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Maintenance and Troubleshooting

6-1

MAINTENANCE AND TROUBLESHOOTING

The operations in this chapter should only be performed by qualified

service personnel experienced with electrical safety techniques. There

are no operator serviceable components inside the CEM-Humox system.

Never service the controller or sensor unless power has been removed

from the controller and sensor, and the sensor has been allowed to

cool for at least one hour. Also, always use gloves when working on

the sensor.

This chapter describes Series 2000 control unit system and error messages. It also

provides troubleshooting assistance. System and error messages appear on the

fourth line of the display at three second intervals until the condition is corrected

or has ended. If there is more than one message, the messages will alternate on the

display at three second intervals.

These system and error messages are listed in this appendix alphabetically to make

them easier to locate.

System or error messages will not appear on the display when you are

using the control unit keys to access menu functions.

NOTE



Summary of Contents for CEM/Humox

Page 1: ...Thermox CEM Humox Moisture in Flue Gas Analyzer User Manual Thermox 150 Freeport Road Pittsburgh PA 15238 PN 90486VE Rev K ...

Page 2: ... Yao Qiao Road Shanghai 200030 Ph 86 21 6426 8111 Fax 86 21 6426 7054 USA Delaware 455 Corporate Blvd Newark DE 19702 Ph 302 456 4400 Fax 302 456 4444 AMETEK Beijing CITIC Building Room 2305 19 Jianguomenwai Dajie Beijing 100004 Ph 86 10 8526 2111 Fax 86 10 8526 2141 USA Texas 4903 West Sam Houston Parkway North Suite A 400 Houston TX 77041 Ph 713 466 4900 Fax 713 849 1924 FRANCE AMETEK Precision ...

Page 3: ...3 INSTALLATION Inspect Shipping Contents 3 1 Mechanical Installation 3 1 Mounting the Wet and Dry CEM O2 Sensors 3 2 Sample Gas Requirements Connection 3 3 Calibration Setup 3 4 Control Unit Mounting 3 5 Wiring 3 8 General Wiring and Conduit Requirements 3 9 Control Unit Mains Supply Connections 3 10 RS 485 Communications Connections 3 19 CHAPTER 4 CONTROLLER USER INTERFACE Areas of the Control Un...

Page 4: ...Aborted 6 2 Power Down Detected 6 2 Primary Calibration 6 3 System Calibrating 6 3 System Verifying Cal 6 3 Error Messages 6 4 Cell is Over Temp Wet or Dry 6 4 Excessive Cal Error 6 4 Memory is Corrupted 6 5 Span Gas Range Error 6 5 Temp Rise Failure Wet or Dry Cell 6 6 T C Thermocouple Circuit Failure 6 6 Thermocouple Failure Wet or Dry Cell 6 7 Zero Gas Range Error Wet or Dry Cell 6 7 Diagnostic...

Page 5: ...placement Cleaning 7 4 Thermocouple Replacement 7 6 Furnace Replacement 7 8 Parts Replacement 7 10 APPENDIX A SERIAL COMMUNICATIONS APPENDIX BMENU OPTION CHARTS APPENDIX CCURRENT OUTPUTS OTHER APPLICATIONS APPENDIX DDRAWINGS AND CUSTOM INSTRUCTIONS ...

Page 6: ... 61326 1997 Measuring Equip Heavy Industrial Emissions EN 55011 1998 Class B ISM Equipment Safety Compliance UL 3101 1 ULListed Inspection and Measuring Electrical Equipment CAN CSA 22 2 No 1010 1 92 cUL Listed Inspection and Measur ing Electrical Equipment Low Voltage Directive 206 95 EC EN61010 1 1993 Amendment A2 1995 Electrical Equipment for Measurement Controls and Laboratory Use Series 2000 ...

Page 7: ...ety 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 mandato...

Page 8: ...lone Analyzer is not supplied with the 24 VDC power supply option Explosion Hazard Substitution of Components May Impair Suitability for Class I Division 2 Explosion Hazard Do Not Disconnect Equipment Unless Power Has Been Switched Off or the Area is Known to be Non Hazardous All input and output wiring must be in accordance with Class I Division 2 wiring methods NEC Sec 501 4 b or CEC 18 152 and ...

Page 9: ...m 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 administrati...

Page 10: ... neglect abuse or improper use Misuse or abuse of the equipment or any part thereof shall be construed to include but shall not be limited to damage by negligence accident fire or force of the elements Improper use or misapplications shall be construed to include improper or inadequate protection against shock vibration high or low temperature overpres sure excess voltage and the like or operating...

Page 11: ...in the customer s wet and dry sample flow paths should be matched i e vortex cooler permeation dryer refrigeration chiller etc to ensure that both the wet and dry readings are measured by the two different zirconium oxide cells at the same time to ensure consistency and accuracy Both zirconium oxide cells are standard WDG type cells and the same zirconium oxide measuring principles are used as wit...

Page 12: ...e customer provided cooler dries the sample Knowing the cooler temperature setpoint or using the Platinum 100 ohm RTD provided to measure the cooler exhaust temperature the residual moisture contained in the gas stream after the cooler can be calculated and added to the moisture calculated from the wet and dry O2 readings The sensing element itself is a closed end tube or disk made from ceramic zi...

Page 13: ...s obtained from the formula Where A is a constant T is the cell temperature on an absolute scale C 273 and O2 Unk is the unknown oxygen concentration of the gas to be analyzed and which is calculated by the analyzer The cell produces zero voltage when the same amount of oxygen is on both sides and the voltage increases as the oxygen concentration of the sample decreases The voltage created by the ...

Page 14: ...able data for temperatures from 0 C to 32 2 C 32 F to 90 F The resulting function is sued in the Humox software to calculate the residual moisture C residual moisture 0 63e 064 Cooler Temperature in C The wet and dry O2 by Volume are calculated using the following Nernst equa tions O2 wet 20 9 O2 wet 10 wet cell mV AT O2 dry 20 9 O2 dry 10 dry cell mV AT AT Cell logarithmic slope ideally 48 mV per...

Page 15: ...When working on the plumbing inside the sensor cabinet turn the power off the oxygen cell heater has exposed windings and a short to the plumbing will blow the fuse and could damage the furnace or thermocouple Caution should be used if performing maintenance on the sensor while the process is running Removing any part of the sensor can allow process gases and gases of high temperature to escape in...

Page 16: ...ry to provide this information when receiving service Cell millivolts Thermocouple millivolts Cell temperature Box temperature See the Display section in the Controller User Interface chapter for help on how to display this information on your Series 2000 control unit If you need to return equipment you will be asked to provide the following informa tion before obtaining a Return Material Authoriz...

Page 17: ... scalable Hold or track during calibration and select degree of damping Maximum load 1200 ohms Alarms Four independent sensor alarms each high or low selectable One alarm can be allocated to moisture calibrate or verify Set relays to energize or de energize on alarm Contact rating 0 5A 30V 10VA max noninductive load AC or DC Diagnostics Watchdog timer and service alarms System test for A D RAM EEP...

Page 18: ...on 2 areas Hazardous Area Meets NEC Class I Division 23 without requiring purge apparatus Calibration Oxygen cell lifetime extender Calibrate or verify calibration Store last calibration and verification data Selectable calibration gas run time and process recovery time Timed automatic calibration with optional remote calibration unit Bias adjustment 2 for process calibration to EPA Method 4 if re...

Page 19: ...nstallation Category II IEC Pollution Degree 2 Max Altitude 2000 meters Ambient Temperature 18 C to 50 C 0 F to 122 F Relative Humidity 10 to 90 noncondensing Power Requirements 115 VAC 10 47 63 Hz 230 VAC 10 47 63 Hz 313 VA max Calibration Gas Requirements Use calibration gases 0 1 to 1 0 L min 0 6 L min recommended Zero Gas From 0 1 to 10 O2 balance N2 Span Gas Minimum one decade above zero gas ...

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Page 21: ...the sensor This chapter shows you how to install your sensor components and includes the following sections Inspect Shipping Contents Mechanical Installation Wiring Series 2000 Control Unit Option Card Installation Inspect Shipping Contents Remove any packing material from the sensor and check for damage If any is found notify the shipper Mechanical Installation This section describes how to perfo...

Page 22: ... The cell is replaced by lifting it through the top of the sensor enclosure The sensor should be located as close to the sampling system as possible The ambient temperature must be in the range of 18 to 50 C 0 to 122 F The sensor relies on a convection principle to flow sample gas over the oxygen cell Therefore it must be mounted vertically The Series 2000 Control unit is housed in a 19 rack The t...

Page 23: ...y condensing moisture the entire sample line should be heat traced The sensor may operate at a steady internal pressure up to 20 WC 5 kPa Outlet restrictions that raise the pressure beyond this level may cause false or unstable readings The sample gas flow rate must be between 2 and 20 SCFH 0 94 to 9 4 L min The maximum sample temperature is 204 C 400 F Figure 3 1 Sensor mounting ...

Page 24: ...me flow rate for calibrations and daily operations The span gas must be a higher oxygen content than the zero gas by a factor of 10 for example if zero gas is 1 0 span gas must be 10 or higher If zero gas is 1 span gas must be 1 or higher Span gas instrument air 20 9 or from 1 0 to 100 O2 balance N2 Zero gas from 1 to 10 O2 balance N2 2 is recommended Always use tubing that is free of oil and dirt...

Page 25: ...panel mounting di mensions for the Series 2000 weatherproof enclosure Use 1 4 diameter fasteners to mount the control unit to the panel Weatherproof Wall Pole Figure 3 4 shows the wall and pole mount ing dimensions for the Series 2000 weath erproof enclosure For wall mount installa tions use 1 4 diameter fasteners to mount the control unit to a wall For pole mount installations the two slots on th...

Page 26: ... set the pressure and flow as indicated on the warning tag on the control unit Z Purge Shutdown Procedure Hot internal parts are above the ignition tempera ture of combustible gases Remove power from both the sensor and control unit for 1 hour while maintaining purge air flow before door is opened unless the area is demonstrated to be nonhazardous Z Purge Start up Procedure Power shall not be rest...

Page 27: ... purpose 19 rack mount enclosure Use 10 screws to mount the control unit to a rack whose holes are spaced per E I A standard RS 310 C universal spacing General Purpose Wall Figure 3 8 shows the mounting dimensions for the Series 2000 general purpose wall enclosure Use 1 4 diameter fasteners to mount the control unit to the wall Figure 3 6 Series 2000 general purpose panel mount Figure 3 8 Series 2...

Page 28: ...ount versions the wiring card is located on the rear of the control unit Figure 3 9 shows the orientation of the wiring card for general purpose rack and panel mount versions for all other versions the wiring card is 180 degrees from this view To access the wiring card for all general purpose versions of the control unit un screw the four screws on the wiring card chassis cover plate For the weath...

Page 29: ...ibes general wiring and conduit requirements Sensor wiring conductors must be rated at a minimum of 80 C All other wir ing conductor ratings should be for the minimum temperature required for the equipment being connected to the analyzer but not less than 60 C Use only the applicable NEMA approved conduit fittings or cable fittings to maintain the NEMA rating for the Series 2000 controller or sens...

Page 30: ...e Series 2000 control unit can operate using between 85 to 250 volts AC 47 to 63 Hertz There is no power switch or circuit breaker on the control unit We sug gest you protect it by installing it on a circuit protected line maximum 15 amperes with a switch or circuit breaker in close proximity to the control unit and within easy reach of an operator Mark the switch or circuit breaker as the control...

Page 31: ...hould you leave cable shields disconnected at one end or both ends of the cable sensor or control unit or other device You must use twisted pair cable in rigid metal conduit or use twisted pair cable with an overall braided shield All cable shields or conduits connecting to the control unit must be chassis grounded EMC Grounding Method Shield Ring Method Connect all shields for that conduit entry ...

Page 32: ...t suppressers include MOVs TRANSORBs and RC snubbers AC mains supply wiring should not be run in the same conduit with mains sup ply wiring that feeds heavy inductive loads Avoid running signal wiring in the same cable or conduit with wires that power inductive loads unless all the cables within the conduit are shielded the induc tive loads are small and transient suppressers are used at the loads...

Page 33: ...for the applicable options for your analyzer All sensor connections require that you access the sensor board see Fig ure 3 12 Sensor cabling must be twisted pairs in rigid metal conduit or in an overall braided shield Follow all wiring guidelines as specified in Figure 3 10 in the front of this wiring section Figure 3 12 Dry and wet sensor board connections NOTE ...

Page 34: ...stem product has or needs no specific LINE or NEUTRAL connection for any function safety or otherwise The N terminal is not internally grounded nor needs to be The system will operate normally regardless of what AC input terminal L or N that AC Line or Neutral is connected to or if there is a Neutral used at all i e 208 VAC US power connection There is no power switch on the sensor and it must be ...

Page 35: ... 14 Figure 3 13 Dry sensor connections Figure 3 14 Wet sensor connections CONTROL UNIT LABEL DRY SENSOR TERMINAL NUMBER Cell Cell 1 one pair 2 Furnance 15V COM 3 one pair 4 T C T C 5 one pair 6 15V SPLY 12 CONTROL UNIT LABEL WET SENSOR TERMINAL NUMBER MIZ POT W MIZ POT MIN 1 one pair 2 TC EFF I V3 TC EFF IV 3 5 one pair 6 Blank 15V COM 3 one pair 4 15V SPLY 12 other wire of pair goes to 12 on Dry ...

Page 36: ...rent output settings in soft ware Be sure to observe polarity when connecting current output devices to these terminals Analog output 2 is reserved for furnace control Current outputs 1 3 and 4 are capable of driving up to 1200 ohm loads These cur rent outputs are isolated from the control unit but are not isolated from each other If you intend to power current outputs from an external power suppl...

Page 37: ...tion If you have a watchdog event and the system returns to normal operations then the watchdog alarm will reset The system will retain in memory the last time the watchdog condition occurred see the Exception Log section in the Alarm Key section for help on how to view this information The Service Alarm connections are labeled as follows ALARM 2A ALARM 2B See the Service Alarm in the Alarm Key se...

Page 38: ...3 18 Thermox CEM Humox Analyzer Figure 3 16 Series 2000 alarm connections example ...

Page 39: ...ect all the 2 wire pluses and all the 2 wire minuses in parallel with all the devices in a daisy chain fashion including all the control units on the network and the host computer In addition on the host computer connect the receive and transmit terminal block connections see Figure 3 17 Be sure to use twisted pair cable for all connections 2 Wire termination resistor The Series 2000 control unit ...

Page 40: ...3 20 Thermox CEM Humox Analyzer Figure 3 17 Series 2000 2 wire RS 485 communication connection ...

Page 41: ... Series 2000 Control Unit is equipped with termination resistors that can be used for the last control unit on the network The switch settings are SW1 1 ON SW1 2 ON SW1 3 ON This provides 120 ohm termination resistors in the RS 485 circuit See the Option Card Installation section at the end of this Installa tion chapter for help on how to remove and access the display module You may need to experi...

Page 42: ...3 22 Thermox CEM Humox Analyzer Figure 3 18 Series 2000 4 wire RS 485 communication connections ...

Page 43: ...oved before you can remove the display module 3 Pull on the display module handle to then pull out the display module 4 Reverse these steps to reinstall the display module or power supply keypad module ShouldyouneedtoreplacefuseF1onthedisplaymodule itisaLittlefusetype 273microfuseorequivalent voltagerating 125VAC ampererating 50mA Should you need to replace fuse F1 on the wiring card it is a Littl...

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Page 45: ... Figure 4 1 shows you the various areas of the control unit including the locations of the power supply keypad module and display module The control unit is operated by pressing keys on the keypad and by viewing information on the main display Password Restrictions For menu options where you can change system settings and a password exists you will be required to first enter the password to access...

Page 46: ...that you can also use the Display menu option to place your own text messages on one of the first three lines The last display line is reserved for system and error messages If an alarm condition exists alarm information in the form of an Up or Down ar row corresponding to a high or low alarm will appear next to the process reading on that display line See Alarm Setpoints in the Alarm Key section ...

Page 47: ...rrow key until the arrow pointers are pointing at the menu option then press the Enter key If you are in a menu where you are asked to select from choices the currently se lected choice will have an asterisk in front of it For example if you select the Display option from the Setup key then select Display Line 1 the current choice to appear on display line 1 will appear with the asterisk in front ...

Page 48: ...stem exits the menu you were in and returns the system to normal operations exits out of all menus On Line Help When you select a menu you can press the Help key to get a description of what function any of the menu options within that menu performs Press the Help key again to exit on line help and return to the menu options or press the Cancel or Enter key For example to get on line help on the P...

Page 49: ... unit System Serial Perform a primary calibration on the sensor Primary Calibration This is not a typical calibration A primary calibration is intended to extend the life of your sensor Do not perform this type of calibration unless replacing the cell or thermocouple or if the system fails a regular calibration through the Calibrate key Define Series 2000 communication parameters Communication Pre...

Page 50: ...Y Menu Options Functions Options Display Select info for Display Line 1 Select info for Display Line 2 Select info for Display Line 3 Passwords Create a system password Dry Process Pressure Select a positive or negative DRY process pressure Enter process pressure value Wet Process Pressure Select a positive or negative WET process pressure Enter process pressure value System Tests Perform internal...

Page 51: ... first position To then enter text use the Up and Down arrow keys on your control unit keypad to scroll through the ASCII text characters Once the letter you wish to enter appears in that position press the Right arrow key to move to the next position You can also press the Left arrow key to move back one position in your text message When you are finished entering your message press the Enter key...

Page 52: ...ess this Password option and enter a new system password 1 Select Passwords from the Setup key menu You will be prompted to enter a new system password Enter NEW Password 2 Enter a four digit password To protect the identification of the password the numbers you enter are displayed as blocks rather than as text You are then prompted to reenter the password to verify it Reenter to Verify 3 Reenter ...

Page 53: ...to enter your system process pressure Pressure xx x PSIG New Value 3 Enter your process pressure up to one decimal point is allowed for example 1 5 PSIG then press the Enter key If you select a positive pressure a plus sign will appear before your value If you select a negative pressure a negative sign will appear before your value The process pressure you entered will now appear on the third disp...

Page 54: ...d to enter your system process pressure Pressure xx x PSIG New Value 3 Enter your process pressure up to one decimal point is allowed for example 1 5 PSIG then press the Enter key If you select a positive pressure a plus sign will appear before your value If you select a negative pressure a negative sign will appear before your value The process pressure you entered will now appear on the third di...

Page 55: ...s used to ensure that the control unit is recognizing any option modules you have installed into the control unit This is automatically done during system start up Test Digital In allows you to test the system digital input Erase RAM allows you to erase all RAM memory locations Erase EEPROM allows you to erase internal EEPROM memory locations if your control unit is not operating properly Be caref...

Page 56: ...e set point control temperature If you take a Type K table you should be able to measure the voltage on terminals C and D on the sensor board and then add the appropriate amount of mVs for the board ambient your cor responding temperature from a Type K thermocouple should be the actual furnace set point temperature 695 C T C Ratio memory location 88 Use the Type K table to determine the mV change ...

Page 57: ... of the following limits you will receive a zero or span gas range error At this point you should perform a primary calibration and then attempt a standard calibration again If you get an excess cal error during primary calibration then the furnace temperature set point cannot be increased any further to prevent damage to the cell housing and or furnace assembly Failure limits for standard calibra...

Page 58: ...from the Calibrate key before starting your primary calibration see the Cal Gas Values section in the Calibrate Key Chapter for help 1 Select Primary Calib from the Setup key 2 You will be placed into a manual calibration where you will be told to inject your span gas into the calibration gas inlet port From this point operations work as they do for a regular calibration Please see the Initiate Ca...

Page 59: ...o the host computer can identify the control unit if using network communications see below Note that each control unit must be assigned a unique address otherwise communication results will be unpredictable Enable serial this option allows you to temporarily disable control unit serial communications See Serial Communications in Appendix A for complete information Cooler Temp This menu allows you...

Page 60: ...the Enter a Password section for help on how to enter a system password so you can then access Analog Range key functions Information on how to define or disable passwords is discussed in the Setup Key section The remainder of this chapter provides help on how to do the following Define what information should be sent to the analog output port during a calibration Decide whether to hold the output...

Page 61: ...nalog Range key menu options are presented in the order in which they appear on your control unit screen from top to bottom Figure 4 5 provides an overview of the functions covered by each Analog Range key menu option Enter a Password System passwords are created using the Setup key Please see the Setup Key Chapter for information on defining or disabling a system Figure 4 5 Overview of Analog Ran...

Page 62: ...readings Output Filtering Analog Range key menu options are presented in the order in which they appear on your control unit screen from top to bottom Figure 4 5 provides an overview of the functions covered by each Analog Range key menu option Enter a Password System passwords are created using the Setup key Please see the Setup Key Chapter for information on defining or disabling a system passwo...

Page 63: ...e This menu option allows you to define the range of readings that the 0 to 20 or 4 to 20 mA milliamp output will represent You can also choose to set a reverse analog output range so for example 0 mA can correspond to the high end of the oxygen range and 20 mA can correspond to the low end of the oxygen range The range of readings the current output represents is also a function of what type of p...

Page 64: ...or this example the output port that will appear depends on the analog port you selected 2 Type the value to correspond to the 20 mA analog output You will then be prompted to define the value to correspond to the 0 or 4 mA analog output Out y 4 ma xx New Value where xx is the value that the current output currently represents 3 Type the value to correspond to the 4 or 0 mA analog output ...

Page 65: ... Set Track Hold from the Analog Range key after selecting an analog output port 2 You can choose to either hold process readings or track calibration readings on the analog output port Separate choices can be made for calibration and verify operations For calibration operations select one of the following Hold during cal or Track during cal After you select one of these options your choice will be...

Page 66: ...elect Function section 1 Select the Set Current Mode menu option from the Analog Range key after selecting an analog output port 2 Select 4 to 20 mA Mode or 0 to 20 mA Mode The following will then appear on the display Out 1 is set for 4 20 ma or Out 1 is set for 0 20 ma Default Selection 4 to 20 mA Output Filtering The Output Filtering menu option allows you to filter out quick transitions in rea...

Page 67: ...alog output port should track Choices are as follows Percent moisture Percent oxygen wet or dry Cell temperature wet or dry Cell millivolts wet or dry Thermocouple millivolts T C mv wet or dry 1 Choose Select Function from the Analog Range menu after selecting an analog output port 2 Select the function you wish the selected analog output port to track see bullets above The Series 2000 control uni...

Page 68: ...it wiring card The Alarm key allows you to do the following Define whether alarm 3 activates based on oxygen levels the start of a calibra tion or the start of a verification Select Function Other alarms activate only on sensor readings Define whether alarms should be set high or low Alarm Configure Define whether alarm relays should energize or deenergize on alarm Relay Configure The selection yo...

Page 69: ...s only to alarm 3 The Relay Configure menu option applies to all alarms except for the watchdog and service alarms which always deenergizes on alarm fail safe Figure 4 7 Alarm Key overview ALARM NUMBER FUNCTION Select Function Alarm Configure Relay Configure Alarm 3 Sensor readings Cal Start High sensor alarm Low sensor alarm only selectable if Se lect Function is other than calibrate or verify st...

Page 70: ...at alarms 1 and 2 are reserved for the watchdog and service alarms and are therefore not software selectable Press the Enter key to continue to the configurable alarms You will be prompted to define the alarm 3 set point value this option won t appear if alarm 3 is not set to activate based on a sensor reading but rather is set to activate based on the start of a calibration or verification see th...

Page 71: ...and also to select what reading to track See the Alarm Set Points section for help on how to define alarm set point values Whether Alarm 3 is set high or low only applies if it is set to track sen sor readings If Alarm 3 is set to trigger at the start of a calibration or verification this option does not apply 1 Select Alarm Configure from the Alarm menu 2 Define your alarms as high or low alarms ...

Page 72: ...n deenergize on alarm This menu option applies to all alarms except for the service and watchdog alarms which are always set to deenergize on alarm fail safe 1 Select Relay Configure from the Alarm menu 2 Select Deenergize on Alarm or Energize on Alarm If you select Energize on Alarm the following message will appear Relays are set to ENERGIZE on Alarm If you select Deenergize on Alarm the followi...

Page 73: ...of a calibration or verification the alarm will deactivate once the calibration or verification has been completed including any recovery duration you have specified see the Calibrate Key Chapter for further details on calibrations and verifications To select the function for alarms use the Alarm Configure menu option 1 Choose Select Function from the Alarm menu 2 Select the type of alarm you wish...

Page 74: ...nor mally closed system failure causes open contacts The watchdog alarm relay deenergizes when the system watchdog timer times out The watchdog timer will time out and cause the control unit to reset itself to prevent the control unit from becoming lost due to such things as noise spikes or power surges You can use this relay to activate a remote indicator to notify you if the watchdog timer times...

Page 75: ...log entry on line four of the display and shows when this event was recorded on line three Line three of the display also shows the order in which events are recorded into the log with number 1 indicating the most recent entry into the log The system is able to store the 20 most recent entries into this exception log Pressing the Down arrow key shows later exception log entries Pressing the Up arr...

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Page 77: ...tem to periodically calibrate itself Sensor alarms are disabled during calibrations including the recovery time after a calibration For analog outputs you can set whether they should follow the calibration readings or hold at the last process read ing see the Analog Range Key section Figure 5 1 Calibrate Key menu options NOTE Initiate Verify Inject Cal Gas Set Cal Timers Initiate Cal Cal Verify Da...

Page 78: ... the gas values and their known values is recorded Internal calibration parameters are not changed Verify operations are often used to check that the instrument is running within required tolerances Dur ing a calibration operation software algorithms adjust the difference between the current readings and the known calibration gas values until they are equal When we speak in this chapter about a ca...

Page 79: ...llows you to perform manual calibrations only The CEM Humox does not support automatic or remote calibration since the Remote Calibration Unit cannot be connected to the Series 2000 All references to remote or automatic calibration in this manual should be ignored NOTE ...

Page 80: ...alibration unit RCU gases without per forming a calibration or verification Inject Cal Gas Define cycle times for automatic calibrations or verifications Set Cal Timers Set Auto Timers Set the current date and time Set Cal Timers Set Time and Date Temporarily enable or disable auto calibrations or verifications Set Cal Timers Auto Cal On Off Define how long calibration gases should be applied to t...

Page 81: ...ion CALIBRATE KEY MENU FUNCTION OPTIONS Initiate Cal Initiate Verify Start an automatic remote or manual calibration Cal Verify Data View latest calibration and verify data Cal Gas Values Enter calibration gas values Inject Cal Gas Set pressure and flow on RCU gases without per forming a calibration Set Cal Timers applies only for auto cal operations with RCU except for setting time and date Set C...

Page 82: ...enabled you will be required to correctly enter this password before accessing certain Calibrate key functions When you select the Calibrate key you will be prompted to enter your system password assuming a password has been defined Enter password Enter the four digit system password To protect the identification of the pass word the numbers you enter will not be displayed You will then be allowed...

Page 83: ...that these options are not installed it will automatically prompt you with a manual calibration or verification operation when you select either the Initi ate Cal or Initiate Verify menu options If you replaced a cell or your cell has failed a regular calibration due to a deteriorating cell you will need to perform a primary cali bration rather than a regular calibration See the Primary Calibra ti...

Page 84: ...ibration gas The span display then appears D O2 xx xx Set xx xx W O2 xx xx Set xx xx Press ENTER to Span 5 Press the Enter key once the O2 reading on the far left of the first display line stabilizes The reading on the far right of the first display line shows the setpoint value you entered using the Cal Gas Values menu option This setpoint value should match the cal gas cylinder for the O2 span g...

Page 85: ...on the far right of the first display line shows the setpoint value you entered for the O2 zero gas using the Cal Gas Values menu option This O2 zero gas setpoint value should match the cal gas cylinder for the O2 zero gas Then if you specified a recovery time the system will display the recovery time remaining Recovery xx xx System Calibrating The system then returns to monitoring process reading...

Page 86: ...tween the entered calibration gas value and the calibration gas values read by the system Both the latest calibration and verification data will be stored in memory 1 Select Cal Verify Data from the Calibrate key menu 2 Select Calibration Data or Verify Data depending on whether you wish to see the latest calibration or verification results The display then shows the dry cell span gas calibration ...

Page 87: ...key menu 4 Press the Enter key You are then prompted with the calibration data for the wet oxygen cell The time when the calibration or verification was completed then appears on the display End time hr mn End date mm dd yr If the date or time has not been set random characters will appear instead of the time and date when the calibration or verification was completed If this occurs reset the cont...

Page 88: ...stallation chapter for recommended calibration gases 1 Select Cal Gas Value from the Calibrate key menu You are prompted to enter the span gas value Span Gas xx x O2 Dry New Value 2 Enter the span gas value then press the Enter key You can also include a decimal point for example 20 9 O2 If you wish to keep the current span gas value unchanged press the Enter key without entering a value You are t...

Page 89: ...so always use gloves when working on the sensor This chapter describes Series 2000 control unit system and error messages It also provides troubleshooting assistance System and error messages appear on the fourth line of the display at three second intervals until the condition is corrected or has ended If there is more than one message the messages will alternate on the display at three second in...

Page 90: ...the span gas or zero gas was out of range Calibration Required Once you complete a primary calibration this message is displayed to inform you that a regular calibration is required after a primary calibration is performed you must always then perform a regular calibration This message will not clear from the display by removing and restoring power to the control unit If you see this message selec...

Page 91: ...riod after the primary calibration System Calibrating This message indicates that a system calibration is in progress It will appear during the entire automatic calibration cycle or during the recovery period of a remote or manual calibration System Verifying Cal This message indicates that a system verification is in progress It will appear during the entire automatic verification cycle or during...

Page 92: ...ry sensor temperature is 30 degrees Celsius or more over its correct operating temperature The software shuts off the furnace until the temperature returns to a normal operating range If this message soon goes away it indicates that the temperature has returned to an acceptable range If there is a problem with the sensor temperature control system you will see another error message after this mess...

Page 93: ...m the display This message will not clear by removing and restoring power to the unit If you receive this message you should reset your control unit to the values required for your application including Setup key parameters Calibrate key parameters etc Span Gas Range Error This error message occurs if the calibration span gas does not read within the soft ware s allowable limits Once this error oc...

Page 94: ...C line power problem at the sensor Open furnace Over temperature protection circuit trip on the sensor board Sensor board failure Loss of furnace drive signal Interconnecting wiring problem T C Thermocouple Circuit Failure This message appears when the control unit recognizes a sudden drop in temperature greater than 100 C The thermocouple circuit failure message can be the result of one of the fo...

Page 95: ...rol unit display module failure Zero Gas Range Error Wet or Dry Cell This error message occurs if the calibration zero gas does not read within the soft ware s allowable limits Once this error occurs calibration of the system is aborted This error indicates one of the following problems Calibration gas setup problem Process pressure incorrectly entered Cell wiring reversed Cell and Cell wires Fail...

Page 96: ...ormation will be helpful should you need to contact the factory for assistance Be sure to always include your analyzer model and serial number when calling the factory for technical support Diagnostic checks are broken down as follows Wiring Checks Thermocouple Checks AC Power Checks Furnace Checks Process Pressure Checks Cell Checks Exercise care when working on the sensor Turn off power allow th...

Page 97: ...and measure across terminals 5 and 6 on the sensor board If shorted correct the inter connecting problem To verify the operation of the thermocouple itself remove the thermocouple from the sensor and heat its ceramic tip to a known temperature Measure the millivolt output with a proper temperature indicating meter Type K thermocouple If the thermocouple reads inaccurately replace it Reversed therm...

Page 98: ...tage replace the sensor board For a furnace temperature set point for a 615 C oxygen cell temperature the furnace thermocouple output would be about 27 mVs take memory location 88 which is the T C Ratio calculated during the primary thermal calibration and divide the cell temperature by this value to come up with the furnace temperature set point Note The cell thermocouple compensation circuit on ...

Page 99: ...Inject Cal Gas menu option from the Calibrate key section for help on how to do this Calibration line check Ensure that your calibration line is not contaminated with such things as pipe dope cutting fluid oil or solvents All these contaminants produce hydrocarbon vapors that interfere with the proper calibration of your analyzer The result of this will be lower than expected oxygen readings To te...

Page 100: ...tage is present and the system is not heating remove power and check the furnace resistance see Furnace Checks section If no voltage is present at terminals R and S on the sensor board check for the DC furnace drive signal at terminals 3 and 4 at the sensor board The furnace drive is a 15 VDC pulse train and depending on the frequency of the pulse train the measured voltage will be between 5 and 1...

Page 101: ...k for leaks see the Calibration in the Diagnostics section for help on checking your calibration gas setup If the analyzer has been operating for some time and you feel the oxygen reading is inaccurate first check by running a known calibration gas to verify the analyzer s response If the analyzer responds to the calibration gas correctly it indicates either leaking or plugged plumbing see the Lea...

Page 102: ...ils on the placement of the gasket For processes under vacuum you can check for leaks by sniffing the fittings with another gas for example nitrogen or pure oxygen being sure to avoid the area over the top of the cell Use a piece of tygon or plastic tubing with a 1 8 stainless steel nozzle to apply the gas from a cylinder using stainless steel prevents any problems that might occur with plastic me...

Page 103: ...wer has been removed from the controller and sensor and the sensor has been al lowed to cool for one hour This chapter is divided into the following sections Cell Replacement Cleaning Thermocouple Replacement Furnace Replacement Replacement Parts List You can clean the outside of the sensor or controller or Remote Calibration Unit using normal household or commercial general purpose cleaners cloth...

Page 104: ...xtremely careful when performing maintenance on the sensor while the process is running especially if the process is under significant positive pres sure Removing any part of the sensor plumbing can allow process gases and gases of high temperature to escape into the sensor Always use a backup wrench when working on sensor plumbing This helps to prevent damaging welds and distorting sensor plumbin...

Page 105: ...Service and Parts 7 3 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 106: ... and cell O ring and retrieve the new cell with supplied cell O ring Avoid touching the bare cell instead hold the cell by one of its hex nuts 5 Place the cell O ring on top of the cell housing as shown in Figure 7 1 6 Insert the new cell into the cell housing Do not touch the bare cell when rein serting Tighten the cell into the cell housing using the lower hex nut the upper hex nut is pre tighte...

Page 107: ...Service and Parts 7 5 Figure 7 1 Cell replacement ...

Page 108: ...hing the cell housing or furnace heater coil 6 Put the screw back in to the thermocouple mounting clamp this secures the thermocouple to the furnace 7 Attach the thermocouple wires to terminals C and D on the sensor board ob serving polarity yellow wire to terminal C red wire to terminal D 8 Using an ohm meter check for short circuits of the heater coil to the metal thermocouple sheath To do this ...

Page 109: ...Service and Parts 7 7 Figure 7 2 Thermocouple replacement Thermocouple Thermocouple mounting clamp Convection loop mounting clamp Cell housing Compression fitting Top View Furnace ...

Page 110: ...ve the convection loop mounting clamp being sure to save the mounting clamp for when you install the new furnace 6 Gently pull the cell housing out of the furnace and remove the furnace 7 Slip the new furnace onto the cell housing and attach the cell housing using the convection loop mounting clamp 8 Remount the cell housing reverse the actions taken in step 4 9 Reinstall the thermocouple reverse ...

Page 111: ...Service and Parts 7 9 Figure 7 3 Furnace replacement Convection loop mounting clamp Cell housing Furnace Union fitting Thermocouple Compression fitting ...

Page 112: ... 300 mA P N 25644JE Display Processor Module P N 7000 679 SE Power Supply Keypad Module P N 90253VE Backplane Assembly P N 80439SE Humox FurnaceRelay Board P N 80516SE Card Dual CEM O2 P N 80517SE When ordering provide the serial number of your analyzer to ensure proper parts are ordered AMETEK Process Analytical Instruments Division 150 Freeport Road Pittsburgh PA USA 15238 Phone 412 828 9040 Fax...

Page 113: ...000 control unit must match the baud rate of the host device Baud rates are user programmable See Communication in the Setup Key section for help on defining control unit baud rates The communication protocol is a basic master slave command response protocol The master initiates each communication transfer There is one master on the com munication line but there can be multiple Series 2000 Control...

Page 114: ...ommand see below and where the number of characters returned also depends on the command Limit is 20 characters The Checksum is the sum of all the preceding characters excluding the char acter modulo 256 The End Character is a carriage return equivalent to ASCII decimal character number 13 The system disables any checking of the checksum if the checksum char acter is equal to is equivalent to 2 AS...

Page 115: ...en with the following string FEF0536 CR Returned string A20 9 O2D4 Write Number H This command allows you to set a value at the Series 2000 controller The data sec tion of this command is a two digit hex number 00 FF to point to the location to write from the variable table see Table A 1 followed by the value of the variable A simple acknowledge is returned if the command was accepted Read Date an...

Page 116: ... Format J This command is used to check how data is output through the serial link For each variable that is accessible through the Read Number and Write Number commands a string is returned that describes the format of the number This response data consists of three characters Format Access Location Where format is F Float H Hexadecimal U Unsigned decimal Access is as follows r read only w write ...

Page 117: ...s A 5 Command List This section provides the command letters you can use Letter Description A Echo B Bad Command C Acknowledge F Read Number G Calibrate H Write Number J Data Format M Read Date and Time N Set Date and Time ...

Page 118: ...rns a variety of responses that can be broken into two categories success and failure Success All successful responses start with an A If there is data returned it will follow the A and have a checksum after it All responses end with a carriage return Sucess Data Checksum End Character A ncharacters 2hexASCII CR characters Sucess End A CR ...

Page 119: ... serial communication 05 Parameter out of range 08 Error in receipt of a character 09 Cannot calibrate verify now 0A Internal error 0B Illegal access read only variable Failure All failure responses start with a N followed by a two hex digit failure code and a carriage return Failure Failure Code End Character N 2 hex ASCII characters CR ...

Page 120: ...s bit 6 excessive cal error true when the primary calibration cannot adjust the temperature of the cell enough to make the cell read the correct mv The up per actual temperature for the insitu is 800C for the 3 in 1 925C and for all others 850C bit 7 calibration required true after a primary cal or if the EEPROM has been erased and the unit is using default values bit 8 thermocouple failure bit 9 ...

Page 121: ...ibration 0 is hold analog output 2 during calibration bit 5 analog output 2 tracks during verify 0 is hold analog output during verify bit 6 analog output 2 set for 0 to 20 ma 0 is 4 to 20 ma bit 7 Future use bit 8 analog output 3 tracks during calibration 0 is hold analog output 3 during calibration bit 9 analog output 3 tracks during verify 0 is hold analog output 3 during verify bit 10 analog o...

Page 122: ...lue Oxygen alarm value for alarm 5 Value is always in percent Read and Write 21h 033d Alm6_value Oxygen alarm value for alarm 6 Value is always in percent Read and Write 22h 034d Reserved N A 23h 035d Reserved N A 24h 036d Reserved N A 25h 037d Reserved N A 26h 038d Gas1_time Amount of time oxygen span gas will flow Read and Write 27h 039d Gas2_time Amount of time oxygen zero gas will flow Read an...

Page 123: ...ved N A 55h 085d Reserved N A 56h 086d Dry_AT Dry Cell slope Read only 57h 087d Dry_AT_ratio Dry Cell slope used during last calibration Read only 58h 088d Dry_Tc_ratio Cell thermocouple compensation multiplier Read only 59h 089d Reserved N A 5Ah 090d Reserved N A 5Bh 091d Calcycle Interval between auto cals 1 hour to 90 days Read and Write 5Ch 092d Vercycle Interval between auto verifies 1 hour t...

Page 124: ... during last verify Read only 75h 117d Wet_Ver_zero Wet Oxygen zero gas read during last verify Read only 76h 118d Wet_O2_zero Wet Zero gas millivolts read during last calibration Read only 77h 119d Reserved N A 78h 120d Reserved N A 79h 121d Wet_AT Wet Cell slope Read only 7Ah 122d Wet_AT_ratio Wet Cell slope used during last calibration Read only 7Bh 123d Wet_Tc_ratio Cell thermocouple compensat...

Page 125: ...NDOM AS 1 String to be echoed T Test Message Address of the series 2000 controller Address 254 Build the message M HEX Address A T M M Checksum M Continue sending message until key pressed Assumes that Series 2000 controller is connected WHILE INKEY PRINT 1 M LINE INPUT 1 A Show results PRINT Sent M PRINT Returned A PRINT WEND CLOSE 1 STOP FUNCTION Checksum M DIM Sum AS LONG Sum 0 Skip FOR i 2 TO ...

Page 126: ... 3 If an acknowledge is returned A cr the calibration command is accepted If not accepted the sensor may not be at a proper operating temperature or may already be performing a system calibration 4 Read the Gas_ctr variable to determine the position in the calibration cycle Use this variable to determine when to activate solenoids if not controlling solenoids using the Series 2000 control unit 5 R...

Page 127: ... or negative DRY process pressure Enter process pressure value Wet Process Pressure Select a positive or negative WET process pressure Enter process pressure value System Tests Perform internal diagnostics on Series 2000 System Serial View serial number for Series 2000 View manufacturing number for Series 2000 Primary Calibration Perform an automatic remote or manual primary calibration Communicat...

Page 128: ...rm Alarm 6 Moisture O2 Wet O2 Dry High sensor alarm Low sensor alarm Note Alarms 1 and 2 are reserved for the watchdog timer and service alarms and are not software selectable ANALOG KEY MENU OPTIONS FUNCTIONS OPTIONS Set Current Range Range of readings that the analog output represents for example 4 O2 4 mA 4 O2 20 mA Set Track Hold Hold output at last process reading during a cal or verify Set C...

Page 129: ...a Cal Gas Values Enter calibration gas values Inject Cal Gas Set pressure and flow on RCU gases without per forming a calibration Set Cal Timers applies only for auto cal operations with RCU except for setting time and date Set Control unit time date Enable or disable auto cal cycles Set cal gas timer for auto cal verify operations Define recovery durations after a cal verity Bias Adjustment Pos M...

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Page 131: ... JP2 on the Series 2000 control unit display module is used to allow you to define which power source to use If JP2 is in factory default the control unit uses the internal supply to power the current output circuits If you try to use an external voltage at this time the system will use whichever voltage is higher control unit voltage is normally about 28 volts If the JP2 jumper is removed the ext...

Page 132: ...ply required to power the current outputs use the following formula VEXTmin 02 amps RLoad Rwires 4 volts where VEXTmin the minimum external voltage required to power current output circuit RLoad the load resistance of the current output device Rwires the resistance of the wires ...

Page 133: ...re the same power supply if both of these channels are used or two power supplies can be ORed together using a diode from each power supply positive terminal diode anode to power supply to the VEXT1 2 terminal The power supply minuses would be tied together and connected to one side of the both loads The other side of one of the loads would be connected to IOUT1 terminal and the other side of the ...

Page 134: ...C 4 Thermox CEM Humox Analyzer Figure C 1 Modulation of external power supply OPTIONAL ...

Page 135: ...es any custom drawings or instructions you have ordered If you didn t order any customer options the standard Interconnect drawing is provided If you ordered special options the drawings or special instructions provided here supersede any drawings or options provided elsewhere in the manual ...

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