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Maintenance and Troubleshooting | 6-1

MAINTENANCE AND TROUblEShOOTING

The operations in this chapter should be performed only by qualified
service personnel with a knowledge of electrical safety techniques.

There are no operator-serviceable components inside the CEMO

2

/TM

system. An operator should never remove the cover from the controller
or sensor. Qualified service personnel should never service the control-
ler or sensor unless power has been disconnected from the controller and
the sensor, and the sensor has been allowed to cool for at least one hour.
Always wear gloves when working on sensor components.

This chapter describes Series 2000 control unit system error messages as
well as 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

NOTE

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Summary of Contents for Thermox CEM O2/TM

Page 1: ...Thermox CEM O2 TM Oxygen Analyzer User Manual Thermox 150 Freeport Road Pittsburgh PA 15238 P N 90496VE Rev G...

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 Jianguo...

Page 3: ...ibration Unit RCU 2 4 chapter 3 Installation Mounting the Sensor 3 2 Sample Gas Requirements Connection 3 3 Remote Calibration Mechanical Installation Optional 3 4 Customer Supplied Remote Calibration...

Page 4: ...Key 4 5 Analog Range Key 4 18 Alarm Key 4 26 Service Alarm 4 33 Watchdog Relay 4 33 Exception Log 4 34 chapter 5 Calibration Definitions 5 2 Types of Calibrations 5 2 Overview 5 3 Aborting a Calibrati...

Page 5: ...eplacement Cleaning 7 4 Thermocouple Replacement 7 6 Furnace Replacement 7 8 Parts Replacement List 7 10 appendix a Serial Communications appendix b Menu Option Charts appendix c Current Outputs Other...

Page 6: ...Safety Up to 5 kV may be present in the analyzer housings Always shut down power source s before performing maintenance or troubleshooting Only a qualified electrician should make electrical connecti...

Page 7: ...a technique allowing high frequency shield bonding while avoiding the AC ground metal connection In the case of shielded cables the drain wire or braid connection must be kept short A two inch connec...

Page 8: ...g or wiring modules Explosion hazard 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 Division 2 Gro...

Page 9: ...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 ser vice Metals plastics and oth...

Page 10: ...Measuring Equipment Heavy Industrial Emissions EN 55011 1998 Class A ISM Equipment Safety Compliance UL 3101 1 UL Listed Inspection and Measuring Electrical Equipment CAN CSA 22 2 No 1010 1 92 cUL Lis...

Page 11: ...subject to misuse 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 fireorforc...

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Page 13: ...TM analyzer consists of the following basic systems The Plumbing All inlet and outlet tubing cell housing the sensing cell and the sensing cell fitting The Measuring System Sensing cell interconnectin...

Page 14: ...s produced See Figure 1 1 The magnitude of this voltage is a function of the ratio of the two oxygen partial pressures If the oxygen partial pressure of one gas is known the voltage produced by the ce...

Page 15: ...burn When this occurs the cell will gener ate high millivolts and cause the display to indicate less oxygen than is actually in the gas net oxygen content Hydrocarbons When hydrocarbons are present i...

Page 16: ...side the sensor cabinet turn the power off The heater has exposed windings and a short to the plumb ing will blow the fuse and could damage the furnace or thermocouple Do not handle the cell excessive...

Page 17: ...the enclosure Interconnect the control unit and the sensor per the appropriate inter connecting drawing The specified cable must be used in order to insure proper opera tion of the systems Keep the i...

Page 18: ...ctory to provide this information when receiving service Cell millivolts Thermocouple millivolts Cell temperature See the Display section in the Controller User Interface chapter for help on how to di...

Page 19: ...e mV or cell mV Each output can be 4 20 mA 0 20 mA 20 4 mA or 20 0 mA and is fully scalable Hold or track during calibration and select degree of damping Maximum load 1200 ohms Alarms Two independent...

Page 20: ...ount UL Type 4 NEMA 4 IP56 and UL Type 4 NEMA 4 X IP56 enclosures available All are UL Listed for NEC Class I Division 2 areas Calibration Store last calibration and verification data Selectable calib...

Page 21: ...conds at 1 0 l min 2 scfh to 90 of 2 decade step change Repeatability Percent 0 5 of reading or 0 1 O2 absolute whichever is greater PPM 0 5 of reading or 0 1 PPM O2 absolute whichever is greater Drif...

Page 22: ...TES 1 All static performance characteristics are with operating variables con stant 2 System accuracy referenced to 0 1 to 10 calibrated range 3 Response is to calibration gas Remote Calibration Unit...

Page 23: ...reason Qualified service personnel should 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 h...

Page 24: ...ure is outside the specified limits or the vibration is excessive please contact Thermox Sales or Service Department at 412 828 9040 Special options exist to address ambient temperatures outside the l...

Page 25: ...sor Provide at least six inches clear ance above the sensor so you can later replace the cell The cell is replaced by lifting it through the top of the sensor enclosure The sensor should be located as...

Page 26: ...ns Span gas Minimum one decade above zero gas 10 times greater For example if zero gas is 1 0 span gas must be 10 or higher If zero gas is 0 1 span gas must be 1 or higher Zero gas from 0 1 ppm to 10...

Page 27: ...y Provided Re mote Calibration Unit Setup section below or the signals from the con trol unit to create your own remote calibration sequence using your own control valves to switch between the process...

Page 28: ...times reduces calibration gas expense and reduces the chance of contaminants in the calibration gas plumbing The maximum ambient temperature for the RCU should be less than 160 F 70 C Do the followin...

Page 29: ...5 RCU flow diagram Figure 3 4 RCU calibration gas connections Instrument air inlet 1 4 NPT F Zero gas inlet 1 8 NPT F regulated to 10 psi by RCU LEFT SIDE Calibration gas outlet to sensor cal gas inl...

Page 30: ...s an example of a calibration setup using the factory pro vided RCU Figure 3 6 RCU calibration setup example SERIES 2000 CONTROL SAMPLE GAS VACUUM TO PULL SAMPLE REMOTE CALIBRATION UNIT PROCESS CAL CO...

Page 31: ...igure 3 7 Control Unit signals to initiate a remote calibration CONTROL SIGNALS HIGH OR LOW SIGNAL FROM CONTROL UNIT Calibration Control Signal labeled Aspirator on control unit System Calibrating Hig...

Page 32: ...panel mounting dimensions for the Series 2000 weatherproof enclosure Use 1 4 diameter fasteners to mount the control unit to the panel Weatherproof Wall Pole Figure 3 9 shows the wall and pole mountin...

Page 33: ...r and control unit for 1 hour while maintaining purge air flow before door is opened unless the area is demonstrated to be non haz ardous Z Purge Startup Procedure Power shall not be restored after th...

Page 34: ...nel mounting dimensions for the Series 2000 general purpose enclosure This version can be mounted in panels up to 1 thick General Purpose Wall Figure 3 13 shows the mounting dimen sions for the Series...

Page 35: ...ontrol unit Figure 3 14 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 wi...

Page 36: ...t AC mains supply wiring to sensor Control unit to sensor Control unit to remote calibration unit Control unit to alarm devices Control unit to current output devices Control unit to host computer RS...

Page 37: ...codes for your location Follow proper grounding shielding and noise protection practices as described in this section Use twisted pair cable with an overall braided shield or twisted pair cable in rig...

Page 38: ...tch or circuit breaker as the control unit disconnecting device AC L and N markings are provided by the terminal block for connection of AC power These markings are for reference purposes only such as...

Page 39: ...hod Shield Ring Method Connect all shields for that conduit entry other than power to a sup plied shield terminal ring see Figure 3 16 This shield ring is a stain less steel ring with a metal tab Plac...

Page 40: ...oad as possible Examples of transient 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 inductiv...

Page 41: ...and sensor before making sensor con nections This section describes required wiring connections between the control unit and the sensor Follow the connection instructions for the applicable options f...

Page 42: ...ck 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 an...

Page 43: ...or and within easy reach of an operator Mark the switch or circuit breaker as the sensor disconnecting device Standard Sensor Connections Make these connections from the control unit to the dry sensor...

Page 44: ...outputs 1 and 2 are capable of driving up to 1200 ohm loads The standard control unit with no options provides two current outputs These two current outputs 1 and 2 are isolated from the control unit...

Page 45: ...Installation 3 23 Figure 3 20 Current output connections example...

Page 46: ...then the watchdog alarm will reset The system will retain in memory the last time the watchdog condition occurred see the Exception Log segment in the Alarm Key section for help on how to view this in...

Page 47: ...Installation 3 25 Figure 3 21 Series 2000 standard alarm connections...

Page 48: ...RCU ASPIR Process Cal Control Valve Signal SPAN1 15 on RCU VALVE COMMON 16 on RCU Digital Input to Initiate Remote Calibration Unit The digital input connections on the wiring card allow you to initi...

Page 49: ...Installation 3 27 Figure 3 22 Series 2000 controller RCU connections...

Page 50: ...wire communications on the wiring card are labeled as follows 4WTX 2W 4WTX 2W Connect all the 2 wire pluses and all the 2 wire minuses in parallel with all the devices in a daisy chain fashion includi...

Page 51: ...Installation 3 29 Figure 3 23 Series 2000 2 wire RS 485 communications connections...

Page 52: ...r 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 120 ohm...

Page 53: ...Installation 3 31 Figure 3 24 Series 2000 4 wire RS 485 communications connections...

Page 54: ...display module or power supply keypad module on the control unit see Figure 3 25 1 Open the access door below the display module hinges down 2 Pull on the handle of the power supply keypad module and...

Page 55: ...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 power supply keypad module Removing an Option Card D...

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Page 57: ...er provides a brief overview on how to use the Series 2000 con trol unit This includes the following topics Areas of the Control Unit Password Restrictions Control Unit Display Auto Ranging Feature Co...

Page 58: ...ay module The con trol unit is operated by pressing keys on the keypad Password Restrictions For menu options to change system settings in which a password is required you must first enter the passwor...

Page 59: ...alarm condition is reached an Up Arrow will appear next to the high hydrocarbon message Auto Ranging Feature If the oxygen reading falls below 0 5 O2 the display switches from the percent scale to th...

Page 60: ...isplay line it indicates that there are more menu options available by pressing the Up Arrow Key Exiting Menu Options To cancel out of a specific menu press the Cancel Key To exit all menus continue t...

Page 61: ...Pres sure Perform system tests System Tests View the serial and manufacturing number for your control unit Sys tem Serial Perform a primary calibration on the sensor Primary Calibration This is not a...

Page 62: ...t info for Display Line 1 Select info for Display Line 2 Select info for Display Line 3 Passwords Create a system password Process Pressure Select a positive or negative process pressure Enter process...

Page 63: ...end that you put the information that is most critical for you to view on the first and second display lines Setting Up the Display 1 Select Display from the Setup menu 2 Select Display Line 1 Display...

Page 64: ...to the Capital letter A Pressing the number 3 Key moves you to the Capital letter Z Pressing the number 7 Key moves you to the small letter a Pressing the number 9 Key moves you to the small letter z...

Page 65: ...e provided so you can access this 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 fou...

Page 66: ...tup Key menu 2 Select Positive Pressure or Negative Pressure You are then prompted to enter your system process pressure Pressure xxx x kPa New Value 3 Enter your process pressure up to one decimal po...

Page 67: ...Memory RAM 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 p...

Page 68: ...y 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 opera tion and troubleshooting System Serial Thi...

Page 69: ...hould 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 615 C 0 9 683 C If you measure the voltage at terminals C and D...

Page 70: ...ell Temp C Max T C Ratio Min T C Ratio 615 1 3 0 7 650 1 24 0 74 695 1 22 0 777 824 1 139 0 861 790 same as 824 C For a cell operating temperature of 615 C the T C ratio low limit is 0 7 and the high...

Page 71: ...it you will be prompted to select Auto Calibrate Remote Calibrate or Manual Calibrate If you don t have the auto calibration option you will be placed into a manual calibration where you will be told...

Page 72: ...drocarbon upset condition If the oxygen reading drops to 0 PPM and the millivolt value you entered is reached or exceeded the system displays a low oxygen high hydrocarbons message rather than the ox...

Page 73: ...e that each control unit must be assigned a unique address other wise communication results will be unpredictable Enable Serial This option allows you to temporarily disable control unit serial com mu...

Page 74: ...to do the following Define what information should be sent to the analog output port during a calibration Decide whether to hold the output at the last process reading taken before the start of calib...

Page 75: ...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 Figure 4 5 Overview of Analo...

Page 76: ...ntification of the password the numbers you enter will not be displayed You will then be able to access Analog Range Key functions Analog Output Port Before you can define any Analog Range Key functio...

Page 77: ...the selected current output represents 1 Select Set Current Range from the Analog Range Key menu after selecting an analog output port 2 If tracking oxygen select whether you want to enter the 20 mA...

Page 78: ...le you can elect to hold the last process reading during verifica tions but track calibration gas readings during calibrations Setting track or hold 1 Select Set Track Hold from the Analog Range Key a...

Page 79: ...a 0 to 20 or 4 to 20 mA analog output range for the selected analog output port This output is dependent on both the range of readings you define see the Set Current Range section and on the function...

Page 80: ...Analog Range Key after selecting an analog output port You will be prompted to enter an output filtering value 100 FAST 1 SLOW Fltr XX New where XX is the current filter value Note that 100 equals no...

Page 81: ...lts cell mv Selecting the function 1 Choose Select Function from the Analog Range menu after selecting an analog output port 2 Select the function you want the selected analog output port to track see...

Page 82: ...ing temperature See the Wiring section in the Installation chapter for help on alarm con nections and how alarms are labeled on the control unit wiring card The Alarm Key allows you to set control uni...

Page 83: ...ize or de energize on alarm Relay Configure The selection you make using the Relay Configure menu option applies to all alarms except the watchdog and service alarms which always de energize on alarm...

Page 84: ...on alarm fail safe ALARM NUMBER FUNCTION Select Function Alarm Configure Relay Configure Alarm 3 O2 Cal Start Verify Start High O2 Alarm Low O2 Alarm Only selectable if Select Function is oxygen Disa...

Page 85: ...O2 alarm and Alarm 4 for a high O2 alarm and the O2 value exceeds both the Alarm 3 and Alarm 4 set points two up arrows will appear next to the O2 value on the display Defining alarm set points Do the...

Page 86: ...lies only if it is set to track oxygen levels O2 If Alarm 3 is set to trigger at the start of a cali bration or verification this option does not apply If you select Hydrocarbon Upset as the Sensor Co...

Page 87: ...n alarm This menu option applies to all alarms except for the service and watchdog alarms which are always set to de energize on alarm fail safe Configuring the relay 1 Select Relay Configure from the...

Page 88: ...ry duration you have specified If you select Hydrocarbon Upset as the Sensor Config option from the Setup Key menu Alarm 4 is fixed as both a high oxygen alarm and the alarm that triggers during a hyd...

Page 89: ...ormally closed system failure causes open contacts The watchdog alarm relay de energizes when the system watchdog timer times out The watchdog timer will time out and cause the control unit to reset i...

Page 90: ...most recent exception 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 lo...

Page 91: ...i brate your analyzer The Series 2000 control unit provides features that make calibrating your analyzer easy and even includes a way for the system to periodically calibrate itself All oxygen alarms...

Page 92: ...tions require a remote calibration unit RCU that automatically switches the calibration gases and an auto calibration card installed in your control unit Manual cali brations are performed without an...

Page 93: ...he 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 CALIBRATE KEY Menu Options Functions Options I...

Page 94: ...d during a calibra tion Password System passwords are created using the Setup key Please see the Password section in the Setup Key section of the Controller User Interface chapter for information on d...

Page 95: ...sing the Set Cal Timers Set Auto Timers menu option Once you ve set these cycle times you don t need to select the Initiate Cal menu option to run an automatic calibration See the Remote Calibration U...

Page 96: ...me period for the system to recover from reading the cali bration gas value to reading process gases Set Cal Timers Recovery Duration Start the auto calibrate as follows 1 Select the Initiate Cal opti...

Page 97: ...ft of the display had stabilized yet is not near the setpoint value on the far right of the display you should check the cal gas value you entered to ensure that this value matches the cal gas cylinde...

Page 98: ...brate You are then prompted to apply the O2 span gas to the calibration gas inlet port of the sensor tubing must be free of oil and dirt Inject Span Gas Vrfy Gas ENTER to Continue CANCEL to Abort 4 Pr...

Page 99: ...e Enter key once the zero gas reading on the left of the display has stabilized The reading on the far right of the first display line shows the setpoint value you entered for the O2 zero gas using th...

Page 100: ...elp on how to trigger an automatic calibration using a digital input If using a digital input to trigger the auto verify you must make sure that for the Setup Key Remote Switch Config selection must b...

Page 101: ...ote Verify To initiate a remote verify do the following Enter the verify gas value to match the verify gas cylinder you intend to use to verify your system and also determine the acceptable verify ran...

Page 102: ...atch Then the system will display the recovery time remaining Recovery xx xx System Verifying Cal After the recovery period the system returns to process readings Manual Verify 1 Enter the verify gas...

Page 103: ...nt value should match the value on your verify gas cylinder If your O2 reading on the far left of the display has stabilized yet is not near the set point value on the right of the display check the c...

Page 104: ...e value the system reads from the cal gas The term Span Drift or Zero Drift is the difference between the entered calibration gas value and the calibration gas values read by the system Both the lates...

Page 105: ...ibration was completed If this occurs reset the analyzer s time and date Verify data For verify data the display shows the verify gas data Verify Value xx Verify Gas xx Verify Diff xx The term verify...

Page 106: ...Gas Value from the Calibrate key menu 2 Choose whether you wish to enter the span gas value using a percent or PPM scale You are then prompted to enter the span gas value Span Gas xx New Value 3 Enter...

Page 107: ...gas pressure and flow requirements It is important that all calibration gases as well as the sample gas flow through the analyzer at the same flow rate 1 Connect the span and zero gas cylinders to th...

Page 108: ...gas to the sensor Zero gas is flowing 4 Adjust the pressure and flow for the zero gas to the desired levels You will then be prompted to end the cycle CANCEL to quit 5 Press the Cancel key to end the...

Page 109: ...e 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 switc...

Page 110: ...rs from the Set Cal Timers menu 2 Select Auto Cal Cycle if defining an automatic calibration cycle Se lect Auto Verify Cycle if defining an automatic verification cycle 3 Select Set Cycle in DAYS or S...

Page 111: ...or verification will take place at midnight Set Cal Timers Set Time and Date This menu option allows you to set the date or time for the internal con trol unit clock Make sure the current time and dat...

Page 112: ...emporarily disable the automatic calibration or verification cycle When the process is again operating you can re enable the auto calibration or verification cycle and retain all your timer settings 1...

Page 113: ...l be prompted to enter the new span gas duration time O2 Span Time xx yy Enter new time Mn Sc 2 Enter the new span gas duration time then press the Enter key If performing an automatic verification en...

Page 114: ...your last calibration gas is 2 this option gives the system time to recover back to reading the 6 process gas This menu option also can be used to prevent triggering of alarms if for example your low...

Page 115: ...press the Enter key If you wish to keep the current verify gas value unchanged press the Enter key without entering a value 4 Enter the acceptable verify range For example if you enter a verify gas ra...

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Page 117: ...d the sensor has been allowed to cool for at least one hour Always wear gloves when working on sensor components This chapter describes Series 2000 control unit system error messages as well as troubl...

Page 118: ...Aborted This message indicates that the calibration has been aborted by the user Calibration Required This message is displayed to inform the operator that a regular calibra tion is required after a p...

Page 119: ...emoving and restoring power to the unit Primary Calibration This message appears when the system is performing a Primary Calibra tion The message continues to be displayed during the one hour recov er...

Page 120: ...e The software shuts off the furnace until the temperature returns to normal operating range If this message soon goes away it indicates that the temperature has returned to an acceptable range If the...

Page 121: ...g and then restoring power to the unit If you see this message you should reset the control unit to the values required for your application including Setup Key Calibrate Key Alarm Key and Analog Rang...

Page 122: ...ction circuit trip on the sensor board Sensor board failure Loss of furnace drive signal from control unit Thermocouple failed shorted or opened Interconnecting wiring problem Polarity of thermocouple...

Page 123: ...ithin the range you defined If you receive this message calibrate the analyzer Zero Gas Range Error This error message occurs if the calibration zero gas does not read within the software s allowable...

Page 124: ...echnical support Diagnostic checks are broken down as follows Wiring checks Thermocouple checks Calibration aspirator setup checks AC power checks Furnace checks Process pressure checks Cell checks Ex...

Page 125: ...K test meter First display the thermocouple millivolts on the front panel display The display should measure a positive voltage If the display measures a negative voltage reverse the wires leading to...

Page 126: ...ce the fuse 1 4 amp 125 volts IEC speed type FF Check the interconnecting wiring for shot circuits before applying power to the control unit If you do not measure 15 volts at terminals 2 and 12 of the...

Page 127: ...the display module to sense the current sourced from the AD592 The compensation current produces a voltage drop across the resistor on the display module and then adds this voltage to the raw T C mVs...

Page 128: ...alibration chapter for help on how to set up flow and inlet pressure Check that the PPM calibration gas cylinders are made of aluminum and not steel Check that the calibration gas cylinders are less t...

Page 129: ...ignal 3 Connect the vacuum port side of the pressure gauge for example a Magnehelic gauge to the T fitting 4 Connect the sample gas outlet to the T fitting 5 Connect an aspirator to the T fitting 6 Co...

Page 130: ...ignal present verify the proper flow If no signal is present check the interconnecting wiring between the control unit and the RCU If wiring is correct replace the Auto Cal Card If the solenoid drive...

Page 131: ...ge Select the Cal Gas Duration option from the Calibrate Set Cal Timers menu to set calibration gas times If performing a manual calibration ensure that you are waiting for the reading to stabilize on...

Page 132: ...FURNACE and 15V COM on the control unit wiring card for the furnace drive signal If the signal is not present check fuse F1 on the wiring card If this fuse is OK replace the control unit power supply...

Page 133: ...ssion fitting and pipe thread connections are leak tight You can check for leaks by sniffing the fittings with another gas Use a piece of tygon or plastic tubing with a 1 8 stainless steel nozzle to a...

Page 134: ...es 2000 controller auto calibration card LEDs are clearly labeled on the card All auto calibration card LEDs denote that the Series 2000 controller has sent out a 15 volt signal to the RCU to activate...

Page 135: ...controller or sensor unless power has been removed from the control ler and sensor and the sensor has been allowed to cool for at least one hour This chapter shows you how to replace system parts and...

Page 136: ...grees F 260 degrees C inside the cover even after power has been removed from the sensor Use caution and wear appropriate gloves when handling system com ponents Always use a backup wrench when workin...

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Page 138: ...pplied cell O ring Avoid touching the bare cell instead hold the cell by one of its hex nuts 7 Place the new cell O ring on top of the cell housing as shown in Fig ure 7 1 8 Insert the new cell into t...

Page 139: ...Service and Parts 7 5 Figure 7 1 Cell replacement...

Page 140: ...ce It should go in freely if necessary wiggle a little to position without forcing it in The thermocouple should be near but not touching the cell housing or furnace heater coil 6 Put the screw back i...

Page 141: ...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 142: ...and remove the convection loop mounting clamp being sure to save the mounting clamp and screws for when you install the new furnace 6 Gently pull the cell housing out of the furnace and remove the fur...

Page 143: ...Service and Parts 7 9 Figure 7 3 Furnace replacement...

Page 144: ...N 80467SE P N 70718SE P N 88021QE Remote Calibration Unit RCU Remote Calibration Unit PPM P N 90296JE Calibration Gas Solenoid Valve P N 25370JE When ordering provide the serial number of your analyz...

Page 145: ...ntrol unit must match the baud rate of the host device Baud rates are user programmable See the Communication section in the Setup Key Chapter for help on defining control unit baud rates The communic...

Page 146: ...ds 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 preceding characters excluding the charact...

Page 147: ...hese variables and their location codes If a variable is selected beyond the end of the Variable Table shown an error will be returned The value returned is followed by a text string for the units whe...

Page 148: ...is used to read the date and time of the last calibration and 2 is used to read the date and time of the last verification Date and time is returned as mm dd yy hh mm in 24 hour military time Set Dat...

Page 149: ...mat 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 describe...

Page 150: ...n provides the command letters you can use Figure A 1 Serial communication commands list Command Letter Description A Echo B Bad Command C Acknowledge F Read Number G Calibrate H Write Number J Data F...

Page 151: ...a returned it will follow the A and have a checksum after it All responses end with a car riage return Examples A Simple acknowledge AFF0050 Acknowledge with data Failure All failure responses start w...

Page 152: ...escription 01 Bad command letter 02 Bad checksum 03 Input overrun in serial communica tion 05 Parameter out of range 08 Error in receipt of a character 09 Cannot calibrate verify now 0A Internal error...

Page 153: ...tes 03 Iout_flags see Table A 7 Read Write H 2 bytes 04 Probe_type Type of probe Read Write U connected to 0 Insitu system 1 WDG 2 HP 3 TM2000 4 3 in 1 05 Line1_flg Display Line 1 Read Write U 0 off 2...

Page 154: ...ags_3 variable table Bit Description Read Write Format 0 sensor at op temp 1 over under temp 2 inject cal gas active Read Only 1 true 0 false 3 auto cal is active 4 auto verify is active 5 reserved 6...

Page 155: ...ro gas range error 3 span gas range error 4 primary calibration 5 memory is corrupted 6 excessive cal error Read only 1 true 0 false 7 calibration required 8 thermocouple failure 9 thermocouple compen...

Page 156: ...Reserved N A 5 auto verify time is set 1 true 0 false 6 auto verify timer is enabled 1 false 0 true 7 auto cal cycle 1 hours 0 days programmed in hours days 8 auto verify cycle All Read Write 1 hours...

Page 157: ...track 0 hold 5 track hold output 2 during verify 1 track 0 hold 6 current mode select for output 2 All Read Write 1 0 20 mA 0 4 20 mA 7 Reserved N A 8 track hold output 3 during cal 1 track 0 hold 9 t...

Page 158: ...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 tha...

Page 159: ...gative 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...

Page 160: ...Values Span Gas Zero Gas Inject Cal Gas N A Set Cal Timers see Set Cal Timers table Configure Verify Define Verify Gas Value Define Verify Gas Acceptable Range CALIBRATE KEY SET CAL TIMERS SUBMENU FUN...

Page 161: ...3 only O2 Start of Calibration Start of Verify Exception Log N A Figure B 5 Analog Range Key menu ANALOG KEY MENU OPTIONS FUNCTIONS OPTIONS Set Current Range Range of readings that the analog output...

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Page 163: ...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...

Page 164: ...pply and a load device All current output channels IOUT1 and IOUT2 can be connected in the same manner as shown in this figure IOUT1 and IOUT2 must share the same power supply if both of these chan ne...

Page 165: ...Outputs Other Applications C 3 Figure C 1 Modulation of external power supply OUTPUT DEVICE COMPUTER OR CHART RECORDER MAX LOAD RESISTANCE 1200 OHMS OPTIONAL EXTERNAL LOOP POWER SUPPLY MAX VOLTAGE 30...

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Page 167: ...s any custom drawings or instructions you have ordered If you didn t order any cutom options the standard Interconnect drawing is provided If you ordered special options the drawings or special instru...

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