Ametek 5000 User manual

AMETEK Western Research
5000 Moisture Analyzer
Essential Health & Safety
Requirements
PN 500088003, Rev E
Process Instruments
455 Corporate Blvd.
Newark, DE 19702

© 2000 AMETEK
This manual is a guide for the use of the Model 5000 Moisture Analyzer (Single Point). Data herein has been verified 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 specified herein,
confirmation 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
Analyzer Serial Number Location
The analyzer serial number label is located on the left-
hand side of the analyzer base.
SALES AND MANUFACTURING:
USA - Delaware
455 Corporate Blvd., Newark DE 19702 • Tel: [phone], Fax: [phone]
USA - Pennsylvania
150 Freeport Road, Pittsburgh PA 15238 • Tel: [phone], Fax: [phone]
CANADA - Alberta
2876 Sunridge Way N.E., Calgary, AB T1Y 7H9 • Tel: [phone], Fax: [phone]
WORLDWIDE SALES AND SERVICE LOCATIONS:
USA - TexasTel: 713-466-4900, Fax: [phone]
CHINA
Beijing / Tel: [phone], Fax: [phone]
Chengdu / Tel: [phone], Fax: [phone]
Shanghai / Tel: [phone], Fax: [phone]
FRANCE
Tel: [phone], Fax: [phone]
GERMANY
Tel: [phone], Fax: [phone]
MIDDLE EAST - Dubai
Tel: [phone], Fax: [phone]
SINGAPORE
Tel: [phone], Fax: [phone]
www.ametekpi.com
2 | 5000 Moisture Analyzer

Table of Contents
Offices ..................................................................................................................... 2
Analyzer Serial Number Location..............................................................2
About This Document .......................................................................................... 5
Safety Notes..................................................................................................... 5
Important Safety Information ...................................................................... 5
Warnings....................................................................................................6
Cautions .....................................................................................................7
SPECIAL WARNINGS AND INFORMATION FOR USE IN HAZARDOUS
LOCATIONS .......................................................................................................... 8
5000 CONTROLLER ...............................................................................8
5000 Field Unit ..........................................................................................8
When 5000 System includes EEx Sample System Components................8
Special Conditions for safe use: ..........................................................8
Warning Labels...................................................................................................... 9
Specifications ....................................................................................................... 10
Utility Requirements.................................................................................... 10
Outputs .......................................................................................................... 10
Alarm Contacts.............................................................................................. 10
Allowable Inlet Pressure.............................................................................. 10
Operating Pressure....................................................................................... 11
Gas Flow Requirements............................................................................... 11
Approvals and Certifications...................................................................... 11
Analyzer Markings.............................................................................................. 12
Special Conditions to Certification................................................................... 13
INSTALLATION
Prior to Installation ............................................................................................. 15
Unpacking and Inspection ................................................................................ 15
Field Unit Installation......................................................................................... 16
Controller Installation ........................................................................................ 17
Electrical Connections ........................................................................................ 22
Power Requirements.................................................................................... 22
Explosion Hazard Warning........................................................................ 22
Installation Requirements ........................................................................... 23
Hazardous installation requirements .......................................................23
Zone 1 ................................................................................................23
NEC Division 1 and 2 .......................................................................24
Installation Procedure.................................................................................. 24
Sample System..................................................................................................... 28
Sample Tap .................................................................................................... 29
Sample Pressure, Temperature, and Flow Rate ....................................... 29
Essential Health & Safety Requirements | 3

Sample Lines & Connections...................................................................... 29
Sample Conditioning................................................................................... 29
Conditioned sample gas used as reference ................................................30
Separate Gas Source Used As Reference...................................................31
Gas Connections to Analyzer............................................................................ 32
TROUBLESHOOTING AND MAINTENANCE
System Alarms ..................................................................................................... 33
Computer Operating Properly Alarm ............................................................. 34
System Tests Menu.............................................................................................. 35
Scheduled Maintenance..................................................................................... 38
Weekly ........................................................................................................... 38
Quarterly....................................................................................................... 38
Yearly ............................................................................................................. 38
System Inspection ............................................................................................... 39
Troubleshooting................................................................................................... 40
Field Unit Electronics ......................................................................................... 43
Power Distribution ....................................................................................... 43
Power distribution failure symptoms .......................................................43
Electronics control board voltage checks...................................................43
Heat Control ................................................................................................. 43
Solenoid Control .......................................................................................... 44
Cell Output ................................................................................................... 44
Field Unit ............................................................................................................. 47
Lid Removal .................................................................................................. 47
Cell Replacement ......................................................................................... 47
Cell Oven Replacement .............................................................................. 47
Moisture Generator Sample/Reference Valve Assy................................. 48
Electronics Control Board .......................................................................... 49
Thermal Cutout Link S2 .............................................................................. 49
Moisture Generator Reservoir Refilling ................................................... 49
Filter Frit (PN 560503901) Replacement ................................................... 50
Dryer or Trap Refilling................................................................................. 50
Leak Testing................................................................................................... 51
Valve Operation and Heater Cycling ........................................................ 51
Oven Temperature Adjustment ................................................................. 52
Moisture Generator Temperature Adjustment ........................................ 52
4 | 5000 Moisture Analyzer

About This Document
This document primarily describes the essential health and safety requirements for the compo-
nents that make up the Model 5000 Moisture Analyzer intended for use in explosive atmosphere
locations. These sections are described below.
The procedures and information discussed in this document include only abbreviated steps
to install, operate, and perform maintenance on the Model 5000 Moisture Analyzer. They do,
however, include all relevant safety warnings and cautions to ensure the safety of personnel and
the analyzer in explosive atmosphere locations. [For complete and detailed descriptions of the
procedures discussed in this guide, refer to the analyzer User Manual.]
Safety Notes
WARNINGS, CAUTIONS, and NOTES contained in this manual emphasize critical instructions
as follows:
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 equipment.
Important information that should not be overlooked.
Important Safety Information
Before working on the analyzer, read and understand the following Notes, Warnings, and
Cautions, which contain important safety and general information that applies to all aspects of
working on the analyzer.
Additional Notes, Warnings, and Cautions are included in individual procedures in this docu-
ment (and in the analyzer User Manual) to indicate special conditions to consider during instal-
lation, before opening its covers or doors, and while working on the analyzer.
!
CAUTION

NOTE
!
WARNING
Essential Health & Safety Requirements | 5

Warnings
Review and follow these Warnings to avoid personal injury or environmental contamination.
High voltages are present in the analyzer housing. Always disconnect power and/or external
power sources to the analyzer before opening any covers or doors on the analyzer to check or
perform maintenance on any components within the enclosures.
If it is necessary to open the analyzer’s covers or doors while the circuits are live, first monitor
the area for flammable gases (and proceed only when the area is safe).
When the enclosure is open, take appropriate precautions to avoid electrical shock. Hazardous
voltages are present inside.
All electrical connections, adjustments, or servicing of the analyzer should be performed only
by properly trained and qualified personnel.
All electrical connections, materials, and methods (plus all safety policies and procedures)
must be made in compliance with local wiring regulations and electrical code for the hazardous
area, as specified by the Owner Company, local electrical-inspection authority, and National/
EU regulations.
Follow appropriate regulatory and/or company procedures to lock out the analyzer while work-
ing on the analyzer electronics.
Before working on the analyzer, test the area for flammable gases. If a flammable gas atmo-
sphere is present, do not open any doors without first disconnecting power and/or alternate
power sources to the analyzer.
The field unit may contain flammable or toxic process gas. Remove the field unit dome lid in a
well-ventilated area only after electrical power is removed and the surrounding are is known to
be nonhazardous..
Before working on the sample system, confirm that the system has been purged with Zero fluid
and is isolated (blocked in) from the process.
If the Sample System Enclosure is heated, the components within it will be hot; take precau-
tions to avoid burning yourself.
Verify ground continuity of all equipment before applying power.
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
WARNING
6 | 5000 Moisture Analyzer

The sample gas may contain highly toxic and corrosive substances. Proper personal protective
equipment including fresh air breathing apparatus, eye protection, and skin protection MUST
BE worn when installing the sample tap and/or opening the lid for inspection or maintenance.
If sampe gases contain highly toxic and corrosive compounds, analyzed sample must be re-
turned to the process or vented to a safe area.
Cautions
Review and follow these Cautions to avoid damaging the equipment.
The electronic circuit boards and other static-sensitive components should be stored and trans-
ported in static-shielding carriers or packages.
For electrical-shock protection, the analyzer must be operated from a grounded power source
that has a securely connected protective-ground contact.
If it becomes necessary to handle any of the electronic circuit boards, do not subject the boards
to static discharge. The ideal solution is a static-safe work area. Since such areas typically
are not available at analyzer installation sites, the use of a wrist strap connected directly to a
ground is recommended. If a wrist strap is not available, you should at the very least touch the
metal chassis (to ground yourself) before handling or touching the boards.
Take extreme care to avoid damaging the threads on the cable entry glands. Clean, defect-free
threads are essential to ensure a flameproof connection.
The lid weighs 8.2 kg (18 lb). Use proper lifting methods and wear protective footwear when
removing.
!
CAUTION
!
WARNING
!
WARNING
!
CAUTION
!
CAUTION
!
CAUTION
!
CAUTION
Essential Health & Safety Requirements | 7

SPECIAL WARNINGS AND INFORMATION FOR USE IN HAZARDOUS
LOCATIONS
5000 CONTROLLER
This Equipment is Suitable for Use in Class I, Division 2, Groups ABCD,T4, ATEX Zone 1, IIC, T6,
or Non-Hazardous Areas Only.
Explosion Hazard - Substitution of Components May Impair Suitability for Class I, Division 2 and
or ATEX Zone 1.
Explosion Hazard - Do Not Disconnect Equipment Unless Power Has Been Switched Off or
the Area is Known to be Non-Hazardous.
5000 Field Unit
To reduce the risk of ignition of hazardous atmospheres, disconnect the equipment from the
supply circuit before opening. Keep assembly tightly closed when in operation.
To reduce the risk of ignition of hazardous atmospheres, conduit runs must have a sealing fit-
ting connected within 18 inches of the enclosure.
When 5000 System includes EEx Sample System Components
Special Conditions for safe use:
The special conditions for safe use give in the European certificates mentioned in the manufac-
turer technical file are still relevant. Be aware of special instructions and warnings on all sample
system components.
When an IS type option is provided, proper grounding, selection of certified barriers, energy
considerations, and use of accepted wiring methods is the responsibility of the end user / install-
er. See manufacturer’s certificate for entity parameters.
Refer to Section 501.4(b) of the NEC or 18-152 of the CEC for proper wiring connections to the
service and installation accessible field terminals on the customer wiring module. See Section
501-3b(6) of the NEC or 18-172, 174 of the CEC for flexible mains connect.
Do not use the “Alarm” or “Relay” Functions on the customer wiring module to energize motors,
pumps, or any other device that could present an overload condition during normal operation.
Refer to Customer Wiring Diagrams and Installation Instructions contained in this Manual and
the Document Package included with this Instrument.
!
CAUTION
!
WARNING
!
WARNING
!
WARNING
8 | 5000 Moisture Analyzer

PROTECTIVE CONDUCTOR TERMINAL
CAUTION - Risk of electric shock
CAUTION - Refer to accompanying documents
CAUTION - Hot Surface
Warning Labels
These symbols may appear on the instrument in order to alert you of existing condi-
tions.
Essential Health & Safety Requirements | 9

Specifications
For a complete listing of all analyzer specifications, refer to the analyzer User Manual.
Utility Requirements
All systems are available with choice of nominal AC voltages:
Field Unit:
• 100V ±10%, 50/60 Hz, 175W max.
• 115V ±10%, 50/60 Hz, 175W max.
• 230V ±10%, 50/60 Hz, 175W max.
Controller:
• 95–230V ±10%, 47-63 Hz, 75 W max.
Outputs
• 80-character vacuum fluorescent display
• Two 4 to 20 mA DC analog signals with completely user-defined span; one analog
output is auto-ranging
• RS-485 bidirectional serial port
Alarm Contacts
• System Alarm
• Concentration Alert
• Range or Verification Alert
(Contacts rated 30 VAC / 60 VDC, 50 VA maximum, 1A maximum, resistive)
Allowable Inlet Pressure
207 to 690 kPa gauge (30 to 100 PSIG)
10 | 5000 Moisture Analyzer

Operating Pressure
103 kPa gauge (15.0 PSIG)
Gas Flow Requirements
250 mL/min each at 103 kPa gauge (15 PSIG) for sample, reference, and moisture generator.
Approvals and Certifications
UL/CSA General Safety Requirements
Controller:
UL/CSA Class I, Division 2, Groups ABCD, T4
ATEX, Zone 1,
Ex db IIC, T6 Gb
-12˚C ≤ Tamb ≤ 60˚C
Field Unit:
UL Class I, Division 1, Groups BCD
CSA Class I, Division 1, Groups BCD, special acceptance
ATEX, Ex db IIC, T5 Gb
-20˚C ≤ Tamb ≤ 50˚C
Electromagnetic Compatibility Directive; 2014/30/EU
EN 61326-1: 2013
Low Voltage Directive; 2014/35/EU
EN 61010-1: 2010
Pressure Equipment Directive
ATEX Directive; 2014/34/EU
EN 60079-0: 2012/A11: 2013
EN 60079-1: 2014
Russian Gosstandart Pattern Approval
Russian Ex Proof Certification 1ExdIICT6
Essential Health & Safety Requirements | 11

Analyzer Markings
The Model 5000 Moisture Analyzer will be marked with a corresponding label to indicate its
ATEX certification.
Figure 1.
5000 Field Unit ATEX Label.
Figure 2.
5000 Controller ATEX Label.
12 | 5000 Moisture Analyzer

Special Conditions of Certification
Specific Conditions of Safe Use
- There is no intention for any adjustments or repair to be made on the flame-
path joints
- All unused openings in protected enclosures must be fitted with blanking ele-
ments with protection types and IP ratings compatible with the respective
enclosure
- All cable glands used must not invalidate the specific characteristics of the
Moisture Analyzer’s type of protection
NPT Union GUF-1-EX:
• All threads MUST be installed wrench-tight regardless of final orientation of the
angled components of ‘elbow’ type fittings or adaptors.
• The fittings are not intended for field installation. Any assembly of enclosure
and conduit fitting must be submitted for full approval before installation in a
hazardous area.
• The fittings and adaptors MUST NOT be loosened for alignment purposes. Any
Equiment certificates issued which utlise these components must re-state this
as a Condition of Use for users.
• It is the final assemblers/ users responsibility to ensure the threaded joint be-
tween the fitting and the associated enclosure meet all the requirements of the
applicable standards for the assembly.
• Only one fitting shall be used at any single entry on the associated enclosure.
Essential Health & Safety Requirements | 13

This page intentionally left blank.
14 | 5000 Moisture Analyzer

Essential Health & Safety Requirements |15
INSTALLATION
Read this section of the manual before beginning installation of the Model 5000 ana-
lyzer system. Failure to do so may impair the protection against fire, electrical shock,
and personal injury originally provided for by this equipment. In addition, failure to
follow the installation and start-up instructions may void the instrument’s warranty.
Prior to Installation
The 5000 Field Unit is approved for the following hazardous area classifications:
• Class I; Group B, C, D; Division 1 as defined by the U.S. National Elec-
trical Code (NEC) and
• Zone 1.
The Model 5000 analyzer system is typically installed with the field unit near the sample
tap (normally in a hazardous area) and the 5000 controller located in a control room.
The controller is suitable for installation in NEC Class 1 ; Groups A, B, C & D; Division
2 areas. The field unit and controller may be separated by up to 600 meters (2000 feet).
Prior to installation, a site plan should be prepared defining the mounting locations of
the field unit, controller, and sample system components. The plan should also detail the
AC input(s), interconnect wiring, and sample line routing.
Unpacking and Inspection
Remove components from the packing case(s) carefully and check contents against pack-
ing list. Inspect all components for obvious damage and broken/ loose parts or fittings.
Notify the carrier and AMETEK Service (1-800-222-6789) immediately if parts are miss-
ing or damage is found.
!
CAUTION

16 | 5000 Single-Point Moisture Analyzer
Field Unit Installation
Figure 3-1 shows installation dimensions for standard (Division 1 and 2) and Zone 1 ver-
sions of the field unit. Locate the field unit as near as possible to the sample tap and bolt
into place. The unit should be protected from direct exposure to weather and located so
that the ambient temperature specifications will not be exceeded.
TB1
LOCATED BEHIND TB1
GROUND CONNECTION
DRYER
100 PSIG
MAXIMUM PRESSURE
WARNING
THIS END UP
LABEL CERTIFICATION CENELEC
SEE NOES 2 & 5 1/8" TB FTG WET GAS IN
SEE NOTES 4 & 6
DRYER (TYP)
[3.50]
89
1/8" TB FTG, SEE NOTES 2 & 5
DRY GAS OUT TO ANALYZER
SEE NOTE 2
[18.00]
457
7. FIELD UNIT EQUIPPED WITH CENELEC REQUIREMENTS PER EN500812. SUPER-ACTIVATED MOLECULAR SIEVE DRYER. 6. THE SAME DRYER DIMENSIONS CAN BE USED FOR CONTAMINANT TRAP AND PROLONG EXPOSURE TO MOIST AIR MAY REDUCE DRYER LIFE. PRIOR TO INSTALLATION. MINIMIZE INTERNAL CONTACT WITH AMBIENT MOISTURE. 5. REMOVE DRYER SEAL PLUGS AND INSTALL SUPPLIED NUTS AND FERRULES JUST 4. POSITION VERTCALLY WITH END UP AS NOTED ON BODY. MINIMIZE TUBE LENGTHS. 3. CUSTOMER TO MOUNT DRYER CHAMBER TO 5000 ANALYZER FIELD UNIT TO 2. FERRULES AND NUTS ARE PLACED IN PLASTIC BAG AND ADHERED TO DRYER. 1. XXX DIMENSIONS ARE IN MILLIMETERS. (XXX) DIMENSIONS ARE IN INCHES. NOTES:
L
C
3/4-14 NPT
SIGNAL
3/4-14 NPT
POWER
GROUND LUG
FRONT VIEW
LEFT SIDE VIEW
TOP VIEW
GENERATOR FLOW ADJUSTMENT
1/8" NPT(F)
SAMPLE IN,
FROM CONDITIONED SOURCE
REFERENCE INLET, 1/8" NPT(F)
SAMPLE ADJUSTMENT
5mm HEX LOCKING SCREW
BACK PRESSURE GAUGE
BACK PRESSURE ADJUSTMENT
REFERENCE ADJUSTMENT
CLEARANCE
MINIMUM
[28.00]
711
[9.26]
235
[16.94]
430
[8.06]
205
[8.06]
205
[4.75]
121
[3.71]
94
[3.25]
83
[12.32]
313
[Ø.31]
Ø8
[10.75]
273
4 PLACES
[.78]
20
4 PLACES
[1.51]
38
[13.69]
348
[12.13]
308
Figure 2.
Installation / dimensional layout for
Model 5000 field unit (Zone1)

Essential Health & Safety Requirements |17
Controller Installation
Mount the controller indoors in desired location and bolt in place. Figures 3-2a through
3-2d show installation dimensions for all controller mounting configurations.
Figure 3a.
Surface Mounted
Model 5000 controller.
(.50)
13 (0.44)
11
(5.25)
133
(5.25)
133
(9.1)
231
(1.2)
31
(.63)
16
(10.25)
260
(10.38)
264
(7.62)
194
(5.38)
137
(11.50)
292
(11.38)
289
(0.4)
10
7.36
RIGHT SIDE VIEW
LEFT SIDE VIEW
FRONT VIEW
DIA, 4 HOLES
(.29)
ALARM 3/4 CONDUIT
SIGNAL I/O 3/4" CONDUIT
SIGNAL I/O 3/4" CONDUIT
VALVE 3/4" CONDUIT
POWER 1/2" CONDUIT
ARE IN INCHES.
1. XXX DIMENSIONS ARE IN MILLIMETERS, (XXX) DIMENSIONS
NOTES:

18 | 5000 Single-Point Moisture Analyzer
Figure 3b.
19 inch (~48.26 cm) rack Mount Model
5000 controller.
(5.25)
133
(4.95)
126
(1.48)
38
(2.25)
57
(0.4)
10
(12.6)
320
(0.5)
13
(0.25)
6
(9.1)
231
(19.0)
483
HIGH UNITS 3 DIN
ARE IN INCHES.
1. XXX DIMENSIONS ARE IN MILLIMETERS, (XXX) DIMENSIONS
NOTES:
3/4" CONDUIT HOLES FOR
1/2" CONDUIT HOLE FOR
3/4" CONDUIT HOLES FOR
POWER
VALVE
SIGNAL I/O
ALARM
SIGNAL I/O
TYP
TYP

Essential Health & Safety Requirements |19
(0.12)
3
(12.4)
316
(0.3)
7.6
(0.25)
6.4
(10.0)
254
(9.5)
241
(5.6)
142
(9.1)
231
(6.57)
167
(5.25)
133
(0.52)
13.2
(10.45)
266
LG
38
4 PLCS
(1.5)
#10-32 THD
(4 HOLES)
DIA
PANEL CUTOUT
SIGNAL I/O
ALARM
SIGNAL I/O
VALVE
POWER
3/4" CONDUIT HOLES FOR
1/2" CONDUIT HOLE FOR
3/4" CONDUIT HOLES FOR
ARE IN INCHES. 1. XXX DIMENSIONS ARE IN MILLIMETERS, (XXX) DIMENSIONS
NOTES:
6.35
(0.25)
127
(5.0)
Figure 3c.
Through-panel mounted
Model 5000 controller.

20 | 5000 Single-Point Moisture Analyzer
Figure 3d.
Surface mounted Model 5000 controller in
NEMA 4X enclosure.
(10.00)
254
(12.55)
319
(14.55)
369
(14.94)
379
(8.31)
211
138
(0.51)(0.31) X SLOT, 4 PLCS
FRONT VIEW
BOTTOM VIEW
ALARM 3/4 CONDUIT
SIGNAL I/O 3/4" CONDUIT
SIGNAL I/O 3/4" CONDUIT
VALVE 3/4" CONDUIT
POWER 1/2" CONDUIT
WINDOW
NOTES:
1. XXX DIMENSIONS ARE IN MILLIMETERS; (XXX) DIMENSIONS ARE IN INCHES.