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Service and Parts | 6-1

SERVICE AND PARTS

The operations in this appendix should be performed only by qualified

service personnel with a knowledge of electrical safety techniques.

Never service the sensor unless power has been removed from the sen-

sor, and the sensor has been allowed to cool for one hour.

This chapter is divided into the following sections:

• Cell Replacement

• Thermocouple Replacement

• Furnace Replacement

• Flow Sensor Replacement

• Box Heater Wiring

• RCU (Remote Calibration Unit) Solenoid Valve Replacement

• Electronics Board Replacement

• Recommended Maintenance Schedule

• Replacement Parts List

You can clean the outside of the sensor using normal household or com-

mercial general purpose cleaners, cloths, or sponges. You can also use

water. Always turn off power before attempting to clean the enclosure.

Figure 6-1 is a wiring diagram that shows the locations of all wiring con-

nections on a standard sensor. If your sensor requires different wiring, this

is provided in an appendix.

Содержание Thermox WDG-V UOP

Страница 1: ...Thermox IECEx ATEX WDG V UOP Combustion Analyzer User Manual Thermox 150 Freeport Road Pittsburgh PA 15238 PN 9000 280 VE Rev B...

Страница 2: ...456 4444 GERMANY AMETEK GmbH Rudolf Diesel Strasse 16 D 40670 Meerbusch Ph 49 21 59 91 36 0 Fax 49 21 59 91 3680 USA Texas 4903 West Sam Houston Parkway North Suite A 400 Houston TX 77041 Ph 713 466...

Страница 3: ...ures xi Use Caution When Lifting xi Use Proper Attire xi Chapter 1 System Overview 1 1 UOP CCR Platforming Process 1 1 History 1 1 CCR Continuous Catalyst Regeneration 1 1 Thermox and WDG UOP Series 1...

Страница 4: ...haust Tube Installation 3 5 Sensor Mounting 3 5 Calibration Aspirator Air 3 7 Required Calibration Gases and Tubing 3 7 Rapid Exchange Purge System 3 8 Connections 3 8 Purging Operation 3 8 Purging In...

Страница 5: ...munications 4 4 Intermittent Communications 4 4 Customer I O Connections 4 5 Retrofitting the WDG V UOP to WDG IV UOP 4 6 Chapter 5 Troubleshooting 5 1 General Troubleshooting 5 2 Leak Check 5 2 Sniff...

Страница 6: ...vi Thermox WDG V UOP IECEx ATEX Electronics Replacement 6 13 Recommended Maintenance Schedule 6 14 Calibration 6 14 Replacement Parts List 6 15 Sensor 6 15 Remote Calibration Unit RCU 6 15...

Страница 7: ...before servicing 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 sho...

Страница 8: ...ved conduit fittings or cable glands for cable entry IIC IP40 minimum No holes shall be left unplugged 4 Internal temperature rises above the rated T class The end user must take immediate action on t...

Страница 9: ...nt and to conserve our natural resources AMETEK recommends that you arrange to recycle this product when it reached its end of life Waste Electrical and Electronic Equipment WEEE should never be dispo...

Страница 10: ...e hazard do not apply a voltage to a terminal that is outside the range specified for that terminal Ground the Product Follow the grounding instructions provided in the Installation chapter of this us...

Страница 11: ...the voltage specified Do Not Operate with Suspected Failures If you suspect there is damage to this product have it inspected by qualified service personnel Use Caution When Lifting Use caution when l...

Страница 12: ...misuse neglect abuse or improper use Misuse or abuse of the equip ment or any part thereof shall be construed to include but shall not be limited to damage by negligence accident fire or force of the...

Страница 13: ...n even at the required low octane severi ties With appropriate prefractionation the process produces the low ben zene low vapor pressure material mandated by reformulated gasoline World Wide Web page...

Страница 14: ...s the risk of permanent damage to the catalyst and so the combustion must be controlled This is done by controlling the oxygen content The catalyst is the key ingredient used in the catalytic reformin...

Страница 15: ...r used to check for plugging in the return line that were part of the WDG III and WDG IV UOP analyzer designs Since the process piping of the CCR is 316 stainless steel and the process was adjusted to...

Страница 16: ...low 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...

Страница 17: ...ters the type K thermocouple maintains cell operating temperature The sensing cell operates at a constant temperature The WDG V is a com plete standalone unit No separate controller is required Analyz...

Страница 18: ...ecome ionic As long as the oxygen partial pressures on either side of the cell are equal the movement is random and no net flow of ions occurs If however gases having different oxygen partial pressure...

Страница 19: ...nk is the unknown oxygen concentration of the gas to be analyzed and which is calculated by the analyzer The cell produces zero voltage when the same amount of oxygen is on both sides Voltage increase...

Страница 20: ...n The WDG V UOP analyzer has a specially treated Zirconium Oxide cell which is used to survive the destructive effects of halogen oxidation The sensor uses a nitrogen operated aspirator to draw a samp...

Страница 21: ...location The RTD flow sensor monitors the sample flow through the fast loop as well as the temperature of the gas flowing past it An alarm is generated when the temperature reaches 100 C lower than t...

Страница 22: ...s above 225 C Cell Temperature The oxygen cell is controlled to 680 C The cell temperature is measured by dual Type K thermocouples Dual thermocouples are used for self check of the cell temperature T...

Страница 23: ...ata Valid Three 3 configurable process alarm relays One 1 RS 485 2 wire MODBUS RTU interface 57 6K baud Current Output Connections Standard Current Outputs There are three current outputs on the WDG V...

Страница 24: ...re referenced as Relay 3 Relay 4 and Relay 5 in the AMEVision Relay 3 ALM 1 Relay 4 ALM 2 Relay 5 ALM 3 Service Alarm The service alarm indicates that a critical alarm exists and the analyzer needs re...

Страница 25: ...nly Remote Calibration Unit RCU connections on the WDG V wiring card and their RCU connections are as follows ZERO GAS WDG V Terminal Z to Pin 13 on RCU ASPIRATOR WDG V Terminal A to Pin 14 on RCU O2...

Страница 26: ...tion to work you must have a remote calibration unit The system monitors the digital input and when the switch closes it sends the system into an automatic calibration The switch you connect to this d...

Страница 27: ...System Overview 1 15 BOX HEATER 200W 2X NOT USED NOT USED NOT USED RTD FLOW SENSOR CONNECTIONS NOT USED NOT USED Figure 1 6 Terminal Block Detail customer connections located in the center section...

Страница 28: ...l support run test gases and record the following values you may be asked by the factory to provide this information when receiving service Cell millivolts Thermocouple millivolts Cell temperature If...

Страница 29: ...C Sample Pressure 14 69 psig 60 psig 101 28 kPa 413 7 kPa Environment Ambient Temp 5 F to 140 F 20 C to 60 C Relative Humidity 10 to 90 non condensing Max Altitude 2000 meters Enclosure Hinged IP65 NE...

Страница 30: ...IECEx IEC 60079 0 2017 Edition 7 0 IEC 60079 2 2014 07 Edition 6 0 IECEx ETL 19 0039X ATEX 2014 34 EU EN 60079 0 2018 EN 60079 2 2014 ITS19ATEX14526X General Safety 2014 35 EU US CAN EN 61010 1 2010...

Страница 31: ...UL Type 4X NEMA 4X IP66 Div II Environment Ambient Temperature Humidity Max Altitude IEC Installation IEC Pollution Degree 2 18 C to 60 C 0 to 90 non condensing 2000 Meters Category II System Complian...

Страница 32: ...toute maintenance ou depannage Uyilisaez des conducteurs en cuivire 90 minimum AVERTISSEMENT IECEx ETL 19 0039X US C CM L I S T E D Intertek ITS19ATEX14526X WARNING USE 90 C COPPER CONDUCTORS NO OPERA...

Страница 33: ...H2O MAX 3 64 H20 MAX PURGE MAX LEAKAGE RATES 15 LPM PURGE AIR STARTUP PROCEDURE WARNING POWER SHALL NOT BE RESTORED AFTER THE ENCLOSURE HAS BEEN OPENED UNTIL THE ENCLOSURE HAS BEEN PURGED FOR 10 MINU...

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Страница 35: ...fore the CCR is pressurized During process start up and whenever power is removed from the analyzer the aspirator should be turned off and nitrogen applied to the calibration gas port at 3 schf flow t...

Страница 36: ...erface The installation location should be free from excessive vibration and the ambient temperature is required to be within the limits listed in the specifications If the ambient temperature is outs...

Страница 37: ...ore these subjects are discussed before the sections on how to mount the sensor to the process Orient the probe so that the longer side faces the gas flow The sample inlet probe is how the sample gas...

Страница 38: ...e rear of the sensor then mount the sensor Figures 3 1a and 3 1b Sampling Probe Exhaust to Process Mounting Flange Assembly Long Venturi Gasket 3 300 Backplate part of Sensor TOP VIEW Hook Inlet Tube...

Страница 39: ...below 1 Thread the 1 4 18 NPT sample inlet probe into the mounting flange Orient the probe so the longer side faces towards the flow of gases this prevents large particles from entering the sensor Th...

Страница 40: ...3 6 Thermox WDG V UOP IECEx ATEX Figure 3 2 Sensor Mounting A 7 16 wrench is required to open both doors to the sensor...

Страница 41: ...igh gas the zero gas the low gas The span gas must be 10 times greater than the zero gas For example if the zero gas is 1 O2 the span gas must be 10 O2 or higher O2 Span Gas Instrument air 20 9 or fro...

Страница 42: ...ower explosive limit in the process The flame arrestor is not however intended to protect the process where the combustibles levels are always high Purging Operation Safe pressure for purposes of this...

Страница 43: ...Installation Guide 3 9 Figure 3 3a UOP Rapid Exchange Purge System Front Figure 3 3b UOP Rapid Exchange Purge System Rear...

Страница 44: ...Gauge at Safe pressure The Pres sure Loss Alarm Switch if being used should then activate to silence the alarm system 5 Carefully remove the T Bar Valve Key from EPCV stem Ensure Enclo sure Pressure...

Страница 45: ...s shut down turn off the aspirator to avoid plugging problems Connect N2 aspirator supply to the aspirator inlet on the sensor see Fig ure 3 4 Adjust the aspirator regulator to the minimum pressure re...

Страница 46: ...4 shows mounting dimensions for a standard RCU Use two 10 screws to mount the RCU Note that only the top left and lower right holes are used the other holes hold the RCU to its mounting plate The ambi...

Страница 47: ...yzer with RTD type combustibles detector the combustibles span calibration gas would also include the methane span calibration concentration 4 Using appropriate tubing connect the calibration gas outl...

Страница 48: ...44 36 48 1 44 36 48 1 44 36 48 C L 3 3 4 2 70cm CONDUIT ENTRIES 2 1 2 2 22cm CONDUIT ENTRIES 5 97 151 58 12 00 304 80 TYP Figure 3 6 AMEVision mount Wiring Remove AC mains power from the controller b...

Страница 49: ...WDG V UOP If not using a conduit entry leave the factory NEMA approved plugs intact Never leave any holes unplugged Follow all applicable electrical codes for your location Follow proper grounding shi...

Страница 50: ...e Mains supply connections to the control unit are as follows L Line connection N Neutral connection USA Chassis Stud Equipment ground protective conductor Use the 1 2 conduit entry hole in the WDG V...

Страница 51: ...ust be chassis grounded EMC Grounding Method Shield Ring Method Connect all shields for that conduit entry other than power to a sup plied shield terminal ring Figure 3 8 This shield ring is a stainle...

Страница 52: ...D METHOD Shield Terminal Ring Conduit Housing Cable Shield s Max Length 1 inch Conduit Nut Quick Disconnect 1 4 Capacitor Conduit Nut Cable Shield s Max Length 2 inches Nut Washer Ring Terminal Condui...

Страница 53: ...sible Examples of transient suppressors include MOVs TRANSORBs and RC snubbers AC mains supply wiring should not be run in the same conduit with mains supply wiring that feeds heavy inductive loads Av...

Страница 54: ...ure to observe the polarity 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 th...

Страница 55: ...The service alarm indicates that a critical alarm exists and the analyzer needs repair Readings are not valid when this alarm is active The relay contacts are normally open and are OPEN de energized w...

Страница 56: ...3 22 Thermox WDG V UOP IECEx ATEX BOX HEATER 200W 2X NOT USED NOT USED NOT USED RTD FLOW SENSOR CONNECTIONS NOT USED NOT USED Figure 3 9 Wiring...

Страница 57: ...VALVE COMMON WDG V UOP Terminal V to pin 16 on RCU Figure 3 10 RCU Connections Digital Input to Initiate Remote Calibration Unit The digital input connections on the wiring card allow you to initiate...

Страница 58: ...xample combustible gas detectors should be considered to ensure that the ducting is free of flammable concentra tions of gas vapor Additional Purge Time to Account for Ducting The purge duration shoul...

Страница 59: ...te and monitor a single analyzer It is connected to the PC using a two wire MODBUS RTU interface Connecting to the WDG V UOP Setting the Address using the Dip Switch The address on the WDG V UOP analy...

Страница 60: ...to the PC Figure 3 12 Connecting analyzer using USB converter and PC software Once the analyzer has been connected to the PC use the Configurator software to set up options and calibrate the unit Inst...

Страница 61: ...structions in Chapter 3 The AMEVision Display Unit Figure 4 1 Standard AMEVision Display User Interface The AMEVision Display User Interface is an intuitive remote graphical user interface and communi...

Страница 62: ...connected to a single user interface unit Each attached analyzer must have a unique address The address on the WDG V UOP analyzer is set using the dip switch on the front of the elec tronics PCB Figu...

Страница 63: ...hen only one analyzer is connected set the address to 1 Multiple Analyzer Connections Up to eight 8 analyzers can be connected to a single AMEVision Display User Interface The WDG V UOP analyzer has e...

Страница 64: ...een the AMEVision Display User Inter face and the analyzer is 4000 feet 1219 2 meters Instructions on using the AMEVision software to configure and cali brate the analyzer as well as analyzer status r...

Страница 65: ...AMEVision Display Installation Guide 4 5 Customer I O Connections...

Страница 66: ...sponding Series 2000 circuit board terminal designation see Figure 4 3 3 Disconnect wiring and conduit entries from the existing Series 2000 control unit 4 Remove the existing WDG IV UOP Sensor from t...

Страница 67: ...ANALOG OUTPUT 2 ANALOG OUTPUT 2 ANALOG OUTPUT 3 ANALOG OUTPUT 3 SERVICE ALARM SERVICE ALARM DATA VALID ALARM DATA VALID ALARM PROCESS ALARM 1 PROCESS ALARM 1 PROCESS ALARM 2 PROCESS ALARM 2 PROCESS AL...

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Страница 69: ...nsor This chapter describes error messages It also provides troubleshooting assistance System and error messages scroll on the bottom line of the AMEVision display at three second intervals until the...

Страница 70: ...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 compone...

Страница 71: ...r gloves 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 plu...

Страница 72: ...mmend monitoring the thermocouple millivolts and cell millivolts be displayed during troubleshooting as a troubleshooting aid This information will be helpful should you need to contact the factory fo...

Страница 73: ...f remove the thermocouple 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 thermocoup...

Страница 74: ...ylinder to the sensor calibration 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 RC...

Страница 75: ...s 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 reading...

Страница 76: ...as setup and there 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...

Страница 77: ...ulty T C connection Low Power Only after warm up is complete Cell Temp Rise Failure Cell heater failed to heat the cell Bad Cell furnace heater Bad heater connection Shorted T C Bad T C con nection Un...

Страница 78: ...on Cell Mv Mismatch The cell mv measurement does not match the real time cell measurement Bad A D circuit Bad elec tronics Analog Output 1 Error The analog output measurement does not match the settin...

Страница 79: ...aturated high or low Improperly set range Analog Output 3 Out Of Range The analog output value is saturated high or low Improperly set range Last O2 Span Cali bration Failed The last oxygen span calib...

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Страница 81: ...ment Furnace Replacement Flow Sensor Replacement Box Heater Wiring RCU Remote Calibration Unit Solenoid Valve Replacement Electronics Board Replacement Recommended Maintenance Schedule Replacement Par...

Страница 82: ...e 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...

Страница 83: ...Service and Parts 6 3 BOX HEATER 200W 2X NOT USED NOT USED NOT USED RTD FLOW SENSOR CONNECTIONS NOT USED NOT USED Figure 6 1 Wiring diagram for standard sensor...

Страница 84: ...sening the cell may require a good deal of torque 5 If cleaning the cell wash with water or alcohol Dry the cell thoroughly before reinstalling Always use a new cell O ring If replacing the cell disca...

Страница 85: ...Service and Parts 6 5 Cell Clips Cell Housing Washer Cell O Ring Hex Nut Figure 6 2 Cell replacement...

Страница 86: ...osition 3 Disconnect thermocouple wires from terminals TC on the sensor board 4 Remove the 2 speed clips from the thermocouple mounting tabs Use needle nose pliers to remove the clips 5 Pull the therm...

Страница 87: ...Service and Parts 6 7 Speed Clips Thermocouple Thermocoouple Figure 6 3 Thermocouple replacement...

Страница 88: ...D flow sensor wires from the sensor board at Termi nal Cact 4 Disconnect the RTD flow sensor from the J hook by unscrewing the Swagelok nut indicated in the image below Figure 6 4 Location of Swagelok...

Страница 89: ...tion 3 Disconnect cell furnace wires 4 Remove the Thermocouple assembly from the furnace 5 Remove the Cell 6 Remove the Flow Sensor 7 Loosen the swage nut at the bottom of the furnace Loosen the swage...

Страница 90: ...the inlet and outlet of the process Shut off levers should be in the vertical position 3 Disconnect heater wires 4 Remove the Heater block from the Aspirator block 5 Remove the snap rings Use needle...

Страница 91: ...Service and Parts 6 11 Box Heater Block Furnace Wires Heater Figure 6 6b Box Heater Replacement...

Страница 92: ...inals Connect the remaining two wires together into the other HTR2 terminal 230VAC Wiring Series Connect one wire from box heater 1 into one of the terminals HTR2 Then connect one of the wires from bo...

Страница 93: ...6 7 1 Disconnect all wires 2 LOOSEN the eight 8 kep nuts located on the electronics plate DO NOT remove the nuts 3 Slide the board down to release 4 Replace the electronics board 5 Properly tighten t...

Страница 94: ...6 14 Thermox WDG V UOP IECEx ATEX Recommended Maintenance Schedule Calibration Check calibration and or recalibrate the analyzer every 90 days...

Страница 95: ...E Threaded Exhaust Tube 70619KE Sample Probe by serial number Cell Housing Inconel 70597SE Cell Housing Hastelloy C 70678SE Aspirator Block Stainless Steel 75494SE Aspirator Block Hastelloy C 75495SE...

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