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Service and Parts | 7-1

SERVICE AND PARTS

The operations in this chapter should be performed only by qualified
service personnel with a knowledge of electrical safety techniques.
There are no operator-serviceable components inside the TM2000
system.

This appendix shows you how to replace system parts, and is divided into
the following sections:

• Thermocouple Replacement

• Cell Replacement

• Furnace Replacement

See the Installation Chapter for help on how to remove or replace Series
2000 control unit modules or option cards, including the display module,
power supply/keypad module, wiring module, and the auto calibration
option card.

You can clean the outside of the sensor or controller (or remote calibration
unit) using normal household or commercial general purpose cleaners,
cloths, or sponges. You can also use water. Always turn off power before
attempting to clean the enclosure.

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Содержание Thermox TM2000

Страница 1: ...Thermox TM2000 Oxygen Analyzer User Manual Thermox 150 Freeport Road Pittsburgh PA 15238 PN 90287VE Rev T...

Страница 2: ...ian Yao Qiao Road Shanghai 200030 Ph 86 21 6426 8111 Fax 86 21 6426 7054 USA Delaware 455 Corporate Blvd Newark DE 19702 Ph 302 456 4400 Fax 302 456 4444 AMETEK Beijing CITIC Building Room 2305 19 Jia...

Страница 3: ...PECIFICATIONS CHAPTER 3 INSTALLATION AND START UP Unpacking 3 1 Mechanical Installation 3 2 Sensor Mounting 3 2 Sample Gas Calibration Gas Plumbing 3 2 Clean Gas RCU Installation Optional 3 8 PPM Meas...

Страница 4: ...Cal Gas Value 5 17 Inject Cal Gas 5 18 Set Cal Timers 5 20 Configure Verify 5 25 CHAPTER 6 MAINTENANCE AND TROUBLESHOOTING System Messages 6 2 Error Messages 6 4 Diagnostic Checks 6 8 General Trouble...

Страница 5: ...trical 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 co...

Страница 6: ...DE D CHARGE LECTRIQUE Achtung Hochspannung Lebensgefahr Caution Refer to accompanying documents ATTENTION SE R FERER AUX DOCUMENTS JOINTS Achtung Beachten Sie beiliegende Dokumente CAUTION Hot Surfac...

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

Страница 8: ...ea is Known to be Non Hazardous Risque d explosion Avant de d connecter l quipement coupez le courant o vous assurez que l emplacement est design non dangereux All input and output wiring must be in a...

Страница 9: ...ste system residential trash The Wheelie Bin marking on this product is a reminder to dis pose of the product properly after it has completed its useful life and been removed from service Metals plast...

Страница 10: ...vy Industrial EN 61000 6 2 1999 EU Generic Heavy Industrial Equipment Emissions EN 55011 1998 Class A ISM Equipment Safety Compliance UL 3101 1 UL Listed Inspection and Measuring Electrical Equipment...

Страница 11: ...ch has been subject to misuse neglect abuse or improper use Misuse or abuse of the equipment or any part thereof shall be construed to include but shall not be limited to damage by negligence accident...

Страница 12: ...xii Thermox TM2000 Oygen Analyzer This page intentionally left blank...

Страница 13: ...umbing Flow control valve all inlet and outlet tubing the sens ing cell and the sensing cell fitting The Measuring System Sensing cell sensor board interconnecting wiring and the control unit The Temp...

Страница 14: ...ial pressures are on either side of the cell a potentiometric voltage is produced See Figure 1 1 The magnitude of this voltage is a function of the ratio of the two oxygen partial pressures If the oxy...

Страница 15: ...e of the cell combustible gases that are present may burn When this occurs the cell will gener ate high millivolts and cause the display to indicate less oxygen than is actually in the gas net oxygen...

Страница 16: ...bing inside the sensor cabinet turn the power off The heater has exposed windings and a short to the plumbing will blow the fuse and could damage the furnace or ther mocouple Do not handle the cell ex...

Страница 17: ...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...

Страница 18: ...1 6 Thermox TM2000 Oxygen Analyzer This page intentionally left blank...

Страница 19: ...help are also provided Analog Output Two isolated linear current outputs Select O2 cell temperature thermo couple mV or cell mV Each output can be 4 20 mA 0 20 mA 20 4 mA or 20 0 mA and is fully scala...

Страница 20: ...ution Degree 2 Enclosure Standard weatherproof NEMA 4 IP56 wall pannel mount Optional GP General Purpose wall mount GP 19 rack mount GP panel mount or stainless steel weatherproof NEMA 4X IP 56 wall p...

Страница 21: ...at 0 6 L min 1 3 scfh over one decade Repeatability Percent 0 5 of reading or 0 1 O2 absolute whichever is greater PPM 0 5 of reading or 0 1 PPM O2 absolute whichever is greater Ambient Temperature 18...

Страница 22: ...as From 0 1 PPM to 10 O2 balance N2 Span Gas Minimum one decade above zero gas 10 times greater System Compliance EMC Directive 2004 108 EC Low Voltage Directive 73 23 EEC Remote Calibration Unit RCU...

Страница 23: ...onnel should never service the controller or sen sor unless power has been disconnected from the controller and sensor and the sensor has been allowed to cool for at least one hour Also always use glo...

Страница 24: ...ensor with the sample bypass option The sensor should be mounted as close to the sampling system as pos sible This improves the response time of the sensor and also reduces the chances of condensing m...

Страница 25: ...Installation and Start Up 3 3 Figure 3 1 Sensor Mounting no sample bypass...

Страница 26: ...calibration gases is 70 C 160 F The sample gas must also be clean and dry If the sample contains any condensing moisture you should heat trace the entire sam ple line to prevent condensation Any cond...

Страница 27: ...ressure fluctua tions can lead to inaccurate sensor readings Also make sure that the inlet pressure is high enough to maintain the desired flow rates but not over 20 PSIG The next paragraph describes...

Страница 28: ...CU and to the sensor If you did not purchase the factory provided RCU you must provide a way to switch between your sample gas and the calibration gases Sensor mechanical setup no sample bypass Figure...

Страница 29: ...Installation and Start Up 3 7 Figure 3 4 Manual calibration setup with sample bypass Figure 3 3 Manual calibration setup...

Страница 30: ...this distance improves the response time of the sensor and saves money on calibration gases The maximum distance is 15 feet 4 58 meters The maximum ambient temperature for the RCU is 122 F 50o C 2 To...

Страница 31: ...Installation and Start Up 3 9 Figure 3 5 Clean gas RCU mounting dimensions Figure 3 6 Clean gas RCU plumbing connections...

Страница 32: ...also required if you have the sample bypass op tion 1 Connect the sample gas from your process to the sample inlet on the TM2000 sensor see Figure 3 8 This connection is located on the bot tom of the...

Страница 33: ...Installation and Start Up 3 11 Figure 3 8 TM2000 sensor connections with bypass Figure 3 9 Clean gas RCU calibration setup...

Страница 34: ...t calibration gases are less sensitive to hydrocarbons in the cali bration tank than are PPM calibration gases If using a low PPM oxygen calibration tank even a few hydrocarbons in the tank can signif...

Страница 35: ...Even a small amount of contamination in tubing line can affect PPM oxygen readings Quick Response To improve the response time of the TM2000 use as small a sample tube diameter as possible The smaller...

Страница 36: ...weatherproof panel mount Weatherproof panel Figure 3 10 shows the panel mounting dimensions for the Series 2000 weather proof enclosure Use diameter fas teners to mount the control unit to the panel W...

Страница 37: ...ning purge air flow before the door is opened unless the area is demonstrated to be nonhazardous Z Purge start up procedure Power should not be restored after the enclosure has been opened until the e...

Страница 38: ...RS 310 C universal spacing General Purpose Wall Figure 3 15 shows the mounting dimen sions for the Series 2000 general purpose wall enclosure Use diameter fasten ers to mount the control unit to the...

Страница 39: ...l purpose wall mount version Figure 3 16 shows the orientation of the wiring card for general purpose rack and panel mount versions for all other versions the wiring card is rotated 180 degrees To acc...

Страница 40: ...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 Follow all app...

Страница 41: ...There is no power switch or circuit breaker on the control unit It must be protected by installing it on a circuit protected line with maximum 15 amperes a switch or circuit breaker in close proximit...

Страница 42: ...ng Method Shield Ring Method Connect all shields for that conduit entry other than power to a sup plied shield terminal ring see Figure 3 18 This shield ring is a stain less steel ring with a metal ta...

Страница 43: ...transient suppressors include MOVs TRANSORBs and RC snubbers AC mains supply wiring should not be run in the same conduit with mains supply wiring that feeds heavy inductive loads Avoid running signal...

Страница 44: ...ng sensor con nections This section describes required wiring connections between the control unit and the sensor Follow the connection instructions for the applicable options for your analyzer All se...

Страница 45: ...ker on the sensor It must be pro tected by installing it on a circuit protected line maximum 15 amperes with a switch or circuit breaker in close proximity to the sensor and within easy reach of an op...

Страница 46: ...ting current output devices to these terminals Current outputs 1 and 2 are capable of driving up to 1200 ohm loads The standard control unit with no options provides two current outputs These two curr...

Страница 47: ...Installation and Start Up 3 25 Figure 3 22 Current output connections example...

Страница 48: ...con trol unit ALARM 1A ALARM 1B See the Watchdog Relay section in the Controller User Interface chapter for complete information on the watchdog timer alarm The watchdog alarm contacts are normally c...

Страница 49: ...3 27 Oxygen Alarm connections are configurable in software to activate under a variety of user defined conditions and are labeled as follows ALARM 3A ALARM 4A ALARM 3B ALARM 4B Figure 3 23 Series 2000...

Страница 50: ...han the control unit see Figure 3 25 For this option to work you must have a remote calibra tion unit and an auto calibration card The system monitors the digital input and when the switch closes it s...

Страница 51: ...Installation and Start Up 3 29 Figure 3 25 Series 2000 controller RCU connections...

Страница 52: ...ll 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 host computer In addition on the host c...

Страница 53: ...Installation and Start Up 3 31 Figure 3 26 Series 2000 2 wire RS 485 communications connections...

Страница 54: ...ions 4 Wire Termination Resistor The Series 2000 Control Unit is equipped with termination resistors that can be used for the last control unit on the network SW1 1 ON SW1 2 ON SW1 3 ON This provides...

Страница 55: ...Installation and Start Up 3 33 Figure 3 27 Series 2000 4 wire RS 485 communication connections...

Страница 56: ...l unit see Figure 3 28 and provides fuse ratings for the one fuse on the display module as well as the one fuse on the wiring card Disconnect power from the control unit before working on it 1 Open th...

Страница 57: ...e card is properly seated by pressing on both sides firmly If the card is not properly seated the access door may not close 4 Reinstall the power supply keypad module Removing an Option Card 1 Remove...

Страница 58: ...3 36 Thermox TM 2000 Oxygen Analyzer This page intentionally left blank...

Страница 59: ...er provides a brief overview on how to use the Series 2000 con trol unit This includes the following topics Areas of the Control Unit Password Restrictions Control Unit Display Auto Ranging Feature Co...

Страница 60: ...sword is required you must first enter the password to access that menu s func tions See the Setup Key section of this chapter for help on how to create a system password Control Unit Display The main...

Страница 61: ...cale Control Unit Keys This section provides an introduction to the main Series 2000 control unit keys Each of these keys provides a menu of choices that can be selected When in a menu enter values by...

Страница 62: ...first display line it indicates that there are more menu options available by pressing the Up Arrow Key Exiting Menu Options To cancel out of a specific menu press the Cancel Key To exit all menus con...

Страница 63: ...Pres sure Perform system tests System Tests View the serial and manufacturing number for your control unit Sys tem Serial Perform a primary calibration on the sensor Primary Calibration This is not a...

Страница 64: ...y Select info for Display Line 1 Select info for Display Line 2 Select info for Display Line 3 Passwords Create a system password Process Pressure Select a positive or negative process pressure Enter...

Страница 65: ...that you put the information that is most critical for you to view on the first and second display lines Setting Up the Display 1 Select Display from the Setup menu 2 Select Display Line 1 Display Lin...

Страница 66: ...es you to the Capital letter A Pressing the number 3 Key moves you to the Capital letter Z Pressing the number 7 Key moves you to the small letter a Pressing the number 9 Key moves you to the small le...

Страница 67: ...e provided so you can access this option and enter a new system password 1 Select Passwords from the Setup Key menu You will be prompted to enter a new system password Enter NEW Password 2 Enter a fou...

Страница 68: ...the Setup Key menu 2 Select Positive Pressure or Negative Pressure You are then prompted to enter your system process pressure Pressure xxx x kPa New Value 3 Enter your process pressure up to one deci...

Страница 69: ...Memory RAM Test Keyboard Tests that each key is functioning correctly Test EEPROM Tests the electrically erasable programmable read only memory Module Detect Allows the control unit to check for the p...

Страница 70: ...the user This is used to test communication settings and wiring Read Memory Location This is used to view internal software variables used for system opera tion and troubleshooting System Serial This...

Страница 71: ...13 07 mVs If you have a T C ratio of 0 9 the corresponding furnace temperature set point should be 615 C 0 9 683 C If you measure the voltage at terminals C and D on the sensor board with a 50 C ambie...

Страница 72: ...of 615 C the T C ratio low limit is 0 7 and the high limit is 1 3 which corresponds to a thermocouple indicated temperature range of 473 C to 878 C If the analyzer is configured for a cell operating...

Страница 73: ...u will be prompted to select Auto Calibrate Remote Calibrate or Manual Calibrate If you don t have the auto calibration option you will be placed into a manual calibration where you will be told to in...

Страница 74: ...the hy drocarbon upset condition If the oxygen reading drops to 0 PPM and the millivolt value you entered is reached or exceeded the system displays a low oxygen high hydrocarbons message rather than...

Страница 75: ...are using to communicate Choices are 300 600 1200 2400 4800 and 9600 baud Node Address This parameter allows you to define the physical address for the con trol unit between 0 and 255 on a network so...

Страница 76: ...alibration or a verify Remote Switch Config See the Installation chapter for help on connecting wiring between the digital input and the TM2000 control unit to activate a digital input signal Configur...

Страница 77: ...analog output port The Analog Range key Figure 4 4 section of this chapter provides help on how to do the following Define what information should be sent to the analog output port during a calibrati...

Страница 78: ...tering Analog Range Key menu options are presented in the order in which they appear on your control unit screen from top to bottom Figure 4 5 provides an overview of the functions covered by each Ana...

Страница 79: ...ification of the password the numbers you enter will not be displayed You will then be able to access Analog Range Key functions Analog Output Port Before you can define any Analog Range Key functions...

Страница 80: ...ent Setting the current range To set the range of readings that the selected current output represents 1 Select Set Current Range from the Analog Range Key menu after selecting an analog output port 2...

Страница 81: ...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 for example you can elect to hold the last...

Страница 82: ...ay Out 1 will TRACK during Calibration or Out 1 will HOLD during Calibration For verify operations select one of the following Hold during verify or Track during verify After you select one of these o...

Страница 83: ...utput Setting the current mode 1 Select the Set Current Mode menu option from the Analog Range Key after selecting an analog output port 2 Select 4 to 20 mA Mode or 0 to 20 mA Mode The following will...

Страница 84: ...llows you to select what type of infor mation the analog output port should track Choices are as follows Oxygen Cell temperature Thermocouple millivolts T C mv Cell millivolts cell mv Selecting the fu...

Страница 85: ...s are disabled during start up until the sensor reaches its proper operating temperature Oxygen alarms are also disabled during a system alarm condition See the Wiring section in the Installation chap...

Страница 86: ...menu option applies to all alarms except the watchdog and service alarms which always de energize on alarm Define alarm set point values Alarm Set Points Whether these alarms are set to activate for h...

Страница 87: ...high alarm occurs an up arrow will appear to the right of the O2 value If for example you set Alarm 3 for a high O2 alarm and Alarm 4 for a high O2 alarm and the O2 value exceeds both the Alarm 3 and...

Страница 88: ...PPM value this option won t appear if Alarm 3 is not set to activate based on an O2 reading but rather is set to activate based on the start of a calibration or verification 3 You will be prompted to...

Страница 89: ...lect Alarm 4 as a low oxygen alarm Alarm 3 however can still be selected as a high or low oxygen alarm Configuring the alarms 1 Select Alarm Configure from the Alarm menu 2 Define Alarm 3 and Alarm 4...

Страница 90: ...fication the alarm will deacti vate once the calibration or verification has been completed including any recovery duration you have specified If you select Hydrocarbon Upset as the Sensor Config opti...

Страница 91: ...ormally closed system failure causes open contacts The watchdog alarm relay de energizes when the system watchdog timer times out The watchdog timer will time out and cause the control unit to reset i...

Страница 92: ...u the most recent exception log entry on line four of the display and shows when this event was recorded on line three Line three of the display also shows the order in which events are recorded into...

Страница 93: ...ncludes a way for the system to periodically calibrate itself All oxygen alarms are disabled during calibrations or verifications in cluding the recovery time after a calibration or verification For a...

Страница 94: ...alibrations require a remote calibration unit RCU that automatically switches the calibration gases and an auto calibration card installed in your control unit Manual cali brations are performed witho...

Страница 95: ...librations or verifications Set Cal Timers Set Auto Timers Set the current date and time Set Cal Timers Set Time and Date Figure 5 2 Overview of Calibrate Key functions Calibrate Key Menu Function Opt...

Страница 96: ...mers Cal Gas Dura tion Define recovery duration times Set Cal Timers Recovery Duration Define verify gas values to match known values of verify gas cylin ders enter acceptable verify range Configure V...

Страница 97: ...ot be displayed You will then be allowed to access Calibrate key functions Initiate Cal The Initiate Cal menu option allows you to perform an automatic re mote or manual calibration The Auto Calibrate...

Страница 98: ...tion gas value to match the zero calibration gas cylin der you intend to use to calibrate your system Define how long you want the calibration gas to flow through the sen sor Set Cal Timers Cal Gas Du...

Страница 99: ...g During this time the RCU has switched the solenoid valves and has intro duced the zero gas to the sensor Then the system will display the recovery time remaining Recovery xx xx The system then retur...

Страница 100: ...he far left of the display had stabilized yet is not near the setpoint value on the far right of the display you should check the cal gas value you entered to ensure that this value matches the cal ga...

Страница 101: ...te You are then prompted to apply the O2 span gas to the calibration gas inlet port of the sensor tubing must be free of oil and dirt Inject Span Gas Vrfy Gas ENTER to Continue CANCEL to Abort 4 Press...

Страница 102: ...on This O2 zero gas setpoint value should match the cal gas cylinder for the O2 zero gas Then if you specified a recovery time the system will display the recovery time remaining Recovery xx xx System...

Страница 103: ...the span gas port of the RCU Auto Verify Before you can start an auto verify you must do the following Enter the verify gas value to match the verify gas cylinder you intend to use to verify your syst...

Страница 104: ...rify This value is referred to in this section as a set point value 1 Select Initiate Verify from the Calibrate key menu 2 Select Remote Verify The following then appears on your display O2 xx x Set x...

Страница 105: ...tem returns to process readings Manual Verify 1 Enter the verify gas value to match the verify gas you intend to use to calibrate your system and also determine the acceptable verify range see the Con...

Страница 106: ...is set point value should match the value on your verify gas cylinder If your O2 reading on the far left of the display has stabilized yet is not near the set point value on the right of the display c...

Страница 107: ...alue the system reads from the cal gas The term Span Drift or Zero Drift is the difference between the entered calibration gas value and the calibration gas values read by the system Both the latest c...

Страница 108: ...en the calibration was completed If this occurs reset the analyzer s time and date Verify Data For verify data the display shows the verify gas data Verify Value xx Verify Gas xx Verify Diff xx The te...

Страница 109: ...s Value from the Calibrate key menu 2 Choose whether you wish to enter the span gas value using a percent or PPM scale You are then prompted to enter the span gas value Span Gas xx New Value 3 Enter t...

Страница 110: ...libration gas pressure and flow requirements It is important that all calibration gases as well as the sample gas flow through the analyzer at the same flow rate 1 Connect the span and zero gas cylind...

Страница 111: ...to the sensor Zero gas is flowing 4 Adjust the pressure and flow for the zero gas to the desired levels You will then be prompted to end the cycle CANCEL to quit 5 Press the Cancel key to end the cyc...

Страница 112: ...ation cycle Auto Cal On Off Define how long cal gases should flow through the sensor during automatic calibrations or verifications Cal Gas Duration Define a recovery duration during which time the se...

Страница 113: ...from the Set Cal Timers menu 2 Select Auto Cal Cycle if defining an automatic calibration cycle Se lect Auto Verify Cycle if defining an automatic verification cycle 3 Select Set Cycle in DAYS or Set...

Страница 114: ...libration or verification will take place at midnight Set Cal Timers Set Time and Date This menu option allows you to set the date or time for the internal con trol unit clock Make sure the current ti...

Страница 115: ...orarily disable the automatic calibration or verification cycle When the process is again operating you can re enable the auto calibration or verification cycle and retain all your timer settings 1 Se...

Страница 116: ...ou 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 the Enter key If performing an automatic verificat...

Страница 117: ...for example your low alarm is set to activate if readings fall below 3 and your calibration gas is 2 1 Select Recovery Duration from the Set Cal Timers menu You will be prompted to enter a calibratio...

Страница 118: ...xample if you enter a verify gas range of 1 and the verify gas value is 10 then the acceptable range is between 11 and 9 If during a verify operation Initiate Verify menu option the system finds that...

Страница 119: ...the sensor has been allowed to cool for at least one hour Always wear gloves when working on sensor components This chapter describes Series 2000 control unit system error messages as well as trouble...

Страница 120: ...n Aborted This message indicates that the calibration has been aborted by the user Calibration Required This message is displayed to inform the operator that a regular calibra tion is required after a...

Страница 121: ...emoving and restoring power to the unit Primary Calibration This message appears when the system is performing a Primary Calibra tion The message continues to be displayed during the one hour recov er...

Страница 122: ...ure The software shuts off the furnace until the temperature returns to normal operating range If this message soon goes away it indicates that the temperature has returned to an acceptable range If t...

Страница 123: ...g and then restoring power to the unit If you see this message you should reset the control unit to the values required for your application including Setup Key Calibrate Key Alarm Key and Analog Rang...

Страница 124: ...tection circuit trip on the sensor board Sensor board failure Loss of furnace drive signal from control unit Thermocouple failed shorted or opened Interconnecting wiring problem Polarity of thermocoup...

Страница 125: ...ithin the range you defined If you receive this message calibrate the analyzer Zero Gas Range Error This error message occurs if the calibration zero gas does not read within the software s allowable...

Страница 126: ...tion aspirator setup checks AC power checks Furnace checks Process pressure checks Cell checks Exercise care when working on the sensor Turn off power allow the unit to cool and wear gloves Wiring Che...

Страница 127: ...doesn t solve the problem remove the thermocouple from the sensor and connect a Type K test meter Using a thermometer check the temperature of an environment Place the thermocouple in this same enviro...

Страница 128: ...ake memory location 88 which is the T C Ratio calculated during the primary thermal calibration and divide the cell temperature by this value to come up with the furnace temperature set point Note The...

Страница 129: ...e Calibration chapter for help on how to set up flow and inlet pressure Check that the PPM calibration gas cylinders are made of aluminum and not steel Check that the calibration gas cylinders are les...

Страница 130: ...ignal 3 Connect the vacuum port side of the pressure gauge for example a Magnehelic gauge to the T fitting 4 Connect the sample gas outlet to the T fitting 5 Connect an aspirator to the T fitting 6 Co...

Страница 131: ...wiring is correct replace the Auto Cal Card If the solenoid drive signal is not present it indicates a problem with one of the solenoid valves Replace the solenoid valve being sure that the solenoid O...

Страница 132: ...aiting for the reading to stabilize on the display before switching to the next calibration gas AC Power Checks Loss inadequate AC voltage to the sensor Measure the AC voltage to the sensor board at t...

Страница 133: ...eck across FURNACE and 15V COM on the control unit wiring card for the furnace drive signal If the signal is not present check fuse F1 on the wiring card If this fuse is OK replace the control unit po...

Страница 134: ...put the analyzer through a primary calibration If this does not work check the following Check the proper flow rate and pressure of the gases Check for leaks or plugged plumbing in the sensor Check t...

Страница 135: ...commend a low PPM gas for the best results to the inlet of the sensor This pulls the low calibration gas into the sensor Allow the gas to stabilize and then measure the cell millivolts Spray 100 oxyge...

Страница 136: ...lenoid valve 1 Normal Operations When lit this indicates that the system is not in calibration This LED remains off for the entire calibration cycle then turns back on during the calibration recovery...

Страница 137: ...ions Thermocouple Replacement Cell Replacement Furnace Replacement See the Installation Chapter for help on how to remove or replace Series 2000 control unit modules or option cards including the disp...

Страница 138: ...The outside of the sensor cover and all sensor assembly components are extremely hot up to 500 F 260 C inside the cover even after power has been removed from the sensor Use caution and wear appropria...

Страница 139: ...mbly remove the screw and accompanying lock washer from the thermocouple mounting tab save the screw and lock washer for when you insert the new thermocouple 3 Pull the thermocouple straight up and re...

Страница 140: ...7 4 Thermox TM2000 Oxygen Analyzer Figure 7 1 Cell replacement Figure 7 2 Furnace replacement Ceramic Washers Ferrule O Ring Fitting Cell Fingers Cell O Ring Cell Clip Cell Inlet Tube...

Страница 141: ...cell Leave the white inlet tube in place If accidentally removed re seat the white inlet tube back into the O ring body 7 Retrieve the new cell and cell O ring 8 Place cell O ring over the cell so it...

Страница 142: ...flat washers and lockwashers see Figure 7 2 Keep this hardware for when you reinstall the furnace 4 Lift the furnace off the furnace base 5 Remove the screw and accompanying lock washer from the therm...

Страница 143: ...N 90296VE Calibration Gas Solenoid Valve P N 25370JE Interconnect Cable to Control Unit P N 21197JE Control Unit Display Module P N 90219VE Power Supply Keypad Module P N 90253VE Auto Calibration Card...

Страница 144: ...7 8 Thermox TM2000 Oxygen Analyzer This page intentionally left blank...

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

Страница 146: ...g 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...

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

Страница 148: ...time 1 is used to read the date and time of the last calibration and 2 is used to read the date and time of the last verification Date and time is returned as mm dd yy hh mm in 24 hour military time...

Страница 149: ...mat J This command is used to check how data is output through the serial link For each variable that is accessible through the Read Number and Write Number commands a string is returned that describe...

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

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

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

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

Страница 154: ...A 4 Flags_3 variable table Bit Description Read Write Format 0 sensor at op temp 1 over under temp 2 inject cal gas active Read Only 1 true 0 false 3 auto cal is active 4 auto verify is active 5 rese...

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

Страница 156: ...false 4 Reserved N A 5 auto verify time is set 1 true 0 false 6 auto verify timer is enabled 1 false 0 true 7 auto cal cycle 1 hours 0 days programmed in hours days 8 auto verify cycle All Read Write...

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

Страница 158: ...FOR RANDOM AS 1 String to be echoed T Test message Address of the series 2000 controller Address 254 Build the message M HEX Address A T M M Checksum M Continue sending message until key pressed Assu...

Страница 159: ...gative process pressure Enter process pressure value System Tests Perform internal diagnostics on Series 2000 System Serial View serial number for Series 2000 View manufacturing number for Series 2000...

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

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

Страница 162: ...B 4 Thermox TM2000 Oxygen Analyzer This page intentionally left blank...

Страница 163: ...JP2 on the Series 2000 control unit display module is used to al low 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...

Страница 164: ...external power supply and a load device All current output channels IOUT1 and IOUT2 can be connected as shown in Figure C 1 IOUT1 and IOUT2 must share the same power supply if both of these channels a...

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

Страница 166: ...C 4 Thermox TM2000 Oxygen Analyzer This page intentionally left blank...

Страница 167: ...ibration gases See the Controller User Interface chapter for help on how to set up the calibration process from software Figure D 1 Control unit signals to initiate a remote calibration If measuring P...

Страница 168: ...D 2 Thermox TM2000 Oxygen Analyzer This page intentionally left blank...

Страница 169: ...s any custom drawings or instructions you have ordered If you didn t order any cutome options the standard Intercon nect drawing is provided If you ordered special options the drawings or special inst...

Страница 170: ...E 2 Thermox TM2000 Oxygen Analyzer This page intentionally left blank...

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