Ametek 5800 User manual

5830 Moisture Analyzer
User Manual
Process Instruments
455 Corporate Boulevard
Newark, DE 19702
PN 583054901 Rev.YA
Configurator Version 3.0

ii | 5830 Moisture Analyzer
Offices
© 2009 AMETEK
This manual is a guide for the use of the 5830 Moisture Analyzer. 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.
SALES AND MANUFACTURING:
USA - Delaware
455 Corporate Blvd., Newark DE 19702 • Tel: [phone], Fax: [phone]
USA - Oklahoma
2001 N. Indianwood Ave., Broken Arrow OK 74012 • 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

Contents | iii
Table of Contents
Sample Gas............................................................................................................vi
Safety Notes ..........................................................................................................vi
Electrical Safety.....................................................................................................vi
Grounding.............................................................................................................vi
Warning Labels ....................................................................................................vii
Electromagnetic Compatibility (EMC)............................................................viii
Special Warnings and Information....................................................................ix
Dryer Warning...................................................................................................... ix
European Standards Information....................................................................... x
Chapter 1 5830 MOISTURE ANALYZER
Overview .............................................................................................................1-1
Controller / Communications....................................................................1-2
Contact Closure Signals..............................................................................1-2
Moisture Sensor ...........................................................................................1-3
Quartz Crystal Microbalance (QCM).....................................................1-3
Gas measurement cycle............................................................................1-3
Gas Flow........................................................................................................1-3
Sample system .........................................................................................1-3
Sample flow .............................................................................................1-4
Solenoid valves ........................................................................................1-5
Zero gas module ......................................................................................1-6
Zeroing the Analyzer ..................................................................................1-6
Verifying the Analyzer................................................................................1-7
Dew/Frost Point Measurements ................................................................1-7
Chapter 2 Specifications
Chapter 3 Installation and Start-Up
Analyzer Requirements.....................................................................................3-2
Space Requirements ...................................................................................3-2
Utility Requirements...................................................................................3-4
Electrical requirements............................................................................3-4
Instrument air supply .............................................................................3-4
Sample Temperature and Pressure Requirements.................................3-4
Analyzer Installation .........................................................................................3-5
User-Supplied Items ...................................................................................3-5
Rear Panel Connections and Interface Board .........................................3-6
Installing the Dryers (Figures 3-4a and b) ...............................................3-8
Gas Connections (Figure 3-5)...................................................................3-10
Electrical Connections (Figure 3-6).........................................................3-11
Voltage selection ....................................................................................3-11
Power connection...................................................................................3-12
Communication Connections (Figure 3-9) ............................................3-13

iv | 5830 Moisture Analyzer
RS-485 communications .......................................................................3-14
Signal Connections (4 to 20 mA ) ............................................................3-15
Overview of keypad ...............................................................................3-16
Function keys.........................................................................................3-16
Overview of display...............................................................................3-17
Initial Start-Up............................................................................................3-18
Dry-down period ..................................................................................3-18
Procedure for speeding up the dry down period....................................3-19
Performing an Initial Zero........................................................................3-19
Chapter 4 User Interface
Zero Key...............................................................................................................4-3
Hold Outputs ...............................................................................................4-3
Adjust Offset/Span ......................................................................................4-3
Zero................................................................................................................4-3
Verify..............................................................................................................4-3
Abort ..............................................................................................................4-3
Alarm Key............................................................................................................4-4
Range Key............................................................................................................4-5
Config Key...........................................................................................................4-6
Display...........................................................................................................4-6
Communication ...........................................................................................4-7
Sample Gas ...................................................................................................4-8
Custom gas ..............................................................................................4-8
Clock ..............................................................................................................4-9
Zero Schedule ............................................................................................4-10
Verify Schedule ..........................................................................................4-11
System Test ........................................................................................................4-13
Chapter 5 Serial Communications
Protocol ................................................................................................................5-1
Special Addresses.........................................................................................5-3
Address $F0.............................................................................................5-3
Defined Commands (master to slave)......................................................5-3
Echo (A)...................................................................................................5-4
Bad Command (B) ...................................................................................5-4
Acknowledge (C ).....................................................................................5-4
Read Data (F) ..........................................................................................5-4
Write Data (H) ........................................................................................5-5
Write Cell EEPROM (L).........................................................................5-5
Quit (Q) ..................................................................................................5-5
Zero (Z) ...................................................................................................5-5
Defined Responses (slave to master)........................................................5-6
Simple Acknowledge................................................................................5-6
Acknowledge with Data...........................................................................5-6
Failure .....................................................................................................5-6

Contents | v
Chapter 6 Troubleshooting
Alarms ..................................................................................................................6-1
Chapter 7 Service and Parts
Parts Replacement..............................................................................................7-1
Sensor ............................................................................................................7-3
Removing the sensor ..................................................................................7-3
Installing the sensor ................................................................................7-3
Mass Flow Meter..........................................................................................7-4
Removing the mass flow meter................................................................7-4
Installing the mass flow meter.................................................................7-4
Moisture Generator ....................................................................................7-6
Removing the moisture generator ...........................................................7-6
Installing the new moisture generator ....................................................7-7
Solenoid Valves ............................................................................................7-8
Removing the solenoids ...........................................................................7-8
Installing the new solenoid......................................................................7-9
Dryers ..........................................................................................................7-10
Removing the dryers .............................................................................7-10
Installing the new dryer ........................................................................7-11
Maintenance of the Electronic Module ........................................................7-12
Removing the Electronic Module from the Model 5830 .....................7-12
Tools required.............................................................................................7-12
Procedure for removing the electronics module.....................................7-12
Analog Interface PCB................................................................................7-14
Removing the analog interface PCB......................................................7-14
Replacing the analog interface PCB .....................................................7-14
MCU PCB....................................................................................................7-14
Removing the MCU PCB......................................................................7-14
Replacing the MCU PCB ......................................................................7-14
Pilot Valve Manifold..................................................................................7-16
Removing the pilot valve manifold........................................................7-16
Replacing the pilot valve manifold ........................................................7-17
Reinstalling the Electronic Module ........................................................7-17
Board Connections...........................................................................................7-18
User Interface Board .................................................................................7-18
Spare Parts.........................................................................................................7-19
Appendix A PC Interface
AMETEK UHP Moisture Configurator Software.........................................A-1
Configurator Software ..............................................................................A-1
Configurator Software Installation...............................................................A-1
Configuring the 5830....................................................................................A-2

vi | 5830 Moisture Analyzer
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 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
Hazardous voltages are present in the analyzer housings when power is applied to the system.
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 protection are void
if instrument is operated from an improperly grounded power source.
Verify ground continuity of all equipment before applying power.
!
WARNING
!
CAUTION

NOTE
Sample Gas
Potential hazards of the sample gas should be taken into consideration before
connecting the sample to the analyzer. Personal protective equipment and
proper ventilation should be used if sample gas is toxic, flammable, or corro-
sive. Check the sample line and all connections for leaks before powering up.
Consult plant safety personnel for appropriate exhaust venting guidelines for
specific sample gas type.
!
WARNING

NOTE

Contents | vii
Warning Labels
These symbols may appear on the instrument in order to alert you of existing conditions.
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 product, contact
our office listed in the front of the instruction manual.

viii | 5830 Moisture Analyzer
Electromagnetic Compatibility (EMC)
Read and follow the recommendations in this section to avoid performance
variations or damage to the internal circuits of this equipment when installed
in harsh electrical environments.
The various configurations of the 5830 Moisture Analyzer should not produce, or fall victim to,
electromagnetic disturbances as specified in the European Union’s EMC Directive. Strict compli-
ance 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 techniques and wiring practices to be followed.
In meeting the EMC requirements , the various Analyzer configurations described in this man-
ual rely heavily on the use of metallic shielded cables used to connect to the customer’s equip-
ment and power. Foil and braid shielded I/O and DC power cables are recommended for use in
otherwise unprotected situations. In addition, hard conduit, flexible 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 sufficient protection depending on the electronic environment.
Connecting one shield ground via a 0.1 microfarad ceramic capacitor is a technique allowing
high frequency shield bonding while avoiding the AC-ground metal connection. In the case of
shielded 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 termi-
nal 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 back-
wards 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 appro-
priate 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 unshielded 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 electrical events and devices known for the generation of harmful
electromagnetic disturbances include motors, capacitor bank switching, storm related transients,
RF welding equipment, static, and walkie-talkies.
!
CAUTION

Contents | ix
SPECIAL WARNINGS AND INFORMATION
EQUIPMENT USED IN CLASS I, DIVISION 2 HAZARDOUS LOCATIONS
Explosion Hazard - Substitution of Components May Impair Suitability for Class I, Division 2.
Risque d’explosion - La substitution de composants peut rendre ce materiel inaccept-
able pour les emplacements de Classe I, Division 2.
Refer to the “Safety Critical Components” in the Spare Parts list in
section 7 of this manual.
Explosion Hazard - Do Not Disconnect Equipment Unless Power Has Been Switched Off or
the Area is Known to be Non-Hazardous.
Risque d’explosion - Avant de déconnecter l’équipement, coupez le courant où vous as-
surez que l’emplacement est designé non dangereux.
All input and output wiring must be in accordance with Class I, Division 2 wiring methods (NEC
Sec 501.4(b) or CEC 18-152) (UL1604/CSA#213) and in accordance with the authority having
jurisdiction.
Dryer Warning
When removing and installing dryers, please follow all handling guidelines provided in the
MSDS (located in the back of the manual). When shipping the analyzer with the dryers in-
stalled, consult the MSDS for appropriate shipping information and instructions.
!
WARNING
!
WARNING
!
AverƟssement
!
WARNING
!
AverƟssement

x | 5830 Moisture Analyzer
Notice: Not Valid until signed and dated.
F-0094 Rev 1
Onasis Greene
Compliance Engineer
AMETEK Process & Analytical Instrument Division
455 Corporate Blvd, Newark DE 19702
EU Declaration of Conformity
Manufacturer’s Name: AMETEK Process & Analytical Instruments
Division (ISO 9001: 2008 Registered)
Manufacturer’s Address:
Declare under our sole responsibility that the product
Product Name: Moisture Analyzer
Model Number (s): Models 5800, 5830, 5812 & 2850
Conforms to the following standards:
EMC Directive 2014/30/EU:
EN 55011: 2009 + A1:2010 Industrial, Scientific and medical equipment –Class A, Group 1
EN 61326-1: 2006 Electrical Equipment for Measurement, Control, and Laboratory Use
EMC Requirements- Table 2
EN 61000-4-2: 2009 Electrostatic discharge immunity
EN 61000-4-3:2006 Radiated Electromagnetic Field Immunity
EN 61000-4-4:2004+A1:2010 Electrical Fast transients/Burst Immunity
EN 61000-4-5:2006 Power Line Surge Immunity
EN 61000-4-6: 2009 Conducted RF Immunity
EN 61000-4-11: 2004 Power Line Voltage dips/Interrupts
LV Directive 2014/35/EU:
EN 61010-1:2010 Safety requirements for electrical equipment for measurement, control
and laboratory use –Part 1
EU Authorised Representative:
AMETEK GmbH
Rudolf-Diesel-Strasse 16
D-40670 Meerbusch Germany
Contact: Dr. Jurgen Gassen
OOnasis EE. GGreene 66/30//2016
455 Corporate Blvd
Newark, DE 19702
United States of America
Phone: [phone]
Fax: [phone]
Web Address:
www.ametekpi.com
150 Freeport Road
Pittsburgh, PA 15238
United States of America
Phone: [phone]
Fax: [phone]
Web Address:
www.ametekpi.com