Ametek Thermox WDG-V UOP User manual

Thermox® IECEx/ATEX
WDG-V UOP Combustion Analyzer
User Manual
Thermox
150 Freeport Road
Pittsburgh, PA 15238
PN 9000-280-VE Rev. B

© 2019 AMETEK
This manual is a guide for the use of the Thermox WDG-V UOP. 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rma-
tion 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.
O󰀩ces
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Pittsburgh, PA 15238
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Fax [phone]
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Contents | iii
Contents
Offices ............................................................................................................................ ii
Safety Notes ................................................................................................................ vii
Electrical Safety...........................................................................................................vii
Grounding...................................................................................................................vii
Special Conditions for Safe Use..............................................................................viii
HAZARDOUS LOCATION LIMITATIONS ...................................................viii
Warning Labels............................................................................................................ ix
Environmental Information (WEEE) ....................................................................... ix
General Safety Summary ............................................................................................ x
Use Proper Wiring ................................................................................................ x
Avoid Electrical Overload .................................................................................... x
Ground the Product.............................................................................................. x
Do Not Operate without Covers ........................................................................ x
Use Proper Fuse..................................................................................................... x
Product Damage Precautions.................................................................................... xi
Use Proper Power Source.................................................................................... xi
Do Not Operate with Suspected Failures......................................................... xi
Use Caution When Lifting .................................................................................. xi
Use Proper Attire .................................................................................................. xi
Chapter 1 System Overview ........................................................................................1-1
UOP CCR Platforming Process............................................................................... 1-1
History.................................................................................................................. 1-1
CCR - Continuous Catalyst Regeneration.....................................................1-1
Thermox and WDG UOP Series....................................................................1-3
Analyzer Operations ................................................................................................ 1-4
Basic Elements of the Analyzer.............................................................................. 1-5
Analyzer I/O...................................................................................................1-5
Analyzer Communications.............................................................................1-5
How the Oxygen Measuring Cell Works........................................................ 1-6
Measuring Non-Combustible Gases...............................................................1-7
Hydrocarbons in the Gas Sample ...................................................................1-7
Sensor Operations - WDG-V UOP .................................................................. 1-8
RTD Flow Sensor ................................................................................................ 1-9
Temperature Zones and Heaters.................................................................... 1-10
Flame Arrestors................................................................................................. 1-10
Electronics ................................................................................................................ 1-11
I/O ...................................................................................................................... 1-11
Current Output Connections......................................................................... 1-11
Standard Current Outputs ..........................................................................1-11
Standard Alarm Connections.......................................................................1-12

iv | Thermox WDG-V UOP IECEx/ATEX
Remote Calibration Unit Connections.......................................................... 1-13
Oxygen-Only Remote Calibration Unit Connections .................................1-13
Digital Input to Initiate Remote Calibration Unit ......................................1-14
Terminal Block Connections ........................................................................... 1-14
Technical Support.................................................................................................... 1-16
Chapter 2 Specications..............................................................................................2-1
Sensor : WDG-V UOP .............................................................................................. 2-1
Approvals and Certifications for WDG-V UOP ................................................... 2-2
Remote Calibration Unit (RCU).............................................................................. 2-3
WDG-V UOP Series Analyzer Rating Labels........................................................ 2-4
WDG-V UOP Series Analyzer Markings............................................................... 2-5
Chapter 3 Installation Guide........................................................................................3-1
Analyzer Location ..................................................................................................... 3-2
Inspect Shipping Contents ...................................................................................... 3-2
Mechanical Installation ............................................................................................ 3-3
Sample Inlet Probe Installation ........................................................................ 3-3
Standard 1/4"NPT probe installation............................................................3-4
Exhaust Tube Installation .................................................................................. 3-5
Sensor Mounting ................................................................................................ 3-5
Calibration/Aspirator Air................................................................................... 3-7
Required Calibration Gases and Tubing.........................................................3-7
Rapid Exchange Purge System......................................................................... 3-8
Connections....................................................................................................3-8
Purging Operation .........................................................................................3-8
Purging Instructions....................................................................................3-10
Aspirator and Manual Calibration Connections ......................................... 3-11
Aspirator N2Connections ............................................................................3-11
Manual Calibration .......................................................................................... 3-11
Standard RCU Mechanical Installation ........................................................ 3-12
AMEVision Display User Interface Mounting.................................................... 3-14
Wiring........................................................................................................................ 3-14
General Wiring and Conduit Requirements................................................ 3-15
WDG-V UOP Mains Supply Connections ................................................... 3-16
EMC Grounding, Shielding and Noise Protection ......................................3-17
EMC Grounding Method.............................................................................3-17
Transient and RFI interference.....................................................................3-19
Current Output Connections......................................................................... 3-20
Standard current outputs.............................................................................3-20
Alarm Contact Connections............................................................................ 3-21
Standard alarm connections.........................................................................3-21
Remote Calibration Unit Connections.......................................................... 3-23
Digital Input to Initiate Remote Calibration Unit ......................................3-23

Contents | v
Standard Connection using PC Configurator Software ................................... 3-25
Overview ........................................................................................................... 3-25
Connecting to the WDG-V UOP.................................................................... 3-25
Setting the Address using the Dip Switch...................................................3-25
Connecting the PC to the Analyzer..............................................................3-26
Chapter 4 AMEVision Display Installation Guide ......................................................4-1
The AMEVision Display Unit ........................................................................... 4-1
Communication Options ...............................................................................4-1
Setting the Analyzer Address ........................................................................... 4-2
Connecting the Analyzers................................................................................. 4-3
Single Analyzer Connection...........................................................................4-3
Multiple Analyzer Connections .....................................................................4-3
Final Daisy Chain Connection Configuration Setting ..................................4-4
Troubleshooting.................................................................................................. 4-4
No Communications: .....................................................................................4-4
Intermittent Communications: ......................................................................4-4
Customer I/O Connections...................................................................................... 4-5
Retrofitting the WDG-V UOP to WDG-IV UOP.................................................. 4-6
Chapter 5 Troubleshooting..........................................................................................5-1
General Troubleshooting ......................................................................................... 5-2
Leak Check .......................................................................................................... 5-2
Sniffing for Leaks ...........................................................................................5-2
Pressurizing for Leaks....................................................................................5-2
Plugged Plumbing Check ................................................................................. 5-3
Diagnostics Checks ................................................................................................... 5-4
Thermocouple Checks....................................................................................... 5-5
Calibration/Aspirator Setup Checks................................................................ 5-6
AC Power Checks ............................................................................................... 5-7
Furnace Checks................................................................................................... 5-7
Process Pressure Checks (Only if above 2 psig) ............................................ 5-8
Cell Checks .......................................................................................................... 5-8
Alarm and Warning Messages ................................................................................ 5-9
ALARMS .............................................................................................................. 5-9
WARNINGS....................................................................................................... 5-11
Chapter 6 Service and Parts........................................................................................6-1
Warnings ................................................................................................................... 6-2
Cautions...................................................................................................................... 6-2
Cell Replacement/Cleaning ..................................................................................... 6-4
Thermocouple Replacement ................................................................................... 6-6
Flow Sensor Replacement........................................................................................ 6-8
Furnace Replacement............................................................................................... 6-9
Box Heater Replacement........................................................................................ 6-10

vi | Thermox WDG-V UOP IECEx/ATEX
Electronics Replacement........................................................................................ 6-13
Recommended Maintenance Schedule............................................................... 6-14
Calibration ......................................................................................................... 6-14
Replacement Parts List ........................................................................................... 6-15
Sensor ................................................................................................................. 6-15
Remote Calibration Unit (RCU) ..................................................................... 6-15

| vii
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.
Burn hazard. Hot surface. Do not touch, allow to cool before servicing.
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.

viii | Thermox WDG-V UOP IECEx/ATEX
Special Conditions for Safe Use
The WDG-V UOP is designed to be used in Category 3 hazardous locations
where explosive gases may be present. Protection against explosion is provid-
ed by purge technique. There are four rules that must always be followed:
1. Do not open the enclosure unless the power is removed from both sensor
and control unit for 90 minutes while maintaining pressurization, or the
area is demonstrated to be non-hazardous.
2. Perform purge system maintenance as described in Chapter 3 of the user
manual.
3. Use only appropriate approved conduit fittings or cable glands for cable
entry (IIC, IP40 minimum). No holes shall be left unplugged.
4. Internal temperature rises above the rated T-class. The end user must take
immediate action on the loss of pressure to reinstate purge.
HAZARDOUS LOCATION LIMITATIONS
The WDG-V UOP is a Category 3 analyzer specifically designed and certified
for use in ATEX II 3 G and IECEx hazardous locations. It can be safely oper-
ated in a location in which:
• No gases are present with a higher probability of ignition than hydrogen
(e.g., acetylene).
• The ambient temperature does not exceed 60°C.
• Voltages are 104-127 VAC or 207-253 VAC, 740 VA.
Make sure the location in which the WDG is installed meets all of the
Hazardous Location Limitation criteria for a Category 3 analyzer de-
scribed above.

| ix
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 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
reached 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.
•In some cases, your “end of life” product may be traded in for credit to-
wards 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 o󰀩ce listed in the front of the instruction manual.

x | Thermox WDG-V UOP IECEx/ATEX
General Safety Summary
Review the following safety precautions to avoid injury and prevent damage
to this product or any products connected to it.
Use Proper Wiring
To avoid fire hazards, use only the wiring specified in the Installation chapter
of this user’s manual.
Avoid Electrical Overload
To avoid electrical shock or fire hazard, do not apply a voltage to a terminal
that is outside the range specified for that terminal.
Ground the Product
Follow the grounding instructions provided in the Installation chapter of this
user manual. Before making connections to the input or output terminals of
this product, ensure that the product is properly grounded.
Do Not Operate without Covers
To avoid electric shock or fire hazard, do not operate this product with covers
or panels removed.
Use Proper Fuse
To avoid fire hazard, use only the fuse type and rating specified for this prod-
uct.