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User Guide

Page 5 - 4

Genesis WDG-1200/1210

Insitu Oxygen Probes

Fault Description

Key to Elements column of each fault:

Probe

Fault is related to probe

Wiring

Fault is related to wiring of system

Mains

Fault is related to mains power supply

ACU

Fault is related to Remote Calibration Unit

NOTE

For all actions referring to the Remote Calibration Unit refer to the relevant

operating manual.

(a) Heater temperature out of control band 00.02.

The probe temperature has not increased/decreased or is too high during the

warm up period.

CAUSE

ELEMENT

ACTION

1. Heater not connected.

Probe

Check probe wiring.

2. Heater fuse blown.

Probe

Replace heater fuse and check

wiring.

3. Heater failed.

Probe

Replace probe heater.

4. Thermocouple failure.

Probe

See faults under

Thermocouple fault

and heater above maximum limit

identification number 40.00.

5. Cold junction sensor
failed.

Probe

See faults under

Cold junction

temperature fault

, identification

number 600.0.

6. Signal noise.

Wiring

Re-route probe signal cable away

from power cables.

7. Mains voltage low.

Mains

Obtain suitable analyzer supply.

8. Electronic failure.

Probe

Contact Service Engineer

Summary of Contents for LAND Genesis WDG-1200

Page 2: ...he user documentation supplied before installing and operating the equipment The safety of any system incorporating this equipment is the responsibility of the assembler Protective Clothing Face and Eye Protection It is possible that this equipment is to be installed on or near to machinery or equipment operating at high temperatures and high pressures Suitable protective clothing along with face ...

Page 3: ...vent damage during transit You must include a written report of the problem together with your own name and contact information address telephone number email address etc Design and Manufacturing Standards The Quality Management System of Land Instruments International is approved to BS EN ISO 9001 for the design manufacture and on site servicing of combustion environmental monitoring and non cont...

Page 4: ...User Guide Genesis WDG 1200 1210 Insitu Oxygen Probes ...

Page 5: ...4 Pre operational Checks Final Checks 3 22 4 User Interface and Calibration 4 1 4 1 Control Panel 4 1 4 2 Abbreviations Used on the Control Panel 4 2 4 3 Using the Probe for the First Time 4 3 4 4 Probe Display Settings 4 5 5 Maintenance and Troubleshooting 5 1 5 1 Identifying Faults 5 1 5 2 In Situ Probe Testing and Checking 5 8 5 3 Maintenance 5 12 6 Service and Parts 6 1 6 1 Inner Probe Assembl...

Page 6: ...User Guide Genesis WDG 1200 1210 Insitu Oxygen Probes ...

Page 7: ...all components is easily performed While the outer protection tube remains in the process the inner tube structure which houses the oxygen cell and furnace thermocouple assembly can be removed easily see Figure 6 1 Because there is no need to return the probe to the factory extensive downtime and expensive repairs on the probe are no longer necessary Key Features and Benefits LED display used to v...

Page 8: ... of the other gas A reference gas usually air 20 9 O2 is used for one of the gases Since the voltage of the cell is temperature dependent the cell is maintained at a constant temperature The oxygen content is then determined from the Nernst equation E RT 4F O1 O2 ln where R and F are constants T is absolute temperature and O1 and O2 are the oxygen partial pressures on either side of the cell For m...

Page 9: ...e The Measuring System The sensing cell interconnecting wiring and integrated user interface The Temperature System The electrical zirconium oxide cell heater with internal type K thermocouple and the control unit The sensing cell of the analyzer is operated at a constant temperature Heat is supplied to the cell by an electrically powered internal heater Inside the heater is a thermocouple used in...

Page 10: ... the parts inside the probe are hot and will cause severe burns if touched Use gloves wrenches and care when working inside the sensor 1 4 Technical Support AMETEK LAND is committed to providing you the best technical support in the industry If you need service or application assistance please call AMETEK at 44 01246 417691 or your local AMETEK LAND representative Before you call the factory for t...

Page 11: ...1200 Inistu Probe Length and Weight Overall length of probe Approximate Weight 0 457 m 18 in 0 9144 m 36 in 1 828 m 72 in 2 743 m 108 in 9 3 kg 20 lb 11 5 kg 25 lb 18 3 kg 40 lb 22 9 kg 50 lb WDG 1210 Inistu Probe Length and Weight Overall length of probe Approximate Weight 0 457 m 18 in 0 9144 m 36 in 1 828 m 72 in 2 743 m 108 in 7 3 kg 16 lb 9 5 kg 21 lb 16 3 kg 36 lb 20 9 kg 46 lb Head dimensio...

Page 12: ...e 10 psi 0 7 bar nominal It may be necessary to use a regulator pressure of up to 30 psi 2 0 bar to achieve the required flow Environmental Protection Probe Head IP65 protected Operating temperature 20 C to 70 C 4 F to 158 F Relative Humidity 10 to 90 non condensing Performance Data Measuring range Selectable range 0 to 1 0 to 25 v v O2 Accuracy 1 of full scale Repeatability 0 5 of full scale on a...

Page 13: ...ent may suffer permanent damage if it is operated from a supply which cannot deliver the required current User Interface Display type Single line 4 digit LED Parameters O2 concentration Calibration gas Cell temperature Fault messages Cell Thermocouple Information Analogue outputs Single channel isolated 0 to 10 0 to 20 2 to 20 4 to 20mA menu selectable Max impedance 500 Ω Ranges Selectable range 0...

Page 14: ...User Guide Page 2 4 Genesis WDG 1200 1210 Insitu Oxygen Probes ...

Page 15: ...ents inside the WDG 1200 1210 Insitu probe Never service the Insitu probe unless power has been removed from the probe and it has been allowed to cool for at least one hour This chapter shows you how to install the WDG 1200 1210 Insitu probes including the following Unpacking Mechanical Installation Electrical Connections Final Checks 3 1 Unpacking Remove any packing material from the probe and th...

Page 16: ...nting solutions can be provided for excessive vibration installation locations Handle the probe with care do not drop the probe The probe contains fragile ceramic components which are easily damaged The probe should be removed from the stack flue when high pressure cleaning with a water hose as this can crack the zirconia cell Select a suitable accessible position where the probe is located in the...

Page 17: ...the shipping protection 1 Remove the Anti shock rubber cap see the picture below Anti shock rubber cap 2 Unpack the Mullite ceramic tube as below Mullite tube 3 Put the Mullite tube into the probe as below 4 Fit the filter or shield to the end of the probe as described below ...

Page 18: ...ceramic filter or stainless steel filter depending on the application The example below shows a ceramic filter with stainless steel protector Once the packing material has been removed screw the filter or screen onto the end of the probe tube as shown Loosen the filter protector and slide it over the filter Extend the protector approximately 1 2 in 1 27 cm past the tip of the filter Align the filt...

Page 19: ...thick weatherproof insulation If the pipe nipple is over 4 in 10 16 cm long it should be heat traced Optional Filter Deflector 6 25 158 8 2 59 65 9 6 75 171 5 5 98 152 6 02 153 1 08 27 5 1 08 27 5 1 2 NPSF 2 Places 24 6 3 50 89 1 04 26 5 2 NPT M Calibration Gas Inlet 1 4 Compression Fitting Figure 3 2a WDG 1200 Insitu sensor mounting 6 02 153 5 98 152 1 08 27 43 1 08 27 43 1 2 NPSF 2 PLACES C L 4 ...

Page 20: ...5 Zero Calibration Gas typically 1 O2 in N2 6 Heater Supply Input to Probe 7 Cell Thermocouple and Cold Junction Signals from Probe 8 Mains Power Supply Input to Control Unit 9 Signal Outputs Relays customer connections 10 Automatic Calibration Trigger and Pressure Signals 11 Mains Power Supply to Remote Calibration Unit 12 External Mains Isolation Switch customer supplied 13 Calibration Gas Input...

Page 21: ...le 2 There should be a minimum of 150 mm 6 in clearance below to enable both the electrical connections and signal cable connections to be made 3 Ensure that there is an accessible route for connection to the measurement probe and the remote calibration unit 4 Maximum length of interconnecting cable between the measurement probe and the control unit should not exceed 150 meters or 500 feet Figure ...

Page 22: ...Controller All dimensions are given in millimetres inches Figure 3 5 Control Unit Dimensional Information Mounting the Control Unit The Control Unit is mounted to a vertical flat surface using the four 4 7mm 0 28 in mounting holes as seen in Figure 3 5 Figure 3 6 Mounting Details ...

Page 23: ...ibration gases and tubing Use calibration gases at 10 psig 0 7 bar Shorter probes use 3 scfh 1 4 l min 6 and 9 foot probes use 6 scfh 2 8 l min The span gas oxygen concentration must be higher than the zero gas by a factor of 10 Span gas analyzer air 20 9 or from 10 to 25 O2 balance N2 Zero gas from 1 to 10 O2 balance N2 1 is recommended NOTE Always use 1 4 in OD Teflon or stainless steel tubing t...

Page 24: ...oxygen probe the optional remote calibration unit where applicable any additional equipment e g chart recorder etc Remote Calibration Unit optional Signal connections must be made for Automatic Trigger Pressure Signals WARNING The automatic trigger circuit is not isolated from internal DC circuits and provides only for Basic insulation Circuits connected to this set of terminals must be connected ...

Page 25: ...lay System OK relay NOTE Normal for normally open N O and normally closed N C is defined as the analyzer in measurement mode not in calibration or maintenance indicating no faults or alarms Plug Plate Connector Designation WDG 1200 Insitu 1 2 3 4 5 PLUG PLATE CONNECTOR DESIGNATIONS view from underside of probe 1 Mains Power Inlet 2 8 way link to Automatic Gas Calibration Control Unit option 3 19 w...

Page 26: ...s are designed to protect the analyzer from dust and water ingress All external terminals must be fitted with either a mating plug or have a dust cover fitted in order for the instruments to maintain IP65 weatherproof rating System Cables WARNING The power supply must be isolated before any electrical connections are made Recommendations for Laying Cable Mains and signal cables should be laid sepa...

Page 27: ...wer supply before beginning adjustment WARNING The PROBE CONTROLLER mains power supply voltage used is auto switching for 100 to 240VAC 50 60Hz No adjustment is necessary The REMOTE CAL UNIT mains power supply must be selected refer to the RCU user manual Grounding The analyzer must be grounded Ground continuity must be checked before the unit is switched on for the first time The use of a circuit...

Page 28: ...ommendations Ref Description Max o d mm No of Cores Core Size mm2 Core Size strands dia Core Size awg Shielded 1 Mains Supply 11 3 0 5 16 0 2 22 No 2 Calibration 13 6 0 2 7 0 2 24 Yes 3 Outputs Relays 15 17 0 2 7 0 2 24 Yes 1 2 3 Cables 1 and 3 are supplied with the analyzer Cable 2 is supplied with the remote calibration unit ...

Page 29: ... 2 22 Yes Cables 1 3 4 and 5 are supplied with the analyzer Cable 2 is supplied with the remote calibration unit Pin Designations 1200 1210 Insitu The following is a list of pin designations for Connectors 1 2 and 3 Connector Ref Insert Arrangements Pin Function Wire Colour 1 Mains Power 1 Live Brown 2 Neutral Blue Earth Green Yellow Connector Ref Insert Arrangements Pin Function 2 Remote Calibrat...

Page 30: ...ellow J System OK Common Yellow Green K System OK N C Green Green L System OK N O Blue Blue M Not used N A N A N Calibration Maintenance in Progress N C Violet Blue P Calibration Maintenance in Progress N O Grey Blue R Calibration in Progress Common White Blue S Alarm Common Pink Red T Alarm N O Turquoise Red U Alarm N C Yellow Red Red V Screen at customer end Red The following is a list of pin de...

Page 31: ...ake the connections ensuring the cables are routed correctly as shown in Figure 3 8 KEY 1 Cell ve 2 Cell ve 3 Thermocouple ve 4 Thermocouple ve 5 Cold junction ve 6 Cold junction ve 7 Heater Live Line 8 Heater Neutral Return 9 Not Used 10 Earth Ground 11 Ground Stud Figure 3 8 Probe Electrical Connections ...

Page 32: ...Probes Grounding External grounding points are provided These should be connected to local ground Correct grounding is essential for compliance with EMC regulations Calibration Gas Port Ground Point Ground Point Calibration Gas Port Ground Point Ground Point ...

Page 33: ...asher x2 4 Black rubber washer segmented for adjustment 5 Connector backshell 6 Plug pins 7 Pin socket receptacle and connector Crimped Connector Assembly Procedure 1 Remove approximately 15mm 0 6 in of the cable outer cover exposing the inner cores 2 Thread the exposed cores through the cable clamp 3 Thread the exposed cores through the washer assembly leaving sufficient length exposed to connect...

Page 34: ... 3 4 5 6 7 3 6 Screw the pin socket receptacle and connector 7 into the cable housing 5 Pull any slack cable through 7 Push the two washer systems 3 and 4 inside the connector backshell 5 to secure the cores 8 Ensure that the clamp 2 is screwed finger tight into the cable housing 5 9 Secure the clamp 2 on the cable 1 using the two adjustment screws The plug is now fully assembled NOTE Ensure the b...

Page 35: ...or body 5 Connect the individual cores to the screw terminals 6 Screw the parts of the connector together to ensure that the rubber sealing washer fits snugly around the cable Fitting of Plug Connectors Do not push or force the plugs onto the connectors This may result in permanent damage NOTE The plugs will only fit the connectors in one orientation Special lugs on both the plugs and connector sh...

Page 36: ...tted to the calibration gas connector on the probe NOTE If the blanking plug is not fitted air leaking into the probe via the connector can cause measurement errors In a pressurised flue gases venting to atmosphere through the connector could cause corrosion of the test gas tube In a negative pressure flue air leakage can cause high O2 reading errors ...

Page 37: ...tics information can be accessed in the event of system malfunction A C F E D B Figure 4 1 Control Panel A Mode Key Used to move through the menu options B Return Key Used to enter values and select options C Up Down Keys Used to select values ready to enter D Heater OK This indicator flashes when the heater is functioning corrrectly E System OK Indicates the analyzer is functioning correctly F Sy...

Page 38: ... of cell CELT Temperature of cell CJC Cold junction compensation temperature CONF Configuration CTI Cal time interval DIAG Diagnostics DPNG Damping F Faults PRAD Probe address PRTY Probe type RES Resistance test SCAL Manual calibration SETL Calibration settling time SGAS Span gas calibration SYST System configuration TRAC Analog track or hold during calibration TTNC Time to next calibration ZGAS Z...

Page 39: ...e test gas tube Ensure installation has been completed including any optional equipment for example a remote calibration unit Check that all of the connections have been completed Warm Up Procedure 1 After a short period the Heater OK LED will begin to flash indicating the heater is operating 2 Until the probe has reached working temperature the probe will default to a reading of 20 90 3 The Syste...

Page 40: ...nance relay option The maintenance relay option must be set to YES to activate or NO to deactivate it and then entered before the Menu Spine can be viewed Set the maintenance relay by pressing the UP and DOWN keys accordingly The maintenance relay is provided as an indication to an external acquisition system that the measurements may not be valid If no key is pressed for approximately five minute...

Page 41: ...on Probe Type Value Baud Value Negative Reading Y N Probe Address Value Rev No Display ALARM MENU Display Action Alarm Value CALIBRATION MENU Display Action Display Action Configuration Menu Auto Cal Y N Span gas conc Value Zero gas conc Value Manual Cal Menu Cal time interval Value Zero Value Time to next cal Value Span Value Cal settling time Value O2 Display Password Yes No Calibration Menu Ala...

Page 42: ...lowing information is required Span gas concentration Zero gas concentration If the automatic calibration option is selected the following settings are also needed Time until first calibration Time necessary for the calibration gas flow to stabilize Time interval between calibrations Display Action CONFIGURATION Sub menu Span gas conc Enter value Zero gas conc Enter value Cal time interval Enter v...

Page 43: ...ts of three sub menus Configuration Automatic Calibration Manual Calibration To access these menus from the Calibration menu press Enter Use the F1 key to scroll through the menus Each option within the sub menu is set by pressing Enter selecting the appropriate value using the UP and DOWN keys and pressing Enter again The value is set and the display will scroll on to the next option ...

Page 44: ...n N2 It is not possible to calibrate on 0 oxygen therefore the recommended minimum concentration is 0 1 O2 in N2 OPTIONS Set concentration of zero calibration gas RANGE 0 1 to 18 O2 in nitrogen DEFAULT 1 O2 in nitrogen Calibration time interval CAL COnF Cti To set the time between calibrations Press Enter Select a value using the UP and DOWN keys Press Enter again e g 24hrs daily calibration OPTIO...

Page 45: ...rm the calibration and then return to the O2 display OPTIONS Perform automatic calibration RANGE NOT APPLICABLE DEFAULT NOT APPLICABLE Zero calibrati on CAL SCAL ZEro A zero calibration is performed manually by pressing Enter If the reading shown is inaccurate press Enter again If the reading is accurate the zero calibration can be bypassed by pressing F1 OPTIONS Perform zero calibration RANGE NOT...

Page 46: ... the alarm display The option is set by selecting a value using the UP and DOWN keys and pressing Enter again Alarm Setting ALAr OPTIONS Set the alarm RANGE 0 to 25 O2 DEFAULT 1 00 If an alarm is set the alarm relay will be activated as the analyzer measures the selected oxygen concentration value or above The relay will remain activated until the analyzer measurement falls below the selected valu...

Page 47: ...cessary to set analyzer outputs can be accessed using the Analog Outputs menu The Analog Outputs menu consists of five sub menus Zero Span Damping Base Track These sub menus are accessed by pressing Enter from the Analog Outputs display To scroll through the menu use F1 To set option within the sub menu is set by pressing Enter selecting the appropriate value using the UP and DOWN keys and pressin...

Page 48: ...or the output to stabilize the reading under noisy signal conditions Press Enter Select a value using the UP and DOWN keys Press Enter again OPTIONS Setting the damping rate RANGE 0 to 999 0 sec DEFAULT 10 00 sec Base setting AO bASE The output range required will determine the base selected Ranging from 0 10mA to 4 20mA To make a selection Press Enter Select the preferred option using the UP and ...

Page 49: ...lts Cell status Resistance test To access these menus from the Diagnostics display press Enter To scroll through the menu press F1 Each option within the sub menu can be viewed by pressing Enter Display Action FAULT LIST Display Display Action EMF OF CELL Display Cell temperature Display Cold junction temp Display Display Action RESISTANCE TEST Display ...

Page 50: ...the temperature of the cell It is the actual temperature of the cell measured independently of the heater OPTIONS Display cell temperature RANGE NOT APPLICABLE DEFAULT NOT APPLICABLE Cold junction temperature diAg CEL CJC Press Enter to display the temperature at the cold junction of the thermocouple OPTIONS Display cold junction temperature RANGE NOT APPLICABLE DEFAULT NOT APPLICABLE Cell resista...

Page 51: ...ess Revision number These sub menus are accessed by pressing Enter from the System Configuration display Scroll through the menus pressing F1 Each option within the sub menu can be set by pressing Enter selecting the appropriate value using the UP and DOWN keys and pressing Enter again The value will be set and the display scrolls on to the next option Display Action Probe type Enter value Display...

Page 52: ... values SySt nEg Negative values are not normally displayed but are sometimes required for diagnostic purposes The system can be set to display negative values by pressing Enter selecting YES using the UP key and then pressing Enter again Selecting NO using the DOWN key returns the display to normal OPTIONS NO YES RANGE NOT APPLICABLE DEFAULT NO Probe address SySt PrAd To set the probe address for...

Page 53: ... is held at the last reading prior to calibration and resumes after the final calibration settling period Output Held Settling Time ACTIVATED ACTIVATED ACTIVATED DEACTIVATED DEACTIVATED DEACTIVATED Analog Outputs Set to HOLD NO selected Analog Outputs Set to TRACK YES selected Span Level Zero Level Calibration in Progress Relay During Automatic Calibration Calibration in Progress Relay During Span...

Page 54: ...To set the analog outputs you must enter the password set the maintenance relay and select the Analog Outputs menu From menu spine Display Action ZERO Enter value Display Action SPAN Enter value Display Action DAMPING Enter value Display Action BASE Enter value Display Action TRACK Y N ...

Page 55: ...eading This is the reading to be output when the analyzer measures at the zero calibrated value To set the reading Press Enter Select a value using the UP and DOWN keys Press Enter again Span Reading This is the reading to be output when the analyzer measures at the span calibrated value To set the reading Press Enter Select a value using the UP and DOWN keys Press Enter again Damping This is a sm...

Page 56: ...u Oxygen Probes Track Setting The analog output may be set to track the O2 levels or hold the last reading during calibration This is set by pressing Enter selecting YES to track or NO to hold using the UP and DOWN keys and then pressing Enter again ...

Page 57: ...l the display shows bAud Press Enter and use the up and down arrows to change the baud code When correct press and hold Enter until the display flashes Proceed to next section Slave Address and Floating Point Format The default slave address is 11 To change the slave address first set the baud rate as in previous section then Press F1 The display shows PrAd Press enter and use the up and down arro...

Page 58: ... offset 0 Data Types Integer variable Single register Registers Numbers for Instrument Readings integer value Address Variable Scaling 23 O2 Reading 1000 27 Cell Temperature o C 10 Command Register Address Variable Scaling 30 Status and Calibration Start 1 To start the calibration sequence write the value 1 to register 30 Maintenance Status Register Address Variable Scaling 19 Maintenance State 1 ...

Page 59: ...User Guide Page 4 23 Genesis WDG 1200 1210 Insitu Oxygen Probes Modbus RS485 Interface Figure 4 3 RS485 Bus topology Figure 4 4 Two wire RS485 connection ...

Page 60: ... O P Damping 1 11 Analog O P Base 1 12 Probe Type 10 13 Baud Rate 1 14 Zero Coefficient 1 15 Span Coefficient 1 16 Cell Temperature 10 17 Display negative values 1 18 Track During Cal 1 19 Maintenance State 1 20 Time to Next Cal 1 21 Calibration Timer Hours 1 22 Calibration Timer Mins 1 Volatile Lost on power down Address Variable Scaling 23 O2 Reading 1000 24 Not Used 1 25 Cell resistance Ω 1 26 ...

Page 61: ...status The meaning of each bit is as shown in the table below Bit Meaning 0 LSB Start Calibration Write 1 to start calibration 1 Zero Calibration acknowledged 2 Span Calibration acknowledged 3 to 9 Not used 10 Failed in Calibration 11 Cold Junction Error 12 Cell too hot 13 Zero Coefficient out of range 14 Span Calibration out of range 15 MSB Temperature out of range 5 degrees ...

Page 62: ...oncentration Time until first calibration Time necessary for the calibration gas flow to stabilize Time interval between calibrations Access to Calibration Menu from Menu Spine Oxygen Concentration The oxygen concentration measured by the probe is displayed first and will take no longer than 20 minutes to stabilize after connecting the power supply Password Access the password by pressing F1 from ...

Page 63: ...ction Configuration Sub menu Span gas conc Enter value Zero gas conc Enter value Cal time interval Enter value Time to next cal Enter value Cal settling time Enter value Display Action AUTO CAL Enter or F1 Display Action MANUAL CAL Sub menu Zero Enter or F1 Span Enter or F1 ...

Page 64: ...ings to settle during calibration Span Calibration Gas Concentration The recommended span calibration gas concentration is 20 9 O2 Zero Calibration Gas Concentration The recommended zero calibration gas concentration is 1 O2 in nitrogen Calibration Time Interval Automatic zero and span calibrations can be set to occur at selected intervals up to 9999 minutes NOTE If set to 0 automatic calibration ...

Page 65: ...perform a zero calibration first and then a span calibration The calibration gases will be allowed to flow automatically from the calibration gas unit To bypass this option press F1 NOTE Check that the zero and span gases are turned on and regulated at 10 PSI 0 7 bar nominal at the gas bottles Remote Triggering Analyzer calibration can be triggered remotely from the plant control system When trigg...

Page 66: ...UST be calibrated together Manual Calibration Zero and span calibration are performed manually from this sub menu NOTE Set all configuration options before performing calibrations Zero Calibration Supply calibration gases to the probe using the calibration gas inlet at a steady flow of 1 4 l min 3 ft3 hour to 2 8 l min 6 ft3 hour and then press Enter The reading displayed will need approximately 1...

Page 67: ...The reading displayed will need approximately 120 seconds to settle NOTE Recommended span calibration gas concentration is 20 90 O2 i e ambient air Span Calibration Reading Calibration is necessary if the reading displayed is incorrect i e not equal to the span calibration gas concentration It is performed by holding Enter for two seconds If the reading displayed is correct the option can be bypas...

Page 68: ...User Guide Page 4 32 Genesis WDG 1200 1210 Insitu Oxygen Probes ...

Page 69: ...ce the probe unless power has been removed from the probe and it has been allowed to cool for one hour 5 1 Identifying Faults Faults are always indicated by the illumination of the System Fault LED and the activation of the fault relay Fault status will also be transmitted along the Modbus Most faults can be found on the Fault menu specific problems may be referred to any of the LAND sales service...

Page 70: ...he Diagnostics menu on the Menu Spine If a fault occurs a fault identification number is displayed This identification number refers to possible faults on the Fault Identification Table Table 1 If no fault has been identified by the analyzer then a zero 0 00 will be displayed From menu spine Display Action FAULT LIST Display ...

Page 71: ...epresent a multiple fault in which case the individual identification numbers are added together Use the table below as a quick reference for faults listed above Identification Number Fault Identification Number Fault 00 02 a 600 0 e 00 10 b 600 1 b e 00 12 a b 603 0 c e 03 00 c 603 1 b c e 03 02 a c 640 0 d e 03 10 a b 640 1 b d e 03 12 a b c 643 0 c d e 40 00 d 643 1 b c d e 40 02 a d 7000 f 40 ...

Page 72: ...s not increased decreased or is too high during the warm up period CAUSE ELEMENT ACTION 1 Heater not connected Probe Check probe wiring 2 Heater fuse blown Probe Replace heater fuse and check wiring 3 Heater failed Probe Replace probe heater 4 Thermocouple failure Probe See faults under Thermocouple fault and heater above maximum limit identification number 40 00 5 Cold junction sensor failed Prob...

Page 73: ... 4 Sensor deterioration Probe Ensure correct calibration procedure is followed 5 ve Span Gas Coefficient Probe ACU Replace sensor Check for correct calibration gas perform calibration c Zero coefficient out of range 03 00 The calculated zero coefficient from a zero calibration cycle is outside the expected value range CAUSE ELEMENT ACTION 1 Sensor poor connection Probe Check probe wiring and conne...

Page 74: ...rature fault 600 0 The analyzer is reading an unexpected voltage from starting or correctly completing an auto calibration cycle CAUSE ELEMENT ACTION 1 Sensor not connected or incorrectly wired Probe Check probe wiring 2 Probe cold junction temperature too high Probe Re site probe or cool connection box 3 Sensor failed Probe Replace sensor diode f Failed in calibration 7000 A fault on the system h...

Page 75: ...lity 2 Periodically check the cell EMF reading after the initial stabilizing time has expired 3 The reading should settle at the cell constant of typically 0V 2mV for a new cell 4 When the cell attains its constant typically 1 hour apply a zero calibration gas and check the cell EMF If necessary carry out a full calibration NOTE The cell can take up to three hours to fully settle If the cell respo...

Page 76: ...lexible tubing to fit the outside diameter of the pipe in OD 3 Apply the test gas at a rate of 2 l min 4 5 ft3 hour and allow 5 minutes for the analyzer reading to settle If the analyzer response is normal when measuring calibration gas but sluggish and insensitive when measuring flue gas replace the ceramic filter If you cannot obtain the correct calibration gas response measure the cell output v...

Page 77: ... thermocouple T C contacts at the probe Refer to Table 2 WARNING Mains power connections on the probe High risk of electric shock KEY 1 Cell ve 2 Cell ve 3 Thermocouple ve 4 Thermocouple ve 5 Cold junction ve 6 Cold junction ve 7 Heater Live Line 8 Heater Neutral Return 9 Not Used 10 Earth Ground ...

Page 78: ...30 20 68 30 38 45 113 29 34 19 66 2 30 42 44 111 2 29 38 18 64 4 30 47 43 109 4 29 42 17 62 6 30 51 42 107 6 29 47 16 60 8 30 55 41 105 8 29 51 15 59 30 59 40 104 29 55 14 57 2 30 63 39 102 2 29 59 13 55 4 30 67 38 100 4 29 63 12 53 6 30 72 37 98 6 29 67 11 51 8 30 76 36 96 8 29 72 10 50 30 80 35 95 29 76 9 48 2 30 84 34 93 2 29 80 8 46 4 30 88 33 91 4 29 84 7 44 6 30 92 32 89 6 29 88 6 42 8 30 97...

Page 79: ... a wiring fault rather than a faulty thermocouple If the thermocouple appears to be faulty replace the probe insert including thermocouple and heater assembly If the thermocouple appears to be in order continue from Step 8 8 Switch off the power supply disconnect the heater leads from their terminals on the User Interface and measure the resistance across these leads at the probe terminal head and...

Page 80: ...mplete calibration unless automatic calibration is enabled Every 6 months COMPONENT PROCEDURE ACTION Ceramic Filter Visual inspection Remove and clean Change if damaged or contaminated Zirconia Cell Check Cell resistance If resistance exceeds 1200 Ohms the cell needs to be replaced Calibration Gas Check supply pressure Replace cylinder if the pressure falls below specified pressure Calibration Gas...

Page 81: ...r Insitu probe unless power has been removed from the controller and the probe has been allowed to cool for one hour This chapter shows you how to replace sensor parts This includes the following Inner Probe Assembly removal Cell replacement Thermocouple replacement List of Replacement Parts You can clean the outside of the sensor or controller using normal household or commercial general purpose ...

Page 82: ...re from the top right corner of the terminal box 3 Remove the two 1 4 20 nuts using a 7 16 in nut driver and locking star washers that hold the positioning bracket to the retaining brackets This will also free the chassis ground wire 4 Remove the one 8 32 kep nut using a 11 32 in nut driver and the two 8 32 screws using a flat blade screwdriver with the attached split lock washers 5 Remove the pos...

Page 83: ...the two remaining holes Tighten using a flat blade screwdriver Place the 8 32 kep nut removed in Step 4 over the 8 32 stud Using a 11 32 in nut driver Tighten the kep nut If the inner probe assembly does not slide out freely remove the 10 32 screw from the sheet metal plate and insert a longer screw thumb screw provided in insitu accessory kit into this threaded hole to force the inner probe assem...

Page 84: ... orientation of the white cell lead wire For example if white cell lead wire is positioned at 3 o clock place a mark at 3 o clock on the left hex nut of the cell assembly and inner probe assembly see Figure 6 2 for location of left hex nut 3 Loosen the U bolts around the heater but don t remove using a 3 8 in nut driver then remove the 10 32 screw on the sheet metal plate and accompanying lock was...

Page 85: ... so that the cell assembly end is on your right and the sheet metal plate is on your left rotate both the sheet metal plate handle end of probe and the left hex nut counterclockwise at the same time until the left hex nut becomes unthreaded from the inner probe assembly Fig 6 3 Cell and heater replacement ...

Page 86: ...ecures them until they can be placed on the new cell 11 Slide the heater cell clips and cell leads into the inner probe assembly so the end of the heater is 2 in inside the end of the assembly wrench flats end of probe assembly 12 Using a flat blade screwdriver remove the metal O ring on the end of the inner probe assembly and discard a new metal O ring is provided with the cell replacement kit Fi...

Page 87: ...he other side of the white band on the cell from where the white wire cell clip is positioned NOTE The blue cell lead should be positioned approximately 180 degrees from the white cell lead Do not allow the white ceramic tube that connects to the cell clip to be trapped between the cell clip and the cell Only the cell clip should touch the cell 12 Using a flat blade screwdriver snap the new retain...

Page 88: ...t hex nut is 90 degrees away from aligning with the mark on the inner probe assembly 16 Align the sheet metal plate holes with the holes on the inner probe assembly 17 Insert 10 32 screw and lock washer into the sheet metal plate and tighten onto the flange using a flat blade screwdriver Ensure that other holes remain aligned while tightening this screw 18 Slide the heater into the inner probe ass...

Page 89: ...User Guide Page 6 9 Genesis WDG 1200 1210 Insitu Oxygen Probes Fig 6 5 Cell and retainer clip placement ...

Page 90: ... be placed 10 in from the tip of the plasma sprayed end heater end The other spiders are placed every 12 in thereafter Replacing Heater 1 Slide the new heater through the spiders taking care to avoid touching the white coating on the heater against the spider 2 Position the spiders on the heater using the marks made in Step 6 above For the alignment spider tighten the 1 16 in set screws on the ali...

Page 91: ...9 WDG 1200 1210 power data cables 805718 WDG 1210 probe to controller cables 805719 Probe Spares Genesis 1200 1210 WDG probes Cell Zirconia Electrochemical 805669 End cap for WDG 1210 probe 703 963 Bushing Screen 72015SE 805663 Cell Lead Kits 9 805664 Cell Lead Kits 18 805665 Cell Lead Kits 36 805666 Cell Lead Kits 72 805667 Cell Lead Kits 108 805668 Clip Spring Cell Contact 805670 Filter Flame Ar...

Page 92: ...r Thermocouple 18 805685 Heater Thermocouple 36 805686 Heater Thermocouple 72 805687 Heater Thermocouple 108 805688 Inner Probe Std 9 805689 Inner Probe Std 18 805690 Inner Probe Std 36 805691 Inner Probe Std 72 805692 Inner Probe Std 108 805693 Insulating Tube Mullite 805694 O Ring Insitu Cell 805695 Washer Ceramic 805696 Washer Ceramic Notched 805697 ...

Page 93: ...rawings or instructions you may have ordered in addition to the standard WDG 1200 1210 Insitu probes If you didn t order any custom options the standard Interconnect Drawing is provided If you did order any special options the drawings or special instructions provided here supersede any drawings or options provided elsewhere in this manual ...

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Page 96: ...Manufacturers address in Europe Land Instruments International Dronfield S18 1DJ Tel 44 0 1246 417691 Email land combustion ametek co uk Web www landinst com ...

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Ametek LAND Genesis WDG-1200, User Manual

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