Ametek Thermox WDG Insitu User manual

Thermox
150 Freeport Road
Pittsburgh, PA 15238
WDG Insitu
with Series 2000 Control Unit
User Manual
PN 90271VE, Rev. U

ii | Thermox Series 2000 WDG Insitu Analyzer
© 2012 AMETEK
This manual is a guide for the use of the Thermox WDG Insitu. Data herein has been veried and validated and is believed adequate for the intended
use of this instrument. If the instrument or procedures are used for purposes over and above the capabilities specied herein, conrmation of their
validity and suitability should be obtained; otherwise, AMETEK does not guarantee results and assumes no obligation or liability. This publication is not
a license to operate under, or a recommendation to infringe upon, any process patents.
OFFICES
USA - Pittsburgh
150 Freeport Road
Pittsburgh, PA 15238
Ph. 412-828-9040
Fax [phone]
CHINA
AMETEK Shanghai (SPL)
Room 408, Metro Tower
#30 Tian Yao Qiao Road
Shanghai 200030
Ph. 86 21 6426 8111
Fax [phone]
USA - Delaware
455 Corporate Blvd.
Newark, DE 19702
Ph. 302-456-4400
Fax [phone]
AMETEK Beijing
CITIC Building, Room 2305
19, Jianguomenwai Dajie
Beijing 100004
Ph. 86 10 8526 2111
Fax [phone]
USA - Texas
4903 West Sam Houston Parkway North
Suite A-400
Houston, TX 77041
Ph. 713-466-4900
Fax [phone]
FRANCE
AMETEK Precision Instruments France
Rond Point de l’épine des champs
Buroplus Bat D
78990 Elanbourt
Ph. 33 1 30 68 89 20
Fax [phone]
CANADA
2876 Sunridge Way N.E.
Calgary, AB T1Y 7H9
Ph. 403-235-8400
Fax [phone]
GERMANY
AMETEK GmbH
Rudolf-Diesel-Strasse 16
D-40670 Meerbusch
Ph. 49 21 59 91 36 0
Fax [phone]
MIDDLE EAST – Dubai
AMETEK
PO Box 17067
Jebel Ali Free Zone
Dubai, UAE
Ph. 971-4-881 2052
Fax [phone]
SINGAPORE
AMETEK Singapore Pte. Ltd.
No 43, Changi South Avenue 2, #04-01
Singapore 486164
Ph. 65-64842388
Fax [phone]

| iii
Contents
OFFICES .................................................................................................................ii
Safety Notes ...........................................................................................................v
Electrical Safety......................................................................................................v
Grounding..............................................................................................................v
Environmental Information (WEEE) ...............................................................vii
OVERVIEW
Sensor ..................................................................................................................... 1
Basic Elements of the Sensor ........................................................................ 3
The Oxygen Measuring Cell......................................................................... 3
Common Operator Errors ................................................................................... 5
Start-Up Checklist ................................................................................................. 6
Technical Support.................................................................................................. 7
Specications
Series 2000 Control Unit....................................................................................... 1
Remote Calibration Unit (RCU).......................................................................... 3
Installation
Analyzer Location ................................................................................................. 1
Installing the Filter/Flame Arrestor (Optional).......................................... 2
Sensor Mounting................................................................................................... 3
Division 2 Option ........................................................................................... 3
Gas Requirements and Connections ........................................................... 7
RCU Installation (Option)............................................................................. 7
Control Unit Mounting ........................................................................................ 9
Wiring.................................................................................................................... 12
General Wiring and Conduit Requirements............................................ 13
Control Unit Mains Supply Connections ................................................. 14
Sensor Connections...................................................................................... 18
Current Output Connections ..................................................................... 21
Alarm Contact Connections........................................................................ 22
Remote Calibration Unit Connections...................................................... 24
RS-485 Communications Connections...................................................... 26
Option Card Installation.................................................................................... 30
Removing Display Module or Power Supply/Keypad Module ............ 30
Adding an Option Card............................................................................... 31
Removing an Option Card.......................................................................... 31
Sensor Wiring Schematic ................................................................................... 32

iv | Thermox Series 2000 WDG Insitu Analyzer
CONTROLLER / USER INTERFACE
Areas of the Control Unit..................................................................................... 1
Control Unit Display...................................................................................... 1
Selecting Menu Options................................................................................ 2
Exiting Menu Options ................................................................................... 2
Automatic Menu Exit Feature....................................................................... 3
On-Line Help .................................................................................................. 3
System Password ............................................................................................ 3
Setup Key................................................................................................................ 4
Display.............................................................................................................. 5
Process Pressure.............................................................................................. 6
System Tests..................................................................................................... 7
System Serial # ............................................................................................... 7
Primary Calibration........................................................................................ 8
Sensor Config ................................................................................................ 11
Communication ............................................................................................ 12
Analog Range Key............................................................................................... 13
Analog Output Port...................................................................................... 14
Set Current Range ........................................................................................ 15
Set Track/Hold Option ................................................................................. 16
Set Current Mode ......................................................................................... 17
Output Filtering Option.............................................................................. 17
Select Function.............................................................................................. 18
Alarm Key............................................................................................................. 19
Overview of Alarm Functions .................................................................... 20
Alarm Set Points............................................................................................ 20
Alarm Configure........................................................................................... 22
Relay Configure ............................................................................................ 22
Select Function.............................................................................................. 23
Service Alarm ................................................................................................ 23
Watchdog Relay ............................................................................................ 24
Exception Log................................................................................................ 24
Calibration
Definitions.............................................................................................................. 2
Calibrations vs. Verifications......................................................................... 2
Span and Zero Calibration Gas Definitions ............................................... 2
Types of Calibrations............................................................................................. 3
Overview ................................................................................................................ 4
Aborting a Calibration .......................................................................................... 4
Initiate Cal and Initiate Verify ............................................................................. 5
Auto Calibrate/Auto Verify ............................................................................ 5
Remote Calibrate/Remote Verify.................................................................. 6
Manual Calibrate/Manual Verify.................................................................. 8
Cal/Verify Data..................................................................................................... 10

| v
Cal Gas Value ....................................................................................................... 12
Inject Cal Gas ....................................................................................................... 13
Set Cal Timers ...................................................................................................... 14
Set Cal Timers - Set Auto Timers................................................................ 14
Set Cal Timers - Set Time and Date ........................................................... 15
Set Cal Timers - Auto Cal On/Off............................................................... 16
Set Cal Timers - Cal Gas Duration ............................................................. 17
Set Cal Timers - Recovery Duration .......................................................... 17
Maintenance and Troubleshooting
System Messages................................................................................................... 2
Auto Cal Pending............................................................................................ 2
Auto Verify Pending ....................................................................................... 2
Calibration Aborted........................................................................................ 2
Calibration Required...................................................................................... 2
Cal Verify Aborted .......................................................................................... 2
Power Down Detected................................................................................... 2
Primary Calibration........................................................................................ 2
System Calibrating ......................................................................................... 2
System Verifying Cal ...................................................................................... 2
Error Messages....................................................................................................... 3
Diagnostics Checks ............................................................................................... 5
Wiring Checks ................................................................................................. 6
Thermocouple Checks ................................................................................... 6
Calibration/Aspirator Setup Checks ............................................................ 8
AC Power Checks.......................................................................................... 10
Furnace Checks............................................................................................. 10
Process Pressure Checks.............................................................................. 10
Cell Checks .................................................................................................... 10
General Troubleshooting.................................................................................... 12
Leak Check .................................................................................................... 12
Plugged Plumbing Check............................................................................ 13
Series 2000 LEDs.................................................................................................. 14
Auto Calibration Card LEDs ....................................................................... 14
Sensor Board (80471SE) LEDs..................................................................... 15
Service and Parts
Inner Probe Assembly Removal.......................................................................... 2
Cell Replacement................................................................................................... 4
Heater/Thermocouple Replacement................................................................ 10
Sensor Board Replacement................................................................................ 11
RCU Solenoid Valve Replacement ................................................................... 12
Parts Replacement List ....................................................................................... 13

vi | Thermox Series 2000 WDG Insitu Analyzer
Serial Communications
Communication Protocols............................................................................. 1
Command Message Format.......................................................................... 2
General Serial Communication Commands .............................................. 3
Development Serial Communication Commands.................................... 4
Responses......................................................................................................... 6
Variable Table ......................................................................................................... 7
Sample Program .................................................................................................. 24
Starting/Monitoring a Calibration: An Example ............................................ 25
Menu Option Charts
Current Outputs: Other Applications
Powering Current Outputs from an External Power Supply ........................ 1
Modulation of External Power Loop Using Current Outputs....................... 3
Drawings and Custom Instructions
Series 2000 Controller Setup Parameters...........................................................1
Sensor Default Settings

| vii
Safety Notes
WARNINGS, CAUTIONS, and NOTES contained in this manual emphasize criti-
cal instructions as follows:
An operating procedure which, if not strictly observed, may result in personal
injury or environmental contamination.
An operating procedure which, if not strictly observed, may result in damage
to the equipment.
Important information that should not be overlooked.
Electrical Safety
Up to 5 kV may be present in the analyzer housings. Always shut down power
source(s) before performing maintenance or troubleshooting. Only a qualified
electrician should make electrical connections and ground checks.
Any use of the equipment in a manner not specified by the manufacturer may
impair the safety protection originally provided by the equipment.
Grounding
Instrument grounding is mandatory. Performance specifications and safety pro-
tection are void if instrument is operated from an improperly grounded power
source.
Verify ground continuity of all equipment before applying power.
NOTE


viii | Thermox Series 2000 WDG Insitu
SPECIAL WARNINGS AND INFORMATION
No operator serviceable components inside any components of the WDG system.
Do not remove the cover from any WDG component. Refer servicing to qualified
personnel.
This equipment is suitable for use in Class I, Division 2, Groups A, B, C, and D or
nonhazardous locations only.
The following applies to the Series 2000 Control unit and the WDG-Insitu Divi-
sion 2 Models:
Power, input, and output (I/O) wiring must be in accordance with Class I, Di-
vision 2 wiring methods [Article 501-4(b) of the National Electric Code, NFPA
70] and in accordance with the authority having jurisdiction.
Warning - explosion hazard - substitution of components may impair suitabil-
ity for Class I, Division 2.
Warning - explosion hazard - when in hazardous locations, turn off power
before replacing or wiring modules.
Warning - explosion hazard - do not disconnect equipment unless power has
been switched off or the area is known to be nonhazardous.
For the Division 2 Insitu Option, the Division 2 classification applies only
to the enclosure side, and does not apply where the probe is inserted into the
process.
The maximum ambient temperature for the Series 2000 control unit is 50°C
(122°F)
The Series 2000 Control Unit with WDG-Insitu sensor is a complex piece of equip-
ment that should only be serviced by a qualified service technician with expertise
in instrument technology and electrical systems. AMETEK recommends that all
equipment requiring service be sent back to the factory. You should only attempt
to repair or service this equipment after receiving training from an AMETEK/
P&AI Division training representative. If you decide to service this equipment
be aware that high voltages, high temperatures, and other potentially hazardous
conditions may arise.
NOTE


| ix
Environmental Information (WEEE)
This AMETEK product contains materials that can be reclaimed and recycled.
In some cases the product may contain materials known to be hazardous to the
environment or human health. In order to prevent the release of harmful sub-
stances into the environment and to conserve our natural resources, AMETEK
recommends that you arrange to recycle this product when it reached its “end of
life”.
Waste Electrical and Electronic Equipment (WEEE) should never be disposed of
in a municipal waste system (residential trash). The Wheelie Bin marking on this
product is a reminder to dispose of the product properly after it has completed
its useful life and been removed from service. Metals, plastics, and other com-
ponents are recyclable and you can do your part by doing one of the following
steps:
•When the equipment is ready to be disposed of, take it to your local
or regional waste collection administration for recycling.
•In some cases, your “end of life” product may be traded in for credit
towards the pur-chase of new AMETEK instruments. Contact your
dealer to see if this program is avail-able in your area.
•If you need further assistance in recycling your AMETEK product,
contact our ofce listed in the front of the instruction manual.

x | Thermox Series 2000 WDG Insitu
Declaration of Conformity
Manufacturer’s Name: AMETEK/Thermox®
Manufacturer’s Address: Process & Analytical Instruments Division
150 Freeport Road
Pittsburgh, PA 15238
declares that the products:
Product Names: WDG Insitu using Series 2000 Controller
O2-Only RCU
Conform to the following standards:
EMC compliance:
EMC Directive 2004/108/EC
Immunity:
EN 50082-2:1995 Generic - Heavy Industrial Equipment
EN 50082-1:1997 Generic - Residential, Commercial, Light Industrial Equipment
EN 61000-6-2:1999 Generic - Heavy Industrial Equipment
EN 61326:1997 Measuring Equipment (Heavy Industrial)
Emissions:
EN 55011:1998 Class A, ISM Equipment
EN 61000-3-2:1995 Class A, Harmonic Current Emission
EN 61000-3-3:1995 Limitation of Voltage Fluctuations
Safety Compliance:
UL 3101-1 UL Listed Inspection and Measuring Electrical Equipment
CAN/CSA 22.2 No. 1010.1-92 cUL Listed Inspection and Measuring Electrical Equipment
Low Voltage Directive 73/23/EEC:
EN61010-1:1993,
Amendment A2: 1995 Electrical Equipment for Measurement, Controls,
and Laboratory Use
WDG Insitu probes with the suffix Div. 2, Series 2000 Controller and O2 -Only RCU, O2 also
conform to the following safety standard:
UL 1604 UL Listed Process Control Equipment for Use in Hazardous Locations
Manufacturer’s Address in Europe:
AMETEK Precision Instruments Europe GmbH
Rudolf-Diesel-Strasse 16
D-40670 Meerbusch, Germany
Mark Coppler
Compliance Engineer
May 2001