Ametek 5830 User manual

5830 Moisture Analyzer
PN 583054901 Rev YA
USER MANUAL

To obtain a PDF of this manual, visit our Products page at www.ametekpi.com.
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The information and descriptions in this document are the sole property of AMETEK Process Instruments and may not be copied, reproduced, disseminated, or
distributed without explicit written permission from AMETEK Process Instruments.
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liable for any loss or damage, including consequential or special damages, resulting from any use of this information, even if loss or damage is caused by AMETEK
Process Instruments as a result of negligence or any other fault.
Every successful enterprise has as its driving force someone with vision, courage and determination to
make it succeed. Within the AMETEK Process Moisture Analysis business, such a person was John Day.
Over a period of many years of practical experience working with customers, John became the committed
“product champion”of the Quartz Crystal Microbalance method of moisture measurement. He constantly
provided ideas on applications, marketing and product improvements which he felt were desirable for
increasing the worldwide business.
Sadly, John was not to live to see the full results of this inspiration, so we proudly dedicate this new
product to his memory.
JOHN DAY
1952 – 1997

PN 583054901, Rev YA
Contents
Safety Notes................................................................................................................................................vii
Electrical Safety ....................................................................................................................................... viii
Grounding................................................................................................................................................. viii
Sample Gas ............................................................................................................................................... viii
Personnel and Equipment Safety Information................................................................................ix
Special Warnings and Information......................................................................................................xi
Equipment Used in Class I, Division 2 Hazardous Locations..............................................xi
Dryer Warning.....................................................................................................................................xi
Electromagnetic Compatibility (EMC)...............................................................................................xii
Warning Labels........................................................................................................................................ xiii
Environmental Information – WEEE................................................................................................. xiii
OVERVIEW .............................................................................................................................1-1
Controller/Communications...............................................................................................................1-2
Contact Closure Signals........................................................................................................................1-3
System Alarm ...................................................................................................................................1-3
Moisture Concentration Alarm ..................................................................................................1-3
Data Valid...........................................................................................................................................1-3
Moisture Sensor ......................................................................................................................................1-4
Quartz Crystal Microbalance (QCM).........................................................................................1-4
Gas Measurement Cycle...............................................................................................................1-4
Gas Flow.....................................................................................................................................................1-5
Sample System ................................................................................................................................1-5
Sample Flow .....................................................................................................................................1-6
Solenoid Valves................................................................................................................................1-7
Zero Gas Module.............................................................................................................................1-8
Zeroing the Analyzer.............................................................................................................................1-8
Verifying the Analyzer...........................................................................................................................1-9
Changing Gasses.....................................................................................................................................1-9
Dew/Frost Point Measurements..................................................................................................... 1-10
INSTALLATION AND START-UP............................................................................................2-1
Safety Considerations ...........................................................................................................................2-1
Pre-Installation Requirements ...........................................................................................................2-2
Personnel Technical Level Required for Installation...........................................................2-2
Analyzer Requirements ........................................................................................................................2-2
Space Requirements......................................................................................................................2-2
Unpacking and Inspecting the Equipment...........................................................................2-4
Contents | iii

PN 583054901, Rev YA
Tools, Equipment, and Supplies Required for Installation...............................................2-4
Electrical Requirements................................................................................................................2-5
Instrument Air Supply...................................................................................................................2-5
Sample Temperature and Pressure Requirements..............................................................2-6
Analyzer Installation..............................................................................................................................2-7
User-Supplied Items ......................................................................................................................2-7
Interconnect Wiring...............................................................................................................2-7
External Sample Tubing .......................................................................................................2-7
Rear Panel Connections and Interface Board.......................................................................2-8
Installing the Dryers....................................................................................................................2-10
Gas Connections ..........................................................................................................................2-12
Electrical Connections ...............................................................................................................2-13
Voltage Selection .................................................................................................................2-13
Power Connection.......................................................................................................................2-14
Communication Connections .................................................................................................2-16
Signal Connections (4–20 mA)................................................................................................ 2-17
Overview of the Keypad.................................................................................................................... 2-18
Function Keys................................................................................................................................2-18
Overview of Display.................................................................................................................... 2-19
Initial Start-Up....................................................................................................................................... 2-20
Dry-Down Period .........................................................................................................................2-20
Procedure for Speeding up the Dry Down Period.........................................................2-21
Performing an Initial Zero.........................................................................................................2-21
Conguring the 5830 Analyzer for Serial Communications................................................. 2-22
Protocol ...........................................................................................................................................2-22
Special Addresses ........................................................................................................................2-24
Address $F0 ...........................................................................................................................2-24
Dened Commands (Master to Slave).................................................................................. 2-24
Echo (A)...................................................................................................................................2-25
Bad Command (B) ...............................................................................................................2-25
Acknowledge (C) ..................................................................................................................2-25
Read Data (F) ........................................................................................................................2-25
Write Data (H).......................................................................................................................2-26
Write Cell EEPROM (L) .........................................................................................................2-26
Quit (Q)...................................................................................................................................2-26
Zero (Z) ...................................................................................................................................2-26
Dened Responses (Slave to Master) ...................................................................................2-27
Simple Acknowledge...........................................................................................................2-27
Acknowledge with Data.....................................................................................................2-27
Failure .....................................................................................................................................2-27
Variables Table ......................................................................................................................................2-28
iv | 5830 Moisture Analyzer

PN 583054901, Rev YA
CONTROLLER/INTERFACE....................................................................................................3-1
Working From the Built-in User Interface ......................................................................................3-1
Zero Key .............................................................................................................................................3-3
Alarm Key...........................................................................................................................................3-4
Range Key..........................................................................................................................................3-5
Cong Key .........................................................................................................................................3-6
Display......................................................................................................................................3-6
Communication .....................................................................................................................3-7
Sample Gas.............................................................................................................................. 3-8
Clock........................................................................................................................................3-10
Zero Schedule .......................................................................................................................3-11
Verify Schedule .....................................................................................................................3-12
Production Codes.................................................................................................................3-13
Moisture Unit ........................................................................................................................3-13
System Test ............................................................................................................................3-14
Working From the 5830 Congurator Software....................................................................... 3-15
Congurator Software Installation........................................................................................ 3-15
Conguring the 5830 .................................................................................................................3-16
Working From the General Tab.........................................................................................3-16
Saving Analyzer Conguration Settings ........................................................................3-18
Working From the Device Communication Tab ...........................................................3-19
Conguring Multiple Analyzers........................................................................................3-19
Changing Communication Parameters.........................................................................3-19
Saving Your Settings ...........................................................................................................3-20
Working From the Setup Tab.............................................................................................3-21
Working From the Schedule Tab ......................................................................................3-23
Saving Your Settings ...........................................................................................................3-26
Working From the Status Tab............................................................................................3-27
Working From the Monitor Tab ........................................................................................3-28
Data Capture ........................................................................................................................3-29
MAINTENANCE AND TROUBLESHOOTING.........................................................................4-1
Aftermarket Excellence and Long-Term Commitment to Safety and Quality ..................4-2
5830 Analyzer Replacement Parts....................................................................................................4-3
Servicing the 3050-AM Analyzer.......................................................................................................4-4
Sensor .................................................................................................................................................4-6
Removing the Sensor ............................................................................................................4-6
Installing the Sensor..............................................................................................................4-6
Mass Flow Meter .............................................................................................................................4-7
Removing the Mass Flow Meter..........................................................................................4-7
Installing the Mass Flow Meter........................................................................................... 4-8
Moisture Generator................................................................................................................................4-9
Removing the Moisture Generator ....................................................................................4-9
Installing the New Moisture Generator...........................................................................4-11
Contents | v

PN 583054901, Rev YA
Solenoid Valves..................................................................................................................................... 4-12
Removing the Solenoids...........................................................................................................4-12
Installing the New Solenoid...............................................................................................4-14
Dryers......................................................................................................................................4-15
Removing the Dryers...................................................................................................4-15
Installing the New Dryer.............................................................................................4-16
Maintenance of the Electronics Module ..................................................................................... 4-17
Removing the Electronics Module From the 5830 ..........................................................4-17
Tools Required ..............................................................................................................................4-17
Procedure for Removing the Electronics Module .........................................................4-17
Proportional Solenoid Valve (PSV) Board............................................................................4-19
Analog Interface PCB.................................................................................................................. 4-19
Removing the Analog PCB.................................................................................................4-19
Replacing the Analog Interface Board............................................................................4-19
MCU Board ..................................................................................................................................... 4-20
Removing the MCU Board .................................................................................................4-20
Replacing the MCU Board..................................................................................................4-20
Pilot Valve Manifold.....................................................................................................................4-22
Removing the Pilot Valve Manifold .................................................................................4-22
Replacing the Pilot Valve Manifold..................................................................................4-23
Reinstalling the Electronics Module .....................................................................................4-23
Board Connections.............................................................................................................................. 4-24
User Interface Board...................................................................................................................4-24
Alarm Messages ................................................................................................................................... 4-25
SPECIFICATIONS....................................................................................................................5-1
Compatible Gases...................................................................................................................................5-1
High Pressure ..........................................................................................................................5-1
Low Pressure Compatible Gases.........................................................................................5-1
5830 Moisture Analyzer Specications...........................................................................................5-2
5830 Moisture Analyzer Approvals and Certications..............................................................5-3
APPENDIX A – QUICK REFERENCE CARD............................................................................ A-1
vi | 5830 Moisture Analyzer

PN 583054901, Rev YA
Safety Notes
WARNINGS, CAUTIONS, and NOTES contained in this manual emphasize critical
instructions as follows:
Important information that should not be overlooked.
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.
Burn hazard. Hot surface. Do not touch, allow to cool before servicing.
Read this manual before beginning the installation and operation of the 5830
Analyzer. Failure to do so, and or use of the equipment in a manner not speci-
ed in this manual or accompanying documents, may impair the protection
against re, electrical shock and injury originally provided by this equipment.
In addition, failure to follow the installation and start-up instructions may void
the instrument warranty.
Contents | vii

PN 583054901, Rev YA
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 trouble-
shooting. 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 instrument is operated from an improperly grounded power source.
Verify ground continuity of all equipment before applying power.
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, ammable, 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
specic sample gas type.
viii | 5830 Moisture Analyzer

PN 583054901, Rev YA
Personnel and Equipment Safety Information
This section describes important safety information to avoid personal injury and dam-
age to the equipment while installing, operating, maintaining, or servicing the equip-
ment. All safety regulations, standards, and procedures at the analyzer location must
be followed.
All personnel involved with the installation, start-up, operation, maintenance, service, or
troubleshooting of the analyzer must review and follow these Warnings and Cautions.
Do Not Operate without Covers
To avoid electric shock or re hazard, do not operate this product with covers
or panels removed.
Use Caution When Lifting
Use caution when lifting the analyzer from its crate.
Use Proper Attire
Equipment is hot, user should wear protective groves while handling the
equipment.
Use Proper Wiring
To avoid re hazards, use only the wiring specied in the “Installation and
Start-Up” chapter of this manual.
Avoid Electrical Overload
To avoid electrical shock or re hazard, do not apply a voltage to a terminal
that is outside the range specied for that terminal.
Ground the Product
Follow the grounding instructions provided in the “Installation and Start-Up”
chapter of this manual. Before making connections to the input or output
terminals of this product, ensure that the product is properly grounded.
Use Proper Fuse
To avoid re hazard, use only the fuse type and rating specied for this product.
Contents | ix

PN 583054901, Rev YA
Use Proper Power Source
Do not operate this product from a power source that applies more than the
voltage specied.
Do Not Operate with Suspected Failures
If you suspect there is damage to this product, have it inspected by qualied
service personnel.
Do Not Operate in Explosive Atmosphere
To avoid injury or re hazard, do not operate this product in an explosive
atmosphere unless you have purchased options that are specically designed
for these environments.
x | 5830 Moisture Analyzer

PN 583054901, Rev YA
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.
AVERTISSEMENT – Risque d’explosion – La substitution de composants peut
rendre ce materiel inacceptable pour les emplacements de Classe I, Division 2.
Refer to the“Safety Critical Components”in the 5830 Analyzer Replacement Parts list in
Chapter 4 of this manual.
Explosion Hazard – Do Not Disconnect Equipment Unless Power Has Been
Switched O or the Area is Known to be Non-Hazardous.
AVERTISSEMENT – Risque d’explosion – Avant de déconnecter l’équipement,
coupez le courant où vous assurez que l’emplacement est designé non dan-
gereux.
All input and output wiring must be in accordance with Class I, Division 2 wiring meth-
ods (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 installed, consult the MSDS for appropriate shipping
information and instructions.
Contents | xi

PN 583054901, Rev YA
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 congurations of the 5830 Moisture Analyzer should not produce, or fall victim to, electro-
magnetic 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 pow-
er. Foil and braid shielded I/O and DC power cables are recommended for use in otherwise unprotect-
ed situations. 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 eective 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 sucient protec-
tion depending on the electronic environment. Connecting one shield ground via a 0.1 microfarad ce-
ramic 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 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 oending 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 dis-
turbances include motors, capacitor bank switching, storm related transients, RF welding equipment,
static, and walkie-talkies.
xii | 5830 Moisture Analyzer

PN 583054901, Rev YA
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 Oberäche
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 environ-
ment 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 doing one of the following steps:
• When the equipment is ready to be disposed of, take it to your
local or regional waste collection administration for recycling.
• If you need further assistance in recycling your AMETEK product,
contact us through our Customer Support page at
https://www.ametekpi.com/customersupport/requestsupport.
Contents | xiii

PN 583054901, Rev YA
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xiv | 5830 Moisture Analyzer

Overview
The 5830 Moisture Analyzer reliably measures low concentrations of moisture
in high purity gases at concentrations down to 20 parts-per-billion by volume
(PPBV), using a quartz crystal microbalance (QCM) sensor. The calibrated range
of the analyzer is 0 to 100 PPMV with a trend indication for measured concen-
trations to 1000 PPMV. The QCM-sensor technology used in this analyzer is
compatible with inert gases, air, oxygen, nitrogen, hydrogen, Freons (12, 22,
32, 114, 116, 125, 134A, and 152), methane, ethane, propane, and some spe-
cialty gases (e.g., sulfur hexauoride). Carbon dioxide requires a custom Sensor
assembly. Please contact the factory to conrm compatibility with other gases.
Figure 1-1.
5830 Moisture Analyzer.
Overview |1-1
PN 583054901, Rev YA

PN 583054901, Rev YA
Controller/Communications
All analyzer functions are controlled by microprocessors housed within the
analyzer. These include:
•One (1) fully congurable Analog Output (4–20 mA) that can be self-pow-
ered or externally powered.
•Three (3) alarm contacts (Data Valid, Concentration Alarm, and System
Alarm).
•One (1) RS-232 or one (1) RS-485 serial interface provides communication
between the analyzer and your recording or data acquisition equipment.
The 5830 Moisture Analyzer is congured, and analyzer parameters are set, by
using either the analyzer display, keypad and function keys, or using an exter-
nal PC.
•4-line x 20-character LCD display that provides moisture data, system oper-
ating parameters, system messages, and alarm conditions.
•An 18-button keypad on the front of the unit that is used to set or change
operating parameters and system values.
•Serial interface to an external PC.
1-2 | 5830 Moisture Analyzer

Contact Closure Signals
The analyzer provides the following contact closure signals.
System Alarm
Activates (contact opens) when a condition exists that makes analyzer output
questionable. Such conditions include:
•Cell Temperature alarm
•Zero error
•Battery alarm
Moisture Concentration Alarm
Activates (contact opens) when a moisture concentration exceeds the pro-
grammed alarm levels.
Data Valid
Activates (contact opens) when any System Alarm is present. Additionally, the
contact will open when the analyzer is in a Zero or Verication cycle.
Overview |1-3
PN 583054901, Rev YA

PN 583054901, Rev YA
Moisture Sensor
Quartz Crystal Microbalance (QCM)
The 5830 Moisture Analyzer uses a quartz crystal microbalance Sensor to mea-
sure water vapor concentration. This is a piezoelectric device that is capable of
extremely sensitive mass measurement. To make the QCM sensitive to water
vapor the surface is coated with a thin lm of hygroscopic material. When gas
ows through the Sensor, the coating absorbs or desorbs moisture, changing
the natural resonance frequency of the crystal.
Gas Measurement Cycle
The gas measurement cycle is divided into two periods.
•During the rst period of the cycle, dry Reference gas ows through the
Sensor assembly and the frequency is recorded.
•During the second period of the cycle, Sample gas ows through the Sen-
sor and a second measurement of the Sensor frequency is recorded.
•The dierence between these two frequency measurements is known as
the delta frequency (∆ƒ). The ∆ƒ value is a function of the moisture con-
centration in the Sample gas.
1-4 | 5830 Moisture Analyzer

Gas Flow
Sample System
The 5830 Moisture Analyzer sample system enables the analyzer to make reliable
water vapor measurements at concentrations down to 20 PPBV. The Sample Sys-
tem serves several purposes:
•It controls the sample conditions at the Sensor assembly (e.g., ow rate,
temperature, pressure). Hence, the QCM-based Sensor is isolated from
variations in the ambient conditions that would otherwise alter the re-
sponse characteristics of the Sensor.
•The Sample System is designed to continuously switch the Sensor assem-
bly between the Sample gas and a dry Reference gas. This sample switch-
ing scheme yields both higher sensitivity and reduced drift in the Sensor
readings.
•The 5830 Sample System’s design provides a means of challenging the an-
alyzer with a known source of dry gas to validate the baseline readings and
to compensate for any minor changes in background osets. In addition,
the analyzer contains a permeation tube-based moisture standard that can
be used to challenge the analyzer with a known moisture concentration.
As such, the 5830 is designed to deliver reliable, long-term performance
from the QCM-based sensor.
Overview |1-5
PN 583054901, Rev YA

PN 583054901, Rev YA
Sample Flow
Normal operation of the 5830 Moisture Analyzer uses an internal bypass,
which increases the response speed of the system. However, the 5830 is ca-
pable of running in a gas-saver mode as well, which allows the analyzer to run
on a sample volume of approximately 150 SCCM.
In normal operation of the analyzer, the sample gas enters the analyzer and
ows directly through the diaphragm valve (DV2); the other two diaphragm
valves (DV1 and DV3) remain closed to isolate the rst dryer.
Figure 1-2.
Flow schematic, 5830 sample
manifold.
DRYER
DRYER
PERMEATION TUBE
ASSEMBLY
VENT SENSOR
ASSEMBLY
MASS-FLOW
METER
DV1 DV3
DV2
SV1
PSV SV2
SV3
SV4
GAS INLET
ZERO GAS
MODULE
CAPILLARY
CAPILLARY
CAPILLARY
CAPILLARY
BYPASS FLOW
Pressure
Transducer
SV5
There are four separate sample paths in the 5830 Moisture Analyzer manifold.
•The rst is a simple bypass that allows for an increased ow rate of sample
gas. This means that when you open the bypass valve (SV1), you reduce
the time required to equilibrate all portions of the Sample System that
exist upstream of the bypass valve. A capillary tube (the coil shape in
Figure 1-2), located immediately downstream of SV1, limits the ow rate
to approximately one (1) standard liter per minute (the exact value of the
bypass ow is a function of the inlet pressure to the analyzer).
1-6 | 5830 Moisture Analyzer