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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 experienced in electrical safety techniques.

There are no operator-serviceable components inside the WDG system.
Never service the controller or sensor unless power has been removed
from the controller and sensor, and the sensor has been allowed to cool
for at least one hour. Also, always use gloves when working on the sensor.

This chapter describes Series 2000 control unit system and error messages.
It also provides troubleshooting assistance. System and error messages
appear on the fourth line of the display at three second intervals until the
condition is corrected or has ended. If there is more than one message, the
messages will alternate on the display at three second intervals. These sys-
tem and error messages are listed in this chapter 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

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Summary of Contents for Thermox Series 2000 WDG-IV

Page 1: ...Thermox Series 2000 WDG IV WDG IVC WDG IVCM User Manual Thermox 150 Freeport Road Pittsburgh PA 15238 PN 90269VE Rev Y ...

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

Page 3: ... Technical Support 1 10 CHAPTER 2 Specifications Series 2000 Control Unit 2 1 Sensor WDG IV 2 2 Sensor WDG IVC 2 3 Sensor WDG IVCM 2 4 Sensor WDG IVC 0 500 PPM 2 6 Remote Calibration Unit RCU 2 7 CHAPTER 3 Installation Analyzer Location 3 1 Inspect Shipping Contents 3 2 Mechanical Installation 3 3 Sample Inlet Probe Installation 3 3 Probe Heater Installation 3 6 Exhaust Tube Installation 3 7 Senso...

Page 4: ...splay 4 1 Selecting Menu Options 4 2 Exiting Menu Options 4 2 Automatic Menu Exit Feature 4 3 On Line Help 4 3 System Password 4 3 Setup Key 4 4 Display 4 5 Process Pressure 4 7 System Tests 4 8 System Serial 4 8 Primary Calibration 4 9 Sensor Config 4 12 Communication 4 13 Combustibles Option 4 13 Analog Range Key 4 14 Analog Output Port 4 15 Set Current Range 4 15 Set Track Hold Option 4 16 Set ...

Page 5: ...nject Cal Gas 5 18 Set Cal Timers 5 20 Set Auto Timers 5 21 Set Time and Date 5 22 Auto Cal On Off 5 22 Cal Gas Duration 5 23 Recovery Duration 5 24 Set K Factors 5 25 Sensitivity 5 25 Chapter 6 Maintenance and Troubleshooting System Messages 6 2 Auto Cal Pending 6 2 Auto Verify Pending 6 2 Calibration Aborted 6 2 Calibration Required 6 2 Cal Verify Aborted 6 2 Power Down Detected 6 2 Primary Cali...

Page 6: ...ling Sample from Process 6 12 Series 2000 LEDs 6 13 Auto Calibration Card LEDs 6 13 Combustibles Card LEDs 6 13 Combustibles and Methane Card LEDs 6 14 Sensor Board 80471SE LEDs 6 14 Chapter 7 Service and Parts Cell Replacement Cleaning 7 4 Thermocouple Replacement 7 6 Furnace Replacement 7 8 Combustibles Detector Replacement 7 10 Hot Wire Combustibles Detector Replacement 7 10 Box Heater Diagram ...

Page 7: ...Current Outputs Other Applications Powering Current Outputs from an External Power Supply C 1 Modulation of External Power Loop Using Current Outputs C 3 Appendix D Drawings and Custom Instructions Appendix E Series 2000 Controller Setup Parameters ...

Page 8: ... Electrical Safety Up to 5 kV may be present in the analyzer housings Always shut down power source s before performing maintenance or troubleshooting Only a qualified electrician should make electrical connections and ground checks Any use of the equipment in a manner not specified by the manufacturer may impair the safety protection originally provided by the equipment Grounding Instrument groun...

Page 9: ... MODULES WARNING 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 GROUPS A B C AND D OR NONHAZARDOUS LOCATIONS ONLY The maximum ambient temperature for the Series 2000 control unit is 50 C 122 F The Series 2000 Control Unit with WDG IV sensor is a complex piece of equip m...

Page 10: ...l waste system residential trash The Wheelie Bin marking on this product is a reminder to dispose of the product properly after it has completed its useful life and been removed from service Metals plastics and other components are recyclable and you can do your part by doing one of the following steps When the equipment is ready to be disposed of take it to your local or regional waste collection...

Page 11: ...tput 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 or panels removed Use Proper Fuse To avoid fire hazard use only the fuse type and rating specified for this prod uct Do Not Operate in Explosive Atmosphere To avoid injury or fire hazard do not operate this product ...

Page 12: ...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 Listed Inspection and Measuring Electrical Equipment Low Voltage Directive 73 23 EEC EN61010 1 1993 Amendment A2 1995 Electrical Equipment for Measurement Controls and Laboratory Use Series 2000 Controller also ha...

Page 13: ... abuse or improper use Misuse or abuse of the equipment or any part thereof shall be construed to include but shall not be limited to damage by negligence accident fire or force of the elements Improper use or misapplica tions shall be construed to include improper or inadequate protection against shock vibra tion high or low temperature overpressure excess voltage and the like or operating the eq...

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Page 15: ...ve the dewpoint of the gas Follow these cautions when working on the sensor Do not turn on the aspirator until the analyzer has been turned on and is hot preferably 24 hours Also if you turn off the analyzer or the process is shut down turn off the aspirator air to avoid plugging problems Remove AC power from the sensor and control unit and allow the sensor to cool for at least one hour before per...

Page 16: ...nace from the AC mains connected to the sensor This board also provides cold junction compensation to the thermocouple circuit The Oxygen Measuring Cell The sensing element itself is a closed end tube or disk made from ceramic zirconium oxide stabilized with an oxide of yttrium or calcium Porous platinum coatings on the inside and outside serve as a catalyst and as electrodes At high temperatures ...

Page 17: ...la tion The oxygen content is then determined from the Nernst equation E In RT 4F O1 O2 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 measuring oxygen in non combustibles gases the calibration of an analyzer is obtained from the formula AT 48 0 at 695 C E A T Log 20 9 O2 Unk Where A is a constant T is the cell te...

Page 18: ...in the gas net oxygen content Hydrocarbons When hydrocarbons are present in the gas sample a combustion process occurs when this gas sample is exposed to the high temperature of the zirconia cell An indication that hydrocarbons may be present in the gas sample is that the oxygen reading will be lower than expected For exam ple if a calibration gas cylinder has an oxygen value of 20 PPM and 5 PPM o...

Page 19: ...at use natural gas for start up and oil fuel gas or coal for primary fuel Process gas is drawn into the analyzer s primary sample loop by an aspirator and returns to process Gas enters the split flow block that is separted by a baffle and contacts the hot wire catalytic combustibles and methane detector It then passes the zirconium oxide cell where the oxygen concentration is measured before retur...

Page 20: ...k and contacts RTD type combustibles detec tor The gas then travels into the hot wire methane detector flow block where it contacts the methane sensor It then passes the zirconium oxide cell where the oxygen concentration is measured before returning to the main sample loop and then back to the process ZIRCONIUM OXIDE OXYGEN CELL HOT WIRE TYPE METHANE DETECTOR RTD TYPE COMBUSTIBLES DETECTOR ASPIRA...

Page 21: ...We recommend that you use an even mixture of CO and H2 as the combustibles component within your span gas although you can also use all CO if needed The combustibles span gas for calibration should be 60 to 80 ppm range or 40 to 60 percent ranges of the selected combustibles recorder output range Methane The Methane Detector is a dual element device The elements differ only in that one is coated w...

Page 22: ...analyzers if they contain a mixture of oxygen and combustibles Note however that this is acceptable for combustibles span gases used only if you purchased the combustibles option Always introduce calibration gases at the recommended flow rate When working on the plumbing inside the sensor cabinet turn the power off The oxygen cell heater has exposed windings and a short to the plumbing will blow t...

Page 23: ...upply to the aspirator air supply inlet but DO NOT turn on the air until the sensor is at operating temperature If the analyzer is turned off or the process is shut down the aspirator air should be turned off to avoid plugging problems Do not create any additional conduit entries in the enclosure Interconnect the control unit and the sensor per the appropriate inter connecting drawing The specifie...

Page 24: ... by the factory 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 display this information on your Series 2000 control unit If you need to return equipment you will be asked to provide the follow ing information before obtaining a Return Material Authorizati...

Page 25: ...arms optional Set relays to energize or de energize on alarm Contact Rating 1A 30V max noninductive load AC or DC Diagnostics Watchdog timer and service alarms System test for A D RAM EEPROM and keypad Display Line 4 reserved for full text error and diagnostic mes sages Twenty entry event log Calibration Oxygen cell lifetime extender Calibrate or verify calibration Store last calibration and verif...

Page 26: ...r gauge Environment Ambient Temp 5 F to 160 F 20 C to 71 C 5 F to 140 F 20 C to 60 C with Div 2 Option Relative Humidity 10 to 90 non condensing Enclosure Lift off NEMA 3R weather resistant stainless steel Optional hinged NEMA 4X IP56 explo sion proof purged and floor mount versions available Power Requirements 115 VAC 10 47 63 Hz 600VA max 650 VA max floor mount op tion 230 VAC 10 47 63 Hz 1850 V...

Page 27: ...20 C to 60 C with Div 2 Option Relative Humidity 10 to 90 non condensing Enclosure Lift off NEMA 3R weather resistant stainless steel Optional hinged NEMA 4X IP56 explo sion proof purged and floor mount versions available Power Requirements 115 VAC 10 47 63 Hz 600VA max 650 VA max floor mount option 230 VAC 10 47 63 Hz 1850 VA max 1900 VA max floor mount option Calibration Gas Requirements Use cal...

Page 28: ...4 L min at 15 to 100 psig 1 05 to 7 04 kg cm2 Max Flue Gas Temp Probe Type Lengths 1300 F 704 C 1875 F 1024 C 3000 F 1649 C 316 SS 310 SS Hexoloy 36 108 91 cm 271 cm 36 108 91 cm 271 cm 24 72 60 cm 182 cm Max Sample Dewpoint 392 F 200 C Sample Pressure 10 inch water gauge Environment Ambient Temp 5 F to 160 F 20 C to 71 C 5 F to 140 F 20 C to 60 C with Div 2 Option Relative Humidity 10 to 90 non c...

Page 29: ...s for RTD Type Combustibles Detector Use calibration gases 10 PSIG 1 5 SCFH 0 70 kg cm2 0 7 L min O2 Span Gas Air or from 1 0 to 100 O2 balance N2 Comb CH4 Span Gases From 0 1 to 10 O2 balance N2 Comb Span Gas Use a combined combustibles and methane span gas containing 60 to 80 of the full scale combustibles operating range in certified mixtures of CO or CO H2 2 CH4 8 to 10 O2 balance N2 System Co...

Page 30: ... F to 140 F 20 C to 60 C with Div 2 Option Relative Humidity 10 to 90 non condensing Enclosure Hinged stainless steel weatherproof NEMA 4X IP56 Flame arrestors standard Optional CENELEC and NEC Class I Division 2 available Power Requirements 115 VAC 10 47 63 Hz 600VA max 650 VA max floor mount option 230 VAC 10 47 63 Hz 1850 VA max 1900 VA max floor mount option Calibration Gas Requirements Use ca...

Page 31: ...bustibles Methane RCU Enclosure UL Type 4X NEMA 4X IP56 Environment Ambient Temperature Humidity Max Altitude IEC Installation IEC Pollution Degree 2 18 C60 C 0 to 90 non condensing 2000 Meters Category II System Compliance EMC Compliance 2004 108 EC Safety Compliance 73 23 EEC ...

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Page 33: ...id plugging problems Analyzer Location Observe the following guidelines when selecting an analyzer installation location 1 Select a readily accessible position for the analyzer to allow for routine maintenance Comfort levels for maintenance personnel should be considered in placement of the sensor and control interface 2 The installation location should be free from excessive vibration and the amb...

Page 34: ... have an oxygen only analyzer without the combustibles option the combustibles and methane options described in this chapter do not apply These combustibles and methane sections are clearly identified Likewise if you have the combustibles option but not the methane option 3 in 1 analyzer you can skip all sections pertaining to methane Inspect Shipping Contents Remove any packing material from the ...

Page 35: ... exhaust tube Therefore these subjects are discussed before the sections on how to mount the sensor to the process The sample inlet probe is how the sample gas gets to the sensor Aspira tor air within the sensor is used to pull process gas from the sample probe into the sensor The sample inlet probe is identified by the threads on both ends Figure 3 1 shows how to install the standard 1 8 NPT prob...

Page 36: ...on Connect a standard 1 8 NPT sample inlet probe to the sensor as follows If your probe is 4 feet or less simply screw the probe into the back of the sample probe port on the rear of the sensor then mount the sensor see Figure 3 1 Figure 3 1 WDG IV 1 8 NPT probe installation ...

Page 37: ...o do this loosen the fitting connecting the inlet hook to the aspirator block and pull the hook out of the sensor 4 Unscrew the bushing that was plugged into the sensor inlet port and discard The probe comes with its own bushing and fitting 5 Thread the sensor probe into the sensor inlet port on the sensor backplate Do not let the probe hit against the Thermox provided pipe nipple as you insert th...

Page 38: ...ch the optional probe heater to the probe heater port on the backplate of the sensor to heat the sample gas see Figure 3 3 This will prevent plugged plumbing due to condensation of the sample gas For example when a fuel containing only a few thousand parts per million of sulfur is burned with a high level of excess oxygen over 4 percent the resulting sulfuric acid mist may condense at temperatures...

Page 39: ...ensor to the process Enclosed in the envelope with the probe heater is a stainless steel exhaust tube that allows you to extend the aspirator exhaust The exhaust tube can be identified by having a thread on only one end of it To install the exhaust tube thread the exhaust tube into the exhaust port on the rear of the sensor as shown in Figure 3 3 Sensor Mounting The sensor ambient temperature rang...

Page 40: ...cess using a customer supplied pipe nipple using a customer supplied flange Each of these methods is explained in the sections that follow The flush mount method is preferred because it positions the sensor as close to the process as possible and minimizes the chances of the sample gas cooling below its dewpoint Figure 3 4 Mounting dimensions Lift off sensor ...

Page 41: ...clud ing the Z purge option are provided in Figure 3 5 If the protection nipple provided by AMETEK Thermox extends past the inside of the refractory wall on a process that has a gas tempera ture over 1200 F 650 C the nipple should be cut down before installation in order to remain flush with the inside wall Figure 3 5 Mounting dimensions Hinged sensor NOTE ...

Page 42: ... possible and mini mizes any chance that the sample gas will cool below its dewpoint Figure 3 6 WDG IV sensor flush mount preferred Customer supplied pipe nipple sensor mounting If you can t mount the sensor flush with the process as described in the previous section for example the process wall is curved sharply covered with insulation or obstructed with reinforcing members you can instead 1 Weld...

Page 43: ...tomer supplied pipe nipple sensor mounting 2 Weld the 7 x 7 5 8 17 78 cm x 19 37 cm supplied plate to the end of the nipple taking care to center it over the hole 3 Wrap the nipple with at least 1 2 54 cm weatherproof insulation and heat trace it 4 Then bolt the sensor to the plate If mounting the sensor using this method you can also install the probe heater to minimize the possibility of the sam...

Page 44: ...lows 60 to 80 ppm range or 40 to 60 range of the full combustibles operating range in certified mixtures of CO or CO H2 with an equal amount of O2 balance N2 For example if using an operating range of 0 to 2000 ppm combus tibles use 800 ppm CO 800 ppm H2 1 to 2 O2 balance N2 If using a 0 to 1 combustibles range use 0 3 CO 0 3 H2 1 to 2 O2 balance N2 Combustibles Span Gas for 3 in 1 If using a WDG ...

Page 45: ...ure indication in order to meet NFPA 496 requirements You must not exceed the maximum temperature rating listed in the specifications Process pressure is assumed to always be subatmospheric vacuum unless the High pressure option is installed The WDG IV sensor contains a flame arrestor to prevent it from being an ignition source to the process for short periods of high combustible levels 25 of LEL ...

Page 46: ... be nonhazardous The Z purge apparatus provided by Thermox meets NFPA 496 under certain conditions Power must not be restored after the enclosure has been opened until the enclosure has been purged for 65 minutes at a pressure of 0 4 of water CAL GAS INLET 1 4 COMPRESSION FITTING LIFT OFF ENCLOSURE FRONT VIEW ASPIRATOR AIR INLET 1 4 NPT F CAL GAS INLET PORT 1 4 COMPRESSION FITTING INSTRUMENT AIR I...

Page 47: ...this is 5 psi Do not turn on the aspirator until the sensor has been turned on and is hot preferably 24 hours 2 A calibration gas inlet port is provided to allow you to calibrate the system as shown in Figure 3 9 During calibration you turn off the aspirator air supply and inject your calibration gases into the calibra tion gas inlet port on the sensor During normal operations you plug this calibr...

Page 48: ... 10 shows the panel mounting dimen sions for the Series 2000 weatherproof enclo sure Use 1 4 diameter fasteners to mount the control unit to the panel Figure 3 10 Series 2000 weatherproof panel mount Weatherproof Wall Pole Figure 3 11 shows the wall and pole mounting dimensions for the Series 2000 weatherproof enclosure For wall mount installations use 1 4 diameter fasteners to mount the control u...

Page 49: ...s nonhazardous Z purge shutdown procedure Remove power from the control unit for one hour while maintaining purge air flow before door is opened unless the area is demonstrated to be nonhazardous Z purge start up procedure Do not restore power after the enclosure has been opened until the enclo sure has been purged for 1 hour at a pressure of 0 4 of water Pressure Gauge 1 2 Conduit Entry 2 22 cm T...

Page 50: ... 26 4 95 12 57 General Purpose 19 Rack Figure 3 14 shows the mounting dimen sions for the Series 2000 general pur pose 19 rack mount enclosure Use 10 screws to mount the control unit to a rack whose holes are spaced per E I A stan dard RS 310 C universal spacing Figure 3 14 Series 2000 general purpose rack mount 4 Holes for 1 4 fasteners 10 38 26 37 11 38 28 90 11 5 29 21 10 26 26 06 7 65 19 43 Ge...

Page 51: ...ol unit Figure 3 23 shows the orientation of the wiring card for general purpose rack and panel mount versions for all other versions the wiring card is 180 degrees from this view To access the wiring card for all general purpose versions of the control unit unscrew the four screws on the wiring card chassis cover plate For the weatherproof versions of the control unit first open the front door of...

Page 52: ... long distances through conduit General Wiring and Conduit Requirements This section describes general wiring and conduit requirements Sensor wiring conductors must be rated at a minimum of 80 C All other wiring conductor ratings should be for the minimum tempera ture required for the equipment being connected to the analyzer but not less than 60 C Use only the applicable NEMA approved conduit fit...

Page 53: ... METHANE 8 to 40 ft 12 40 to 10000 ft must use remote sense 18 AWG Figure 3 17 Required sensor cable wiring minimum acceptable grades Control Unit Mains Supply Connections Do not run control unit AC mains supply wiring in the same conduit with other AC line power wires By keeping this wiring separated you prevent transient signals from reaching the control unit The Series 2000 control unit can ope...

Page 54: ...hielding and noise protection For EMC purposes under no circumstances should you leave cable shields disconnected at one end or both ends of the cable sensor or control unit or other device You must use twisted pair cable in rigid metal conduit or use twisted pair cable with an overall braided shield All cable shields or conduits connect ing to the control unit must be chassis grounded EMC groundi...

Page 55: ...I interference This section describes transient and RFI interference precautions Although there are transient and noise protectors on all control unit I O connections communications current outputs sensor etc this protection is intended to act as a last line of defense against unwanted transient and RFI interference Proper installation practices to prevent the introduction of transients and noise ...

Page 56: ... wiring should be connected to a circuit separate from any circuit that could introduce transients into the system As an example do not run mo tors blowers or air conditioners using the same mains supply circuit or conduit as the control unit s mains supply circuit or conduit Sensor Connections Make sure that power has been removed from the control unit and sensor before making sensor connections ...

Page 57: ...within easy reach of an operator Mark the switch or circuit breaker as the sensor disconnecting device AC L and N markings are provided by the terminal block for connec tion 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 any function safety or oth erwise The N termin...

Page 58: ...u have a combustibles detector in your sensor also make the fol lowing connections between the control unit wiring card and the sensor board on the sensor H2 represents the hydrogen carbon monoxide style of combustibles detector This detector can measure both CO and H2 refer to Figure 3 27 Control Unit Label Sensor Terminal Number H2 Act 7 one pair H2 Act 8 H2 REF 9 one pair H2 REF 10 Methane conn...

Page 59: ...Installation 3 27 Figure 3 20 Sensor connections with all sensor options ...

Page 60: ...between the control unit wiring card and sensor as shown in Figure 3 21 You will end up having two wires connected to each combustible detec tor connection on the sensor board T C CH4 REF CH4 REF CH4 ACT CH4 ACT H2 REF H2 REF H2 ACT H2 ACT 15 16 13 14 10 9 7 8 sensor connections H2 ACT H2 ACT H2 REF H2 REF CH4 ACT CH4 ACT CH4 REF CH4 REF W8 T A M O R E L O C W6 S S E L W5 S S W7 W12 W10 S S W9 S S...

Page 61: ...If you intend to power the current outputs from an external power supply see the External Powering and Modulation of External Power Using Current Outputs appendix Combustibles option current outputs If you have the combustibles option the connections for current outputs 3 and 4 on the wiring card allow you to monitor combustibles information They are labeled as follows IOUT3 IOUT4 IOUT3 IOUT4 Thes...

Page 62: ...e labeled as follows on the con trol unit ALARM 1A ALARM 1B The watchdog alarm contacts are normally closed during system opera tions deactivated A watchdog event 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 last time the watchdog condition occurred...

Page 63: ...Installation 3 31 Computer dry contact input Load Max 30VA Transient protector for inductive loads Power Supply Max 30v Figure 3 22 Series 2000 alarm contact connections ...

Page 64: ...ctor option two sets of alarm relay contacts are available to activate for high methane levels and are labeled as follows see Figure 3 29 ALARM 7A ALARM 8A ALARM 7B ALARM 8B Remote Calibration Unit Connections If you don t have the remote calibration unit RCU option skip this sec tion Oxygen only remote calibration unit connections Oxygen Only Remote Calibration Unit RCU connections on the Series ...

Page 65: ...G IVCM with RTD type combustibles detector you make the following connection SPAN2 17 on RCU For a WDG IVCM with hot wire detector Remote Calibration Unit connects SPAN2 17 on RCU SPAN3 18 on RCU Remote cal switch normally open dry contact closure All common wires to pin 16 on RCU and valve commons on control unit Overall braided shield or rigid metal conduit Figure 3 23 Series 2000 controller RCU...

Page 66: ...mmunicate with other computers that use the same protocol and have the same hardware inter face 2 wire connections The connections used for RS 485 2 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 including all the control units on the network and the hos...

Page 67: ...Installation 3 35 Figure 3 24 Series 2000 2 wire RS 485 communication connections ...

Page 68: ...re termination 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 120 ohm termination resistors in the RS 485 circuit See the Option Card Installation section in this chapter for help on how to remove and access the display module You may need to expe...

Page 69: ...Installation 3 37 Figure 3 25 Series 2000 4 wire RS 485 communication connections ...

Page 70: ... unit This section shows you how to install an option card if you later add that option to the control unit This section also shows you how to access the display module and power supply keypad module on the control unit in case you need to replace these modules or change a component in them for example install new software Removing Display Module or Power Supply Keypad Module This section describe...

Page 71: ...g an Option Card Do the following to add an option card to the Series 2000 control unit this includes the auto calibration card or the combustibles card 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 out 3 Insert the option card into any of the three available slots underneath...

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Page 73: ...ontrol unit display and keypad Control Unit Display You can view different types of information on the main control unit display The first three lines of the display display user defined informa tion programmed using the Setup key Display option 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 ...

Page 74: ... For example if you select the Display option from the Setup key and then select Display Line 1 the current choice on display line 1 will have an asterisk in front of it for example oxygen If all menu options are not able to be listed on the display there will be a Down arrow on the far right of the last line of the display This indicates that there are more menu options to view When the Down arro...

Page 75: ...s disabled If you don t want to enable a system password you can skip this section You can also use this menu option to disable the password requirement Setting up a system password If you have forgotten the correct password you can call AMETEK Thermox and a service password will be provided so that you can ac cess the Password option and enter a new system password 1 From the menu key menu select...

Page 76: ...cess pressure value System Tests Perform internal diagnostics on Series 2000 System Serial View serial and manufacturing number for the control unit Primary Calib Perform an automatic remote or manual primary calibration This is not a typical calibration A primary calibration is intended to extend the life of your sensor Do not perform this type of calibration unless specifically instruct ed to do...

Page 77: ...play 2 Select Display Line 1 Display Line 2 or Display Line 3 de pending on where you want to place the information 3 Select the type of information you want to place on the display line Entering User Text The Down arrow found on the third line of the display allows you to see your current position when entering user text When you first select the User Text option this Down arrow moves to above th...

Page 78: ...cted for the Combustibles Option from the Setup key If you select Methane the display will always show methane Option Full Scale Range combustibles 0 to 5 PPM combustibles 0 10 000 PPM methane 0 to 5 An incorrect combustibles reading is always displayed after the initial installation the information on the combustibles display line wraps around to the display line below and over rides a few charac...

Page 79: ...ure You are 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 If you select a positive pressure a plus sign will appear If you select a negative pressure a negative sign will appear The process pressure you entered will now appear on the third display line 4 If the pr...

Page 80: ... system start up Test Digital In Allows you to test the system digital input Erase RAM Allows you to erase all RAM memory locations Erase EEPROM Allows you to erase internal EEPROM memory locations if your control unit is not operating properly Be careful though because selecting this option will erase all settings in your control unit and the default values will be reinstalled Watchdog Timer Allo...

Page 81: ...wever if you perform a primary calibration incor rectly or if the cell really starts to deteriorate the actual cell response to calibra tion gas will drop off The primary calibration is a way to extend the life of the cell The furnace control temperature can be increased to reduce the atrophy and extend the cell life as the cell ages and the output starts to drop off its original factory cal furna...

Page 82: ...d with a 50 C ambient the voltage should be 32 125 772 C 2 02 mV 50 C 30 1 mV If you add in the compensation voltage for 50 C the voltage at terminals 5 and 6 should be 30 1 mV 12 05 mV 42 15 mVs which should also be the voltage that you measures at T C and T C terminals on the Series 2000 wiring card terminals and also the displayed T C mV value that you can set one of the display lines to view i...

Page 83: ...itiate Verify section in Chapter 5 for help on how to perform the calibration If you have the combustibles option during a primary calibration the system will not use the combustible span gas to calibrate the system When the primary calibration is finished the system will notify you that a standard calibration is required by displaying a Calibration Required message Oxygen readings on the display ...

Page 84: ...Unit Selecting the wrong sensor will damage sensor components and could invalidate your warranty coverage SENSOR OPERATING TEMPERATURE C Insitu Probe Normal Cell Range High Cell mV Range 615 650 WDG IV or HP Series Normal Cell Range High Cell mV Range 3 in 1 WDG IVCM 695 824 695 CEM O2 Normal Cell Range High Cell mV Range 695 812 Table 4 3 Sensor temperatures by analyzer type Configurating the sen...

Page 85: ...ow Note that each control unit must be assigned a unique address otherwise communication results will be unpredict able Enable Serial Allows you to temporarily disable control unit serial communi cations Combustibles Option Combustibles Scale Choices are combustibles or PPM combustibles The combustibles full scale range is 0 to 5 The PPM combustibles full scale range is 0 10 000 PPM If you have th...

Page 86: ...tion All functions in this chapter are directed to a specific analog output port ANALOG KEY FUNCTIONS OPTIONS Set Current Range Define what information should be sent to the analog output port during a calibration For example 4 O2 4 mA 10 O2 20 mA Set Track Hold Hold output at last process reading during a cal or verify or track the calibration readings Set Current Mode Define analog output range ...

Page 87: ...ect Current Output 3 or Cur rent Output 4 You can then select any of the menu options described in the remainder of this chapter and they will apply to the analog output port you selected Set Current Range Define the range of readings that the 0 to 20 or 4 to 20 mA output will represent You can also choose to set a reverse analog output range For example 0 mA can correspond to the high end of the ...

Page 88: ...o correspond to the 4 or 0 mA analog output Set Track Hold Option Define the signals to send to the selected analog output port during a cali bration or verification You have the option to either hold the last process reading or track calibration readings Separate decisions can be made for verify and calibrate operations so you can hold the last process readings during verifications but track cali...

Page 89: ...our choice will be confirmed on the display Out 1 will TRACK during Verify or Out 1 will HOLD during Verify Set Current Mode Define either 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 read ings you define and on the function you track on the analog output Setting the current mode 1 Select an analog output port 2 From ...

Page 90: ...put filtering 1 Select an analog output port 2 From the Analog Range key select Output Filtering You will be prompted to enter an output filtering value 100 FAST 1 SLOW Fltr XX New where XX is the current filter value 100 equals no filtering and 1 equals the highest possible filter value The default value is 100 no filtering 3 Type a number between 1 and 100 then press Enter Note that you should e...

Page 91: ...ble only for current out puts 3 and 4 and cannot be set for analog output ports 1 or 2 Selecting the function 1 Select an analog output port 2 From the Analog Range key select Select Function 3 Select the function you want the analog output port to track The Series 2000 control unit then prompts you with the Set Current Range menu option to choose the range of readings that the 0 to 20 mA or 4 to ...

Page 92: ...hdog Timer and Service alarms and are not software selectable Oxygen combustibles and methane alarms are all disabled during a primary or regular calibration In addition alarms are disabled dur ing start up until the sensor reaches its proper operating 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...

Page 93: ...ze on alarm De energize on alarm Alarm 4 Not selectable O2 only Alarm 5 Not selectable combustibles only Not Selectable high alarms only Disabled during calibration cycle Alarm 6 Alarm 7 Not selectable methane only Alarm 8 The Select Function menu option applies only to Alarm 3 All other alarms are restricted to activate based on process reading levels Alarm Set Points For oxygen alarms these valu...

Page 94: ... and alarm 4 for a high high O2 alarm and the O2 value exceeds both the high and high high alarm set points two up arrows will appear next to the O2 value on the display Defining alarm set point 1 From the Alarm menu select Alarm Set Points Once you select the Alarm Set Points menu option the system alerts you that Alarms 1 and 2 are reserved for the watchdog and ser vice alarms and are not softwa...

Page 95: ...larms can t be set up as a low alarm You are prompted to enter the Alarm 6 set point value Alarm 6 xx yy New Value where xx is the current value and yy is either PPM combustibles or combustibles depending on the combustibles scale you are using 5 Enter the Alarm 6 set point value Note that combustibles alarms are always high alarms So for example Alarm 5 can be high and Alarm 6 can be high high If...

Page 96: ...larm 6 could be a high high combustibles alarm Whether Alarm 3 is set high or low only applies 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 Configuring the alarms 1 From the Alarm menu select Alarm Configure 2 Define Alarm 3 and Alarm 4 as high or low alarms 3 Press Cancel to exit this menu option Rela...

Page 97: ...cation When the system starts a calibration or a verification dual function When tracking the start of a calibration or verification the alarm will de activate once the calibration or verification has been completed including any recovery time you have specified Defining the select function 1 From the Alarm menu select Select Function 2 Select Alarm3 Oxygen Alarm3 In Cal Alarm3 In Verify or Alarm3...

Page 98: ...as normally 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 itself to prevent the control unit from becoming lost due to such things as noise spikes or power surges You can use this relay to activate a remote indicator to notify you if the watchdog timer ti...

Page 99: ... recent exception log entry on line four of the display It also displays when the event was recorded on line three Line three of the display indicates the order in which events are recorded into the log with number 1 being the most recent entry into the log The system is able to store the 20 most recent entries in this exception log Pressing the Down arrow key shows later exception log entries Pre...

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Page 101: ...al Gas Set Cal Timers Set K Factor Sensitivity Figure 5 1 Calibrate Key menu options Sensor alarms are disabled during calibrations and the recovery time after a calibration You can set whether analog outputs should follow the calibration readings or hold at the last process reading before the calibration NOTE ...

Page 102: ...rify operations are often used to check that the instru ment is running within required tolerances On the other hand during a calibration software algorithms adjust the difference between the current readings and the known calibration gas values until they are equal In this chapter when we speak about a calibra tion in a general sense we are referring to either a verification or a calibra tion Spa...

Page 103: ... four hours every two days etc The system cali brates 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 With the digital input method you can only initiate an automatic calibration not an automatic veri fication You can also start an auto calibration using the keypad the calibr...

Page 104: ...libration or verification Set Cal Timers Set Auto Timers applies only for auto cal operations with RCU except for setting time and date Set control unit time date Enable or disable auto cal cycles Set cal gas times for auto cal verify opera tions Define recovery durations after a cal verify Set K Factor not used on WDG IV Series Enter Value Sensitivity View the Sensitivity Slope determined during ...

Page 105: ...scussions on automatic remote and manual calibrations or verifications Auto Calibrate Auto Verify Before you can start an auto calibration or verification 1 Create auto cal timers to tell the system when to perform the automatic calibrations By doing this you don t have to select the Calibrate key later to run the calibra tion it does it automatically at the frequencies you defined This is not req...

Page 106: ...d the zero gas to the sensor Combustibles and Methane Options If you have the combustibles option the following message appears Comb Span Gas xx xx System Calibrating During this time the RCU switched the solenoid valves and introduced the combustibles span gas to the sensor If you set the duration time for the combustibles span gas to 0 from the Set Cal Timers menu you will not see this message I...

Page 107: ... the cal gas cylinder value If your O2 reading on the far left of the display has stabilized yet is not near the setpoint value on the far right of the display you should check the cal gas value you entered and ensure that this value matches the cal gas cylinder for that gas in the RCU When performing a primary calibration or the first calibration after a primary calibration the reading and the se...

Page 108: ...e recov ery time remaining Recovery xx xx System Calibrating The system returns to monitoring process readings Manual Calibrate Manual Verify Verify the type of combustibles detector Hot Wire or RTD type in stalled on the unit before proceeding Specific instructions are given for the Hot Wire and the RTD type To perform a manual calibration or verification follow these steps 1 Enter the calibratio...

Page 109: ... This setpoint value should match the cal gas cylinder for the O2 span gas If your O2 reading on the far left of the display has stabilized yet is not near the setpoint value on the right of the display you should check the cal gas value you entered and ensure that this value matches the cal gas cylinder for the gas you applied to the cal gas inlet port of the sensor You are then prompted to apply...

Page 110: ...his O2 zero gas setpoint value should match the cal gas cylinder for the O2 zero gas You are also prompted to apply the combustibles span gas to the calibra tion gas inlet port of the sensor tubing must be free of oil and dirt Inject Comb Span Gas ENTER to Continue CANCEL to Abort 2 Press Enter when you have applied this calibration gas You are prompted to calibrate the combustibles span gas If yo...

Page 111: ... O2 xx x Cmb yyyy Set yyyy CH4 zzzz Set zzzz Press ENTER to Span Meth 5 Press Enter when the methane span gas reading stabilizes on the far left of the display If you specified a recovery time the system will display the recovery time remaining Recovery xx xx System Calibrating The system then returns to monitoring process readings Be sure to reinsert the 1 4 tube cap on the calibration inlet port...

Page 112: ...isplay stabi lizes 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 Values menu option This O2 zero gas setpoint value should match the cal gas cylinder for the O2 zero gas If you have the Comb CH4 span gas option you are also prompted to apply the Comb CH4 span gas to the calibration gas inlet port of the sensor tubi...

Page 113: ...g Recovery xx xx System Calibrating The system returns to monitoring process readings Be sure to reinsert the 1 4 tube cap on the calibration inlet port on the sensor once you have completed the manual calibration This pre vents air from getting into the sample gas line during normal opera tions NOTE ...

Page 114: ...ation gas value and the calibration gas values read by the system Both the latest calibration and verification data will be stored in memory 1 From the Calibrate key menu select Cal Verify Data 2 Select Calibration Data or Verify Data depending on whether you want to see the latest calibration or verification results The display then shows the span gas calibration data Span Value xx O2 Span Gas xx...

Page 115: ...Gas Values option from the Calibrate key menu 4 Press Enter The time when the calibration or verification was completed will then ap pear on the display End time hr mm End date mm dd yr If the date or time has not been set random characters will appear instead of the time and date when the calibration or verification was completed If this occurs reset the control unit s time and date ...

Page 116: ...Cal Gas Value You are prompted to enter the span gas value Span Gas xx xx O2 New Value 2 Enter the span gas value then press Enter You can also include a decimal point for example 20 9 O2 If you want to keep the current span gas value unchanged press Enter without entering a value You are prompted to enter the zero gas value Zero Gas xx xx O2 New Value 3 Enter the zero gas value then press Enter Y...

Page 117: ... press Enter without entering a value 5 If you have a 3 in 1 analyzer includes methane you will also be prompted to enter the methane span gas value Meth Span x xx New Value 6 Enter the methane span gas value then press the Enter key If you want to keep the current methane span gas value unchanged press the Enter key without changing the value ...

Page 118: ...following message will appear on your display indicating that the RCU has introduced the span gas to the sensor Span gas is flowing You will be prompted to press Enter when you have manually set the pressure and flow for the span gas ENTER for next Gas CANCEL to quit 3 When you have adjusted the pressure and flow for the span gas to the desired levels press Enter The following message will appear ...

Page 119: ...end the cycle CANCEL to quit If you have the methane option you will be prompted to press Enter when you have set the pressure and flow for the zero gas ENTER for next Gas CANCEL to quit 6 When you have adjusted the pressure and flow for the zero gas to the desired levels press Enter The following message will appear on your display indicating that the RCU has introduced the combustibles span gas ...

Page 120: ...n verification cycle times Set Time and Date Set the current time and date Auto Cal On Off Enable or disable the auto calibration cycle Cal Gas Duration Define how long cal gases should flow through the sen sor during automatic calibrations or verifications Recovery Duration Define a recovery duration during which time the sensor switches from measuring calibration gas readings to measuring proces...

Page 121: ...ll automatically prompt you to enter the current time and date You will be prompted to enter the frequency for the calibration or verifica tion cycle either in days or hours depending on what you selected Cal Cycle 01 days New Value xx 4 Enter the number of days or hours for the automatic calibration or verify cycle As you enter the values they overwrite the XXs on the display To enter 1 day or 1 ...

Page 122: ...tes the mo da yr text on the display Enter the month the day the year then press Enter If the current date is correct press Enter without changing the value Set Cal Timers Auto Cal On Off Disable or re enable the auto calibration or auto verification cycle If you know your process will be down for an extended period of time you may want to temporarily disable the automatic calibration or verificat...

Page 123: ...on we suggest that you also add a buffer to this time frame to be certain that the gas has stabilized 1 From the Set Cal Timers menu option select Cal Gas Duration You will 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 Enter Mn equals minutes and Sc seconds As you type the new span gas duration time it ...

Page 124: ... in your automatic calibration sequence If you want to use the currently displayed time press Enter without entering a new value Set Cal Timers Recovery Duration Define a recovery time so the control unit can return to reading process gases after reading calibration gases without affecting the analog outputs or the triggering of alarms This menu option also can be used to prevent triggering of ala...

Page 125: ...Calibration 5 25 Set K Factors This menu option is not used on the WDG IV Series 2000 The de fault factor is always set to 1 00 Sensitivity Select this option to display the Sensitivity slope NOTE ...

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Page 127: ...lways use gloves when working on the sensor This chapter describes Series 2000 control unit system and error messages It also provides troubleshooting assistance System and error messages appear on the fourth line of the display at three second intervals until the condition is corrected or has ended If there is more than one message the messages will alternate on the display at three second interv...

Page 128: ... will not clear from the display by remov ing and restoring power to the control unit If you see this message select the Calibrate key and perform a calibration Cal Verify Aborted The verification was successfully aborted by the system at your request Power Down Detected The system detected that power was removed such as from a power outage Acknowledge this system message by setting or reading any...

Page 129: ...sage indicates a problem either with your calibration setup or the combustibles detector Excessive Cal Error If a primary calibration cannot correct the sensor temperature within the software s allowable limits this message displays to indicate the primary calibration has failed This message could indicate one of the following problems Calibration gas setup problem Process pressure incorrectly ent...

Page 130: ... Interconnecting wiring problem T C Thermocouple Circuit Failure This message appears when the control unit recognizes a sudden drop in temperature greater than 100 C The thermocouple circuit failure message can be the result of one of the following problems Shorted thermocouple Faulty interconnecting wiring Control unit display module failure Sensor board failure If this message is soon followed ...

Page 131: ...ivolts and cell millivolts be displayed during troubleshooting as a troubleshooting aid see the Display section in Chapter 4 for help on how 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 for technical support Diagnostic checks are broken down as f...

Page 132: ...hermocouple from the sensor and heat its ceramic tip to a known temperature Measure the millivolt output with a proper temperature indicating meter type K thermocou ple If the thermocouple reads inaccurately replace it Reversed Thermocouple Wires First have one of the control unit display lines show the sensor cell temperature If the thermocouple leads are reversed the displayed temperature will b...

Page 133: ...emperature by this value to come up with the furnace temperature set point NOTE The cell thermocouple compensation circuit on the 80471SE 80485SE 80467SE and 80505SE sensor boards is different in comparison to the 80418SE sensor board that was supplied with Series 2000 based systems prior to 1996 CE Marked Systems Sensor Board 80418SE prior to 1996 CE Marked Systems The 80418SE used the 40 2 ohm r...

Page 134: ... the possibly contaminated line Aspirator Not Turned OFF during Calibration WDG IV only Verify that the aspirator air is turned off during calibration man ual or through the RCU If the problem is with the RCU refer to the next section Remote Calibration Unit Problem Remote Calibration Unit RCU Problem The RCU contains one normally open solenoid the aspirator air solenoid All other solenoids are no...

Page 135: ...ce of the furnace should be 32 ohms 10 If the furnace resistance is not within allowable tolerances replace the furnace Loss of AC Power to the Furnace If the furnace drive signal is not present Verify the correct line voltage at L1 and L2 of the sensor board With line voltage present check the voltage at terminals R and S on the sensor board If voltage is present and the system is not heating rem...

Page 136: ...on how to check for leaks see the Calibration Aspirator Air Checks section earlier in this chapter for help on checking your calibration gas setup If the analyzer has been operating for some time and you feel the oxy gen reading is inaccurate First check by running a known calibration gas to veri fy the analyzer s response If the analyzer responds to the calibration gas correctly it indicates eith...

Page 137: ...s for example nitrogen or pure oxygen being sure to avoid the area over the top of the cell 1 Use a piece of tygon or plastic tubing with a 1 8 stainless steel nozzle to apply the gas from a cylinder using stainless steel prevents any problems that might occur with plastic melting the nozzle on hot sen sor components 2 Monitor the response from the cell When the cell millivolt reading changes it i...

Page 138: ...situ users 1 Examine the inlet and exhaust for plugging problems When possible rod out the probe and exhaust 2 If this doesn t solve the problem disassemble the analyzer to locate the plug Clean the plumbing using hot water and a bottle brush 3 When assembly is complete check for leaks using a leak detecting liquid Aspirator Air Not Pulling Sample from Process This check only applies for WDG IV us...

Page 139: ...n gas solenoid is energized and the O2 span gas should be flowing into the sensor 3 O2 Zero O2 zero gas solenoid is energized and the zero gas should be flowing through the sensor 4 Combustibles Span Combustibles span gas solenoid is energized and the combustibles span gas should be flow ing into the sensor 5 through 12 Not used Combustibles Card LEDs Combustibles alarm relays are labeled on the w...

Page 140: ...ne 2 Methane Alarm 2 relay is energized contact closed Corresponds to Alarm 8 in software Sensor Board 80471SE LEDs Two diagnostic LED indicators are on the sensor board DS1 is located near the relay on the board and DS2 is located near the end of the num bered terminal strip LED INDICATOR STATUS FUNCTION DS1 Oxygen cell furnace over temperature shutdown circuit status GREEN Furnace is operating n...

Page 141: ... Combustibles Detector Replacement optional Box Heater Wiring RCU Remote Calibration Unit Solenoid Valve Replacement Replacement Parts List See the Installation chapter for help on how to remove or replace Series 2000 control unit modules or option cards You can clean the outside of the sensor or controller or Remote Calibra tion Unit using normal household or commercial general purpose clean ers ...

Page 142: ...priate gloves when handling components Be extremely careful when performing maintenance on the sensor while the process is running especially if the process is under signifi cant positive pressure Removing any part of the sensor plumbing can allow process gases and gases of high temperature to escape into the sensor Cautions Always use a backup wrench when working on sensor plumbing This helps to ...

Page 143: ...Service and Parts 7 3 Figure 7 1 Wiring diagram for standard sensor ...

Page 144: ...e 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 hold the cell by one of its hex nuts 5 Place the cell O ring on top of the cell housing as shown in Figure 7 2 6 Insert the new cell into the cell housing Do not touch the bare cell when reinserting Tighten the cell into the cell ho...

Page 145: ...Service and Parts 7 5 Figure 7 2 Cell replacement ...

Page 146: ...uld be near but not touching the cell housing or furnace heater coil 6 Put the screw back into the thermocouple mounting clamp This se cures the thermocouple to the furnace 7 Attach the thermocouple wires to terminals C and D on the sensor board observing polarity yellow wire to terminal C red wire to ter minal D 8 Disconnect the furnace wires from sensor board terminals R and S Using an Ohm meter...

Page 147: ...Service and Parts 7 7 TOP VIEW FURNACE 1 Cell housing 2 Thermocouple mounting tab 3 Thermocouple 4 Convection loop mounting clamp 5 Compression fitting Figure 7 3 Thermocouple replacement ...

Page 148: ... fitting 5 While holding the furnace in one hand remove the convection loop mounting clamp Be sure to save the mounting clamp for when you install the new furnace 6 Gently pull the cell housing out of the furnace and remove the fur nace 7 Slip the new furnace onto the cell housing and attach the cell housing using the convection loop mounting clamp 8 Remount the cell housing reverse the actions ta...

Page 149: ...Service and Parts 7 9 CELL ASSEMBLY CELL HOUSING CONVECTION LOOP MOUNTING CLAMP UNION FITTING COMPRESSION FITTING FURNACE Figure 7 4 Furnace replacement ...

Page 150: ...h detector leads at the same time Place a mark on the edge of the combustibles detector at the 12 o clock position after you have determined the correct orientation Figure 7 5 Place detector elements in detector block vertically 4 Install the new combustibles detector with nut and ferrules Be ex tremely careful not to damage the detector elements when installing Ensure that the mark you made in St...

Page 151: ...arts 7 11 Furnace assembly Combustibles Detector Block Ferrule Detector head Compression Fitting Nut Side View Front View Sample flow flow Place Mark 12 o clock Figure 7 5 Combustibles detector replacement Hot Wire ...

Page 152: ...ector leads at the same time To do this ensure that the flat part of the combustibles detector is facing down see Figure 7 6 for correct orientation 4 Install the new combustibles detector with nut and ferrules Be ex tremely careful do not damage the detector elements when install ing Ensure the proper orientation of the combustibles detector in the combustibles detector block 5 Reconnect the dete...

Page 153: ...to wire box heaters using the sensor board 115 VAC BOX HEATER 115 VOLT CONFIGURATION SENSOR BOARD BOX HEATER BOX HEATER HTR HTR HTR HTR L N 230 VAC BOX HEATER 230 VOLT CONFIGURATION SENSOR BOARD BOX HEATER BOX HEATER HTR HTR NC NC L N Figure 7 7 Box heater diagram ...

Page 154: ...d Valve P N 36023JE Flow Meter O2 Only RCU P N 37030JE Flow Meter Combustibles RCU P N 37020JE Control Unit Display Module P N 90219VE Power Supply Keypad Module P N 90253VE Auto Calibration Card P N 80436SE Combustibles Card WDG IVC P N 80461SE Combustibles Card WDG IVCM RTD type P N 80449SE Combustibles Card WDG IVCM Hot Wire type P N 80561SE Backplane Assembly P N 80439SE Wiring Card WDG IV P N...

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Page 156: ...xed at 9600bps The communication protocol is a basic master 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 can be connected on one network Start Character Node Address Command Letter Data Checksum End Character ASCII charac ter 3E Hex 2 Hex ASCII char...

Page 157: ...II A Z upper case only Data is a string 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 preceding characters excluding the character modulo 256 or the characters is equivalent to 2 ASCII 3F hex characters The End Character is a carriage return equivalent to...

Page 158: ... 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 The data consists of a single digit where 0 is used to read the current date and time 1 is used to read the date and time of the last calibration 2 is used to read the date and time of the last verification and 3 is used to read the...

Page 159: ...Data Format J This command is used to check how data is output through the serial link For each variable that is accessible through the Read Number and Write Number commands a string is returned that describes the format of the number This response data consists of three characters Format Access Location Where Format is F Float H Hexadecimal U Unsigned decimal Access is as follows r read only w wr...

Page 160: ...the Series 2000 software Command List The following command letters are available Letter Description A Echo B Bad Command C Acknowledge F Read Number G Calibrate H Write Number J Data Format Series 2000 software only M Read Date and Time N Set Date and Time NOTE ...

Page 161: ... Data n characters Checksum 2 hex ASCII characters End Character Examples A Simple acknowledge AFF0050 Acknowledge with data Failure All failure responses start with a N followed by a two hex digit failure code and a carriage return Failure N Failure Code 2 hex ASCII characters End Character Failure Code Description 01 Bad command letter 02 Bad checksum 03 Input overrun in serial communication 05 ...

Page 162: ...ure use IQ bit 1 Future use bit 2 Future use bit 3 Future use bit 4 Power Down Detected bit 5 Watchdog Failure bit 6 Detector B Fault IQ bit 7 Detector A Fault IQ bit 8 Combustble cal error bit 9 Methane cal error bit 10 Warming up bit 11 RTC Not Running IQ bit 12 Box Under 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 Ce...

Page 163: ...ion enabled only for RSS bit 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 time bit 7 auto calibration cycle is programmed in hours 0 if in days bit 8 auto verify cycle time is programmed in hours 0 if in days bit 9 Future use used on S2000 bit 10 ...

Page 164: ...n alarm If not they deenergize 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 calibration will occur at the auto calibration time 0 true 1 false bit 11 real time clock is set bit 12 Step Function enabled only for RSS bit 13 auto verify time is set an auto ve...

Page 165: ...cks during verify 0 is hold analog output during verify bit 6 analog output 2 set for 0 to 20 ma 0 is 4 to 20 ma bit 7 Future use bit 8 analog output 3 tracks during calibration 0 is hold analog output 3 during calibration bit 9 analog output 3 tracks during verify 0 is hold analog output 3 during verify bit 10 analog output 3 set for 0 to 20 ma 0 is 4 to 20 ma bit 11 Future use bit 12 analog outp...

Page 166: ...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 bit 9 analog output 1 tracks during verify 0 is hold analog output during verify bit 10 Analog output 1 is set to 0 20 0 Output 1 is set to 4 20ma bit 11 Future use bit 12 analog output 2 tracks during calibration 0 is hold analog output 2 during...

Page 167: ...mbustibles 18 combustible voltages IQ 20 methane voltages IQ 22 time and date 24 user text S2 AF Ratio IQ 26 WOBBE IQ R W 07 07 Line3_flg What is displayed on line 3 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 combustible voltages IQ 20 methane voltages IQ 22 time and date 24 user text ...

Page 168: ...uple mv IQ 3 cell mv IQ 4 thermocouple mv S2 box temp IQ 5 combustibles IQ 6 cell mv S2 methane IQ 7 AF Ratio IQ 8 WOBBE IQ R W 10 16 Out3_flg What analog output 3 corresponds to 0 oxygen IQ 1 cell temperature IQ 2 thermocouple mv IQ 3 cell mv IQ 4 box temp IQ 5 combustibles 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 correspond...

Page 169: ...alue is always in percent R 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 Alm6_value Combustibles PPM alarm 6 setpoint S2 R W 22 34 Alm5_percent Combustibles percent alarm 5 setpoint S2 R W 23 35 Alm6_percent Combustibles percent alarm 6 setpoint ...

Page 170: ...ration Read only 35 53 Cal_zero Oxygen zero gas reading from last calibration Read only 36 54 Ver_cgas2 Oxygen setpoint value used during last verify Read only 37 55 Ver_zero Oxygen zero gas read during last verify Read only 38 56 O2_zero Zero gas millivolts read during last calibration Read only 39 57 Cal_cgas3 Combustibles span gas setpoint during last calibration Read only 3A 58 Cmbspan Combust...

Page 171: ...rence voltage reading for Combustibles 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 the Methane channel Read only 54 84 Mthact Active voltage reading for Methane channel Read only 55 85 Mthgnd Ground reading for Methane channel Read only 56 86 AT Cel...

Page 172: ...bit 6 high combustible 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 use bit 14 Future use bit 15 Future use R W Alm_config S2 Configuration for oxygen alarms high or low If a bit is 1 that is the condition that the indicated alarm will trip on bit 0...

Page 173: ...s flowing 1st time 5 Step func Span 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 Normal operation if not in a cal or verify per loc 60 95 Read only 60 96 Calflag Which type of calibration the unit is in 0 In normal calibration 1 In verify 2 In pri...

Page 174: ...bit 10 high combustible 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 0 low oxygen alarm 3 bit 1 high oxygen alarm 3 bit 2 low oxygen alarm 4 bit 3 high oxygen alarm 4 bit 4 high combustion alarm 5 bit 5 high combustion alarm 6 bit 6 high methane alar...

Page 175: ...ed S2 bit 3 Methane detector installed 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 Tspan_mv Cell mv value measured with the span gas flowing during last calibration Read only 65 101 Tzero_mv Cell mv value measured with the zero gas flowing during cal...

Page 176: ...ne gas if 3 span value 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 Methane sensitivity associated with the last calibration Read only 78 120 AFRatio The calculated A F ratio Read only 79 121 AFRatio_CalSP The zero cal gas A F ratio set point R W 7A 122...

Page 177: ... number 9 see Exception Chart Read 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 only 8C 140 Excep_13 Exception number 13 see Exception Chart Read only 8D 141 Excep_14 Exception number 14 see Exception Chart Read only 8E 142 Excep_15 Exception numb...

Page 178: ...E 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 16 Excessive Cal Error 15 Memory is Corrupted 14 Primary Calibration 13 Span Gas Range Error 12 Zero Gas Range Error 11 Cell is Over Temp 10 Temp Rise Failure 0F Furnace Over Temp IQ 0E Furnace Circuit Open IQ 0D Box...

Page 179: ...t OPEN COM2 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 analyzer is connected WHILE INKEY PRINT 1 M LINE INPUT 1 A Show results PRINT Sent M PRINT Returned A PRINT WEND CLOSE 1 STOP FUNCTION Checksum M DIM Sum AS LONG Sum 0 Skip FOR i 2 TO LEN M Sum Sum...

Page 180: ...knowledge is returned A the calibration command is ac cepted If not accepted the sensor may not be at a proper operating temperature or may already be performing a system calibration 4 Read the Gas_ctr variable to determine the position in the calibration cycle Use this variable to determine when to activate solenoids if not controlling solenoids using the IQ analyzer 5 Read the Cal_flag variable ...

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Page 182: ... automatic remote or manual primary calibration Sensor Configuration Select sensor type Communications Define communications parameters Combustibles Define combustibles scale or PPM Define combustible detector type Table B 1 Setup Key Menu ANALOG KEY Menu Options Functions Options Set Current Range Range of readings that the analog output represents for example 4 O2 4 mA 10 O2 20 mA Set Track Hold...

Page 183: ...on or Verify Exception Log N A Table B 3 Alarm Key menu ALARM NUMBER FUNCTION Select Function Alarm Configure Relay Configure Alarm 3 O2 Cal Start Verify Start Cal Verify Start High O2 Alarm Low O2 Alarm Energize on alarm De energize on alarm Alarm 4 Not selectable O2 only Alarm 5 Not selectable combustibles only Not Selectable high alarms only Disabled during calibration cycle Alarm 6 Alarm 7 Not...

Page 184: ...ure and flow to RCU gases without performing a calibration Set Cal Timers applies only for auto cal operations with RCU except for setting time and date Set control unit time date Enable or disable auto cal cycles Set cal gas times for auto cal verify operations Define recovery durations after a cal verify Set K Factor not used on WDG IV Series Enter Value Sensitivity View the Sensitivity Slope de...

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Page 186: ... the Series 2000 control unit display module is used to allow you to define which power source to use If JP2 is in factory default the control unit uses the internal supply to power the current output circuits If you try to use an external voltage at this time the system will use whichever voltage is higher control unit voltage is normally about 28 volts If the JP2 jumper is removed the external v...

Page 187: ... 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 to power the current output circuits If you try to use an external voltage at this time the system will use whichever voltage is higher control unit voltage is normally about 28 volts If the jumper is...

Page 188: ...ORed together using a diode from each power supply positive terminal diode anode to power supply to the VEXT1 2 terminal The power supply minuses would be tied together and connected to one side of the both loads The other side of one of the loads would be connected to IOUT1 terminal and the other side of the other load would be connected to the IOUT2 terminal For each current output channel used ...

Page 189: ...eries 2000 WDG IV IVC IVCM Skip this section if you don t measure combustibles In addition both of the combustibles current outputs can be used in a modulation scheme using the following VEXT3 VEXT4 VEXT3 VEXT4 NOTE ...

Page 190: ... instructions you may have ordered in addition to the standard WDG analyzer If you didn t or der any custom options the standard Interconnect Drawing is provided If you did order any special options the drawings or special instructions provided here supercede any drawing or options provided elsewhere in this manual ...

Page 191: ...D 2 Thermox Series 2000 WDG IV IVC IVCM This page intentionally left blank ...

Page 192: ... SENSOR CONFIGURE COMB WDG IVC WDG HPIIC SENSOR CONFIGURE METHANE WDG IVCM SENSOR NODE ADDRESS 0 BAUD RATE 9600 ENABLE SERIAL ENABLED COMBUSTIBLE TYPE HOTWIRE COMBUSTIBLE TYPE RTD COMBUSTIBLE SCALE PPM PROCESS PRESSURE 0 00 PSIG O2 SPAN GAS SETPOINT 20 90 O2 ZERO GAS SETPOINT 2 COMB SPAN GAS SETPOINT 1600 PPM METHANE GAS SETPOINT 2 00 AUTO CAL CYCLE TIME 8 00 AUTO CAL CYCLE FREQ 1 DAY AUTO VERIFY ...

Page 193: ...PAN GAS SETPOINT 20 90 O2 ZERO GAS SETPOINT 2 COMB SPAN GAS SETPOINT 1600 PPM METHANE GAS SETPOINT 2 00 AUTO CAL CYCLE TIME 8 00 AUTO CAL CYCLE FREQ 1 DAY AUTO VERIFY CYCLE TIME 9 00 AUTO VERIFY CYCLE FREQ 1 DAY AUTO CAL VERIFY DAYS HRS DAYS DAYS AUTO CAL ENABLE DISABLE ENABLED AUTO VER ENABLE DISABLE ENABLED O2 SPAN GAS DURATION 2 00 MINUTES O2 ZERO GAS DURATION 2 00 MINUTES COMB SPAN GAS DURATIO...

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