Ametek Thermox 2000 ATEX Series User Manual Download Page 1

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Thermox

Series 2000 ATEX

WDG-HPII and WDG-HPIIC

User Manual

Thermox

150 Freeport Road

Pittsburgh, PA 15238

PN 90571VE, Rev

Summary of Contents for Thermox 2000 ATEX Series

Page 1: ...Thermox Series 2000 ATEX WDG HPII and WDG HPIIC User Manual Thermox 150 Freeport Road Pittsburgh PA 15238 PN 90571VE Rev B...

Page 2: ...te Blvd Newark DE 19702 Ph 302 456 4400 Fax302 456 4444 USA Texas 9750 Whithorn Drive Houston TX 77095 Ph 281 463 2820 Fax281 463 2701 CANADA 2876 Sunridge Way N E Calgary AB T1Y 7H9 Ph 403 235 8400 F...

Page 3: ...r Connection to Sensor 3 2 Mounting the Sensor 3 4 Mounting the Sensor to the Process 3 11 Calibration 3 12 Required Calibration Gases and Tubing 3 12 Connections 3 12 Purging Operation 3 13 Manual Ca...

Page 4: ...alibrate Remote Verify 5 10 Manual Calibrate Manual Verify 5 12 Cal Verify Data 5 15 Cal Gas Value 5 17 Inject Cal Gas 5 18 Set Cal Timers 5 21 6 MAINTENANCE TROUBLESHOOTING System Messages 6 2 Error...

Page 5: ...V 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 ch...

Page 6: ...ing or wiring IQ Link modules Do not disconnect equipment unless power has been switched off or the area is known to be nonhazardous This equipment is suitable for use in Class I Zone 2 Groups IIC or...

Page 7: ...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 oth...

Page 8: ...the input or output terminals of this product ensure that the product is properly grounded Do Not Operate without Covers To avoid electric shock or fire hazard do not operate this product with covers...

Page 9: ...General Requirements EN 50016 IEC 60079 2 Electrical Apparatus for Potentially Explosive Atmospheres Pressurized Apparatus p sensors EN 50021 IEC 60079 15 Electrical Apparatus for Potentially Explosiv...

Page 10: ...isuse 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 el...

Page 11: ...tempera ture difference generates a density difference which circulates the gas through the system Process gas enters and replenishes the gas inside the filter by diffusion only Thus the filter never...

Page 12: ...with an oxide of yttrium or calcium Porous platinum coatings on the inside and outside serve as a catalyst and as elec trodes At high temperatures generally above 1200 F 650 C oxygen mol ecules comin...

Page 13: ...ch 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 voltag...

Page 14: ...he resistance of the catalyzed element to change The resis tance change is interpreted by the microprocessor and the corresponding combustibles reading is displayed The Thermox catalytic combustibles...

Page 15: ...ygen and combustibles Note however that this is ac ceptable for combustibles span gases used only if you purchased the combustibles option Always introduce calibration gases at the recommended flow ra...

Page 16: ...portion of the pipe insulate from the process wall to the mounting flange of the sensor Install the control unit The ambient temperature must not exceed 50 C 120 F Do not create any additional conduit...

Page 17: ...n when receiving service Cell millivolts Thermocouple millivolts Cell temperature Box temperature See Display under the Setup key section in the Controller User Inter face chapter for help on how to g...

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Page 19: ...track during calibration and select degree of damping Alarms Two independent oxygen alarms each high or low selectable Two high combustibles alarms One loss of purge alarm on Sensor One alarm can be a...

Page 20: ...nless Steel available as option Calibration Oxygen cell lifetime extender Calibrate or verify calibration Store last cali bration and verification data Selectable calibration gas run time and pro cess...

Page 21: ...cale output range Response Oxygen 90 of a step change 30 secs with 24 probe Max Flue Gas Temperatures Probe Type Probe Lengths 704 C 316 SS 61 cm 91 cm 122 cm 1024 C 310 SS 61 cm 91 cm 122 cm 1537 C C...

Page 22: ...740 VA 207 253 VAC 1990 VA Calibration Gas Requirements Use calibration gases 0 70 kg cm2 0 7 Lmin O2 Span Gas Air or from 1 0 to 100 O2 balance N2 O2 Comb Zero Gas from 0 1 to 10 O2 2 recommended bal...

Page 23: ...NEMA 4X IP56 Environment AmbientTemperature 18 C to 70 C Humidity 0 to 90 non condensing Max Altitude 2000 Meters IEC Installation Overvoltage Category II IEC Pollution Degree 2 Compliance EMC Compli...

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Page 25: ...ess power has been removed and it has been allowed to cool for at least one hour Also always use gloves when working on the sensor This chapter shows you how to install your sensor components and in c...

Page 26: ...from excessive vibration and the ambient temperature is required to be within the limits listed in the specifications appendix contained in this manual If the ambient temperature is outside the speci...

Page 27: ...to prevent loosening by vibration but does not need to be leak tight Coating the threads with a Neolube graphite coating or a similar non silicone graphite material will also help prevent galling 3 T...

Page 28: ...ree methods of mounting the WDG HPII to the process are as fol lows 1 Directly weld the Thermox supplied mounting plate to the process In this case the pipe nipple attached to the mounting plate is in...

Page 29: ...4cm 19 50 49 53 4 00 10 17 21 50 54 61 3 75 9 53 5 88 14 94 ENCLOSURE PROTECTION VENT TERMINAL BOX C L PROBE LOC L PROBE LOC C 9 00 22 86 SIDE HINGE INCH CM MAGNAHELIC GAUGE SET PRESSURE 15 TO 35 INCH...

Page 30: ...plate directly through the refractory If the pipe nipple pro vided by Thermox extends past the inside of the refractory wall on a process which has a gas temperature over 650o C the nipple should be...

Page 31: ...2 7 8 OD X 9 LONG NIPPLE AMETEK SUPPLIED MOUNTING PLATE GASKET BY AMETEK PLATE IS WELDED TO WALL BY CUSTOMER SENSOR BOLTED TO MOUNTING PLATE AFTER PROCESS WALL FRONT VIEW POSITION AT 12 O CLOCK SINGL...

Page 32: ...nipple the better 2 Insert the Thermox supplied pipe nipple on the end of the Thermox supplied mounting plate into your pipe nipple If the Thermox sup plied pipe nipple extends past the inside of the...

Page 33: ...GASKET BY AMETEK PLATE IS WELDED TO NIPPLE BY CUSTOMER FILTER PROCESS WALL SIDE VIEW SUPPLIED BY CUSTOMER PIPE NIPPLE PORTION OF NIPPLE INSULATION AROUND EXPOSED REQUIRES 1 2 54cm MIN INSTALLATION NE...

Page 34: ...mounting bolts if using a raised face flange This will prevent damaging the backplate of the sensor CAUTION Figure 3 5 Customer flange mounting EXHAUST TUBE GASKET BY AMETEK SENSOR BOLTED TO MOUNTING...

Page 35: ...e careful not to knock the filter against the pipe nipple as you insert the probe into the process 4 Line up the three studs on the mounting plate with the three holes in the back of the sensor then m...

Page 36: ...Combustibles span gas 60 to 80 ppm range or 40 to 60 percent range of the full combustibles operating range in certified mixtures of equal parts CO H2 with an equal amount of O2 or more balance N2 Exa...

Page 37: ...5 inch of water column Regulator may be in the locked position upon arrival To adjust regulator pull handle to outward position Carefully insert T bar valve key to align valve stem tip of both valves...

Page 38: ...vate to silence the alarm system 5 Carefully remove T bar Valve Key from Enclosure Pressure Control Valve stem Ensure Enclosure Pressure Gauge Safe pressure setting is stable 6 Utilizing the T bar Val...

Page 39: ...CONTROL VALVE STEM ENCLOSURE PRESSURE GAUGE RAPID EXCHANGE PRESSURE GAUGE SYSTEM START UP INSTRUCTIONS R R Figure 3 7 Sensor inlet ports ENCLOSURE PROTECTION VENT TERMINAL BOX SIDE HINGE PURGE AIR INL...

Page 40: ...ambient temperature range for the RCU is 20 to 70o C Mount the RCU as close to the sensor as possible Figure 3 8 shows mounting dimentions Shorter calibration plumbing improves response times re duces...

Page 41: ...r the location of the sensor calibra tion gas inlet Install the supplied check valve in this line as close to the sensor as possible O2 and Combustibles RCU Connections Make the following calibration...

Page 42: ...ENSOR 1 4 NPT F ZERO GAS INLET 1 8 NPT F 10 PSI COMBUSTIBLE SPAN GAS 1 8 NPT F 10 PSI METHANE SPAN GAS 1 8 NPT F 10 PSI ASPIRATOR AIR OUTLET 1 8 NPT F OPTIONAL COMBUSTIBLES MIDRANGE VERIFY SPAN GAS 1...

Page 43: ...alve Sensor Gas line Calibration To be kept to a minimum Valve Check 1psi 1 4 OD Flowmeter Calibration Gas Plugged 10psi set factory Regulator Air Inlet Instrument Gas Inlet Combustibles Solenoid Gas...

Page 44: ...Unit Mounting The Weatherproof Series 2000 Control Unit is availabae with different mounting options Panel Wall Pole Weatherproof Panel Mount Figure 3 12 shows the panel mounting dimensions for the S...

Page 45: ...sure For wall mount installations use 1 4 diam eter fasteners to mount the control unit to a wall For pole mount installa tions the two slots on the backplate of the enclosure can be used to accom mod...

Page 46: ...te For the weatherproof versions of the control unit first open the front door of the weatherproof enclosure to gain access to the wiring card shield Re move the three screws on this shield to gain ac...

Page 47: ...OUT2 IOUT1 IOUT1 VEXT1 2 VEXT1 2 1 CELL CELL T C T C CH4 REF CH4 REF CH4 ACT CH4 ACT H2 REF H2 REF H2 ACT H2 ACT 15V COM 15V SPLY 15V COM FURNACE TC EFF I V3 TC EFF I V3 EFF I V2 EFF I V2 EFF I V1 EFF...

Page 48: ...for the Series 2000 controller or sensor enclosure If not using a conduit entry leave the factory NEMA approved plugs intact Never leave any holes unplugged Follow all applicable electrical codes for...

Page 49: ...L and N markings are provided by the terminal block for con nection of AC power These markings are for reference purposes only such as for use on system wiring diagrams etc The system product has or...

Page 50: ...method Shield Ring Method Connect all shields for that conduit entry other than power to a supplied shield terminal ring see Figure 3 15 This shield ring is a stainless steel ring with a metal tab Pla...

Page 51: ...d as possible Examples of tran sient suppressors include MOVs TRANSORBs and RC snubbers AC mains supply wiring should not be run in the same conduit with mains supply wiring that feeds heavy inductive...

Page 52: ...lock for connection of AC power These markings are for reference purposes only such as for use on system wiring diagrams etc The system product has or needs no specific LINE or NEUTRAL connection for...

Page 53: ...REF H2 Ref 9 10 one pair Table 3 3 Sensor connections CONTROL UNIT LABEL SENSOR TERMINAL NUMBER Cell Cell 1 2 one pair Furnace 15V COM 3 4 one pair T C T C 5 6 one pair 15V SPLY 15V SPLY 12 12 one pa...

Page 54: ...ense setup you can obtain the best accuracy of your combustibles detector readings See Table 3 2 for the number of pair required and the type of wire required To use the remote sense setup you must fi...

Page 55: ...2 REF H2 ACT H2 ACT 15V SPLY 15V COM 15V COM 1 2 12 5 15 16 13 14 10 9 7 8 3 4 6 Not actual order of sensor connections Option H2 ACT H2 ACT H2 REF H2 REF CH4 ACT CH4 ACT CH4 REF CH4 REF CELL CELL T C...

Page 56: ...tion cur rent outputs 3 and 4 are also isolated from the control unit and from cur rent outputs 1 and 2 If you intend to power current outputs from an external power sup ply see the external Powering...

Page 57: ...LOAD RESISTANCE 1200 OHMS These combustibles current outputs are cable of driving up to 1200 ohm loads Current outputs 3 and 4 are isolated from the control unit as are isolated from current outputs...

Page 58: ...nt triggers these alarm contacts to an open condition 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 l...

Page 59: ...Installation 3 35 Figure 3 18 Series 2000 alarm connections example Computer dry contact input Load Max 30VA Transient protector for inductive loads Power Supply Max 30v...

Page 60: ...labeled as follows see Figure 3 18 ALARM 5A ALARM 6A ALARM 5B ALARM 6B Loss of Pressurization Alarm Contact If pressure drops below 0 15 of water column 0 02 contact will transfer on the pressure swi...

Page 61: ...n Unit RCU connections on the Series 2000 control unit wiring card and their RCU connections are as follows see Figure 3 21 ZERO 13 on RCU SPAN1 15 on RCU VALVE COMMON 16 on RCU Figure 3 21 Series 200...

Page 62: ...e a normally open switch Digital input connections are labeled as follows on the wiring card DIGIN DIGIN RS 485 Communications Connections The Series 2000 control unit has the ability to communicate w...

Page 63: ...resistor The Series 2000 control unit is equipped with a termination resistor that can be used for the last control unit on the network Switch 3 on SW1 of the display module allows you to place a 120...

Page 64: ...resistor The 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...

Page 65: ...4WTX 2W 4WRX 4WRX RS 485 GND 4WTX 2W 4WTX 2W SERIES 2000 4WRX 4WRX 2000 SERIES HOST TX TX RX RX 4WRX 4WTX 2W 4WRX 4WTX 2W RT USE 2 TERMINATION RESISTORS AT HOST EACH 120 ohms SW1 1 OFF SW1 2 ON SW1 3...

Page 66: ...ontrol unit see Figure 3 24 1 Open the access door below the display module hinges down 2 Pull on the handle of the power supply keypad module and remove this module from the control unit it slides ou...

Page 67: ...available slots underneath the display module Make sure the card is properly seated by pressing on both sides firmly If the card is not properly seated the access door may not close 4 Reinstall the p...

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Page 69: ...nit 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...

Page 70: ...Note 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 conditio...

Page 71: ...Down arrow key until the arrow point ers 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 cur rently selected choice will h...

Page 72: ...he system 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 func...

Page 73: ...unit access to autho rized personnel Passwords y Define the pressure at which your system will operate Process Pressure y Perform system tests System Tests y View the serial and manufacturing number f...

Page 74: ...combustibles detector s Figure 4 3 Overview of setup key functions SETUP KEY MENU OPTIONS FUNCTION OPTIONS Display Select info for Display line 1 Select info for Display line 2 Select info for Displa...

Page 75: ...t Display from the Setup menu 2 Select Display Line 1 Display Line 2 or Display Line 3 depending on where you want to place the information 3 Select the type of information you want to place on the di...

Page 76: ...number 7 key scrolls you to the small letter a y Pressing the number 9 key scrolls you to the small letter z y Pressing the number 5 key scrolls you to the space character y Pressing 0 takes you to th...

Page 77: ...he 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 pr...

Page 78: ...then prompted to enter your system process pressure Pressure xxx x kPa New Value 3 Enter your process pressure up to one decimal point is allowed for example 1 5 kPa then press the Enter key If you s...

Page 79: ...AM Test Keyboard Tests that each key is functioning correctly Test EEPROM Tests the electrically erasable programmable read only memory Module Detect Allows the control unit to check for the presence...

Page 80: ...the user This is used to test communication settings and wiring Read Memory Location This is used to view internal software variables used for system operation and troubleshooting System Serial This...

Page 81: ...he voltage should be 11 05 mV 273 C 2 02 mV 50 C 13 07 mVs If you have a T C ratio of 0 9 the corresponding furnace temperature set point should be 695 C 0 9 772 C If you measure the voltage at termin...

Page 82: ...0 74 695 1 22 0 777 824 1 139 0 861 790 same as 824 C For a cell operating temperature of 695 C the T C ratio low limit is 777 and the high limit is 1 222 which corresponds to a thermocouple indi cat...

Page 83: ...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 Cal Initiate Verify section in Chapter 5 f...

Page 84: ...sensor used with the Series 2000 Control Unit Selecting the wrong sensor will damage sensor components and could invalidate your warranty coverage Configurating the sensor 1 Select Sensor Config from...

Page 85: ...e that each control unit must be assigned a unique address otherwise communication results will be unpredictable Enable Serial Allows you to temporarily disable control unit serial communica tions Com...

Page 86: ...ve the combustibles option Analog output parameters are defined using the Analog Range Key menu See the Select an Analog Output Port section in this chapter for help on how to select an analog output...

Page 87: ...and if enabled how much to smooth out abrupt changes in 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...

Page 88: ...Analog Range key functions you must first choose whether they will apply to analog output ports 1 or 2 on the rear of the control unit In addition if you have the combustibles option you can also use...

Page 89: ...20 mA or 4 to 20 mA scale To set the range of readings that the selected current output represents do the following 1 Select Set Current Range from the Analog Range key menu after selecting an analog...

Page 90: ...old 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 mad...

Page 91: ...g 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...

Page 92: ...Cell millivolts y Combustibles optional The combustibles option is available only for current outputs 3 and 4 and cannot be set for analog output ports 1 or 2 Selecting the function 1 Choose Select F...

Page 93: ...allation chapter for help on alarm connections and how alarms are labeled on the control unit wiring card The Alarm key allows you to do the following y Define whether Alarm 3 activates based on oxyge...

Page 94: ...ory of events such as system or error messages alarm condi tions and the start of calibrations or verifications Overview of Alarm Functions Figure 4 8 provides an overview of how alarms can be set y A...

Page 95: ...4 8 Alarm Key overview Note Alarms 1 and 2 are reserved for the watchdog timer and service alarms and are not software selectable Alarm Set Points This menu option allows you to set your alarm limits...

Page 96: ...point value this option won t appear if Alarm 3 is not set to activate based on a O2 reading but rather is set to activate based on the start of a calibration or verifica tion see the Select Function...

Page 97: ...Alarm Configure This menu option allows you to define whether alarms should trigger based on a high alarm or a low alarm condition See the Alarm Set Points section for help on how to define alarm set...

Page 98: ...ge will appear Relays are set to ENERGIZE on Alarm If you select De energize on Alarm the following message will appear Relays are set to DE ENERGIZE on Alarm Select Function This menu option allows y...

Page 99: ...rigger the service alarm to activate are as follows y Error condition detected by software y System operational variance such as an over temperature or under temperature condition y Calibration failur...

Page 100: ...stem or error messages y Alarm conditions y Reset conditions y Start of calibrations or verifications y Choose Exception Log from the Alarm menu The system shows you the most recent exception log entr...

Page 101: ...yzer easy and even includes a way for the system to periodically calibrate itself Sensor alarms are disabled during calibrations and the recovery time after a calibration You can set whether analog ou...

Page 102: ...y operations are often used to check that the instrument is running within required tolerances On the other hand during a calibration software algorithms adjust the difference between the current read...

Page 103: ...calibrates itself at those predefined times You can also use a digital input to activate an automatic calibration see the Remote Calibration Unit Connections section in the Chapter 2 for help on how...

Page 104: ...e 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...

Page 105: ...calibration gas values Inject Cal Gas Set pressure and flow of RCU gases without performing a calibration Set Cal Timers Set control unit time date applies only for auto cal operations with RCU Enable...

Page 106: ...nter the four digit system password To protect the identification of the password the numbers you enter will not be displayed You will then be allowed to access Calibrate key functions Aborting a Cali...

Page 107: ...apter for details Once you ve set these cycle times you don t need to select the Initiate Cal or Initiate Verify menu options for an automatic calibration to occur The Auto Calibrate Auto Verify and R...

Page 108: ...see the Set Cal Timers Cal Gas Duration section Remember that with an auto calibration or verification the RCU automatically switches the span and zero calibration gases based on the calibration gas d...

Page 109: ...Span Gas xx xx System Calibrating During this time the RCU has switched the solenoid valves and has introduced the combustibles span gas to the sensor Then if you specified a recovery time the system...

Page 110: ...pear if you have the combustibles option O2 xx x Set xx x Cmb y Press ENTER to Span 4 Press the Enter key once the O2 reading on the far left of the first display line stabilizes The reading on the fa...

Page 111: ...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 connected to yo...

Page 112: ...il and dirt Inject Span Gas ENTER to Continue CANCEL to Abort 4 Press the Enter key once you have applied this calibration gas The span display then appears display line 2 will only appear if you have...

Page 113: ...tion you only need to wait until the O2 zero gas value stabilizes The reading on the far right of the first display line shows the setpoint value you entered for the O2 zero gas using the Cal Gas Valu...

Page 114: ...a recovery time the system will display the recov ery time remaining Recovery xx xx System Calibrating The system then returns to monitoring process readings Be sure to reinsert the 1 4 tube cap on th...

Page 115: ...n Drift or Zero Drift is the differ ence between 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...

Page 116: ...m zero gas is the setpoint value entered using the Cal Gas Values option from the Calibrate key menu 4 Press the Enter key The time when the calibration or verification was completed will then appear...

Page 117: ...s value 1 Select Cal Gas Value from the Calibrate key menu You are prompted to enter the span gas value Span Gas xx x O2 New Value 2 Enter the span gas value then press the Enter key You can also incl...

Page 118: ...tion you are then prompted to enter the combustibles span gas value Comb Span xxxx YY New Value 4 Enter the combustibles span gas value then press the Enter key If you want to keep the current combust...

Page 119: ...your display indicating that the RCU has introduced the span gas to the sensor Span gas is flowing You will be prompted to press the Enter key once you have manually set the pressure and flow for the...

Page 120: ...y indicating that the RCU has introduced the combustibles span gas to the sensor Comb gas is flowing Once you have set the pressure and flow for the span gas the system prompts you to press the Cancel...

Page 121: ...le Auto Cal On Off Define how long cal gases should flow through the sensor during automatic calibrations or verifications Cal Gas Duration Define a recovery duration during which time the sensor swit...

Page 122: ...r Set Cycle in HOURS depending on whether you want to set the frequency of calibrations or verifications in days or hours If you are setting the auto timers for the first time the Series 2000 software...

Page 123: ...etting any auto cal auto verify parameters 1 Select Set Time Date from the Set Cal Timers menu You are prompted to enter the new time The time is YY XX Enter new time HR Mn 2 Enter the new time then p...

Page 124: ...on cycle Select Enable Auto Cal or Enable Auto Verify to enable the auto calibration or verification cycle The system will confirm your enabling or disabling selection Auto Cal is ENABLED or Auto Cal...

Page 125: ...equals minutes and Sc seconds As you type the new zero gas duration time it overwrites the Mn Sc text If you want to use the currently displayed time press the Enter key without entering any text If...

Page 126: ...to reading the 6 process gas This menu option also can be used to prevent triggering of alarms if for example your low alarm is set to activate if readings fall below 3 and your calibration gas is 2 T...

Page 127: ...unless the sensor control board was replaced or the EEPROM is cleared The default factor of 1 00 is set on a new control board or after the EEPROM is erased The factor must be re entered to assure acc...

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Page 129: ...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 Sy...

Page 130: ...use the span gas or zero gas was out of range Calibration Required Once you complete a primary calibration this message is displayed to in form you that a regular calibration is required after a prima...

Page 131: ...od after the primary calibration System Calibrating This message indicates that a system calibration is in progress It will ap pear during the entire automatic calibration cycle or during the recovery...

Page 132: ...a normal operating range If this message soon goes away it indicates that the temperature has re turned to an acceptable range If there is a problem with the sensor tem perature control system you wi...

Page 133: ...ear by removing and restoring power to the unit If you receive this message you should reset your control unit to the val ues required for your application including Setup key parameters Cali brate ke...

Page 134: ...of furnace drive signal y 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 ther...

Page 135: ...this error occurs calibration of the system is aborted This error indicates one of the following problems y Calibration gas setup problem y Process pressure incorrectly entered y Cell wiring reversed...

Page 136: ...to display these items This information 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 f...

Page 137: ...t 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 thermoco...

Page 138: ...and 6 on the sensor board Twelve mil livolts should be measured this signal is a function of ambient tempera ture and may vary up to 2 millivolts at extreme ambient temperatures If you don t measure...

Page 139: ...see the Inject Cal Gas menu option from the Calibrate key chapter for help on how to do this Calibration line check Ensure that your calibration line is not contaminated with such things as pipe dope...

Page 140: ...solenoid drive signal is present The aspirator air solenoid is closed when the drive signal is applied Other solenoids are open when the drive signal is applied cal gas flowing With the drive signal...

Page 141: ...control unit display Then add a one minute buffer to each of these times Also make sure the cylinder regula tors are set to the correct pressure See the Flow Section of the System Interconnect Drawing...

Page 142: ...t 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...

Page 143: ...lp on how to check for leaks see the Calibra tion Aspirator Air Checks section earlier in this chapter for help on check ing your calibration gas setup If the analyzer has been operating for some time...

Page 144: ...s Monitor the response from the cell When the cell millivolt reading changes it indicates a leak in that area of the plumbing the vacuum of the process pulls in the gas If not convenient to view the c...

Page 145: ...nd the O2 span gas should be flowing into the sensor 3 O2 Zero when lit indicates that the O2 zero gas solenoid is ener gized and the zero gas should be flowing through the sensor 4 Combustibles span...

Page 146: ...tor OFF Oxygen only system no RTD and SW1 all positions to ON Blinking GREEN Sensor enclosure not at setpoint temperature GREEN Sensor enclosure at setpoint temperature Blinking GREEN Blinking RED Sen...

Page 147: ...Box Temperature RTD Replacement Furnace Replacement How Wire Combustibles Detector Replacement optional RCU Remote Calibration Unit Solenoid Valve Replacement Replacement Parts List See the Installat...

Page 148: ...eful when performing maintenance on the sensor while the process is running especially if the process is under significant positive pressure Removing any part of the sensor plumbing can al low process...

Page 149: ...Service and Parts 7 3 Figure 7 1 Wiring diagram for standard sensor...

Page 150: ...ore reinstalling and always use a new cell O ring If replacing the cell discard the old cell and cell O ring and retrieve the new cell with supplied cell O ring Avoid touching the bare cell Instead ho...

Page 151: ...Service and Parts 7 5 Figure 7 2 Cell replacement...

Page 152: ...g it in The thermocouple should be near but not touching 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...

Page 153: ...Service and Parts 7 7 Figure 7 3 Furnace thermocouple replacement...

Page 154: ...or board 3 Remove the screw on the finned heater block see Figure 7 3 4 Remove RTD from the mounting tab on finned heater block 5 Insert new box thermocouple into the slot in the clamp on the finned h...

Page 155: ...Service and Parts 7 9 Figure 7 4 Box temperature RTD replacement RTD and Loop Clamp 8 32 Screw 10 32 Screw 8 32 Nut Bracket Splitlock Washer Manifold Block Finned Heater Block...

Page 156: ...loosen the other fitting 5 While holding the furnace in one hand remove the convection loop mounting clamp being sure to save the mounting clamp for when you install the new furnace 6 Gently pull the...

Page 157: ...Service and Parts 7 11 Figure 7 5 Furnace replacement...

Page 158: ...detector block sample flow path must contact both detector leads at the same time To do this place a mark on the edge of the combustibles detector at the 12 o clock position once you have determined...

Page 159: ...Service and Parts 7 13 Figure 7 6 Combustibles detector replacement Hot Wire...

Page 160: ...shows how to wire box heaters using the sensor board Figure 7 7 Box heater diagram HTR HTR HTR HTR Box Heater Box Heater L N HTR N NC NC L HTR Box Heater Box Heater 120VAC 230VAC Box Heater 230 Volt...

Page 161: ...the solenoid counter clockwise 3 Insert new valve and turn the knurled ring clockwise 4 Reconnect wiring The purpose of the drawing is to identify various solenoid valves on the RCU ATEX HPII Series 2...

Page 162: ...36034JE Calibration Gas Solenoid Valve P N 36088JE Flow Meter P N 37020JE Control Unit Display Processor Module P N 90219VE Power Supply Keypad Module P N 90253VE Auto Calibration Card P N 80436SE Bac...

Page 163: ...ter slave command response protocol The master initiates each communication transfer There is one master on the communication line but there can be multiple sensors act ing as slaves Up to 32 sensors...

Page 164: ...ring of characters whose meaning depends on the command 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 prec...

Page 165: ...le table followed by the value of the variable A simple acknowledge is returned if the command was accepted Read Date and Time M This command is used to read the dates and times stored in the analyzer...

Page 166: ...a simple acknowledge This command can also be used later to check that the IQ sensor is on line and ready to communicate Data Format J This command is used to check how data is output through the ser...

Page 167: ...to determine where the data is stored internally to the analyzer and act accordingly This command is only available via the Series 2000 software Command List The following command letters are availab...

Page 168: ...ss 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 car riage return Success End A CR S...

Page 169: ...ure Failure Code End Character N 2 hex ASCII characters CR Failure Codes are as follows Failure Code Description 01 Bad command letter 02 Bad checksum 03 Input overrun in serial communication 05 Param...

Page 170: ...rating temperature bit 1 Over under Flag for tuning temperatureS2 bit 2 inject cal gas active bit 3 Auto Cal is occurring S2 bit 4 Auto Verify is occurring S2 bit 5 in a menu S2 bit 6 No limit msg S2...

Page 171: ...nder Temp IQ bit 13 Box Over Temp IQ bit 14 Furnace Circuit Open IQ bit 15 Furnace Over Temp IQ bit 16 Temp Rise Failure bit 17 Cell is Over Temp bit 18 Zero Gas Range Error bit 19 Span Gas Range Erro...

Page 172: ...it 5 auto verify time is set an auto verify will happen at the set time if the auto verify is enabled bit 6 auto verify timer is enabled if this is enabled an auto verify will occur at the auto verify...

Page 173: ...ze bit 9 auto calibration time is set an auto calibration will happen at the set time if the auto calibration is enabled bit 10 auto calibration timer is enabled since this is enabled an auto calibrat...

Page 174: ...d 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...

Page 175: ...analog output 4 during verify bit 6 analog output 4 set for 0 to 20 ma 0 is 4 to 20 ma bit 7 Future use bit 8 analog output 1 tracks during calibration 0 is hold analog output 1 during calibration bi...

Page 176: ...000 WDG HPII HPIIC ATEX 04 04 Probe_type 0 Insitu IQ 1 Cem 02 IQ 2 WDG IQ 3 HP IQ 4 EI 20 IQ 5 SA F IQ A Insitu S2 B CEM O2 S2 C WDG S2 D HP S2 E TM S2 F 3 in 1 S2 R W Location Hex Decimal Variable Na...

Page 177: ...ne2_flg What is displayed on line 2 of the display 0 blank line 2 oxygen 4 cell temperature 6 cell mv 8 thermocouple mv 10 box temp IQ 12 combustibles 14 methane 16 methane and combustibles 18 combust...

Page 178: ...mal Variable Name Description Access Location Hex Decimal Variable Name Description Access 0E 14 Out1_flg What analog output 1 corresponds to 0 oxygen 1 cell temperature IQ 2 cell temperature S2 therm...

Page 179: ...ustibles IQ 6 methane IQ 10 combustibles S2 12 methane S2 7 AF Ratio IQ 8 WOBBE IQ R W 11 17 Out4_flg What analog output 4 corresponds to 0 oxygen IQ 1 cell temperature IQ 2 thermocouple mv IQ 3 cell...

Page 180: ...W 1F 31 Alm4_value alarm setpoint for Alarm 2IQ Oxygen alarm setpoint for Alarm 4 S2 Value is always in percent R W 20 32 Alm5_value Combustibles PPM alarm 5 setpoint S2 Alarm 3 setpointIQ R W 21 33...

Page 181: ...percent_gas Methane percent span gas setpoint value R W 2F 47 Cal_cgas1 Oxygen span gas setpoint for last calibration Read only 30 48 Cal_span Oxygen span gas reading for last calibration Read only 31...

Page 182: ...s read during last verify Read only 3D 61 Cmbzero Combustibles zero gas read during last calibration Read only 3E 62 Vcmbzero Combustibles zero gas read during last verify Read only 3F 63 Cal_cgas4 Me...

Page 183: ...les channel Read only 51 81 Cmbact Active voltage reading for Combustibles channel Read only 52 82 Cmbgnd Ground reading for Combustibles channel Read only 53 83 Mthref Reference voltage reading for t...

Page 184: ...ble alarm 2 IQ bit 7 high methane alarm 2 IQ bit 8 high oxygen alarm 3 IQ bit 9 low oxygen alarm 3 IQ bit 10 high combustible alarm 3 IQ bit 11 high methane alarm 3 IQ bit 12 Future use bit 13 Future...

Page 185: ...gas flowing 6 Step func Zero gas flowing 7 Step func Process gas flowing 2nd time 0x80 User Aborted Cal set from abort to recovery completed 0x81 Recovery Period if in a cal or verify per loc 60 95 No...

Page 186: ...ible alarm 3 bit 11 high methane alarm 3 bit 12 Future use bit 13 Out of Range for SA F sensor bit 14 Future use bit 15 Future use Read only Alarm_flags S2 Which oxygen alarm has been set and why bit...

Page 187: ...ed IQ 3 in 1 option installed S2 bit 4 Dig ma module installed IQ bit 5 HART module installed IQ bit 6 RS485 module installed IQ bit 7 3 span value RCU IQ Invalid option module S2 Read only 64 100 Tsp...

Page 188: ...lue RCU installed 4 Process gas R W 74 116 Node_Addr The current node address R W 75 117 Read only 76 118 Cmbsens Combust sensitivity associated with the last calibration Read only 77 119 Mthsens Meth...

Page 189: ...only 89 137 Excep_10 Exception number 10 see Exception Chart Read only 8A 138 Excep_11 Exception number 11 see Exception Chart Read only 8B 139 Excep_12 Exception number 12 see Exception Chart Read on...

Page 190: ...o Cal Pending 1E Auto Verify Pending 1D System Calibrating 1C System Verifying Cal 1B Calibration Aborted 1A Cal Verify Aborted 19 T C Circuit Failure 18 Thermocouple Failure 17 Calibration Required 1...

Page 191: ...M2 9600 N 8 1 FOR RANDOM AS 1 String to be sent T 08 Address of the analyzer Address 0 Build the message M HEX Address F T M M Checksum M Continue sending message until key pressed Assumes that analyz...

Page 192: ...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...

Page 193: ...Pressure Select positive or negative process pressure Enter process pressure value System Tests Perform internal diagnostics on Series 2000 System Serial View Serial for Series 2000 View Mfg for Seri...

Page 194: ...readings CALIBRATE KEY MENU OPTIONS FUNCTION OPTIONS Initiate Cal Initiate Verify Start an automatic remote or manual calibration Cal Verify Data View latest calibration and verify data Cal Gas Value...

Page 195: ...ints Alarm 3 Value Alarm 4 Value Alarm 5 Value Alarm 6 Value Alarm Configure High O2 for alarms 3 and 4 Low O2 Relay Configure Energize on Alarm De energize on Alarm Select Function Oxygen for alarm 3...

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Page 197: ...P2 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 o...

Page 198: ...current output 4 Jumper JP2 on the combustibles card allows you to define which source to use to power current output 3 If the jumper is in factory default the control unit uses its own power supply...

Page 199: ...xternal power supply IOUT1 and IOUT2 must share 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 termin...

Page 200: ...es 2000 WDG HPII HPIIC ATEX Skip this section if you don t measure combustibles NOTE In addition both of the combustibles current outputs can be used in a modulation scheme using the following VEXT3 V...

Page 201: ...instructions you may have ordered in addition to the standard WDG analyzer If you didn t order any custom options the standard Interconnect Drawing is pro vided If you did order any special options th...

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