STACK - Procal 2000 Operating Manual

PROCAL 2000
Analyser Unit
Operating Manual
PROCAL 2000 Operating Manual
Kittiwake Procal Limited
Published by Kittiwake Procal Limited.
All possible care has been taken in the preparation of this publication, but
Kittiwake Procal Ltd its agents and distributors, accept no liability for any
inaccuracies that may be found.
Kittiwake Procal Limited reserves the right to make changes without notice both
to this publication and the products which it describes.
No part of this publication may be reproduced, stored in a retrieval system or

transmitted in any form or by any means electronic, mechanical, photocopying,
recording or otherwise without the express prior written permission of the
copyright holder.
Part Number 7-3204-04 Issue 02 August 2011
© Kittiwake Procal Limited 2004 - 2011
Kittiwake Procal Limited

5 Maxwell Road
Woodston
PETERBOROUGH PE2 7HU
United Kingdom
PROCAL, PULSI and XSENS are trademarks of Kittiwake Procal Limited.
page 2 KITTIWAKE PROCAL LTD Issue 4

Contents
1 Introduction ........................................................................................................... 1-1

About this manual ............................................................................................................................. 1-1
About the PROCAL 2000 series ....................................................................................................... 1-1
PROCAL 2000 - an overview............................................................................................................ 1-2
Documentation conventions.............................................................................................................. 1-4
Further Information............................................................................................................................ 1-5
2 Installation ............................................................................................................. 2-1

Introduction........................................................................................................................................ 2-1
Unpacking the system components .................................................................................................. 2-1
Pre-installation information ............................................................................................................... 2-2
Preparing the process gas duct ........................................................................................................ 2-3
Preparing the Analyser Unit .............................................................................................................. 2-5
Auto Zero/Verification Units .............................................................................................................. 2-11
Verifying Correct Zero/Test Gas Flow Rate ...................................................................................... 2-13
3 Operation ............................................................................................................... 3-1

Introduction........................................................................................................................................ 3-1
4 Technical description ........................................................................................... 4-1

Introduction........................................................................................................................................ 4-1
Infra-red absorption theory................................................................................................................ 4-1
IR theory applied to the PROCAL 2000 ............................................................................................ 4-3
Cross-sensitivity ................................................................................................................................ 4-4
Gas filter correlation .......................................................................................................................... 4-4
Analyser Unit ..................................................................................................................................... 4-8
Integral Auto Verification Unit ........................................................................................................... 4-10
5 Maintenance .......................................................................................................... 5-1

Introduction........................................................................................................................................ 5-1
Routine maintenance schedule......................................................................................................... 5-1
Cleaning ............................................................................................................................................ 5-2
Field calibration check....................................................................................................................... 5-3
Sintered Panel Flow Test .................................................................................................................. 5-5
Fault-finding....................................................................................................................................... 5-6
Repair policy...................................................................................................................................... 5-7
Spares list.......................................................................................................................................... 5-8
Changing PROCAL 2000 components ............................................................................................. 5-8
Changing the filter wheel motor ........................................................................................................ 5-11
6 Disposal instructions............................................................................................ 6-1

Introduction........................................................................................................................................ 6-1
Zinc Selenide optics .......................................................................................................................... 6-1
7 Order-specific information ................................................................................... 7-1

Introduction........................................................................................................................................ 7-1
7-5823-00 Air Specification............................................................................................................... 7-3
Appendix A - The PROCAL 2000 with ATEX/IECEx approval .............................. A-1

Appendix B – Procal Controllers with Input Output Unit ..................................... B-1
Appendix C – Quality Standard for Instrument Air………………………............... C-1
Appendix D - In-Situ Heater..................................................................................... D-1
Appendix F - Procal analysers for US EPA compliance....................................... F-1
Appendix G - Procal analysers with Hot Access Port .......................................... G-1
Appendix H – By-Pass ............................................................................................. H-1
Appendix J – In-Situ Steam Heater......................................................................... J-1
Appendix K – Steam Heater By Pass ..................................................................... K-1
Appendix L – Air Preparation Panel ....................................................................... L-1
In-service history
Issue 4 KITTIWAKE PROCAL LTD page 3

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page 4 KITTIWAKE PROCAL LTD Issue 4

1 Introduction
About this manual
This manual is intended to assist the user in the safe and efficient installation,
operation and maintenance of the Procal 2000 series of analyser units. It has
been written in accordance with the requirements of British Standard BS4884
Technical manuals Part 1: 1992.
It is split into a number of sections. Introduction (this section) gives a brief

overview of both this manual and the systems which it describes, together with
sources of further information and product support. Installation gives pre-
installation information and goes on to describe how a PROCAL 2000 system is
installed. Operation gives information necessary to operate the analyser unit.
Technical description gives the background to the principles behind the
operation of the analyser and describes the system, but is not required reading
for a routine operator. Maintenance lists and describes routine maintenance
tasks, and provides fault finding information down to the level of user-
replaceable parts. Calibration instructions are given, together with spares lists.
Disposal instructions details how the analyser and peripherals may be disposed
of safely and without environmental damage. Order-specific information gives
additional information specific to the instrument you have purchased. Appendix
A gives details of the ATEX and IECEx approvals, which may be applicable.
Appendix B gives details of the Input Output Unit, Appendix D describes the
optional In-Situ Heater and how it should be installed. Appendix F covers issues
involved with US EPA compliance. Appendix G covers issues involved with the
Hot Access Port.
About the PROCAL 2000 series
The PROCAL 2000 series is a range of high-performance infrared gas

process/emission analyser systems. These systems are intended to be used for
measuring gas concentrations, particularly in continuous industrial processes and
flue stacks.
Principles behind the system are described in the section entitled Technical
description, together with descriptions of the different component parts that
make up the system. Every system including a PROCAL 2000 Analyser Unit
also incorporates an Analyser Controller. An In-Situ Heater (ISH) is available
as an option, as an Input Output Unit (IOU).
The Procal 1100 (Analyser Control for Windows Network software only for
installation on customer support PC) which can control up to Six Analyser Units,
is supplied with its own Operating Manual. Information relating to additional
equipment that can be used in the system is given in this manual and in the
Procal 1200 manual.
Issue 4 KITTIWAKE PROCAL LTD page 1-1

PROCAL 2000 - an overview
Within the PROCAL 2000, up to six gases may be measured on up to six

channels. The second digit of the model number indicates the number of
measuring channels. For example, the PROCAL 2030 has three measuring
channels.
An optical diagram of the PROCAL 2000 system is shown in Figure 1-1 below.
Filtered IR radiation passes from the Analyser Unit into the sample cell, which is
fitted into the process duct. This sample cell has sintered panels, so allowing the
gas under study to permeate through the sample cell. IR radiation passes
through the sample gas, is reflected by a retro-reflector, and passes through the
sample gas once more back to the Analyser Unit. A PT100 platinum resistance
thermometer is situated in the sample cell. This provides temperature
information to the Procal 1000 series, which acts as the basis for the temperature
compensation.
The Procal 2000 has a built in Auto Verification Unit (AVU) which enables both
automatic and manual purging of the In-Situ Sample Cell.
Figure 1-1 PROCAL 2000 optical diagram
A schematic diagram of the PROCAL 2000 system appears as Figure 1-2

opposite. This shows the various interconnections between different parts of the
system, and some of the external devices that may be connected to the Procal
1000 Analyser Controller.
page 1-2 KITTIWAKE PROCAL LTD Issue 4

1 Introduction
Procal 1200
Stack
Procal 2000
Optional Outputs
110V / 240V
Local PSU
110V / 240V
Calibration Gas
Figure 1-2 PROCAL 2000 system schematic
The Procal 1200 is an Analyser Control Unit which is supplied with Procal 1100 (ACW) software
installed and optionally an internal Input/Output Unit Integrally mounted.

Documentation conventions
Abbreviations
Within this manual, the following abbreviations are used:
Procal 1000 Series

 Procal 1100 (Software supplied to be installed on conventional PC)
formerly known as ACWn
 Procal 1200 (Packaged panel PC with optional I/O Unit) formerly
known as the ACU Mk 4
IOU Input Output Unit
IR Infra-red
ISH In-Situ Heater
AU Analyser Unit
Lists
Often in this manual, instructions or information are presented in list form. Use
of black squares  indicates that there is no special order to the instructions
or information. However, when instructions are numbered, it is important that
the individual instructions or points are followed sequentially.
Figures
Figures in the text are always numbered in the form Figure X-Y, where X is the
section number, and Y is the sequential figure number within that section. For
example, Figure 3-2 is the second figure in section 3. When a figure reference is
in brackets (Figure 9-4), this refers you to that figure, usually to confirm the
location of a component, control or indicator.
Screen displays
Screen displays on the Procal 1000 are presented in this manual as
approximations. When values are shown on screens, it should be remembered
that these appear by way of example only. It is highly unlikely that the values
displayed on your screen will be the same as in this manual.
Some systems will have different screens because of custom modifications. If

so, this will be highlighted in the section of this manual entitled Order-specific
information.
Screen messages, prompts or options are repeated in text in a different typeface

to the main text, for example: Auto-zero NOW.
Italics
Paragraphs in italics usually indicate background information which may be of
benefit to the reader. Groups of words in italics are usually cross-referring the
reader to a section or sub-section by name.

1 Introduction
Dimensions
All dimensions in this Operating Manual are in mm (millimetres) unless
otherwise indicated.
Analyser Identification
Instrument Identification
Fig 1-3
It is important to identify the analyser and ensure it is correctly located especially in

multi analyser systems.
In all correspondence associated with the analyser please use the serial number.
Further information
This Operating Manual, when used in conjunction with the Operating Manual
for the Procal 1000 series, should give you all the information you require to
install, operate and dispose of your PROCAL 2000 system. If you require any
further information regarding the system or its use, you should contact Kittiwake
Procal Ltd., or your Procal distributor or agent as shown in the panel below:
Kittiwake Procal Ltd

5 Maxwell Road
Woodston
PETERBOROUGH PE2 7HU
United Kingdom
tel: +44 1733 232495 (international)

01733 232495 (within the UK)
fax: +44 1733 235255 (international)
01733 235255 (within the UK)
e-mail: post@procal.com
internet: www.procal.com


2 Installation
Introduction
This section describes how to install the standard PROCAL 2000 Analyser.
WARNINGS
YOU MUST NOT ATTEMPT TO INSTALL THIS SYSTEM UNLESS YOU ARE
QUALIFIED, COMPETENT AND AUTHORIZED TO WORK ON ELECTRICAL
EQUIPMENT OPERATING AT YOUR LOCAL MAINS ELECTRICAL SUPPLY
VOLTAGE.
READ THIS SECTION IN ITS ENTIRETY BEFORE ATTEMPTING TO
INSTALL ANY PART OF THE SYSTEM. IF THERE IS ANYTHING YOU DO
NOT UNDERSTAND, OR YOU DO NOT FEEL CONFIDENT OF YOUR
ABILITY TO FOLLOW THE INSTALLATION INSTRUCTIONS, DO NOT
PROCEED. CONTACT KITTIWAKE PROCAL OR YOUR PROCAL-
AUTHORISED DISTRIBUTOR.
ALWAYS ENSURE THAT YOU HAVE A VALID PERMIT TO WORK ON THE
PIPEWORK OR DUCTING TO WHICH THE PROCAL 2000 ANALYSER UNIT
IS TO BE FITTED.
ALWAYS ENSURE THAT YOU COMPLY WITH LOCAL SAFETY

REGULATIONS AND PROCEDURES.
INSTALLATION OF AN INSTRUMENT AIR PURGE SUPPLY MUST BE
COMPLETED BEFORE MOUNTING THE INSTRUMENT ON THE PROCESS
GAS DUCT, TO AVOID POSSIBLE DAMAGE.
Caution
The PROCAL 2000 Analyser Unit contains factory-set optical components. No
alignment or focusing of these components is required during installation or
operation. Adjustment of any mirrors, lenses or filters may invalidate the
warranty and will almost certainly prevent the system from functioning properly.
Unpacking the system components

If this has not already been done, unpack the system components and check that they
correspond to the units ordered and listed on the accompanying packing note. If there
is any discrepancy, or any damage is apparent, do not attempt to install the system.
Contact Kittiwake Procal, or your Procal distributor or agent.

Pre-installation information
Before installing the system, you must confirm that:
 Suitable locations are available for all components of the system to be

installed
 Using the instrument serial number check the analyser is being installed in
the correct location.
 A suitably fused, switched, mains electrical power is available at 110 V /

230 V single-phase 50-60 Hz 1100W, adjacent to where the AU will be
fitted
 Sufficient working space for two people to work is available around the
point at which each Analyser Unit is to be fitted. The working platform
should be adequately fenced
 Clean and dry instrument air, (Procal Standard ISO 8573-1 1 2 1 see 7-5823-
00 in Appendix C) at up to 10 l/min (intermittent) and 6.0 barG maximum
(nominal inlet pressure 2.5 to 3 barG) is available adjacent to where the AU
will be fitted
 The cable route from Analyser Unit to Procal 1000 is not more than 1,000
m (greater distances may be possible: please consult Procal)
 All the interconnecting cables specified in this installation procedure are

available.
 In the section of this manual entitled Order-specific information, you will

find PROCAL installation drawings which may be useful during
installation. The precise nature of these drawings will vary, depending on
the PROCAL 2000 model, the mains electrical voltage, the options supplied
and the configuration.
An optimum flange installation into a process duct is shown in Figure 2-1 below.
200mm
Instrument Identification (8”)
and serial number Minimum
Stack
Flange
Stack
Insulation
Figure 2-1 Optimum flange installation of the AU into a process duct

2 Installation
Preparing the process gas duct

A special flange must be welded directly to the process duct to form a gas-tight entry
exactly as shown in Figure 2-2. This flange may be manufactured from a
3 inch, 150 lb ANSI flange. This item is available from Procal, part number 4-1114
The mating surface of the process duct flange must be of a quality that will allow a gas-
tight joint to be made when a gasket is used between the flange and the Analyser Unit
(or In-Situ Heater if fitted). The use of a flange and stub arrangement should be
avoided unless absolutely necessary, since this could lead to acidic condensation
forming. Figure 2-2 below gives mounting details for the flange.
Figure 2-2 Flange Mounting

Stack Flange – Good Practice
M16 Studs
Preferred – With the flange wielded directly to the

stack, duct or process pipe
Stack, duct or process pipe
50mm
Acceptable – With an insulated standoff of up to

50mm
Insulation
Un‐acceptable

2 Installation
Preparing the Analyser Unit for Wiring

During preparation of the Analyser Unit, you may need to refer to the relevant
wiring table or Order-specific information installation drawing in the section of
this manual, particularly if you will be making up your own interconnecting
cables.
1. Place the Analyser Unit (AU) carefully on the ground or workbench,

such that it is stable and horizontal.
2. Remove and retain the Four 5 mm pozi drive screws securing the
cover of the Junction Box on the side of the GRP cover.
3. Identify the system wiring configuration to suit your installation
a. Option 1 Analyser (AU) → Procal 1200 (ACU MK 4)

with Remote Power Supply Unit (PSU)
b. Option 2 Analyser (AU) → Procal 1100 (ACWn) with

Remote Power Supply Unit (PSU)
c. Option 3 Analyser (AU) → Power Supply Unit (PSU)

1-1971 → Procal 1200 (ACU MK 4)
d. Option 4 Analyser (AU) → Power Supply Unit (PSU)

1-1971 → Procal 1100 (ACWn)
Remove Cover to Access

Terminal Block TB1
Figure 2‐3

4. Locate the relevant cable as identified in the wiring tables. Gently feed this
end of the cable through the cable gland underneath the AU junction box.
You should leave a 'loop' in the cable so that the AU can be withdrawn from
the process duct without disconnecting the cable.
5. Repeat this procedure for all cables as indicated in the wiring table relevant
to the installation.
a. Connecting additional analysers Analyser 1 → Analyser 2 →

Analyser 3 → Analyser 4
b. Connecting Auxiliary Inputs → Analyser
c. Connecting In-Situ Heater → Analyser
Figure 2-4

2 Installation
Wiring Table
Option 1 - Analyser → Procal 1200 (ACU MK 4) with Remote Power Supply Unit (PSU) (see drawing 7-2498)
Procal 1200 (ACU MK 4 Cable Specification
Function Analyser Terminal Box
+ IOU)
Data Return B TB1 – 1B TS6 - 1 2 Twisted pair with O/All screened Znom
50-120ohms Belden 9842 or equivalent
Data Return A TB1 – 2B TS6 - 2
Data Out B TB1 – 3B TS6 - 3
Data Out A TB1 –4B TS6 - 4
Screen Not Connected TS6 - 7
+24 V TB1 – 26B 2 core 1.5mm2 unscreened

From Remote PSU
0V TB1 – 29B
Option 2 - Analyser → Procal 1100 (ACWn) with Remote Power Supply Unit (PSU) (see drawing 7-2103)
Procal 1100 (ACWn) (1- Cable Specification
Function Analyser Terminal Box
2773) (TX100I)
Data Return B TB1 – 1B RX-(A) O/All screened Znom 50-120ohms Belden
9842 or equivalent
Data Return A TB1 – 2B RX-(B)
Data Out B TB1 – 3B TX-(A)
Data Out A TB1 –40B TX-(B)
Screen Not Connected SGND
+24 V TB1 – 26B 2 core 1.5mm2 unscreened

From Remote PSU
0V TB1 – 29B
Option 3 Analyser → Power Supply Unit (PSU) 1-1971 → Procal 1200 (ACU MK 4)
Analyser Terminal Box Power Supply Unit (PSU) 1-1971 Procal 1200 (ACU MK 4)
Cable 1 Cable 1 Cable 2 A/B Cable 2A Cable 2B
Function ACU ACU
AU IN Mk4 + Mk4 2 Twisted
1OU (A53) pair with
O/All
Data Return B TB1 – 1B TB1 – 7B 6B TS6 - 1 TB-4
screened
Data Return A TB1 – 2B TB1 – 10B 9B TS6 - 2 TB-3 Znom 50-
120ohms
Data Out B TB1 – 3B TB1 – 13B 12B TS6 - 3 TB-2 Belden
9842 or
Data Out A TB1 – 4B TB1 – 16B 15B TS6 - 4 TB-1 equivalent
Screen Not Connected TB1-3B N/C TS6 - 7 TB-5
+24 V TB1 – 26B TB1 – 5B N/A N/A 2 core
1.5mm2
0V TB1 – 29B TB1 – 4B N/A N/A unscreened

Option 4 Analyser → Power Supply Unit (PSU) 1-1971 → Procal 1100 (ACWn)
Power Supply Unit (PSU) 1- Procal 1100 Cable Specification
Analyser Terminal
Function 1971 (ACWn) (See 7-
Box
AU IN 2103) (TC100I)
Data Return 2 Twisted pair with
TB1 – 1B TB1 – 7B TB1 – 6B RX-A
B O/All screened Znom
Data Return 50-120ohms Belden
A
TB1 – 2B TB1–10B TB1 – 9B RX-B 9842 or equivalent
Data Out B TB1 – 3B TB1–13B TB1 – 12B RX-A
Data Out A TB1 – 4B TB1– 16B TB1 – 15B RX-B
Screen Not Connected TB1– 3B Not Connected SGND
+24 V TB1 – 26B TB1 – 5B N/A 2 core 1.5mm2
unscreened
0V TB1 – 29B TB1 – 4B N/A
Connecting additional Analysers Analyser 1 → Analyser 2 → Analyser 3 → Analyser 4

Analyser 1 Terminal Analyser 2 Terminal Analyser 3 Terminal Analyser 4 Terminal
Function Box Box Box Box
OUT IN OUT IN OUT IN
Data Return B TB1-7B 1B 7B 1B 7B TB1 – 1B
Data Return A TB1-8B 2B 8B 2B 8B TB1 – 2B
Data Out B TB1-9B 3B 9B 3B 9B TB1 – 3B
Data Out A TB1-10B 4B 10B 4B 10B TB1 – 4B

Not Not
Screen Not Connected 6B 6B TB1-6B
Connected Connected
TB1-26B TB1 – 26B TB1-26B TB1 – 26B
+24 V
(Remote PSU #1) (Remote PSU #2) (Remote PSU #3) (Remote PSU #4)
TB1-29B TB1 – 29B TB1-29B TB1 – 29B (Remote
0V
(Remote PSU #1) (Remote PSU #2) (Remote PSU #3) PSU #4)
Connecting Auxiliary Inputs → Analyser

Analyser Terminal
Function
Box
AUX I/P -VE TB1 – 20B
AUX I/P1 + TB1 – 17B
Connecting In-Situ Heater → Analyser

Analyser Terminal Cable Specification
Function In-Situ Heater (ISH)
Box
+ 24V DC TB1 – 13B SSR+ 2 Core 0.22mm2
unscreened
Heater SSR TB1 – 15B SSR-

2 Installation
Table 2-1
All unused glands must be sealed before commissioning the analyser
Analyser Covers
Procal analyser’s are fitted with two basic types of Cooler / Heater however there are the following
exceptions:
 Analysers supplied with ATEX / IEC Certification
 Special Application Heater / Coolers
Refer to order specific drawings in these cases.
Option 1 – Fan Cooled Electrically Heated Cover fitted to Product Code:
PROCAL 2000 AC/AVU-F-24V
This type can be identified by the presence of a 100mm spigot protruding from
the base of the analyser cover.
Analyser Mounting Flange
Auto Verification Unit
Spigot
In‐Situ Probe
Analyser Junction Box
Under Side of Fan Cooled Electrically Heated PROCAL 2000 AC/AVU-F-24V Analyser Cover
Figure 2-5
The cover is fitted with an electrical heater and fan which enables the analyser
to operate in ambient temperatures of -30 ºC to +50 ºC. The heater / cooler
function is controlled by the AU, the set point is factory.

Forced air from an integral low voltage electrical fan is channelled past the AU
to draw heat away from the analyser. The Control of the fan is by the Analyser
Unit and cooling capacity is dependent on the ambient air temperature.
Services required – None additional to an AU. Note the Fan requires an
additional 0.8 amp allowance on the 24 Volt power supply. The Heater requires
an additional 2.5 amp allowance on the 24 Volt power supply, Fan and Heater
are not on at the same time.
As the Cover insulates the AU from the ambient air, then if the Fan is disabled
the AU can self-heat to a higher than normal temperature. It is advisable to
configure the system to have a high alarm on the head temperature of +55ºC
and to remove the AU power if this limit is exceeded.
The cover is fitted with a 100mm spigot to enable a flexible hose to be
connected allowing cool air to be ducted to the analyser if installed in a high
ambient temperature environment. Note the analyser will be delivered with a
300mm length of hose if an extended hose is not to be fitted then this should be
attached.
The cover also incorporates as standard an Auto Verification Block internally
piped and wired. The function of Auto Verification Block is described later.
Vortex Air Supply

Analyser Mounting Flange
Vortex Cooler Cover
In‐Situ Probe
Analyser Junction Box
Under Side of Vortex Cooled Electrically Heated PROCAL 2000 AC/AVU-V-24V Analyser Cover
Figure 2-6

2 Installation
Option 2 – Vortex Cooled Electric Heated Cover fitted to Product Code:
PROCAL 2000 AC/AVU-V-24V

This type can be identified by the Vortex Cooler Cover protruding from the base
of the analyser cover.
The cover is fitted with an electrical heater and vortex cooler which enables the
analyser to operate in ambient temperatures of -30 ºC to +65 ºC. The heater /
cooler function is controlled by the AU, the set point is factory set.
The Vortex cooler is a pressurised air powered cooler requiring an air supply;
cooled air is generated by the vortex tube and is used in a special cover to cool
the Analyser Unit. Control of the air supply is by the Analyser Unit. The Vortex
Cooler system is designed to operate with ambient temperatures up to 65ºC
and has a cooling capacity of 20ºC.
Services required - A supply of high-pressure plant air at 6.8-8 bar (100 -110
psi) and 311 l/min (11scfm). (Procal Standard ISO 8573-1242 see 7-5823-00
in appendix C).
As above, a high alarm on the head temperature is required at +55ºC.
The cover also incorporates as standard an Auto Verification Block internally
piped and wired. The function of Auto Verification Block is described below.
Three Solenoid Valves
Figure 2-7
Auto Zero / Verification Units
Both types of covers are fitted with wired and piped Auto Zero / Verification Units to facilitate
automatic zero and verification / calibration routines. It is mandatory that the analyers is configured to
instigate automatic zero’s every 12 or 24 hours depending on application.
Note: The following services are required:

Clean dry instrument air (Procal Standard ISO 8573-1 1 2 1 see 7-5823-00
in Section 7. page 7-2) at pressure of 1 barG above the process gas
pressure, up to a maximum 6.8 barG. The flow-rate available should be
between 0.5 l/min (constant) and up to 10 l/min (intermittent during auto-
zero/auto-purge)
Pressurised gas cylinders (Up to two) containing a known mixture of the

gases under analysis.
 Note the air supply fitted with an appropriate regulator, filter and isolation valve should be
located within 1 meter of the AU.
100mm
Spigot
Figure 2-8
The Auto Zero / Verification function is achieved by activating a series of solenoid valves mounted on
a manifold block. The block is mounted on an access plate which is secured to the Cover by four M4
socket headed screws.
Note: It is not necessary to remove the access plate during installation.
Connection of Zero and Test Gas to the Analyser

Function From To
Zero / Purge Supply Wall Mounted Regulator Set to 2 Barg Analyser Cover Port 1
Calibration Gas Gas Cylinder 1 Regulator Set to 2 Barg Analyser Cover Port 4
Calibration Gas Gas Cylinder 2 Regulator Set to 2 Barg Analyser Cover Port 5
Notes:
All pipe fittings 1/8” BSP
The unit is supplied with all internal wiring and piping necessary for the operation of the analyser

2 Installation
Verifying Correct Zero / Test Gas Flow Rate.
The zero (Instrument Air) and test gas flow rates are controlled by a need valve mounted on the
manifold block. The correct flow is set during the analyser manufacture and therefore there should be
no need to readjust.
The slotted screw flow valve is located on the Auto Verification Unit manifold accessible by removing
the AU outer case.
Figure 2-9
Note: It is important during commissioning that the Zero / Cal Gas flow rate is verified as
process conditions have to be taken into account. To verify that the flow rate is correct the
pressure signal during zero should be approximately 20mbar above process conditions.
If required the flow rate can be adjusted by turning the needle valve mounted within the manifold.
Additional Functions of the Auto Zero / Verification Manifold
 Void Purge
The space in the reflector tube referred to as the void is continuously purge,
the flow rate is controlled using a orifice therefore no adjustment required.
 Analyser Purge
The cast aluminium enclosure containing the main optical components is also
continuously purged, the flow rate is controlled using a orifice therefore no
adjustment required.


3 Operation
Introduction
The Procal 2000 Analyser Unit must be operated as part of a system

incorporating a Procal Analyser Controller. There are no user accessible
controls or indicators on the AU as the whole system operates under the control
of the Procal 1100 or Procal 1200. Full operating instructions for both the
Procal 1100 or Procal 1200 and the complete Procal system are given in the
Operator's Manual supplied with the Procal 1100 or Procal 1200

Procal 2000 Operating Manual

4 Technical description
Introduction
This section outlines the basic theory of infrared measurement of gas

concentrations, and explains how this theory is applied to the PROCAL 2000
range of analysers.
Following a brief overview of the PROCAL 2000, each of the individual

components is described - Analyser Unit, ACU. The optional In-Situ Heater is
described in Appendices to this manual.
This section is intended for those people who need or would like to know how the
Procal 2000 analyser works as a measuring instrument. Understanding the
technical aspects of the analyser and the theory behind its operation are not
necessary for installation and routine operation.
Infra-red absorption theory
Infra-red (IR) radiation lies in the electromagnetic spectrum at wavelengths

between 2 µm and 16 µm (10-6 m). When a beam of broadband IR radiation
passes through most types of gas, the level of IR emerging will be reduced at
certain wavelengths. This is due to absorption by the gas of some of the
radiation at particular wavelengths. The pattern of such absorption - known as
an absorption spectrum - is characteristic of a particular gas. Absorption spectra
are highly effective in identifying gases and concentrations.
A typical absorption spectrum for Carbon Dioxide (CO2) is shown in the

illustration below. It can be seen that CO2 absorbs IR radiation most readily at
wavelengths of 4.4 µm and 2.7 µm. Consequently, these two wavelengths are
widely used in the detection and concentration measurement of CO2.
(CM-1)
5000 2500 2000 1500 1000 700
100 0
80 .1
.2
Transmission%
60
.3
40 .4
.5
Carbon .6
20 Dioxide .8
CO2 1.0
1.5
2 4 6 8 10 12 14
Wavelength(μm)
Figure 4-1 Typical absorption spectrum for CO2.

The amount of radiation absorbed by a gas at its critical wavelength(s) is directly

proportional to the concentration of the gas under study. The illustration below
plots the radiation absorbance of CO2 against its concentration. This plot is
known as a calibration curve. Using this calibration curve allows the
concentration of a CO2 sample to be calculated by measuring its absorbance.
200
160
Absorbance mAu
120
80
40
0 5 10 15 20
CO2 (%)
Figure 4-2 Calibration curve for CO2
Most process gas analysers - including the PROCAL 2000 - operate at a number
of fixed wavelengths, which are chosen according to the gases to be measured.
Within the analyser is an IR source which emits broadband IR radiation. An IR
detector detects the radiation which has passed through the sample gas. With a
single gas, it should be a straightforward matter to measure absorbance, identify
the gas and calculate concentration. In practice, however, there are usually
several gases. More than one gas may exhibit absorption at a given wavelength.
This effect is termed 'cross-sensitivity', and may be compensated for such that
accurate concentrations of individual gases may still be displayed.
IR theory applied to the PROCAL 2000

In the PROCAL 2000, interference filters are placed in the path of the broadband
IR radiation. Two filters are used per component. One selects a measuring
wavelength, while the other selects a reference wavelength. The filters are
mounted on a rotating disc immediately in front of the IR source. This
arrangement gives rise to an IR beam alternating rapidly between measuring
wavelength and reference wavelength for each component. This alternating
beam passes through the gas to be measured, eventually striking the IR detector.
Filters have been selected such that if any of the gas to be measured is present,
then a significant amount of radiation will be absorbed at the measuring
wavelength, with very little or none at the reference wavelength.
The quantity of radiation per unit time is a function of two factors: (1) the
number of molecules within the optical path and (2) the extent to which these
molecules absorb radiation, expressed as the absorption coefficient.
Absorbance may be defined in the following expression:
A = E.C.l = -log10 (IM/IR) + OZ
where: A is the absorbance

E is the Extinction Coefficient
C is the gas concentration
l is the length of sample through which the beam has passed
IM is the IR signal strength at the measuring wavelength
IR is the IR signal strength at the reference frequency
OZ is the zero offset.
It will be seen that there is a logarithmic relationship between the concentration

and the ratio of the IR signal strengths at the measuring and reference
wavelengths.
It is these two signal strengths which are shown on the TEST screen under the
titles measured value and reference value.
During calibration of the analyser, the measured absorbance is recorded for

known sample gas concentrations over the range required for the specific
application. Results of this exercise are recorded within the system's memory in
the form of a look-up table. During live operation of the analyser, the system
calculates concentration levels from absorbance levels by continual reference to
this look-up table.

Cross-sensitivity
While IR absorption measurement is the optimum solution for many continuous

process gas analysis requirements, it is not perfect. Conventional IR analysers
can suffer from the problem of cross-sensitivity, caused when more than one
gaseous component absorbs radiation at a selected wavelength.
Water vapour is the most common component to cause cross-sensitivity,

followed by carbon dioxide. Water vapour exhibits absorption across a wide
part of the IR spectrum. Since most flue emissions contain high percentages of
water vapour, conventional cross-stack IR analysers often suffer from
inaccuracies caused by cross-sensitivity. When using extractive analysers, water
needs to be removed by condensation.
PROCAL 2000 analysers do not suffer appreciably from cross-sensitivity due to

water vapour, carbon dioxide or other 'problem' gases. PROCAL 2000 units
configured for applications where cross-sensitivity would normally be a problem
are equipped with additional measuring channels and the unique PROCxsens
(iterative) calculating software. NOX analysis provides a good example of how
these additions work. Normally, a 3-channel analyser would be used, analysing
NO, NO2 and the sum of these NOX gases. Measurement of NO is subject to
cross-sensitivity to water vapour. So, the PROCAL 2000 for NOX has two
additional undisplayed channels, measuring water vapour and carbon dioxide.
Once the absorbances of these two components at NO measuring wavelengths
are known, they can be compensated for, to arrive at a true figure for NO
concentration.
Gas filter correlation
Gas filter correlation spectroscopy is used in the PROCAL 2000 series of IR

analysers in order to enhance their sensitivity and reduce their cross-sensitivity
to interfering components. This technique is useful for gases at lower
concentrations and those that have a lot of fine structure in their IR spectrum.
The technique effectively increases the resolution of the interference filters used,
which typically have a bandwidth of 2% of their peak transmission wavelength.
In terms of spectroscopy, this is quite broad. Figure 4-3 shows the structured
spectrum of HCl with sharp, narrow bands which are too narrow to be well
matched to the interference filter. The absorption, which is sensed when a filter
on its own is used, is the average absorption rather than the much higher peak
absorption of the HCl gas.
One way of increasing the selectivity of gases when using interference filters is
to use sealed cells filled with the gas under study. Kittiwake Procal has
produced sealed cells filled with HCl, NO, Methane and CO, and is likely to add
other gases to this range. To show how these sealed cells work, refer to Figure
4-4. A matched pair of filters is used with both filters being as similar as
possible in their transmission and wavelength characteristics.

If they were used individually, they would produce identical reference and
measurement pulses at the IR detector, and both would react to the presence of
the gas being measured. The example given is for hydrogen chloride, HCl.
However, if a gas cell filled with HCl is put in series with one of the filters, the
pulses become unbalanced and the pulse caused by the reference filter becomes
weaker. When HCl gas enters the sample tube of the PROCAL analyser, the
measurement pulse falls much more than the reference pulse. The reason for this
is that the reference pulse has been filtered by the sealed cell, so the sharp
narrow bands of wavelength at which HCl absorbs are absent. Therefore, further
absorption by the HCl is small. The measurement pulse, on the other hand,
reacts to HCl in the normal way. Therefore, the introduction of the sealed gas
cell has sensitised the pair of matched filters to HCl.
When interfering gases - such as water vapour - come into the sample cell, both
pulses reduce in almost the same proportion. This is because the water vapour
absorption is broadband and does not follow the same pattern as the HCl
absorption. It therefore causes absorption of both pulses. The method of signal
processing divides the intensity of the measurement pulse by the intensity of the
reference pulse before calculating the absorbance. Therefore, equal,
proportionate changes which occur to both pulses are cancelled out. This shows
that substantial immunity to water vapour and other interfering gases can be
achieved in this elegant fashion.
There are further advantages in the use of gas filter correlation, as opposed to the
conventional use of reference wavelengths. Since the measurement and reference
wavelengths are the same, and as they come from matched filters and only differ
by the filtering caused by the gas in the sealed cell, any effect due to temperature
change of the source also cancels out. When different wavelengths are used
there can still be some effect due to temperature fluctuations in the infra-red
source. The signal-noise ratio has been raised by the use of gas filter correlation,
permitting the measurement of smaller amounts of gas. Kittiwake Procal uses
gas filter correlation in combination with software, such as PROCxsens and
matrix algebra, which enable complete correction to cross-sensitivity to be
achieved, even eliminating the small cross-sensitivities that remain after gas
filter correlation cells are used. In practice, an improvement in the immunity to
water vapour of more than a order of magnitude is achieved. In the case of
measuring HCl - one of the most demanding analyses - the main improvement is
in the immunity to the interference effects of hydrocarbons.

Figure 4-3 IR absorption spectrum of HCl gas

R M
Matched
Filters
Detector
signal
R M
HCl
Gas filled
cell
Detector
signal with
zero gas R M
Detector
signal
H20 M
R
introduced
Detector
signal
HCl
introduced R M
Figure 4-4 Detector responses with HCl sealed cell

Analyser Unit
The Analyser Unit is shown, with its cover removed, in Figure 4-5 below. All
the principal components are as notated on the illustration, and described in text.
Figure 4-5 PROCAL 2000 Analyser Unit with inner and outer cover removed
Within the AU is a broadband infra-red (IR) source, which is an enclosed

electrical filament consuming about 8 W and running at about 1100°C.
Radiation from the source passes through the filter wheel. This wheel is fitted
with up to 8 filters, and up to 3 gas cells. Drive of the filter wheel is by means of
a DC motor at a controlled speed of around 7.5 revolutions per second. On the
rim of the filter wheel are a series of slots. These slots pass through a light
source-detector assembly on either side of the wheel. The time is detected,
amplified on the filter wheel pcb, and passed to the AU processor. The AU
processor uses the timing pulses to match each reading with the filter in the
optical path at any moment.
Once the IR beam has passed through the filter, it passes through the head exit
lens and into a void that is purged with a non-absorbent gas. This void acts as a
spacer between the AU and the sample cell so that the latter can be inserted fully
into the duct, thus avoiding stratification of the gas which can occur near the
wall of the duct. The lens is normally made of calcium fluoride. For
measurement of longer wavelengths, a zinc selenide lens is used. Lens materials
are selected for their good IR transmission characteristics and their inert nature.

When the IR beam has passed through the sample gas and been returned to the
AU, it is incident on the detector. This detector is a high-performance solid state
device working on the pyro-electric principle. Radiation striking the detector
causes minute temperature changes which are translated into electrical signals.
These signals are proportional to the level of irradiation, and are largely
independent of wavelength.
Within the AU is the intelligent head pcb. This has a number of functions. It
amplifies the signal from the IR detector, and passes this to the ACU. It supplies
and regulates DC power to all parts of the AU. Lastly, it amplifies and transmits
the temperature signals from the two temperature sensors in the sample cell and
the AU respectively.
Analyser Unit specification

Principle of operation Infra-red absorption with multiple wavelength
selection using Gas Filter Correlation (GFC)
where advantageous. Interference filters and
gas cells mounted on a rotating filter wheel.
Sample cell uses the enveloped folded beam
principle.
Gases measured Up to 6 hetero-atomic gases as determined by

the application.
Spectral range Specific application-dependent wavelengths

(up to 8) are selected between 2 µm and
12 µm.
Infra-red source Enclosed hot filament.
Infra-red detector Solid state pyro-electric type.
Sample path length 1 m.
Sample Temperature Up to 350°C.
Cross-sensitivity Minimal, due to the wavelength selection, gas

filter correlation technique and advanced
algorithms in the processor software.
Accuracy Typically ±2% of full scale concentration, but

dependent on application.
Response time Application-dependent, but typically less than

120 seconds to 90% of full scale.
Calibration requirements Supplied pre-calibrated. Short term drift of less

than the quoted accuracy is removed by
automatic zero calibration, performed
automatically at preset intervals, typically
4 - 24 hours. Span verification recommended
every 3 - 6 months, depending on application.
Enclosure Outer GRP Cover housing the Auto

Verification Unit and Fan or Vortex IP65,
NEMA 4X
Inner: Aluminium alloy casting with high

protection finish, sealed to IP65, NEMA 4X.
Operating environment Operating temperature range: -10°C to +55°C.

Materials contacting sample Calcium fluoride, glass, 316 stainless steel,

graphite.
Services required 24Vdc power for the electronics provided by a

Local Power Supply Unit 115/230 V ac 100w
Instrument air for the analyser purge, auto-zero

and sample cell protection, controlled by the
integral Auto-zero/Auto-purge Unit. Pressure
regulated to 6.0 bar max; flow rate 60
litres/hour constant and 600 litres/hour
intermittent during Auto-zero (typically 5
minutes every 12 hours).
Interconnecting cable 4-way 2 twisted pair with overall screen.

Maximum resistance 4.0 ohm: 0.5 mm2 cross
section cable normally used which allows 1000
m spacing between AU and Control Unit.
Power connection (3 core) to local PSU (The

PSU is normally installed adjacent to the AU.)
Auxiliary inputs Up to three analogue inputs, 0/4 - 20 mA or

0 - 5 V (link selectable) as specified by the
customer.
Outputs Optional Control Outputs (24v Switching) for

In-Situ Heater / Optional Blow Back / In-Situ
Cooler
Integral Auto Verification Unit
All PROCAL 2000 analysers is supplied with an Auto Verification Unit

mounted in the AU outer cover..
The integral Auto Verification Unit has two primary & three secondary
functions.
Primary Functions
1 It provides totally automatic zeroing of the system, and secondly it

acts as a safety purging system to prevent condensation forming in
the sample cell of the Analyser Unit.
In its Auto-zero function, a zero check is instigated on a periodic

basis by a command signal from the Procal 1000 (ACU or ACWn).
The control voltage switches a solenoid valve on the Auto
Verification Unit which diverts a regulated flow of instrument air in
to the Analyser Unit In-Situ Cell.
After a predetermined stabilisation period, the Procal 1000 will read

the zero gas signal and, if necessary, adjust the zero offsets on every
channel until a true zero is obtained. Once zeroed in this manner, a
further signal from the Procal 1000 will shut off the supply of
instrument air, and natural purging action will quickly refill the
sample cell with process gas. The unit will go back to on-line
process measurements.
During this Auto-zero procedure, all displays and outputs are frozen
at the last 'on line' levels before commencement of the Auto-zero
routine. This includes the time required for the sample cell to purge

clear of instrument air at the end of the Auto-zero cycle. The

frequency and duration of the flush times in the Auto-zero routine can
be altered as described in the Operation section of the ACU
Operating Manual.
2 In the event of a power failure to the system, the In-Situ Heater element (when
fitted) and the sample cell will cool, possibly to below the dewpoint.
Condensation could then occur on the process side of the sample lens. The de-
energised solenoid valve on the Auto Verification Unit opens and floods the
sample cell with dry instrument air, thus removing the possibility of
condensation. The unit will continue to purge the cell until the fault condition is
rectified.
The Auto Verification system hardware is a single panel of components mounted

inside the outer AU Cover. The software to operate the system is fully pre-
programmed into the Procal 1000 and the AU.
Secondary Functions
1 Optionally if the system is set up for Auto Calibration the Auto Verification
Unit can switch on 1 of 2 Calibration Gas lines in the required sequence under
control of the Procal 1000 to facilitate Span Calibration or verification.
2 To eliminate the ingress of moisture or absorbing gases into the VOID a

continuous low purge is applied utilising an restrictor mounted on the Auto
Verification Unit. The analyser is supplied with the AU purge piped.
Note No action is required during installation
3 To eliminate the ingress of moisture or absorbing gases into the analyser

optical housing a continuous low purge is applied utilising an restrictor
mounted on the Auto Verification Unit. The analyser is supplied with the
purge piped.
Note No action is required during installation
Auto Verification Unit specification

This unit will, on automatic command from the Procal 1000, divert a flow of instrument
air to the Procal 2000 analyser. This will occur under either condition below;
1 when an auto-zero is required
2 when the sample temperature falls below a preset level, typically 120°C.
The AVU contains:
 Manifold with three solenoid valves fitted
o Solenoid valve (controlled automatically by the ACU or

ACWn)
o Two off - Calibration gas valves (controlled automatically

by the ACU or ACWn.)
 Needle valve (Mounted in the manifold)
 Void purge Restrictor
 Optical purge restrictor
Services required: Clean, dry instrument air (Procal Standard

ISO 8573-1 1 2 1 see 7-5823-00 in Section 7. page 9)
at a maximum of 10 barG


5 Maintenance
Introduction
The PROCAL 2000 is a high-technology analytical tool. Like other specialised

industrial equipment, it needs regular maintenance if it is to operate at peak
performance.
It is strongly recommended that if a PROCAL 2000 system is purchased, a

service contract is taken out. This will cover regular cleaning, calibration and
routine preventative maintenance. A service contract will assure priority
response to emergency call-outs. Please contact Kittiwake Procal or Procal
distributors for further information about service contracts.
Caution
While the instrument is accurately aligned and calibrated as part of the
standard production procedure, it is possible that components may
become misaligned due to prolonged vibration in operation. If
misalignment is suspected, the user should not attempt to re-align the
instrument. Incorrect realignment will invalidate the calibration. Call
Kittiwake Procal or your Procal distributor.
Routine maintenance schedule
If the user does not have a service contract and decides to undertake routine
preventative maintenance in-house, the following schedules should be strictly
followed.
Please note that if the system is not properly maintained, the manufacturer's
guarantee may be voided or limited.
Calibration may be required more frequently by the local pollution inspectorate

or other regulatory authority.
Quarterly (three-monthly) schedule

visual inspection of Analyser Unit for cracks, corrosion or any other signs of
physical damage
access the TEST screen on the Control Unit, and check all operational data
displayed
keep a record of the signal readings so that any deterioration due to lens
clouding or electrical faults can be quickly identified.
visual inspection of all cables and gas connections for integrity, and for cracks,
corrosion or any other signs of physical damage.

calibration (see under the heading Field calibration check within this section);
note that calibration may
need to be performed more frequently if required by regulatory authorities
Annual schedule
 internal visual inspection of Analyser Unit for signs of ingress of dust, moisture
or process fluids and/or gases
 check that the source is emitting and that its lens is clean
 check all mirrors, lenses and optical filters for cleanliness
 check the filter wheel motor (when unplugged) for ease of rotation, and replace
the motor if any friction is apparent
 visual inspection of all cables and gas connections for integrity, and for cracks,
corrosion or any other signs of physical damage.
 Pt100 platinum resistance thermometer resistance check. The resistance should

be 100 + (38/100) x temperature.
If the results of any of the above checks cause you any concern, contact
Kittiwake Procal, or your Procal distributor or agent, immediately.
Cleaning
Please do not attempt to clean any of the optical surfaces within the instrument.
Contact Kittiwake Procal, or your Procal distributor or agent, for a cleaning
service. If you attempt to clean optical surfaces and cause damage, the warranty
on the PROCAL 2000 system may be voided or limited.

5 Maintenance
Field calibration check
Introduction
The gases used in the original factory calibration are of known accuracy and the
calibration achieved using them should not be discarded lightly.
Each test can be carried out individually or as part of a comprehensive field

calibration check.
Note that the Routine maintenance schedule within this section calls for an
annual Field Calibration Check.
Calibration Equipment
The calibration gases must be in cylinders that can be located close to the AU.
Each cylinder must be fitted with a regulator. It is very important that each
cylinder has a supplier certificate of calibration, since experience has shown that
large variations in actual concentration can be encountered.
It is important that the person carrying out the calibration should be aware that
he/she is dealing with toxic gases and carries out all safety procedures associated
with the handling of high-pressure gas cylinders.
Other equipment required for the tests:
 pressure gauge with 1/8 BSP taper male fitting (Pipe thread EN 10226 R1/8);
scaled 1 barG FSD
 if water concentration is to be checked: Procal 9000 Field Calibrator

(Procal Part number 1-2775 or 1-2764)
Void pressure Test

You will require:
o A pressure gauge (0 – 3barg) connected to a 150mm length
of 6mm flexible pipe.
o A Ball valve connected to a 150mm length of 6mm flexible
pipe
1 Turn the air supply to the AU
2 Remove the AU outer Cover
3 Unscrew the sintered muffler fitted at the Void purge outlet. Screw to the Void
purge outlet the pressure gauge with the 1/8 BSP taper male fitting, sealed with
PTFE tape.
4 Identify the void air feed connection on the auto verification unit and disconnect.
Ensuring the restrictor is still connected to the auto verification unit. Insert the ball
valve between the auto verification unit void air feed and the void pipe ensuring the
ball valve is in the off position.
5 Switch on the air supply to the AU
6 Open the ball valve until the gauge reads approximately 1 bar, and then turn the ball
valve to the off position.

7 After 10 minutes check that the gauge reading has dropped by less than 5%.
If the drop has been greater than this, check that the pressure gauge fitting is
not leaking and then repeat the test. If the test fails again it is likely that the
sealing of the centre lens is defective. In this case, the analyser will have to
be dismantled and the centre lens re-sealed.
8 Switch off the air supply to the AU
9 Remove the gauge from the Void Purge port and refit the sintered muffler.
Remove the ball valve and reconnect the void purge pipe.
10 Ensure all connections disturbed during the test are correctly fitted.
11 Switch on the air supply to the AU
Sintered Panel Flow Test
Observe the stack pressure under normal operation and note the reading (this is
found on the TEST SCREEN in the Analogue and derived Channels Table and
is labelled as P SAMPLE). From the AUTOZERO drop down menu select
MANUAL AIR PURGE, wait for the pressure to stabilize and then note the
reading. If the increase in pressure is greater than 50mbar (0.72 psi), the sintered
panel is partially blocked.
Gas Calibration
(For US EPA instruments see Appendix F)

In order to carry out the Gas calibration check of the analyser the testing
engineer must be at ENGINEER access level. Details of switching between
Access Levels can be found in the operator manual. It should be noted that NO
CHANGES should be carried out for calibration without the approval of the
customer based on QAL 3 results.
1) On the Test Screen of ACWn select START AUTOZERO NOW from the
AUTOZERO drop down menu, and allow the analyser to go through the whole
cycle, noting pressure, abs and concs readings. Upon completion of Auto-zero,
select MANUAL AIR PURGE from the same drop down menu, wait for the
readings to stabilise and then record the results. Readings should be as close to
zero as possible, to provide a baseline for calibration.
Figure 5-1: Selection of Auto Zero and Manual Air
2) Connect the outlet of the gas cylinder via the necessary fittings and regulator to
the AVU CAL port to be used located on the underside of the AU outer cover
(Usually Port 4 – CAL gas 1). From the AUTOZERO menu (fig.1) select MAN
CAL GAS 1, open gas regulator and set pressure to approx 1.9barG/27psiG.

5 Maintenance
3) To ensure that all water vapour and auto-zeroing gas has been driven out of the
sample cell wait for at least three minutes before taking any readings. Observe the
TEST screen and note the reading for water vapour, which should have reduced to
a level of less than 2% of the abs reading during normal operation (e.g. if abs
during normal operation is 100, reading should be <= 2). If it is higher, slightly
increase the gas flow.
4) After allowing enough time for the calibration gas in question to stabilise (around
3 minutes) record the readings. If the displayed concentration reading is within
±2% of actual bottle value no calibration is necessary and the user can go to Step
6.
5) If the display shows a calibration reading that is >±2% of the gas bottle,
recalibration is required using steps 7 to 9.
6) Turn off the gas regulator and gas bottle and allow regulator to drop to 0, then
select MANUAL AIR PURGE from the AUTOZERO menu (fig.1). Repeat steps 2
to 5 AFTER readings on TEST screen have stabilised around 0.
7) On the TEST screen go to MANUAL CALIBRATION on the main menu and

select CALIBRATE COMPONENTS from the drop down menu. If the manual
calibration choice is greyed out it is because operator access level is selected.
Change to Engineer level, and continue.
Figure 5-2: Selection of Manual Calibration
8) After selecting CALIBRATE COMPONENTS the window shown in figure 3 will

open. To calibrate the gas in question select it from the drop-down text box, enter
into the EXPECTED VALUE box the ACTUAL Gas Bottle concentration, and
then click the ADJUST BUTTON.
Figure 5-3: Adjusting the Calibration of the selected Gas
9) The software automatically recalculates the coefficients for the given gas so that
returning to the TEST screen should give the correct reading. An indication in the
information window will display a successful calibration. To return to the TEST
screen simply select the EXIT button shown in figure 3. Figure 4 shows the
selection of Hydrogen Chloride from the drop down menu, and a successful
calibration.

Figure 5-4: Choices in drop down menu
10) When all necessary channels have been calibrated disconnect the cylinder from
CAL Gas port, and select MAN AIR PURGE from AUTOZERO menu (fig.1).
After taking zero readings select MANUAL AIR PURGE again from
AUTOZERO menu to turn off air (MANUAL AIR PURGE should NOT have a
tick next to it). This returns the analyser to the normal process operation.
Water Vapour Calibration Check
A water vapour calibration should only be performed in the field if there is good
reason to doubt the readings obtained. This is because laboratory conditions
CANNOT be repeated in the field. A calibration carried out in the field IS NOT as
accurate as one done in the factory.
To carry out the calibration a KITTIWAKE PROCAL 9000 Field Calibrator is

required.
1) Connect the KITTIWAKE Procal 9000 Field Calibrator as described in the

calibrator handbook.
2) Using the ACU options menu, or ACWn Main screen selection turn off the Auto
Zero function
3) Set the Calibrator to give a level of 80% of the FULL RANGE water vapour.
4) Monitor the H2O readings and wait for them to settle (approx 5-10 minutes)
5) If the displayed concentration reading is within ±5% of the set concentration, no

recalibration is necessary.
6) If the displayed concentration reading shows a deviation of >±5% from the set
water vapour concentration recalibration should be carried out by following steps
7 to 10.
7) If operating with ACU use the SERVICE menu (described earlier in the manual)
to select Calibration option, if using ACWn, select MANUAL CALIBRATION
from the TEST SCREEN menu, and then CALIBRATE COMPONENTS (fig.2)
8) The analyser will average the water vapour reading for 1 minute and then display
it as shown in the calibration graph. If the set concentration figure is significantly
different from the previously observed average, then it is likely that one of the
surges occurred during the 1 minute averaging time. In this case, repeat steps 3 to
8 of this procedure.

5 Maintenance
9) On the ACU adjust the required concentration to read the same as the value set on
the calibrator, with ACWn check the Measured value against the Expected value
10) On ACU select calibrate option and apply, on ACWn click the Adjust button. The
analyser will immediately recalculate the calibration table values for water vapour
so that on return to the TEST screens the correct value should be displayed
11) Disconnect the KITTIWAKE PROCAL 9000 Field Calibrator and replace the
“Hot Access” blanking plug
12) Using ACU turn on the Auto Zero via the options selection, with ACWn turn on
Auto Zero via AutoZero selection (fig.1)
Fault-finding
Presented below is a list of faults which Kittiwake Procal considers can be

diagnosed and rectified by some users.
WARNING
You must not attempt to FAULT-FIND OR REPAIR this system unless
you are qualified, competent and authorized to work on electrical
equipment operating at your local mains electrical supply voltage.
MAIN screen shows variable readings

1 Check whether the TEST screen shows rapid changes in concentration,
inconsistent with expected levels.
2 If the TEST screen shows low readings, check for condensation on, or
contamination of lenses and mirrors.
3 The quality of the IR signal may be poor. Check with an oscilloscope that the
waveform shown in Figure 5-2 (a) appears at TP1 on the OHU pcb (with ground
connection to E). It is important that the observed waveform is as smooth as in
Figure 5-2.
4 Connect the second channel of a dual-beam oscilloscope to the AU terminal

LK21 (top). With the oscilloscope trace mode set to 'CHOP', check that the
'phasing' of the wheel pulses shown in Figure 5-2 (b) is such that they coincide
with the peaks and troughs in the IR signal. If they do not, please contact Procal
as your system may need recalibration. DO NOT UNDER ANY
CIRCUMSTANCES ATTEMPT ANY ADJUSTMENT OF YOUR AU.

+5V DC
(a) WAVEFORM AT OHU TP1
0 volts DC
-4V DC
16.7 ms
133 ms
(b) WAVEFORM AT OHU LK21 (top)
5V–
0V–
Figure 5-5 Expected IR signal at the AU
Repair policy
Kittiwake Procal recommends that repairs to the PROCAL 2000 system are only
made by its own trained support staff, or by those of its distributors world-wide.
If you have the necessary technical qualifications, training and experience you
may wish to make straightforward repairs in-house. A spares list is given for
this purpose. However, you should note that if a repair is incorrectly carried out,
this may void or limit the warranty on the system. You should also note that this
manual is not intended to describe fault-finding or repair down to component
level.
WARNING
You must not attempt to FAULT-FIND OR REPAIR this system unless
you are qualified, competent and authorized to work on electrical
equipment operating at your local mains electrical supply voltage.

5 Maintenance
Spares list
Part No Description Number

1-2716J Source Element 1
1-2743 Brushless Motor Assembly 1
1-1336 Sintered Tube Assembly 1
4-8048 Mirror 1
1-2322 PRT Assembly P200/P500 1
2-1145 Filter Wheel PCB Mk3 1
2-1180J IHPCB 1
4-8047 Process Lens 1
4-0047 Main Lens 1
1-8013 P200/P500 Seals Kit 1
The figure in the right-hand column is the quantity of that part fitted to the
analyser.
If you wish to order a spare part, please contact Kittiwake Procal, or your Procal
distributor or agent.
If you require a spare part that is not listed here, please contact Kittiwake Procal,
or your Procal distributor or agent.
When ordering spare parts, please quote both the Part Number and the serial
number of the part of your system concerned - AU, Procal 1000, or ISH. This
will provide you with a quick and efficient service.
Kittiwake Procal Ltd. reserves the right to change the prices, specifications or
manufacture of any component parts at any time.
Changing PROCAL 2000 components
Certain components can be changed by the user within the PROCAL 2000
system, when necessary.
Changing the integral IR source filament

This procedure will be necessary if the filament has become open circuit. This
will be indicated by the alarm message on the P1000 series controller screen and
will be confirmed by very low signal levels on the TEST screen.
The IR source has a replaceable filament, part number 1-2716J, that is the only
part which needs replacing. Provided the protective air purge is maintained
through the analyser during the time that it is switched off, it is possible to
change an IR source filament without withdrawing the AU from the process
duct.

Figure 5-6 AU unit with cover removed, showing position of IR source
1. Switch off the mains supply to the local PSU. Check that the air purge
has automatically switched on.
2. Remove the AU Outer Cover
3. Remove and retain the eight 5 mm socket head screws securing the
inner cover of the AU to the AU case.
4. Lift the cover clear and place to one side.
5. Locate the Integral IR source by reference to Fig 5-3.
6. Unplug the two-pin (Berg-type) pcb connector on the end of the cable
from PL1 on the optical head pcb. Figure 5-4 shows the position of
PL1.

5 Maintenance
PL 1 PL 2 PL3
Detector Not Used Sample TS1
Temp. 1
2
PL 4 3
Filter Wheel 4
PL1 5
Source 6
PL 4 7
Transition 8
PCB 9
10
11
12
13
14
15
16
Analyser Main PCB Assembly Connections
Figure 5-7 Analyser Main PCB, showing positions of connectors
7. Loosen the two pan head M3 screws at the top of the integral source
that hold the filament in position until it is possible to rotate the
filament through 90o and withdraw it. Note the orientation of the
filament flange as it is withdrawn.
8. Taking great care not to damage it, insert the new filament carefully
into the hole in the top of the Integral source observing the same
orientation as when the old filament was withdrawn.
9. Rotate the inserted filament through 90o so that the elongated portion of
the flange is positioned under the M3 screws, and then tighten them.
10. Restore mains power to the Local PSU and check that the filament can
be seen glowing inside the Integral source.
11. Replace the AU inner cover and tighten the eight fixing screws.
12. Replace the AU outer cover.
Note: Select manual air purge. When readings have stabilised de-select manual air
purge, the perform Auto zero now.

Changing the filter wheel motor (Part number 1-2743)

This procedure will be necessary if the motor has ceased to rotate despite there
being at least 1.5V dc across its terminals. If this occurs, the number shown
adjacent to Q on the TEST screen will be less than 50.
1 Switch off the mains supply to the Local PSU.
2 Remove the AU outer cover lid
3 Remove and retain the eight M6 socket head screws securing the inner
cover of the AU to the AU case.
4 Lift the cover clear and place to one side.
5 Locate the filter wheel motor by reference to Fig 5-3.
6 Unplug the FE PCB, remove and retain the two M3 socket head screws
and washers securing the filter wheel pcb to the bracket, then place the
pcb to one side (taking care not to strain the ribbon cable connected to the
pcb).
7 Note the connector to which the motor cable is connected, and the
orientation, then disconnect the cable.
8 Remove and retain the two M3 counter sink screws that secure the filter
wheel bracket to the base plate then withdraw the assembly from the AU.
9 Using a 1.5 mm Allen key, loosen the screw holding the filter wheel on to
the motor spindle and withdraw the filter wheel. This contains a number
of fragile optical filters so should be placed where it is protected from
damage.
10 Locate the three small pan head motor fixing screws on the newly-
exposed face of the bracket. Remove and retain these screws, then
remove the motor.
11 Fit the new motor to the bracket using the three small pan head screws
and tighten them.
12 Fit the filter wheel on to the motor spindle with the wheel boss facing the
motor. Leave the centre fixing screw fairly loose at this stage.
13 Screw the bracket to the base plate with the two retained sets of screws
and washers. Rotate the filter wheel by hand and check that it rotates
freely, tighten shaft grub screw.
14 Fit the Filter Wheel PCB to the top of the bracket using the retained
screws and washers.
15 Connect the motor cable to the connector noted in step 8 above,

observing the correct orientation.
16 Restore mains power to the Local PSU.
17 Replace the AU cover and tighten the eight fixing screws.
18 Replace the AU outer cover lid.

5 Maintenance

6 Disposal instructions
Introduction
It is important that, at the end of their working lives, all parts of the PROCAL
2000 are disposed of in accordance with all local environmental statutes and
regulations which have the force of law.
If you are ever in any doubt about how to dispose of the PROCAL 2000, you
may return it to Kittiwake Procal in the United Kingdom, carriage-paid.
Kittiwake Procal will dispose of the system for you. There will be no charge for
this service, but neither will you receive any payment or allowance for any
components or materials recovered.
This manual is an integral part of the PROCAL 2000 analyser system. If you
pass the system on other than for final disposal, you should always pass this
manual on with it.
Zinc Selenide optics
Certain long-wavelength PROCAL analysers are fitted with optics of Zinc

Selenide, a highly toxic substance. If your PROCAL 2000 has such optics, this
will be stated in the section of this manual entitled Order-specific information.
WARNING
YOU MAY ONLY DISPOSE OF ZINC SELENIDE OPTICS BY
DELIVERING THEM TO AN ENVIRONMENTAL WASTE DISPOSAL
AGENCY THAT ACCEPTS SUCH MATERIAL OR BY RETURNING THE
OPTICS TO KITTIWAKE PROCAL IN STRONG PROTECTIVE
PACKAGING.
DISPOSAL BY ANY OTHER MEANS MAY LEAD TO DAMAGE TO
HUMAN HEALTH.

Page intentionally left blank.

7 Order-specific information
Introduction
This section contains summary installation diagrams and information specific to the
PROCAL 2000 series system with which you have been supplied. The following
standard drawings of the version current at date of publication are included as a
guide only.
Drawing Title
7-2489 Installation overview – Analyser/Procal 1200 (ACU Mk 4)
7-2105 Installation overview – Analyser/Procal 1100 (ACWn)
For full installation details and for installation drawing versions applying to your
specific delivery refer to the Drawing Package referenced below as delivered with
the equipment.
7-4864, Installation Drawing Package – PROCAL 2000
Included for reference - Air Specification
7-5823-00 Quality Standard for Instrument Air Supplied to Procal

Analysers – see appendix C


Appendix A - The PROCAL 2000 with ATEX/IECEx
approval
Introduction
Versions of the PROCAL 2000 have been granted ATEX II 2 G Ex d IIB T6

approval (Type Examination Certificate Number Baseefa 05ATEX0082X) and
IECEx Ex d IIB T6 approval (Certificate of Conformity Number IECEx BAS
05.0030X) both for use in flammable atmospheres, Zones 1 and 2 and an ambient
temperature range -20°C to 40°C.
To achieve this, the equipment has undergone rigorous tests at the Baseefa
authority against the British and European Standards BS EN 60079-0:2004 and BS
EN 60079-1:2004
These tests and QA in production ensure that the equipment cannot cause an
explosion when operated correctly in the stated hazardous areas.
Quality assurance during production
To comply with the requirements of the approval, several steps have to occur
during production under the terms of the licence M1655 held by Kittiwake Procal
Ltd.
(a) The materials used in safety critical parts are supplied with Certificates of
Conformity
(b) Certain mechanical parts have to be inspected to drawing to ensure that critical
dimensions are correct and records are kept.
(c) The optical head casting is subject to a pressure of 10.65 bar (g) for a minimum of
10 minutes without distortion.
(d) The thermopocket of the reflector tube is subject to a pressure test of 47.5 Bar
for 1 minute in line with the certified product requirements. No leaks, distortion
or deformation are accepted.
(e) The completed analyser is subject to final inspection against the overall approval
drawing.
Details are available on request to Kittiwake Procal Ltd.
Allowed environments
 The standards above detail the gases, and environments in with which
the ATEX approved equipments are allowed to be used. Reference
may be made to them.
 The PROCAL 2000 (Formally Pulsi 200)) may be used for potentially
explosive gas atmospheres classified as IIB
Issue 4 KITTIWAKE PROCAL LTD page A-1

 The PROCAL 2000 may be used for the ambient temperature range
–20°C to +40 °C
 The PROCAL 2000 has a surface temperature classification T6 which

indicates a maximum surface temperature of 85 °C.
 Note the Procal 2000 is fitted with a Vortex cooler maximum surface
temperature is 135ºc therefore classification is T4.
IT IS THE USER’S RESPONSIBILITY TO ENSURE THAT THE

ANALYSER IS BEING USED IN AN APPLICATION FOR WHICH IT IS
APPROVED.
Installation additional requirernent
In addition to the installation as described in the manual respect to the maximum

penetration of any fastening bolts used into the four M8 threaded holes provided
should be no more than 6.75mm thereby leaving a minimum of one free thread as
required.
Maintenance additional requirements
General Maintenance operations are described in the chapters of the PROCAL

2000 operating manual. However special precautions are essential in hazardous
areas because if certain parts of the PROCAL 2000 are changed, this may affect
the analyser’s certification status.
When ordering spare parts for the PROCAL 2000, please state to Kittiwake
Procal or their distributor its serial number and whether it is for use in an area
with an explosive gas atmosphere.
The Special Conditions of Safe Use on label 1-2645J (available on request to

Kittiwake Procal Ltd) shall be observed.
All glands and hole blanking plugs including any replacement must have the
same thread form as the original items, and bear the ATEX mark for flameproof
enclosure use.
The joint surfaces of the enclosure and its cover shall be wired clean before re-
assembly. If there is any damage to these surfaces consult Kittiwake Procal Ltd
or their distributor. All 8 stainless steel fixing bolts size M6 X 16 must be used
and they shall have a mark A2-70. Missing or damaged ones must only be
replaced by screws ordered from Kittiwake Procal Ltd.
Laws and regulations about flammable atmospheres that apply to the customer
should be observed in addition to these ATEX requirements.
page A-2 KITTIWAKE PROCAL LTD Issue 4

Appendix B - Procal 1400 Input Output Units
Introduction
Input Output Units can be added to the Procal Instrument Serial Cable to provide
addition inputs, current outputs and relay outputs to any system.
Each Unit can provide up to 32 Input or Output Modules (mixed allocation), has up
to 32 Relays and provides 16 Digital Inputs.
The controller software can allocate any channel to any output, any alarm to any
relay and configure any input as an additional channel.
All Input Modules and Output Modules are fully isolated. The Relay outputs are
Voltage Free and the Digital Inputs are isolated in voltage or current mode.
The addressing of the Units by the controller does not affect the system ability to
address Analyser Units.
The IOU is mains (line) powered and can be used in place of a Local Power
Supply in certain configurations.
Services required
The following services are required for this option:
Mains Supply 180VA Max. 90-132/180-264V – autoranging. 47-63 Hz.
WARNINGS
YOU MUST NOT ATTEMPT TO INSTALL THIS SYSTEM UNLESS YOU
ARE QUALIFIED, COMPETENT AND AUTHORIZED TO WORK ON
ELECTRICAL EQUIPMENT OPERATING AT YOUR LOCAL MAINS
ELECTRICAL SUPPLY VOLTAGE.
READ THIS SECTION IN ITS ENTIRETY BEFORE ATTEMPTING TO
INSTALL ANY PART OF THE SYSTEM. IF THERE IS ANYTHING YOU
DO NOT UNDERSTAND, OR YOU DO NOT FEEL CONFIDENT OF
YOUR ABILITY TO FOLLOW THE INSTALLATION INSTRUCTIONS,
DO NOT PROCEED. CONTACT KITTIWAKE PROCAL OR YOUR
PROCAL-AUTHORISED DISTRIBUTOR.
Unpacking the system components
If this has not already been done, unpack the system components and check that
they correspond to the units ordered and listed on the accompanying packing
note. If there is any discrepancy, or any damage is apparent, do not attempt to
install the system. Contact Kittiwake Procal, or your Procal distributor.
Issue 4 KITTIWAKE PROCAL LTD page B-1

Fitting and preparing the IOU
Mount the IOU in the control room, shelter or other designated location securely
mounted by its locating brackets. Mounting details are shown in Fig. 1. The
IOU weighs 11kg (24lb). The IOU should be mounted in the chosen
configuration before wiring is attempted.
ALL WIRING SHOULD FOLLOW THE DETAILS GIVEN ON THE

INSTALLATION DRAWINGS PROVIDED. DRAWINGS INCLUDED IN
THIS MANUAL SHOULD BE TAKEN AS A GUIDE ONLY.
Figure 1 – Mounting Details.
page B-2 KITTIWAKE PROCAL LTD issue 4

Appendix B
WARNING
DO NOT CONNECT THE MAINS CABLE (POWER CORD) TO THE
ELECTRICAL SUPPLY UNTIL ALL CONNECTIONS WITHIN THE IOU
HAVE BEEN MADE. FAILURE TO FOLLOW THIS WARNING MAY
RESULT IN SERIOUS OR FATAL INJURY FROM ELECTRIC SHOCK.
Gaining internal access to the IOU

Slacked the four self-retaining screws securing the front panel to the casing of
the IOU. The front panel and chassis can now be separated but will be still
attached by the protective earth wire. Position the cover so that this wire is not
damaged. Access to the terminal connections inside the unit ( as shown in Figure
2) can now be made. A view of the Terminal pcb is shown in Figure 3.

Figure 2 – Main Board Connections

Appendix B
Figure 3 – Terminal PCB.

Preparing cables for the IOU

During preparation of the IOU, you should refer to the relevant installation
drawing in the Order-specific information section of the accompanying system,
particularly if you will be making up your own interconnecting cables.
The typical cables used to connect other system components to the IOU are
shown in Figure 4a and 4b.
Figure 4a – Interconnection Cables

Appendix B
Figure 4b – Interconnection Cables

Feeding cables into the IOU

There is a gland plate provided in the IOU casing. Remove the plate and prepare
suitable glands for the Power Supply (mains or line) Cable (Cable 1), and for
each of the Serial Connection Cables (Cables 6 or 13). Other suitable glands
should be provided for the other Input/Output Cables (Cables 3 and 4)
When the IOU is wall mounted, cable glands are recommended to be on the
underside of the unit.
Connecting the system to the supply

The IOU has been designed to operate on either of two power supplies:
 110 V ac nominal (low limit 90 V, high limit 132 V), 47-63 Hz.
 230 V ac nominal (low limit 180 V, high limit 264 V), 47-63 Hz.
No user adjustment is necessary as the IOU automatically detects the input

voltage. The procedure to connect the system to the mains supply is:
1 Ensure that all wiring between the IOU, AUs, Control Unit and ancillary
equipment is correct. To connect the above power supply the Terminal Block
Cover will need to be removed, ensure this is replaced before continuing to
power the unit.
2 Connect the free end of the mains cable to a suitable ac supply. Follow local
regulations for permanently installed equipment. It is recommended as good
practice that a means of disconnection is provided within 2 meters and an RCD
or ELB is also fitted.
The installation is now complete and the system is ready for operation.

Appendix B
System configuration
The System Database provided will be configured to suit the Inputs and Outputs
configurations ordered. If changes need to be made consult the relevant section
in the Controller Unit Manual.
Module configuration
See IOU Configuration Sheet (7-7806) form entries for this delivery Module
setup details.
See IOU Customer Connections drawing 7-4384 for Module locations, Relay
Links and Digital Input Link locations.
Output Modules – No configuration required.
Input Modules – Link selection for three modes.

J2 in, J1 out for 0-20mA or 4-20mA range.
J2 and J1 out for 5V range.
J1 and J2 in for Switch detection.
Digital inputs. – Link selection for four detection modes.

Links A, B, C out; 24V Logic.
Link B in.; 5V or 20mA Logic.
Links A, B, C in; Contact detection.
Relay Outputs – Link selection for NO (Normally Open) and NC (Normally

Closed) operation. When powered off the IOU relays will be in the Normal
position. By default the error condition is this power off condition.
Relay Rating - 28V dc max, 1A max.
Not suitable for mains switching nor signal switching.
Operation
NOTE: If the IOU is powered without communications from the Control

Software then all relays will be in their alarm state and all current transmitters
will output 2mA. A timeout is provided after communications is established to
ensure the above occurs only in the case of a communications fault.
The Output Modules have an LED on the module which is illuminated in an

Error condition. This error is the result of the Module being unable to create any
current output. This will be normally be because the output for this module is
open circuit. Hence these LEDs can be used to check the system wiring. Note
this requires operating the IOU with the cover removed. This should only be
done by a qualified service engineer and the earlier warning as to operation on
Mains Voltage applies.
CPU Board 2-1117 has LEDs which indicate power on and program running.
LED1 – ON – 5V power applied.
LED4 – Pulsing once per second indicated program running.
LED2 and LED3 are blank, used by Procal in programming the board.

AU Power connections
The system communications connectors TS5 and TS6 .can also, by use of the
Links 1,2,3,4,5 and 6, either supply 24V or be used to feed an existing 24V
supply to the next unit on the cable.
Links 1 and 2 IN will connect the IOU 24V power supply to TS5 pins 5 and 6.
Similarly Links 5 and 6 IN for TS6 pins 5 and 6.
If the Links 1,2,5,6 are removed and Links 3 and 4 are fitted then TS5 pins 5 and
6 are connected to TS6 pins 5 and 6 only, allowing an external supply to be
connected through the unit.
The IOU can supply 3.5A at 24V for powering Procal AU instruments only.
The electrical connections are detailed on drawing 7-4384.

Appendix C – Quality Standard for Instrument Air
Supplied to Procal Analysers
Introduction
It is essential that the air used for optical purge, void purge and auto zero is of the
required standard. This section describes the quality of air supplied. If in doubt it
essential that the Quality of Air is tested to confirm that it meets the required
standard as stated below.
If the air is shown to be inadequate please install an Air Preparation Panel (see
appendix L).
Issue 4 KITTIWAKE PROCAL LTD page C-1

7-5823-00 issue 03
Quality Standard for Instrument Air Supplied to Proca Analysers
The quality of instrument air should meet the Class 1 standard given in ISO 8573-1
The Procal standard is ISO 8573-1 1 2 1
A is the figure for Solid Particulates (A=1)

3
Defined as: - The Maximum number of particulates per m allowed whose size is between 0.1µm
and 0.5µm diameter is 100, and the Maximum number of particulates per m3 allowed whose size is
between 0.5 and 1.0µm diameter is 1. None are allowed above 1.0µm. Particles allowed below
0.1µm diameter is not specified.
B is the figure for Humidity or liquid water classes (B=3)

e.g. The Pressure Dew point =< -20°C
(very dry with water condensing out at –20°C)
C is the figure for Total Oil classes (C=1)

The concentration of Total Oil (aerosol, liquid and vapour) should be less than =<0.01 mg/m3.
Particulates
Limit of 40µm Particulate Size - ISO Class 7.

Humidity
Pressure Dew Pont of 18°F below minimum temperature encountered.

Or not exceeding 39°F at line pressure – Approximately ISO Class 4
(< +3 C)
Total Oil
Lubricant content should in no circumstances exceed 1 part per million by weight or volume. – Very
approximately ISO Class 4. (< 5mg/m3 or < 0.006 ppm) being the maximum class size quoted
Hence to achieve the ISO standard additional air conditioning equipment is required.
Page C-2 KITTIWAKE PROCAL LTD Issue 4

Appendix C
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Issue 4 KITTIWAKE PROCAL LTD page C-3

Appendix D - In-Situ Heater
Introduction
Some PROCAL 2000 systems are supplied with an optional In-Situ Heater
(ISH). This Appendix describes this option, and details how to install it.
In-Situ Heater description
An optional In-Situ Heater (ISH) may be fitted around the sample cell, and is
recommended for applications involving flue gases at temperatures below
120°C, or on applications with high acid dew point or where monitoring is
required when process is off. The ISH contains an electrical heater, which has
the effect of keeping the temperature of the sample cell well above the dew
point, thus preventing condensation onto any optics in contact with the process
gas.
Regulation of the ISH is from the PROCAL 2000 and is automatic.
The additional power requirement for the In-Situ Heater is 1 kW.
Fitting the In-Situ Heater
WARNING
DO NOT CONNECT ANY MAINS CABLE (LINE CORD) TO THE
ELECTRICAL SUPPLY UNTIL ALL CONNECTIONS WITHIN THE ISH
HAVE BEEN MADE AND THE UNITS ARE SECURELY CLOSED ONCE
MORE. FAILURE TO FOLLOW THIS WARNING MAY RESULT IN
SERIOUS OR FATAL INJURY FROM ELECTRIC SHOCK.
Issue 4 KITTIWAKE PROCAL LTD page D-1

Caution
Do not attempt to connect any mains cable (line cord) to the ISH if the
voltage configuration of the ISH differs from your local electrical supply
voltage. Contact Kittiwake Procal, or your Procal-authorised distributor.
Using an incorrect supply voltage will result in the In-Situ Heater failing to
function properly.
Connecting the optional In-Situ Heater to the Mains

Supply.
In-Situ Hater (ISH) ISH Junction Box
Sample Inlet
Sample Outlets
Earth Lead to Lid Underside of Procal 2000
Link 110V / 240V

Earth Connection Power
(Earth MUST be connected)
If an In-Situ Heater (ISH) is to be fitted, a cable rated at 3 A (230 V) or 6 A (115

V) must supplied to the ISH.
IT IS ESSENTIAL FOR CONFORMANCE WITH EN61010 THAT A FIXED

MAINS INSTALLATION HAS AN ISOLATOR FITTED IN THE SUPPLY,
AND THIS SHOULD BE PROVIDED BY THE SITE SUPPLY
DISTRIBUTION POINT.
1. Determine voltage of supply 110V or 240V (Others consult Kittiwake Procal Ltd or
Distributor)
2. Remove and retain the four screws securing the cover of the ISH junction box.
page D-2 KITTIWAKE PROCAL LTD Issue 4

Appendix D
3. Feed through one end of the ISH power cable through the cable gland in the ISH
junction box.
4. Connect the power cable: 110V (Note colours may change depending on local code)
Brown (live) Terminal 1 on SSR
Blue (neutral) TB 2 (Retain link)
Green/yellow (earth) to the earth stud
Blue (neutral) TB 1 (Discard link)
6. Finger-tighten the cable glands in the ISH junction box.
7. Connect the AU control to the ISH SSR wiring the control cable through the other
gland.
a. SSR + to AU Terminal Box T1 – 13
b. SSR - to AU Terminal Box T1 – 15
8. Ensure the control cable is securely connected and with adequate clearance from the
mains supply terminations.
9. Tighten all glands and replace the cover securely, ensuring the cover earth wire is
fitted.
Connecting the mains voltage to the ISH

When you are satisfied that the voltage configuration of the ISH and the local
electrical supply voltage are the same, you can connect the mains supply voltage
to the ISH - noting the previous WARNING.

WARNING
PHYSICALLY DISCONNECT THE MAINS VOLTAGE SUPPLY BEFORE
FITTING THE IN-SITU HEATER. FAILURE TO FOLLOW THIS
WARNING COULD RESULT IN SERIOUS OR FATAL INJURY FROM
ELECTRIC SHOCK.
During installation of the In-Situ Heater, you may need to refer to the relevant
installation drawing in the Order-specific information section of this manual,
particularly if you will be making up your own interconnecting cables.
1 Fit the supplied circular gasket to the four M16 bolts on the vertical flange
already fitted to the process gas duct.
2 Offer up the ISH to the vertical flange. Introduce the heater gently into the duct
and fit the ISH flange onto the four M16 bolts.
3 If the AU is not to be fitted immediately, fit nuts to the four bolts, and finger-
tighten to retain the ISH safely.
4 Once the In-Situ Heater has been fitted, you may go on to fit the Analyser Unit.

Fault on the ISH

When an ISH is fitted, the TEST screen will display the heater power level. This
should start at 100% when the analyser is cold, and then reduce to a lower
percentage as the analyser warms up and reaches its setpoint.
If the set point shown on the Procal 1000 TEST screen is consistently below
120oC, then it is likely that the ISH is not working properly. Take the following
actions:
1. Check set point of ISH in S/W is correct
2. Measure the voltage between TB1-13B and TB1-15B on the AU junction box.
This should show a steady or pulsing 24 V dc.
2 Check that all the connections between the AU and the Control Unit are properly
made.
3 Confirm that a steady or slowly switching mains voltage appears between the
L and N terminals in the ISH mains connection box.
page D-4 KITTIWAKE PROCAL LTD Issue 4

Appendix D

Appendix F - Procal analysers for US EPA compliance
Introduction
To satisfy the environmental regulations in the USA and some other countries, it is
necessary to both check and demonstrate that the analyser is within its quoted
calibration accuracy. This requires that the Autozero facility should be augmented
by an automatic check of the span calibration of the analyser.
Once a day the analyser zero and span accuracy is to be checked and recorded.
This record is maintained on a rolling 7-day basis, and the record for the previous
seven days should be available for viewing and printing at any time on demand.
This appendix describes the implementation of US EPA 40 CFR Part 75 in the
Procal 2000. It must be read in conjunction with the main technical manual.
Services
The following services are required for this option:
ZERO GAS Clean, dry instrument air at a continuous 0.5 litre/min for the
analyser void purge and 5 litres/min for 4 minutes. The zero
gas solenoid is energised-closed so that in the event of a power
failure the analyser sample cell is filled with zero gas, thus
preventing damage due to acidic condensation of the sample
gas in the sample cell.
SPAN GAS This should be a gas mixture containing all the gases for which
verification is required. The concentration of each gas should
be between 80% and 100% of the full-scale sensitivity of its
measured channel. Consumption is 5 litres/min for 4 minutes
every 24 hours. NO, CO, SO2 etc. should be mixed with N2.
NO2 should be mixed with pure air. The span gas
concentration (from the certificate) must be entered at the
menu item ‘Calibration verification’ on the Control Unit each
time a new gas bottle is installed. For US EPA compliance
purposes it should be EPA Protocol 1, calibration gas, vendor
certificated.
Issue 4 KITTIWAKE PROCAL LTD page F-1

Operation
Manual operation of Auto-Zero is carried out using the following steps;
1) If not already on the TEST screen select the EYE symbol to navigate there.
2) Select AUTOZERO from the menu, this will give a drop down menu giving the
serial number of the Analyser head ACWn is looking at. Ensure the serial
number is for the head requiring the Auto-Zero.
3) Select START AUTOZERO NOW from the drop down menu.
The above steps assume that MANUAL AIR PURGE is NOT on. An Auto-Zero
cannot be carried out with manual air on, so this should be turned off before
hand. This is done by following the above steps but selecting MANUAL AIR
PURGE instead of Start AutoZero Now.
An automatic Auto-Zero is done on a settable time interval – usually every

12hours, the set up for which is done on the MAIN SCREEN. This is also the
place where the Auto-Zero function can be turned ON or OFF, the procedure for
this is detailed in the ACWN Control Manual.
During the first Auto-Zero cycle after midnight a calibration routine is included
in the operation, this data will be recorded once per day over a 7-day period.
This data can be inspected and printed as described in Viewing the results.
During calibration phase the introduction of the gases causes the pressure in the
cell to increase slightly. To allow for both variations in the process pressure and
in the pressure during auto calibration, a transducer in the analyser is used to
provide continuous pressure compensation. In addition, to ensure that
calibration gas is present, the calibration gas cylinder pressure is sensed by a
pressure switch (set to operate at 100psi) integral with its regulator. An alarm is
set up within ACWn that can be set to trigger if the gas pressure is low.
A further function is for the remote start of an Autozero cycle, which overrides
the internal automatic timer. This facility is activated by shorting 2 inputs on the
Analyser Unit with the volt-free contact.
page F-2 KITTIWAKE PROCAL LTD Issue 4

Appendix F
Figure 2 shows a table giving the phases of the calibration cycle including Auto-Zero,
their default timings and the states of the gas solenoids during the automatic calibration.
Note that the Zero gas solenoid valve is energized-closed so that in the event of a power
failure the valve opens, flooding the sample cell with dry air and excluding low
temperature sample gas that could cause acidic condensation and hence corrosion.
Default Zero Gas Span Gas

Phase Name Function Duratio Solenoid State Solenoid State
n (AIR) (Cal Gas)
Normal Analyser Energised De-energised

1 ANALYSE 12 hours
Operation on Process (CLOSED) (CLOSED)
Introduce zero gas

ZERO De-energised De-energised
2 (air), thereby purging 4 mins
FLUSH (OPEN) (CLOSED)
the sample gas
ZERO Average readings on De-energised De-energised

3 2 mins
CALCULATE zero (OPEN) (CLOSED)
Log the concentration

ZERO Energised De-enrgised
4 reading and reset the 1 sec
UPDATE (CLOSED) (CLOSED)
zero level
Introduce span gas,

Energised Energised
5 SPAN FLUSH thereby purging the 4 mins
(CLOSED) (OPEN)
zero gas
SPAN Energised Energised

6 Average the readings 2 mins
CALCULATE (CLOSED) (OPEN)
Log the concentration

SPAN Energised Energised
7 reading and act upon 1 sec
UPDATE (CLOSED) (OPEN)
the error accordingly
Switch off the span gas

PROCESS Energised De-enrgised
8 allowing sample gas to 4 mins
FLUSH (CLOSED) (CLOSED)
re-enter
Figure 1: Table showing solenoid states for AUTOZERO/AUTO CAL

Action on calibration error
If a calibration error occurs, the action required depends on the scale of the
error:
 If the error is less than 2.5% of full scale, no action is required as the calibration
is within specification
 for a change in calibration of between 2.5% and 5% of full scale, the analyser
calibration is automatically adjusted to give the correct reading and the calibration
is OK
 if an error is greater than 5% error or if the gas cylinder pressure falls below 100
psi, the analyser is considered to be out of calibration; no re-calibration action is
taken and the readings on the MAIN screen are shown thus:
(235) PPM Total NOx
Viewing the results
The results of this are accessed via the MENU item “Calibration verification”.
The following items are shown on the screen with some example values:
Channel NOx
Print this day
Print last 7 days
Date 1st Jan
Time 00:00
(status) OK
Cal Gas conc (PPM) 300
Zero conc (PPM) 0
Zero error (%) 0.0
Span conc (PPM) 300
Span error (%) 0.0
If ‘Print this day’ is selected then the report for that day is printed. Similarly, if
‘Print last 7 days’ is selected then the reports for that period are printed.
Electrical connections
The electrical connections to enable the Calibration Gas controls are detailed on
the Installation Drawing 7-2054
page F-4 KITTIWAKE PROCAL LTD Issue 4

Appendix F
Page intentionally left blank.

Appendix G - Hot Access Port
Introduction
The Hot Access Port has been added to the reflector tube on the PROCAL 2000
analyser (See Figure G2 for location) to enable water vapour injection while
minimising condensation in the analyser probe. This will hence enable water
vapour based re-calibration on site from a suitably accurate water vapour
generator. The Procal 9000 Field Calibrator, including Water Vapour control is
available, see Procal Data Sheet 7-3057 for details.
Additionally this port can be used as a sample extraction port without

disconnection of any other gas lines on the instrument.
Warning
AS THIS PORT IS CONNECTED TO THE INSTRUMENT MEASURING
CELL IT MUST BE CLOSED GAS TIGHT TO AVOID LEAKAGE OUT OR IN
WHEN NOT IN USE. A LEAK WILL INVALIDATE BOTH THE AUTO
ZERO / AUTOCAL RESULT AND CONTINUOUS MEASUREMENT
RESULTS.
This port is on the main stack flange; an optional insulation jacket is available, to
raise the port’s temperature whilst allowing access. See Figure G1 – Insulation
Jacket for details.
Operation
For most installations the use of the hot access port for water vapour injection
will require the fitting of an insulated jacket (Procal Part No 4-5455) around the
port to reduce the risk of condensation. See Fig G1 for fitting details. When the
jacket is fitted the system temperature should be allowed to stabilise before
continuing with any measurements. This may take up to 30 minutes. The jacket
allows for connection or disconnection without removal of the insulation as
shown on Fig.G1.
Before using the Hot Access Port for calibration first carry out an AutoZero with
the Hot Access Port closed off.
Carefully remove the plug with a 5mm Allen Key (Procal part 6-9901-87) and
place in a secure location for re-installing later. See Figure G1 – Insulation
Jacket and Figure G2 – Reflector Tube for details. Note that gases from the
process may escape from this port when it is open. Suitable precautions must be
taken, ie avoid breathing the hot escaping gas.
When applying water vapour a heated line or a purpose designed close coupled
evaporator should be used, and any exposed pipe or fittings containing hot
vapour should be insulated. See Figure G3 – Water Vapour Line Fitting
PROCAL 2000. On completion of tests remove the connecting line and replace it
with the hot access port plug, a 1/8 BSP taper plug, Procal part 6-6060-20 using
PTFE tape (Procal part 9-2900-01) to seal the thread. Ensure this is tightened to
form a gas tight seal.
Issue 4 KITTIWAKE PROCAL LTD page G-1

Drawings
Figure G1 – Insulation Jacket.
page G-2 KITTIWAKE PROCAL LTD Issue 4

Appendix G
Figure G2 – Reflector Tube
Issue 4 KITTIWAKE PROCAL LTD page G-3

Figure G3 – Water Vapour Line Fitting PROCAL 2000
page G-4 KITTIWAKE PROCAL LTD Issue 4

Appendix H – By Pass
Introduction
Some PROCAL 2000 systems are supplied with an optional By-Pass Assembly
For the follwing applications
 Where the process temperature is > 350°C and < 800°C (> 660°F and
< 1112°F)
 For small diameter Stacks / Ducts < 900mm ( < 3 ft )
This Appendix describes this option, and details how to install it.
By-Pass description
The optional By-Pass assembly is used in high temperature

applications or where the stack or duct size does not allow the
analyser to be fully inserted. The assembly requires two flanges
to be wielded to the stack or duct. The spacing, specification and
orientation of the flanges is critical, refer to the appropriate By-
Pass drawing. In some applications with a high flow rate an
orifice plate may have to be fitted between one of the stack
mounting flanges and the By-Pass assembly.
The By-Pass assembly also includes a heater assembly to

maintain the Analyser In-Situ sample cell at the control
temperature. The electrical heater, which has the effect of
keeping the temperature of the sample cell well above the dew
point, thus preventing condensation onto any optics in contact
with the process gas.
Control of the Heater is from the PROCAL 2000 and is

automatic.
The additional power requirement for the In-Situ Heater is 1

kW.
The assembly also includes a sample scoop which can be fitted

to either branch of the by pass. A proportion of the stack /
process gas is diverted through the By-Pass and passed the
Procal 2000 In-Situ Cell enabling the gas concentrations to be
monitored. The stack gas is driven through the By-Pass by both
the action of the scoop and a “Chimney” effect caused by the
dissimilar gas temperature in the stack and By-Pass. It is
therefore recommended that when the stack temperature is
higher than the By-Pass Heater set point the scoop is mounted
on the upper By-Pass branch and when the stack temperature is lower than the
By-Pass temperature the scoop is mounted on the lower branch.
Issue 4 KITTIWAKE PROCAL LTD page H-1

Fitting the Optional By-Pass

Note - Before commencing installation of the By-Pass it is imperative that you have access
to the correct instlation drawing. The By-Pass part number as stated on the packing note
should appear as the drawing number in the bottom right hand corner of the installation
drawing.
There are two basic By-Pass designs.

 1-1989 Heated By-Pass - main wetted parts Stainless Steel
 1-2060 Heated By-Pass - main wetted parts Hastelloy C276 / Heater Assy
Inconel 825
Other order specific By-Pass assemblies may be supplied, contact Kittiwake Procal Ltd or
the local distributor to obtain the appropriate installation drawing
The By-Pass consists of three main components

 By-Pass Assembly
 Heater Assembly
 Scoop – Note the length of the scoop is application specific and therefore must be
defined at the order stage. The scoop can be attached to either of the By-Pass
branches and is secured by four counter sunk screws. The appropriate branch to fit
the scoop is included in the By-Pass description section.
Mounting Flanges
The By-Pass is mounted on two 4” 150lb flat face ANSI Flanges with (Not normally
supplied by Kittiwake Procal Ltd). The flanges are welded to the stack using, it is important
the weld is gas tight. Note the correct orientation of the flange is observed.
24mm NOM
Note Flange Orientation
50mm
136.0mm
8 M16 Studs Equally Spaced on

229mm 190.5 PCD Welded to Flange NOM
NOM
Stack Mounting Flanges
page H-2 KITTIWAKE PROCAL LTD Issue 4

Appendix H
Mounting By-Pass to the stack.
The scoop should be attached to the appropriate branch before installation of the By-Pass.
The is supplied with graphite gaskets, these should be inspected before installation. It is
important the supplied gaskets are used in the installation
Part Number: 4-6049 4” 150lb Graphite Gasket
Secure the By-Pass to the stack mounted flanges using 8 x M16 nuts & washes per flange.
Heater Assembly
The By-Pass is supplied with the Heater Assembly fitted, it can be removed for inspection
and cleaning. If removed a new gasket should be used on re installation.
Working on the Heater Assembly

WARNING
PHYSICALLY DISCONNECT THE MAINS VOLTAGE SUPPLY BEFORE
FITTING THE IN-SITU HEATER. FAILURE TO FOLLOW THIS
WARNING COULD RESULT IN SERIOUS OR FATAL INJURY FROM
ELECTRIC SHOCK.
To remove the Heater Assembly 1-1986/1-2046
 Remove the AU ensuring it is stored in a safely in a clean and dry

environment taking precautions not to damage any of the cables, glands
or pie fitting protruding from the base of the AU cover.
 With the Heater disconnected remove the four M16 nuts which are
recessed in the horizontal By-Pass Flange.
 The Heater Assembly can then be removed for inspection.
 Before reinstalling ensure all particulates have been removed from the
Heater Assembly and By-Pass.
 It is important that both gasket between the Heater Assembly and AU

are replaced during reassembly.
Gasket Part Number 4-6041-00

Connecting the Heater

WARNING
DO NOT CONNECT ANY MAINS CABLE (LINE CORD) TO THE
ELECTRICAL SUPPLY UNTIL ALL CONNECTIONS WITHIN THE
HEATER HAVE BEEN MADE AND THE UNITS ARE SECURELY
CLOSED ONCE MORE. FAILURE TO FOLLOW THIS WARNING MAY
RESULT IN SERIOUS OR FATAL INJURY FROM ELECTRIC SHOCK.
Caution
Do not attempt to connect any mains cable (line cord) to the Heater if the
voltage configuration of the Heater differs from your local electrical supply
voltage. Contact Kittiwake Procal, or your Procal-authorised distributor.
Using an incorrect supply voltage will result in the In-Situ Heater failing to
function properly.
Connecting the By-Pass Heater to the Mains Supply.
Underside of Procal 2000
Earth Lead
Earth Connection Power to Lid
(Earth MUST be
)
Heater
Junction Box
By-Pass
Link 110V / 240V

Appendix H
Power cable required for Heater supply - rated at 3 A (230 V) or 6 A (115 V)
IT IS ESSENTIAL FOR CONFORMANCE WITH EN61010 THAT A FIXED

MAINS INSTALLATION HAS AN ISOLATOR FITTED IN THE SUPPLY,
AND THIS SHOULD BE PROVIDED BY THE SITE SUPPLY
DISTRIBUTION POINT.
1. Determine voltage of supply 110V or 240V (Others consult Kittiwake Procal Ltd or
Distributor)
2. Remove and retain the four screws securing the cover of the Heater junction box.
3. Feed through one end of the Heater power cable through the cable gland in the
Heater junction box.
Blue (neutral) TB 2 (Retain link)
Blue (neutral) TB 1 (Discard link)
6. Finger-tighten the cable glands in the Heater junction box.
7. Connect the AU control to the Heater SSR wiring the control cable through the
other gland.
a. SSR + to AU Terminal Box T1 – 13B
b. SSR - to AU Terminal Box T1 – 15B
8. Ensure the control cable is securely connected and with adequate clearance from the
mains supply terminations.
9. Tighten all glands and replace the cover securely, ensuring the cover earth wire is
fitted.
Connecting the mains voltage to the Heater

When you are satisfied that the voltage configuration of the Heater and the local
electrical supply voltage are the same, you can connect the mains supply voltage
to the Heater - noting the previous WARNING.
Fault on the HEATER

When an HEATER is fitted, the TEST screen will display the heater power
level. This should start at 100% when the analyser is cold, and then reduce to a
lower percentage as the analyser warms up and reaches its setpoint.
If the sample temperature shown on the Procal 1000 TEST screen is consistently
below 120oC, then it is likely that the HEATER is not working properly. Take
the following actions:

1 Measure the voltage between TB1-13B and TB1-15B on the AU junction box.
This should show a steady or pulsing 24 V dc.
2 Check that all the connections between the AU and the Control Unit are properly
made.
3 Confirm that a steady or slowly switching mains voltage appears between the
L and N terminals in the Heater mains connection box.
Over Heating
If the sample temperature is higher than the Heater set point it is
necessary to reduce the flow through the By-Pass this can be achieved
by introducing a Orifice plate in the branch which does not have the
scoop attached.
Consult Kittiwake Procal Ltd or the local distributor for advice.

Appendix H

Appendix J - In-Situ Steam Heater
Introduction
Some PROCAL 2000 systems are supplied with an optional In-Situ Steam
Heater (ISSH). This Appendix describes this option, and details how to install it.
For the following applications
 Hazardous Areas (It is the responsibility of the customer to determine

that the equipment is suitable for the hazardous are it is to be installed
in, taking into account the maximum permitted surface temperature).
In-Situ Steam Heater description
An optional In-Situ Steam Heater (ISSH) may be fitted around the sample cell,
and is recommended for applications involving flue gases at temperatures below
120°C. The ISH contains an electrical heater, which has the effect of keeping
the temperature of the sample cell well above the dew point, thus preventing
condensation onto any optics in contact with the process gas.
Regulation of the ISH is controlled by a Steam Regulator and steam trap not
supplied with the ISH
Typical Steam Pressure required to maintain the Probe at 150°C is 6 barg.

Consult the supplier of the steam regulator for detailed advice and
recommendations.
Issue 4 KITTIWAKE PROCAL LTD page J-1

Fitting the In-Situ Steam Heater
Fitting the In-Situ Steam Heater

During installation of the In-Situ Steam Heater, you may need to refer to the
relevant installation drawing in the Order-specific information section of this
manual.
There are two basic In-Situ Steam Heater designs.

 1-2061-00 In-Situ Steam Heater - main wetted parts Inconel 825
 1-2062-00 In-Situ Steam Heater - main wetted parts Hastelloy C276
In-Situ Steam Heater ISSH Stack Mounting Flange
1 Fit the supplied circular gasket to the four M16 bolts on the vertical flange already fitted to the process gas
2 Offer up the ISSH to the vertical flange. Introduce the heater gently into the duct and fit the ISSH flange o
Sample Gas Inlet Sample gas outlet (Must be
in stack
3 If the AU is not to be fitted gas flow)fit nuts to the four bolts, and finger-tighten to retain the ISSH saf
immediately,
4 Once the ISSH has been fitted, you may go on to fit the Analyser Unit.
Steam Inlet and Outlet
10mm Tube

WARNING
PHYSICALLY ISOLATE THE STEAM SUPPLY BEFORE FITTING OR
WORKING ON THE IN-SITU STEAM HEATER. FAILURE TO FOLLOW
THIS WARNING COULD RESULT IN SERIOUS OR FATAL INJURY
1 Fit the supplied circular gasket to the four M16 bolts on the vertical flange
already fitted to the process gas duct.
2 Offer up the ISSH to the vertical flange. Introduce the heater gently into
the duct and fit the ISSH flange onto the four M16 bolts.
3 If the AU is not to be fitted immediately, fit nuts to the four bolts, and
finger-tighten to retain the ISSH safely.
4 Once the In-Situ Heater has been fitted, you may go on to fit the Analyser
Unit.
5 Connect the steam supply to the Inlet and Outlet 10mm OD Tubes using
appropriate pipefittings.
6 Observe the temperature of the sample (T Sample) on the TEST screen of

the Procal 1000, adjust the Steam Regulator until T Sample is maintained
at the calibration temperature (T Cal), as stated in the analyser dispatch
data Analyser Configuration Sheet 7-7618.
page J-2 KITTIWAKE PROCAL LTD Issue 4

Appendix J
Fault on the ISSH

When an ISSH is fitted, the TEST screen will display the temperature of the
sample (T Sample) this should be within ± 10°C (±50°F) of the calibration
temperature (T Cal), as stated in the analyser dispatch data Analyser
Configuration Sheet 7-7618.
If the sample temperature shown on the Procal 1000 TEST screen is consistently
below T Cal, then it is likely that the ISSH is not working properly. Take the
following actions:
1 Check setting on the Steam Regulator
Issue 4 KITTIWAKE PROCAL LTD page J-3

page J-4 KITTIWAKE PROCAL LTD Issue 4

Appendix K – Steam Heated By Pass
Introduction
Some PROCAL 2000 systems are supplied with an optional Steam Heated By-
Pass Assembly
For the follwing applications
 For small diameter Stacks / Ducts < 900mm ( < 3 ft ) in Hazardous

Areas (It is the responsibility of the customer to determine that the
equipment is suitable for the hazardous are it is to be installed in,
taking into account the maximum permitted surface temperature).
This Appendix describes this option, and details how to install it.
By-Pass description
The optional By-Pass assembly is used in hazardous area

applications where the stack or duct size does not allow the
analyser to be fully inserted. The assembly requires two flanges to
be wielded to the stack or duct. The spacing, specification and
orientation of the flanges is critical, refer to the appropriate Steam
Heated By-Pass drawing. In some applications with a high flow
rate an orifice plate may have to be fitted between one of the
stack mounting flanges and the Steam Heated By-Pass assembly.
The Steam Heated By-Pass assembly maintain the Analyser In-

Situ sample cell at the control calibration temperature. The steam
heater, which has the effect of keeping the temperature of the
sample cell well above the dew point, thus preventing
condensation onto any optics in contact with the process gas.
Regulation of the Steam Heated By-Pass is controlled by a Steam

Regulator not supplied with the Steam Heated By-Pass
Typical Steam Pressure required to maintain the Probe at 150°C

is 6 barg. Consult the supplier of the steam regulator for detailed
advice and recommendations. Steam
The assembly also include a sample scoop which can be fitted to

either branch of the by pass. A proportion of the stack / process
gas is diverted through the By-Pass and passed the Procal 2000
In-Situ Cell enabling the gas concentrations to be monitored. The
stack gas is driven through the By-Pass by both the action of the
scoop and a “Chimney” effect caused by the dissimilar gas
temperature in the stack and By-Pass. It is therefore
recommended that the scoop is mounted on the lower branch.
Issue 4 KITTIWAKE PROCAL LTD page K-1

Fitting the Optional Steam Heated By-Pass

Note - Before commencing installation of the By-Pass it is imperative that you have access
to the correct instlation drawing. The By-Pass part number as stated on the packing note
should appear as the drawing number in the bottom right hand corner of the installation
drawing.
There are two basic By-Pass designs.

 1- 2864 Steam Heated By-Pass - main wetted parts Stainless Steel
Other order specific By-Pas assemblies may be supplied, contact Kittiwake Procal Ltd or
the local distributor to obtain the appropriate installation drawing
The By-Pass consists of three main components

 Steam Heated By-Pass Assembly
 Scoop – Note the length of the scoop is application specific and therefore must be
defined at the order stage. The scoop can be attached to the By-Pass branch and is
secured by four counter sunk screws.
Mounting Flanges
The By-Pass is mounted on two 4” 150lb flat face ANSI Flanges with (Not normally
supplied by Kittiwake Procal Ltd). The flanges are wielded to the stack using, it is
important the wield is gas tight. Note the correct orientation of the flange is observed.
24mm NOM
Note Flange Orientation
50mm
136.0mm
8 M16 Studs Equally Spaced on

229mm 190.5 PCD Welded to Flange NOM
NOM
Stack Mounting Flanges
page K-2 KITTIWAKE PROCAL LTD Issue 4

Appendix K
The scoop should be attached to the appropriate

branch before installation of the By-Pass. The is
supplied with graphite gaskets, these should be
inspected before installation. It is important the
supplied gaskets are used in the installation
Part Number: 4-6049 4” 150lb Graphite

Gasket
AU Flange
3 in 150lb
Secure the By-Pass to the stack mounted flanges
using 8 x M16 nuts & washes per flange.
Stack Mounting
Flange Steam Heater
4 in 150lb
The By-Pass has an integral steam heater
Steam Inlet /
Outlet Working on the Steam Heated By-
½ in 150lb Pass Heater
Raised Face WARNING
Flange
PHYSICALLY ISOLATE THE STEAM
SUPPLY BEFORE FITTING OR WORKING
ON THE IN-SITU STEAM HEATER.
Scoop FAILURE TO FOLLOW THIS WARNING
COULD RESULT IN SERIOUS OR FATAL
INJURY
The scoop should be attached to the appropriate branch before installation of the By-Pass.
The is supplied with graphite gaskets, these should be inspected before installation. It is
important the supplied gaskets are used in the installation
Part Number: 4-6049 4” 150lb Graphite Gasket
Secure the By-Pass to the stack mounted flanges using 8 x M16 nuts & washes per flange.
Connecting Steam

1. Connect the steam supply to the Inlet and Outlet 1 Steam Inlet /
Outlet
½ in 150lb Raised Face Flange
2. Observe the temperature of the sample (T Sample) on the TEST

screen of the Procal 1000, adjust the Steam Regulator until T Sample
is maintained at the calibration temperature (T Cal), as stated in the
analyser dispatch data Analyser Configuration Sheet 7-7618.
Over Heating
If the sample temperature is higher than the Heater set point it is
necessary to reduce the flow through the By-Pass this can be achieved
by introducing a Orifice plate in the branch which does not have the
scoop attached.
Consult Kittiwake Procal Ltd or the local distributor for advice.
page K-4 KITTIWAKE PROCAL LTD Issue 4

Appendix K

Appendix L – Air Preparation Panel
Introduction
As stated on page 7-1 instrument supplied to the analyser must conform to the
specification as laid in document:
7-5823-00 Quality Standard for Instrument Air Supplied to Procal Analysers
On installations where the quality of instrument air does not meet the required
specification it is strongly recommended that the optional Air Preparation Panel Part
Number 1-2938 is installed.
The Input Air must come from an Oil Free Compressor
300mm (11.8”) 132mm (5.2”)

250mm (9.8”) CRS 25mm (1”)
Item 1
¼” BSP Port ¼” BSP

310mm (12.2”) CRS
Item 5
360mm (14.2”)
Instrument Air Port

Supply Connected
5.5 – 12.5 bar to Analyser
Item 4
Item 2
Item 3
Fig Shows the Air Preparation Panel
Issue 4 KITTIWAKE PROCAL LTD page L-1

Component Identification
Item Description Note
Isolate assembly before maintenance or

1 Isolation Ball Valve
inspection
2 Particulate Filter
Under normal operation a continuous purge

3 Membrane Dryer
exhausts and must be kept clear
4 Active Carbon Filter
5 Pressure regulator Set at 1 barG above process pressure.
Maintenance
The Air Preparation Panel should be inspected at regular intervals for visible signs of
moisture / particulate or oil contamination in the filter housings. The frequency of filter
element will depend on the quality of the air supply however as a minimum the filters
should be changed at least annually.
Filter Elements
Housing Comment
Part No.
Particulate Filter 6-9714 Remove Filter Bowl to access element
Remove Lower section of housing to

Membrane Dryer 6-9715
access element
Active Carbon Filter 6-9716 Remove Filter Bowl to access element
page L-2 KITTIWAKE PROCAL LTD Issue 4

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PROCAL 2000

Kittiwake Procal Limited

Published by Kittiwake Procal Limited.

No part of this publication may be reproduced, stored in a retrieval system or

Part Number 7-3204-04 Issue 02 August 2011

© Kittiwake Procal Limited 2004 - 2011

Kittiwake Procal Limited

PROCAL, PULSI and XSENS are trademarks of Kittiwake Procal Limited.

page 2 KITTIWAKE PROCAL LTD Issue 4

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

2 Installation ............................................................................................................. 2-1

3 Operation ............................................................................................................... 3-1

4 Technical description ........................................................................................... 4-1

5 Maintenance .......................................................................................................... 5-1

6 Disposal instructions............................................................................................ 6-1

7 Order-specific information ................................................................................... 7-1

Appendix A - The PROCAL 2000 with ATEX/IECEx approval .............................. A-1

Issue 4 KITTIWAKE PROCAL LTD page 3

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page 4 KITTIWAKE PROCAL LTD Issue 4

About this manual

It is split into a number of sections. Introduction (this section) gives a brief

About the PROCAL 2000 series

The PROCAL 2000 series is a range of high-performance infrared gas

Issue 4 KITTIWAKE PROCAL LTD page 1-1

PROCAL 2000 - an overview

Within the PROCAL 2000, up to six gases may be measured on up to six

Figure 1-1 PROCAL 2000 optical diagram

A schematic diagram of the PROCAL 2000 system appears as Figure 1-2

page 1-2 KITTIWAKE PROCAL LTD Issue 4

Figure 1-2 PROCAL 2000 system schematic

Issue 4 KITTIWAKE PROCAL LTD page 1-3

Procal 1000 Series

ISH In-Situ Heater

Some systems will have different screens because of custom modifications. If

Screen messages, prompts or options are repeated in text in a different typeface

page 1-4 KITTIWAKE PROCAL LTD Issue 4

It is important to identify the analyser and ensure it is correctly located especially in

Kittiwake Procal Ltd

tel: +44 1733 232495 (international)

Issue 4 KITTIWAKE PROCAL LTD page 1-5

Page intentionally left blank

page 1-6 KITTIWAKE PROCAL LTD Issue 4

ALWAYS ENSURE THAT YOU COMPLY WITH LOCAL SAFETY

Unpacking the system components

Issue 4 KITTIWAKE PROCAL LTD page 2-1

 Suitable locations are available for all components of the system to be

 A suitably fused, switched, mains electrical power is available at 110 V /

 All the interconnecting cables specified in this installation procedure are

 In the section of this manual entitled Order-specific information, you will

Figure 2-1 Optimum flange installation of the AU into a process duct

Issue 4 KITTIWAKE PROCAL LTD page 2-2

Preparing the process gas duct

Figure 2-2 Flange Mounting

Issue 4 KITTIWAKE PROCAL LTD page 2-3

Stack Flange – Good Practice

Preferred – With the flange wielded directly to the

Stack, duct or process pipe