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Ametek Thermox Series 2000 WDG-IV User Manual

Ametek Thermox Series 2000 WDG-IV
193 pages
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Thermox
®
Series 2000
WDG-IV, WDG-IVC, WDG-IVCM
User Manual
Thermox
150 Freeport Road
Pittsburgh, PA 15238
PN 90269VE , Rev. Y

Table of Contents

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Ametek Thermox Series 2000 WDG-IV Specifications

General IconGeneral
Enclosure RatingNEMA 4X/IP66
Measurement TypeOxygen
TechnologyZirconium Oxide
Measurement Range0-25% O2
Response Time<5 seconds
Output4-20 mA
Power50/60 Hz

Summary

Safety Notes

Electrical Safety

Emphasizes safe electrical practices for analyzer operation and maintenance.

Grounding

Mandates instrument grounding for performance and safety compliance.

Environmental Information (WEEE)

General Safety Summary

Operational Safety Guidelines

Covers wiring, overload, grounding, covers, fuses, and atmosphere operation.

Product Handling Precautions

Includes using proper power source and not operating with suspected failures.

Declaration of Conformity

WARRANTY AND CLAIMS

OVERVIEW

Sensor Operations

Explains how the sensor functions in flue gas analysis applications.

Detectors

Combustibles

Explains the function and operation of the combustibles detector.

Methane

Explains the function and operation of the methane detector.

Common Operator Errors

Start-Up Checklist

Technical Support

Specifications

Series 2000 Control Unit

Details specifications for the Series 2000 control unit.

Sensor : WDG-IV

Lists specifications for the WDG-IV sensor.

Sensor : WDG-IVC

Lists specifications for the WDG-IVC sensor.

Sensor : WDG-IVCM

Lists specifications for the WDG-IVCM sensor.

Sensor : WDG-IVC - 0-500 PPM

Lists specifications for the WDG-IVC sensor with 0-500 PPM range.

Remote Calibration Unit (RCU)

Details specifications for the Remote Calibration Unit (RCU).

INSTALLATION

Analyzer Location

Guidelines for selecting an appropriate installation location for the analyzer.

Inspection of Shipping Contents

Instructions for checking shipping contents for damage.

Mechanical Installation

Details procedures for mounting and connecting sensor components.

Probe Heater Installation

Instructions for installing the probe heater.

Exhaust Tube Installation

Instructions for installing the exhaust tube.

Sensor Mounting

Guidelines and considerations for mounting the sensor to the process.

Sensor flush mount (Preferred Method)

Details the preferred method for sensor flush mounting.

Customer-supplied pipe nipple sensor mounting

Alternative method for mounting the sensor using a pipe nipple.

Calibration/Aspirator Air/Z-Purge Connections

Details required calibration gases, tubing, and Z-purge connections.

Control Unit Mounting

Instructions for mounting the Series 2000 control unit in various configurations.

Wiring

General requirements and procedures for controller and sensor wiring.

Sensor Connections

Required wiring connections between the control unit and the sensor.

Current Output Connections

Details standard and optional current output connections on the control unit.

Alarm Contact Connections

Describes standard and option-specific alarm contact connections.

RS-485 Communications Connections

Details RS-485 communication connections (2-wire and 4-wire).

Option Card Installation

Instructions for installing or removing option cards in the control unit.

CONTROLLER / USER INTERFACE

Control Unit Overview

Describes control unit areas, keys, and system password settings.

Setup Key Functions

Explains menu options for configuring the control unit, including display and sensor settings.

Process Pressure Configuration

Steps to define and enter the system process pressure value.

System Diagnostics

Procedures for running internal diagnostics and checking system serial numbers.

Sensor Configuration

Steps to select and configure the correct sensor type.

Communication Settings

Configuration parameters for RS-485 serial communications.

Analog Output Configuration

Menu for configuring analog output signals, ports, and ranges.

Alarm Management

Menu for configuring alarm functions, set points, relays, and logs.

CALIBRATION

Definitions

Defines calibration, verification, span, and zero gas terms.

Types of Calibrations

Describes automatic, remote, and manual calibration types.

Initiate Cal and Initiate Verify

Steps to perform automatic, remote, or manual calibration/verification.

Remote Calibrate/Remote Verify

Steps to initiate remote calibration or verification processes.

Manual Calibrate/Manual Verify

Steps for performing manual calibration or verification.

Cal Gas Value

Entering calibration gas values for oxygen and combustibles.

Inject Cal Gas

Procedures for injecting calibration gases manually or automatically.

Set Cal Timers

Setting automatic calibration cycle timers and durations.

Set Cal Timers - Auto Cal On/Off

Enables or disables automatic calibration/verification cycles.

Set Cal Timers - Cal Gas Duration

Defines duration for span and zero calibration gas flow.

Set Cal Timers - Recovery Duration

Defines recovery time after calibration for system stabilization.

MAINTENANCE AND TROUBLESHOOTING

System Messages

Lists and explains system messages displayed on the control unit.

Error Messages

Lists and explains error messages indicating analyzer operation problems.

Diagnostics Checks

Procedures to check sensor areas for possible problems.

Wiring Checks

Procedures to check sensor wiring for problems.

Calibration/Aspirator Setup Checks

Checks related to calibration gas, aspirator, and RCU setup.

AC Power Checks

Checks for adequate AC voltage supply to the sensor and furnace.

Furnace Checks

Procedures for checking furnace operation and resistance.

General Troubleshooting

General steps for diagnosing and resolving inaccurate readings.

Leak Check

Procedures for checking the system for leaks to ensure accurate readings.

Plugged Plumbing Check

Steps to check for and clear plugged plumbing in the sensor.

Series 2000 LEDs

Explains the status indicated by LEDs on the control unit and option cards.

SERVICE AND PARTS

Cell Replacement

Step-by-step instructions for replacing the oxygen cell.

Thermocouple Replacement

Instructions for replacing the thermocouple in the sensor.

Furnace Replacement

Steps for replacing the furnace component of the sensor.

Combustibles Detector Replacement

Instructions for replacing the hot-wire combustibles detector.

RTD Combustibles Detector Replacement

Instructions for replacing the RTD combustibles detector.

Box Heater Diagram

Wiring diagram for connecting box heaters to the sensor board.

Replacement Parts List

List of part numbers for sensor, RCU, and control unit components.

SERIAL COMMUNICATIONS

Communication Protocols

Defines the RS-485 communication protocols and word format.

Command Message Format

Details the structure of command messages for serial communication.

General Serial Communication Commands

Lists common commands for reading and writing analyzer data.

Development Serial Communication Commands

Commands used during initial serial communication design and testing.

Responses

Describes successful and failure communication responses from the analyzer.

Variable Table

Summarizes variable locations, names, and descriptions for serial communication.

Menu Option Charts

SETUP KEY Menu Options

Lists the menu options available under the Setup Key.

ANALOG KEY Menu Options

Lists the menu options available under the Analog Range Key.

ALARM KEY Menu Options

Lists the menu options available under the Alarm Key.

CALIBRATE KEY Menu Options

Lists the menu options available under the Calibrate Key.

Current Outputs: Other Applications

Powering Current Outputs from an External Power Supply

How to power current outputs using an external voltage source.

Modulation of External Power Loop Using Current Outputs

Example connection for modulating an external power loop with current outputs.

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