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

| xi
WARRANTY AND CLAIMS
We warrant that any equipment of our own manufacture or manufactured for us pursuant to
our specications which shall not be, at the time of shipment thereof by or for us, free from
defects in material or workmanship under normal use and service will be repaired or replaced
(at our option) by us free of charge, provided that written notice of such defect is received by
us within twelve (12) months from date of shipment of portable analyzers or within eighteen
(18) months from date of shipment or twelve (12) months from date of installation of perma-
nent equipment, whichever period is shorter. All equipment requiring repair or replacement
under the warranty shall be returned to us at our factory, or at such other location as we may
designate, transportation prepaid. We shall examine such returned equipment, and if it is
found to be defective as a result of defective materials or workmanship, it shall be repaired
or replaced as aforesaid. Our obligation does not include the cost of furnishing any labor in
connection with the installation of such repaired or replaced equipment or parts thereof, nor
does it include the responsibility or cost of transportation. In addition, instead of repairing
or replacing the equipment returned to us as aforesaid, we may, at our option, take back the
defective equipment, and refund in full settlement the purchase price thereof paid by Buyer.
The warranty shall not apply to any equipment (or part thereof) which has been tampered
with or altered after leaving our control or which has been replaced by anyone except us, or
which has been subject to misuse, neglect, abuse or improper use. Misuse or abuse of the
equipment, or any part thereof, shall be construed to include, but shall not be limited to, dam-
age by negligence, accident, re or force of the elements. Improper use or misapplications
shall be construed to include improper or inadequate protection against shock, vibration, high
or low temperature, overpressure, excess voltage and the like, or operating the equipment
with or in a corrosive, explosive or combustible medium, unless the equipment is specically
designed for such service, or exposure to any other service or environment of greater severity
than that for which the equipment was designed.
The warranty does not apply to used or secondhand equipment nor extend to anyone other
than the original purchaser from us.
THIS WARRANTY IS GIVEN AND ACCEPTED IN LIEU OF ALL OTHER WARRAN-
TIES, WHETHER EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION
AND WARRANTIES OF FITNESS OR OF MERCHANTABILITY OTHER THAN AS
EXPRESSLY SET FORTH HEREIN, AND OF ALL OTHER OBLIGATIONS OR LIABILI-
TIES ON OUR PART. IN NO EVENT SHALL WE BE LIABLE UNDER THIS WARRAN-
TY OR ANY OTHER PROVISION OF THIS AGREEMENT FOR ANY ANTICIPATED
OR LOST PROFITS, INCIDENTAL DAMAGES, CONSEQUENTIAL DAMAGES, TIME
CHANGES OR ANY OTHER LOSSES INCURRED BY THE ORIGINAL PURCHASER
OR ANY THIRD PARTY IN CONNECTION WITH THE PURCHASE, INSTALLATION,
REPAIR OR OPERATION OF EQUIPMENT, OR ANY PART THEREOF COVERED
BY THIS WARRANTY OR OTHERWISE. WE MAKE NO WARRANTY, EXPRESS OR
IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTIES OF FITNESS
OR OF MERCHANTABILITY, AS TO ANY OTHER MANUFACTURER’S EQUIPMENT,
WHETHER SOLD SEPARATELY OR IN CONJUNCTION WITH EQUIPMENT OF OUR
MANUFACTURE. WE DO NOT AUTHORIZE ANY REPRESENTATIVE OR OTHER
PERSON TO ASSUME FOR US ANY LIABILITY IN CONNECTION WITH EQUIP-
MENT, OR ANY PART THEREOF, COVERED BY THIS WARRANTY.

xii | Thermox Series 2000 WDG Insitu
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Overview | 1-1
OVERVIEW
Sensor
The WDG Insitu is a direct-insertion-type oxygen probe where the zirco-
nium oxide cell is directly placed in the stream of the products of combus-
tion. This patented insitu is designed for applications where the flue gas
temperature does not exceed 1250 °F (675 °C), and where combustibles
measurements are not required. The outer probe material is RA330 which
is highly resistant to corrosion.
With the unique design of the insitu probe, you can easily replace compo-
nents in the field. While the outer protection tube remains in the process,
the inner tube structure that houses the oxygen cell and furnace/thermo-
couple assembly, can be easily removed. See Figure 1-1. With no need to
return the probe to the factory, extensive downtime and expensive repairs
on your probe are no longer necessary.
Cautions to Observe
Even following a considerable period after shutdown, the components
inside the probe can be hot enough to cause burns.
Exercise proper safety precautions.
Turn off power to the probe and control unit when working on the
probe case. The probe is powered even when the control unit is turned
off since the probe power is a separate power source.

1-2 | Thermox Series 2000 WDG Insitu Analyzer
Cell
Heater / Thermocouple
Cell Housing
Metal O-ring
Ceramic Rings
Positive Lead w/Cell Clip
(white insulation on ange end)
U-Bolt
Sheet Metal Plate
Heater
10-32 Screw
FRONT VIEW
TOP VIEW
Inner Tube
Flange
Negative Lead w/Cell Clip
(blue insulation on ange end)
Heater
Center HTR/TC in
Center of Spider
Set Screw
1/16” Socket Head
Spider
ALIGNMENT SPIDER DETAIL
Figure 1-1. Insitu probe components.

Overview | 1-3
Sensor
Basic Elements of the Sensor
The WDG-IV series analyzer consists of the following basic systems:
 The Plumbing
All inlet and outlet tubing (cell housing), the oxygen cell, the oxygen
cell fitting, and the combustibles flow block and detector (for combus-
tibles). Also includes the calibration gas inlet and aspirator assembly,
with the aspirator used to pull the sample into the sensor.
 The Measuring System
The oxygen cell, combustibles detector (RTD or hot-wire type), meth-
ane detector, interconnecting wiring, and control unit.
 The Temperature System
The electrical cell heater (furnace), sensor case heaters, the type “K”
thermocouple (maintains cell operating temperature), and the sensor
board containing cold junction compensation. The sensing cell oper-
ates at a constant temperature. The circuit board in the sensor terminal
box switches power to the furnace from the AC mains connected to
the sensor. This board also provides cold junction compensation to the
thermocouple circuit.
The Oxygen Measuring Cell
The sensing element itself is a closed-end tube or disk made from ceramic
zirconium oxide stabilized with an oxide of yttrium or calcium. Porous
platinum coatings on the inside and outside serve as a catalyst and as
electrodes. At high temperatures (generally above 1200°F/650°C), oxygen
molecules coming in contact with the platinum electrodes near the sensor
become ionic. As long as the oxygen partial pressures on either side of the
cell are equal, the movement is random and no net flow of ions occurs.
If, however, gases having different oxygen partial pressures are on either
side of the cell, a potentiometric voltage is produced (See Figure 1-1).
The magnitude of this voltage is a function of the ratio of the two oxygen
partial pressures. If the oxygen partial pressure of one gas is known, the
voltage produced by the cell indicates the oxygen content of the other gas.
A reference gas, usually air (20.9% O2), is used for one of the gases.

1-4 | Thermox Series 2000 WDG Insitu Analyzer
Figure 1-1. Zirconium oxide cell principle of operation.
Since the voltage of the cell is temperature dependent, the cell is main-
tained at a constant temperature. Some newer high temperature insitu
models use the heat from the process to heat the sensor, and the process
temperature is continuously measured and used in the software calcula-
tion. The oxygen content is then determined from the Nernst equation:
E = In
RT
4F
O1
O2
where R and F are constants, T is absolute temperature, and O1and O2
are the oxygen partial pressures on either side of the cell.
For measuring oxygen in non-combustibles gases, the calibration of an
analyzer is obtained from the formula:
AT = 48.0 at 695°C
E = A*T*Log 20.9%
O2Unk%
Where Ais a constant, Tis the cell temperature on an absolute scale (°C +
273) and O2 Unk% is the unknown oxygen concentration of the gas to be
analyzed, and which is calculated by the analyzer.

Overview | 1-5
The cell produces zero voltage when the same amount of oxygen is on
both sides, and the voltage increases as the oxygen concentration of the
sample decreases. The voltage created by the difference in the sample gas
and the reference air is carried by a cable to the microprocessor control
unit, where it is linearized to an output signal.
Because of the high operating temperature of the cell, combustible
gases that are present may burn. When this occurs, the cell will gener-
ate high millivolts and cause the display to indicate less oxygen than
is actually in the gas (net oxygen content).
Common Operator Errors
There are some common errors to avoid. If they are avoided, your ana-
lyzer will operate with a minimum of maintenance and troubleshooting.
All the parts inside the probe are hot and will cause severe burns if
touched. Use gloves, wrenches and care when working inside the sen-
sor cabinet.
Do not use pipe dope or any other contaminant that gives off combus-
tible vapor that can cause erroneous measurements on any joints of
the sample tubing.
Do not use calibration gases if they contain a mixture of oxygen and
combustibles.
Do not handle the cell or heater (white end) excessively. Do not try to
clean the cell. When handling, grasp by touching the seal fitting.
NOTE


1-6 | Thermox Series 2000 WDG Insitu Analyzer
Start-Up Checklist
Review the Installation chapter (Chapter 3).
Install the sensor on the process
- If the sensor is on a pipe nipple, insulate the pipe from the process
wall to the mounting flange of the sensor.
Install the control unit.
- Do not create any additional conduit entries in the enclosure.
Interconnect the control unit and the sensor as shown in the intercon-
necting drawings.
- The specified cable must be used to ensure proper operation of the
system
- Keep the interconnecting located in the control unit as short as pos-
sible. You do not need to use a service loop.
- Maintain the ordered wire pairs as shown in the drawings.
Connect the AC mains supply to the control unit and the sensor. Make
sure that the AC voltage is within specified limits.
Configure your analyzer as explained in Chapter 4 - Controller/User
Interface.
Calibrate your system as described in the Chapter 5 - Calibration.

Overview | 1-7
Technical Support
AMETEK/Thermox is committed to providing the best technical support
in the industry. If you need service or application assistance, please call
AMETEK at [phone], or your local AMETEK/Thermox representa-
tive.
Before you call the factory for technical support, run test gases and record
the following values (you may be asked by the factory to provide this
information when receiving service):
Cell millivolts
Thermocouple millivolts
Cell temperature
See the “Display” section in the Controller / User Interface chapter for
help on how to display this information on your Series 2000 control unit.
If you need to return equipment, you will be asked to provide the follow-
ing information before obtaining a Return Material Authorization (RMA)
number.
Billing and shipping address
Model number
Serial number
Purchase order number
Telephone number
Before returning material, you must get an RMA number from the
factory.
NOTE


1-8 | Thermox Series 2000 WDG Insitu Analyzer
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