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PN 9000-280-VE, Rev B

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Maintenance and Troubleshooting

3-3

Содержание WDG-V UOP

Страница 1: ...WDG V UOP Combustion Analyzer ATEX IECEx USER MANUAL PN 9000 280 VE_Rev C...

Страница 2: ...iability for any errors or inaccuracies that may appear in this document AMETEK Process Instruments is not responsible for any infringement of patents or other rights of third parties that may result...

Страница 3: ...l Works 1 6 Measuring Non Combustible Gases 1 7 Hydrocarbons in the Gas Sample 1 7 About the Analyzer Sample System 1 8 About the Analyzer Electronics 1 10 Communicating With the Analyzer 1 11 Working...

Страница 4: ...ns 2 25 Oxygen Only Remote Calibration Unit Connections 2 25 Digital Input to Initiate Remote Calibration Unit 2 25 Notes About Ducting 2 26 Installing the User Interface Communications Options 2 27 I...

Страница 5: ...in the Measuring Cell 3 10 Replacing the Thermocouple 3 12 Replacing the Flow Sensor 3 14 Replacing the Furnace 3 15 Replacing the Box Heater 3 16 Replacing the Sensor Board 3 19 Recommended Maintena...

Страница 6: ...ing Electrical Safety High voltages are present in the analyzer housings Always shut down power source s before performing maintenance or troubleshooting Only a qualified electrician should make elect...

Страница 7: ...not operate this product with covers or panels removed Use Caution When Lifting Use caution when lifting the analyzer from its crate Use Proper Attire Equipment is hot user should wear protective gro...

Страница 8: ...s prod uct Use Proper Power Source Do not operate this product from a power source that applies more than the voltage specified Do Not Operate with Suspected Failures If you suspect there is damage to...

Страница 9: ...tings 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 immedi ate action on the loss of pre...

Страница 10: ...l resources AMETEK recommends that you arrange to recycle this product when it reaches its end of life Waste Electrical and Electronic Equipment WEEE should never be disposed of in a municipal waste s...

Страница 11: ...yield of hydrogen even at the required low octane severities With appropriate prefractionation the process produces the low benzene low vapor pressure material mandated by reformulated gasoline World...

Страница 12: ...age to the catalyst and so the com bustion must be controlled This is done by controlling the oxygen content The catalyst is the key ingredient used in the catalytic reforming process and oxygen measu...

Страница 13: ...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 adjust ed to incl...

Страница 14: ...n working on the analyzer Do not turn on the aspirator until the analyzer has been turned on and is hot preferably 24 hours Also if you turn off the analyzer or the process is shut down turn off the a...

Страница 15: ...K Thermocouple maintains Cell operating temperature The sensing Cell operates at a constant temperature The WDG V is a complete standalone unit No separate controller is required Analyzer I O All req...

Страница 16: ...e 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 pressures are on either side of t...

Страница 17: ...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 increases as t...

Страница 18: ...has a specially treated Zirconium Oxide Cell which is used to survive the destructive effects of halogen oxidation The analyzer uses a nitrogen operated aspirator to draw a sample of gas from the cata...

Страница 19: ...to the oxygen Cell The box temperature is controlled with an RTD mounted on the aspirator block The box heater consists of two 2 150 W cartridge heaters located in the aluminum heater block at the bot...

Страница 20: ...m alarm relays Service and Data Valid Three 3 configurable process alarm relays One 1 RS 485 2 wire MODBUS RTU interface 57 6K baud Current Outputs There are three 3 current outputs on the WDG V UOP A...

Страница 21: ...rough the software while configuring or calibrating the analyzer or simply viewing analyzer data AMEVision Display User Interface This user interface option consists of a separate remotely mounted gra...

Страница 22: ...ple at left Supplemental Information Where Can I Find It Some analyzers are configured with optional equipment or functionality that may require supplementary information The analyzer User Manual and...

Страница 23: ...erator serviceable components inside the analyzer Refer all servic ing to qualified personnel Reference pressure must be applied before the CCR Continuous Cata lyst Regeneration is pressurized During...

Страница 24: ...nd ed storage conditions include Temperature 0 C to 50 C 32 F to 122 F Relative Humidity 70 Failure to comply with these storage conditions will void your warranty Analyzer Site Preparation Observe th...

Страница 25: ...require replacement prior to safely installing and operating the analyzer equipment Tools Equipment and Supplies Required for Installation To install the analyzer you need the following tools equipmen...

Страница 26: ...s flow The sample inlet probe is how the sample gas gets to the analyzer Aspirator air within the analyzer is used to pull process gas from the sample probe into the analyzer The sample inlet probe is...

Страница 27: ...sembly Long Venturi Gasket 3 300 Backplate part of Sensor TOP VIEW Hook Inlet Tube with RTD Flow Sensor Exhaust Tube Connector 1 2 T x 3 8NPT M Figure 2 1 1 WDG V UOP Probe and optional Exhaust Tube i...

Страница 28: ...to the analyzer before mounting the analyzer to the process The hastelloy exhaust tube allows you to extend the aspirator exhaust The exhaust tube has a thread on only one end of the tube To install...

Страница 29: ...he analyzer This inlet pipe does not need to be leak tight When mounting the analyzer to your process flange see Step 2 the mounting flange must also be sealed to your process flange using the factory...

Страница 30: ...PN 9000 280 VE Rev B A 7 16 wrench is required to open both enclosure doors Figure 2 3 Analyzer Mounting 2 8 Thermox WDG V UOP ATEX IECEx Analyzer...

Страница 31: ...ibles use 1200 ppm CO 1 2 O2 balance N2 Flow Calibration A flow calibration must be performed upon analyzer startup The WDG V UOP analyzer should be mounted on the process fully up to normal operating...

Страница 32: ...ss The flame arrestor is not however intended to protect the process where the combustibles levels are always high Purging Operation Safe Pressure Safe pressure for purposes of this manual is defined...

Страница 33: ...PN 9000 280 VE Rev B Figure 2 4 1 UOP Rapid Exchange Purge System Front Figure 2 4 2 UOP Rapid Exchange Purge System Rear Installation and Start Up 2 11...

Страница 34: ...e Pressure 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 Enclosure Pressure Gauge Safe pressure setting...

Страница 35: ...he 3 SCFH nitrogen purge through the calibration port should be maintained until the analyzer is turned on and is hot preferably 24 hours Do not turn on the aspirator until the analyzer has been turne...

Страница 36: ...erature range for the RCU is 20 C to 70 C Mount the RCU as close to the analyzer as possible Shorter calibration plumbing improves response times reduces calibration gas expense and reduces the chance...

Страница 37: ...PN 9000 280 VE Rev B Figure 2 5 1 RCU Mounting Dimensions Figure 2 5 2 RCU Schematic Flow Diagram Installation and Start Up 2 15...

Страница 38: ...allation and User Manual for com plete installation and operation details Figure 2 6 AMEVision dimension installation 9 14 232 19 9 00 228 60 10 00 254 2 00 50 80 1 50 38 10 HINGE SIDE DISPLAY KEYPAD...

Страница 39: ...nected to the analyzer but not less than 60 C Use only the applicable NEMA approved conduit fittings or cable fittings to maintain the NEMA rating for the analyzer enclosure or WDG V UOP If not using...

Страница 40: ...PN 9000 280 VE Rev B Figure 2 7 Conduit Entries 2 18 Thermox WDG V UOP ATEX IECEx Analyzer...

Страница 41: ...Rev B Figure 2 8 Terminal Block Detail customer connections located in the center section BOX HEATER 200W 2X NOT USED NOT USED NOT USED RTD FLOW SENSOR CONNECTIONS NOT USED NOT USED Installation and...

Страница 42: ...o 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 UOP for AC mains supply wiri...

Страница 43: ...ure 2 9 This shield ring is a stainless steel ring with a metal tab Place the shield ring under the conduit nut Crimp the shields from all cables for that conduit entry to a 1 4 female quick disconnec...

Страница 44: ...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 wiring in...

Страница 45: ...he polarity when connecting current output devices to these terminals Each current output is capable of driving up to a 1000 ohm load The current outputs can be selected for the following ranges 0 20...

Страница 46: ...ormally open and are OPEN de energized when a critical alarm exists Data Valid The Data Valid Alarm indicates if the concentration readings are represen tative of the process When this alarm is active...

Страница 47: ...nal A to Pin 14 on RCU O2 SPAN WDG V UOP Terminal S1 to Pin 15 on RCU VALVE COMMON WDG V UOP Terminal V to Pin 16 on RCU Digital Input to Initiate Remote Calibration Unit The digital input connections...

Страница 48: ...ctors should be considered to ensure that the ducting is free of flammable concentrations of gas vapor Additional Purge Time to Account for Ducting The purge duration should be increased by the time n...

Страница 49: ...his section and continue with Installing the AMEVision Display User Interface Secondary Commu nication Option later in this chapter Install the PC Configurator Software on a PC as instructed in the WD...

Страница 50: ...to the PC use the PC Configurator Soft ware to set up parameters and calibrate the unit For instructions on how to work in the PC Configurator Software to configure and calibrate the analyzer and to v...

Страница 51: ...ude MODBUS RTU Web Interface TCP IP USB Flash Drive If you are using the PC Configurator Software to communicate with the WDG V UOP Analyzer skip this section and continue with Install ing the PC Conf...

Страница 52: ...RTU A maximum of eight 8 ana lyzers can be connected to a single user Display User Interface unit Each con nected analyzer must have a unique address The address on the WDG V UOP Analyzer is set using...

Страница 53: ...Single Analyzer to AMEVision Display Unit connection When only one analyzer is connected set the address to 1 Connecting Multiple Analyzers Up to eight 8 analyzers can be connected to a single AMEVis...

Страница 54: ...ont of the User Interface board SW 5 ON Termination Enabled SW 5 OFF Termination Disabled The maximum distance between the AMEVision Display User Interface and the analyzer is 1219 2 meters 4000 feet...

Страница 55: ...PN 9000 280 VE Rev B Customer I O Connections Figure 2 17 Customer I O Connections Installation and Start Up 2 33...

Страница 56: ...es 2000 circuit board terminal designation see Figure 2 18 2 Disconnect wiring and conduit entries from the existing Series 2000 con trol unit 3 Remove the existing WDG IV UOP Analyzer from the proces...

Страница 57: ...OUTPUT 1 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 P...

Страница 58: ...or damaged or broken connections Replace or fix the connections as needed Intermittent Communications Possible Cause Corrective Action Poor wiring i e lack of shielded twisted pair Check the wiring to...

Страница 59: ...Alarm Warning messages It also provides troubleshooting assistance System Status and Error messages scroll on the bottom line of the AMEVision Display Unit at three sec ond intervals until the conditi...

Страница 60: ...incidents unplanned releases unplanned down situations and running analyzers to failure come at a much higher cost Our customer commitment continues well beyond the start up and com missioning of anal...

Страница 61: ...etekpi com customersupport requestsupport To request training visit our main Customer Support page and choose Analyzer Training Requesting Authorization to Return Equipment Before returning equipment...

Страница 62: ...be for use with flame arresters 7001 225 TE Cell Clip Assembly Inside 72329SE 3 1 Cell Clip Assembly Outside 72328SE 3 1 Kit WDG V Replacement 240 VAC Heater Coil and Push Nut 7000 841 TE RTD Box Temp...

Страница 63: ...SI External Air Regulator 39004JE 2 5 2 0 60 Regulator Gauge 37018JE 2 5 1 Aspirator Air Solenoid Valve normally open 36090JE 2 5 2 Calibration Gas Solenoid Valve normally closed 36088JE 2 5 2 Flow Me...

Страница 64: ...the analyzer Measure across terminals TC on the Sensor board with an ohm meter If an open is measured replace the thermocouple Shorted Failed Thermo couple Check that the thermocouple leads are not s...

Страница 65: ...tion line with a clean calibration line directly from cylinder to the analyzer cali bration inlet port using a flow meter to set the proper flow and compare the response with that from the possibly co...

Страница 66: ...Drawing for the system flow and pressure requirements This drawing is included with your installation package Select Cal Gas Duration from the Calibration menu to set calibration gas times AC Power Ch...

Страница 67: ...n im proper calibration gas 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...

Страница 68: ...e the entire Cell assem bly See the note in Figure 3 1 Loosening the Cell may require an exceptional amount of torque 5 If cleaning the Cell wash with water or alcohol Dry the Cell thoroughly before r...

Страница 69: ...PN 9000 280 VE Rev B Cell Clips Cell Housing Washer Cell O Ring Hex Nut Figure 3 1 Cell disassembly Maintenance and Troubleshooting 3 11...

Страница 70: ...nnect thermocouple wires from terminals TC on the Sensor board 4 Remove the two 2 speed clips from the thermocouple mounting tabs Use needle nose pliers to remove the clips 5 Pull the thermocouple str...

Страница 71: ...PN 9000 280 VE Rev B Speed Clips Thermocouple Thermocoouple Figure 3 2 Thermocouple replacement Maintenance and Troubleshooting 3 13...

Страница 72: ...nsor wires from the Sensor board at Terminal Cact 4 Disconnect the RTD flow sensor from the J hook by unscrewing the Swagelok nut indicated in the image below 5 Install the new RTD flow sensor into th...

Страница 73: ...connect Cell furnace wires 4 Remove the Thermocouple assembly from the furnace 5 Remove the Cell 6 Remove the Flow Sensor 7 Loosen the Swagelok nut at the bottom of the furnace Loosen the Swagelok nut...

Страница 74: ...outlet of the process Shutoff 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 nose pliers or...

Страница 75: ...PN 9000 280 VE Rev B Box Heater Block Furnace Wires Heater Figure 3 5 2 Box Heater Replacement Maintenance and Troubleshooting 3 17...

Страница 76: ...wo wires together into the other HTR2 terminal 230 VAC Wiring Series Connect one wire from box heater 1 into one of the HTR2 terminals Then connect one of the wires from box heater 2 into the other te...

Страница 77: ...isconnect all wires 2 Loosen but DO NOT REMOVE the eight 8 kep nuts located on the elec tronics plate 3 Slide the board down to release 4 Replace the Sensor board 5 Replace and properly tighten the nu...

Страница 78: ...nts near the beginning of this manual This information describes procedures to follow to avoid personal injury and or damage to the equipment All regulatory agency and personnel safety proce dures for...

Страница 79: ...in Chapter 2 for details on the placement of the gasket Sniffing for Leaks For processes under vacuum you can check for leaks by sniffing the fittings with another gas for example nitrogen or pure ox...

Страница 80: ...he liquid from reaching the furnace If the furnace does get wet allow it sufficient time to thoroughly dry Plugged Plumbing Check Exercise care when working on the analyzer Allow the unit to cool and...

Страница 81: ...ections and inspect it for damage cuts nicks burn marks etc Check the Thermocouple for a short or open circuit Replace the Thermocouple if necessary Contact AMETEK to verify operation before removing...

Страница 82: ...pect them for damage cuts nicks burn marks etc Check the Cell Thermocouple for a short or open circuit Replace the Thermocouple if necessary Contact AMETEK to verify operation before removing the Ther...

Страница 83: ...er temperature condition Open Thermocouple Failed Temperature Control Circuit Corrective Action From the AMEVision User Interface or PC Configurator Software Check the Cell Temp reading to verify if t...

Страница 84: ...upon analyzer power up while the analyzer is warming up to its normal oper ating temperature but will clear after the analyzer has properly warmed up to its normal operating tempera ture Faulty Heater...

Страница 85: ...eplace the RTD if necessary Contact AMETEK to verify operation before removing the RTD Check the Box Heater for proper operation Replace the Heater if necessary Contact AMETEK to verify opera tion bef...

Страница 86: ...ions open the Analyzer door and Check the A D circuit for proper operation This could indicate faulty electronics Analog Output 1 Error The analog output measurement does not match the setting Trigger...

Страница 87: ...ulty Thermocouple circuit Corrective Action Take appropriate safety precautions open the Analyzer door and Check the Thermocouple wiring for proper connections and inspect it for damage cuts nicks bur...

Страница 88: ...rective Action Check to determine if there has been a Hydrocarbon upset in the plant Analog Output 1 Out Of Range The analog output value is saturated high or low Trigger Conditions Incorrect range se...

Страница 89: ...low the Span Calibration gas to flow through the O2 Sensor and to stabilize Refer to Calibration Aspirator Air Setup Checks in this chapter for additional information Check the Calibration gas solenoi...

Страница 90: ...nlet Probe for plugging problems Refer to the section Plugged Plumbing Check for information on how to check for plugging problems Check the O2 Cell for proper operation Oxygen Calibration Required O2...

Страница 91: ...Specifications included in this chapter are typical for the ranges listed For custom ranges applications refer to accompanying Manual Supplements shipped with the analyzer or consult with your AMETEK...

Страница 92: ...AMETEK configuration software or AMEVision User Interface HART option available Diagnostics Low sample flow Cell and Detector age tracking Cell resistance calibration required analog current verifica...

Страница 93: ...analyzer Host capable of up to eight analyzers Digital Outputs Two or four wire Modbus RTU TCP IP Ethernet with embedded web server RJ 45 connection USB port for data collection or software update En...

Страница 94: ...1 DIVISION 2 GROUPS A B C AND D PRESSURIZATION TYPE NFPA 496 TYPE Z Ex TYPE Z Ex pxc IICTS Gc TEMPERATURE CODE T3 180C INT FREE VOLUME 40 3L PROTECTIVE GAS CLEAN DRY INSTRUMENT AIR ONLY 20 TO 60C 80...

Страница 95: ...0 280 VE Rev B Remote Calibration Unit RCU Directives and Standards EMC Directive 2004 108 EC Low Voltage Directive Directive 73 23 EEC IEC Installation Category II IEC Pollution Degree 2 Specificatio...

Страница 96: ...PN 9000 280 VE Rev B WDG V UOP Series Analyzer Rating Labels 4 6 Thermox WDG V UOP ATEX IECEx Analyzer...

Страница 97: ...available Through process application consulting we create custom designed solutions that meet the needs of your specific application or process ametekpi com USA Pennsylvania 150 Freeport Road Pittsb...

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