Ametek Thermox WDG-V User manual

AMETEK/Thermox®
WDG-V, WDG-VC, WDG-VCM
Combustion Analyzer with
Pneumatic Blow Back
User Manual
Thermox
150 Freeport Road
Pittsburgh, PA 15238
PN 9000-250-VE Rev B

© 2018 AMETEK
This manual is a guide for the use of the AMETEK/Thermox WDG-V (VC / VCM) with Blow Back. 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]
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]
USA - Delaware
455 Corporate Blvd.
Newark, DE 19702
Ph. 302-456-4400
Fax [phone]
GERMANY
AMETEK GmbH
Rudolf-Diesel-Strasse 16
D-40670 Meerbusch
Ph. 49 21 59 91 36 0
Fax [phone]
USA - Texas
4903 West Sam Houston Parkway North
Suite A-400
Houston, TX 77041
Ph. 713-466-4900
Fax [phone]
MIDDLE EAST – Dubai
AMETEK
PO Box 17067
Jebel Ali Free Zone
Dubai, UAE
Ph. 971-4-881 2052
Fax [phone]
CANADA
2876 Sunridge Way N.E.
Calgary, AB T1Y 7H9
Ph. 403-235-8400
Fax [phone]
SINGAPORE
AMETEK Singapore Pte. Ltd.
No 43, Changi South Avenue 2, #04-01
Singapore 486164
Ph. 65-64842388
Fax [phone]
CHINA
AMETEK Shanghai (SPL)
Room 408, Metro Tower
#30 Tian Yao Qiao Road
Shanghai 200030
Ph. 86 21 6426 8111
Fax [phone]
INDIA
India Private Ltd.
Plot 148, EPIP Zone Phase 2
Featherlite Tech Park, 1st Floor
Whiteeld, Bangalore 560066
Tel: [phone]
Fax: [phone]
AMETEK Beijing
CITIC Building, Room 2305
19, Jianguomenwai Dajie
Beijing 100004
Ph. 86 10 8526 2111
Fax [phone]
BRAZIL
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Tombadouro, Indaiatuba
Sao Paulo, Brazil 13337-300
Tel: [phone]
Fax: [phone]

Contents | iii
Contents
Offices ......................................................................................................................ii
Safety Notes ...........................................................................................................ix
Electrical Safety...............................................................................................ix
Grounding .......................................................................................................ix
Important Notice to Users..............................................................................x
Environmental Information (WEEE)...........................................................xi
General Safety Summary .............................................................................xii
Product Damage Precautions .................................................................... xiii
Declaration of Conformity........................................................ xiv
Warranty and Claims..................................................................xv
CHAPTER 1 Specications
Sensor : WDG-V ................................................................................................ 1-1
Sensor : WDG-VC ............................................................................................. 1-3
Sensor : WDG-VCM.......................................................................................... 1-4
Remote Calibration Unit (RCU)
O2Only RCU
O2& Comb. RCU
O2, Combustibles & Methane RCU.......................................................1-5
CHAPTER 2 System Overview
Sensor Operations.............................................................................................. 2-1
Sensor .................................................................................................................. 2-2
Basic Elements of the Sensor ..................................................................... 2-2
The Oxygen Measuring Cell...................................................................... 2-3
Hydrocarbons .......................................................................................... 2-4
Sensor Operations - WDG-VCM ..................................................................... 2-5
Close-Coupled Extrative Flue Gas Analyzer ................................................. 2-5
Detectors.............................................................................................................. 2-6
Combustibles................................................................................................ 2-6
Methane ........................................................................................................ 2-7
Flow Sensor......................................................................................................... 2-8
Alarm Limits................................................................................................. 2-8
Troubleshooting........................................................................................... 2-9
Temperature Sensors ....................................................................................... 2-10
Cell Temperature ....................................................................................... 2-10
Combustible/Box Temperature................................................................ 2-10
Blow Back Thermostat.............................................................................. 2-10
Heaters ........................................................................................................ 2-10
Cell Heater............................................................................................. 2-11
Box Heater............................................................................................. 2-11
Blow Back Heater .................................................................................. 2-11
Electronics ......................................................................................................... 2-13

iv | Thermox WDG-V / VC / VCM with Blow Back
I/O ............................................................................................................... 2-13
Analog Outputs ......................................................................................... 2-13
Alarm Contacts .......................................................................................... 2-14
Service Alarm Relay.............................................................................. 2-14
Data Valid Relay ................................................................................... 2-14
Contact Input ............................................................................................. 2-14
Remote Calibration Unit Interface.......................................................... 2-14
Communications Interface ............................................................................. 2-15
Start-Up Checklist ............................................................................................ 2-16
Common Operator Errors .............................................................................. 2-17
Technical Support............................................................................................. 2-18
CHAPTER 3 Installation Guide
Analyzer Location .............................................................................................. 3-2
Inspect Shipping Contents ........................................................................ 3-2
Mechanical Installation ..................................................................................... 3-3
Sample Inlet Probe Installation (Wall/Flange Mount) ........................... 3-3
Pressure Adjustments (Wall/Flange Mount).......................................... 3-4
Sample Inlet Probe Installation (Floor Mount)....................................... 3-5
Pressure Adjustments (Floor Mount) ..................................................... 3-6
Exhaust Tube Installation ........................................................................... 3-6
Sensor Mounting (Wall/Flange Mount) ................................................... 3-7
Methods for Mounting the Sensor .......................................................... 3-7
Sensor Mounting (Floor Mount) .......................................................... 3-10
Calibration/Aspirator Air.......................................................................... 3-11
Required Calibration Gases and Tubing................................................ 3-11
Manual Calibration and Aspirator Air Connections ............................ 3-12
Remote Calibration Unit Mechanical Installation................................ 3-13
Standard RCU Mechanical Installation................................................ 3-13
Standard RCU....................................................................................... 3-14
Combustibles RCU................................................................................ 3-15
Wiring................................................................................................................. 3-19
General Wiring and Conduit Requirements......................................... 3-19
WDG-V Mains Supply Connections ...................................................... 3-20
EMC Grounding, Shielding, and Noise Protection .............................. 3-21
Transient and RFI Interference ............................................................. 3-22
Current Output Connections.................................................................. 3-23
Standard Current Outputs ................................................................... 3-23
Alarm Contact Connections..................................................................... 3-25
Standard Alarm Connections................................................................ 3-25
Remote Calibration Unit (RCU) Connections....................................... 3-26
Oxygen-Only Remote Calibration Unit Connections .......................... 3-26
Combustibles Remote Calibration Unit Connections............................ 3-26
Digital Input to Initiate Remote Calibration Unit ............................... 3-27
Notes About Ducting ............................................................................... 3-28

Contents | v
CHAPTER 4 AMEVision Display User Interface or Communications
Purpose ................................................................................................................ 4-1
Setting the Analyzer Address .................................................................... 4-3
Connecting a Single WDG-V Sensor to the AMEVision ....................... 4-4
Connecting Multiple WDG-V Sensors to the AMEVision .................... 4-4
Troubleshooting........................................................................................... 4-6
WDG-V PC Configurator Software................................................................. 4-7
Overview ...................................................................................................... 4-7
Connecting to the WDG-V......................................................................... 4-7
CHAPTER 5 Troubleshooting
General Troubleshooting .................................................................................. 5-2
Leak Check ................................................................................................... 5-2
Sniffing for Leaks .................................................................................... 5-2
Pressurizing for Leaks............................................................................. 5-2
Plugged Plumbing Check .......................................................................... 5-3
Aspirator Air Not Pulling Sample from Process..................................... 5-3
Diagnostics Checks ............................................................................................ 5-4
Alarm and Warning Messages ......................................................................... 5-9
CHAPTER 6 Service and Parts
Warnings.............................................................................................................. 6-2
Cautions............................................................................................................... 6-2
Cell Replacement/Cleaning .............................................................................. 6-5
Thermocouple Replacement ............................................................................ 6-7
Combustibles/Methane Detector Replacement............................................. 6-9
Combustibles Detector Replacement ....................................................... 6-9
Methane Detector Replacement ............................................................... 6-9
Flow Sensor Replacement............................................................................... 6-11
Flow Sensor Replacement........................................................................ 6-11
Furnace Replacement ...................................................................................... 6-13
Furnace Replacement ............................................................................... 6-13
Heater Replacement ........................................................................................ 6-14
Box Heater Replacement.......................................................................... 6-14
Combustible Block Heater Replacement
(Only on Combustible/Methane Units))................................................ 6-16
Electronics Replacement................................................................................. 6-18
Electronics Replacement .......................................................................... 6-18
Recommended Maintenance Schedule........................................................ 6-20
Calibration .................................................................................................. 6-20
Replacement Parts List .................................................................................... 6-21
Sensor .......................................................................................................... 6-21
Remote Calibration Unit (RCU) .............................................................. 6-22
CHAPTER 7 Customer Modbus Map

vi | Thermox WDG-V / VC / VCM
APPENDIX A PC Software User Guide
WDG-V Configurator Software .......................................................................A-1
Device Connections Screen .......................................................................A-1
HOME Screen ..............................................................................................A-2
PC Configurator Menu Buttons................................................................A-3
Configuration Button ........................................................................................A-5
Configuration_Options ..............................................................................A-5
Configuration_Process Alarms..................................................................A-8
Configuration_Date / Time ........................................................................A-9
Configuration_Sensor Name.....................................................................A-9
Configuration_Process Pressure .............................................................A-10
Configuration_Blow Back ........................................................................A-11
Calibration Button............................................................................................A-13
Types of Calibrations.................................................................................A-14
Manual Calibration.............................................................................. A-14
Automatic Calibration.......................................................................... A-14
Remote Calibration............................................................................... A-14
Calibration_Set Gases to Calibrate..........................................................A-15
Calibration_Calibration History..............................................................A-15
Calibration_Set Cal Gas Values and Timers ..........................................A-17
Perform a Manual Calibration........................................................................A-19
Perform an Automatic Calibration ................................................................A-25
Scheduled Auto Calibration.....................................................................A-25
On-Demand Auto Calibration.................................................................A-26
Perform a Remote Calibration........................................................................A-31
Diagnostics Button...........................................................................................A-35
Sensor Diagnostics ....................................................................................A-35
Oxygen Cell................................................................................................A-36
Combustible Detector ...............................................................................A-37
Methane Detector......................................................................................A-38
I/O - Inputs and Outputs .........................................................................A-38
Inject Gas ....................................................................................................A-39
Blow Back ...................................................................................................A-40
Utilities ........................................................................................................A-40
Parameter Management ....................................................................... A-40
About.................................................................................................... A-41
Upgrade Firmware ............................................................................... A-41
APPENDIX B French Warnings / Avertissements Français
Notes sur la Sécurité ..........................................................................................B-1
Sécurité électrique..............................................................................................B-2
Mise à la terre......................................................................................................B-2
Note importante aux utilisateurs.....................................................................B-3
Sommaire de Sécurité Générale.......................................................................B-4
Utilisez un câblage adéquat.......................................................................B-4
Evitez les surcharges électriques...............................................................B-4

| vii
Mettez à la terre l’analyseur ......................................................................B-4
Ne pas faire fonctionner sans capot .........................................................B-4
Utilisez des fusibles adéquats....................................................................B-4
Ne faites pas fonctionner en atmosphère explosible.............................B-4
Precautions aux Dommages de L’Analyseur .................................................B-5
Utilisez une alimentation électrique adéquate .......................................B-5
Ne faites pas fonctionner avec les défaillances suspectes.....................B-5
Prenez des précautions en levant l’instrument......................................B-5
Utilisez des vêtements adaptés .................................................................B-5

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| ix
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.
NOTE


x | Thermox WDG-V / VC / VCM with Blow Back
Important Notice to Users
The following applies to the WDG-V Division 2 Models:
Power, input, and output (I/O) wiring must be in accordance with Class I, Di-
vision 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 COMPO-
NENTS 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 EQUIP-
MENT 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 analyzer is 60°C (140°F).
The WDG-V sensor and AMEVision Display User Interface is a complex piece
of equipment that should only be serviced by a qualified service technician
with expertise in instrument technology and electrical systems. AMETEK rec-
ommends that all equipment requiring service be sent back to the factory. You
should only attempt to repair or service this equipment after receiving train-
ing 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.