Ametek 5000 User manual

5000 Moisture Analyzer
with Multi-Point Analysis
Instrument Manual
500092901, Rev.T
Process Instruments
455 Corporate Boulevard
Newark, DE 19702, USA

ii 5000 Multi Point Moisture Analyzer
© 2000 AMETEK
This manual is a guide for the use of the Model 5000 Moisture Analyzer (Multi-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

iii
Table of Contents
Safety Notes .........................................................................................................vi
Overview
Theory of Operation...................................................................................1-1
Verification............................................................................................... 1-1
Gas Flow ..................................................................................................1-1
System Components...................................................................................1-4
Analyzer Specifications..............................................................................1-6
Installation
Prior to Installation..................................................................................... 2-1
Unpacking and Inspection........................................................................ 2-1
Field Unit Installation................................................................................. 2-1
Controller Installation................................................................................2-1
5000 Field Unit (CENELEC).................................................................. 2-2
Surface Mounted Controller.................................................................2-3
Rack Mounted Controller .....................................................................2-4
Through Panel Mounted Controller ...................................................2-5
Controller in NEMA 4X Enclosure ...................................................... 2-6
Electrical Connections................................................................................ 2-8
Sample System ............................................................................................ 2-12
Sample Tap ..............................................................................................2-12
Sample Pressure, Temperature, Flow Rate.........................................2-12
Sample Lines and Connections............................................................2-13
Sample Conditioning.............................................................................2-13
Gas Connections to Analyzer....................................................................2-15
Operation
Controller Display.......................................................................................3-1
System Security and Passwords ...............................................................3-1
Function Key Overview.............................................................................3-3
Field Unit Controls & indicators...............................................................3-4
Analyzer Start-Up ....................................................................................... 3-6
Flow Rate and Back Pressure Adjustments........................................3-7
Cell Verification and Span Adjustment...................................................3-10
CALIB Key ...............................................................................................3-10
Alarms and Alerts .......................................................................................3-11
Analog Range Alarm..............................................................................3-11
Concentration Alarms............................................................................ 3-11
ALARM Key............................................................................................. 3-12
Analog Ranges.............................................................................................3-12
ANALOG RANGE Key.......................................................................... 3-13
TEST/CONFIGURATION Key..................................................................3-13
Default System Passwords......................................................................... 3-14a

iv 5000 Multi Point Moisture Analyzer
Software Configuration
Level 2 Configure Menu............................................................................4-1
Constants.............................................................................................4-1
Display (Display Flags) .....................................................................4-2
Analog (Analog Flags).......................................................................4-2
Passwords............................................................................................4-2
Timing .................................................................................................4-3
Moist_Gen...........................................................................................4-4
Serial..................................................................................................... 4-4
Flags1 (Configuration Flags)............................................................ 4-4
Noise .................................................................................................... 4-4
Level 3 Configure Menu............................................................................4-5
PolyCoef (Polynomial Coefficients) ................................................4-6
Labels................................................................................................... 4-6
Constants.............................................................................................4-6
Flags2 (Configuration Flags)............................................................ 4-7
Level 2 Config Menu (Go To)........................................................... 4-7
Timers (Measurement Cycle Timers).............................................. 4-7
Default Memory (Reset to Factory Default) .................................. 4-7
Coef_D (Polynomial Coefficient D) ................................................4-8
Configuring for Multi-Point Operation...................................................4-9
Serial Communication
Hardware Requirements ........................................................................... 5-1
Wiring Configuration and Baud Rate...................................................... 5-1
Serial Communication Wiring ..................................................................5-1
Read and Write Protocol............................................................................ 5-3
Table III: Read Only System Values ........................................................5-3
Table III: Read and Write System Values................................................ 5-4
Troubleshooting & Maintenance
System Alarms.............................................................................................6-1
System Test Menu .......................................................................................6-2
Scheduled Maintenance ............................................................................ 6-4
Troubleshooting...........................................................................................6-5
Field Unit Electronics .................................................................................6-9
Field Unit...................................................................................................... 6-13
Service and Parts
Service...........................................................................................................7-1
Field Unit Parts List ....................................................................................7-2
Controller Parts List....................................................................................7-4
Controller .....................................................................................................7-5
CPU/Display PC Board .............................................................................. 7-6
Relay PC Board............................................................................................ 7-7
5000 INPUT - OUTPUT..............................................................................7-8

v
Wiring Module Schematic......................................................................... 7-9
Dual Current Output Schematic ..............................................................7-12
Appendix A: Miscellaneous Options
Asymmetric Cycle....................................................................................... A-1
Acid Gas Option..........................................................................................A-2
Readout in Pounds/Million Cubic Feet ...................................................A-3
Procedure for Bubble-O-Meter.................................................................A-4
Appendix B: Conversion Factors
Water Vapor Pressure & Temperature .....................................................B-1
Absolute Humidity ..................................................................................... B-1
Relative Humidity....................................................................................... B-2
Dew Point/ Frost Point................................................................................ B-2
Volumetric Measurement ..........................................................................B-2
Conversion Table.........................................................................................B-2
Interference Caused By Gases Other Than Air...................................... B-6
Appendix C: Determination of Offset and Coefficient D Adjustment
For Low Concentration (<1 ppm) applications
Background.................................................................................................. C-1
Procedure .....................................................................................................C-1
Supplemental Information
Factory Calibration Data and Certification
Complete 5000 Controller Menu Map
MSDS For Molecular Sieve And Charcoal

vi 5000 Multi Point Moisture Analyzer
Safety Notes
Warnings, cautions, and notes within the text of this manual emphasize important and critical
instructions as follows:
An operating procedure or practice which, if not strictly observed, could result in personal
injury, affect the operator's health, or contaminate the environment.
An operating procedure or practice which, if not strictly observed, could result in damage to
equipment.
Not considered a hazard but requires attention.
Read the entire Specification and Installation Sections of this manual before beginning the
installation and operation of the 5000 Analyzer System. Failure to do so, and/or use of this
equipment in a manner not specified in this manual or accompanying documents, may impair
the protection against fire, electrical shock and injury originally provided by this equipment.
In addition, failure to follow the installation and start-up instructions may void the instru-
ments warranty.
Electrical Safety Warnings
Up to 240 Vac may be present in the analyzer and controller. Always shut down power sources
before performing any maintenance. Only a qualified electrician should make electrical connec-
tions and ground checks.
Any troubleshooting or maintenance to this Analyzer that requires access to the interior of the
various components must be performed by qualified service personnel only. There are no opera-
tor level serviceable parts, expendables, or maintenance needs inside this equipment.
Instrument grounding is mandatory. Performance specifications and safety features are void if
the system is operated from an improperly grounded source. Check ground integrity to all por-
tions of the analyzer before power up. See Fig. 5e for proper internal grounding instructions.
!
CAUTION

NOTE
!
WARNING
!
WARNING
!
WARNING

vii
Sample Gas
Potential hazards of the sample gas should be taken into consideration before connecting sample
to the analyzer. Personal protective equipment and proper ventilation must be used if sample
is toxic or corrosive. Eliminate all fire hazards if sample is flammable. Do not trap explosive gas
inside enclosure when installing the lid.
WARNINGS
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 shut off and the surrounding
area is known to be nonhazardous.
Check sample system for leaks before connecting to analyzer.
The lid weighs 8.2 kg (18 lb). Use proper lifting methods and wear protective footwear when
removing.
All operating, calibration, and maintenance procedures contained in this manual must be
strictly adhered to. If output is questionable, the system should be checked immediately for
proper function and calibration.
!
WARNING
!
WARNING

NOTE

viii 5000 Multi Point Moisture Analyzer
Warning Labels
These symbols may appear on the instrument in order to alert you of conditions that exist.
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 Oberfläche
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 product 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 regional 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 prod-
uct, contact our office listed in the front of the instruction manual.

ix
SPECIAL WARNINGS AND INFORMATION FOR USE OF THE
5000 CONTROLLER IN HAZARDOUS LOCATIONS
This equipment is suitable for use in Class I, Division 2, Groups ABCD or Non-Hazard-
ous Areas Only.
Warning - Explosion Hazard - Substitution of components may impair suitability for Class I,
Division 2.
AVERTISSEMENT - RISQUE D’EXPLOSION - LA SUBSTITUTION DE COMPOSANTS
PEUT RENDRE CE MATERIAL INACCEPTABLE POUR LES EMPLACEMENTS DE
CLASSE I, DIVISION 2.
Warning - Explosion Hazard - Do not disconnect or open equipment unless power has been
switched off or the area is known to be non-hazardous
AVERTISSEMENT - RISQUE D’EXPLOSION - AVANT DE DECONNECTER OU OUVRIR
L’EQUIPEMENT, COUPER LE COURANT OU S’ASSURER QUE L’EMPLACMENT EST
DESIGNE NON DANGEREUX.
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.

NOTE
!
CAUTION

NOTE
!
Avertissement
!
Avertissement
!
WARNING
!
WARNING

x 5000 Multi Point Moisture Analyzer
This page intentionally left blank.