insulated
conductors down the
center.
6. Remove the
conductor insulation 1/4"
from both conductors.
13.2 SR Heater (Low Temperature Self-Regulating Heater)

Unitherm employs two different Self Regulating Heating Elements in its 2256 and 2266 Series
bundles. A Low Temperature Self Regulating (SR) heater is used for freeze protection applications
while a High Temperature SR heater is used for viscosity maintenance applications and where
steam blow-down of lines is used.
Both heaters are continuous parallel heaters (no zones) and can be cut at any point without loss of
heating capabilities.
JACKET 1.Push back braid 4
CONDUCTIVE CORE inches from the end of
BUS the heater. Secure
WIRES temporarily with tape.
2.Remove the outer
jacket about 1 inch from
the end of the heater,
1/8" exposing the black,
conductive polymer
core.
3.Cut out the web of
1/4" core material 1/8 inch
wide and 3/4 inch long.
4.Strip the conductive

3/4" core 3/8 inch from the
end of each bus wire,
Figure 13 using wire strippers.
1"

13.0 Heater Insulation stripping Instructions (Contd)

13.3 SR Heater (High Temperature Self-Regulating Heater)
1 Push back braid 4 inches from the end of the heater. Secure temporarily with tape.
2 Remove the outer jacket about 1 inch from the end of the heater, exposing the black, high
temperature conductive core.
3 Cut out the web of core material 1/8 inch wide and 3/4 inch long.
4 Score around each bus wire 1/4 inch from the end, being careful not to cut the wires inside.
5 Bend the core material at the scored points of each bus wire with pliers to break the core-to-wire
bond.
6 Remove the core material from the conductor with a razor blade or utility knife.
14.0 Special Braid Termination for Class 1 Div. 2 areas

This procedure must be followed to correctly terminate the metallic braid when installing the
heater in Class I Division 2 Hazardous Areas.
1.Slightly flare out the
GROMMET heating element's metallic
braid and slide it back
HEATING METAL about 3 inches.
METAL BRAID 2.Feed the heating
ELEMENT
WASHERS element through the cap,
washers, and grommet of
connector assembly.
3.Slide the metallic braid

through the cap and then
between the metal
CONNECTOR CAP washers.
BODY 4.Push washers against
the grommet, with braid
EXPLODED VIEW OF CLASS I, DIVISION 2 captured between them,
install cap and carefully
BRAID TERMINATION tighten. (See Figure 14)
Fig 14
14.1 Termination Procedure

Both the CPD and SR heaters are terminated in a similar manner. Care must be taken that the bus
wires are not tied together at this end. Care must also be taken that the metallic braid does not
come into contact with the bus wires, the fine gauge heating wire on the CPD heater, or the black
conductive core on the SR heaters. (See Figure 15)
HIGH-TEMPERATURE TAPE 1.Push back metallic braid 3 inches from the end of
BRAIDED the heater and temporarily secure with tape.
HEATING ELEMENT 2.Trim the end of the heater so that one bus wire is
1/4 inch shorter than the other, making sure that the
conductors are not shorted together.
3.Apply RTV sealant liberally to the end of the heater

and into the end of the white silicone end boot
provided in the kit.
4.Slide the end boot over the end of the heater and
secure with high temperature fiberglass/silicone
2" tape.
END BOOT FIG 15 5.Slide the copper braid over the end cap, twist the
ends of the braid together to form a short pigtail.
6.Anchor the heater to the bundle core with high
temperature tape.

15.0 Sealing Termination End of Bundle

The termination end of the bundle can be sealed from moisture using the RTV sealant supplied in
the kit.
1 Push thermal insulation inside the bundle end about 1/4 inch.
2 Fill void with RTV sealant.
If the end of the bundle is in a "wash-down" area or any place where additional protection is
necessary, a double seal can be provided using a Unitherm 1540-10000 Seal Patch kit. (See
Figure 16)
1.Seal the end of the
1540 SEAL PATCH KIT bundle as outlined
above.
INSULATION END BOOT 2.Wrap thermal
insulation supplied in
Seal Patch kit around
core, building to the
diameter of the bundle.
3.Form Seal Patch over
insulation and bundle
jacket and seal
together.
RTV SEALANT
4.Press back thermal
TERMINATION CONNECTION insulation and seal with
FIG 16 RTV as outlined above.
15.1 Installation without Connection Kits

Use of the DEKORON/UNITHERM 1548-10000 connection kit is a convenient way to insure a safe
power connection and termination in all applications, and is required if the installer is terminating in a
are classified as hazardous under the National Electric Code. If the installation does not require the
use of these connection kits, certain procedures must be followed:
1 The heating wires must be connected to the cold lead wire or spliced together with an approved
crimp connector which will withstand the temperatures generated.
2 The connections should be insulated with high temperature electrical insulating tape.
3 The ends of the product should be sealed to prevent the entry of water. Sealing can be done by
using a sealing grommet type bulkhead connector for entrance into an instrument enclosure,
analyzer cabinet or a power supply cabinet. A high temperature sealant or cement, such as Part
No. 1535-02080 End Sealant can be used to encapsulate the end. Whichever method is used, the
National Electrical Code and all local codes must be followed.
Allow a minimum braid length of 6" for input power and termination kits and 12" for input
power splice and splice kits.
16.0 Accessory Installation Notes

Detailed and comprehensive installation instructions for all accessory items are provided with the
kits.
Thermostat (1660-13A12 & 1660-18912)
The thermostat can be used in conjunction with a connection kit or in line with the power supply. If
the thermostat is to be kit mounted, the kit must be placed so the thermostat will sense the true
ambient or tube temperature and not the temperature generated by a boiler, reactor, heat
exchanger, or other heat source.

17.0 Final Check

1 Check that all hangers and supports are secure to bundle, but not overly tight.
2 Check for extreme jacket kinking and for bends less than the minimum radius.
3 Check that all electrical connections are tight and properly insulated.
4 Check that heating element is not in contact with the temperature sensor.
5 Check that all connection kit covers have gaskets and are fastened tightly.
6 Check that all connections and components meet NEC and all Local Codes.
In addition to the above tests, the installer may elect to run a series of pre-commissioning tests.
These tests check the electrical and pneumatic integrity of the analyzer bundle. Unitherm has
developed a series of pressure / vacuum / electrical tests for this purpose.
18.0 Pre-Commissioning Test Program for

DEKORON/UNITHERM Analyzer Bundles
18.1 Scope
This procedure covers pressure and vacuum tests run on sample line tubing and electrical tests run
on electric heating elements prior to commissioning Unitherm electrically heated analyzer bundles.
18.2 Equipment required

1 pressure gauge capable of reading 0-30 psig
2 vacuum pump with gauge and flowmeter (typically analyzer sample pump)
3 portable volt-ohm meter
4 portable megger
18.3 Procedure
18.3.1 Pressure Test
The purpose of the pressure test is to determine if there are any leaks or pinholes in the sample
tubing.
1 Cap the tubing at the probe end of the bundle.
2 Pressurize the sample tube to 30psig and close off the supply.
3 Watch the pressure gauge for any drop. Typically, the tube pressure could drop up to 5 psig over 10
minutes due to cooling of the air, any further drop could indicate a leak.
4 If the gauge pressure drops more than 5 psig in 10 minutes, check all connections to insure that
there are no leaks at the connection points, and repressurize the tube.
5 If the gauge pressure again drops, and there are no detectable leaks at the fittings, check for
mechanical damage at the ends of the bundle, where the tubing is unprotected.
6 Continued pressure drop with no observable leaks indicates a pinhole within the bundle.

18.3 Procedure (Contd)

18.3.2 Vacuum Test
The purpose of the vacuum test is to determine if the tubing is plugged or kinked within the bundle.
1 Attach the probe end of the bundle to a filter to prevent dust and dirt from being drawn into the
sample tube.
2 Attach the analyzer end to the analyzer pump or auxiliary vacuum pump.
3 Energize the pump and record the air flow rate and vacuum level.
4 The values recorded above must be within the analyzer manufacturer's specification to insure that
the proper sample volume is pulled into the analyzer.
5 A high vacuum level with very little flow could indicate a kink or plug in the sample line.
6 A moderate to high vacuum level with normal flow could indicate the sample line is undersized for
the flow rate required and the length of the sample line.
7 A moderate to low vacuum level with normal flow indicates there are no plugs or kinks in the sample
tubing.
18.3.3 Electrical Test
The purpose of the electrical tests are to insure that the heater is continuous and has no faults in its
electrical insulation.
1
2 Read the resistance across these bus wires from the probe end of the bundle. Typical bus wire
resistance should be less than 10 ohms. A high bus wire resistance indicates a broken lead wire
within the bundle.
3 Tie the two heater bus wires together at the probe end of the bundle and electrically insulate them to
insure they do not short out against the braid or any ground point adjacent to the heater cable.
Note, the bus wires are tied together only for this test. They must be separated for final installation
and termination.
4 Attach a portable megger at the analyzer end of the bundle
The positive lead of the megger should be connected to the two heater bus wires that were twisted
together in the earlier test. The negative lead of the megger should be connected to the heater
braid.
5 Megger the heater at 500 VDC. The megger reading should be greater than 10Meg Ohm.
6 If the megger reading is less than 10Meg Ohm, check for contact between the braid and the heater
bus wires at both ends of the bundle.
18.3.4 Test Complete

On completion of the above tests, the sample line is ready for final installation and commissioning.
Install termination and input power kits to bundle per the instructions supplied with the kits.
18.3.5 Summary
The following list summarizes some of the important items to remember when installing Unitherm
bundles.
INSTALLATION
Don'ts Dos
DO NOT EXCEED MINIMUM BEND RADIUS. DO PROVIDE LONG, SWEEPING BENDS
WHERE POSSIBLE.
DO NOT EXCEED RECOMMENDED SUPPORT
CENTERS. DO SEAL ALL EXPOSED INSULATION
WITH RTV END SEALANT.
DO NOT OVERTIGHTEN SUPPORT CLAMPS-JACKET
SHOULD NOT BE PINCHED. DO SEAL FITTINGS AND SPLICES
WITH A SEAL PATCH
DO NOT TIE MULTIPLE RUNS TOGETHER TO
FORM ONE BUNDLE-PROPER DO STRIP JACKET TO MAKE TIGHT
SPACING(1/2" MINIMUM) IS REQUIRED 90 BENDS-USE A UNION ELBOW
FOR HEAT DISSIPATION. WHERE TIGHT BENDS ARE NECESSARY
AND SEAL INSULATION.
DO NOT SEVERELY CRIMP JACKET AS THIS MAY
AFFECT INSULATION PROPERTIES, SOME DO USE A MANDREL TO ASSURE
SLIGHT CRIMPING CAN BE EXPECTED CONSTANT RADIUS BENDS WHERE
WITH HAND-FORMED BENDS. POSSIBLE.
DO NOT REMOVE EXCESSIVE AMOUNTS OF DO SLOPE FOR CONDENSATE 3/4 IN.

JACKET AND INSULATION AT PER FOOT.
FITTINGS.
DO CHECK THAT ALL ELECTRICAL
DO NOT ALLOW THE HEATING ELEMENT CONNECTIONS ARE TIGHT AND SEALED.
TO BE IN CONTACT WITH THE
SENSOR DO CHECK THAT ALL CONNECTION BOX
COVERS HAVE GASKETS AND ARE
DO NOT ROUTE ELECTRIC TRACE BUNDLES FASTENED TIGHTLY.
WHERE THE AMBIENT WILL BE
ABOVE 120 DEG. F DO SECURE END KITS WHEN USING
TEFLON TUBE TRACE PRODUCTS TO
REDUCE STRAIN ON THE FITTINGS.
FIG 16
Temperature & Process
Controller
Operators Manual

NEWPORT Electronics, Inc.
http://www.newportUS.com/i
Additional products from

NEWPORT Electronics, Inc.
Counters Rate Meters
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PID Controllers Totalizers
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Printers Meters
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On/Off Multimeters
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Recorders Testers
Relative pH pens
Humidity pH Controllers
Transmitters pH Electrodes
Thermocouples RTDs
Thermistors Thermowells
Wire Flow Sensors
For Immediate Assistance

In the U.S.A. and Canada: 1-800-NEWPORT
In Mexico: (95) 800-NEWPORTSM
Or call your local NEWPORT Office.
NEWPORTnet On-Line Service SM
Internet e-mail
www.newportUS.com info@newportUS.com
It is the policy of NEWPORT to comply with all worldwide safety and EMC/EMI regulations that apply. NEWPORT is constantly
pursuing certification of its products to the European New Approach Directives. NEWPORT will add the CE mark to every
appropriate device upon certification.
The information contained in this document is believed to be correct but NEWPORT Electronics, Inc. accepts no liability for any
errors it contains, and reserves the right to alter specifications without notice.
WARNING: These products are not designed for use in, and should not be used for, patient connected applications.
TRADEMARK NOTICE: , NEWPORT, NEWPORT, newportUS.com, and the Meter Bezel Design are
trademarks of NEWPORT Electronics, Inc.
PATENT NOTICE: This product is covered by one or more of the following patents: U.S. Pat. No. Des. 336,895; 5,274,577;
6,243,021 / CANADA 2052599; 2052600/ ITALY 1249456; 1250938 / FRANCE BREVET No. 91 12756 / SPAIN 2039150;
2048066 / UK PATENT No. GB2 249 837; GB2 248 954 / GERMANY DE 41 34398 C2. The is a Trademark of OMEGA
Engineering, Inc. Used Under License. Other US and International Patents pending or applied for.
This device is marked with the international caution symbol. It is important to read the Setup Guide before installing or
commissioning this device as it contains important information relating to safety and EMC.
TABLE OF CONTENTS
Part 1: Introduction............................................................................................2
1.1 Description .................................................................................2
1.2 Safety Considerations ...............................................................3
1.3 Before You Begin .......................................................................4
Part 2: Setup.......................................................................................................5
2.1 Front Panel .................................................................................6
2.2 Rear Panel Connections............................................................7
2.3 Electrical Installation .................................................................7
2.3.1 Power Connections........................................................7
2.3.2 Thermocouple - Input Connection................................8
2.3.3 Two / Three / Four Wire RTD-Hookups .........................9
2.3.4 Process Current - Wiring Hookup...............................10
2.3.5 Process Voltage - Wiring Hookup ...............................10
2.3.6 Wiring Outputs - Wiring Hookup.................................11
2.3.7 Dual Display Color Setup ............................................13
Part 3: Operation: Configuration Mode .........................................................14

3.1 Introduction ..............................................................................14
Turning your Instrument On for the First Time
Buttons Functions in Configuration Mode
3.2 Menu Configuration ................................................................15
3.2.1 ID Number .....................................................................16
3.2.2 Setpoints .......................................................................17
3.2.3 Configuration Menu ....................................................18
3.2.4 Input Type Menu ...........................................................18
Input Type (Thermocouple) ........................................19
Input Type (RTD)...........................................................20
Input Type (Process) ...................................................21
3.2.5 Reading Configuration Menu .....................................21
3.2.6 Alarm 1 Menu ...............................................................25
3.2.7 Analog Output (Retransmission) Menu......................29
3.2.8 Alarm 2 Menu................................................................32
3.2.9 Loop Break Time Menu/Field Calibration...................33
3.2.10 Output 1 Menu ..............................................................35
3.2.11 Output 2 Menu ..............................................................42
3.2.12 Ramp and Soak Menu ..................................................45
3.2.13 ID Code Menu ...............................................................47
3.2.14 Communication (Options) Menu.................................49
3.2.15 Display Color Selection Menu.....................................55
Part 4: Specifications ......................................................................................58
Part 5: Factory Preset Values .........................................................................62
Part 6: CE APPROVAL INFORMATION...........................................................64

i
LIST OF FIGURES:
Figure 2.1 Front Panel Display ..............................................................................5
Figure 2.2 Rear Panel Power and Output Connector Labels..............................6
Figure 2.3 Rear Panel Input Connector Labels....................................................6
Figure 2.4 Main Power Connections.....................................................................7
Figure 2.5 Thermocouple Wiring Hookup ............................................................8
Figure 2.6 Two/Three/Four-wire RTD
a) RTD-1000 ohm and 500 ohm Wiring Hookup ..............................9
b) RTD-100 ohm Wiring Hookup .......................................................9
Figure 2.7 Process Current Wiring Hookup
(Internal and External Excitation) .....................................................10
Figure 2.8 Process Voltage Wiring Hookup
a) Without Sensor Excitation ..........................................................10
b) With Sensor Excitation ................................................................10
Figure 2.9 Output Connections:
a) Mechanical Relay and SSR Outputs Wiring Hook up ............11
b) Pulse and Analog Outputs Wiring Hook up............................11
Figure 2.10 Typical Application .............................................................................11
Figure 2.11 Communication Output:
a) RS-232 Output Wiring Hook up ...............................................12
b) RS-485 Output Wiring Hook up ...............................................12
Figure 2.12 Excitation Output................................................................................12
Figure 2.13 Snubber Circuits Wiring Hookup ......................................................12
Figure 2.14 i/8DH and i/8DV Locations of S1 and Jumper Positions ................13
Figure 2.15 i/16D Location of S1 and Jumper Positions ....................................13
Figure 3.1 Flow Chart for ID and Setpoints........................................................15
Figure 3.2 Flow Chart for Configuration Menu ..................................................18
Figure 3.3 Flow Chart for Input Type Menu........................................................18
Figure 3.4 Flow Chart for Reading Configuration .............................................21
Figure 3.5 Flow Chart for Alarm 1 .......................................................................25
Figure 3.6 Flow Chart for Analog Output (Retransmission) .............................29
Figure 3.7 Flow Chart for Alarm 2 .......................................................................32
Figure 3.8 Flow Chart for Loop Break Time/Field Calibration..........................33
Figure 3.9 Flow Chart for Output 1 .....................................................................35
Figure 3.10 Flow Chart for Output 2 .....................................................................42
Figure 3.11 Flow Chart for Ramp and Soak .........................................................45
Figure 3.12 Flow Chart for ID Code.......................................................................47
Figure 3.13 Flow Chart for Communication Option ............................................49
Figure 3.14 Flow Chart for Display Color Selection ............................................55
LIST OF TABLES:
Table 2.1 Front Panel Annunciators....................................................................5
Table 2.2 Rear Panel Connector ..........................................................................6
Table 2.3 Fuse Requirement ................................................................................7
Table 2.4 TC Wire Color Chart .............................................................................8
Table 3.1 Button Function in Configuration Mode...........................................14
Table 3.2 Conversion Table................................................................................24
Table 4.1 Input Properties ..................................................................................61
Table 5.1 Factory Preset Values ........................................................................62
ii
NOTES, WARNINGS and CAUTIONS
Information that is especially important to note is identified by following labels:
NOTE
WARNING or CAUTION
IMPORTANT
TIP
NOTE: Provides you with information that is important to successfully

setup and use the Programmable Digital Meter.
CAUTION or WARNING: Tells you about the risk of electrical shock.
CAUTION, WARNING or IMPORTANT: Tells you of circumstances or

practices that can effect the instruments functionality and must refer
to accompanying documents.
TIP: Provides you helpful hints.
1
PART 1
INTRODUCTION
1.1 Description
This device can be purchased as monitor (read process value only) or as
a controller.
The iSeries controller offers unparalleled flexibility in process measurement.

Each unit allows the user to select the input type, from 10 thermocouple
types (J, K, T, E, R, S, B, C, N and J DIN), Pt RTDs (100, 500 or 1000 ,
with either 385 or 392 curve), DC voltage, or DC current. The voltage/current
inputs are fully scalable to virtually all engineering units, with selectable
decimal point, perfect for use with pressure, flow or other process input.
The temperature control can be achieved by using on/off or PID heat/cool

control strategy. Control can be optimized with an auto tune feature. The
instrument offers a ramp to setpoint with timed soak period before switching
off the output.
The iSeries device features a large, three color programmable display with
capability to change a color every time the Alarm is triggered. The standard
features include dual outputs with relay, SSR, dc pulse, analog voltage or
current. Options include programmable RS-232 or RS-485 serial
communication and excitation. Analog Output is fully scalable and may be
configured as a proportional controller or retransmission to follow your
display. Universal power supply accepts 90 to 240 Vac. Low voltage power
option accepts 24 Vac or 12 to 36 Vdc.
2
1.2 Safety Considerations
This device is marked with the international caution symbol. It is important
to read this manual before installing or commissioning this device as it
contains important information relating to Safety and EMC
(Electromagnetic Compatibility).
This instrument is a panel mount device protected in accordance with

EN 61010-1:2001, electrical safety requirements for electrical equipment
for measurement, control and laboratory. Installation of this instrument
should be done by qualified personnel. In order to ensure safe operation,
the following instructions should be followed.
This instrument has no power-on switch. An external switch or circuit-

breaker shall be included in the building installation as a disconnecting
device. It shall be marked to indicate this function, and it shall be in close
proximity to the equipment within easy reach of the operator. The switch or
circuit-breaker shall meet the relevant requirements of IEC 9471 and
IEC 947-3 (International Electrotechnical Commission). The switch shall
not be incorporated in the main supply cord.
Furthermore, to provide protection against excessive energy being drawn

from the main supply in case of a fault in the equipment, an overcurrent
protection device shall be installed.
Do not exceed voltage rating on the label located on the top of the
instrument housing.
Always disconnect power before changing signal and power
connections.
Do not use this instrument on a work bench without its case for safety
reasons.
Do not operate this instrument in flammable or explosive atmospheres.
Do not expose this instrument to rain or moisture.
Unit mounting should allow for adequate ventilation to ensure
instrument does not exceed operating temperature rating.
Use electrical wires with adequate size to handle mechanical strain
and power requirements. Install without exposing bare wire outside the
connector to minimize electrical shock hazards.
EMC Considerations
Whenever EMC is an issue, always use shielded cables.
Never run signal and power wires in the same conduit.
Use signal wire connections with twisted-pair cables.
Install Ferrite Bead(s) on signal wires close to the instrument if EMC
problems persist.
Failure to follow all instructions and warnings may result in injury!

3
1.3 Before You Begin
Inspecting Your Shipment:
Remove the packing slip and verify that you have received everything
listed. Inspect the container and equipment for signs of damage as soon
as you receive the shipment. Note any evidence of rough handling in
transit. Immediately report any damage to the shipping agent. The carrier
will not honor damage claims unless all shipping material is saved for
inspection. After examining and removing the contents, save the packing
material and carton in the event reshipment is necessary.
Customer Service:
If you need assistance, please call the nearest Customer Service
Department, listed in this manual.
Manuals, Software:
The latest Operation and Communication Manual as well as free
configuration software and ActiveX controls are available from the
website listed in this manual or on the CD-ROM enclosed with your
shipment.
For first-time users: Refer to the QuickStart Manual for basic operation
and set-up instructions.
If you have the Serial Communications/Ethernet Option you can easily

configure the controller on your computer or on-line.
To Disable Outputs:
To ensure that menu changes are properly stored, Standby Mode should
be used during setup of the instrument. During Standby Mode, the
instrument remains in a ready condition, but all outputs are disabled.
Standby Mode is useful when maintenence of the system is necessary.
When the instrument is in "RUN" Mode, push d twice to disable all

outputs and alarms. It is now in "STANDBY" Mode. Push d once more
to resume "RUN" Mode.
PUSH d TWICE to disable the system during an EMERGENCY.
To Reset the Meter:

When the controller is in the "MENU" Mode, push c once to direct
controller one step backward of the top menu item.
Push c twice to reset controller, prior to resuming "Run" Mode except
after "Alarms", that will go to the "Run" Mode without resetting the
controller.
4
PART 2 Refer to the Quick Start
SETUP Guide for assembly and
2.1 Front Panel disassembly instructions.
Figure 2.1 Front Panel Display
Table 2.1 Front Panel Annunciators

1 Output 1/Setpoint 1/ Alarm 1 indicator
2 Output 2/Setpoint 2/ Alarm 2 indicator
C C unit indicator
F F unit indicator
PV Upper Display shows the Process Value
SV Lower Display shows the Setpoint 1 Value
a Changes display to Configuration Mode
and advances through menu items*
b Used in Program Mode and Peak Recall*
c Used in Program Mode and Valley Recall*
d Accesses submenus in Configuration Mode
and stores selected values*
* See Part 3 Operation: Configuration Mode
The Dual Display model allows the user to observe the Process Value
(upper display) and Setpoint 1 Value (lower display) at the same time.
5
2.2 Rear Panel Connections
The rear panel connections are shown in Figures 2.2 and 2.3.
6 5 4 6 5 4 6 5 4 3 2 1 3 2 1
8 7 6 5 4 3 2 1
Figure 2.2 Rear Panel Power and Output Connections
Figure 2.3 Rear Panel Input Connections

Table 2.2 Rear Panel Connector
POWER AC/DC Power Connector: All models
Input Connector:
INPUT All models TC, PR (Process), RTD
OUTPUT 1 Based on one of the following models:
Relay SPDT
Solid State Relay
Pulse
Analog Output (Voltage and Current)
OUTPUT 2 Based on one of the following models:
Relay SPDT
Solid State Relay
Pulse
Based on one of the following models:
OPTION RS-232C or RS-485 programmable
Excitation
6
2.3 Electrical Installation
2.3.1 Power Connections

Caution: Do not connect power to your device until you have completed all
input and output connections. Failure to do so may result in injury!
Connect the main power connections as shown in Figure 2.4.
Use copper conductors

only for power connections
Figure 2.4 Main Power Connections

Table 2.3 Fuse Requirement (see specifications)
FUSE Connector Output Type For 115Vac For 230Vac DC
FUSE 1 Power N/A 100 mA(T) 100 mA(T) 100 mA(T)
FUSE 2 Power N/A N/A N/A 400 mA(T)
For the low voltage power option, in order to maintain the same degree of
protection as the standard high voltage input power units (90 - 240 Vac),
always use a Safety Agency Approved DC or AC source with the same
Overvoltage Category and pollution degree as the standard AC unit (90 -
240 Vac).
The Safety European Standard EN61010-1 for measurement, control,

and laboratory equipment requires that fuses must be specified based on
IEC127. This standard specifies for a Time-lag fuse, the letter code T.
The above recommended fuses are of the type IEC127-2-sheet III. Be
aware that there are significant differences between the requirements
listed in the UL 248-14/CSA 248.14 and the IEC 127 fuse standards. As a
result, no single fuse can carry all approval listings. A 1.0 Amp IEC fuse
is approximately equivalent to a 1.4 Amp UL/CSA fuse. It is advised to
consult the manufacturers data sheets for a cross-reference.
7
2.3.2 Thermocouple
The figure below shows the wiring hookup for any thermocouple type. For
example, for Type K hookup, connect the yellow wire to the "2" terminal and the
red wire to the "1(-)" terminal.
When configuring your controller, select Thermocouple and Thermocouple

Type in the Input Type menu (see Part 3).
Figure 2.5 Thermocouple Wiring Hookup
Table 2.4 TC Wire Color Chart

TYPE Input Connector Jacket (external insulation)
Terminal 1 (-) Terminal 2 (+) Extension Grade
J Red White dark-Brown Black
K Red Yellow dark-Brown Yellow
T Red Blue dark-Brown Blue
E Red Purple dark-Brown Purple
N Red Orange dark-Brown Brown
R Red Black - Green
S Red Black - Green
B Red Gray - Black
8
2.3.3 Two/Three/Four-Wire RTD
The figures below show the input connections and input connector jumpers
(shown in bold lines) required to hookup a 2-, 3- or 4-wire RTD.
RTD (1000/500) 4-Wire RTD (100) 4-Wire
RTD (100) 3-Wire

RTD (1000/500) 3-Wire
RTD (100) 2-Wire

RTD (1000/500) 2-Wire
Figure 2.6 a) RTD-1000 ohm and b) RTD-100 ohm Wiring Hookup

500 ohm Wiring Hookup
The two-wire connection is simplest method, but does not compensate for
lead-wire temperature change and often requires calibration to cancel lead-wire
resistance offset.
The three-wire connection works best with RTD leads closely equal in
resistance. The device measures the RTD, plus upper and lower lead drop
voltage and the subtracts twice the measured drop in the lower supply current
lead producing excellent lead-resistance cancellation for balanced
measurements.
The four-wire RTD hookup is applicable to unbalanced lead resistance and

enables the device to measure and subtract the lead voltage, which produces
the best lead-resistance cancellation.
When configuring your controller, select RTD type and RTD value in the
Input Type menu (see Part 3).
If the input wires of the meter get disconnected or broken, it will display
+OPN Input (+) Open message except in case of 500/1000 2-wire
RTD. In this case the display shows -OPN Input (-) Open message. For
safety purpose you may want to set up your alarm to be triggered when
input is open. See Alarm 1 & 2 chapters for details.
9
2.3.4 Process Current
The figure below shows the wiring hookup for Process Current 0 20 mA.
Figure 2.7 Process Current Wiring Hookup

(Internal and External Excitation)
When configuring your instrument, select Process Type in the Input Type Menu
(see Part 3).
2.3.5 Process Voltage

The figure below shows the wiring hookup for Process Voltage 0 100 mV,
0 1 V, 0 10 V.
Figure 2.8
a) Process Voltage Wiring Hookup b) Process Voltage Wiring Hookup
with Sensor Excitation without Sensor Excitation
RL - Voltage limited resistor, which allows to convert 24 Vdc internal excitation
voltage to the appropriate process input value. For instance: if the potentiometer
value is equal to 10 k, the minimum RL is 14 k for 10 V process input.
When configuring your instrument, select Process Type in the Input Type Menu
(see Part 3).
10
2.3.6 Wiring Outputs
This meter has two factory installed outputs. The SPDT Mechanical Relay, SPST
Solid State Relay, Pulse and Analog Output Connection are shown below.
Use copper conductors

only for power connections
Figure 2.9
a) Mechanical Relay and SSR b) Pulse and Analog
Outputs Wiring Hookup Outputs Wiring Hookup
dc CONTROLLED SSR USED WITH TEMPERATURE CONTROLLER WITH dc VOLTAGE SSR DRIVER OUTPUT
TEMPERATURE dc INPUT
CONTROLLER CONTROL SSR LOAD
SIDE SIDE HEATER
4 1
Vac Vac
3 2
0 or 5 Vdc,
TYPICALLY FAST BLOW
FUSE
ac CONTROLLED SSR USED WITH TEMPERATURE CONTROLLER WITH MECHANICAL RELAY OUTPUT
TEMPERATURE ac INPUT
CONTROLLER CONTROL LOAD
SIDE SSR SIDE HEATER
4 1
Vac Vac
3 2
FAST BLOW
Vac FUSE
DRIVING
SSR
ac CONTROLLED SSR USED WITH TEMPERATURE CONTROLLER WITH TRIAC OUTPUT
TEMPERATURE CONTROL SIDE

LOAD ac INPUT
CONTROLLER SSR LOAD
RESISTOR SIDE HEATER
4 1
Vac Vac
3 2
FAST BLOW
Vac FUSE
DRIVING
SSR
Figure 2.10 Typical Applications

11
This device may have a programmable communication output. The
RS-232 and RS-485 Output Connection are shown below.
External RS-232 connections are not available with -EI or C4EI options.
Figure 2.11
a) RS-232 Output Wiring Hookup b) RS-485 Output Wiring Hookup
This device may also have an
excitation output.
If the Dual Display model has a Low
Voltage power supply option, then
excitation is not available.
Excitation is not available if
communication option is installed.
Figure 2.12 Excitation Output
This device has snubber circuits

designed to protect the contacts of the
mechanical relays when it switches to
inductive loads (i.e. solenoids, relays).
These snubbers are internally
connected between the Common (C)
and Normally Open (NO) relay contacts
of Output 1 and Output 2.
If you have an inductive load

connected between Common (C) and
Normally Closed (NC) contacts of the
mechanical relays and you want to
protect them from the rush current
during the switching period, you have
to connect an external snubber circuit
between Common (C) and Normally Figure 2.13
Closed (NC) contacts as indicated in Snubber Circuits Wiring
Figure 2.13. Hookup
12
2.3.7 Dual Display Color Setup
The dual display option allows the user to change the color of the upper and
lower displays.
To change the color of the upper display, see Section 3.2.15

(Display Color section).
To change the color of the lower display follow the instructions below:
The unit should be removed from the panel and opened.
Refer to the Quick Start Guide for assembly and disassembly instructions.
The S1 jumper is located on the back side of the display board.

The location of S1 and pin selection jumpers are shown below.
Use a jumper for GREEN or RED, never leave S1 open.
i/8 DH
Dual
Horizontal
i/8 DV
Dual
Vertical
Figure 2.14 i/8 D Location of S1 and Selectable Jumper Positions
Figure 2.15 i/16D Location of S1 and Selectable Jumper Positions

13
PART 3
OPERATION: Configuration Mode
3.1 Introduction
The instrument has two different modes of operation. The first, Run Mode, is
used to display values for the Process Variable, and to display or clear Peak
and Valley values. The other mode, Menu Configuration Mode, is used to
navigate through the menu options and configure the controller. Part 3 of this
manual will explain the Menu Configuration Mode. For your instrument to
operate properly, the user must first "program" or configure the menu options.
Turning your Controller On for the First Time
The device becomes active as soon as it is connected to a power source. It
has no On or Off switch. The device at first momentarily shows the software
version number, followed by reset RST, and then proceeds to the Run Mode.
For first-time users: Refer to the QuickStart Manual for basic operation
and set-up instructions.
If you have the Serial Communications/Ethernet Option you can easily
configure the controller on your computer or on-line.
Table 3.1 Button Function in Configuration Mode
To enter the Menu, the user must first press a button.
Use this button to advance/navigate to the next menu item. The user can navigate
a
MENU through all the top level menus by pressing a.
While a parameter is being modified, press a to escape without saving the parameter.
Press the up b button to scroll through flashing selections. When a numerical value is
displayed press this key to increase value of a parameter that is currently being modified.
b Holding the b button down for approximately 3 seconds will speed up the rate at which
(UP) the set point value increments.
In the Run Mode press b causes the display to flash the PEAK value press again to
return to the Run Mode.
Press the down c button to go back to a previous Top Level Menu item.
Press this button twice to reset the controller to the Run Mode.
When a numerical value is flashing (except set point value) press c to scroll digits from
left to right allowing the user to select the desired digit to modify.
c When a setpoint value is displayed press c to decrease value of a setpoint that is
(DOWN)
currently being modified. Holding the c button down for approximately 3 seconds will
speed up the rate at which the setpoint value is decremented.
In the Run Mode press c causes the display to flash the VALLEY value press again to
return to the Run Mode.
Press the enter d button to access the submenus from a Top Level Menu item.
Press d to store a submenu selection or after entering a value the display will flash a
d
ENTER STRD message to confirm your selection.
To reset flashing Peak or Valley press d.
In the Run Mode, press d twice to enable Standby Mode with flashing STBY.
Reset: Except for Alarms, modifying any settings of the menu configuration
will reset the instrument prior to resuming Run Mode.
14
3.2 Menu Configuration
It is required that you put the controller in the Standby Mode for any
configuration change other than Setpoints & Alarms.
Figure 3.1 Flow Chart for ID and Setpoints

15
3.2.1 ID Number
SEE ID MENU SELECTION IN CONFIGURATION SECTION FOR
ENABLE/DISABLE OR CHANGE ID CODE.
If ID Code is Disabled or set as Default (0000) the menu will skip ID step
to Setpoint Menu.
If ID Code is set to Full Security Level and user attempts to enter the
Main Menu, they will be prompted for an ID Code.
If ID Code is set to Setpoint/ID Security Level and user attempts to enter

the Configuration Menu, they will be prompted for an ID Code.
ENTERING YOUR NON-DEFAULT FULL SECURITY ID NUMBER.
Press a 1) Display shows ID.

Press d 2) Display advances to ____.
Press b & c 3) Press b to increase digit 0-9. Press c to activate next digit
(flashing). Continue to use b and c to enter your 4-digit ID
code.
Press d 4) If the correct ID code is entered, the menu will advance to the
Setpoint 1 Menu, otherwise an error message ERRo will be
displayed and the instrument will return to the Run Mode.
To change ID Code, see ID Menu in the Configuration section.
ENTERING YOUR NON-DEFAULT SETPOINT/ID SECURITY ID NUMBER.
Press a 5) Display shows SP1 Setpoint 1 Menu.

Press a 6) Display shows SP2 Setpoint 2 Menu.
Press a 7) Display shows ID ID Code Menu.
Press d 8) Display advances to ____.
Press b&c 9) Use b and c to change your ID Code.
Press d 10) If correct ID Code is entered, the display will advance to the
INPT Input Menu, otherwise the error message ERRo will be
displayed and the controller will return to the Run Mode.
To prevent unauthorized tampering with the setup parameters, the

instrument provides protection by requiring the user to enter the ID Code
before allowing access to subsequent menus. If the ID Code entered
does not match the ID Code stored, the controller responds with an error
message and access to subsequent menus will be denied.
Use numbers that are easy for you to remember. If the ID Code is
forgotten or lost, call customer service with your serial number to access
and reset the default to 0000.
16
3.2.2 Set Points
SETPOINT 1:
Press a 1) Press a, if necessary until SP1 prompt appears.

Press d 2) Display shows previous value of Setpoint 1.
Press b & c 3) Press b and c to increase or decrease Setpoint 1
respectively.
Holding b & c buttons down for approximately 3 seconds will speed up the
rate at which the Setpoint value increments or decrements.
Press b & c 4) Continue to use b and c to enter your 4-digit Setpoint 1 value.
Press d 5) Display shows STRD stored message momentarily and then
advances to SP2 only, if a change was made, otherwise press
a to advance to SP2 Setpoint 2 Menu.
SETPOINT 2:
Press d 6) Display shows previous value of Setpoint 2.

Press b & c 7) Press b and c to increase or decrease Setpoint 2
respectively.
Holding b & c buttons down for approximately 3 seconds will speed up

the rate at which the setpoint value increments or decrements.

advances to CNFG only, if a change was made, otherwise press
a to advance to CNFG Configuration Menu.
17
3.2.3 Configuration Menu
Figure 3.2 Flow Chart for Configuration Menu

Enter Configuration Menu:
Press a 1) Press a, if necessary, until CNFG prompt appear.

Press d 2) Display advances to INPT Input Menu.
Press a 3) Pressing and releasing a to scroll through all available
menus of Configuration section.
3.2.4 Input Type Menu
Figure 3.3 Flow Chart for Input Type Menu
18
Input Type (Thermocouple)
ENTER INPUT TYPE MENU:
Press a 1) Press a, if necessary, until CNFG prompt appears.

Press d 3) Display flashes T., RTD or PROC (Thermocouple, RTD or
Process). If the displayed input type is T., press a to skip to
step 6 (T. stops flashing).
THERMOCOUPLE SUBMENU:
Press b 4) Scroll through the available selection to T. (flashing).

T. (not flashing).
Press d 6) Display flashes previous thermocouple type selection. i.e. J
(see below for types).
Press b 7) Scroll through the available thermocouple types to the
selection of your choice.
advances to the RDG Reading Configuration Menu.
Use the Input Type (Thermocouple) (RTD) or (Process) and verify your
Electrical Installation (see section 2.3).
Thermocouple Types: J, K, T, E, N, DIN J, R, S, B, C

Display: J K T E N DNJ R S B C
19
Input Type (RTD)

Process). If the displayed input type is RTD, press a to skip to
step 6 (RTD stops flashing).
RTD SUBMENU:
Press b 4) Scroll through the available selection to RTD (flashing).

RTD (not flashing).
Press d 6) Display flashes previous RTD type selection i.e. 392.2
(see below for RTD types selection).
Press b 7) Scroll through the available RTD types to the selection of
your choice.
advances to RTD RTD value.
RTD Types: 392 385 Two, Three or Four-wire

Display: 392.2, 392.3, 392.4, 385.2, 385.3, 385.4
Last digit indicates: 2-, 3- or 4-wire input.
RTD VALUE SUBMENU:
Press d 9) Display flashes previous RTD value selection i.e. 100_

(see below for RTD value selection).
Press b 10) Scroll through the available RTD values to the selection of
your choice.
advances to RDG Reading Configuration Menu.
RTD Values: 100 ohm 500 ohm 1000 ohm

Display: 100_ 500_ 1000
20
Input Type (Process)
Process). If the displayed input type is PROC, press a to skip to
step 6 (PROC stops flashing).
PROCESS SUBMENU:
Press b 4) Scroll through the available selection to PROC (flashing).
PROC (not flashing).
Press d 6) Display flashes previous Process type selection. i.e. 0-10
(see below for Process types selection).
Press b 7) Scroll through the available Process types to the selection of
your choice.
Press d 8) Display shows STRD stored message and then advances to
RDG Reading Configuration Menu.
Process Types: 100 mV 1 V 10 V 0 20 mA
Display: 0-0.1 0-1.0 0-10 0-20
For 4-20 mA Input select 0-20 mA then adjust the Input/Reading accordingly.
To adjust 4-20 mA input, see example under INPUT/READING submenu. The
factory preset value is 4-20 mA.
3.2.5 Reading Configuration
configuration change other than Set Points & Alarms.
Figure 3.4 Flow Chart for Reading Configuration Menu

21
ENTER READING CONFIGURATION MENU:

Press a 3) Display advances to RDG Reading Configuration Menu.
Press d 4) Display advances to DEC Decimal Point.
DECIMAL POINT SUBMENU:
Press d 5) Display flashes previous selection for Decimal location.

Press b 6) Scroll though the available selections and choose Decimal
location: FFFF or FFF.F (also FF.FF and F.FFF if PROC
Process type was selected in the Input Type Menu).
advances to TEMP Temperature Unit.
Decimal Point for Process Input Type is passive.
TEMPERATURE UNIT SUBMENU:
Press d 8) Display flashes previous Temperature Unit selection.

Press b 9) Scroll though the available selections to the Temperature Unit
of your choice: F or C.
advances to FLTR Filter Constant.
FILTER CONSTANT SUBMENU:
Press d 11) Display flashes previous selection for Filter Constant.

Press b 12) Scroll though the available selections:
0001, 0002, 0004, 0008, 0016, 0032, 0064, 0128
Press d 13) Display shows STRD stored message momentarily only, if
change was made, otherwise press a to advance to the next
menu.
If Process was selected in the Input Type Menu the display will
advance to IN.RD Input/Reading Submenu, otherwise the
display advances to the ALR1 Alarm 1 Menu.
The Filter Constant Submenu allows the user to specify the

number of readings stored in the Digital Averaging Filter.
For PID control select filter value 0001-0004. A filter value of 2 is

approximately equal to 1 second RC low pass time constant.
22
Reading Configuration (If Process was selected)
INPUT/READING (SCALE AND OFFSET) SUBMENU:
Input Voltage or Current can be converted or scaled into values appropriate for
the process or signal being measured. So, a reading may be displayed, for
example, in units of weight or velocity instead of in amperes or volts.
The instrument determines Scale and Offset values based on two user-provided
input values entered with the corresponding readings. Note that In1 Input 1 and
In2 Input 2 are represented and entered as a product of the input
voltage/current and the conversion number from the Table 3.1.
The following instructions include details for a specific scenario in which a

4-20 mA input (in the 20 mA Process Mode) is to be represented as a
measurement of 0-100 percent.
Press d 14) Press d at the IN.RD prompt. Display shows IN1 Input 1
submenu.
Press d 15) Display shows Input 1 value with 1st digit flashing.
Press b & c 16) Use b and c buttons to enter IN1 value.
The IN1 value = min. input value * conversion number.
Disregard the position of the decimal point (2000 counts may

actually appear as 200.0, 20.00, or 2.000).
Example: 4 mA as 4(mA) x 500 = 2000.

Press d 17) Display advances to RD1 Reading 1 Submenu.
Press b & c 18) Use b and c buttons to enter RD1 value.
This value represents IN1 in terms of some meaningful
engineering units. To show the 4 mA as zero percent enter RD1
value = 0000.
Example: RD1 value = 0000.
Press d 19) Display IN!2 Input 2 Submenu.
Press d 20) Display shows Input 2 value with 1st digit flashing.
The IN!2 value = max. input value * conversion number.
Example: 20(mA) x 500 = 10000 (9999).
Press b & c 21) Use b and c buttons to enter IN!2 value.
Press d 22) Display advances to RD!2 Reading 2 Submenu.
Press b & c 23) Use b and c buttons to enter RD!2 value.
Example: RD!2 value = 0100.
Press d 24) Display flashes STRD stored message momentarily and
then advances to ALR1 only, if change was made, otherwise
press d to advance to ALR1 Alarm 1 Menu.
23
Conversion number is a coefficient of conversion between input values
and real full display range (10000 counts shown as 9999). See Table 3.2
below for proper conversion number.
Table 3.2 Conversion Table

RANGE CONVERSION NUMBER
100 mV 10000 / (100 x 1) = 100
1V 10000 / (1000 x 1) = 10
10 V 10000 / (1000 x 10) = 1
0 -20 mA 10000 / (20 x 1) = 500
Example =
0-1V = 0 - 100.0
In 1 = 0
Rd 1 = 0
Inp 2 = 9999
Rd 2 = 100.0
24
3.2.6 Alarm 1
This unit is equipped with two physical outputs that can only be configured as
follows: Alarm 1 & Alarm 2, Alarm 1 & Output 2, Output 1 & Alarm 2, Output 1
& Output 2, Analog Out 1 & Alarm 2, Analog Out 1 & Output 2. Analog Out
available only if Analog Output Option board is factory installed.
If Analog Output Option is installed, the controller will skip Alarm 1 Menu
item to Analog Output.
Alarm must be DISABLED if Ramp is ENABLED.
Figure 3.5 Flow Chart for Alarm 1

ENTER ALARM 1 MENU:

Press a 3) Press a, if necessary, until Display advances to ALR1 Alarm 1
Menu.
Press d 4) Display advances to Alarm 1 ENBL Enable or DSBL Disable
Submenu and flashes the previous selection.
25
ALARM 1 ENABLE/DISABLE SUBMENU:
Press b 5) Scroll though the available selection until ENBL displays to

use Alarm 1.
advances to ABSo only if it was changed, otherwise press a to
advance to ABSo Alarm 1 Absolute/Deviation Submenu.
If DSBL Alarm 1 Disabled was selected, all submenus of Alarm

1 Menu will be skipped and meter advances to ALR2 Alarm 2
Menu. If ENBL Alarm 1 Enabled was selected, Output 1 would
be automatically Disabled, and reassigned as Alarm 1.
ALARM 1 ABSOLUTE/DEVIATION SUBMENU:
Press d 7) Display flashes previous selection. Press b to ABSo

Absolute or _DEV Deviation.
advances to LTH only if it was changed, otherwise press a to
advance to LTH Alarm 1 Latch/Unlatch Submenu.
Absolute Mode allows Alarm 1 to function independently from Setpoint 1. If the

process being monitored does not change often, then "Absolute" Mode is
recommended.
Deviation Mode allows changes to Setpoint 1 to be made automatically to

Alarm 1. Deviation mode is typically the ideal mode if the process temperature
changes often. In Deviation Mode, set Alarm 1 a certain number of degrees or
counts away from Setpoint 1 this relation remains fixed even if Setpoint 1 is
changed.
ALARM 1 LATCH/UNLATCH SUBMENU:
Press d 9) Display flashes previous selection. Press b to LTH

Latched or UNLT Unlatched.
advances to CT.CL only, if it was changed, otherwise press a to
advance to CT.CL Contact Closure Submenu.
Latched Mode: Relay remains "latched" until reset. To reset already latched
alarm, select Alarm Latch and press Max twice (i.e. Unlatch and then back to
Latch) or from a Run Mode, push d twice to put the controller in Standby Mode
and then push d one more time to return to the Run Mode.
Unlatched Mode: Relay remains latched only as long as the alarm condition is
true.
26
CONTACT CLOSURE SUBMENU:
Press d 11) Display flashes previous selection. Press b to N.. Normally
Closed or N.o. Normally Open.
advances to ATV only if it was changed, otherwise press a to
advance to ATV Active Submenu.
Normally Open: If this feature is selected, then the relay is "energized" only
when an alarm condition occurs.
Normally Closed: "Fail Safe" Mode. Relay is energized under "normal"
conditions and becomes de-energized during alarm or power failure.
ACTIVE SUBMENU:
Press d 13) Display flashes previous selection. Press b to scroll through
the available selections: ABoV Above, BELo Below, HI.Lo
HI/Low and BAND Band. (Band is active if _DEV Deviation was
selected).
advances to A.P.oN only if it was changed, otherwise press a to
advance to A.P.oN Alarm Enable/Disable at Power On
Submenu.
Above: Alarm 1 condition triggered when the process variable is greater than the
Alarm Hi Value (Low value ignored).
Below: Alarm 1 condition triggered when the process variable is less than the
Alarm Low Value (Hi value ignored).
Hi/Low: Alarm 1 condition triggered when the process variable is less than the
Alarm Low Value or above the Hi Value.
Band: Alarm 1 condition triggered when the process variable is above or below
the "band" set around Setpoint 1. Band equals Hi Value (Low Value ignored). A
"band" is set around the Setpoint by the instrument only in the "Deviation" Mode.
The Band for the AL 1 would be following the Setpoint 1 value
The Band for the AL 2 would be following the Setpoint 2 value.
The Band or the Deviation Value should be entered under:
AL1 High (if they want Alarm 1)
AL2 High (if they want Alarm 2)
AL Low value is ignored in the Band mode.
Example: if customer requires a Deviation Value of 10 degrees around a
setpoint (using Output 2 as alarm)
Output 2: disabled (this enables the Alarm 2)
Alarm 2: - Deviation
Contact Closure type: Deviation---Band
AL2 High: 10 (Band they want around Setpoint 2)
Then the Band Value is to be entered under AL2 HI: 10 not 80+10 = 90
27
ALARM ENABLE/DISABLE AT POWER ON:
Press d 15) Display flashes previous selection. Press b to ENBL enable

or DSBL disable.
Press d 16) Display shows STRD stored message. momentarily and then
advances to ALR.L only if it was changed, otherwise press a to
advance to the ALR.L Alarm 1 Low Value Submenu.
If the alarm is enabled at Power On, the alarm will be active right after
reset. If the alarm is disabled at Power On, the alarm will become
enabled when the process value enters the non alarm area. The alarm is
not active while the process value is approaching Setpoint 1.
ALARM 1 LOW VALUE SUBMENU:
Press d 17) Display flashes 1st digit of previous value. Use b and c to
enter new value.
Press b & c 18) Use b and c to enter Alarm 1 Low Value.
Press d 19) Display shows STRD storage message momentarily and
then advances to ALR.H only, if it was changed, otherwise press
a to advance to ALR.H Alarm 1 Hi Value Submenu.
ALARM 1 HI VALUE SUBMENU:
Press d 20) Display flashes 1st digit of previous value. Use b and c to
enter new value.
Press b & c 21) Use b and c to enter Alarm1 Hi Value.
advances to the next menu only, if it was changed, otherwise
press a to advance to the next menu.
28
3.2.7 Analog Output (Retransmission)
Analog Output can be configured as Retransmission or Control outputs.
In this section we will discuss Retransmission Output.
follows: Alarm 1 & Alarm 2, Alarm 1 & Output 2, Output 1 & Alarm 2, Output
1 & Output 2, Analog Out 1 & Alarm 2, Analog Out 1 & Output 2. Analog
Output is available only, if Analog Output Option board is factory installed.
If Analog Output Option is not installed, the instrument will skip to Alarm 2 Menu.
Figure 3.6 Flow Chart for Analog Output (Retransmission)

ENTER ANALOG OUTPUT MENU:
Press a 3) Press a, if necessary, until Display advances to ANLG
Analog Output Menu.
Press d 4) Display advances to Analog Output ENBL Enable or DSBL
Disable Submenu and flashes the previous selection.
29
ANALOG OUTPUT ENABLE/DISABLE SUBMENU:
Press b 5) Scroll though the available selection until ENBL displays to
use Analog Output Retransmission (output proportional to the
input signal).
advances to CURR or VoLT Submenu only if it was changed,
otherwise press a to advance to CURR or VoLT
Current/Voltage Submenu.
If DSBL Analog Output Disabled was selected, all submenus of Analog
Output Menu will be skipped and the meter will advance to ALR2 Alarm 2
Menu. If ENBL Analog Output Enabled was selected, Output 1 would be
automatically Disabled, and reassigned as Analog Output.
CURRENT/VOLTAGE SUBMENU:
Press d 7) Display flashes CURR Current or VoLT Voltage.
Press b 8) Scroll through the available selection: Current or Voltage
(Example VoLT ).
advances to RD1 Submenu only if it was changed, otherwise
press a to advance to RD1 Reading 1 Submenu.
READING 1:
Press d 10) Display flashes 1st digit of previous Reading 1 value.
Press b & c 11) Enter Reading 1 value. (Example 0000)
Press d 12) Display advances to OUT.1 Out 1 Submenu.
OUT 1:
Press d 13) Display flashes 1st digit of previous Out 1 value.
Press b & c 14) Enter Out 1 value. (Example 00.00)
Press d 15) Display advances to RD!2 Reading 2 Submenu.
READING 2:
Press d 16) Display flashes 1st digit of previous Reading 2 value.
Press b & c 17) Enter Reading 2 value. (Example 9999)
Press d 18) Display advances to OUT.2 Out 2 Submenu.
OUT 2:
Press d 19) Display flashes 1stt digit of previous Out 2 value.
Press b & c 20) Enter Out 2 value. (Example 10.00)
Press d 21) Display advances to the ALR2 Alarm 2 Menu.
The above example is for 0-10 V of the entire range of the Process Input
and Analog Output. For 0-20 mA output you need to set Analog Type to
Current and OUT 2 to 20.00.
30
Accuracy of Analog Output board is +/-1% of FS (Full Scale) when following
conditions are satisfied:
1. The input is not scaled below 1% of Input FS (10 mV @ 1 V or 0.2 mA @
20 mA input ranges).
2. Analog Output is not scaled below 3% of Output FS (300 mV @ 10 V or
0.6 mA @ 20 mA output ranges).
Otherwise certain corrections need to be applied.

For example:
For entire range of process input, the Analog Output on 10 V FS scaled for
300 mV output range:
Rd1 = 0000, Out1 = 00.00

RD2 = 9999, Out2 = 00.30
The measured output will be as follows:
Rd1 = 0000, Out1 = -0.07 V

Rd2 = 9999, Out2 = 0.23 V
This means that for 300 mV output range we have -70 mV offset at zero and at
full scale. In order to compensate this 70 mV offset the correct scaling will be
as follows:
Rd1 = 0000, Out1 = 00.07

Rd2 = 9999, Out2 = 00.37
The above corrections need to be applied only for Input scaled below 1% of FS
and Output scaled below 3% of FS or if you need the Analog Output
accuracy to be better than 1% of FS.
31
3.2.8 Alarm 2
follows: Alarm 1 & Alarm 2, Alarm 1 & Output 2, Output 1 & Alarm 2, Output 1
& Output 2, Analog Out 1 & Alarm 2, Analog Out 1 & Output 2. Analog Out
available only if Analog Output Option board is factory installed.
Figure 3.7 Flow Chart for Alarm 2

ENTER ALARM 2 MENU:
Press a 3) Press a, if necessary, until Display advances to ALR2 Alarm 2 Menu.
Press d 4) Display advances to Alarm 2 ENBL Enable or DSBL Disable
Submenu.
ALARM 2 ENABLE/DISABLE SUBMENU:
Press d 5) Display flashes previous selection. Press b until ENBL displays
to use Alarm 2.
advances to ABSo only if it was changed, otherwise press a to
advance to ABSo Absolute/Deviation Submenu.
If DSBL Alarm 2 Disabled was selected, all submenus of Alarm 2 will
be skipped and meter advances to LOOP Loop Break Time Menu. If
ENBL Alarm 2 Enabled was selected, Output 2 will automatically
Disabled, and reassigned as Alarm 2.
The remaining Alarm 2 menu items are identical to Alarm 1 Menu. Modifying
Alarm Settings will not reset the instrument.
32
3.2.9 Loop Break Time/Field Calibration
It is required
that you put
the controller
in the Standby Mode
for any configuration
change other than Set
Points & Alarms.
Figure 3.8 Flow Chart for Loop Break Time/Field Calibration

ENTER LOOP BREAK TIME MENU:
Press a 3) Press a, if necessary, until Display advances to LOOP Loop
Break Time Menu.
Press d 4) Display advances to Loop Break Time ENBL Enable or DSBL
LOOP BREAK ENABLE/DISABLE SUBMENU:
Press b 5) Scroll through the available selections: ENBL or DSBL.
advances to B.TIM Loop Break Time Value Submenu.
Loop Break is an additional safety feature intended to monitor the rate of change of the
process value, while approaching the SP1. It is strictly intended as an additional warning
system, therefore its use is entirely optional. An active Loop Break will cause the Process
Value digits to blink in a rotating pattern. If the process value reaches the set point the
blinking will stop and B.TIM is completed successfully, otherwise BR.AL Break Alarm
warning will flash, and Output 1 will be turned off.
LOOP BREAK TIME VALUE SUBMENU:
Press d 7) Display flashes 1st digit of previous Loop Value.
Press b & c 8) Press b and c buttons to enter a new Loop Value (0 to 99.59).
advances to R.ADJ Reading Adjust Submenu.
Loop Break Time Value allows the user to determine the time interval in MM:SS (from
zero to 99 minutes and 59 seconds) that the Process Value changes at least 10 counts or
if the Input Type is either RTD or Thermocouple, the value changes 4 Fahrenheit or 2
Celsius. At the specified time interval, if the process value change is less than the stated
rate, flashing B.TIM will be displayed, the output 1 will be de-energized, and Alarm 1
energized. Loop break time will be disabled when the Process Value (PV) enters the
control band.
READING ADJUST SUBMENU:
Press d 10) Display flashes 1st digit of previous Reading Adjust value.
Press b & c 11) Press b and c buttons to enter a new Reading Adjust value
(-1999 to 9999).
advances to SP.DV Setpoint Deviation Menu.
33
3.2.9 Loop Break Time/Field Calibration (continued)
Reading Offset Adjust allows the user to fine tune a minor error of the transducer,
however some applications may require a large offset adjust.
(Displayed Process Value = Measured Process Value R.ADJ).
Reading Adjust is adjustable between -1999 to 9999. For Temperature Reading only,
not Process
SETPOINT DEVIATION ENABLE/DISABLE SUBMENU:

Press d 13) Display advances to Setpoint Deviation ENBL Enable or DSBL
Press b 14) Scroll through the available selections: ENBL or DSBL.
advances to CAL1 Menu.
Setpoint Deviation Submenu, if enabled, allows changes to Setpoint 1 to be made
automatically to Setpoint 2. This mode is very helpful if the Process Value changes often.
In Setpoint Deviation Mode, set SP2 a certain number of degrees or counts away from
SP1 - this relation remains fixed when SP1 is changed. For instance: Setting SP1=200
and SP2=20 and enabling SP.DV means that the absolute value of SP2=220. Moving
SP1 to 300, the absolute value of SP2 becomes 320.
THERMOCOUPLE FIELD CALIBRATION SUBMENU:
CAUTION: Do not perform the following steps until you fully

understand this entire section.
RTD and Process are perfectly calibrated. This section is applicable to

Thermocouple (TC) calibration only.
Be sure that the TC being used to calibrate the meter is of the type
selected in the TC submenu. Place the TC in an ice-bath (or other
0C / 32F environment). In ambient temperature conditions: connect the
TC to the meter, apply power to the meter.
CAUTION: Do not proceed with TC calibration unless the above

conditions have been in effect for at least one hour.
Press a 7) Display shows CAL1 .

Press d 8) Display shows flashing 0000.
Press a* 9) Display will still show flashing 0000.
Press d* 10) Display shows OUT1 (meaning Calibration is complete)
* If you accidently engage the flashing 0000 (CAL alert) simply re-press
the last button you pressed, to avoid unintentionally mis-calibrating your
meter.
34
3.2.10 Output 1
Alarm 1 and Output 1 or Analog Output (Retransmission) share the same contacts
on the rear panel connector. If Alarm 1 or Analog Output (Retransmission) is
Enabled, Output 1 is automatically Disabled.
It is required that you put
the controller in the
Standby Mode for any
configuration change other
than Set Points & Alarms.
Figure 3.9 Flow Chart for Output 1
35
ENTER OUTPUT 1 MENU:
Press a 3) Press a, if necessary, until Display advances to OUT1 Output
1 Menu.
Press d 4) Display advances to SELF Self Submenu.
SELF SUBMENU:
The Self Option allows the output of the instrument to be controlled manually
from the front panel.
Press d 5) Display flashes the current setting of Self, ENBL Enabled or

DSBL Disabled.
Press b 6) Press the b button to select between Enable and Disable.
Press d 7) If Self ENBL Enabled was selected, display shows STRD
stored message momentarily and then advances to the next
menu (Output 1 setting is completed).
The output is now under the direct control of the operator and
can be adjusted in the Run Mode (M00.0 to M99.9), by pressing
the b and c buttons, where M calls for the Manual (Self)
Control. For example, setting of M50.0 of an Analog Output of 0
to 10 Vdc would produce roughly 5 Vdc at the output.
8) If Self DSBL Disabled was selected, display shows STRD

stored message momentarily and then advances to oPLO
Minimum/Percent Low Submenu of Output 1 Menu.
There is a shorter way to Enable or Disable Self Mode. From a Run
Mode, press d and then press a. Self Mode is Enabled now. Press b or
c to display MXX.X. To disable Self, press d and then press a. Display
goes to the Run Mode. Self Mode is Disabled now.
MINIMUM/PERCENT LOW SUBMENU:

Specify in percent, the minimum value (0000) for control output. If the output is
analog proportional (Current or Voltage), then the minimum voltage or current, in
percent, is specified. If the output is time proportional (Relay, SSR or Pulse),
then the minimum duty-cycle, in percent, is specified.
Press d 9) Display flashes 1st digit of previous Percent Low setting.

Press b & c 10) Use b and c buttons to enter a new value for Percent Low.
advances to oPHI Maximum/Percent High Submenu.
36
MAXIMUM/PERCENT HIGH SUBMENU:
Specify in percent, the maximum value (99) for control output. If the output is
analog proportional (Current or Voltage), then the maximum voltage or current, in
percent, is specified. If the output is time proportional (Relay, SSR, or Pulse),
then the maximum duty-cycle, in percent, is specified.
Press d 12) Display flashes 1st digit of previous Percent High setting.
Press b & c 13) Use b and c buttons to enter a new value for Percent High.
advances to CTRL Control Type Submenu.
Example: On an Analog Output of 0~10 Vdc, a setting of %LO = 10 and %HI = 90,
cause the minimum on the control output to be 1 V and the maximum on the
control output to be 9 V. The same setting on a time proportional output, will
cause 10% duty cycle for the minimum control output and 90% duty cycle for
maximum control output. To disable %LO/HI, set LO to 00 and HI to 99. If %LO/HI
is at other values than the default (%LO = 00, %HI = 99), SOAK is disabled.
*CONTROL TYPE OUTPUT:
(Relay, SSR, Pulse or Analog)

Press d 15) Display flashes ON.OF On/Off or PID Proportional, Integral,
Derivative.
Press b 16) Scroll through the available selections: ON/OFF or PID.
Press d 17) Display flashes STRD stored message momentarily and
then advances to ATN only, if it was changed, otherwise press
a to advance to ATN Action Type Submenu.
The ON/OFF control is a coarse way of controlling the process. The Dead
Band improves the cycling associated with the On/Off control. The PID control is
best for processes where the Setpoint is continuously changing and/or a tight
control of the process variable is required. PID control requires tuning and
adjustment of the "Proportional", "Integral or Reset" and "Derivative or Rate"
terms by a trial-and-error method. The instrument provides an "Auto Tuning"
feature making the tuning process automatic, possibly optimum.
* If Analog Output (Current/Voltage) is your control Output 1, this menu i.e. CTRL
type will not appear, instead 4-20 Current will be displayed. Select ENBL for a
4-20 mA current (2-10 V Voltage) outputs or DSBL for a 0-20 mA current (0-10 V
Voltage) outputs. If 4-20 mA is enabled, %HI/LO setting will have no effect.
Both Current and Voltage control outputs are active simultaneously.
37
ACTION TYPE SUBMENU:
The error that results from the measurement of the Process Variable may be
positive or negative since it may be greater or smaller than the Setpoint. If a
positive error should cause the instrument output to increase (i.e. cooling), it would
be called Direct Acting. If a negative error should cause the output to increase
(i.e. heating), it would be called Reverse Acting.
Press d 18) Display flashes DRT Direct or RVRS Reverse.

Press b 19) Scroll through the available selections: Direct or Reverse.
advances to AUTo only, if it was changed, otherwise press a to
advance to AUTo Auto PID Submenu (if PID Control Type was
selected).
If ON/OFF was selected in the Control Type, the display skips

to the Dead Band Submenu.
AUTO PID SUBMENU:
Press d 21) Display flashes ENBL or DSBL.

Press b 22) Scroll through the available selections: Enable or
Disable.
advances to ANTL only, if it was changed, otherwise press a to
advance to ANTL Anti Integral Submenu.
If Enabled, the controller can determine, by enabling Start PID, the

optimum values for the three adjustments Proportional, Reset and
Rate corresponding to P, I, and D. These values may be changed once
the auto tuning is complete.
If Disabled is selected, the user will manually enter these three

adjustment values. If you want the instrument to do the auto PID and the
P , PI or PID, first select auto disable and enter 0000 for unwanted
parameter. i.e. for PI enter 0000 for the rate.
ANTI INTEGRAL SUBMENU:

Press b 25) Scroll through the available selections: Enable or Disable.
advances to STRT only, if it was changed, otherwise press a to
advance to STRT to Start Auto Tune PID Submenu (If auto PID
was Enabled).
If Auto PID was disabled display advances to PRoP
Proportional Band Submenu.
38
If Anti Integral (Anti Windup) Submenu Enabled, this feature allows
the error term outside the proportional band to be calculated and
accumulated for integration. This may be an important feature in
applications where fast response time is desirable.
START AUTO TUNE PID:

advances to CYCL only, if it was changed, otherwise press a to
advance to CYCL Cycle Time Submenu.
If Enabled, the controller is ready to calculate P, PI or PID parameters.

The instrument performs this by activating the output and observing the
delay and rate at which the Process Value changes. The setpoints must
be at least 18F or 10C above the (PV) Process Value in order to
perform Auto Tune, otherwise an error message will be displayed.
To start Auto Tune PlD select PID, enable Auto PID and enable Start PID.
Sometimes Auto PID parameter needs fine tuning i.e. for each 5F over
shoot increase the Proportional Band (PB) by 15% and for each 1F
fluctuation at the Setpoint (SP) increase reset by 20%.
Once started, display shows A.TUN with letters blinking in the rotating
pattern. When auto tune stops, display will show process value. Do not
perform any operations or settings before first stopping Auto Tune. Any
alarms or other output is disabled during Auto Tune.
If AUTO PID was DISABLED, the display will show the following
three submenus. This allows the user to manually enter values for
Proportional, Reset and Rate terms corresponding to P, I, and D. It also
can be used for auto PID for disabling unwanted parameter i.e. PI enter
0000 for rate.
PROPORTIONAL BAND SUBMENU:
Press d 30) Display flashes 1st digit of the previous P PRoP Proportional
band value.
Press b & c 31) Press b and c buttons to enter a new Proportional Band
value.
advances to REST only, if it was changed, otherwise press a to
advance to REST Reset Setup Submenu.
Proportional band is in degrees of temperature or counts of process. Proportional

band is defined, as the change in the instrument input to cause a 100% change in
the controller output.
39
RESET SETUP SUBMENU:
Press d 33) Display flashes 1st digit of the previous I REST Reset value.
Press b & c 34) Press b and c buttons to enter a new Reset value.
advances to RATE only, if it was changed, otherwise press a to
advance to RATE Rate Setup Submenu.
Reset unit is in seconds 0-3999.
RATE SETUP SUBMENU:
Press d 36) Display flashes 1st digit of previous D RATE Rate value.
Press b & c 37) Press b and c buttons to enter a new RATE value.
advances to the CYCL only, if it was changed, otherwise press a
to advance to CYCL Cycle Time submenu for RTD and
Thermocouple types.
Rate unit is in seconds 000.0-399.9.
If the Output 1 is Analog Option the display skips to Damping

Factor.
CYCLE TIME SUBMENU:
Press d 39) Display flashes 1st digit of the previous CYCL Cycle Time
value.
Press b & c 40) Press b and c buttons to enter a new Cycle Time value.
(1 to 199 seconds)
advances to DPNG only, if it was changed, otherwise press a to
advance to DPNG Damping Factor Submenu.
A Cycle Time selected between 1 and 199 seconds determines the total On/Off
time of each proportional cycle. For example, a 15 second cycle time means that
every 15 seconds the output will turn on for part or all of the cycle. For Relay
control outputs, do not select a cycle time of less than 7 seconds or the relays
lifetime will be shortened. For a cycle time of less than 7 seconds select SSR or
DC pulse. Use an external SSR with the DC pulse option for higher currents
(higher than 1 Amp).
40
DAMPING FACTOR SUBMENU:
Press d 42) Display flashes the previous Damping Factor selection.

Press b 43) Scroll through the available selections: 0000, 0001, 0002,
0003, 0004, 0005, 0006, 0007.
Press d 44) Display flashes STRD stored message and then advances
to OUT2 only, if it was changed, otherwise press a to advance
to OUT2 Output 2 Menu.
Damping Factor is a measure of speed, overshoot, and undershoot in which the

process variable responds to the output changes of the instrument, which were
used during the Auto Tune. This value is typically set to the ratio of Rate to
Reset. This Default value is (0003). For fast response time, this value should be
decreased while for slow response time it should be increased.
The "DEADBAND" Submenu will only appear if "ON/OFF" was

selected from the "Control Type" Menu.
DEADBAND SUBMENU:
Press d 45) Display flashes 1st digit of the previous DEAD Deadband
value.
Press b & c 46) Press b and c buttons to enter a new Deadband value.
OUT2 only, if it was changed, otherwise press a to advance to
OUT2 Output 2 Menu.
Dead Band units are the same as Proportional Band units.
The Dead Band or neutral zone is the number of degrees or counts

(if Input Type is Process) around the Setpoint which the Process Variable
must pass above or below the Setpoint, before the output changes state.
41
3.2.11 Output 2
Output 2 and Alarm 2 share the same contacts on the rear panel connector. If
Alarm 2 is Enabled, Output 2 is automatically Disabled.
It is required that you put

the controller in the
Standby Mode for any
configuration change other
than Set Points & Alarms.
Figure 3.10 Flow Chart for Output 2

ENTER OUTPUT 2 MENU:

Press a 3) Press a, if necessary, until Display advances to OUT2
Output 2 Menu.
Press d 4) Display advances to CTRL Control Type Submenu.
CONTROL TYPE SUBMENU:
Press d 3) Display flashes ON.OF ON/OFF, or PID PID.

Press b 4) Scroll through the available selections: ON/OFF or PID.
advances to ATN only, if it was changed, otherwise press a to
advance to ATN Action Type Submenu.
The ON/OFF control is a coarse way of controlling the Process. The Dead
Band improves the cycling associated with the ON/Off control. The PID control
is best for processes where the Setpoint is continuously changing and/or tight
control of the Process Variable is required.
42
ACTION TYPE SUBMENU:
The error that results from the measurement of the Process Variable may be
positive or negative since it may be greater or smaller than the Setpoint. If a
positive error should cause the instrument output to increase (i.e. cooling), it
would be called Direct Acting. If a negative error should cause the output to
decrease (i.e. heating), it would be called Reverse Acting.
Press d 6) Display flashes DRT Direct or RVRS Reverse.

Press b 7) Scroll through the available selections: Direct or Reverse.
advances to AUTo only, if it was changed, otherwise press a to
advance to AUTo Auto PID Submenu (If PID Control type was
selected).
If ON/OFF was selected in the Control Type, the display skips to

the Dead Band Submenu.
AUTO PID SUBMENU:
Press d 9) Display flashes ENBL Enable or DSBL Disable.

If "Enabled", the PID parameter of Output 1 will be copied to

Output 2.
advances to the next submenu only, if it was changed, otherwise
press a to advance to the next submenu.
If AUTO PID was ENABLED", the display skips to the CYCL

CYCLE TIME submenu. If "AUTO PID" was "DISABLED", the
display will show PRoP PROPORTIONAL BAND Submenu
allowing the user to manually enter the Proportional Band value.
The Reset and Rate value are the same as Output 1.
PROPORTIONAL BAND SUBMENU:
Press d 12) Display flashes 1st digit of the previous Proportional Band
value.
Press b & c 13) Press b and c buttons to enter a new Proportional Band
value.
advances to CYCL only, if it was changed, otherwise press a to
advance to the CYCL Cycle Time Submenu.
Refer to Proportional Band Submenu of Output 1 Menu.
43
CYCLE TIME SUBMENU:
Press d 15) Display flashes 1st digit of the previous Cycle Time value.
Press b & c 16) Press b and c buttons to enter a new Cycle Time value
(1 to 199 seconds).
advances to RAMP only, if it was changed, otherwise press a to
advance to RAMP Ramp Value Submenu.
A cycle time selected between 1 to 199 seconds indicates the total On/Off time
of each proportional cycle. For example, a 15 second cycle time means that
every 15 seconds the output will turn on for part or all of the cycle. For Relays
Control Outputs, do not select a cycle time of less than 7 seconds or the relays
lifetime will be shortened. For a cycle time of less than 7 seconds select SSR or
DC pulse. Use an external SSR with the DC pulse option for higher current
(higher than 1 Amp).
The DEADBAND Submenu will only appear if the ON/OFF was

selected from the "Control Type" Submenu.
DEADBAND SUBMENU:
Press d 18) Display flashes 1st digit of the previous Dead Band value.
Press b & c 19) Press b and c buttons to enter a new Dead Band value.
advances to RAMP only, if it was changed, otherwise press a to
advance to RAMP Ramp Value Menu.
Dead Band units are the same as Proportional Band units.
The Dead Band or neutral zone is the number of degrees or counts

(if Input Type is Process) around the Setpoint which the Process Variable
must pass above or below the Setpoint, before the output changes state.
44
3.2.12 Ramp & Soak
configuration change other than Set Points & Alarms.
Figure 3.11 Flow Chart for Ramp and Soak

ENTER RAMP AND SOAK MENU:

Press a 3) Press a, if necessary, until Display advances to RAMP Ramp
and SOAK Soak Menu.
RAMP ENABLE/DISABLE SUBMENU:
Press d 4) Display advances to Ramp Enable/Disable Submenu and

flashes ENBL or DSBL.
advances to SOAK Soak Enable/Disable Menu.
If RAMP Disable was selected, display skips to the next menu
item (ID Code).
45
SOAK ENABLE/DISABLE SUBMENU:

advances to Ramp Value Submenu.
Ramp & Soak provides users with the flexibility to slowly bring the Process
Variable (PV) to the desired setpoint. Ramp & Soak values are specified in
HH.MM format. The Ramp value indicates the time specified to bring the
process variable to Setpoint 1 (SP1). Once the set point is reached, the PID
takes over and the Process Variable will be controlled at the desired set point
indefinitely. If Soak is enabled, PID will control the Process Variable at the
specified Setpoint for the duration of Soak time and then will turn off Output 1.
To start a new Ramp/Soak cycle, reset the instrument by pressing a and then c
button.
An active Ramp/Soak will change SP1 one degree above the PV and will cause
the most significant digit to blink. The SP1 will be incremented by one degree
until it reaches the original SP1. The minimum Ramp time must be at least twice
the time that it will take the PV to reach the Setpoint Value (SV) with OUT 1 fully
ON.
RAMP VALUE SUBMENU:
Press d 10) Display flashes 1st digit of previous stored Ramp Value.
Press b & c 11) Press b and c buttons to enter a new Ramp Value.
advances to Soak Value Submenu.
SOAK VALUE SUBMENU:
Press d 13) Display flashes 1st digit of previous stored Soak Value.
Press b & c 14) Press b and c buttons to enter a new Soak Value.
Press d 15) Display shows STRD stored message and advances to the
ID ID Code Menu.
The Ramp and Soak time is 00:00 to 99:59 i.e. HH.MM. (from zero to 99 hours
and 59 minutes) During Ramp & Soak do not perform any operations or settings
before first stopping it. Any alarms or other output are disabled during this time.
To stop Ramp & Soak first put instrument into Standby Mode, then go to Ramp &
Soak Menu and disable it.
46
3.2.13 ID CODE
Figure 3.12 Flow Chart for ID Code

ENTER ID CODE MENU:

Press a 3) Press a, if necessary, until Display advances to ID ID Code
Menu.
ENTERING OR CHANGING YOUR (NON-DEFAULT) ID CODE:
Press d 4) Display advances to ____ with 1st under score flashing.

Press b & c 5) Press b and c to enter your 4-digit ID Code number.
Press d 6) Display advances to CH.ID Change ID Code Submenu.
If entered ID Code is incorrect display shows ERRo Error

message momentarily and then skips to the Run Mode.
Press d 7) Display flashes the first digit of previous entered ID Code

number.
Press b & c 8) Press b and c buttons to enter your new ID Code number.
advances to the FULL Full Security Submenu.
47
ENTERING OR CHANGING YOUR (DEFAULT) ID CODE:
Enter ID menu (Repeat steps from 1 to 3).
Press d 10) Display advances to CH.ID Change ID Code Submenu.

Press d 11) Display shows 0000 message with flashing 1st digit.
If you want to change your default ID Code you can do it now,

otherwise press a and menu will skip to FULL Full Security
Submenu.
Press b & c 12) Press b and c buttons to enter your new ID Code number.
advances to the FULL Full Security Submenu.
FULL SECURITY LEVEL SUBMENU:

advances to SP.ID Setpoint/ID Submenu.
If "Full" Security Level is "Enabled" and the user attempts to

enter the Main Menu, they will be prompted for an ID Code. The
ID Code should be correct to enter the instrument Menu item.
SETPOINT/ID SECURITY LEVEL SUBMENU:
This Security Level can be functional only if FULL Security

Level is Disabled.

advances to COMM Communication Submenu.
If "Setpoint/ID" Security Level is "Enabled" and the user

attempts to advance into the CNFG Configuration Menu, he will
be prompted for ID Code number. The ID Code should be
correct to proceed into the Configuration Menu, otherwise
display will show an Error and skip to the Run Mode.
If Full and Setpoint/ID Security Levels are "Disabled", the

ID code will be Disabled and user will not be asked for ID
Code to enter the Menu items (ID Submenu will not show up in
ID/Setpoint Menu).
48
3.2.14 COMMUNICATION OPTION
Purchasing the controller with Serial Communications permits an instrument to be configured
or monitored from an IBM PC compatible computer using software available from the
website or on the CD-ROM enclosed with your shipment. For complete instructions on
the use of the Serial Comm.Option, refer to the Serial Comm. Reference Manual.
* Valid only for -C24

and -EI options.
** Valid only for -C24
and -C4EI options.
External RS-232 connections are not available with -EI or -C4EI options.
Figure 3.13 Flow Chart for Communication Option
49
ENTER COMMUNICATION OPTION MENU:
Press a 3) Press a, if necessary, until Display advances to COMM
Communication Options Menu.
Press d 4) Display advances to C.PAR Communication Parameters
Submenu.
If Communication Option is not installed, the display shows NONE
and skips to the Color Display Menu.
COMMUNICATION PARAMETERS SUBMENU:
Allows the user to adjust Serial Communications Settings of the instrument.
When connecting an instrument to a computer or other device, the
Communications Parameters must match. Generally the default settings
(as shown in Section 5) should be utilized.
Press d 5) Display advances to BAUD Baud Submenu.
BAUD SUBMENU:
Press d 6) Display flashes previous selection for BAUD value.
Press b 7) Scroll through the available selections: 300_, 600_, 1200,
2400, 4800, 9600, 19.2K.
advances to PRTY only, if it was changed, otherwise press a to
advance to PRTY Parity Submenu.
PARITY SUBMENU:
Press d 9) Display flashes previous selection for Parity.
Press b 10) Scroll through the available selections: NO, ODD, EVEN.
advances to DATA only, if it was changed, otherwise press a to
advance to DATA Data Bit Submenu.
DATA BIT SUBMENU:
Press d 12) Display flashes previous selection for Data Bit.
Press b 13) Scroll through the available selections: 7-BIT, 8-BIT.
STOP only, if it was changed, otherwise press a to advance to
STOP Stop Bit Submenu.
50
STOP BIT SUBMENU:
Press d 15) Display flashes previous selection for Stop Bit.
Press b 16) Scroll through the available selections: 1-BIT, 2-BIT.
advances to BUS.F only, if it was changed, otherwise press a to
advance to BUS.F Bus Format Submenu.
BUS FORMAT SUBMENU:
Determines Communications Standards and Command/Data Formats for
transferring information into and out of the controller via the Serial
Communications Bus. Bus Format submenus essentially determine how and
when data can be accessed via the Serial Communications of the device.
Press d 18) Display advances to M.BUS Modbus Submenu.
MODBUS PROTOCOL SUBMENU:
Press d 19) Display flashes previous selection for M.BUS.
Press b 20) Scroll through the available selections: NO, YES.
advances to _LF_ only, if it was changed, otherwise press a to
advance to _LF_ Line Feed submenu.
To select iSeries Protocol, set Modbus submenu to No.
To select Modbus Protocol, set Modbus submenu to Yes.
If Modbus Protocol was selected, the following Communications
Parameters must be set as: No Parity, 8-bit Data Bit, 1-Stop Bit. Do not
attempt to change these parameters.
LINE FEED SUBMENU:

Determines if data sent from the instrument will have a Line Feed appended to
the end - useful for viewing or logging results on separate lines when displayed
on communications software at a computer.
Press d 22) Display flashes previous selection for Line Feed.
advances to ECHO only, if it was changed, otherwise press a to
advance to ECHO Echo Submenu.
ECHO SUBMENU:
When valid commands are sent to the instrument, this determines whether the
command will be echoed to the Serial Bus. Use of echo is recommended in most
situations, especially to help verify that data was received and recognized by the
controller.
51
Press d 25) Display flashes previous selection for Echo.
Press d 27) Display flashes STRD stored message momentarily and then
advances to STND only if it was changed, otherwise press a to
advance to STND Communication Standard Submenu.
COMMUNICATION INTERFACE STANDARD SUBMENU:

Determines whether device should be connected to an RS-232C serial port
(as is commonly used on IBM PC-compatible computers) or via an RS-485 bus
connected through appropriate RS-232/485 converter. When used in RS-485
Mode, the device must be accessed with an appropriate Address Value as
selected in the Address Submenu described later.
Press d 28) Display flashes previous selection for Standard.
Press b 29) Scroll through the available selections: 232C, 485.
advances to MoDE only, if it was changed, otherwise press a to
advance to MoDE Data Flow Mode Submenu.
DATA FLOW MODE SUBMENU:
Determines whether the instrument will wait for commands and data requests
from the Serial Bus or whether the instrument will send data automatically and
continuously to the Serial Bus. Devices configured for the RS-485
Communications Standard operate properly only under Command Mode.
Press d 31) Display flashes previous selection for Mode.
Press b _ Command,
32) Scroll through the available selections: CMD_
CoNT Continuous.
advances to SEPR only, if it was changed, otherwise press a to
advance to SEPR Data Separation Submenu.
DATA SEPARATION CHARACTER SUBMENU:
Determines whether data sent from the device in Continuous Data Flow Mode
will be separated by spaces or by Carriage Returns.
Press d 34) Display flashes previous selection for Separation Submenu.
Press b 35) Scroll through the available selections: SPCE Space or
_R_ Carriage Return.
advances to DAT.F only, if it was changed, otherwise press a to
advance to DAT.F Data Format Submenu.
52
DATA FORMAT SUBMENU:
Preformatted data can be sent automatically or upon request from the controller.
Use the Data Format Submenus to determine what data will be sent in this
preformatted data string. Refer to the iSeries Communications Manual for more
information about the data format. At least one of the following suboptions must
be enabled and hence output data to the Serial Bus.
This menu is applicable for Continuous Mode of RS-232 communication.
Press d 37) Display advances to STAT Alarm Status Submenu.

ALARM STATUS SUBMENU:
Includes Alarm Status bytes in the data string.
Press d 38) Display flashes previous selection for Status (alarm status).
advances to RDNG only, if it was changed, otherwise press a to
advance to RDNG Reading Submenu.
MAIN READING SUBMENU:
Includes Main Reading in the data string.
Press d 41) Display flashes previous selection for Reading.
advances to PEAK only, if it was changed, otherwise press a to
advance to PEAK Peak Submenu.
PEAK VALUE SUBMENU:
Includes Peak Value in the data string.
Press d 44) Display flashes previous selection for PEAK Submenu.
advances to VALY only, it was changed, otherwise press a to
advance to VALY Valley Submenu.
VALLEY VALUE SUBMENU:
Includes Valley Value in the data string.
Press d 47) Display flashes previous selection for Valley.
advances to UNIT only, if it was changed, otherwise press a to
advance to UNIT Temperature Unit Submenu.
53
TEMPERATURE UNIT SUBMENU:
Includes a byte in the data string to indicate whether reading is in Celsius or
Fahrenheit.
Press d 50) Display flashes previous selection for UNIT.
advances to ADDR only, if it was changed, otherwise press a to
advance to ADDR Address Setup Submenu.
ADDRESS SETUP SUBMENU:

This menu is applicable to the RS-485 Option only.
Press d 53) Display advances to Address Value (0000 to 0199) Submenu.
ADDRESS VALUE SUBMENU:

Press d 54) Display flashes 1st digit of previously stored Address Value.
Press b & c 55) Press b and c to enter new Address Value.
advances to TR.TM only, if it was changed, otherwise press a to
advance to TR.TM Transmit Time Interval Submenu.
TRANSMIT TIME INTERVAL SUBMENU:

This menu is applicable if Continuous Mode was selected in the Data
Flow Mode Submenu and the device is configured as an RS-232C
Standard device. Also, one or more options under the Data Format
Submenu must be enabled.
Press d 57) Display advances to Transmit Time Value Submenu.
TRANSMIT TIME INTERVAL VALUE SUBMENU:

Determines the interval at which data will be emitted to the RS-232 Serial Bus
when the instrument is in Continuous Data Flow Mode.
Press d 58) Display flashes 1st digit of previous Transmit Time Value in
seconds.
Press b & c 59) Press b and c to enter new Transmit Time Value, e.g.
0030 will send the data every 30 seconds in Continuous Mode.
advances to COLR only, if it was changed, otherwise press a to
advance to COLR Color Display Selection Menu.
For more details, refer to the Communication Manual available at

the website listed in the cover page of this manual.
54
3.2.15 DISPLAY COLOR SELECTION
This submenu allows the user to select the color of the display.
Figure 3.14 Flow Chart for Display Color Selection

ENTER DISPLAY COLOR SELECTION MENU:

Press a 3) Press a, if necessary, until Display advances to COLR
Display Color Selection Menu.
Press d 4) Display advances to N.CLR Normal Color Submenu.
NORMAL COLOR DISPLAY SUBMENU:
Press d 5) Display flashes the previous selection for Normal Color.

Press b 6) Scroll through the available selections: GRN, RED or AMBR.
advances to 1.CLR only, if it was changed, otherwise press a to
advance to 1.CLR Alarm 1 Display Color Submenu.
The menu below allows the user to change the color of display when alarm is
triggered.
ALARM 1 DISPLAY COLOR SUBMENU:
Press d 8) Display flashes previous selection for Alarm 1 Color

Display.
advances to 2.CLR only, if it was changed, otherwise press a to
advance to 2.CLR Alarm 2 Display Color Submenu.
55
ALARM 2 DISPLAY COLOR SUBMENU:
Press d 11) Display flashes previous selection for Alarm 2 Color Display.
momentarily shows the software version number, followed by
RST Reset, and then proceeds to the Run Mode.
IN ORDER TO DISPLAY ONE COLOR, SET THE SAME DISPLAY
COLOR ON ALL THREE SUBMENUS ABOVE.
If user wants the Display to change color every time when both Alarm 1
and Alarm 2 are triggered, the Alarm values should be set in such a way
that Alarm 1 value is always on the top of Alarm 2 value, otherwise value
of Alarm 1 will overwrite value of Alarm 2 and Display Color would not
change when Alarm 2 is triggered.
Example 1:
Output 1 & Output 2 = SSR
Alarm Setup: Absolute, Above, Alarm 2 HI Value ALR.H = 200, Alarm 1
HI Value ALR.H = 400
"Color Display" Setup: Normal Color N.CLR = Green, Alarm 1 Color
1.CLR = Amber, Alarm 2 Color 2.CLR = Red
Display Colors change sequences:
GREEN RED AMBER

-------------------------------------------------------------------------------------------
0 AL2.H = 200 AL1.H = 400
Example 2:
Output 1 & Output 2 = Pulse
Alarm Setup: Absolute, Below, Alarm 2 Low Value ALR.L = 300, Alarm 1
Low Value ALR.L = 100
Color Display Setup: "N.CLR" = Green, "1.CLR" = Amber, "2.CLR" = Red
AMBER RED GREEN

------------------------------------------------------------------------------------------- --
0 AL1.L = 100 AL2.L = 300
56
Example 3:
Output 1 = Analog Output (Alarm 1 disabled), Setpoint 1 = 300,
Output 2 = Relay, Setpoint 2 = 200
Alarm 1 & 2 Setup: Deviation, Band, ALR.H = 10
Color Display Setup: N.CLR = Green, 1.CLR = Amber, 2.CLR = Red
RED RED RED GREEN RED

----------------------------------------------------------------------------------------
0 190 200 210 290 300 310
Alarm 1 is designed to monitor the Process Value around the Setpoint 1.
Alarm 2 is designed to monitor the Process Value around the Setpoint 2.
If Analog Output Option board is installed (Alarm 1 is disabled), only
Alarm 2 is active and only two colors are available.
Example 4:
Alarm 1 Setup: Deviation, Band, ALR.H = 20
Alarm 2 Setup: Deviation, Hi/Low, ALR.H = 10, ALR.L = 5
Color Display Setup: N.CLR = Green, 1.CLR = Amber, 2.CLR = Red
Display colors change sequences:
AMBER RED GREEN GREEN RED AMBER

----------------------------------------------------------------------------------------------
0 180 195 200 210 220
Reset: The instrument automatically resets after the last menu of

the Configuration Mode has been entered. After the instrument
resets, it advances to the Run Mode.
57
PART 4 INPUT
SPECIFICATIONS Input Types
Thermocouple, RTD, Analog Voltage,
Accuracy Analog Current
0.5C temp; 0.03% reading process
Thermocouple Type (ITS 90)
Resolution J, K, T, E, R, S, B, C, N, L
1/0.1; 10 V process
Thermocouple Lead Resistance
Temperature Stability 100 ohm max
1) RTD: 0.04C/C
2) TC @ 25C (77F): 0.05C/C RTD Input (ITS 68)
- Cold Junction Compensation 100/500/1000 Pt sensor, 2-, 3- or
3) Process: 50 ppm/C 4-wire; 0.00385 or 0.00392 curve
NMRR Voltage Input
60 dB 0 to 100 mV, 0 to 1 V, 0 to 10 Vdc
CMRR Input Impedance
120 dB 10 M for 100 mV
1 M for 1 or 10 Vdc
A/D Conversion
Dual slope Current Input
0 to 20 mA (5 ohm load)
Reading Rate
3 samples per second Configuration
Single-ended
Digital Filter
Programmable Polarity
Unipolar
Display
4-digit, 9-segment LED Step Response
10.2 mm (0.40"): i32, i16, i16D (Dual 0.7 sec for 99.9%
Display), i8DV (Dual Vertical)
21 mm (0.83"): i8 Decimal Selection
10.2 mm (0.40) and 21 mm (0.83): None, 0.1 for temperature
i8DH (Dual Horizontal) None, 0.1, 0.01 or 0.001 for process
red, green and amber programmable
colors for process variable, set point Setpoint Adjustment
and temperature units -1999 to +9999 counts
Warm up to Rated Accuracy Span Adjustment
30 min. 0.001 to 9999 counts
Offset Adjustment
-1999 to +9999
CONTROL
Action
Reverse (heat) or direct (cool)
58
Modes DC Pulse
Time and Amplitude Proportional Non-Isolated; 10 Vdc @ 20 mA
Control Modes; selectable Manual or
Auto PID, Proportional, Proportional Analog Output (Output 1 only)
with Integral, Proportional with Non-Isolated, Proportional 0 to 10 Vdc
Derivative with Anti-reset Windup and or 0 to 20 mA; 500 max
ON/OFF
NETWORK AND COMMUNICATIONS
Rate (Optional -C24, -C4EI, -EI)
0 to 399.9 seconds Ethernet: Standards Compliance IEEE
802.3 10Base-T
Reset Supported Protocols: TCP/IP, ARP,
0 to 3999 seconds HTTPGET
Cycle Time RS-232/RS-422/RS-485/MODBUS:
1 to 199 seconds; set to 0 for ON/OFF Selectable from menu; both ASCII and
operation modbus protocol selectable from menu.
Programmable 300 to 19.2 K baud;
Gain complete programmable setup
0.5 to 100% of span; Setpoints 1 or 2 capability; program to transmit current
display, alarm status, min/max, actual
Damping measured input value and status.
0000 to 0008
RS-485
Soak Addressable from 0 to 199
00.00 to 99.59 (HH:MM), or OFF
Connection
Ramp to Setpoint Screw terminals
00.00 to 99.59 (HH:MM), or OFF
ALARM 1 & 2 (programmable):
Auto Tune Type
Operator initiated from front panel Same as Output 1 & 2
CONTROL OUTPUT 1 & 2 Operation
Relay High/low, above/below, band,
250 Vac or 30 Vdc @ 3 A latch/unlatch, normally open/normally
(Resistive Load); configurable for closed and process/deviation; front
on/off, PID and Ramp and Soak panel configurations
Output 1: SPDT type, can be ANALOG OUTPUT (programmable)
configured as Alarm 1 output Non-Isolated, Retransmission 0 to 10
Vdc or 0 to 20 mA, 500 max (Output
Output 2: SPDT type, can be 1 only). Accuracy is + 1% of FS when
configured as Alarm 2 output following conditions are satisfied.
1) Input is not scaled below 1% of
SSR Input FS.
20-265 Vac @ 0.05-0.5 A 2) Analog Output is not scaled below
(Resistive Load); continuous 3% of Output FS.
59
EXCITATION Environmental Conditions
(optional in place of Communication) All models: 0 to 55C (32 to 131F),
24 Vdc @ 25 mA 90% RH non-condensing
Not available for Low Power Option i8DV, i8DH, i8C, i16D: 0 to 50C
(32 to122F) for UL only.
INSULATION 90% RH non-condensing
Power to Input/Output
2300 Vac per 1 min. test Protection
1500 Vac per 1 min. test NEMA-4x/Type 4x/IP65 front bezel:
(Low Voltage/Power Option) i32, i16D, i8C
Power to Relays/SSR Outputs NEMA-1/Type 1 front bezel: i8, i8DH,
2300 Vac per 1 min. test i8DV
Relays/SSR to Relay/SSR Outputs
2300 Vac per 1 min. test
RS-232/485 to Inputs/Outputs Dimensions
500 Vac per 1 min. test i/8 Series:
48 H x 96 W x 127 mm D
Approvals (1.89 x 3.78 x 5")
FM, UL, C-UL, and
see CE Approval Section i/8 Compact Series:
48 H x 96 W x 74 mm D
GENERAL (1.89 x 3.78 x 2.91")
Line Voltage/Power i/16 Series:

90-240 Vac +/-10%, 50-400 Hz* 48 H x 48 W x 127 mm D
110-375 Vdc, equivalent voltage (1.89 x 1.89 x 5")
4 W, power for i8, i8C, i16, i32 Models
5 W, power for i8DV, i8DH, i16D Models i/32 Series:
* No CE compliance above 60 Hz 25.4 H x 48 W x 127 mm D
(1.0 x 1.89 x 5")
Low Voltage/Power Option
12-36 Vdc, 3 W, power for i8, i16, i32 Panel Cutout
20-36 Vdc, 4 W, power for i8DV, i8DH, i16D i/8 Series: 45 H x 92 mm W
External power source must meet (1.772" x 3.622 "), 1/8 DIN
Safety Agency Approvals.
* Units can be powered safely with 24 Vac i/16 Series:
power but, no Certification for CE/UL are 45 mm (1.772") square, 1/16 DIN
claimed.
i/32 Series:
External Fuse Required 22.5 H x 45 mm W
Time-Delay, UL 248-14 listed: (0.886" x 1.772"), 1/32 DIN
100 mA/250 V
400 mA/250 V (Low Voltage/Power Option) Weight
Time-Lag, IEC 127-3 recognized: i/8 Series: 295 g (0.65 lb)
100 mA/250 V i/16 Series: 159 g (0.35 lb)
400 mA/250 V (Low Voltage/Power Option) i/32 Series: 127 g (0.28 lb)
60
Table 4.1 Input Properties
TC Input Type Range Accuracy*
Iron-Constantan -210 to 760C 0.4C
J -346 to 1400F 0.7F
-270 to -160C 1.0C
K CHROMEGA-
ALOMEGA
-160 to 1372C
-454 to -256F
0.4C
1.8F
-256 to 2502F 0.7F
-270 to -190C 1.0C
Copper-Constantan -190 to 400C 0.4C
T -454 to -310F 1.8F
-310 to 752F 0.7F
-270 to -220C 1.0C
CHROMEGA- -220 to 1000C 0.4C
E Constantan -454 to -364F 1.8F
-364 to 1832F 0.7F
-50 to 40C 1.0C
Pt/13%Rh-Pt 40 to 1788C 0.5C
R -58 to 104F 1.8F
104 to 3250F 0.9F
-50 to 100C 1.0C
Pt/10%Rh-Pt 100 to 1768C 0.5C
S -58 to 212F 1.8F
212 to 3214F 0.9F
200 to 640C 1.0C
30%Rh-Pt/ 640 to 1820C 0.5C
B 6%Rh-Pt 212 to 1184F 1.8F
1184 to 3308F 0.9F
5%Re-W/ 0 to 2354C 0.4C
C 26%Re-W 32 to 4253F 0.7F
-250 to -100C 1.0C
Nicrosil-Nisil -100 to 1300C 0.4C
N -418 to -148F 1.8F
-148 to 2372F 0.7F
J -200 to 900C 0.4C
L DIN -328 to 1652F 0.7F
Pt, 0.00385, 100 , 200 to 900C 0.4C
RTD 500 , 1000 -328 to 1652F 0.7F
Pt, 0.00392, 100 , -200 to 850C 0.4C
RTD 500 , 1000 -328 to 1562F 0.7F
Voltage 0 to 100 mV, 0 to 1 V, 0.03% rdg
PROCESS
0 to 10 Vdc 0.03% rdg
PROCESS Current 0 to 20 mA, 4 to 20 mA 0.03% rdg
61
PART 5
FACTORY PRESET VALUES
Table 5.1 Factory preset value
MENU ITEMS FACTORY PRESET VALUES NOTES
Set Point 1 (SP1) 000.0
Set Point 2 (SP2) 000.0
Input:
Input Type (INPT) TC, type K
Reading Configuration (RDG):
Decimal Point (DEC.P) FFF.F
Temperature unit (TEMP) F
Filter value (FLTR) 0004
Alarm 1 & 2:
Alarm 1 (ALR1), Alarm 2 (ALR2) Disable (DSBL)
Absolute/Deviation (ABSO/DEV) Absolute (ABSO)
Latch/Unlatch (LTCH/UNLT) Unlatch (UNLT)
Contact Closure (CT.CL) Normally Open (N.O.)
Active (ACTV) Above (ABOV)
Alarm At Power On (A.P.ON) Disable (DSBL) Alarm 1 only
Alarm Low (ALR.L) -100.0
Alarm High (ALR.H) 400.0
LOOP:
Loop Break Time (LOOP) Disable (DSBL)
Loop Value (B.TIM) 00:59
Reading Adjust Value (R.ADJ) 000.0
Setpoint Deviation (SP.dV) Disable (DSBL)
ANALOG OUTPUT (Retransmission):
Analog Output (ANLG) Enabled (ENBL)
Current/Voltage (CURR/VOLT) Voltage (VOLT)
Scale and Offset Reading: 0 - 999.9 cts, Output: 0 - 10 V
OUTPUT 1 & 2:
Self (SELF) Disabled (DSBL) Output 1 only
% Low Value (%LO) 0000 Output 1 only
% High Value (%HI) 0099 Output 1 only
Control Type (CTRL) On/Off
Action Type (ACTN) Reverse (RVRS)
Dead Band (DEAD) 020.0
PID Auto (AUTO) Disable (DSBL)
Anti Integral (ANTI) Disable (DSBL) Output 1 only
Proportion Value (PROP) 020.0
Reset Value (REST) 0180 Output 1 only
Rate Value (RATE) 0000 Output 1 only
Cycle Value (CYCL) 0007
Damping Factor (DPNG) 0003
62
MENU ITEMS FACTORY PRESET VALUES NOTES
Ramp & Soak (RAMP):
Ramp (RAMP) Disable (DSBL)
Soak (SOAK) Disable (DSBL)
Ramp Value (RAMP) 00:00
Soak Value (SOAK) 00:00
ID:
ID Value 0000
Full ID (FULL) Disable (DSBL)
Set Point ID (ID.SP) Disable (DSBL)
Communication Parameters:
Baud Rate (BAUD) 9600
Parity (PRTY) Odd
Data bit (DATA) 7 bit
Stop Bit 1 bit
Modbus Protocol (M.BUS) No
Line Feed (LF) No
Echo (ECHO) Yes
Standard Interface (STND) RS-232 (232C)
Command Mode (MODE) Command (CMD)
Separation (SEPR) Space (SPCE)
Alarm Status (STAT) No
Reading (RDNG) Yes
Peak No
Valley (VALY) No
Units (UNIT) No
Multipoint Address (ADDR) 0001
Transmit Time (TR.TM) 0016
Display Color (COLR):
Normal Color (N.CLR) Green (GRN)
Alarm 1 Color (1.CLR) Red (RED)
Alarm 2 Color (2.CLR) Amber (AMBR)
63
PART 6
CE APPROVALS INFORMATION
This product conforms to the EMC directive 89/336/EEC amended by
93/68/EEC, and with the European Low Voltage Directive 72/23/EEC.
Electrical Safety EN61010-1:2001

Safety requirements for electrical equipment for measurement, control and laboratory.
Double Insulation
Pollution Degree 2
Dielectric withstand Test per 1 min
Power to Input/Output: 2300Vac (3250Vdc)
Power to Input/Output: 1500Vac (2120Vdc)
(Low Voltage dc Power Option*)
Power to Relays/SSR Output: 2300Vac (3250Vdc)
Ethernet to Inputs: 1500Vac (2120Vdc)
Isolated RS232 to Inputs: 500Vac (720Vdc)
Isolated Analog to Inputs: 500Vac (720Vdc)
Analog/Pulse to Inputs: No Isolation
Measurement Category I
Category I are measurements performed on circuits not directly connected to the
Mains Supply (power). Maximum Line-to-Neutral working voltage is 50Vac/dc.
This unit should not be used in Measurement Categories II, III, IV.
Transients Overvoltage Surge (1.2 / 50uS pulse)
Input Power: 2500V
Input Power: 1500V
(Low Voltage dc Power Option*)
Ethernet: 1500V
Input/Output Signals: 500V
Note: *Units configured for external low power dc voltage, 12-36Vdc
EMC EN61326:1997 + and A1:1998 + A2:2001

Immunity and Emissions requirements for electrical equipment for measurement,
control and laboratory.
EMC Emissions Table 4, Class B of EN61326
EMC Immunity** Table 1 of EN61326
Note: **I/O signal and control lines require shielded cables and these cables
must be located on conductive cable trays or in conduits. Furthermore,
the length of these cables should not exceed 30 meters
Refer to the EMC and Safety installation considerations (Guidelines) of this manual
for additional information.
64
NOTES
65
NOTES
66
Warranty/Disclaimer
NEWPORT Electronics, Inc. warrants this unit to be free of defects in materials and workmanship for a period of one
(1) year from the date of purchase. In addition to NEWPORTs standard warranty period, NEWPORT Electronics will
extend the warranty period for four (4) additional years if the warranty card enclosed with each instrument is
returned to NEWPORT.
If the unit should malfunction, it must be returned to the factory for evaluation. NEWPORTs Customer Service
Department will issue an Authorized Return (AR) number immediately upon phone or written request. Upon
examination by NEWPORT, if the unit is found to be defective it will be repaired or replaced at no charge.
NEWPORTs WARRANTY does not apply to defects resulting from any action of the purchaser, including but not
limited to mishandling, improper interfacing, operation outside of design limits, improper repair, or unauthorized
modification. This WARRANTY is VOID if the unit shows evidence of having been tampered with or shows evidence
of being damaged as a result of excessive corrosion; or current, heat, moisture or vibration; improper specification;
misapplication; misuse or other operating conditions outside of NEWPORTs control. Components which wear are not
warranted, including but not limited to contact points, fuses, and triacs.
NEWPORT is pleased to offer suggestions on the use of its various products. However, NEWPORT neither
assumes responsibility for any omissions or errors nor assumes liability for any damages that result from
the use of its products in accordance with information provided by NEWPORT, either verbal or written.
NEWPORT warrants only that the parts manufactured by it will be as specified and free of defects.
NEWPORT MAKES NO OTHER WARRANTIES OR REPRESENTATIONS OF ANY KIND WHATSOEVER,
EXPRESSED OR IMPLIED, EXCEPT THAT OF TITLE, AND ALL IMPLIED WARRANTIES INCLUDING ANY
WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY
DISCLAIMED. LIMITATION OF LIABILITY: The remedies of purchaser set forth herein are exclusive and the
total liability of NEWPORT with respect to this order, whether based on contract, warranty, negligence,
indemnification, strict liability or otherwise, shall not exceed the purchase price of the component upon
which liability is based. In no event shall NEWPORT be liable for consequential, incidental or special
damages.
CONDITIONS: Equipment sold by NEWPORT is not intended to be used, nor shall it be used: (1) as a Basic
Component under 10 CFR 21 (NRC), used in or with any nuclear installation or activity; or (2) in medical applications
or used on humans. Should any Product(s) be used in or with any nuclear installation or activity, medical application,
or used on humans, or misused in any way, NEWPORT assumes no responsibility as set forth in our basic
WARRANTY / DISCLAIMER language, and additionally purchaser will indemnify NEWPORT and hold NEWPORT
harmless from any liability or damage whatsoever arising out of the use of the Product(s) in such a manner.
Return Requests/Inquiries
Direct all warranty and repair requests/inquiries to the NEWPORT Customer Service Department.
BEFORE RETURNING ANY PRODUCT(S) TO NEWPORT, PURCHASER MUST OBTAIN AN
AUTHORIZED RETURN (AR) NUMBER FROM NEWPORTS CUSTOMER SERVICE DEPARTMENT (IN
ORDER TO AVOID PROCESSING DELAYS). The assigned AR number should then be marked on the
outside of the return package and on any correspondence.
The purchaser is responsible for shipping charges, freight, insurance and proper packaging to prevent
breakage in transit.
FOR WARRANTY RETURNS, please have the FOR NON-WARRANTY REPAIRS, consult
following information available BEFORE NEWPORT for current repair charges. Have the
contacting NEWPORT: following information available BEFORE contacting
1. P.O. number under which the product was NEWPORT:
PURCHASED, 1. P.O. number to cover the COST of
2. Model and serial number of the product the repair,
under warranty, and 2. Model and serial number of product, and
3. Repair instructions and/or specific 3. Repair instructions and/or specific problems
problems relative to the product. relative to the product.
NEWPORTs policy is to make running changes, not model changes, whenever an improvement is possible.
This affords our customers the latest in technology and engineering.
NEWPORT is a registered trademark of NEWPORT Electronics, Inc.
Copyright 2006 NEWPORT Electronics, Inc. All rights reserved. This document may not be copied,
photocopied, reproduced, translated, or reduced to any electronic medium or machine-readable form, in
whole or in part, without prior written consent of NEWPORT Electronics, Inc.
For immediate technical or application assistance please call:
Newport Electronics, Inc.

2229 South Yale Street Santa Ana, CA 92704 U.S.A.
TEL: (714) 540-4914 FAX: (203) 968-7311
Toll Free: 1-800-639-7678 www.newportUS.com e-mail:info@newportUS.com
ISO 9001 Certified
Newport Technologies, Inc.

976 Bergar Laval (Quebec) H7L 5A1 Canada
TEL: (514) 335-3183 FAX: (514) 856-6886
Toll Free: 1-800-639-7678 www.newport.ca e-mail:info@newport.ca
Newport Electronics, Ltd.

One Omega Drive River Bend Technology Centre
Northbank, Irlam Manchester M44 5BD United Kingdom
Tel: +44 161 777 6611 FAX: +44 161 777 6622
Toll Free: 0800 488 488 www.newportuk.co.uk e-mail:sales@newportuk.co.uk
Newport Electronics spol s.r.o.

Frystatska 184, 733 01 Karvin Czech Republic
TEL: +420 59 6311899 FAX: +420 59 6311114
Toll Free: 0800-1-66342 www.newport.cz e-mail: info@newport.cz
Newport Electronics GmbH

Daimlerstrasse 26 D-75392 Deckenpfronn Germany
TEL: 49 7056 9398-0 FAX: 49 7056 9398-29
Toll Free: 0800 / 6397678 www.newport.de e-mail: sales@newport.de
Mexico and Latin America

FAX: 001 (203) 359-7807
En Espaol: 001 (203) 359-7803
M3355/N/0906

SOLENOID VALVES . . .
MAINTENANCE AND CLEANING INSTRUCTIONS

SERIES 20, 30, & 50 VALVES
1. Shut off the pressure to the valve and electric current. The valve 4. If the valve develops a loud buzzing noise, examine the inside of
need not be removed from the line. the sleeve assembly and upper portion of the plunger and remove
all foreign matter imbedded in these parts. Caution: in Three-Way
2. Remove nut at the top of the housing. Bottom flux plate (if present), and Two-Way Normally Open Valves, be careful not to damage the
housing and coil can then be removed from the body (the series 70 sleeve seat. Do not clean plunger assembly or seals with any type
also has a Yoke inside the housing). cleaning fluid.
3. Using the special Peter Paul wrench (Part GP-010, GP-007 or GP- REASSEMBLY:
191) unscrew the sleeve assembly from the body. DO NOT use a Reassemble the valve by following the disassembly procedure in
pipe wrench, since a wrench may crush or mar the sleeve assembly reverse order. Make sure the seal of the flange end of the assembly
and make the valve inoperative. and the return spring are in place when the sleeve is screwed into
the body. After screwing the flange into the body and before
INSPECTION assembling the coil to the valve, it is advisable to apply pressure to
1. If the valve fails to operate, the coil and control circuitry should be the port which leads to the body chamber and check for leakage
checked to make sure it is not burned out or open. around the flange. If the valve has a sleeve port, this port at the top
of the valve must be capped to make this test. If the medium is air
2. Occasionally, if mishandled, valves may leak at the flange seal. If or gas, leakage can be noted by applying water to the joint and
the medium is a liquid, such a leak may damage the coil. A flange watching for air bubbles. If the medium is liquid, leakage is readily
leak may be corrected by tightening the sleeve assembly into the apparent. DO NOT tighten the nut at the top of the coil housing
valve body or replacing the gasket. Use wrench, Peter Paul Part excessively, since doing so will put undue strain on the sleeve
GP-418 or GP-191. assembly.
3. If the valve leaks at the seat or the plunger sticks in the energized REPLACEMENT PARTS:
position, examine the soft inserts in the plunger and the inside of Orders for replacement parts should include (1) Part Description,
the sleeve assembly for the presence of excessive dirt or wear. If (2) Valve number, (3) Voltage.
the inserts show considerable wear, the plunger should be
replaced.
Install in 5 minutes
Directions:
With wrench supplied remove top nut and housing. Using the
same wrench remove sleeve assembly plunger, spring, and seal.
Discard all these underlined items do not re-use any portion of them.
Insert new components supplied. The re-assembled valve is ready for

service. This simple operation brings the valve to the original
performance level.
When ordering repair packs, add AC or DC to complete pack

number
(example) Pack No. K 21GDX AC
Repair pack consists of: Sleeve Assembly-Plunger-Spring-Seals-

Wrench
Repair packs are listed along side of corresponding valve numbers

beginning on page 6.
Consult factory for repair packs not listed.
REPAIR PACKS Install in 5 minutes
Another Peter-Paul innovation. The pack consists of critical

components necessary to bring valves back into service, quickly and
conveniently. The life of our quality valves can be extended
economically and effectively in this manner.
82
HORIBA
ENDA-4000 Series Priority A
Consumable Spare Parts List
QTY. PER
PART NO. SYSTEM DESCRIPTION PRIORITY
100682 1 Thermal Compound A
100726 3 Tubing, Peristaltic Pump (Norprene) per foot A
100828 1 Silicone Grease, 5g packet A
303002 1 Mist Catcher (6 per set) A
303126 2 Diaphragm Assembly for Pumps (GP-2201) A
384270 1 Primary Filter (12 per set) A
384272 1 Holder Cap for Primary Filter (10 per set) A
384273 1 Element Cap for Primary Filter (10 per set) A
384280 1 Diaphragm Assembly for Low CO Pumps A
503748 2 Secondary Filters (10 per box) A
200930-1 1 NOx Converter Tube (NOx /SO2 Option) A
253767-1 1 NOx Converter Recharge Tube (NOx Option) A
253768-1 1 Purifier Recharge Tube (CO Option) A
F020032900 5 O-Ring for Primary Filter A
ENDA 4000 SPARE PARTS A

Printed on 7/25/2013
Page 1 of 2
HORIBA
ENDA-4000 Series Priority B & C
Recommended Spare Parts List
QTY. PER
300005 1 Capillary, SA-102-QJ (All) B
303128 1 Pump GP2201 B
320050 4 Filter P8 B
380033 2 Packing, Sheet (for solenoids) B
383979 2 Connector, Viton 6 x 3mm B
383983 2 Connector Viton 6 x 3mm B
384381 2 Connector Elbow Viton 6 x 3mm B
385132 2 O-Ring P3 B
385442 2 Capillary, SA-201-QJ (All) B
503212 1 Check Valve, 1 PSI (probe) B
503354 1 Solenoid Valve 2-way (Shelter Only) B
503585 2 Connector, 1/4 x 1/4 B
503653 2 Connector, 1/4 x 6mmT Teflon B
503700 1 Impinger 5" Stainless Steel B
503709 1 Elbow 1/8 x 1/4 B
503733 1 Connector Reducing 5/32B x 3/16 B
503734 1 Orifice, Barbed (for VSW1) B
503744 2 Connector, Barbed 3/8 x 5/16 B
503749 1 Valve, Needle TFE B
503750 1 Filter Housing (Kynar) B
512746 1 Temperature Controller, Digital B
512851 2 Fuse 2 Amp B
512985 2 Fuse 3 Amp PC Board B
512986 2 Fuse 1 Amp PC Board B
519203 6 Fuse 5 Amp B
519371 2 Fuse 6 Amp B
529095 1 Solenoid Valve, 120VAC (blowback prb) B
530429 1 Fan, for TEC (HII p/n 530475 & 476) B
F022861200 2 Gasket, Graphite (Probe) B
H230732-01 1 SV. Pattern (SV block) B
H434654-02 2 Connector, Viton 8 x 6 mm B
H465413-05 2 Connector Elbow Viton 6 x 6mm B
H534574-01 1 Elbow Viton 8 x 6 mm B
H569526-01 1 Block, Fitting B
G201581 2 SV. Assembly MV-14, (SV1 SV2) B
100695 1 Tubing Viton 5/16 x7/16 C
100696 5 Tubing Tygon 3/8 x 9/16 C
100697 1 Tubing Viton 3/16 x 5/16 C
100698 5 Tubing Tygon 5/16 x 1/2 C
100699 5 Tubing Tygon 1/2 x 11/16 C
100700 10 Tubing Tygon 3/8 x 3/16 C
100702 1 Tubing Viton 16 C
385162 1 Fan D09T-24PH C
503735 1 Switch, Vacuum C
503746 1 Flowmeter with valve (FM1) C
510224 1 Power Supply 24 VDC C
519131 1 Vent Fan 3" C
530475 1 Cooler, Thermoelectric C
602295 1 Hanger 3" PVC C
253768-1 1 PUR-1D Catalyst Tube C
ENDA 4000 SPARE PARTS B&C
Page 2 of 2
ENDA-4000 Series Priority B & C

Recommended Spare Parts List
QTY. PER
U801439800 1 PCB Assembly PG-AMP-03 (NDIR) C
Select the applicable bench units required for the particular application:
310515-1 1 Bench Unit CO2 (NDIR) C
310497 1 Bench Unit CO NDIR C
ENDA 4000 SPARE PARTS B&C


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INSTRUMENTS INC.

HORIBA INSTRUMENTS INCORPORATED

SECTION 1 OPERATION MANUAL FOR HORIBA ENDA-4000

SECTION 2 STANDARD MANUFACTURERS MANUALS

SECTION 3 HORIBA PARTS LIST 256894-1

SECTION 4 ENDA-4000 RECOMMENDED SPARE PARTS LIST

SECTION 5 QUALITY ASSURANCE CHECK-OUT LIST & CERTIFICATE

SECTION 6 HORIBA DRAWINGS

201160 Probe Assembly Diagram (2 pages)

Horiba Manual No.: 93130-1

HORIBA INSTRUMENTS INCORPORATED

HORIBA ENDA 4000

Copyright 1995, 1996, 1997 HORIBA INSTRUMENTS, Inc.

All Rights Reserved.

ENDA-4000 and XS are trademarks of Horiba Instruments, Inc.

Hewlett-Packard and HP are trademarks of Hewlett Packard Company.

IBM is a registered trademark of International Business Machines Corporation.

LapLink is a registered trademark of Traveling Software, Inc.

Snoop is a registered trademark of the Scott Specialty Gases division of Scott

All other trademarks are the property of their respective owners.

HORIBA INSTRUMENTS INCORPORATED

Horiba Recycling Policy

Thank you for helping Horiba to protect our environment.

How to Use This Manual

Instructions for Advanced Users

This manual is designed to be useful to personnel at various levels of experience. Users

How This Manual is Organized

This manual is organized as follows:

Chapter 1, Introduction to the ENDA-4000, describes the physical components of the

Chapter 2, ENDA-4000 Hardware Description, presents an in-depth study of all

Chapter 5, Operation, explains everyday operation of the ENDA-4000.

Chapter 6, Maintenance, provides details on scheduled and as-needed maintenance.

Chapter 7, Troubleshooting and Service, explains various options for solving

Warnings and Cautions

READ AND UNDERSTAND THESE IMPORTANT SAFETY

DANGER: The ENDA-4000 enclosure contains electrically energized components.

1WARNING: The ENDA-4000 must be connected to a leak-tight ventilation line that

Horiba Instruments iii

IMPORTANT: Only qualified personnel should perform ENDA-4000 calibration,

IMPORTANT: The ENDA-4000 should be operated only by trained and qualified

lpm Liters per minute

1.0 Introduction .............................................................................. 1-1

2.0 ENDA-4000 Hardware Description .......................................... 2-1

Horiba Instruments vii

2.4.2.8. Mist Catcher (MC1)........................................................................................ 2-13

3.0 Theory of Operation................................................................. 3-1

4.0 XS Analyzer ............................................................................. 4-1

viii Horiba Instruments

4.5.1 Blowback Setup In-Blow Time ........................................................................... 4-19

5.0 Operation ................................................................................. 5-1

6.0 Maintenance ............................................................................ 6-1

7.0 Troubleshooting and Service ................................................... 7-1

8.0 Installation................................................................................ 8-1

8.2.6 Signal and Control Wiring ....................................................................................... 8-6

9.0 System Verification Checks ..................................................... 9-1

10.0 Analyzer Parts List................................................................. 10-1

xii Horiba Instruments

1.2 Overview of Operation

1.2.1 Sample Probe and Primary Filter Assembly

Horiba Instruments 1-1

1.2.2 Sample Line

Figure 1-1: ENDA-4000 Simplified Schematic

1-2 Horiba Instruments