Ametek Thermox WDG-1200 Insitu User Manual Download Page 3

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Contents

Offices .....................................................................................................................ii

Safety Notes ........................................................................................................... vi

Electrical Safety ..................................................................................................... vi

Grounding .............................................................................................................. vi

CHAPTER 1 Overview

System Features ...................................................................................................1-1

Sensor .................................................................................................................1-2

Problems to Avoid ................................................................................................1-4

Technical Support ................................................................................................1-5

CHAPTER 2 Specifications

WDG 1200/1210/Insitu Probe .............................................................................2-1

CHAPTER 3 Installation and Start-Up

Unpacking ............................................................................................................3-1

Mechanical Installation ........................................................................................3-2

Location ........................................................................................................3-2

Unpacking the Shipping Protection ..............................................................3-3

Fitting a Filter or Shield to the Probe ............................................................3-4

Mounting the Sensor .....................................................................................3-5

Mounting the Controller (WDG-1210 Insitu only) .......................................3-6

Mounting Guidelines ..............................................................................

3-7

Installing the Controller .........................................................................

3-8

Mounting the Control Unit .....................................................................

3-8

Calibration Setup ...........................................................................................3-9

Required calibration gases and tubing ...................................................

3-9

Calibration inlet .....................................................................................

3-9

Electrical Connections .......................................................................................3-10

Mains Power Supply ...................................................................................3-10

Remote Calibration Unit (optional) ............................................................3-10

Optional Signal Connections ......................................................................3-11

Plug Plate Connector Designation - WDG-1200 Insitu ..............................3-11

Plug Plate Connector Designation - WDG-1210 Insitu ..............................3-12

System Cables .............................................................................................3-13

Recommendations for Laying Cable ....................................................

3-13

Cable Preparation ................................................................................

3-13

Cable Recommendations - WDG-1200 Insitu ............................................3-14

Cable Recommendations - WDG-1210 Insitu ............................................3-14

Pin Designations - 1200/1210 Insitu ...........................................................3-15

Probe Connections - WDG-1210 Insitu Only .............................................3-18

Grounding ...................................................................................................3-19

Assembly of Connector Plugs .....................................................................3-20

Summary of Contents for Thermox WDG-1200 Insitu

Page 1: ...Thermox WDG 1200 1210 Insitu User Manual Thermox 150 Freeport Road Pittsburgh PA 15238 PN 90685VE Rev L...

Page 2: ...r 30 Tian 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...

Page 3: ...elines 3 7 Installing the Controller 3 8 Mounting the Control Unit 3 8 Calibration Setup 3 9 Required calibration gases and tubing 3 9 Calibration inlet 3 9 Electrical Connections 3 10 Mains Power Sup...

Page 4: ...log Outputs Screens 4 11 Analog Outputs Menu 4 11 Diagnostics Screens 4 13 Diagnostics Menu 4 13 System Configuration Screens 4 15 System Configuration Menu 4 15 Output Setup 4 17 System Outputs 4 17...

Page 5: ...e 5 13 Routine Maintenance Schedule 5 13 Essential Maintenance Tools 5 13 CHAPTER 6 Service and Parts Inner Probe Assembly Removal 6 2 Process under Pressure 6 3 Cell Replacement 6 4 Removing the Cell...

Page 6: ...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...

Page 7: ...idential 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 c...

Page 8: ...o 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 fire or force of the...

Page 9: ...ix...

Page 10: ...y performed While the outer protection tube remains in the process the inner tube structure which houses the oxygen cell and furnace thermocouple assembly can be removed easily see Figure 6 1 Because...

Page 11: ...essures If the oxygen partial pressure of one gas is known the voltage produced by the cell indicates the oxygen content of the other gas A reference gas usually air 20 9 O2 is used for one of the gas...

Page 12: ...tems in the Analyzer The Mechanical System The inner and outer pipes mounting flange and terminal case The Measuring System The sensing cell interconnecting wiring and inte grated user interface The T...

Page 13: ...Calibration gases must contain oxygen Do not use pure nitrogen or any other anaerobic gas or a zero gas Do not use calibration gases if they contain a mixture of oxygen and combus tibles Do not handle...

Page 14: ...rd the following values you may be asked by the factory to provide this information when receiving service Cell millivolts Cell temperature Cold junction temperature Any fault indicators If you need t...

Page 15: ...1 6 Thermox WDG 1200 1210 Insitu Probes This page intentionally left blank...

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

Page 17: ...ator Pressure 10 psi 0 7 bar nominal It may be necessary to use a regulator pressure of up to 30 psi 2 0 bar to achieve the required flow Environmental Protection Probe Head IP65 NEMA4 protected Opera...

Page 18: ...ge if it is operated from a supply which cannot deliver the required current User Interface Display type Single line 4 digit LED Parameters O2 concentration Calibration gas Cell temperature Fault mess...

Page 19: ...2 4 Thermox WDG 1200 1210 Insitu Probes This page intentionally left blank...

Page 20: ...200 1210 Insitu probe Never service the Insitu probe unless power has been removed from the probe and it has been allowed to cool for at least one hour This chapter shows you how to install the WDG 12...

Page 21: ...can be provided for excessive vibration installation locations Handle the probe with care do not drop the probe The probe contains fragile ceramic components which are easily damaged The probe should...

Page 22: ...tection 1 Remove the Anti Shock rubber cap see the picture below 2 Unpack the Mullite ceramic tube as below 3 Put the Mullite Tube into the probe as below 4 Fit the filter or shield to the end of the...

Page 23: ...stainless steel filter depending on the application The example below shows a ceramic filter with stainless steel protector Once the packing material has been removed screw the filter or screen onto t...

Page 24: ...ee Figure 3 2a and 3 2b Insulate the pipe nipple with at least 1 2 54 cm thick weather proof insulation If the pipe nipple is over 4 10 16 cm long it should be heat traced Figure 3 2a WDG 1200 Insitu...

Page 25: ...ation Gas typically 1 O2 in N2 6 Heater Supply Input to Probe 7 Cell Thermocouple and Cold Junction Signals from Probe 8 Mains Power Supply Input to Control Unit 9 Signal Outputs Relays customer conne...

Page 26: ...d be a minimum of 150 mm 6 clearance below to enable both the electrical connections and signal cable connections to be made 3 Ensure that there is an accessible route for connection to the measuremen...

Page 27: ...All dimensions are given in millimeters inches Figure 3 5 Control Unit Dimensional Information Mounting the Control Unit The Control Unit is mounted to a vertical flat surface using the four 4 7mm 0 2...

Page 28: ...se calibration gases at 10 psig 0 7 bar Shorter probes use 3 scfh 1 4 l min 6 and 9 foot probes use 6 scfh 2 8 l min The span gas oxygen concentration must be higher than the zero gas by a factor of 1...

Page 29: ...l remote calibration unit where applicable any additional equipment e g chart recorder etc Remote Calibration Unit optional Signal connections must be made for Automatic Trigger Pressure Signals The a...

Page 30: ...lay Normal for normally open N O and normally closed N C is defined as the analyzer in measurement mode not in calibration or mainte nance indicating no faults or alarms Plug Plate Connector Designati...

Page 31: ...3 Customer I O 4 Power Supply connection to measurement probe 5 Signal Connections from measurement probe cell thermocouple heater Ensure dust covers are fitted to any unused connectors The covers are...

Page 32: ...cables must be suitably protected Cable Preparation Check the mains power supply cable specification for mains power supply volt age and capacity see below for full specification Setting the supply vo...

Page 33: ...are supplied with the analyzer Cable 2 is supplied with the re mote calibration unit Cable Recommendations WDG 1210 Insitu WDG 1210 Insitu Cable Recommendations Ref Description Max o d mm No of Cores...

Page 34: ...n 2 1 Mains Power Ground Green Yel low Green Yel low 1 Line Black1 Orange 2 Neutral Black2 Black 3 not used none none Connector Ref Insert Arrangements Pin Function Wire Color 2 Remote Calibration Uni...

Page 35: ...RS485 Shield Green Red Yellow F RS485 B two wire half duplex Red Brown Yellow G RS485 A two wire half duplex White Red Yellow H Ground 0V Black Yellow J System OK Common Yellow Green K System OK N C...

Page 36: ...Yellow Green 1 Heater Live Line 7 Black1 Red 2 Heater Neutral Return 8 Black2 Black 3 Not Used Shield 9 11 Connector Ref Insert Arrangements Pin Description Probe Con nect Wire Color 5 Interconnect A...

Page 37: ...ctions ensuring the cables are routed correctly as shown in Figure 3 8 KEY 1 Cell ve 2 Cell ve 3 Thermocouple ve 4 Thermocouple ve 5 Cold junction ve 6 Cold junction ve 7 Heater Live Line 8 Heater Neu...

Page 38: ...Grounding External grounding points are provided These should be connected to local ground Correct grounding is essential for compliance with EMC regulations Ground Point Ground Point Calibration Gas...

Page 39: ...k rubber washer segmented for adjustment 5 Connector backshell 6 Plug pins 7 Pin socket receptacle and connector Crimped Connector Assembly Procedure 1 Remove approximately 15mm 0 6 of the cable outer...

Page 40: ...eptacle and connector 7 into the cable housing 5 Pull any slack cable through 7 Push the two washer systems 3 and 4 inside the connector backshell 5 to secure the cores 8 Ensure that the clamp 2 is sc...

Page 41: ...the individual cores to the screw terminals 6 Screw the parts of the connector together to ensure that the rubber sealing washer fits snugly around the cable Fitting of Plug Connectors Do not push or...

Page 42: ...ion gas con nector on the probe If the blanking plug is not fitted air leaking into the probe via the connector can cause measurement errors In a pressurised flue gases venting to atmosphere through t...

Page 43: ...be accessed in the event of system malfunction A C F E D B Figure 4 1 Control Panel A Mode Key Used to move through the menu options B Return Key Used to enter values and select options C Up Down Key...

Page 44: ...Temperature of cell CJC Cold junction compensation temperature CONF Configuration CTI Cal time interval DIAG Diagnostics DPNG Damping F Faults PRAD Probe address PRTY Probe type RES Resistance test SC...

Page 45: ...ure installation has been completed including any optional equipment for example a remote calibration unit Check that all of the connections have been completed Warm Up Procedure 1 After a short perio...

Page 46: ...ption The maintenance relay option must be set to YES to activate or NO to deactivate it and then entered before the Menu Spine can be viewed Set the maintenance relay by pressing the UP and DOWN keys...

Page 47: ...Test Display SYSTEM MENU Display Action Probe Type Value Baud Value Negative Reading Y N Probe Address Value Rev No Display ALARM MENU Display Action Alarm Value CALIBRATION MENU Display Action Displ...

Page 48: ...ation is required Span gas concentration Zero gas concentration If the automatic calibration option is selected the following settings are also needed Time until first calibration Time necessary for t...

Page 49: ...enus Configuration Automatic Calibration Manual Calibration To access these menus from the Calibration menu press Enter Use the F1 key to scroll through the menus Each option within the sub menu is se...

Page 50: ...t possible to calibrate on 0 oxygen therefore the recommended minimum concentration is 0 1 O2 in N2 OPTIONS Set concentration of zero calibration gas RANGE 0 1 to 18 O2 in nitrogen DEFAULT 1 O2 in nit...

Page 51: ...on and then return to the O2 display OPTIONS Perform automatic calibration RANGE NOT APPLICABLE DEFAULT NOT APPLICABLE Zero calibrati on CAL SCAL ZEro A zero calibration is performed manually by press...

Page 52: ...play The option is set by selecting a value using the UP and DOWN keys and pressing Enter again Alarm Setting ALAr OPTIONS Set the alarm RANGE 0 to 25 O2 DEFAULT 1 00 If an alarm is set the alarm rela...

Page 53: ...alyzer outputs can be accessed using the Analog Outputs menu The Analog Outputs menu consists of five sub menus Zero Span Damping Base Track These sub menus are accessed by pressing Enter from the Ana...

Page 54: ...t to stabilize the reading under noisy signal conditions Press Enter Select a value using the UP and DOWN keys Press Enter again OPTIONS Setting the damping rate RANGE 0 to 999 0 sec DEFAULT 10 00 sec...

Page 55: ...esistance test To access these menus from the Diagnostics display press Enter To scroll through the menu press F1 Each option within the sub menu can be viewed by pressing Enter Display Action Fault l...

Page 56: ...re of the cell It is the actual temperature of the cell measured indepen dently of the heater OPTIONS Display cell temperature RANGE NOT APPLICABLE DEFAULT NOT APPLICABLE Cold junction temperature diA...

Page 57: ...r These sub menus are accessed by pressing Enter from the System Configura tion display Scroll through the menus pressing F1 Each option within the sub menu can be set by pressing Enter selecting the...

Page 58: ...nEg Negative values are not normally displayed but are sometimes required for diagnostic purposes The sys tem can be set to display negative values by press ing Enter selecting YES using the UP key an...

Page 59: ...ast reading prior to calibration and resumes after the final calibration settling period Output Held Setting Time ACTIVATED ACTIVATED ACTIVATED DEACTIVATED DEACTIVATED DEACTIVATED Analog Outputs Set t...

Page 60: ...alog outputs you must enter the password set the maintenance relay and select the Analog Outputs menu From menu spine Display Action Zero Enter value Display Action Span Enter value Display Action Dam...

Page 61: ...reading to be output when the analyzer measures at the zero cali brated value To set the reading Press Enter Select a value using the UP and DOWN keys Press Enter again Span Reading This is the readi...

Page 62: ...bes Track Setting The analog output may be set to track the O2 levels or hold the last reading during calibration This is set by pressing Enter selecting YES to track or NO to hold using the UP and DO...

Page 63: ...ws bAud Press Enter and use the up and down arrows to change the baud code When correct press and hold Enter until the display flashes Proceed to next section Slave Address and Floating Point Format T...

Page 64: ...ta Types Integer variable Single register Registers Numbers for Instrument Readings integer value Address Variable Scaling 23 O2 Reading 1000 27 Cell Temperature o C 10 Command Register Address Variab...

Page 65: ...User Interface Calibration 4 23 Modbus RS485 Interface Figure 4 3 RS485 Bus topology Figure 4 4 Two wire RS485 connection...

Page 66: ...1 11 Analog O P Base 1 12 Probe Type 10 13 Baud Rate 1 14 Zero Coefficient 1 15 Span Coefficient 1 16 Cell Temperature 10 17 Display negative values 1 18 Track During Cal 1 19 Maintenance State 1 20...

Page 67: ...g of each bit is as shown in the table below Bit Meaning 0 LSB Start Calibration Write 1 to start calibration 1 Zero Calibration acknowledged 2 Span Calibration acknowledged 3 to 9 Not used 10 Failed...

Page 68: ...Time until first calibration Time necessary for the calibration gas flow to stabilize Time interval between calibrations Access to Calibration Menu from Menu Spine Oxygen Concentration The oxygen conc...

Page 69: ...on Sub menu Span gas conc Enter value Zero gas conc Enter value Cal time interval Enter value Time to next cal Enter value Cal settling time Enter value Display Action Auto cal Enter or F1 Display Act...

Page 70: ...e during calibration Span Calibration Gas Concentration The recommended span calibration gas concentration is 20 9 O2 Zero Calibration Gas Concentration The recommended zero calibration gas concentrat...

Page 71: ...alibration first and then a span calibration The calibration gases will be allowed to flow automatically from the calibration gas unit To bypass this option press F1 Check that the zero and span gases...

Page 72: ...to gether Manual Calibration Zero and span calibration are performed manually from this sub menu Set all configuration options before performing calibrations Zero Calibration Supply calibration gases...

Page 73: ...yed will need approximately 120 seconds to settle NOTE Recommended span calibration gas concentration is 20 90 O2 i e ambient air Span Calibration Reading Calibration is necessary if the reading displ...

Page 74: ...power has been removed from the probe and it has been allowed to cool for one hour Identifying Faults Faults are always indicated by the illumination of the System Fault LED and the activation of the...

Page 75: ...s menu on the Menu Spine If a fault occurs a fault identification number is displayed This identification number refers to possible faults on the Fault Identification Table Table 1 If no fault has bee...

Page 76: ...tiple fault in which case the individual identification numbers are added together Use the table below as a quick reference for faults listed above Identification Number Fault Identification Number Fa...

Page 77: ...creased or is too high during the warm up period CAUSE ELEMENT ACTION 1 Heater not connected Probe Check probe wiring 2 Heater fuse blown Probe Replace heater fuse and check wiring 3 Heater failed Pro...

Page 78: ...ioration Probe Ensure correct calibration procedure is followed 5 ve Span Gas Coefficient Probe ACU Replace sensor Check for correct calibration gas perform calibration c Zero coefficient out of range...

Page 79: ...600 0 The analyzer is reading an unexpected voltage from starting or correctly complet ing an auto calibration cycle CAUSE ELEMENT ACTION 1 Sensor not connected or incorrectly wired Probe Check probe...

Page 80: ...cally check the cell EMF reading after the initial stabilizing time has expired 3 The reading should settle at the cell constant of typically 0V 2mV for a new cell 4 When the cell attains its constant...

Page 81: ...to fit the outside diameter of the pipe o d 3 Apply the test gas at a rate of 2 l min 4 5 ft3 hour and allow 5 minutes for the analyzer reading to settle If the analyzer response is normal when measu...

Page 82: ...le T C contacts at the probe Refer to Table 2 Mains power connections on the probe High risk of electric shock KEY 1 Cell ve 2 Cell ve 3 Thermocouple ve 4 Thermocouple ve 5 Cold junction ve 6 Cold jun...

Page 83: ...7 43 109 4 29 42 17 62 6 30 51 42 107 6 29 47 16 60 8 30 55 41 105 8 29 51 15 59 30 59 40 104 29 55 14 57 2 30 63 39 102 2 29 59 13 55 4 30 67 38 100 4 29 63 12 53 6 30 72 37 98 6 29 67 11 51 8 30 76...

Page 84: ...he thermocouple appears to be faulty replace the probe insert including thermo couple and heater assembly If the thermocouple appears to be in order continue from Step 8 8 Switch off the power supply...

Page 85: ...ion unless automatic calibration is enabled Every 6 months COMPONENT PROCEDURE ACTION Ceramic Filter Visual inspection Remove and clean Change if damaged or contami nated Zirconia Cell Check Cell resi...

Page 86: ...Maintenance and Troubleshooting 5 13 This page intentionally left blank...

Page 87: ...power has been removed from the controller and the probe has been allowed to cool for one hour This chapter shows you how to replace sensor parts This includes the following Inner Probe Assembly remov...

Page 88: ...Also remove the chassis ground wire from the bottom right corner of the terminal box 3 Remove the two 1 4 20 nuts using a 7 16 nut driver and locking star wash ers that hold the positioning bracket to...

Page 89: ...itu accessory kit into the two remaining holes Tighten using a flat blade screwdriver Place the 8 32 kep nut removed in Step 4 over the 8 32 stud Using a 11 32 nut driver Tighten the kep nut If the in...

Page 90: ...n of the white cell lead wire For example if white cell lead wire is positioned at 3 o clock place a mark at 3 o clock on the left hex nut of the cell assembly and inner probe assembly see Figure 6 2...

Page 91: ...ly end is on your right and the sheet metal plate is on your left rotate both the sheet metal plate handle end of probe and the left hex nut counterclockwise at the same time until the left hex nut be...

Page 92: ...gether while placing your index finger on the rear of the cell clip Carefully remove the top portion of the retainer clip from the cell clip using a flat blade screwdriver Then remove the retainer cli...

Page 93: ...ex nut is aligned to where the cell clip is welded to the cell lead Take the white cell clip and snap onto the cell placing it between the white band on the cell and the open end of the cell Don t all...

Page 94: ...you don t have two people and the probe is long you may find it difficult to turn both ends at the same time In this case turn the left hex nut one quarter turn then turn the heater one quarter turn...

Page 95: ...Service and Parts 6 9 Figure 6 4 Cell clip with attached cell leads Figure 6 5 Cell and retainer clip placement...

Page 96: ...ed 10 from the tip of the plasma sprayed end heater end The other spiders are placed every 12 thereafter Replacing Heater 1 Slide the new heater through the spiders taking care to avoid touching the w...

Page 97: ...62SE Filter Insitu 20 Micron SS 72346SE Flame Arrestor Std Insitu 71861SE Heater Thermocouple Assembly For 9 Probe 73050TE For 18 Probe 73051TE For 36 Probe 73052TE For 72 Probe 73053TE For 108 Probe...

Page 98: ...6 12 Thermox WDG 1200 1210 Insitu Probes This page intentionally left blank...

Page 99: ...ions you may have ordered in addition to the standard WDG 1200 1210 Insitu probes If you didn t order any custom options the standard Interconnect Drawing is provided If you did order any special opti...

Page 100: ...A 2 Thermox WDG 1200 1210 Insitu Probes...

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