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]

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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