Ametek Thermox WDG-VRM User Manual Download Page 63

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Calibration

6-1

CALIBRATING YOUR ANALYZER

Oxygen Calibration

To calibrate the analyzer, select Start Calibration from the Calibration Menu.

The WDG-V

analyzer should be allowed to reach temperature before

starting any calibration. It is recommended that the analyzer be allowed

to run for a minimum of 2 hours before starting calibration.

Figure 6-1. Calibration Menu Screen

NOTE



Summary of Contents for Thermox WDG-VRM

Page 1: ...Thermox WDG VRM User Manual Thermox 150 Freeport Road Pittsburgh PA 15238 9000 166 VE REV H...

Page 2: ...ao 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...

Page 3: ...Unpacking 3 1 Mechanical Installation 3 2 Mounting the Sensor 3 2 Sample Gas Requirements Connections 3 4 Calibration 3 4 Required Calibration Gases and Tubing 3 5 Manual Calibration Connections 3 5...

Page 4: ...ation 6 11 CHAPTER 7 DIAGNOSTICS Sensor Diagnostics 7 2 Control Diagnostics 7 3 Inject Gas 7 5 Trend Logging 7 6 Cell Diagnostics 7 8 Utility 7 9 Firmware Upgrade 7 11 USB Transfer 7 12 Reset Age 7 14...

Page 5: ...y Up to 5 kV may be present in the analyzer housings Always shut down power source s before perform ing maintenance or troubleshooting Only a qualified electrician should make electrical connections a...

Page 6: ...ng of the WDG VRM electronics or the instrument sitting above the WDG VRM The WDG VRM sensor and host display is a complex piece of equipment that should only be serviced by a qualified service techni...

Page 7: ...residential trash The Wheelie Bin marking on this product is a reminder to dispose of the product properly after it has completed its useful life and been removed from service Metals plastics and oth...

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

Page 9: ...1000 4 8 2009 Magnetic Field Immunity EN 61000 4 11 2004 Voltage Dips Short Interruptions Variations Emissions EN 55011 2009 Class B ISM Equipment EN 55011 2010 FCC PART 15 SUBPART B Conducted Emissio...

Page 10: ...lect 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 Im...

Page 11: ...op Follow these cautions when working on the sensor Remove AC power from the sensor and control unit and allow the sensor to cool for at least one hour before performing any mainte nance or troublesho...

Page 12: ...a constant tempera ture The circuit board in the sensor electronic box switches power to the furnace from the AC mains connected to the sensor This board also provides cold junction compensation to th...

Page 13: ...System Overview 1 3 Figure 1 1 WDG VRM Schematic...

Page 14: ...ssures are on either side of the cell a potentiometric voltage is pro duced See Figure 1 1 The magnitude of this voltage is a function of the ratio of the two oxygen partial pressures If the oxygen pa...

Page 15: ...r The cell produces zero voltage when the same amount of oxygen is on both sides and the voltage increases as the oxygen concentration of the sample decreases The voltage created by the difference in...

Page 16: ...s measured by a dual Type K thermocouple A dual thermocouple is used for self check of the cell temperature The thermocouples are collocated in a single assembly There is no distinction between the tw...

Page 17: ...wiring i e power I O are directly connected to the analyzer through the rear panel Connections are pluggable I O The WDG V has the following I O available Qty 3 configurable 4 20 mA outputs Qty 2 sys...

Page 18: ...that are compatible with AMETEK s Remote Calibration Unit RCU See wiring section for interface details Communications Interface There is three communications interfaces on the WDG VRM RS485 RS232 MODB...

Page 19: ...ibration gases if they contain a mixture of oxygen and combus tibles Always introduce calibration gases at the recommended flow rate When working inside the instrument cabinet turn the power off Do no...

Page 20: ...e factory to provide this information when receiving service Cell millivolts Thermocouple millivolts Cell temperature Serial number See Display in the Setup Key section for help on how to get this inf...

Page 21: ...From 0 1 to 0 to 100 Oxygen Display 4 2 Color 1 4W VGA with Graphical User Interface GUI Password Protected Keypad 18 Key membrane Accuracy 0 75 of reading or 0 05 O2 absolute whichever is greater Re...

Page 22: ...ble NAMUR configurable Hold and track during calibration Maximum load 1000 ohms Alarm Five independent Normally open alarms Set relays to energize or de energize on alarm Contact Rating 0 5A 30V 10VA...

Page 23: ...Environment Ambient Temp 25 C to 50 C Relative Humidity 10 90 non condensing Max Altitude 3000 meters Enclosure 19 Rack mount 4U Indoor use only Power Requirements 115 VAC 10 47 63 Hz 740 VA max 230 V...

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Page 25: ...sensor unless power has been removed Never service the controller or sensor unless power has been removed and it has been allowed to cool for at least one hour Also always use gloves when working on t...

Page 26: ...re is required to be within the limits listed in the specifications appendix contained in this manual If the ambient temperature is outside the specified limits or the vibration is excessive please co...

Page 27: ...Installation 3 3 Figure 3 1 WDG VRM front view Figure 3 2 WDG VRM mounting dimensions...

Page 28: ...WDG VRM inlet and outlet ports NOTE 19 00 482 60 6 97 177 01 4 00 101 60 18 12 460 20 DISPLAY KEYPAD HANDLES 25 09 637 33 OPTIONAL RACK MOUNT SLIDES 7 00 177 80 1 48 37 71 10 38 263 62 SAMPLE INLET 1...

Page 29: ...Mechanical Installation section below If you didn t order a remote calibration unit we recommend that you insert a control valve before the inlet port of the sensor Figure 3 3 shows the location of th...

Page 30: ...tion gases to the RCU Plumbing the RCU to the sensor See the Wiring section in the Installation chapter for help on how to connect wiring between the sensor and the RCU Do not turn on the aspirator un...

Page 31: ...only the top left and lower right holes are used The ambient temperature range for the RCU is 20 to 70 C Mount the RCU as close to the sensor as possible Shorter calibration plumbing improves respons...

Page 32: ...nstrument air 3 Connect the O2 zero calibration gas to the O2 zero gas inlet connection on the RCU 4 Connect the calibration gas outlet on the right side of the RCU to the calibration gas inlet on the...

Page 33: ...move AC mains power from the controller before performing wiring Connections to the analyzer are made through the rear analyzer panel see Figure 3 7 Any screw terminals not described in this section a...

Page 34: ...3 10 Thermox WDG VRM Figure 3 7a Customer I O Interconnecting WDG VRM...

Page 35: ...Installation 3 11 B DETAIL B SCALE 6 4 Figure 3 7c Customer I O Interconnecting WDG VRM...

Page 36: ...applicable approved conduit fittings or cable fittings to maintain the rating of the sensor enclosure If not using a conduit entry leave the factory approved plugs intact Follow proper grounding shie...

Page 37: ...ace the transient suppressor as close to the load as possible Examples of transient suppressors include MOVs TRANSORBs and RC snubbers AC mains supply wiring should not be run in the same conduit with...

Page 38: ...ity when connecting current output devices to these terminals Each of the current outputs are capable of driving up to 1000 ohm loads The current outputs can be selected for the following ranges 0 20m...

Page 39: ...Installation 3 15 Figure 3 9 Output Device Max load 1000 DETAIL D SCALE 1 1 OUTPUT DEVICE MAX LOAD RESISTANCE 1000...

Page 40: ...e alarm contacts are labeled FLTA B DVLDA B ALM3A B ALM4A B ALM5A B on the rear panel of the analyzer They have a rating of 10 VA maximum 30 volts AC or DC see Figure 3 9 Information on how to set up...

Page 41: ...gen only remote calibration unit connections Oxygen Only Remote Calibration Unit RCU connections on the WDG VRM ana lyzer and their RCU connections are as follows see Figure 3 11 ZERO GAS WDG V Termin...

Page 42: ...CALE 1 1 13 14 15 16 ZERO ASP O2 SPAN COM REMOTE CAL UNIT ALL COMMON WIRES TO PIN 16 ON RCU AND TERMINAL V ON ANALYZER OVERALL BRAIDED SHIELD OR RIGID METAL CONDUIT ADDITIONAL SPAN CHANNELS 17 18 ON R...

Page 43: ...ut must be a normally open switch Modbus RS 232 RS 485 Communications Connections Follow general grounding and shielding requirements for all wiring as described in the General Wiring Requirements sec...

Page 44: ...3 20 Thermox WDG VRM This page intentionally left blank...

Page 45: ...ys concentration values system status and alarms if present The Home screen items include Gas Concentrations Trend Plot 30 min only on O2 Temperatures hidden in normal mode Time Date Sensor Name Last...

Page 46: ...n warnings are present This Home screen is not configurable except the thermometers can be viewed in Normal Mode by pressing the UP arrow They can be hidden again by pressing the DOWN arrow Temperatur...

Page 47: ...4 3 Main Menu The menus have a cover flow system similar to many smartphones The menus wrap in either direction and can be navigated by using the right or left arrows Press Menu to select Figure 4 2 M...

Page 48: ...4 4 Thermox WDG VRM Menu Structure Show below is the complete menu tree for the user interface Figure 4 3 Menu Structure...

Page 49: ...setting up your sensor depending on your particular process and application You can set these by selecting Sensor Configuration in the Configuration Menu Figure 5 1 Configuration Menu Screen For the W...

Page 50: ...to three configurable analog outputs This can be setup through the configuration menu Analog Outputs You can direct process readings to any of the three analog output ports Configurable for Function O...

Page 51: ...is displayed beneath the sensor name is the active output you are configuring Use the navigation arrows to access each of the functions Press the ENTER MENU key to view the drop down menu and use the...

Page 52: ...tput 1 The image below shows the analog output configuration screen Use Left Right Arrow to navigate to the next Analog Output Figure 5 4 Analog Out Screen Track Hold During Cal Options Track during C...

Page 53: ...vels based on what the user has defined in the setup menus have been exceeded Service alarms activate when there is a hardware malfunction and the analyzer is not operating correctly Data Valid alarms...

Page 54: ...n Use Left Right Arrow to navigate to the next Relay Figure 5 6 Alarm Configuration Screen Here set high and low alarm limits and determine whether the signal should energize or de energize upon alarm...

Page 55: ...nications Configuration for TCP IP and customer Modbus Figure 5 8 Configuration Menu Screen TCP IP Configuration Configurable for IP Address Subnet Mask Gateway IP DHCP enable disable Figure 5 9 TCP I...

Page 56: ...5 8 Thermox WDG VRM Modbus Configuration Configurable for Baud Parity Stop Bits Figure 5 10 Modbus Configuration Screen Left Right Arrow to toggle between Modbus and TCP IP configuration...

Page 57: ...time for data logging and system events to log properly Figure 5 11 Configuration Menu Screen Entering The System Time Enter the correct local date and time as shown below Use 24 hour military time no...

Page 58: ...zer configuration A super user level passcode will give access to all menus includ ing the analyzer configuration menu This includes the analog output configuration and passcode configuration among ot...

Page 59: ...hanges to the analyzer configuration The super user passcode will give access to all menus including the configura tion menu All users and super users will be prompted for a pass code when they press...

Page 60: ...nfiguration menu and press the ENTER MENU key 3 Use the keypad to enter the name s of your analyzer s Enter the name as you would on a mobile phone The keypad displays the characters as you enter them...

Page 61: ...down menu to select the untis for use on the analyzer scfh lpm ccm Use the keypad to enter the low flow alarm threshold in the appropriate units Flow readings are not pressure compensated therefore m...

Page 62: ...m the main menu screen press the ENTER MENU key to access the calibration menu 2 Use the left and or right navigation arrows to locate the FLOW SENSOR CALIBRATION menu and press the ENTER MENU key 3 E...

Page 63: ...elect Start Calibration from the Calibration Menu The WDG VRM analyzer should be allowed to reach temperature before starting any calibration It is recommended that the analyzer be allowed to run for...

Page 64: ...r defines the calibration gas values and physically switches the gases Automatic Calibration This is an option that allows the system to calibrate itself The user defines the cali bration gas values t...

Page 65: ...e calibration process under the Start Calibration menu Figure 6 2a Cal Gas Values Menu Figure 6 2b Set Cal Gas Values Figure 6 2c Start Calibration Menu Figure 6 2d Calibration Gas Values 1 From the M...

Page 66: ...riggered by low flow Calibration can start or continue during low flow alarm status The span gas is the high calibration gas The zero gas is the low cali bration gas If you do not select a gas to cali...

Page 67: ...hanged in the Cal Gas Values menu as well 7 When you have entered all of the values press the ENTER MENU key to START the calibration Inject the Oxygen Span Gas You are prompted to inject the O2 span...

Page 68: ...displays the Calibration Results that include drift as well as recovery time If the calibration is successful a large green check mark will be displayed If it is not a large red X is displayed Figure...

Page 69: ...Use the Start Calibration or Set Cal Gas menu to define the gases and values and then use the Start Calibration menu to perform an immediate calibration This requires the user to program the Start Ca...

Page 70: ...Next Calibration Filled Automatically You must exit this menu and re enter to view the next calibration date set by the system You must select the Enabled check box When you have completed this scree...

Page 71: ...in the fields Any changes that you make to these values will be reflected in the Cal Gas Menu as well 9 When you are satisfied with your values press the ENTER MENU key to start the automatic calibrat...

Page 72: ...press the ENTER MENU key 3 Navigate to the drop down box press the ENTER MENU key and choose Re mote 4 Press the right arrow to continue 5 Select the gas es that you want to calibrate 6 Enter the tim...

Page 73: ...f the flow meter is only required if the sample flow is not vented to the atmosphere Performing a calibration will create an offset to compensate for any pressure effect An accurate eternal flow measu...

Page 74: ...6 12 Thermox WDG VRM 5 Flow rate will now be compensated Calibration is valid only if the pressure remains consistent Any sig nificant change in sample pressure will require re calibration NOTE...

Page 75: ...ccur Diagnostics also provide the ability to test customer I O such as analog outputs and relay outputs pro viding information that is useful when troubleshooting the interface to the distributed cont...

Page 76: ...degrees Celsius Cell HDC Box HDC On Time days hours Total on Time days hours 2 Use the right navigation arrow on the AMEVision enclosure to move to the next screen Sensor Diagnostics Screen 2 Cell Mil...

Page 77: ...Mode ON if you make any changes Press the CANCEL key to exit and turn off Diagnostics Mode 2 There are three screens that make up the Control Diagnostics menu Analog I O Relays and Close Contact Contr...

Page 78: ...iagnostic Mode Close Contact screen This screen reflects the status of the contact input on the sensor board inter face The user provides the physical connection to the appropriate terminal block Cont...

Page 79: ...nd press the Enter menu key An X appears in the check box of the option selected 2 Navigate to the START button press the Enter menu key to inject the gas Figure 7 2 Diagnostic Mode Inject Gas screen...

Page 80: ...is also a useful tool for the technician who can see weeks and months of data to determine more easily at what point a problem occurred or to use the data to head off a potential problem The candlesti...

Page 81: ...menu key 2 Select the gas to log and press the Enter menu key An X appears in the check box Figure 7 4a Trend Options Setup menu 3 Use the right arrow to move to the time period and press the Enter me...

Page 82: ...hen it needs to be replaced 1 Use the left and or right navigation arrows to locate the Cell Diagnostics menu and press the Enter menu key 2 Cell diagnostics are displayed as in the chart below Cell A...

Page 83: ...n Menu screen press the Enter menu key to access the Menus 2 Use the left and or right navigation arrows to locate the Utility menu and press the Enter menu key There are four utility menus Parameter...

Page 84: ...Parameter Management menu 2 Press the Enter menu key to access the Sensor Parameters Manage ment menu The Sensor Parameter Management screen displays 3 Use the navigation keys to select the function S...

Page 85: ...n to upgrade and press the Enter menu key 4 You will be directed to Insert the USB drive containing the option s firmware 5 Locate the plug in port for the USB flash drive on the rear of the analyzer...

Page 86: ...a USB drive for use on a computer 1 Use the left and or right navigation arrows to locate the USB Transfer menu and press the Enter menu key 2 Press the Enter menu key to access the USB Transfer scre...

Page 87: ...fer Trend Data 1 Locate the plug in port for the USB flash drive on the rear of analyzer 2 Navigate to the Transfer Trend Data button and press the Enter menu key A screen will display asking if you h...

Page 88: ...ocate the Reset Age menu and press the Enter menu key 2 Press the Enter menu key to access the Reset Age screen 3 Use the up and down arrows to navigate to the option whose age you want to reset and p...

Page 89: ...bout Sensor About Host 1 Navigate to About Host and press the Enter menu key The informa tion screen for the Host displays Host Serial Number Host Firmware Revision 2 Press the CANCEL key to exit the...

Page 90: ...ored by the analyzer This includes all passcode changes To view the Alarm history select Alarms from the Main Menu Figure 7 5 Main Menu Screen Then select Alarm History Figure 7 6 Alarm Menu Screen Th...

Page 91: ...d 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 system and error messages It also provides troubleshoot...

Page 92: ...teel prevents any problems that might occur with plastic melting the nozzle on hot sensor components 2 Monitor the response from the cell When the cell millivolt reading changes it indicates a leak in...

Page 93: ...ommend that the thermocouple mil livolts and cell millivolts be displayed during troubleshooting as a troubleshoot ing aid This information will be helpful should you need to contact the factory for a...

Page 94: ...ound and between terminal TC on the sensor board and chassis ground If shorted replace the thermocouple To verify the operation of the thermocouple itself remove the thermocouple from the sensor and h...

Page 95: ...ion inlet port using a flow meter to set the proper flow and compare the response with that from the possibly contaminated line Remote Calibration Unit RCU Problem The RCU contains one normally open s...

Page 96: ...rawing is included with your Installation package Select Cal Gas Duration from the Calibration menu to set cali bration gas times If performing a manual calibration ensure that you are waiting for the...

Page 97: ...e is not a problem with the cell itself see the Leak Check section later in this chapter for help on how to check for leaks see the Calibration Aspirator Air Checks section earlier in this chapter for...

Page 98: ...ailure Cell heater failed to heat the cell Bad Cell furnace heater Bad heater connection Shorted T C Bad T C con nection Unit must be reset to clear this alarm Over Temp Relay Tripped The cell over te...

Page 99: ...og Ouptut 2 Out Of Range The analog output value is saturated high or low Improperly set range Analog Ouptut 3 Out Of Range The analog output value is saturated high or low Improperly set range Last O...

Page 100: ...a service alarm and is in need of attention Printed Circuit Board PCB Status LED s There are two small surface mount green LED s on the PCB located on the back left corner of the PCB when looking at...

Page 101: ...lip Outside P N 72328SE Coil Heater 300W Furnace 115VAC P N 7000 424 KE Coil Heater 300W Furnace 230VAC P N 7000 563 KE RTD Box Temp Control 100 Ohm P N 1000 630 JE Solenoid NO Asp RCU P N 36088JE Sol...

Page 102: ...M When ordering provide the serial number of your analyzer to ensure proper parts are ordered AMETEK Process Analytical Instruments Division 150 Freeport Road Pittsburgh PA USA 15238 Phone 412 828 904...

Page 103: ...Customer Modbus Map 10 1 Customer Modbus Map...

Page 104: ...44 21 PARID_O2ZEROGAS Float Zero gas value in Writable 45 23 PARID_DATAVALID Unsigned Int 16 Datavalid 1 if valid 0 if not Read Only 48 24 PARID_STATE Unsigned Int 16 Current state of the analyzer Re...

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