Ametek Thermox® WDG-V, WDG-VC, WDG-VCM Combustion Analyzer User Manual Thermox

Thermox® WDG-V, WDG-VC, WDG-VCM Combustion Analyzer User Manual Thermox PN 9000-133-VE Rev. K 150 Freeport Road Pittsburgh, PA 15238 Offices USA - Pittsburgh 150 Freeport Road Pittsburgh, PA 15238 Ph. 412-828-9040 Fax 412-826-0399 FRANCE AMETEK Precision Instruments France Rond Point de l’épine des champs Buroplus Bat D 78990 Elanbourt Ph. 33 1 30 68 89 20 Fax 33 1 30 68 89 29 USA - Delaware 455 Corporate Blvd. Newark, DE 19702 Ph. 302-456-4400 Fax 302-456-4444 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. 713-466-4900 Fax 713-849-1924 MIDDLE EAST – Dubai AMETEK PO Box 17067 Jebel Ali Free Zone Dubai, UAE Ph. 971-4-881 2052 Fax 971-4-881 2053 CANADA 2876 Sunridge Way N.E. Calgary, AB T1Y 7H9 Ph. 403-235-8400 Fax 403-248-3550 SINGAPORE AMETEK Singapore Pte. Ltd. No 43, Changi South Avenue 2, #04-01 Singapore 486164 Ph. 65-64842388 Fax 65-64816588 CHINA AMETEK Shanghai (SPL) Room 408, Metro Tower #30 Tian Yao Qiao Road Shanghai 200030 Ph. 86 21 6426 8111 Fax 86 21 6426 7054 INDIA India Private Ltd. Plot 148, EPIP Zone Phase 2 Featherlite Tech Park, 1st Floor Whitefield, Bangalore 560066 Tel: 91-80-6782-3200 Fax: 91-80-6780-3232 AMETEK Beijing CITIC Building, Room 2305 19, Jianguomenwai Dajie Beijing 100004 Ph. 86 10 8526 2111 Fax 86 10 8526 2141 BRAZIL Rod. Eng. Ermênio de Oliveira Penteado, Km 57 Tombadouro, Indaiatuba Sao Paulo, Brazil 13337-300 Tel: 55 19 3825-8775 Fax: 55 19 3935-8773 © 2014 AMETEK This manual is a guide for the use of the Thermox WDG-V (VC / VCM). Data herein has been verified and validated and is believed adequate for the intended use of this instrument. If the instrument or procedures are used for purposes over and above the capabilities specified herein, confirmation of their validity and suitability should be obtained; otherwise, AMETEK does not guarantee results and assumes no obligation or liability. This publication is not a license to operate under, or a recommendation to infringe upon, any process patents. Contents Offices...................................................................................................................... ii Safety Notes........................................................................................................... vii Important Notice To Users....................................................................................viii Environmental Information (WEEE)...................................................................... ix General Safety Summary......................................................................................... x Product Damage Precautions.................................................................................. xi Declaration Of Conformity.................................................................................... xii Warranty And Claims...........................................................................................xiii CHAPTER 1 Specifications Sensor: WDG-V ...................................................................................................1-1 Sensor: WDG-VC ................................................................................................1-2 Sensor: WDG-VCM.............................................................................................1-3 Remote Calibration Unit (RCU)...........................................................................1-5 CHAPTER 2 System Overview Sensor Operations.................................................................................................2-1 Sensor ..................................................................................................................2-2 Basic Elements of the Sensor.........................................................................2-2 The Oxygen Measuring Cell..........................................................................2-3 Hydrocarbons.................................................................................................2-4 Sensor Operations - WDG-VCM..........................................................................2-5 Close-Coupled Extrative Flue Gas Analyzer........................................................2-5 Detectors...............................................................................................................2-6 Combustibles..................................................................................................2-6 Methane..........................................................................................................2-7 Flow Sensor..........................................................................................................2-7 Overview........................................................................................................2-7 Alarm Limits..................................................................................................2-8 Troubleshooting.............................................................................................2-8 Temperature Sensors.............................................................................................2-9 Cell Temperature Thermocouple....................................................................2-9 Combustible/Box Temperature RTD..............................................................2-9 Heaters..................................................................................................................2-9 Cell Furnace Heater.......................................................................................2-9 Box Heater.....................................................................................................2-9 Electronics..........................................................................................................2-10 I/O ..............................................................................................................2-10 Analog Outputs...................................................................................... 2-11 Alarm Relay Contacts............................................................................ 2-11 Contact Input.........................................................................................2-12 RCU Interface........................................................................................2-12 Communications Interface.....................................................................2-12 Contents | iii Flame Arrestors...................................................................................................2-13 Start-Up Checklist..............................................................................................2-14 Common Operator Errors...................................................................................2-15 Technical Support...............................................................................................2-16 CHAPTER 3 Installation Guide Analyzer Location................................................................................................3-2 Inspect Shipping Contents....................................................................................3-2 Mechanical Installation.........................................................................................3-3 Sample Inlet Probe Installation......................................................................3-3 Probe Heater Installation................................................................................3-6 Exhaust Tube Installation...............................................................................3-7 Sensor Mounting............................................................................................3-7 Calibration/Aspirator Air.............................................................................3-13 Z-Purge Connections....................................................................................3-14 Remote Calibration Unit Mechanical Installation.......................................3-18 Wiring.................................................................................................................3-24 General Wiring and Conduit Requirements.................................................3-25 Mains Supply Connections..........................................................................3-26 Current Output Connections........................................................................3-29 RCU Connections...............................................................................................3-31 CHAPTER 4 AMEVision Display User Interface or Communications Definition of the AMEVision Display User Interface & Purpose........................4-1 AMEVision Display User Interface & Keypad....................................................4-2 Setting the Analyzer Address................................................................................4-3 Connecting to the WDG-V...................................................................................4-4 Connecting a Single Sensor to the AMEVision.............................................4-4 Connecting Multiple Sensors to the AMEVision...........................................4-4 Customer I/O Interconnecting........................................................................4-5 Maximum Distance Between Sensor & AMEVision............................... 4-6 Troubleshooting....................................................................................................4-6 No Communications................................................................................4-6 Intermittent Communications..................................................................4-6 WDG-V PC Configurator Software......................................................................4-7 CHAPTER 5 Flow Setting CHAPTER 6 LED Status Indicator iv | Thermox WDG-V / VC / VCM CHAPTER 7 Troubleshooting General Troubleshooting......................................................................................7-2 Leak Check....................................................................................................7-2 Plugged Plumbing Check...............................................................................7-3 Aspirator Air Not Pulling Sample from Process............................................7-3 Diagnostics Checks...............................................................................................7-4 Wiring Checks................................................................................................7-5 Interconnecting Wiring Problem....................................................................7-5 Thermocouple Checks....................................................................................7-5 Shorted/Failed Thermocouple........................................................................7-5 Reversed Thermocouple Wires......................................................................7-5 Thermocouple Compensation .......................................................................7-5 Circuit Check.................................................................................................7-5 Calibration/Aspirator Setup Checks...............................................................7-7 AC Power Checks..........................................................................................7-8 Furnace Checks..............................................................................................7-8 Process Pressure Checks................................................................................7-8 Cell Checks....................................................................................................7-8 Alarm Messages (Red Bar on AMEVision Display User Interface)....................7-9 Cell T/C Failure..............................................................................................7-9 Cold Junction Compensator Failure...............................................................7-9 Cell Temperature Control...............................................................................7-9 Cell Over Tem................................................................................................7-9 Cell Under Temp............................................................................................7-9 Cell Temp Rise Failure...................................................................................7-9 Over Temp Relay Tripped..............................................................................7-9 RTD Failure....................................................................................................7-9 Box Temp High..............................................................................................7-9 Box Temp Low...............................................................................................7-9 Box Temp Rise Failure...................................................................................7-9 Low Sample Flow........................................................................................7-10 Cell Failure (Open)......................................................................................7-10 Combustible Detector Open.........................................................................7-10 Methane Detector Open...............................................................................7-10 Cell Mv Mismatch.......................................................................................7-10 Analog Output 1 Failure..............................................................................7-10 Flow Sensor Failure.....................................................................................7-10 Cell T/C Measurement Mismatch................................................................7-10 Contents | v Warning Messages (Yellow Bar on AMEVision Display User Interface).......... 7-11 Cell Life Nearing its End............................................................................. 7-11 Comb Detector Life Nearing its End........................................................... 7-11 Methane Detector Life Nearing its End....................................................... 7-11 High Cell Mv............................................................................................... 7-11 Analog Output 1 Out of Range.................................................................... 7-11 Analog Output 2 Out of Range.................................................................... 7-11 Analog Output 3 Out of Range.................................................................... 7-11 Last O2 Span Calibration Failed................................................................... 7-11 Last O2 Zero Calibration Failed................................................................... 7-11 Last Comb Calibration Failed...................................................................... 7-11 Last CH4 Calibration Failed........................................................................ 7-11 Last Flow Calibration Failed........................................................................ 7-11 Oxygen Calibration Required...................................................................... 7-11 Combustible Calibration Required............................................................... 7-11 CH4 Calibration Required............................................................................ 7-11 Chapter 8 Service and Parts Warnings & Cautions............................................................................................8-2 Wiring Diagram....................................................................................................8-3 Cell Replacement/Cleaning..................................................................................8-5 Thermocouple Replacement.................................................................................8-7 Detector Replacement...........................................................................................8-9 Combustibles Detector Replacement.............................................................8-9 Methane Detector Replacement.....................................................................8-9 Flow Sensor Replacement.................................................................................. 8-11 Furnace Replacement.........................................................................................8-13 Heater Replacement............................................................................................8-14 Box Heater Replacement.............................................................................8-14 Combustible Heater Replacement................................................................8-16 Electronics Replacement....................................................................................8-18 Recommended Maintenance Schedule...............................................................8-20 Calibration....................................................................................................8-20 Replacement Parts List.......................................................................................8-21 Chapter 9 Drawings and Custom Instructions Chapter 10 Customer Modbus Map Appendix A French Warnings / Français Avertissements vi | Thermox WDG-V / VC / VCM Safety Notes WARNINGS, CAUTIONS, and NOTES contained in this manual emphasize critical instructions as follows: An operating procedure which, if not strictly observed, may result in personal injury or environmental contamination. An operating procedure which, if not strictly observed, may result in damage to the equipment.  Important information that should not be overlooked. NOTE Burn hazard. Hot surface. Do not touch, allow to cool 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 should make electrical connections and ground checks. Any use of the equipment in a manner not specified by the manufacturer may impair the safety protection originally provided by the equipment. Grounding Instrument grounding is mandatory. Performance specifications and safety protection are void if instrument is operated from an improperly grounded power source. Verify ground continuity of all equipment before applying power. | vii Important Notice to Users The following applies to the WDG-V Division 2 Models: Power, input, and output (I/O) wiring must be in accordance with Class I, Division 2 wiring methods [Article 501-4(b) of the National Electric Code, NFPA 70] and in accordance with the authority having jurisdiction. WARNING - EXPLOSION HAZARD - SUBSTITUTION OF COMPONENTS MAY IMPAIR SUITABILITY FOR CLASS I, DIVISION 2. WARNING - EXPLOSION HAZARD - WHEN IN HAZARDOUS LOCATIONS, TURN OFF POWER BEFORE REPLACING OR WIRING MODULES. WARNING - EXPLOSION HAZARD - DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR THE AREA IS KNOWN TO BE NONHAZARDOUS. THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS I, DIVISION 2, GROUPS A, B, C, AND D OR NONHAZARDOUS LOCATIONS ONLY. The maximum ambient temperature for the analyzer is 60°C (140°F). The WDG-V sensor and AMEVision Display User Interface is a complex piece of equipment that should only be serviced by a qualified service technician with expertise in instrument technology and electrical systems. AMETEK recommends that all equipment requiring service be sent back to the factory. You should only attempt to repair or service this equipment after receiving training from an AMETEK/P&AI Division training representative. If you decide to service this equipment be aware that high voltages, high temperatures, and other potentially hazardous conditions may arise. viii | Thermox WDG-V / VC / VCM Environmental Information (WEEE) This AMETEK product contains materials that can be reclaimed and recycled. In some cases the product may contain materials known to be hazardous to the environment or human health. In order to prevent the release of harmful substances into the environment 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 disposed of in a municipal waste system (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 other components are recyclable and you can do your part by doing one of the following steps: • When the equipment is ready to be disposed of, take it to your local or regional waste collection administration for recycling. • In some cases, your “end of life” product may be traded in for credit towards the pur-chase of new AMETEK instruments. Contact your dealer to see if this program is available in your area. • If you need further assistance in recycling your AMETEK product, contact our office listed in the front of the instruction manual. | ix General Safety Summary Review the following safety precautions to avoid injury and prevent damage to this product or any products connected to it. Use Proper Wiring To avoid fire hazards, use only the wiring specified in the Installation Chapter of this user’s manual. Avoid Electrical Overload To avoid electrical shock or fire 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 user’s manual. Before making connections to the input or 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 removed. Use Proper Fuse To avoid fire hazard, use only the fuse type and rating specified for this product. Do Not Operate in Explosive Atmosphere To avoid injury or fire hazard, do not operate this product in an explosive atmosphere unless you have purchased options that are specifically designed for these environments. x | Thermox WDG-V / VC / VCM Product Damage Precautions 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 this product, have it inspected by qualified service personnel. Use Caution When Lifting The analyzer weighs approximately 20 kg (44 lb). Use caution when lifting it from its crate. Use Proper Attire Equippement is hot, user should wear protective groves while handling the equipment. Contents | xi Declaration of Conformity Manufacturer’s Name: AMETEK/Thermox® Manufacturer’s Address: Process & Analytical Instruments Division 150 Freeport Road Pittsburgh, PA 15238 declares that the products: Product Names: Thermox WDG series of Flue Gas Analyzers using AMEVision Display User Interface: WDG-V WDG-VC WDG-VCM Conform to the following standards: EMC compliance: EMC Directive 2004/108/EC Immunity: EN 50082-2:1995 Generic - Heavy Industrial Equipment EN 50082-1:1997 Generic - Residential, Commercial, Light Industrial Equipment EN 61000-6-2:1999 Generic - Heavy Industrial Equipment EN 61326:1997 Measuring Equipment (Heavy Industrial) Emissions: EN 55011:1998 Class A, ISM Equipment Safety Compliance: UL 3101-1 UL Listed Inspection and Measuring Electrical Equipment CAN/CSA 22.2 No. 1010.1-92 cUL Listed Inspection and Measuring Electrical Equipment Low Voltage Directive 73/23/EEC: EN61010-1:1993, Amendment A2: 1995 Electrical Equipment for Measurement, Controls, and Laboratory Use Ingress Protection: IP65 Manufacturer’s Address in Europe: AMETEK Precision Instruments Europe GmbH Rudolf-Diesel-Strasse 16 D-40670 Meerbusch, Germany June 2013 xii | Thermox WDG-V / VC / VCM WARRANTY AND CLAIMS We warrant that any equipment of our own manufacture or manufactured for us pursuant to our specifications which shall not be, at the time of shipment thereof by or for us, free from defects in material or workmanship under normal use and service will be repaired or replaced (at our option) by us free of charge, provided that written notice of such defect is received by us within twelve (12) months from date of shipment of portable analyzers or within eighteen (18) months from date of shipment or twelve (12) months from date of installation of permanent equipment, whichever period is shorter. All equipment requiring repair or replacement under the warranty shall be returned to us at our factory, or at such other location as we may designate, transportation prepaid. We shall examine such returned equipment, and if it is found to be defective as a result of defective materials or workmanship, it shall be repaired or replaced as aforesaid. Our obligation does not include the cost of furnishing any labor in connection with the installation of such repaired or replaced equipment or parts thereof, nor does it include the responsibility or cost of transportation. In addition, instead of repairing or replacing the equipment returned to us as aforesaid, we may, at our option, take back the defective equipment, and refund in full settlement the purchase price thereof paid by Buyer. The warranty shall not apply to any equipment (or part thereof) which has been tampered with or altered after leaving our control or which has been replaced by anyone except us, or which 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, fire or force of the elements. Improper use or misapplications shall be construed to include improper or inadequate protection against shock, vibration, high or low temperature, overpressure, excess voltage and the like, or operating the equipment with or in a corrosive, explosive or combustible medium, unless the equipment is specifically designed for such service, or exposure to any other service or environment of greater severity than that for which the equipment was designed. The warranty does not apply to used or secondhand equipment nor extend to anyone other than the original purchaser from us. THIS WARRANTY IS GIVEN AND ACCEPTED IN LIEU OF ALL OTHER WARRANTIES, WHETHER EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION AND WARRANTIES OF FITNESS OR OF MERCHANTABILITY OTHER THAN AS EXPRESSLY SET FORTH HEREIN, AND OF ALL OTHER OBLIGATIONS OR LIABILITIES ON OUR PART. IN NO EVENT SHALL WE BE LIABLE UNDER THIS WARRANTY OR ANY OTHER PROVISION OF THIS AGREEMENT FOR ANY ANTICIPATED OR LOST PROFITS, INCIDENTAL DAMAGES, CONSEQUENTIAL DAMAGES, TIME CHANGES OR ANY OTHER LOSSES INCURRED BY THE ORIGINAL PURCHASER OR ANY THIRD PARTY IN CONNECTION WITH THE PURCHASE, INSTALLATION, REPAIR OR OPERATION OF EQUIPMENT, OR ANY PART THEREOF COVERED BY THIS WARRANTY OR OTHERWISE. WE MAKE NO WARRANTY, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION ANY WARRANTIES OF FITNESS OR OF MERCHANTABILITY, AS TO ANY OTHER MANUFACTURER’S EQUIPMENT, WHETHER SOLD SEPARATELY OR IN CONJUNCTION WITH EQUIPMENT OF OUR MANUFACTURE. WE DO NOT AUTHORIZE ANY REPRESENTATIVE OR OTHER PERSON TO ASSUME FOR US ANY LIABILITY IN CONNECTION WITH EQUIPMENT, OR ANY PART THEREOF, COVERED BY THIS WARRANTY. Contents | xiii This page intentionally left blank. xiv | Thermox WDG-V / VC / VCM SPECIFICATIONS Sensor : WDG-V Output Range From 0-1% to 0-100% Accuracy ± 0.75% of measured value or ± 0.05% oxygen, whichever is greater Response 90% of a process step change < 6 secs. Drift < 0.1% of cell output per month (< 0.005% O2 per month with 2% O2 applied) Aspirator Air Requirements ≈ 3 scfh (1.4 L/min) at 15 to 100 psig (1.05 to 7.04 kg/cm2) Max. Flue Gas Temp / Probe Type / Lengths 1300°F (704°C) 1875°F (1024°C) 3000°F (1649°C) 316 SS 310 SS Hexoloy® Max. Sample Dewpoint 392°F (200°C) standard. Sample Pressure ± 6 inch water gauge 36” - 108” (91 cm - 271 cm) 36” - 108” (91 cm - 271 cm) 24” - 72” (60 cm-182 cm) Environment Ambient Temp.: -13°F to 149°F (-25°C to 65°C) -4°F to 140°F (-20°C to 60°C) for Purged Units Relative Humidity: 10% to 90%, non-condensing Max. Altitude: 5000 meters Enclosure Hinged IP65, Optional Div II Power Requirements 115 VAC, ± 10%, 47-63 Hz, 600VA max. 230 VAC, ± 10%, 47-63 Hz, 600 VA max. Calibration Gas Requirements Use calibration gases @ 10 PSIG, 3.0 SCFH (1.4 L/min.) O2 Span Gas: Air or from 1.0 to 100% O2, balance N2 O2 Zero Gas: 2% or from 0.1 to 10% O2, balance N2 System Compliance EMC Compliance: Safety Compliance: 2004/108/EC 73/23/EEC NOTES 1. All static performance characteristics are with operating variables constant. 2. System accuracy referenced to 0.1 to 10% calibrated range. Specifications | 3. Response is to calibration gas. 1-1 Sensor : WDG-VC Output Range Oxygen Combustibles From 0-1% to 0-100% From 0-1% to 0-100% From 0-1,000 ppm to 0-10,000 ppm or from 0-1% to 0-5% Accuracy Oxygen ± 0.75% of measured value or ± 0.05% oxygen, whichever is greater Combustibles ± 2% of full scale output range Response O2 90% of a process step change < 6 secs. Drift < 0.1% of cell output per month (< 0.005% O2 per month with 2% O2 applied) Aspirator Air Requirements ≈ 3 scfh (1.4 L/min) at 15 to 100 psig (1.05 to 7.04 kg/cm2) Max. Flue Gas Temp / Probe Type / Lengths 1300°F (704°C) 1875°F (1024°C) 3000°F (1649°C) 316 SS 310 SS Hexoloy® Max. Sample Dewpoint 392°F (200°C) Sample Pressure ± 6 inch water gauge 36” - 108” (91 cm - 271 cm) 36” - 108” (91 cm - 271 cm) 24” - 72” (60 cm-182 cm) Environment Ambient Temp.: -13°F to 149°F (-25°C to 65°C) -5°F to 140°F (-20°C to 60°C) with Div. 2 Option Relative Humidity: 10% to 90%, non-condensing Max. Altitude: 5000 meters Enclosure Power Requirements 115 VAC, ± 10%, 47-63 Hz, 600VA max. 230 VAC, ± 10%, 47-63 Hz, 600 VA max. Calibration Gas Requirements Use calibration gases @ 10 PSIG, 3.0 SCFH (1.4 L/min.) O2 Span Gas: Air or from 1.0 to 100% O2, balance N2 Comb Span Gas: 60 to 80% (ppm ranges) of the selected comb. recorder output range in certified mixtures of CO + H2, 3-4% O2, balance N2. O2 Zero Gas & Comb Zero Gas: System Compliance EMC Compliance: Safety Compliance: 2% or from 0.1 to 10% O2, balance N2 2004/108/EC 73/23/EEC NOTES: 1. All static performance characteristics are with operating variables constant. 2. System accuracy referenced to 0.1 to 10% calibrated range. 3. Response is to calibration gas (without flame arrestors). 1-2 | Thermox WDG-V / VC / VCM Sensor : WDG-VCM Output Range Oxygen Combustibles Methane From 0-1% to 0-100% From 0-1% to 0-100% From 0-2,000 ppm to 0-10,000 ppm 0 to 5% Accuracy Oxygen ± 0.75% of measured value or ± 0.05% oxygen, whichever is greater Combustibles ± 2% of full scale output range Methane ±5% of full scale output range Response O2 90% of a process step change < 6 secs. Drift < 0.1% of cell output per month (< 0.005% O2 per month with 2% O2 applied) Aspirator Air Requirements ≈ 3 scfh (1.4 L/min) at 15 to 100 psig (1.05 to 7.04 kg/cm2) Max. Flue Gas Temp / Probe Type / Lengths 1300°F (704°C) 1875°F (1024°C) 3000°F (1649°C) 316 SS 310 SS Hexoloy® Max. Sample Dewpoint 392°F (200°C) Sample Pressure ± 6 inch water gauge 36” - 108” (91 cm - 271 cm) 36” - 108” (91 cm - 271 cm) 24” - 72” (60 cm-182 cm) Environment Ambient Temp.: -13°F to 149°F (-25°C to 65°C); -5°F to 140°F (-20°C to 60°C) with Div. 2 Option Relative Humidity: 10% to 90%, non-condensing Max. Altitude: 5000 meters Enclosure Hinged NEMA 3R, weather resistant, stainless steel. Optional hinged NEMA 4X (IP56), explosion-proof, purged, Div II. Power Requirements 115 VAC, ± 10%, 47-63 Hz, 700VA max. (750 VA max. floor mount option) 230 VAC, ± 10%, 47-63 Hz, 1950 VA max. (2000 VA max. floor mount option) Specifications | 1-3 Calibration Gas Requirements for Combustibles Detector Use calibration gases @ 10 PSIG, 3.0 SCFH (0.70 kg/cm2, 0.7 L/min.) O2 Span Gas: O2 Comb & CH4 Zero Gases: Comb Span Gas: CH4 Span Gas System Compliance EMC Compliance: Safety Compliance: Air or from 1.0 to 100% O2, balance N2 From 0.1 to 10% O2, balance N2 60 to 80% (ppm ranges) or 40 to 60% (% ranges) of the selected comb. recorder output range in certified mixtures of CO + H2, 3-4% O2, balance N2. 2% CH4, 8% to 10% O2, balance N2 2004/108/EC 73/23/EEC NOTES: 1. 2. 3. All static performance characteristics are with operating variables constant. System accuracy referenced to 0.1 to 10% calibrated range. Response is to calibration gas (without flame arrestors). 1-4 | Thermox WDG-V / VC / VCM Remote Calibration Unit (RCU) O2 Only RCU O2 & Comb. RCU O2, Combustibles & Methane RCU Enclosure UL Type 4X (NEMA 4X (IP56), 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 Compliance EMC Compliance: 2004/108/EC Safety Compliance: 73/23/EEC Specifications | 1-5 This page intentionally left blank. 1-6 | Thermox WDG-V / VC / VCM SYSTEM OVERVIEW Sensor Operations Designed for fast response in a wide range of flue gas applications, the sensor mounts directly on the combustion process to provide continuous measurement of oxygen, or oxygen and combustibles, or oxygen, combustibles and methane. A sample is drawn from the process stream by means of an air-operated aspirator and is immediately returned to the process. A portion of this gas rises past the oxygen measuring cell and combustibles detector and returns to the primary loop. All sample wetted parts are heated to 200°C maintain the sample above the dewpoint of the gas. Follow 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 down, turn off the aspirator air to avoid plugging problems! Remove AC power from the sensor and allow the sensor to cool for at least one hour before performing any maintenance or troubleshooting activities. The outside of the sensor cover and all sensor assembly components are hot during normal operation (up to 500°F, 260°C inside the cover). Allow sensor components to cool for at least an hour before working inside the sensor. Use caution and wear appropriate gloves when handling components or when touching the sensor cover! System Overview | 2-1 Sensor Basic Elements of the Sensor The WDG-V series analyzer consists of the following basic systems:  The Plumbing All inlet and outlet tubing, O2 cell housing, and the combustibles flow block. Also includes the calibration gas inlet and aspirator assembly, flow sensor, and the aspirator used to pull the sample into the sensor.  The Measuring System The oxygen cell, combustibles detector, methane detector, and flow sensor.  The Temperature System The electrical cell heater (furnace), sensor case heaters, the type “K” thermocouple (maintains cell operating temperature). The sensing cell operates at a constant temperature. 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 the thermocouple circuit. The WDG-V is a complete standalone unit. No separate controller is required. All required I/O is contained within the WDG-V including: • Qty (3) configurable 4-20 mA outputs • Qty (2) system alarm relays (Service and Data Valid) • Qty (3) configurable process alarm relays • Qty (1) RS485, 2 wire, MODBUS RTU interface (57.6 Kbaud) • Qty (1) Contact input (for remote auto calibration trigger) • Valve controls for Remote Calibration Unit (RCU) The WDG-V is configured, calibrated and monitored via the MODBUS RTU interface. AMETEK provides two options for communicating with the WDG-V: • AMEVision Display User Interface • WDG-V Configurator Software via PC (Provided with each unit) Since the interface is industry standard MODBUS, custom user software can also be written. For this purpose, consult the factory for the MODBUS register definitions. 2-2 | Thermox WDG-V / VC / VCM The Oxygen Measuring Cell The sensing element itself is a closed-end tube made from ceramic zirconium oxide stabilized with an oxide of yttrium or calcium. Porous platinum coatings on the inside and outside serve as a catalyst and as electrodes. At high temperatures (generally above 1200°F/650°C), oxygen molecules coming in contact with the platinum electrodes near the sensor become 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 pressures are on either side of the cell, a potentiometric voltage is produced (See Figure 2-1). The magnitude of this voltage is a function of the ratio of the two oxygen partial pressures. If the oxygen partial pressure of one gas is known, the voltage produced by the cell indicates the oxygen content of the other gas. A reference gas, usually air (20.9% O2), is used for one of the gases. Figure 2-1. Zirconium oxide cell principle of operation. Since the voltage of the cell is temperature dependent, the cell is maintained at a constant temperature. The oxygen content is then determined from the Nernst equation: E= O RT In 1 O2 4F where R and F are constants, T is absolute temperature, and O1 and O2 are the oxygen partial pressures on either side of the cell. System Overview | 2-3 For measuring oxygen in non-combustibles gases, the calibration of an analyzer is obtained from the formula: E = A*T*Log 20.9% O2 Unk% AT = 48.0 at 680°C Where A is a constant, T is the cell temperature on an absolute scale (°C + 273) and O2 Unk% 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, and the voltage increases as the oxygen concentration of the sample decreases. The voltage created by the difference in the sample gas and the reference air is carried by a cable to the microprocessor control unit, where it is linearized to an output signal.  NOTE Because of the high operating temperature of the cell, combustible gases that are present may burn. When this occurs, the cell will generate high millivolts and cause the display to indicate less oxygen than is actually in the gas (net oxygen content). Hydrocarbons When hydrocarbons are present in the gas sample, a combustion process occurs when this gas sample is exposed to the high temperature of the zirconia cell. An indication that hydrocarbons may be present in the gas sample is that the oxygen reading will be lower than expected. For example, if a calibration gas cylinder has an oxygen value of 20 PPM and 5 PPM of hydrogen (balance nitrogen), the oxygen analyzer will read 17.5 PPM oxygen. The reduction of oxygen is due to the combustion process where 5 PPM of hydrogen will combine with 2.5 PPM of oxygen to form water. Thus, the oxygen analyzer will read 17.5 PPM rather than the actual 20 PPM oxygen.  NOTE 2-4 | Thermox WDG-V / VC / VCM The amount of oxygen reduction is dependent on the type of hydrocarbons present in the sample gas. Sensor Operations - WDG-VCM Close-Coupled Extrative Flue Gas Analyzer The WDG-VCM analyzer is ideal for natural gas-fired power boilers or for those using gas during start-up and shutdown. With this analyzer, you can monitor oxygen and combustibles for maximum fuel efficiency. In addition, the methane detector can be used for purge and lightoff cycles during start-up and shutdown. WDG-VCM analyzers with a combustibles detector are used for processes that use natural gas for start-up and oil, fuel gas or coal for primary fuel. Process gas is drawn into the analyzer’s primary sample loop by an aspirator and returns to process. Gas enters the split flow block that is separted by a baffle and contacts the hot-wire catalytic combustibles and methane detector. It then passes the zirconium oxide cell, where the oxygen concentration is measured, before returning to the main sample loop and then back to the process.  Detectors are very delicate and should be handled with care. NOTE System Overview | 2-5 Detectors Combustibles The Combustibles Detector is a dual element device. The elements differ only in that one is coated with a catalyst. The catalyst causes oxidation to occur at a lower-than-normal temperature. The temperature of the catalyzed element changes as the combustible mixture burns. The temperature change causes the resistance of the catalyzed element to change. The resistance change is interpreted by the microprocessor and the corresponding combustibles reading is displayed. The Thermox catalytic combustibles detector will detect combustible gas present in a sample. The sample must, however, contain enough oxygen to fully burn the combustible present. The combustibles detector responds to all unburned combustibles gases. This includes gases such as CO and H2. You should attempt to match your calibration gas with a mixture of CO and H2 that most closely matches the combustibles mix in your process. We recommend using an even mixture of CO and H2 as the combustibles component within your span gas. Examples: • Flue gas containing 1000 PPM CO, 1000 PPM H2 and 1% O2 with an H2 O, CO2 and N2 balance will be sensed to contain 2000 PPM combustibles by the catalytic detector (provided the combustibles calibration gas consists of equal parts CO and H2 ). • Flue gas containing 1000 PPM CO, 1000 PPM H2 and 500 PPM O2 with a H2 O, CO2 and N2 balance will be sensed to contain only 1000 PPM Comb. by the catalytic detector, since there is less than stoichiometric oxygen present. In this case, the combustibles detector output will be set to full scale/ • If there is little or no other combustible component in the flue gas, the combustibles sensor can be calibrated on a mixture of CO and air to give a CO meaasurement. 2-6 | Thermox WDG-V / VC / VCM Methane The Methane Detector is a dual element device. The elements differ only in that one is coated with a catalyst. The catalyst causes oxidation to occur at a lowerthan-normal temperature. The temperature of the catalyzed element changes as the mixture burns. The temperature change causes the resistance of the catalyzed element to change. The resistance change is interpreted by the microprocessor and the corresponding reading is displayed. The Thermox catalytic methane detector will detect methane gases present in a sample. The sample must, however, contain enough oxygen to fully burn the methane present. The methane span gas should be 2% CH4 with 8 - 10% oxygen present in the mixture. Flow Sensor Overview The aspirator creates a vacuum and pulls the process gas into the analyzer. There are two paths for the gas to take. 1. Immediately back to the process gas. 2. Through the sample loop, past the cell and/or combustible detector. Calibrated at the factory, the flow sensor measures the sample flow through the sample loop. The flow measurement is updated every 90 seconds. This delay is used to allow the sensor to effectively auto-zero to prevent false alarms. System Overview | 2-7 Alarm Limits The flow sensor reports flow as relative to ideal (ie. 100% is ideal flow, 50% is half of flow). An alarm is generated when the sample flow is less than 45% ideal. The flow measurement is directional, with reverse flow generating an alarm. Troubleshooting The flow sensor contains two resistive elements. Each element should be approximately 8-10 Ω. A Flow Sensore failed alarm will be generated if either element is open.  NOTE To Measure: - Turn off the instrument. - Measure the resistance of each element. (Flow Heater, Flow Sense) at the terminals inside the electronics enclosure. - If resistance is much lower or higher than 8-10 Ω, the flow sensor must be replaced. Flow Sensor Heater Element (Black Wire) Flow Sensor Sense Element (Brown Wire) 2-8 | Thermox WDG-V / VC / VCM Temperature Sensors There are two tightly controlled temperature zones in the WDG-V. The Oxygen Cell Temperature and the combustible block temperature (CM units only). (On Oxygen only units the box temperature is controlled with an RTD mounted on the aspirator block.) 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. The thermocouples are collocated in a single assembly. There is no distinction between the two thermocouples as they are effectively at the same location in the assembly. Combustible/Box Temperature The combustible block/ box temperature is controlled to 225°C. This temperature is measured by 100 ohm platinum RTD. The RTD is embedded in the combustible block. On oxygen only units, the RTD is mounted on the aspirator block. All internal plumbing components are maintained above 200°C. Heaters There are two main heaters in the WDG-V, the cell heater and box heater. In CM units, an additional heater is used for fine temperature control of the combustible block. Cell Heater The Oxygen Cell heater is a 300W coil heater encompassing the cell housing and providing precision heat to the oxygen cell. Box Heater The box heater is a 350W cartridge heater located in the aluminum heater block at the bottom of the aspirator. This heater provides the heat for the enclosure to maintain all plumbing components above 200°C. The combustible heater is a 50W heater used for precise temperature control of the combustible Block. System Overview | 2-9 Electronics • One assembly - mounted to a plate • The electronics/software completely control the sensor. - No external controllers are required. • The configuration/monitoring interface to the electronics is RS485 MODBUS RTU. • Sensor wiring and Customer wiring (i.e. power, I/O) are directly connected to the main electronics. - Connections are pluggable. - Both plugs and headers are laser printed for easy matching. I/O The WDG-V has the following I/O available: • Qty (3) configurable 4-20 mA outputs • Qty (2) system alarm relays (Service and Data Valid) • Qty (3) configurable process alarm relays • Qty (1) RS485, 2 wire, MODBUS RTU interface (57.6 Kbaud) • Qty (1) Contact input (for remote auto calibration trigger) • Valve controls for Remote Calibration Unit (RCU) 2-10 | Thermox WDG-V / VC / VCM Analog Outputs There are 3 analog outputs in the WDG-V. Each analog output can be configured for Mode, Function, and Span, Zero. Mode options include, 0-20ma, 4-20ma and NAMUR. Functions include; Oxygen, cell millivolts, combustibles*, methane* The analog outputs can be powered internally or externally. External power must be greater than 26V. The NAMUR outputs are implemented as follows: 4-20 mA signal 0 mA 3.5 mA 3.8 mA 4 to 20 mA 20.5 mA Analyzer Condition Analyzer unpowered, or completely failed Critical Alarm - analyzer reading unusable (factory default) Reading Under Range (Example: user sets range to 2-10%. Current reading is 1.9% Normal Operation Reading Over Range (Example: range is 0-10%. Current reading is 12% * For combustible and/or methane units only. Alarm Contacts There are 5 alarm contacts in the WDG-V, 1 service alarm, 1 data valid alarm, and 3 configurable process alarms. Service Alarm Relay This relay is used to determine if there is a problem with the analyzer. This relay is normally open. Contacts are closed when in normal mode. The relay will be open when there is a problem with the analyzer or on loss of power. Data Valid Relay This relay is used to determine if the output is representative of the process. This relay is normally open. Contacts are closed when in normal mode. Contacts are open when there is a problem with the analyzer, when the analyzer is calibrating, warming up, when the analyzer is in diagnostic mode, or on loss of power. System Overview | 2-11 Contact Input There is one Contact Input peripheral on the WDG-V. An auto calibration can be initiated using the contact input peripheral. (Only with the RCU option). Auto calibration must be selected in the sensor configuration menu. Remote Calibration Unit Interface The WDG-V has 5 solenoid valve drivers that are compatible with AMETEK’s Remote Calibration Unit (RCU). See wiring section for interface details. Communications Interface There is one communications interface on the WDG-V. • RS485 MODBUS RTU Configuration: - Two wire -57.6 Kbaud - No parity - 1 stop bit The WDG-V is configured, calibrated and monitored via the MODBUS RTU interface. AMETEK provides two options for communicating with the WDG-V: • AMEVision Display User Interface (Reference separate manual) • WDG-V Configurator Software via PC (Provided with each unit) Since the interface is industry standard MODBUS, custom user software can also be written. For this purpose, refer to Chapter 11 for the MODBUS MAP or consult the factory for the MODBUS register definitions. 2-12 | Thermox WDG-V / VC / VCM Flame Arrestors The WDG-V sensor contains two flame arrestors to prevent it from being an ignition source to the process for short periods of high combustible levels (25% of LEL - Lower Explosive Limit) in the process. The flame arrestors are not, however, intended to protect the process where the combustibles’ levels are constantly high. System Overview | 2-13 Start-Up Checklist  Review the installation chapter in the User’s Manual.  Install the sensor on the process. - If the sensor is on the pipe nipple, insulate the pipe from the process wall to the mounting flange on the sensor. - Install the probe. - Install the probe heater, if required.  This type of sensor requires a clean, dry instrument air supply for the aspirator. Connect the air supply to the aspirator air supply inlet but DO NOT turn on the air until the sensor is at operating temperature. If the analyzer is turned off or the process is shut down, the aspirator air should be turned off to avoid plugging problems.  If used, interconnect the AMEVision Display User Interface and the sensor per the appropriate interconnecting drawing. -  The specified cable must be used in order to ensure proper operation of the systems. Connect AC mains supply to the sensor. Make sure that the AC voltage is within specified limits. 2-14 | Thermox WDG-V / VC / VCM Common Operator Errors If you follow the steps below, your analyzer will operate with a minimum of maintenance and troubleshooting.  Connect the air supply to the aspirator air supply inlet but DO NOT turn on the air until the sensor is at operating temperature. If the analyzer is turned off or the process is shut down, the aspirator air should be turned off to avoid plugging problems.  If your process is running and the analyzer is installed on the process, the analyzer must have power applied to it to prevent plugged plumbing and sensor component damage. The case heaters must be on if the process is running to maintain sensor plumbing above 200°C.  Do not use pipe dope or any other contaminant that gives off combustible vapor on any joints of the sample tubing.  For O2 calibration gases, do not use calibration gases to check Thermox analyzers if they contain a mixture of oxygen and combustibles. Note, however, that this is acceptable for combustibles span gases (used only if you purchased the combustibles option).  Always introduce calibration gases at the recommended flow rate of 3.0 scfh.  When working on the plumbing inside the sensor cabinet, turn the power off.  Use caution if performing maintenance on the sensor while the process is running. Removing any part of the sensor can allow process gases and gases of high temperature to escape into the sensor.  Do not handle the cell excessively. Do not try to clean the cell except by rinsing. If you need to handle the cell, grasp by touching the seal fitting at the top; never touch the bare part of the cell.  Do not remove a cell or type “K” thermocouple that you may want to use again when the inside of the furnace is still hot - severe thermal shock can be destructive to either of them.  Always replace the metal cell O-ring when replacing the oxygen cell. System Overview | 2-15 Technical Support AMETEK/Thermox is committed to providing the best technical support in the industry. If you need service or application assistance, please call AMETEK at (412) 828-9040, or your local AMETEK/Thermox representative. Before you call the factory for technical 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 you need to return equipment, you will be asked to provide the following information before obtaining a Return Material Authorization (RMA) number.  Billing and shipping address  Model number  Serial number  Purchase order number  Telephone number  NOTE 2-16 | Thermox WDG-V / VC / VCM Before returning material, you must get an RMA number from the factory. INSTALLATION GUIDE  NOTE The operations in this chapter should be performed only by qualified service personnel experienced in electrical safety techniques. Never service the sensor unless power has been removed from the ensor, and the sensor has been allowed to cool for at least one hour. Also, always use gloves when working on the sensor. Do not turn on the aspirator until the sensor has been turned on and is hot - preferably 24 hours. If you turn off the analyzer or the process is shut down, turn off the aspirator air to avoid plugging problems! Installation Guide | 3-1 Analyzer Location Observe the following guidelines when selecting an analyzer installation location: 1. Select a readily accessible position for the analyzer to allow for routine maintenance. Comfort levels for maintenance personnel should be considered in placement of the sensor and AMEVision Display User Interface. 2. 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 outside the specified limits or the vibration is excessive, please contact Thermox Sales or Service Department at (412) 828-9040. We have special options to address ambient temperatures outside the listed specifications. This chapter shows you how to install your WDG-V sensor components and AMEVision Display User Interface, and includes the following sections: • • • Inspection of Shipping Contents Mechanical Installation Wiring If you have an oxygen-only analyzer without the combustibles option, the combustibles and methane options described in this chapter do not apply. These combustibles and methane sections are clearly identified. Likewise, if you have the combustibles option, but not the methane option, you can skip all sections pertaining to methane. Inspect Shipping Contents Remove any packing material from the WDG-V sensor. Check for damage. If any is found, notify the shipper. 3-2 | Thermox WDG-V / VC / VCM Mechanical Installation This section describes how to mount and connect gases to your WDG-V sensor. This includes the following: • Sample Inlet Probe Installation • Probe Heater Installation (optional) • Exhaust Tube Installation (optional) • Sensor Mounting • Remote Calibration Unit Mounting and Plumbing (optional) Sample Inlet Probe Installation  NOTE For some applications, you must first connect the sample inlet probe to the sensor before mounting the sensor. The same applies if you are installing the probe heater or exhaust tube. Therefore, these subjects are discussed before the sections on how to mount the sensor to the process. The sample inlet probe is how the sample gas gets to the sensor. Aspirator air within the sensor is used to pull process gas from the sample probe into the sensor. The sample inlet probe is identified by the threads on both ends. • Figure 3-1 shows how to install the standard 1/8” NPT probe. • Figure 3-2 shows how to install a ceramic or long probe. • Figure 3-3 shows port locations on the rear of the sensor. You can connect the probe to the sensor before mounting the sensor unless the probe is either very long or made of ceramic. In that case you should mount the sensor first and then install the probe. Installation Guide | 3-3 Standard 1/8” NPT probe installation Connect a standard 1/8” NPT sample inlet probe to the sensor as follows: • If your probe is 4 feet or less, simply screw the probe into the back of the sample probe port on the rear of the sensor, then mount the sensor - see Figure 3-1. Standard Probe lengths 3', 4', 5', 6' and 8' Threaded probes screw into fitting Exhaust extension 3/8"T x 10-3/8"Lg (optional). Threaded extension screws into fitting. Backplate Bushing 3/4"NPT(F) x 3/8"NPT(F) (NA for long probes) Insert Plate Fitting 3/8"P x 3/8"T tapped 1/8"NPT (NA for long probes) Probe Inlet Hook TOP VIEW Probe Support 54-1/8"long Assembly replaces bushing for probes 5', 6 and 8' Figure 3-1. WDG-V Probe installation. 3-4 | Thermox WDG-V / VC / VCM Ceramic probe or long probe installation If you ordered a long probe or a ceramic probe, connect the probe to the sensor as follows: 1. Mount the sensor. See the “Sensor Mounting” section later in this chapter for help. Note, however, that if you are installing the probe heater or exhaust tube, you must connect these items to the sensor before mounting the sensor. 2. Remove the probe inlet hook from the sensor as shown in Figure 3-2. To do this, loosen the fitting connecting the inlet hook to the aspirator block and pull the hook out of the sensor. 3. Unscrew the bushing that was plugged into the sensor inlet port and discard. The probe comes with its own bushing and fitting. 4. Thread the sensor probe into the sensor inlet port on the sensor backplate. Do not let the probe hit against the Thermox-provided pipe nipple as you insert the probe into the process. If inserting a ceramic probe, you must slowly insert it into a hot process to prevent the probe from cracking due to thermal shock. 5. Reconnect the probe inlet hook to both the sensor backplate and the aspirator block and tighten. Backplate Bushing Aspirator Block Probe Inlet Hook TOP VIEW Figure 3-2. WDG-V ceramic probe installation - top view. Installation Guide | 3-5 Probe Heater Installation Do not install the probe heater if your sample gas contains a potentially explosive mixture of combustibles; the probe heater can heat the flue gas to the point of ignition.  The probe heater must be connected to the sensor before mounting the sensor to the process. NOTE For installations where a standard setup allows the sample gas to cool below its acid dewpoint before reaching the sensor, you can attach the optional probe heater to the probe heater port on the backplate of the sensor to heat the sample gas - see Figure 3-3. This will prevent plugged plumbing due to condensation of the sample gas. For example, when a fuel containing only a few thousand parts per million of sulfur is burned with a high level of excess oxygen (over 4 percent), the resulting sulfuric acid mist may condense at temperatures as high as 175°C. The probe heater comes shipped in an envelope, is 8.5” long, has a 3/8 NPT bushing and wires leading out of it. Sample Probe Inlet Port Exhaust Port Probe Heater Port (Remove Plug) Terminal Box Figure 3-3. Port locations on rear of sensor - front view. 3-6 | Thermox WDG-V / VC / VCM Follow the steps below to install the probe heater: 1. Remove and discard the plug from the probe heater port as shown in Figure 3-3. This port is plugged during shipment and should remain plugged if no probe heater is installed. 2. Screw the probe heater into the 3/8” NPT probe heater port. 3. Route the wires from the probe heater to the electronics enclosure. 4. Remove the electronics box cover and connect the wires to an AC power source. Exhaust Tube Installation  If installing an exhaust tube, you must connect it to the sensor before mounting the sensor to the process. NOTE An optional stainless steel exhaust tube is available (PN 70619KE), which allows you to extend the aspirator exhaust. To install the exhaust tube, thread the exhaust tube into the exhaust port on the rear of the sensor as shown in Figure 3-3. Sensor Mounting • The sensor ambient temperature range is -25°C to 65°C. • For purged units, the sensor ambient temperature range is -20°C to 60°C. • When installing a probe heater or exhaust tube along with the sensor, attach it to the back of the sensor before mounting the sensor to the process. Do not open a Z-purge, hinged-sensor enclosure door until you first verify that the area has been classified as nonhazardous. Installation Guide | 3-7 Methods for mounting the sensor There are three methods for mounting a WDG-V sensor to the process: • Flush with the process, • Using a customer-supplied pipe nipple, • Using a customer-supplied flange. Each of these methods is explained in the sections that follow. The flush mount method is preferred because it positions the sensor as close to the process as possible and minimizes the chances of the sample gas cooling below its dewpoint. Mounting dimensions for the hinged style enclosure, including the Z-purge option, are provided in Figure 3-4.  NOTE 3-8 | Thermox WDG-V / VC / VCM If the protection nipple provided by AMETEK/Thermox extends past the inside of the refractory wall on a process that has a gas temperature over 1200°F (650°C), the nipple should be cut down before installation in order to remain flush with the inside wall. 8.48 215.50 4.39 111.44 Exhaust Restrictor Pressure Gauge ` 3.80 96.59 18.61 472.59 Hinge Side 2.51 63.86 Instrument Air Inlet 5.23 132.95 Metering Valve Probe CL 3.64 92.56 Check Valve Terminal Box Figure 3-4. Mounting dimensions - Hinged sensor.  A 7/16” wrench is required to open both doors to the sensor. NOTE Installation Guide | 3-9 Sensor flush mount (Preferred Method) Weld the 7” x 7 5/8” (17.78 cm x 19.37 cm) mounting plate (P/N 70626SE) supplied with the sensor to the process wall over a 3 3/4” (9.52 cm) diameter hole as shown in Figure 3-5. Then bolt the sensor to the mounting plate. This method positions the sensor as close to the process as possible and minimizes any chance that the sample gas will cool below its dewpoint. Sensor bolted to mounting plate after plate is welded to wall by customer. Gasket (by Ametek) Mounting plate supplied by Ametek with 2 7/8"OD x 9"long nipple (7.30cm x 22.86cm) welded to wall over 3 3/4"od (9.52cm) hole by customer. Process wall Probe Single stud at 12 o'clock position SIDE VIEW Proper orientation for mounting plate to flange Figure 3-5. WDG-V sensor flush mount (preferred). Customer-supplied pipe nipple sensor mounting If you can’t mount the sensor flush with the process as described in the previous section (for example, the process wall is curved sharply, covered with insulation, or obstructed with reinforcing members) you can instead: 1. Weld a short 3 1/2” diameter pipe nipple to the process wall and make sure to extend the nipple through the skin of the process (see Figure 3-6). 3-10 | Thermox WDG-V / VC / VCM Sensor bolted to mounting plate after plate is welded to nipple by customer. Gasket (By Ametek) Mounting plate (supplied by Ametek) 1 7/8"OD with 9"long nipple (7.30cm x 22.89cm) welded over 3 3/4"OD (9.52cm) hole by customer. Process wall Probe Required 1" (25.4cm) minimum insulation around exposed portion of nipple Pipe nipple (supplied by customer) SIDE VIEW Single stud at 12 o'clock position Proper orientation for mounting plate and flange Figure 3-6. Customer-supplied pipe nipple sensor mounting. 2. Weld the 7” x 7 5/8” (17.78 cm x 19.37 cm) supplied plate to the end of the nipple, taking care to center it over the hole 3. Wrap the nipple with at least 1” (2.54 cm) weatherproof insulation and heat trace it. 4. Then bolt the sensor to the plate. If mounting the sensor using this method, you can also install the probe heater to minimize the possibility of the sample gas cooling below its dewpoint. Installation Guide | 3-11 Flange sensor mounting method You can also mount the sensor to a 3” x 300# customer-supplied flange. In this case, you will not need the AMETEK-supplied mounting plate with attached protective pipe nipple. If you have a different type of flange, AMETEK supplies a 1 2 number of flange adapters. REV. A B REVISION DESCRIPTION DATE ORIGINAL ISSUE ADD MISSING PARTS 06-11-13 10-14-13 DR APPR SB SB MG CAM CUSTOMERS 3"-300# FLANGE (REDUCING FLANGE IF REQUIRED) CONNECTED TO 2 1/2" MINIMUM SCH 40 PIPE ATTACHED TO WALL BY CUSTOMER. B B PROCESS WALL GASKET BY THERMOX 1" MIN INSULATION AROUND EXPOSED PORTION OF NIPPLE 3"-300# FLANGE MOUNTING A A PRODUCT LINE THERMOX DIMENSIONS ARE IN INCHES TOLERANCES: FRACTIONAL 1/32" ANGULAR: MACH 30' TWO PLACE DECIMAL .010 THREE PLACE DECIMAL .005 SURFACE ROUGHNESS 125 CONFIDENTIAL REPRODUCTION PROHIBITED WITHOUT PERMISSION BY AMETEK P & AI DIVISION Figure 3-7. WDG-V sensor flange mount. MATERIAL 2 3-12 | Thermox WDG-V / VC / VCM SEE BILL OF MATERIALS SB 06-11-13 DOC. CONT. MG 10-8-13 ENGR. APPR. CAM 10-8-13 ORIG. ISSUE CK DRAWN BY SCALE NTS WDG-V PURGE SENSOR MOUNTING & DIMENSIONS SIZE 06-11-13 SHEET 1 OF AMETEK PROCESS & ANALYTICAL INSTRUMENTS DIV. 150 FREEPORT ROAD PROCESS & ANALYTICAL INSTRUMENTS DIVISION PITTSBURGH, PENNSYLVANIA 15235 USA 1 A DWG. NO. 202-645-3 1 REV B Calibration/Aspirator Air Required calibration gases and tubing  See Chapter 2 for information on calibration gases. The span gas is the high gas; the zero gas the low gas. NOTE 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 from 1.0% to 100% O2. O2 Zero Gas From .1 to 10% O2, balance N2 Combustibles Span Gas If using a WDG-VC analyzer, you must also have a combustibles span gas as follows: • 60 to 80% of the full combustibles operating range in certified mixtures of CO, with an equal amount of O2, balance N2. For example, if using an operating range of 0 to 2000 ppm combustibles, use 1200 ppm CO, 1 to 2% O2, balance N2. Methane Span Gas If using a WDG-VCM analyzer, you also must have a methane span gas as follows: • 2% CH4, 8 to 10% O2, balance N2. Installation Guide | 3-13 Z-Purge Connections (Optional) Connect instrument air to the sensor Z-purge inlet. Maintain the pressure and flow as directed on the Z-purge warning label. • You must provide a protective gas supply with an alarm for a loss of pressure indication in order to meet regulatory requirements. • You must not exceed the maximum temperature rating listed in the specifications. • Process pressure is assumed to always be subatmospheric (vacuum) unless the High-pressure option is installed. • The protective gas supply shall be equipped with an alarm to indicate failure of the protective gas supply to maintain the minimum pressurized enclosure pressure. • The indicator shall be located for convenient viewing. • The indicator shall indicate the enclosure pressure. • The sensing point for the indicator shall be located to take into account the most onerous conditions of service. • There shall be no devices between the pressurized enclosure and the protective gas supply alarm other than an isolating valve and/or a pressure of flow controlling mechanism. • Any isolating valve shall - Be marked WARNING - PROTECTIVE GAS SUPPLY VALVE FOLLOW INSTRUCTIONS BEFORE CLOSING - Be capable of being sealed or secured in the open position. - Have an indication of whether it is open or closed. - Be located immediately adjacent to the pressurized enclosure. - Be used only during servicing of the pressurized enclosure. • Any pressure or flow controlling mechanism, if adjustable, shall require a tool to operate it. • No filters shall be fitted between the pressurized enclosure and the protective gas system alarm. • No isolating valve shall be fitted between the indicator and the pressurized enclosure. 3-14 | Thermox WDG-V / VC / VCM • The WDG-V sensor contains two flame arrestors to prevent it from being an ignition source to the process for short periods of high combustible levels (25% of LEL - lower explosive limit) in the process. The flame arrestors are not, however, intended to protect the process where the combustibles levels are always high. Do not install the probe heater if your sample gas contains a potentially explosive mixture of combustibles; the probe heater can heat the flue gas to the point of ignition. Z-Purge Shutdown Procedure Hot internal parts are above the ignition temperature of combustible gases. Power must be disconnected from the sensor for 90 minutes while maintaining purge air flow before the door is opened, unless the area is demonstrated to be nonhazardous. The Z-purge apparatus provided by Thermox meets NFPA 496. Power must not be restored after the enclosure has been opened until the enclosure has been purged for 65 minutes at a pressure of 0.4” of water. Always use tubing that is free of oil and dirt. Stainless steel tubing is recommended. Figure 3-8. Z-purge setup. Installation Guide | 3-15 Calibration Gas Inlet Port 1/4"T Compression Fitting Instrument Air Inlet 1/4"NPT (F) Purge Air Inlet 1/4"T Compression Fitting Figure 3-9. Sensor inlet connections. 3-16 | Thermox WDG-V / VC / VCM Manual calibration and aspirator air connections  NOTE If you have a remote calibration unit (RCU), skip the remainder of this section and proceed to the “RCU Mechanical Installation” section. Aspirator air connection  If you have an AMEVision Display User Interface, you can use the flow gauge to set the flow as described in Chapter 5. NOTE • Connect aspirator air to the aspirator air inlet on the sensor (see Figure 3-9). The recommended initial aspirator pressure setting is 3 psi. This will vary depending on the pressure/vacuum of the process for which the WDG-V is installed. If you purchased an AMEVision Display User Interface, you can use the Flow Sensor output diagnostic screen to set the flow to the ideal rate. If you do not have an AMEVision Display User Interface, it is recommended to adjust the aspirator until you get a response from the analyzer, then increase the pressure by 0.25 to 0.5 psi. Do not turn on the aspirator until the sensor has been turned on and is hot (preferably 24 hours from a cold start; 1 hour after a restart). See page 5-1 for furter detail. Calibration gas connection • A calibration gas inlet port is provided to allow you to calibrate the system as shown in Figure 3-9. During calibration, you turn off the aspirator air supply and inject your calibration gases into the calibration gas inlet port on the sensor. During normal operations, the calibration gas inlet port should be plugged. Installation Guide | 3-17 Remote Calibration Unit Mechanical Installation Remote calibration unit (RCU) mechanical installation includes the following: • Mounting the RCU. • Plumbing calibration gases to the RCU. • Plumbing the RCU to the sensor. This section is divided into instructions for standard RCU and combustibles RCU mechanical installation. Go to the section that applies to the type of RCU you purchased. Do not turn on the aspirator until the sensor 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 aspirator air to avoid plugging problems! Standard RCU mechanical installation Figure 3-10 shows mounting dimensions for a standard RCU. Use two #10 screws to mount the RCU. Note from Figure 3-10 that only the top left and lower right holes are used; the other holes hold the RCU to its mounting plate. 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 response times, reduces calibration gas expense, and reduces the chance of contaminants in the calibration gas plumbing. 3-18 | Thermox WDG-V / VC / VCM Figure 3-10. RCU mounting dimensions - O2-only. Installation Guide | 3-19 Standard RCU Make the following calibration gas connections to the standard RCU. Figure 3-10 shows standard RCU calibration gas connections: 1. Connect instrument grade air that is free of oil or dirt to the instrument air inlet connection on the left side of the RCU. If you are also using instrument air as your span gas, you can skip Step 2 below because instrument air will be used for both aspirator air and the span calibration gas. 2. If you wish to use a span gas other than instrument air, you must purchase the optional alternate span gas kit. Connect the span gas to the alternate span gas inlet on the RCU if your span gas is other than instrument 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 sensor -see Figure 3-9 for the calibration gas inlet connection on the WDG-V sensor. Also, be sure to install the supplied check valve as close to the sensor as possible - note the orientation of the valve. 5. Connect the aspirator air outlet on the RCU to the aspirator air inlet connection on the sensor. Combustibles RCU Figure 3-11 shows mounting dimensions for the combustibles RCU. Mount the RCU as close to the sensor as possible. Shorter calibration plumbing improves response times, reduces calibration gas expense, and reduces the chance of contaminants in the calibration gas plumbing. The ambient temperature range for the combustibles RCU is -20° to 70°C. Make the following calibration gas connections to the combustibles RCU. 3-20 | Thermox WDG-V / VC / VCM COMBUSTIBLES (SPAN 2) CALIBRATION GAS INLET 1/4” COMPRESSION FITTING Figure 3-11. RCU mounting dimensions - Combustibles. 1. Connect the O2 span gas, if other than instrument air, to the alternate O2 span gas inlet. 2. Connect the O2 zero calibration gas to the O2 zero gas inlet connection on the RCU. 3. Connect the combustibles span calibration gas to the combustibles span gas inlet on the RCU. For a WDG-VCM analyzer 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 outlet on the right side of the RCU to the calibration gas inlet on the sensor - see Figure 3-8 for sensor calibration gas inlet connection. 5. Using appropriate tubing, connect the aspirator air outlet on the right side of the RCU to the aspirator air inlet connection on the sensor. Installation Guide | 3-21 Figure 3-12. RCU flow diagram - Single Span. Figure 3-13. RCU flow diagram - 2 Span - Combustibles. 3-22 | Thermox WDG-V / VC / VCM Figure 3-14. RCU plumbing - 3 Span - Combustibles & Methane. Installation Guide | 3-23 Wiring Remove AC mains power from the controller before performing wiring. Connections to the sensor unit are made through the wiring card. The wiring card is located on the front-bottom of the sensor unit.  Any screw terminals on the wiring card not described in this section are reserved for future use. NOTE This wiring section shows you how to make the following connections: • AC mains supply wiring to WDG-V sensor • WDG-V unit to remote calibration unit • WDG-V unit to alarm devices • WDG-V unit to current output devices • WDG-V unit to AMEVision Display User Interface (RS-485 communications) • AC mains supply wiring to AMEVision Display User Interface In addition, this wiring section provides mandatory EMC grounding, shielding, and noise protection requirements. 3-24 | Thermox WDG-V / VC / VCM General Wiring and Conduit Requirements This section describes general wiring and conduit requirements. • Sensor wiring conductors must be rated at a minimum of 80°C. All other wiring conductor ratings should be for the minimum temperature required for the equipment being connected 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 sensor enclosure or WDG-V. 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, shielding and noise protection practices as described in this section. • For all sensor and signal wiring use twisted-pair cable, 18 to 22 AWG (0.82 mm2 to 0.33 mm2 ), with an overall braided shield, or twisted-pair cable in rigid metal conduit. • For AC mains supply wiring, use between 12 and 14 American Wire Gauge (AWG) or equivalent metric between 3.3 mm 2 and 2.1 mm2. • Use the conduit entry point closest to the connections you are making. Do not add any additional conduit entry holes! SS External Ground Stud M5 Ring Terminal 12-10AWG (2) 1/2"NPT Conduit Entries Supplied with Nema Conduit Plugs 42464JE (4) 3/4"NPT Conduit Entries Supplied with Nema Conduit Plugs 42454JE Installation Guide | 3-25 WDG-V Mains Supply Connections Do not run control unit AC mains supply wiring in the same conduit with other AC line power wires. By keeping this wiring separated, you prevent transient signals from reaching the control unit. The WDG-V can operate using between 115 VAC, ± 10% or 230 VAC, ± 10%. There is no power switch or circuit breaker on the sensor, and it must be protected by installing it on a circuit-protected line, maximum 15 amperes, with a switch or circuit breaker in close proximity to the control unit and within easy reach of an operator. Mark the switch or circuit breaker as the control unit disconnecting device. 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 for AC mains supply wiring. Use the chassis stud next to the 1/2” conduit entry hole for equipment ground (protective conductor). AC (L) and (N) markings are provided by the terminal block for connection of AC power. These markings are for reference purposes only, such as for use on system wiring diagrams, etc. The system/product has or needs no specific LINE or NEUTRAL connection for any function, safety or otherwise. The (N) terminal is not internally grounded, nor needs to be. The system will operate normally regardless of what AC input terminal (L or N) the AC Line or Neutral is connected to, or, if there is a Neutral used at all (i.e., 208 VAC US power connection). 3-26 | Thermox WDG-V / VC / VCM EMC grounding, shielding, and noise protection For EMC purposes, under no circumstances should you leave cable shields disconnected at one end or both ends of the cable (sensor or control unit or other device). You must use twisted-pair cable in rigid metal conduit or use twisted pair cable with an overall braided shield. All cable shields or conduits connecting to the sensor unit must be chassis grounded. SHIELD RING METHOD Shield Terminal Ring Quick Disconnect (1/4”) Cable Shield(s) Max. Length 1 inch Capacitor Conduit Housing Conduit Nut GROUND STUD METHOD Conduit Housing Cable Shield(s) Max. Length 2 inches Capacitor Conduit Nut Nut Washer Ring Terminal Figure 3-25. Direct shield grounding methods Installation Guide | 3-27 Transient and RFI interference This section describes transient and RFI interference precautions: • Although there are transient and noise protectors on all sensor unit I/O connections (communications, current outputs, sensor, etc.), this protection is intended to act as a last line of defense against unwanted transient and RFI interference. • Proper installation practices to prevent the introduction of transients and noise into the system must be followed. Inductive loads connected to the sensor unit must have transient suppressors installed at the inductive loads. Be sure to place 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 mains supply wiring that feeds heavy inductive loads. • Avoid running signal wiring in the same cable or conduit with wires that power inductive loads unless all the cables within the conduit are shielded, the inductive loads are small, and transient suppressors are used at the loads. • Do not run signal lines in the same cable or conduit with high voltage lines. • For optimum noise protection, AMEVision Display User Interface mains supply wiring should be connected to a circuit separate from any circuit that could introduce transients into the system. As an example, do not run motors, blowers, or air conditioners using the same mains supply circuit or conduit as the sensor unit’s mains supply circuit or conduit. 3-28 | Thermox WDG-V / VC / VCM Current Output Connections Standard current outputs There are three current outputs on the WDG-V sensor. The current output connections are labeled as follows on the sensor board terminals: Analog Output #1 => +I1Analog Output #2 => +I2Analog Output #3 => +I3- The current outputs are referenced as Analog Outputs 1, 2 and 3 in the AMEVision Display User Interface and PC software. Be sure 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 the following ranges: 0-20mA 4-20mA NAMUR The NAMUR outputs are implemented as follows: 4-20 mA signal 0 mA 3.5 mA 3.8 mA 4 to 20 mA 20.5 mA Analyzer Condition Analyzer unpowered, or completely failed Critical Alarm - analyzer reading unusable (factory default) Reading Under Range (Example: user sets range to 2-10%. Current reading is 1.9% Normal Operation Reading Over Range (Example: range is 0-10%. Current reading is 12% Installation Guide | 3-29 Figure 3-26. Wiring 3-30 | Thermox WDG-V / VC / VCM Alarm Contact Connections This section describes how to make wiring connections for any alarm devices you wish to connect to the control unit. Standard alarm connections The WDG-V sensor provides five sets of normally open alarm contacts as follows: Terminal Block ID Description SVC - Service Alarm DV - Data Valid Alarm ALM1 - Process Alarm 1 (Configurable) ALM2 - Process Alarm 2 (Configurable) ALM3 - Process Alarm 3 (Configurable) The process alarms are referenced as Relay 3, Relay 4 and Relay 5 in the AMEVision. Relay 3 Relay 4 Relay 5 - - - ALM 1 ALM 2 ALM 3 Service Alarm - 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) when a critical alarm exists. Data Valid - The data valid alarm indicates if the concentration readings are representative of the process. When this alarm is active, concentration readings may not be representative of the process and should not be used for control/safety. Examples of this alarm include: Warm-up mode, in calibration, and diagnostics mode. This alarm differs from the service alarm in that there is not necessarily a problem with the analyzer when this alarm is active. The relay contacts are normally-open and are OPEN (de-energized) when the concentration readings are not valid. Installation Guide | 3-31 Remote Calibration Unit Connections If you don’t have the remote calibration unit (RCU) option, skip this section. Oxygen-only remote calibration unit connections Oxygen-Only Remote Calibration Unit (RCU) connections on the WDG-V wiring card, and their RCU connections, are as follows (see Figure 3-27): ZERO GAS - WDG-V Terminal Z to Pin 13 on RCU ASPIRATOR - WDG-V Terminal A to Pin 14 on RCU O2 SPAN - WDG-V Terminal S1 to Pin 15 on RCU VALVE COMMON - WDG-V Terminal ‘V’ to pin 16 on RCU Combustibles remote calibration unit connections If you have the combustibles option (and a combustibles RCU), you must also make the following connection (see Figure 3-27): COMBUSTIBLE SPAN - WDG-V Terminal S2 to Pin 17 on RCU For a WDG-VCM with hot-wire detector, Remote Calibration Unit connects: METHANE SPAN - WDG-V Terminal S3 to Pin 18 on RCU 3-32 | Thermox WDG-V / VC / VCM SPAN 3 SPAN 4 SPAN 2 SPAN 1 Z A VALVE COM CIN VALVE COM Remote cal switch normally open (dry contact closure) Overall braided shield or rigid metal conduit All common wires to pin 16 on RCU and valve commons on control unit Figure 3-27. RCU connections. Digital input to initiate remote calibration unit The digital input connections on the wiring card allow you to initiate a remote calibration from a remote location. For this option 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 digital input must be a normally open switch. Digital input connections are labeled as follows on the wiring card: CIN Installation Guide | 3-33 Notes About Ducting Ducting Between Pressurized Enclosure and Inlet The intake ducting to a compressor should not normally pass through a hazardous area. If the compressor intake line passes through a hazardous area, it should be constructed of non-combustible material and protected against mechanical damage and corrosion. Adequate precautions should be taken to ensure that the ducting is free from leaks in case the internal pressure is below that of the external atmosphere (see Annex C). Additional protective measures, for example, combustible gas detectors, 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 necessary to purge the free volume of those associated ducts which are not part of the equipment by at least five times their volume at the minimum flow rate specified by the manufacturer. Power for Protective Gas Supply The electrical power for the protective gas supply (blower, compressor, etc.) should be either taken from a separate power source or taken from the supply side of the electrical isolator for the pressurized enclosure. Enclosure Maximum Overpressure The user should limit the pressure as specified by the manufacturer. 3-34 | Thermox WDG-V / VC / VCM AMEVISION DISPLAY USER INTERFACE OR COMMUNICATIONS Purpose The AMEVision Display User Interface provides a remote, color, graphical user interface as well as a communications suite for the WDG-V. The AMEVision Display User Interface provides the ability to easily configure, calibrate and monitor up to four WDG-V sensors from a single unit. The interface between the AMEVision Display User Interface and the WDG-V sensor is two-wire MODBUS RTU. The AMEVision Display User Interface provides the following communication interfaces: • MODBUS RTU • Web Interface (TCP/IP) • USB (Flash Drive) Additional features: • 4.2” Color, 1/4 VGA Display • 19 Key Keypad • Intuitive Menus • Alarm and Event logging • Data logging and trending. Data can be graphed on the local display and/or uploaded via USB flash drive • Upgradable firmware for attached sensors and/or AMEVision Display User Interface USB flash drive • Calibration history display and plot • Sensor Diagnotics AMEVision Display User Interface or Communications | 4-1 Color 1/4 VGA Navigation Buttons Enter/ Menu Key Number Pad Help Cancel/Escape Figure 4-1. AMEVision Display User Interface Reference the AMEVision Display User Interface manual for more information. 4-2 | Thermox WDG-V / VC / VCM Setting the Analyzer Address The interface bewteen the AMEVision Display User Interface and the WDG-V sensor is a two-wire MODBUS RTU. Up to four WDG-V sensors can be connected to a single AMEVision Display User Interface unit. Each attached sensor must have a unique address. The address on the WDG-V sensor is set via the dip switch on the front of the electronics PCB. Figure 4-2. Dip Switch Locations 321 Switch Address 001 1 010 2 011 3 100 4 1 = ON (UP) 0 = OFF (DOWN) AMEVision Display User Interface or Communications | 4-3 Connecting a Single WDG-V Sensor to the AMEVision Figure 4-3. Single WDG-V Sensor to the AMEVision Display User Interface  When only one sensor is connected, the WDG-V address should be set to “1”. NOTE Connecting Multiple WDG-V Sensors to the AMEVision Up to four sensors can be connected to a single AMEVision Display User Interface unit. The WDG-V sensor provides extra terminal connections to facilitate easy daisy chain connections. Figure 4-4. Multiple WDG-V Sensors to the AMEVision Display User Interface  NOTE 4-4 | Thermox WDG-V / VC / VCM Each analyzer must have a unique address (reference address setting section). AMEVision Display User Interface or Communications | 4-5 When connecting multiple sensors in a daisy chain configuration, the communication termination resistor should be enable on the last sensor in the chain (farthest from the AMEVision Display User Interface). The termination enable is controlled by switch SW-5 of the dip switch on the front of the electronics PCB. SW-5 on: Termination Enabled SW-5 off: Termination Disabled  The maximum distance between the AMEVision Display User Interface and the WDG-V analyzer is 4000 feet (1219.2 meters). NOTE Troubleshooting The interface between the WDG-V and the AMEVision Display User Interface is simple and robust. However, if you experience connectivity issues, here are some of the possible causes: No Communications: • Polarity reversed • Address not set correctly • Maximum distance exceeded • Broken connection Intermittent Communications: • Poor wiring (i.e. lack of shielded twisted pair) • Termination enabled on more than one unit (on multi-unit systems) • Termination not enabled (on multi-unit systems) • Maximum distance exceeded 4-6 | Thermox WDG-V / VC / VCM WDG-V PC Configurator Software Overview The WDG-V PC Configurator Software provides a convient way to configure, calibrate and monitor a single WDG-V analyzer. The interface between the configurator software and the WDG-V sensor is two-wire MODBUS RTU. Connecting to the WDG-V Using the optional USB to RS485 converter (P/N 1000-724-VE), attach as shown. The address must be set per the Settings >> Address section.  An AMEVision Display User Interface and PC software cannot be simultaneously connected to the analyzer. NOTE 1000-724-JE 1000-724-JE CONNECTOR WDG-V TERMINAL T/R+ T/R- MB+ MB- USB TO COMPUTER Note: Only one connection can be made to the sensor. The AmeVision and Configurator cannot be connected simultaneouslt. AMEVision Display User Interface or Communications | 4-7 This page intentionally left blank. 4-8 | Thermox WDG-V / VC / VCM FLOW SETTING Setting the Flow The recommended initial aspirator pressure setting is 3 psi. This will vary depending on the pressure/vacuum of the process for which the WDG-V is installed. If you purchased an AMEVision Display User Interface, you can use the Flow Sensor output diagnostic screen to set the flow to the ideal rate. If you do not have an AMEVision Display User Interface, it is recommended to adjust the aspirator until you get a response from the analyzer, then increase the pressure by 0.25 to 0.5 psi. Setting the flow using the AMEVision Display User Interface Flow Sensor Diagnostic The internal flow sensor output is displayed is percent to ideal sample loop flow. For example, a reading of 100% indicates ideal flow whereas a reading of 50% indicates half the ideal flow rate. The update interval for the flow sensor is 90 seconds, so you must wait at least 90 seconds for the flow output value to change. It is recommended to operate the sensor between 80% and 120%. A low flow alarm is generated when the flow is 45% or lower. To set the flow, first adjust the aspirator pressure regulator until you get a response from the analyzer. Wait 90 seconds and check the flow sensor output. Adjust the aspirator as necessary until the flow sensor reads approximately 100%. Small increments of 0.25 psi are recommended. Flow Setting | 5-1 This page intentionally left blank. 5-2 | Thermox WDG-V / VC / VCM LED STATUS INDICATOR Main Status LED (Light Pipe Visible From the Front) OFF – Power is off.  NOTE The status LED is NOT directly connected to the WDG-V power supply. In the unlikely event of an error condition, it is possible for the analyzer to be energized with dangerous voltages even though the status LED is off. Always verify power has been removed before servicing the instrument. GREEN – Analyzer is in normal operating mode. YELLOW – Analyzer is in warm-up state or diagnostic state. RED – Analyzer has a service alarm and is in need of attention. Figure 6-1. Analyzer is in normal operating mode. LED Status Indicator | 6-1 Figure 6-2. Analyzer is in warm-up state or diagnostic state. Figure 6-3. Analyzer has a service alarm and is in need of attention. 6-2 | Thermox WDG-V / VC / VCM 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 the analyzer). You must look up into the electronics enclosure to view these LED’s, they are not visible when looking directly at the analyzer. REAR LED – Heart Beat LED. Blinks once a second indicating the analyzer software is operating. If off or not blinking this indicates the power is off or the electronics are not functional. FORWARD LED – Modbus Communications LED. Toggles upon receipt of a valid Modbus message. This LED will blink rapidly in short bursts when communicating properly to the AMEVision Display User Interface. LED Status Indicator | 6-3 This page intentionally left blank. 6-4 | Thermox WDG-V / VC / VCM TROUBLESHOOTING The operations in this chapter should be performed only by qualified service personnel experienced in electrical safety techniques. Never service the sensor unless power has been removed from the 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 AMEVision Display User Interface and error messages. It also provides troubleshooting assistance. System and error messages scroll on the bottom line of the display at three second intervals until the condition is corrected or has ended. These system and error messages are listed in this chapter alphabetically to make them easier to locate.  NOTE System or error messages will not appear on the display when you are navigating the menus. However a system alarm ICON (SHOW ICON) will appear in the top left hand corner of the screen (show display and icon). Troubleshooting | 7-1 General Troubleshooting Your system may pass calibrations, yet still seem to be reading incorrect oxygen levels. If this is the case, you may want to check the following: Leak Check Leaks can lead to inaccurate readings, especially if operating under a significant pressure or vacuum. • Check that all compression fitting and pipe thread connections are leak tight. • Be sure that the mounting plate or mounting flange gasket on the rear of the sensor is in place (see the “Sensor Mounting” section 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 oxygen), being sure to avoid the area over the top of the cell. 1. Use a piece of tygon 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 sensor components). 2. Monitor the response from the cell. When the cell millivolt reading changes, it indicates a leak in that area of the plumbing (the vacuum of the process pulls in the gas). 3. If not convenient to view the AMEVision display, you can also apply a voltmeter to the Cell terminals on the sensor board labeled (+O2-) to see if the cell millivolts change, indicating a leak. Pressurizing for Leaks 1. Remove the sensor from the process (after allowing sensor to cool) and pressurize it with 5 lbs. of air, plugging any exiting ports, the inlet probe, and exhaust tube holes. Then go over the sensor fittings with a leak detector fluid. 2. If you see bubbles, it indicates a leak. If using this method be sure to prevent the liquid from reaching the furnace. If the furnace does get wet, allow it sufficient time to thoroughly dry. 7-2 | Thermox WDG-V / VC / VCM Plugged Plumbing Check Exercise care when working on the sensor. Allow the unit to cool and wear 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 plumbing using hot water and a bottle brush. 3. When assembly is complete, check for leaks using a leak detecting liquid. Aspirator Air Not Pulling Sample from Process The aspirator will need cleaned with the Aspirator Clean Out Tool (P/N 7000-404-KE) per instructions. Troubleshooting | 7-3 Diagnostics Checks This section shows you how to check different sensor areas for possible problems. See the “Error Messages” section for help on what checks you should perform based on the error message displayed. If you don’t see an error message, yet feel your readings are inaccurate, you may also want to check the “General Troubleshooting” section that follows. We recommend 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 for assistance. Be sure to always include your analyzer model and serial number when calling the factory for technical support. Diagnostic checks are broken down as follows:  Wiring Checks  Thermocouple Checks  Calibration/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. 7-4 | Thermox WDG-V / VC / VCM Thermocouple Checks Open Thermocouple Shorted/Failed Thermocouple Reversed Thermocouple Wires Remove power to the sensor. Measure across terminals “+TC-” on the sensor board with an ohm meter. If an open is measured, replace the thermocouple. Check that the thermocouple leads are not shorted to chassis ground by using an Ohm meter to measure between terminal TC+ on the sensor board and chassis ground, 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 heat its ceramic tip to a known temperature. Measure the millivolt output with a proper temperature indicating meter (type K thermocouple). If the thermocouple reads inaccurately, replace it. First, view the cell temperature via the Home screen or Diagnostic screen. If the thermocouple leads are reversed, the displayed temperature will be decreasing as the sensor warms up (this will usually happen at start-up or after you replace a thermocouple). This indicates that the thermocouple wiring is reversed. If you just replaced a thermocouple, check the leads from the thermocouple to the sensor board: yellow wire connects to terminal TC (+), red wire connects to terminal TC (-). Troubleshooting | 7-5 Calibration/Aspirator Setup Checks Calibration Gas Check To check calibration gas values:  Check that the correct calibration gas values have been entered into the analyzer. Select the Cal Gas Value menu option from the Calibrate key on the control unit and check that the calibration gas values entered match the analyzed concentration of the cylinders.  Check that the calibration gas cylinders are turned on and are not empty. Calibration Line Check Ensure that your calibration line is not contaminated with such things as pipe dope, cutting fluid, oil, or solvents. All these contaminants produce hydrocarbon vapors that interfere with the proper calibration of your analyzer, resulting in lower than expected oxygen readings. To test for contaminated lines, you must temporarily bypass your current calibration line with a clean calibration line (directly from cylinder 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. The best calibration gas to use for this check is an O2 zero calibration gas. Remote Calibration Unit (RCU) Problem  Check for the proper flow rate and proper delivery pressure of calibration gases when the remote calibration unit has been activated (see the Inject Cal Gas Diagnostic option in the AMEVision Display User Interface manual for help). The RCU contains one normally open solenoid-the aspirator air solenoid. All other solenoids are normally closed. Problems with the RCU are usually as follows: Plumbing Leak To check for plumbing leaks, disconnect power from the RCU and pressurize the inlets. Apply a leak detecting liquid along the base of the solenoids and any plumbing fittings. Repair any leaks found. Solenoid Not Energizing The solenoid drive signal is a 12 VDC signal. This is used to close the aspirator solenoid and open the appropriate calibration gas solenoid. To test a solenoid valve, select Inject Cal Gas from the Calibrate key menu to energize that solenoid. Verify that the solenoid drive signal is present. The aspirator air solenoid is closed when the drive signal is applied. Other solenoids are open when the drive signal is applied (cal gas flowing). With the drive signal present, verify the proper flow. If no signal is present, check the interconnecting wiring between the control unit and the RCU. If wiring is correct, replace the electronics. If the solenoid drive signal is present, it indicates a problem with one of the solenoid valves. Replace the solenoid valve, being sure that the solenoid O-ring seals are properly positioned. 7-6 | Thermox WDG-V / VC / VCM To check if a calibration gas solenoid is stuck open: Verify that no drive signal is present and check for flow on the RCU flow meter. If flow is indicated when no solenoids are energized, a solenoid is stuck open. Shut off your calibration gases (one at a time) until the flow drops to zero. This identifies the defective solenoid valve (replace the solenoid valve, being sure that the solenoid O-ring seals are properly positioned). Calibration Gas If you are having problems running an auto calibration, you Time Inadequate may not have allowed the calibration gases enough time to flow through the sensor and stabilize. To correct this problem, select Inject Cal Gas from the Diagnostic menu. Turn on each calibration gas and determine how long it takes for each gas to stabilize on the control unit display. Then add a one minute buffer to each of these times. Also make sure the cylinder regulators are set to the correct pressure. See the Flow Section of the System Interconnect 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.  NOTE If performing a manual calibration, ensure that you are waiting for the reading to stabilize on the display before switching to the next calibration gas. AC Power Checks Loss/Inadequate AC Voltage Measure the AC voltage to the sensor board at terminals L and to the Sensor N. Ensure that this voltage is sufficient. Check the measurement technique used by the Volt meter (for example, RMS, average, peak, etc.). Specifications are based on RMS measurements. Furnace Checks Open Furnace Disconnect power to the control unit and the sensor. With Ohm meter, measure across Terminals “FURN” on the sensor board. The resistance of the furnace should be: 32 ohms (±10%) If the furnace resistance is not within allowable tolerances, replace the furnace. Loss of AC Power to the Furnace Verify the correct line voltage at L and N of the sensor board. With line voltage present, check the voltage at terminals FURN on the sensor board. If voltage is present and the system is not heating, remove power and check the furnace resistance (see “Furnace Checks” section). If no voltage is present at terminals FURN on the sensor board, replace the electronics. Troubleshooting | 7-7 Process Pressure Checks (Only if above 2 psig) To check that you entered the process pressure correctly, select Process Pressure from the configuration menu. Also ensure that the calibration process pressure equals normal operating process pressure. Calibration should only be performed under these conditions for highest accuracy. Cell Checks If the cell fails when you first begin to use the analyzer: It is likely that there is a leak in the sensor plumbing or an improper 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 Checks” section earlier in this chapter for help on checking your calibration gas setup). If the analyzer has been operating for some time and you feel the oxygen reading is inaccurate: First check by running a known calibration gas to verify the analyzer’s response. If the analyzer responds to the calibration gas correctly, it indicates either leaking or plugged plumbing. If your analyzer doesn’t respond properly to the calibration gas: This may indicate a problem with the cell. Before replacing the cell, check for leaks or plugged plumbing. 7-8 | Thermox WDG-V / VC / VCM Alarm and Warning Messages ALARMS ALARM DESCRIPTION Possible Causes Cell T/C Failure Thermocouple is not connected or is open Bad T/C, Bad connection Cold Junction Compensator Failure The PCB temperature sensor has failed Bad Electronics Cell Temperature Control A critical overtemperature condition has occurred Shorted, open, or Bad T/C or Failed Temperature Control Circuit. Unit must be reset to clear this alarm Cell Over Temp Cell temperature is 4 degrees or higher above the setpoint Bad Thermocouple, Failed temperature control circuit Cell Under Temp Cell temperature is 4 degrees or lower below the setpoint Faulty heater, faulty heater connection, Faulty T/C, Faulty 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 connection. Unit must be reset to clear this alarm Over Temp Relay Tripped The cell over-temperature relay has tripped Open Thermocouple, Over Temperature condition, Failed Temperature control circuit. Must cycle power to reset the relay RTD Failure The Box Temp RTD Failed Open or Shorted RTD Box Temp High Box temperature is 4 degrees or higher above the setpoint Failed temperature control circuit Box Temp Low Box temperature is 4 degrees or lower below the setpoint Faulty heater, faulty heater connection, Faulty RTD, Faulty RTD connection, Low Power. Only after warm-up time expires Box Temp Rise Failure Box temperature failed to heat Bad box heater(s), Bad heater connection, Bad RTD, Bad RTD connection Troubleshooting | 7-9 Low Sample Flow Low sample flow detected Loss of aspirator air plugged inlet probe, plugged sample system. Active only after warm-up time expires Cell Failure (Open) Cell resistance exceeds the normal limit Bad Cell, Open Cell Connection Combustible Detector Open Comb detector is open or not connected Bad Detector, Bad electronics. Only when configured as WDG-VC Methane Detector Open CH4 detector is open or not connected Bad Detector, Bad electronics. Only when configured as WDG-VCM Cell Mv Mismatch The cell mv measurement does not match the real time cell meas Bad A/D circuit (Bad electronics) Analog Output 1 Error The analog output measurement does not match the setting Open 4-20mA loop or failed output or bad readback circuit Flow Sensor Failure The flow sensor failed (open) Bad flow sensor or circuit Cell T/C Measurement Mismatch The Redundant temperature measurement does not match the real time meas Bad T/C or circuit 7-10 | Thermox WDG-V / VC / VCM WARNINGS Cell Life Nearing Its End The ZrO2 cell is nearing its end of life. This is based on calibration history. Comb Detector Life Nearing Its End The combustible detector sensitivity is near Low detector output its end of life. This is based on calibration history. Methane Detector Life Nearing The methane detector sensitivity is near Its End its end of life. This is based on calibration history. High Cell Mv Low cell output Low Detector output The combustible measurement is no longer Hydrocarbon upset valid (set to full scale) due to lack of O2 Analog Output 1 Out Of Range The analog output value is saturated (high or low) Improperly set range Analog 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 O2 Span Calibration Failed The last oxygen span calibration failed Tank Empty, bad solenoid, didn’t wait long enough, Bad Cell Last O2 Zero Calibration Failed The last oxygen zero calibration failed Tank Empty, bad solenoid, didn’t wait long enough, Bad Cell Last Comb Calibration Failed The last combustible calibration failed Tank Empty, bad solenoid, didn’t wait long enough, bad detector Last CH4 Calibration Failed The last methane calibration failed Tank Empty, bad solenoid, didn’t wait long enough, bad detector Last Flow Calibration Failed The last flow sensor calibration failed Plugged sample system or bad sensor Oxygen Calibration Required O2 Calibration is required Last Calibration failed or unit has never been calibrated Comb Calibration Required Combustible Calibration is required Last Calibration failed or unit has never been calibrated Methane Calibration Required CH4 Calibration is required Last Calibration failed or unit has never been calibrated Troubleshooting | 7-11 This page intentionally left blank. 7-12 | Thermox WDG-V / VC / VCM 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 sensor, 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 • Combustibles/Methane Detector Replacement (optional) • Flow Sensor Replacement • Box Heater Wiring • RCU (Remote Calibration Unit) Solenoid Valve Replacement • Electronics Board • Recommended Maintenance Schedule • Replacement Parts List You can clean the outside of the sensor 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. A wiring diagram for a standard sensor is provided in Figure 8-1. This figure shows the locations of all wiring connections on the sensor. If your sensor requires different wiring, this is provided in an appendix. Service and Parts | 8-1 Warnings • If you turn off the analyzer or the process is shut down, turn off the aspirator air to avoid plugging problems. • 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 a considerable period from shutdown. Turn off the power to the sensor and control unit when working inside the sensor. Use caution and wear appropriate gloves when handling components. • Be extremely careful when performing maintenance on the sensor while the process is running, especially if the process is under significant positive pressure. Removing any part of the sensor plumbing can allow process gases and gases of high temperature to escape into the sensor. • Always use a backup wrench when working on sensor plumbing. This helps to prevent damaging welds and distorting sensor plumbing. • Never use pipe dope or any other contaminant that gives off combustible vapor on any joints of the sample tubing. Combustible vapor in the sample tubing can lead to erroneous readings. Cautions 8-2 | Thermox WDG-V / VC / VCM METHANE DETECTOR REFERENCE ELEMENT RTD METHANE DETECTOR ACTIVE ELEMENT CELL CELL + THERMOCOUPLE + THERMOCOUPLE SIL THERMOCOUPLE + SIL THERMOCOUPLE COMBUSTIBLES DETECTOR ACTIVE ELEMENT COMBUSTIBLES DETECTOR REFERENCE ELEMENT 350W HEATER AC LINE NEUTRAL CUSTOMER CONNECTIONS 50W HEATER AC (HALF WAVE RECTIFIED) CELL FURNACE AC FLOW SENSOR SENSE ELEMENT FLOW SENSOR HEATER ELEMENT Figure 8-1a. Wiring diagram for standard sensor. Service and Parts | 8-3 SPARE PROCESS ALARM (ALARM 5) PROCESS ALARM (ALARM 4) ASPIRATOR SOLENOID ZERO GAS VALVE SPAN 1 CONTROL SPAN 2 ANALOG OUTPUT ANALOG INPUT SENSOR MODBUS MODBUS (DAISY CHAIN) LINE NEUTRAL GND SCREW CONTACT INPUT FUTURE ANALOG OUTPUT ANALOG OUTPUT 24 TO 36VDC ANALOG OUTPUT EXTERNAL VOLTAGE SUPPLY AC PWR SUPPLY 8-4 | Thermox WDG-V / VC / VCM SERVICE ALARM (ALARM 1) DATA VALID ALARM (ALARM 2) PROCESS ALARM (ALARM 3) SPARE 12VDC FOR RCU SOLENOID DRIVE Figure 8-1b. Customer wiring diagram for standard sensor. Cell Replacement/Cleaning Disconnect power from the sensor and control unit and allow the sensor to cool before replacing parts inside the sensor. Use Figure 8-2: 1. Open the sensor cover to expose sensor components. 2. Remove the cell clips. 3. While holding the top of the cell housing with a backup wrench, loosen the lower hex nut (not the top hex nut), then remove the entire cell assembly. (See the * in Figure 8-2).  Loosening the cell may require a good deal of torque. NOTE 4. 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, discard the old cell and cell O-ring and retrieve the new cell with supplied cell O-ring. Avoid touching the bare cell. Instead, hold the cell by one of its hex nuts. 5. Place the cell O-ring on the base of the cell as shown in Figure 8-2. 6. Insert the new cell into the cell housing. Do not touch the bare cell when reinserting. Tighten the cell into the cell housing using the lower hex nut (the upper hex nut is pre-tightened at the factory). The cell O-ring provides a seal for the system. Make sure it is aligned into its proper recess and evenly crushed when tightening the cell. Service and Parts | 8-5 FURNACE CELL HOUSING O-RING CELL HEX NUT WASHER * HOLD CELL HOUSING USING 7/8" OR 1" WRENCH (23mm or 26mm) TURN HEX NUT COUNTER CLOCKWISE USING A 7/8" WRENCH (23mm) CELL CLIPS Figure 8-2. Cell replacement. CELL REPLACEMENT 8-6 | Thermox WDG-V / VC / VCM Thermocouple Replacement  The tip of the thermocouple is positioned in the furnace so that it is near, but not touching, the cell housing or the furnace heater coil. NOTE Use Figure 8-3: 1. Open the sensor door to expose sensor components. 2. Disconnect thermocouple wires from terminals +TC- on the sensor board. 3. Remove the 2 speed clips from the thermocouple mounting tabs. Use needlenose pliers to remove the clips. 4. Pull the thermocouple straight down and remove it from the furnace. 5. Insert the new thermocouple aligning the tab with the two posts on the bottom plate. Be careful not to damage the ceramic tip while inserting the assembly. 6. Attach one new speed nut to each post. 7. Attach the thermocouple wires to the +TC- terminals on the sensor card (yellow wire is positive (+)). 8. Perform an oxygen calibration. Service and Parts | 8-7 Figure 8-3. Thermocouple replacement 8-8 | Thermox WDG-V / VC / VCM Combustibles/Methane Detector Replacement  The Combustible detector will always face outward, and the Methane detector will always face inward from the factory. NOTE Combustibles Detector Replacement Use Figure 8-4: 1. Disconnect the combustible detector (Black and Brown) wires on the sensor board. 2. Loosen the two 4.0 mm hex screws that holds the combustible detector in place and remove the detector from its housing. Save the screws from the detector to use when installing the new combustibles detector. 3. Always use a new O-ring when detector is removed. 4. Install the new combustible detector in place, aligning the two screws on the block. Be careful not to damage the detector element ends while inserting the assembly. Tighten screws until face is flush with the block and gasket is fully compressed. 5. Reconnect the detector leads to the sensor board. Methane Detector Replacement 1. You must remove the block in order to access and replace the Methane detector. 2. Disconnect the methane detector (Blue and White) wires on the sensor board. 3. Loosen the two 4.0 mm hex screws that holds the methane detector in place and remove the detector from its housing. Save the screws from the detector to use when installing the new combustibles detector. 4. Always use a new O-ring when detector is removed. 5. Install the new methane detector in place, aligning the two screws on the block. Be careful not to damage the detector element ends while inserting the assembly. Tighten screws until face is flush with the block and gasket is fully compressed. 6. Reinstall the block. 7. Reconnect the detector leads to the sensor board. Service and Parts | 8-9 Figure 8-4. Combustibles detector replacement 8-10 | Thermox WDG-V / VC / VCM Flow Sensor Replacement Flow Sensor Replacement Use Figure 8-5: 1. Disconnect the flow sensor Red wires (Heater) and the Yellow wires (Sense) on the sensor board. 2. Loosen the nut that connects the heater block and the flow sensor. 3. Loosen the nut that connects the furnace and the flow sensor. Brace the furnace assembly by using a second wrench attached to the sensor nut under the furnace. See Figure 8-5 for reference. 4. Remove the flow sensor.  Handle the new flow sensor with care. It is very delicate when not installed in the system. NOTE 5. Install the new flow sensor in place. Tighten the two connecting nuts. 6. Reconnect the Red wires (Heater) and the Yellow wires (Sense) on the sensor board. Service and Parts | 8-11 Figure 8-5. Flow sensor replacement 8-12 | Thermox WDG-V / VC / VCM Furnace Replacement Furnace Replacement Use Figure 8-6: 1. Disconnect cell furnace wires. 2. Remove the Thermocouple assembly from the furnace. 3. Remove the Cell. 4. Loosen the swage nut at the top and bottom of the furnace. You may need to remove the flow sensor to get the furnace assembly out. 5. Remove the Furnace assembly. 6. Install the new Furnace assembly in place. 7. Reconnect the Thermocouple, Flow Sensor and Cell. 8. Reconnect the wires on the sensor board. Figure 8-6. Furnace Assembly Service and Parts | 8-13 Heater Replacement  There is only one heater in the O2 version. There are two heaters in the Combustible/Methane version of the WDG-V. NOTE Box Heater Replacement Use Figure 8-7: 1. Disconnect heater wires. 2. Remove the speed clip from the mounting tab. Use needle-nose pliers to remove the clip. 3. Remove the box heater by sliding it out. 4. Replace the box heater 5. Attach a new speed nut to the post. 6. Reconnect the wires on the sensor board. 8-14 | Thermox WDG-V / VC / VCM Figure 8-7. Box Heater Replacement Service and Parts | 8-15 Combustible Block Heater Replacement (Only on Combustible/Methane Units)) Use Figure 8-8: 1. Disconnect heater wires. 2. Loosen the 4.0 mm hex screw. 3. Remove the combustible block heater by sliding it out. 4. Replace the box heater 5. Tighten the hex screw into place. 6. Reconnect the wires on the sensor board. 8-16 | Thermox WDG-V / VC / VCM Figure 8-8. Combustible Block Heater Replacement Service and Parts | 8-17 Electronics Replacement Electronics Replacement Use Figure 8-9: 1. Disconnect all wires. 2. Loosen the two Phillips screw located on the back of the electronics plate. 3. Slide the board out until the pegs at the top line up with the holes in the electronics board plate and drop it down. 2. Replace the electronics board. 2. Properly tighten the screws. 8-18 | Thermox WDG-V / VC / VCM Figure 8-9. Electronics Board Removal Service and Parts | 8-19 Recommended Maintenance Schedule Calibration Check calibration and/or recalibrate the analyzer every 90 days. 8-20 | Thermox WDG-V / VC / VCM Replacement Parts List Sensor Assy, Furnace, WDG-V, 120 VAC Assy, Furnace, WDG-V, 240 VAC Kit, WDG-V Replacement Thermocouple For O2 Cell Furnace Combustibles Detector Kit - RTD Detector Combustibles Detector Kit - Hot Wire Detector Methane Detector Kit WDG-V Sensor Main Processor Board For RTD Comb. Detector WDG-V Sensor Main Processor Board For Hot Wire Comb. Detector Assy, WDG-V Boards and Plate For RTD Comb. Detector Assy, WDG-V Boards and Plate For Hot Wire Comb. Detector Kit, Combustibles Block w/Nut and Ferrules Kit, Combustibles/Methane Block w/Nut and Ferrules Kit, Flow Sensor, WDG-V Cell O-Ring Metal Kalrez O-Ring, Combustibles/Methane Detector Housing Standard Zirconia Cell Severe Service Zirconia Cell - Consult Factory For Application Kit, WDG-V Aspirator w/ Nut And Ferrules Flashback Assy, 1” Element Kit, Convection Loop w/ Nut and Ferrules, O2 Only (long tube for use without flame arresters) Kit, Flame Arrester Convection Loop w/ Nut and Ferrules (short tube for use with flame arresters) Cell Clip Assembly - Inside Cell Clip Assembly - Outside Assy, WDG-V, Box Heater, 120VAC Assy, WDG-V, Box Heater, 240VAC Heater Plate WDG-V Kit, Cartridge Heater 350W, 120V, Includes Heater and Push Nut Kit, Cartridge Heater 50W, 120V, Includes Heater and Screw Kit, Cartridge Heater 350W, 240V, Includes Heater and Push Nut Kit, Cartridge Heater 50W, 240V, Includes Heater and Screw Kit, WDG-V Replacement 115 VAC Heater Coil and Push Nut Kit, WDG-V Replacement 240 VAC Heater Coil and Push Nut RTD - Box Temp Control - 100 Ohm (O2 Only) RTD - Box Temp Control - 100 Ohm (Comb/Methane) Threaded Exhaust Tube Sample Probe 7000-719-SE 7000-720-SE 7000-839-TE 7000-815-TE * 7000-816-TE ** 7000-814-TE 8000-119-SE 8000-148-SE 7000-845-SE *** 7001-214-SE *** 7001-226-TE**** 7001-227-TE**** 7000-817-TE 42005JE 3000-337-JE 7000-568-SE 7000-733-SE 7001-216-TE 71212SE 7001-224-TE 7001-225-TE 72329SE 72328SE 7000-843-SE ***** 7000-844-SE ***** 7000-405-KE 7000-846-TE 7000-848-TE 7000-847-TE 7000-849-TE 7000-840-TE 7000-841-TE 25384JE 1000-630-JE 70619KE by serial number Service and Parts | 8-21 Remote Calibration Unit (RCU) Air Regulator Regulator Gauge Aspirator Air Solenoid Valve (normally open) Calibration Gas Solenoid Valve (normally closed) Flow Meter 39004JE 37070JE 36090JE 36088JE 37020JE * The RTD detector is the standard detector for most appications. Requires sensor main processor board 8000-119-SE ** The Hotwire detector is the severe service detector. Consult factory for applications. Requires sensor main processor board 8000-148-SE *** Sensor assembly includes I/O connection board, main processor board, and mounting plate **** The block heater, RTD, and detector are not included ***** Includes heat plate, heater, push nut, and dowel pin 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) 828-9040 Fax: (412) 826-0399 8-22 | Thermox WDG-V / VC / VCM DRAWINGS AND CUSTOM INSTRUCTIONS This appendix provides any custom drawings or instructions you may have ordered in addition to the standard WDG-V analyzer. If you didn’t order any custom options, the standard Interconnect Drawing is provided. If you did order any special options, the drawings or special instructions provided here supercede any drawing or options provided elsewhere in this manual. Drawings and Custom Instructions | 9-1 This page intentionally left blank. 9-2 | Thermox WDG-V / VC / VCM CUSTOMER MODBUS MAP Sensor Host Register Name Data Type Description 1 0 System Alarm Int 32 System alarms reported by the AMEVision Display User Interface Software 1 2 Oxygen Float Oxygen concentration in percentage Writable 1 4 Combustibles Float Combusitble concentration in ppm Writable 1 6 Methane Float Methane concetration in percentage Read Only 1 8 Cell Temperature Float Cell temperature in degree C Read Only 1 10 Box Temperature Float Box temperature in degree C Read Only 1 12 Cell mV Float Oxygen cell in millivolts 1 14 CJ Temperature Float Electronics Temperature (cold junction compensator temp) in degree C 1 16 Process Alarm Mask Unsigned Int 32 Process alarm bit mask Writable 1 18 Command Unsigned Int 16 Command to the analyzer Writable 1 19 Command Response Unsigned Int 16 Response to a command 1 20 Oxygen Span Gas Float Oxygen span gas value 1 22 Zero Gas Float Zero gas value Read Only 1 24 Combustible Span Gas Float Combustible span gas value Read Only 1 26 Methane Span Gas Float Methane span gas value Read Only 1 28 Data Valid Unsigned Int 16 Datavalid (1 if valid, 0 if not) Read Only 1 29 State Unsigned Int 16 Current state of the analyzer Read Only 1 30 Event Mask 1 Unsigned Int 32 Event Mask 1 Writable 1 32 Event Mask 2 Unsigned Int 32 Event Mask 2 Read Only 1 34 Pressure Float Process Pressure Read Only Writable Read Only Writable Writable Customer Modbus Map | 10-1 This page intentionally left blank. 10-2 | Thermox WDG-V / VC / VCM FRENCH WARNINGS / FRANÇAIS AVERTISSEMENTS NOTES SUR LA SECURITE LES AVERTISSEMENTS, LES PRÉCAUTIONS ET LES NOTES CONTENUS DANS CE MANUEL ATTIRENT L’ATTENTION SUR DES INSTRUCTIONS CRITIQUES COMME SUIT : Une procédure de fonctionnement qui n’est pas strictement suivie peut engendrer une blessure de personne ou une contamination de l’environnement. Une procédure de fonctionnement qui n’est pas strictement suivie peut endommager l’équipement.  Informations importantes à ne pas laisser passer : NOTE Risque de brûlure. Surface brûlante. Ne pas toucher, laisser refroidir avant tout travail. French Warnings / Français Avertissements | A-1 Sécurité électrique Une tension jusqu’à 5 kV peut être présente dans le boîtier. Coupez toujours les alimentations électriques avant d’effectuer une maintenance ou un dépannage. Seuls des techniciens qualifiés électriquement doivent effectuer les connexions électriques et les vérifications de terres. Une utilisation quelconque de l’équipement de manière non spécifiée par le constructeur peut compromettre la protection de la sécurité d’origine fournie par l’équipement. Mise à la terre La mise à la terre de l’instrument est obligatoire. Les spécifications de performance et la protection de sécurité sont invalides si le fonctionnement de l’instrument est effectué depuis une alimentation électrique à la terre impropre. Vérifiez la continuité de la terre de tout équipement avant d’alimenter électriquement. A-2 | Thermox WDG-V / VC / VCM Note importante aux utilisateurs Il n’y a pas de composant à maintenir à l’intérieur même des composants de l’analyseur WDG-V. Ne pas retirer le capot d’un analyseur WDG-V. Se référer à du personnel qualifié pour la maintenance. Ce qui suit s’applique aux modèles WDG-V Division 2 : L’alimentation électrique, les entrées et sorties (E/S) doivent être en accord avec les méthodes de câblage en zone Class I Division 2 (se référer au code électrique national) et en accord avec l’autorité locale ayant juridiction. AVERTISSEMENT – RISQUE D’EXPLOSION – LA SUBSTITUTUON DE COMPOSANTS PEUT COMPROMETTRE LA CONFORMITE DE ZONE CLASS I DIVISION 2. AVERTISSEMENT – RISQUE D’EXPLOSION – EN ZONE EXPLOSIBLE, COUPEZ L’ALIMENTATION ELECTRIQUE AVANT DE REMPLACER OU CABLER UN MODULE. AVERTISSEMENT – RISQUE D’EXPLOSION – NE DECONNECTEZ PAS L’EQUIPEMENT SAUF SI L’ALIMENTATION ELECTRIQUE A ETE COUPEE OU SI LA ZONE EST SANS RISQUE. CET EQUIPEMENT EST CONFORME A UNE UTILISATION EN ZONE CLASS I, DIVISION 2, GROUPES A, B, C ET D OU HORS ZONE EXPLOSIBLE SEULEMENT. La température ambiante maximum ce cet analyseur est de 60°C (140°F). L’unité de terrain WDG-V et son afficheur sont des pieces complexes qui doivent être maintenues uniquement par des techniciens qualifies ayant une expertise en technologie de l’instrument et en systèmes électriques. AMETEK recommande que tout analyseur nécessitant un dépannage soit renvoyé à l’usine. Vous devriez seulement essayer de travailler sur cet équipement après avoir reçu une formation d’un représentant AMETEK / Division P&AI. Si vous décidez de travailler sur cet analyseur, ayez conscience que des hautes tensions, des hautes températures et d’autres conditions potentiellement à risque peuvent surgir. French Warnings / Français Avertissements | A-3 Sommaire de Sécurité Générale Lisez attentivement les précautions de sécurité suivantes pour éviter de se blesser et d’endommager l’équipement ou tout produit connecté à ce dernier. Utilisez un câblage adéquat Pour éviter les risques de feu, utilisez seulement le câblage spécifié dans le chapitre Installation de ce manuel de l’utilisateur. Evitez les surcharges électriques Pour éviter une électrocution ou un risque de feu, n’alimentez pas électriquement des bornes qui sont hors de la gamme spécifiée pour ces bornes. Mettez à la terre l’analyseur Suivez les instructions de mise à la terre fournies dans le chapitre Installation de ce manuel de l’utilisateur. Avant de connecter aux bornes d’entrée ou de sortie de l’analyseur, assurez-vous que l’analyseur est correctement mis à la terre. Ne pas faire fonctionner sans capot Pour éviter une électrocution ou un risque de feu, ne faites pas fonctionner l’analyseur sans capot ou avec un panneau retiré. Utilisez des fusibles adéquats Pour éviter tout risque de feu, utilisez des fusibles de types et classes spécifiés pour cet analyseur. Ne faites pas fonctionner en atmosphère explosible Pour éviter toute blessure ou risque de feu, ne faites pas fonctionner l’analyseur dans une atmosphère explosible, sauf si vous avez acheté les options spécifiquement conçues pour ces environnements. A-4 | Thermox WDG-V / VC / VCM Precautions aux Dommages de L’Analyseur Utilisez une alimentation électrique adéquate Ne faites pas fonctionner l’analyseur avec une alimentation électrique qui fournit plus que la tension électrique spécifiée. Ne faites pas fonctionner avec les défaillances suspectes Si vous suspectez que l’analyseur est endommagé, demandez à un technicien qualifié de l’inspecter. Prenez des précautions en levant l’instrument L’analyseur pèse environ 25 kg. Prenez des précautions lorsque vous le levez de sa caisse. Utilisez des vêtements adaptés L’analyseur est brûlant, l’utilisateur doit porter des gants de protection lorsqu’il manipule l’analyseur. French Warnings / Français Avertissements | A-5  NOTE Les opérations dans ce chapitre doivent être effectuées seulement par un technicien qualifié et expérimenté en techniques de sécurité. Il n’y a pas de composant à maintenir à l’intérieur même des composants de l’analyseur WDG-V. Ne jamais travailler sur l’analyseur sans que l’alimentation électrique ait été coupée et que l’analyseur ait pu refroidir pendant au moins une heure. Utilisez aussi des gants si vous travaillez sur l’analyseur. Ne pas installer le chauffage de la sonde si le gaz échantillon contient potentiellement un mélange explosive de combustibles ; le chauffage de la sonde peut chauffer le gaz jusqu’à son point d’inflammation. Ne pas ouvrir une porte à charnière de l’unité de terrain purgée Z avant d’avoir vérifié que la zone n’est pas classée à risque. Des pièces internes chaudes sont au-dessus de la température à laquelle s’enflamment les gaz combustibles. L’alimentation électrique doit être coupée sur les unités de terrain et de contrôle pendant 90 minutes en maintenant le debit d’air de purge avant d’ouvrir la porte, sauf s’il est prouvé que la zone est sure. L’alimentation électrique ne doit pas être remise après ouverture de l’enceinte jusqu’à ce qu’elle ait été purgée pendant 65 minutes à une pression de 10 mm H2O. N’ouvrez pas l’unité de calibration déportée purgée Z jusqu’à ce que vous verifiez que la zone soit classée sans risque. Maintenez aussi la purge Z à la pression et au debit indiqués sur la plaque d’avertissement de l’unité. A-6 | Thermox WDG-V / VC / VCM Coupez l’alimentation électrique du secteur avant d’effectuer un câblage. Ne placez pas les fils d’alimentation électrique de l’unité de contrôle dans les mêmes câbles que d’autres fils d’alimentation électrique. En séparant ces fils, vous empéchez des signaux transitoires d’atteindre l’unité de contrôle. Dans un but de compatibilité électromagnétique, en aucune circonstance vous ne devez laisser l’écran d’un câble déconnecté en une ou deux extrémités (unité de contrôle ou de terrain ou autre appareil). Les operations dans ce chapitre doivent être effectuées seulement par un technicien qualifié et expérimenté en techniques de sécurité électrique. Soyez prudent lorsque vous travaillez sur l’analyseur. Laissez l’analyseur refroidir et portez des gants. Coupez l’alimentation électrique des unités de terrain et de contrôle et laissez l’analyseur refroidir avant de remplacer des pieces dans l’analyseur. French Warnings / Français Avertissements | A-7 This page intentionally left blank. A-8 | Thermox WDG-V / VC / VCM