Ametek TM2000 Pro User manual

TM2000 Pro Oxygen Analyzer
User Manual
Process Instruments
150 Freeport Road
Pittsburgh, PA 15238
PN 90469VE, Rev. L

ii | TM2000 Oxygen Analyzer
USA - HEADQUARTERS
AMETEK Process Instruments
150 Freeport Road
Pittsburgh, PA 15238, USA
Phone: [phone]
Fax: [phone]
USA - Delaware
AMETEK Process Instruments
455 Corporate Boulevard
Newark, Delaware 19702, USA
Phone: [phone] (Main)
800-537-6044 (Service)
800-222-6789 (Ordering)
Fax: [phone]
USA - Texas
AMETEK Process Instruments
9750 Whithorn Drive
Houston, Texas 77095, USA
Phone: [phone]
Fax: [phone]
CANADA
AMETEK Process Instruments
2876 Sunridge Way N.E.
Calgary, Alberta
Canada T1Y 7H9
Phone: [phone]
Fax: [phone]
GERMANY
AMETEK GmbH
Postfach 2165
D-40644 Meerbusch
OR
Rudolf-Diesel Strasse 16
D-40670 Meerbusch
Germany
Phone: [phone]
Fax: [phone]
SINGAPORE
AMETEK Singapore PVT. Ltd.
10 Ang Mo Kio Street 65
#05-12 Techpoint
Singapore 569059
Republic of Singapore
Phone: [phone]
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FRANCE
AMETEK - APIF
Rond Point de l’épine des champs
Buroplus Bat D
78990 Elancourt, France
Phone: [phone]
Fax: [phone]
CHINA
AMETEK Process Instruments
Room 408, Metro Tower
No. 30 Tian Yao Qiao Road
Shanghai, 200030
Phone: [phone]
Fax: [phone]
Ofces
© 2012 AMETEK
This manual is a guide for the use of the TM2000 Oxygen Analyzer. 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.

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Contents
Ofces.................................................................................................................... ii
Safety Notes........................................................................................................ viii
Electrical Safety.................................................................................................. viii
Grounding ........................................................................................................... viii
Warning Labels ......................................................................................................ix
Environmental Information (WEEE).....................................................................ix
Electromagnetic Compatibility (EMC)...................................................................x
Equipment Used in Class I, Division 2 Hazardous Locations...............................xi
CHAPTER 1 Overview
TM2000 Oxygen Analyzer System Features...................................................... 1-1
Sensor ................................................................................................................ 1-2
Basic Elements of the Sensor....................................................................... 1-2
The Oxygen Measuring Cell ........................................................................ 1-2
Hydrocarbons ........................................................................................ 1-3
Proper Sensor Operations............................................................................. 1-4
Technical Support ............................................................................................... 1-5
CHAPTER 2 Specications
Control Unit ........................................................................................................ 2-1
Sensor ................................................................................................................. 2-2
CHAPTER 3 Installation & Start-Up
Mechanical Installation....................................................................................... 3-2
Sensor Mounting .......................................................................................... 3-2
Sample Gas/Calibration Gas Plumbing........................................................ 3-3
Sample gas / calibration gas requirements............................................ 3-3
Pressure and ow requirements............................................................. 3-4
Sample under vaccum - Special Requirements ...................................... 3-4
Manual Calibration Setup (No RCU).................................................... 3-5
Clean Gas RCU Installation ......................................................................... 3-6
RCU Mounting....................................................................................... 3-6
RCU Plumbing....................................................................................... 3-7
PPM Measurement Suggestions................................................................... 3-9
Control Unit Mounting ..................................................................................... 3-10
General Wiring and Conduit Requirements ............................................... 3-15
Control Unit AC Mains Supply Connections............................................. 3-16
EMC grounding, shielding, and noise protection................................ 3-16
EMC grounding method....................................................................... 3-16
Transient and RFI interference............................................................ 3-17
Sensor AC mains supply connections .................................................. 3-18
Standard control unit-to-sensor connections....................................... 3-19
Current Output Connections ...................................................................... 3-19

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Alarm Contact Connections ....................................................................... 3-20
Remote Calibration Unit Connections ....................................................... 3-21
Digital input to initiate remote calibration unit .................................. 3-21
RS-485 Communications Connections ...................................................... 3-22
Option Card Installation ................................................................................... 3-24
Removing Display Module or Power Supply/Keypad .............................. 3-24
Adding an Option Card .............................................................................. 3-25
Removing an Option Card ......................................................................... 3-25
CHAPTER 4 Controller / User Interface
Overview............................................................................................................. 4-1
Series 2000 Control Unit .................................................................................... 4-2
Areas of the Control Unit............................................................................. 4-2
Control Unit Display .................................................................................... 4-2
Alarm Display........................................................................................ 4-2
Auto Ranging Feature .................................................................................. 4-2
Control Unit Keys ........................................................................................ 4-3
Selecting Menu Options............................................................................... 4-3
Exiting Menu Options .................................................................................. 4-3
On-Line Help ............................................................................................... 4-4
Setup Key............................................................................................................ 4-5
Setting Up the Display ................................................................................. 4-5
Entering user text................................................................................... 4-6
Auto ranging feature for oxygen readings............................................. 4-6
Hydrocarbon upset condition ................................................................ 4-6
System Password ................................................................................................ 4-7
Setting Up a System Password..................................................................... 4-7
Process Pressure.................................................................................................. 4-8
Setting Up Process Pressure......................................................................... 4-8
System Tests ....................................................................................................... 4-9
System Serial # ................................................................................................... 4-9
Primary Calibration .......................................................................................... 4-10
Setting Up a Primary Calibration............................................................... 4-10
Sensor Conguration ........................................................................................ 4-11
Congurating the Sensor............................................................................ 4-11
Communication................................................................................................. 4-12
Remote Switch Conguration........................................................................... 4-13
Conguring the Remote Switch ................................................................. 4-13
Single Gas Switch............................................................................................. 4-13
Alarm Key ........................................................................................................ 4-14
Overview of Alarm Functions.................................................................... 4-15
Alarm Set Points ........................................................................................ 4-15
Dening alarm set points..................................................................... 4-15
Alarm Congure......................................................................................... 4-16
Conguring the alarms........................................................................ 4-17
Relay Congure ......................................................................................... 4-17

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Conguring the relay ........................................................................... 4-17
Select Function........................................................................................... 4-17
Dening the select function ................................................................. 4-18
Service Alarm............................................................................................. 4-18
Watchdog Relay ......................................................................................... 4-18
Exception Log ............................................................................................ 4-19
Accessing the Exception Log ............................................................... 4-19
Analog Range Key............................................................................................ 4-20
Analog Output Port .................................................................................... 4-20
Selecting an analog output port........................................................... 4-20
Set Current Range Option .......................................................................... 4-21
Set Track/Hold Option ............................................................................... 4-22
Setting track or hold ............................................................................ 4-22
Set Current Mode Option ........................................................................... 4-23
Setting the current mode ...................................................................... 4-23
Output Filtering Option.............................................................................. 4-23
Setting output ltering ......................................................................... 4-23
Select Function Option............................................................................... 4-24
Selecting the function........................................................................... 4-24
CHAPTER 5 Calibrate Key
Overview............................................................................................................. 5-1
Calibration .......................................................................................................... 5-2
Calibration vs. Verication Operations ........................................................ 5-2
Span vs. Zero Gas ........................................................................................ 5-2
Types of Calibrations ................................................................................... 5-2
Aborting a Calibration.................................................................................. 5-2
Password ............................................................................................................. 5-3
Entering a Password..................................................................................... 5-3
Initiate Cal .......................................................................................................... 5-4
SIngle Gas Calibration........................................................................................ 5-5
Auto Calibrate .............................................................................................. 5-5
Remote Calibrate.......................................................................................... 5-6
Manual Calibrate.......................................................................................... 5-6
Initiate Verify ...................................................................................................... 5-8
Auto Verify................................................................................................... 5-8
Remote Verify .............................................................................................. 5-9
Manual Verify............................................................................................. 5-10
Cal/Verify Data ................................................................................................. 5-12
Setting Up Cal/Verify Data Option ............................................................ 5-12
Calibration data .................................................................................. 5-12
Verify Data ................................................................................................. 5-13
Cal Gas Value.................................................................................................... 5-14
Entering Cal Gas Values............................................................................. 5-14
Inject Cal Gas ................................................................................................... 5-15

vi | TM2000 Oxygen Analyzer
Two-Gas Calibration......................................................................................... 5-18
Auto Calibrate ............................................................................................ 5-18
Remote Calibrate........................................................................................ 5-19
Manual Calibrate........................................................................................ 5-20
Initiate Verify .................................................................................................... 5-22
Auto Verify................................................................................................. 5-22
Remote Verify ............................................................................................ 5-23
Manual Verify............................................................................................. 5-24
Cal/Verify Data ................................................................................................. 5-26
Setting Up Cal/Verify Data Option ............................................................ 5-26
Calibration data .................................................................................. 5-26
Verify Data ................................................................................................. 5-27
Cal Gas Value.................................................................................................... 5-28
Entering Cal Gas Values............................................................................. 5-28
Inject Cal Gas ................................................................................................... 5-29
Set Cal Timers................................................................................................... 5-30
Set Auto Timers.......................................................................................... 5-30
Auto Cal On/Off......................................................................................... 5-32
Cal Gas Duration........................................................................................ 5-33
Single gas calibration.......................................................................... 5-33
Two-gas calibration ............................................................................. 5-33
Congure Verify......................................................................................... 5-34
CHAPTER 6 Mintenance & Troubleshooting
System and Error Messages................................................................................ 6-1
System Messages ................................................................................................ 6-2
Error Messages ................................................................................................... 6-3
Diagnostic Checks .............................................................................................. 6-5
Auto Calibration Card LEDs ............................................................................ 6-10
CHAPTER 7 Service & Parts
Warnings!............................................................................................................ 7-2
Thermocouple Replacement ............................................................................... 7-3
Cell Replacement................................................................................................ 7-5
Furnace Replacement.......................................................................................... 7-6
Parts Replacement List ....................................................................................... 7-7
Sensor........................................................................................................... 7-7
Clean Gas Remote Calibration Unit (RCU)................................................. 7-7
Control Unit ................................................................................................. 7-7
APPENDIX A Serial Communications
Communication Protocol ................................................................................... A-1
Command Message Format......................................................................... A-2
General Serial Communication Commands ...................................................... A-3

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Development Serial Communication Commands ............................................. A-5
Command List ................................................................................................... A-6
Responses .......................................................................................................... A-7
Variable Table .................................................................................................... A-8
Sample Program............................................................................................... A-12
APPENDIX B Menu Option Charts
Setup Key Menu .................................................................................................B-1
Calibrate Key Menu............................................................................................B-2
Calibrate Key - Set Cal Timers Submenu...........................................................B-2
Alarm Key Menu ................................................................................................B-3
Analog Range Key Menu ...................................................................................B-3
APPENDIX C Current Outputs: Other Applications
Powering Current Outputs from an External Power Supply ..............................C-1
Modulation of External Power Loop Using Current Outputs.............................C-2
APPENDIX D Using Series 2000 RCU Signals
APPENDIX E Drawings and Custom Instructions

viii | TM2000 Oxygen Analyzer
Safety Notes
WARNINGS, CAUTIONS, and NOTES contained in this manual emphasize critical instructions as fol-
lows:
An operating procedure which, if not strictly observed, may result in personal injury or envi-
ronmental contamination.
An operating procedure which, if not strictly observed, may result in damage to the equip-
ment.
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 perform-
ing maintenance or troubleshooting. Only a qualied electrician should make electrical connections and
ground checks.
Any use of the equipment in a manner not specied by the manufacturer may impair the safety protection
originally provided by the equipment.
Grounding
Instrument grounding is mandatory. Performance specications and safety protection are void if instru-
ment is operated from an improperly grounded power source.
Verify ground continuity of all equipment before applying power.
NOTE


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PROTECTIVE CONDUCTOR TERMINAL
(BORNIER DE L’ECRAN DE PROTECTION)
Schutzerde
CAUTION - Risk of electric shock
(ATTENTION-RISQUE DE DÉCHARGE ÉLECTRIQUE)
Achtung - Hochspannung Lebensgefahr
CAUTION - (Refer to accompanying documents)
(ATTENTION-SE RÉFERER AUX DOCUMENTS JOINTS)
Achtung (Beachten Sie beiliegende Dokumente)
CAUTION - Hot Surface
(ATTENTION-SURFACE CHAUDE)
Achtung - Heiße Oberäche
Warning Labels
These symbols may appear on the instrument in order to alert you of existing conditions.
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 substances into the environment and to conserve our natural resources, AMETEK
recommends that you arrange to recycle this product when it reaches 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 prod-
uct properly after it has completed its useful life and been removed from service. Metals, plastics and
other components are recyclable and you can do your part by one of the following these steps:
• When the equipment is ready to be disposed of, take it to your local or re-
gional waste collection administration for recycling.
• In some cases, your “end-of-life” product may be traded in for credit towards
the purchase of new AMETEK instruments. Contact your dealer to see if this
program is available 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 | TM2000 Oxygen Analyzer
Electromagnetic Compatibility (EMC)
Read and follow the reommendations in this section to avoid performance variations or dam-
age to the internal circuits of this equipment when installed in harsh electrical environments.
The various congurations of the TM2000 Oxygen Analyzer should not produce, or fall victim to, elec-
tromagnetic disturbances as specied in the European Union’s EMC Directive. Strict compliance to the
EMC Directive requires that certain installation techniques and wiring practices are used to prevent or
minimize erratic behavior of the Analyzer or its electronic neighbors. Below are examples of the tech-
niques and wiring practices to be followed.
In meeting the EMC requirements , the various Analyzer congurations described in this manual rely
heavily on the use of metallic shielded cables used to connect to the customer’s equipment and power.
Foil and braid shielded I/O and DC power cables are recommended for use in otherwise unprotected situ-
ations. In addition, hard conduit, exible conduit, and armor around non-shielded wiring also provides
excellent control of radio frequency disturbances. However, use of these shielding techniques is effective
only when the shielding element is connected to the equipment chassis/earth ground at both ends of the
cable run. This may cause ground loop problems in some cases. These should be treated on a case-by-case
basis. Disconnecting one shield ground may not provide sufcient protection depending on the electronic
environment. Connecting one shield ground via a 0.1 microfarad ceramic capacitor is a technique allow-
ing high frequency shield bonding while avoiding the AC-ground metal connection. In the case of shield-
ed cables the drain wire or braid connection must be kept short. A two-inch connection distance between
the shield’s end and the nearest grounded chassis point, ground bar or terminal is highly recommended.
An even greater degree of shield performance can be achieved by using metallic glands for shielded cable
entry into metal enclosures. Expose enough of the braid/foil/drain where it passes through the gland so
that the shield materials can be wrapped backwards onto the cable jacket and captured inside the gland,
and tightened up against the metal interior.
Inductive loads connected to the low voltage “Alarm Contacts” are not recommended. However, if this
becomes a necessity, adhere to proper techniques and wiring practices. Install an appropriate transient
voltage suppression device (low voltage MOV, “Transzorb,” or R/C) as close as possible to the inductive
device to reduce the generation of transients. Do not run this type of signal wiring along with other I/O or
DC in the same shielded cable. Inductive load wiring must be separated from other circuits in conduit by
using an additional cable shield on the offending cable.
In general, for optimum protection against high frequency transients and other disturbances, do not allow
installation of this Analyzer where its unshieled I/O and DC circuits are physically mixed with AC mains
or any other circuit that could induce transients into the Analyzer or the overall system. Examples of elec-
trical events and devices known for the generation of harmful electromagnetic disturbances include mo-
tors, capacitor bank switching, storm related transients, RF welding equipment, static, and walkie-talkies.