Ametek Thermox Series 2000 WDG-IV User manual

Thermox®Series 2000
WDG-IV, WDG-IVC, WDG-IVCM
User Manual
Thermox
150 Freeport Road
Pittsburgh, PA 15238
PN 90269VE , Rev. Y

© 2000 AMETEK
This manual is a guide for the use of the Thermox Series 2000 WDG-IV (IVC / IVCM). Data herein has been veried and validated and is
believed adequate for the intended use of this instrument. If the instrument or procedures are used for purposes over and above the capabilities
specied herein, conrmation of their validity and suitability should be obtained; otherwise, AMETEK does not guarantee results and assumes no
obligation or liability. This publication is not a license to operate under, or a recommendation to infringe upon, any process patents.
Ofces
USA - Pittsburgh
150 Freeport Road
Pittsburgh, PA 15238
Ph. 412-828-9040
Fax [phone]
CHINA
AMETEK Shanghai (SPL)
Room 408, Metro Tower
#30 Tian Yao Qiao Road
Shanghai 200030
Ph. 86 21 6426 8111
Fax [phone]
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455 Corporate Blvd.
Newark, DE 19702
Ph. 302-456-4400
Fax [phone]
AMETEK Beijing
CITIC Building, Room 2305
19, Jianguomenwai Dajie
Beijing 100004
Ph. 86 10 8526 2111
Fax [phone]
USA - Texas
4903 West Sam Houston Parkway North
Suite A-400
Houston, TX 77041
Ph. 713-466-4900
Fax [phone]
FRANCE
AMETEK Precision Instruments France
Rond Point de l’épine des champs
Buroplus Bat D
78990 Elanbourt
Ph. 33 1 30 68 89 20
Fax [phone]
CANADA
2876 Sunridge Way N.E.
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Ph. 403-235-8400
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Rudolf-Diesel-Strasse 16
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Ph. 49 21 59 91 36 0
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AMETEK
PO Box 17067
Jebel Ali Free Zone
Dubai, UAE
Ph. 971-4-881 2052
Fax [phone]
SINGAPORE
AMETEK Singapore Pte. Ltd.
No 43, Changi South Avenue 2, #04-01
Singapore 486164
Ph. 65-64842388
Fax [phone]

Contents | iii
Contents
Offices ......................................................................................................................ii
Safety Notes .......................................................................................................... vi
Environmental Information (WEEE) .............................................................. viii
General Safety Summary .....................................................................................ix
CHAPTER 1 Overview
Sensor Operations.............................................................................................. 1-1
Sensor .................................................................................................................. 1-2
Basic Elements of the Sensor ..................................................................... 1-2
The Oxygen Measuring Cell...................................................................... 1-2
Sensor Operations - WDG-IVCM.................................................................... 1-5
Close-Coupled Extrative Flue Gas Analyzer ................................................. 1-5
Hot-Wire Type .............................................................................................. 1-5
RTD Type....................................................................................................... 1-6
Detectors.............................................................................................................. 1-7
Combustibles................................................................................................ 1-7
Methane ........................................................................................................ 1-7
Common Operator Errors ................................................................................ 1-8
Start-Up Checklist .............................................................................................. 1-9
Technical Support............................................................................................. 1-10
CHAPTER 2 Specications
Series 2000 Control Unit.................................................................................... 2-1
Sensor : WDG-IV ............................................................................................... 2-2
Sensor : WDG-IVC ........................................................................................... 2-3
Sensor : WDG-IVCM ........................................................................................ 2-4
Sensor : WDG-IVC - 0-500 PPM ..................................................................... 2-6
Remote Calibration Unit (RCU)....................................................................... 2-7
CHAPTER 3 Installation
Analyzer Location .............................................................................................. 3-1
Inspect Shipping Contents ............................................................................... 3-2
Mechanical Installation ..................................................................................... 3-3
Sample Inlet Probe Installation ................................................................. 3-3
Probe Heater Installation ........................................................................... 3-6
Exhaust Tube Installation ........................................................................... 3-7
Sensor Mounting ......................................................................................... 3-7
Calibration/Aspirator Air/Z-Purge Connections................................... 3-12
Weatherproof Wall/Z-Purge Option....................................................... 3-17
Wiring................................................................................................................. 3-19
General Wiring and Conduit Requirements......................................... 3-20
Control Unit Mains Supply Connections.............................................. 3-21
Sensor Connections................................................................................... 3-24

iv | Thermox Series 2000 WDG-IV / IVC / IVCM
Remote Sense Setup Wiring for Combustibles..................................... 3-28
Current Output Connections.................................................................. 3-29
Alarm Contact Connections..................................................................... 3-30
Remote Calibration Unit Connections................................................... 3-32
RS-485 Communications Connections................................................... 3-34
Option Card Installation................................................................................. 3-38
Removing Display Module or Power Supply/Keypad Module......... 3-38
Adding an Option Card ........................................................................... 3-39
Removing an Option Card ...................................................................... 3-39
CHAPTER 4 Controller/User Interface
Areas of the Control Unit.................................................................................. 4-1
Control Unit Display................................................................................... 4-1
Selecting Menu Options............................................................................. 4-2
Exiting Menu Options ................................................................................ 4-2
Automatic Menu Exit Feature.................................................................... 4-3
On-Line Help ............................................................................................... 4-3
System Password ......................................................................................... 4-3
Setup Key............................................................................................................. 4-4
Display .......................................................................................................... 4-5
Process Pressure........................................................................................... 4-7
System Tests.................................................................................................. 4-8
System Serial # ............................................................................................ 4-8
Primary Calibration..................................................................................... 4-9
Sensor Config............................................................................................. 4-12
Communication......................................................................................... 4-13
Combustibles Option................................................................................ 4-13
Analog Range Key............................................................................................ 4-14
Analog Output Port................................................................................... 4-15
Set Current Range ..................................................................................... 4-15
Set Track/Hold Option.............................................................................. 4-16
Set Current Mode...................................................................................... 4-17
Output Filtering Option........................................................................... 4-18
Select Function........................................................................................... 4-19
Alarm Key.......................................................................................................... 4-20
Overview of Alarm Functions................................................................. 4-21
Alarm Set Points......................................................................................... 4-22
Alarm Configure........................................................................................ 4-24
Relay Configure......................................................................................... 4-24
Select Function........................................................................................... 4-25
Service Alarm ............................................................................................. 4-26
Watchdog Relay ......................................................................................... 4-26
Exception Log............................................................................................. 4-27

Contents | v
Chapter 5 Calibration
Definitions........................................................................................................... 5-2
Calibrations vs. Verifications...................................................................... 5-2
Span and Zero Calibration Gas Definitions ............................................ 5-2
Types of Calibrations ......................................................................................... 5-3
Overview............................................................................................................. 5-4
Aborting a Calibration....................................................................................... 5-4
Initiate Cal and Initiate Verify.......................................................................... 5-5
Auto Calibrate/Auto Verify......................................................................... 5-5
Remote Calibrate/Remote Verify............................................................... 5-7
Manual Calibrate/Manual Verify............................................................... 5-8
Calibration: Hot Wire Type Combustibles Detector .............................. 5-10
Calibration with RTD Type Combustibles Detector.............................. 5-12
Cal/Verify Data.................................................................................................. 5-14
Cal Gas Value .................................................................................................... 5-16
Inject Cal Gas .................................................................................................... 5-18
Set Cal Timers ................................................................................................... 5-20
Set Auto Timers.......................................................................................... 5-21
Set Time and Date ..................................................................................... 5-22
Auto Cal On/Off......................................................................................... 5-22
Cal Gas Duration ....................................................................................... 5-23
Recovery Duration .................................................................................... 5-24
Set K-Factors...................................................................................................... 5-25
Sensitivity .......................................................................................................... 5-25
Chapter 6 Maintenance and Troubleshooting
System Messages................................................................................................ 6-2
Auto Cal Pending......................................................................................... 6-2
Auto Verify Pending .................................................................................... 6-2
Calibration Aborted..................................................................................... 6-2
Calibration Required................................................................................... 6-2
Cal Verify Aborted....................................................................................... 6-2
Power Down Detected................................................................................ 6-2
Primary Calibration..................................................................................... 6-2
System Calibrating ...................................................................................... 6-2
System Verifying Cal................................................................................... 6-2
Error Messages ................................................................................................... 6-3
Cell is Over Temp ........................................................................................ 6-3
Combustibles Cal Error .............................................................................. 6-3
Excessive Cal Error...................................................................................... 6-3
Memory is Corrupted................................................................................. 6-3
Methane Cal Error....................................................................................... 6-3
Span Gas Range Error................................................................................. 6-4
Temp Rise Failure......................................................................................... 6-4
T/C (Thermocouple) Circuit Failure ......................................................... 6-4

vi |
Thermocouple Failure ................................................................................ 6-4
Zero Gas Range Error ................................................................................. 6-4
Diagnostics Checks ............................................................................................ 6-5
Wiring Checks.............................................................................................. 6-6
Interconnecting Wiring Problem .............................................................. 6-6
Thermocouple Checks................................................................................ 6-6
Shorted/Failed Thermocouple................................................................... 6-6
Reversed Thermocouple Wires ................................................................. 6-6
Thermocouple Compensation .................................................................. 6-6
Circuit Check................................................................................................ 6-6
Calibration/Aspirator Setup Checks......................................................... 6-8
AC Power Checks ........................................................................................ 6-9
Furnace Checks............................................................................................ 6-9
Process Pressure Checks........................................................................... 6-10
Cell Checks ................................................................................................. 6-10
General Troubleshooting ................................................................................ 6-11
Leak Check ................................................................................................. 6-11
Plugged Plumbing Check ........................................................................ 6-12
Aspirator Air Not Pulling Sample from Process ................................... 6-12
Series 2000 LEDs............................................................................................... 6-13
Auto Calibration Card LEDs.................................................................... 6-13
Combustibles Card LEDs ......................................................................... 6-13
Combustibles and Methane Card LEDs ................................................ 6-14
Sensor Board (80471SE) LEDs ................................................................. 6-14
Chapter 7 Service and Parts
Cell Replacement/Cleaning .............................................................................. 7-4
Thermocouple Replacement ............................................................................ 7-6
Furnace Replacement ........................................................................................ 7-8
Combustibles Detector Replacement............................................................ 7-10
Hot-Wire Combustibles Detector Replacement.................................... 7-10
Box Heater Diagram.................................................................................. 7-13
Replacement Parts List .................................................................................... 7-14
Appendix A Serial Communications
Communication Protocols..........................................................................A-1
General Serial Communication Commands ...........................................A-3
Development Serial Communication Commands.................................A-4
Responses .....................................................................................................A-6
Variable Table ......................................................................................................A-7
Sample Program...............................................................................................A-24
Starting/Monitoring a Calibration: An Example .........................................A-25

| vii
Appendix B Menu Option Charts
Appendix C Current Outputs: Other Applications
Powering Current Outputs from an External Power Supply .................... C-1
Modulation of External Power Loop Using Current Outputs................... C-3
Appendix D Drawings and Custom Instructions
Appendix E Series 2000 Controller Setup Parameters

viii | Thermox Series 2000 WDG-IV / IVC / IVCM
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 dam-
age to the equipment.
Important information that should not be overlooked.
Electrical Safety
Up to 5 kV may be present in the analyzer housings. Always shut down power
source(s) before 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.
NOTE


Contents | ix
Important Notice to Users
No operator serviceable components inside any components of the WDG sys-
tem. Do not remove the cover from any WDG component. Refer servicing to
qualified personnel.
The following applies to the Series 2000 Control unit and the WDG-IV Division
2 Models:
Power, input, and output (I/O) wiring must be in accordance with Class I, Divi-
sion 2 wiring methods [Article 501-4(b) of the National Electric Code, NFPA 70]
and in accordance with the authority having jurisdiction.
WARNING - EXPLOSION HAZARD - SUBSTITUTION OF COM-
PONENTS MAY IMPAIR SUITABILITY FOR CLASS I, DIVISION 2.
WARNING - EXPLOSION HAZARD - WHEN IN HAZARDOUS LO-
CATIONS, TURN OFF POWER BEFORE REPLACING OR WIRING
MODULES.
WARNING - EXPLOSION HAZARD - DO NOT DISCONNECT
EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR
THE AREA IS KNOWN TO BE NONHAZARDOUS.
THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS I, DIVISION
2, GROUPS A, B, C, AND D OR NONHAZARDOUS LOCATIONS
ONLY.
The maximum ambient temperature for the Series 2000 control unit is 50 °C
(122 °F)
The Series 2000 Control Unit with WDG-IV sensor is a complex piece of equip-
ment that should only be serviced by a qualified service technician with expertise
in instrument technology and electrical systems. AMETEK recommends that
all equipment requiring service be sent back to the factory. You should only
attempt to repair or service this equipment after receiving training from an
AMETEK/P&AI Division training representative. If you decide to service this
equipment be aware that high voltages, high temperatures, and other potentially
hazardous conditions may arise.

x | Thermox Series 2000 WDG-IV / IVC / IVCM
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 prod-
uct when it reached its “end of life”.
Waste Electrical and Electronic Equipment (WEEE) should never be disposed of in a munici-
pal 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.
•In some cases, your “end of life” product may be traded in for credit to-
wards the pur-chase of new AMETEK instruments. Contact your dealer to
see if this program is avail-able in your area.
•If you need further assistance in recycling your AMETEK product, contact
our ofce listed in the front of the instruction manual.