Ametek Thermox Series 2000 WDG-IV User Manual
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Ametek Thermox Series 2000 WDG-IV User Manual

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

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Summary of Contents for Ametek Thermox Series 2000 WDG-IV

  • Page 1 ® Thermox Series 2000 WDG-IV, WDG-IVC, WDG-IVCM User Manual Thermox 150 Freeport Road Pittsburgh, PA 15238 PN 90269VE , Rev. Y...

  • Page 2: Offices

    © 2000 AMETEK This manual is a guide for the use of the Thermox Series 2000 WDG-IV (IVC / IVCM). 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;...

  • Page 3: Table Of Contents

    Contents Offices ........................ii Safety Notes ......................vi Environmental Information (WEEE) .............. viii General Safety Summary ..................ix CHAPTER 1 Overview Sensor Operations ....................1-1 Sensor ........................1-2 Basic Elements of the Sensor ..............1-2 The Oxygen Measuring Cell ..............1-2 Sensor Operations - WDG-IVCM ..............1-5 Close-Coupled Extrative Flue Gas Analyzer ..........
  • Page 4 Overview of Alarm Functions ..............4-21 Alarm Set Points ..................4-22 Alarm Configure ..................4-24 Relay Configure ..................4-24 Select Function ................... 4-25 Service Alarm ..................... 4-26 Watchdog Relay ..................4-26 Exception Log ..................... 4-27 iv | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 5 Chapter 5 Calibration Definitions ......................5-2 Calibrations vs. Verifications ..............5-2 Span and Zero Calibration Gas Definitions ..........5-2 Types of Calibrations ..................5-3 Overview ......................5-4 Aborting a Calibration ..................5-4 Initiate Cal and Initiate Verify ................5-5 Auto Calibrate/Auto Verify ................. 5-5 Remote Calibrate/Remote Verify ...............
  • Page 6 Thermocouple Failure ................6-4 Zero Gas Range Error ................. 6-4 Diagnostics Checks .................... 6-5 Wiring Checks ....................6-6 Interconnecting Wiring Problem .............. 6-6 Thermocouple Checks ................6-6 Shorted/Failed Thermocouple ..............6-6 Reversed Thermocouple Wires ..............6-6 Thermocouple Compensation ..............6-6 Circuit Check ....................
  • Page 7 Appendix B Menu Option Charts Appendix C Current Outputs: Other Applications Powering Current Outputs from an External Power Supply ....C-1 Modulation of External Power Loop Using Current Outputs ....C-3 Appendix D Drawings and Custom Instructions Appendix E Series 2000 Controller Setup Parameters | vii...

  • Page 8: Safety Notes

    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. viii | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 9 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.

  • Page 10: Environmental Information (Weee)

    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 prod- uct when it reached its “end of life”.

  • Page 11: General Safety Summary

    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.

  • Page 12: Declaration Of Conformity

    UL Listed Process Control Equipment for Use in Hazardous Locations Manufacturer’s Address in Europe: AMETEK Precision Instruments Europe GmbH Rudolf-Diesel-Strasse 16 D-40670 Meerbusch, Germany Mark Coppler Compliance Engineer April 2002 xii | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 13 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...
  • Page 14 This page intentionally left blank. xiv | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 15: Chapter 1 Overview

    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, combus- tibles and methane. A sample is drawn from the process stream by means of an air-operated aspirator and is immediately returned to the process.

  • Page 16: Sensor

    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% O ), is used for one of the gases. 1-2 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 17 Figure 1-1. Zirconium oxide cell principle of operation. Since the voltage of the cell is temperature dependent, the cell is main- tained at a constant temperature. Some newer high temperature insitu models use the heat from the process to heat the sensor, and the process temperature is continuously measured and used in the software calcula- tion.
  • Page 18 Thus, the oxygen analyzer will read 17.5 PPM rather than the actual 20 PPM oxygen. The amount of oxygen reduction is dependent on the type of hydrocar-  bons present in the sample gas. NOTE 1-4 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 19: Sensor Operations - Wdg-Ivcm

    Sensor Operations - WDG-IVCM Close-Coupled Extrative Flue Gas Analyzer The WDG-IVCM 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.

  • Page 20: Rtd Type

    OXYGEN CELL CONVECTION LOOP RETURN HOT-WIRE TYPE METHANE DETECTOR RTD-TYPE COMBUSTIBLES DETECTOR ASPIRATOR BLOCK RETURN SAMPLE TO PROCESS ASPIRATOR AIR Figure 1-3. WDG-IVCM with RTD-wire type combustibles detector convection loop. 1-6 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 21: Detectors

    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 tem- perature change causes the resistance of the catalyzed element to change.

  • Page 22: Common Operator Errors

    - severe thermal shock can be destructive to either of them. Always replace the metal cell O-ring when replacing the oxygen cell.  1-8 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 23: Start-Up Checklist

    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.

  • Page 24: Technical Support

    Billing and shipping address  Model number  Serial number  Purchase order number  Telephone number  Before returning material, you must get an RMA number from the  factory. NOTE 1-10 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 25: Chapter 2 Specifications

    SPECIFICATIONS Series 2000 Control Unit Four-line x 20-character vacuum fluorescent. Displays combinations of oxy- gen, ppm combustibles, methane, time and date, cell temperature, user-pro- Display grammable text, thermocouple mV or cell mV. Password protection, program- mable pressure compensation and context-sensitive help are also provided. Two isolated linear current outputs for oxygen and one each for combusti- bles and methane if you purchased those options.

  • Page 26: Sensor : Wdg-Iv

    EMc compliance: 2004/108/Ec Safety Compliance: 73/23/EEc NOTES All static performance characteristics are with operating variables constant. System accuracy referenced to 0.1 to 10% calibrated range. Response is to calibration gas. 2-2 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 27: Sensor : Wdg-Ivc

    Sensor : WDG-IVC Output Range From 0-1% to 0-100% Oxygen From 0-1% to 0-100% Combustibles From 0-2,000 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 ±...

  • Page 28: Sensor : Wdg-Ivcm

    115 VAC, ± 10%, 47-63 Hz, 700VA max. 230 VAC, ± 10%, 47-63 Hz, 1950 VA max. Power Requirements (750 VA max. floor mount option) (2000 VA max. floor mount option) 2-4 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 29 Calibration Gas Requirements for Hot-Wire Type Combustibles Detector Use calibration gases @ 10 PSIG, 1.5 SCFH (0.70 kg/cm , 0.7 L/min.) span gas: Air or from 1.0 to 100% o , balance n comb & From 0.1 to 10% o , balance n CH4 Zero Gases: comb span gas:...

  • Page 30: Sensor : Wdg-Ivc - 0-500 Ppm

    Safety Compliance: 73/23/EEc NOTES All static performance characteristics are with operating variables constant. System accuracy referenced to 0.1 to 10% calibrated range. Response is to calibration gas (with flame arrestors) 2-6 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 31: Remote Calibration Unit (Rcu)

    Remote Calibration Unit (RCU) O2 Only RCU O2 & Comb. RCU O2, Combustibles & Methane RCU Enclosure UL Type 4X (NEMA 4X (IP56) Environment Ambient Temperature: -18°c to 60°c Humidity: 0 to 90%, non-condensing Max Altitude: 2000 Meters IEc Installation Category II IEc Pollution Degree 2 System Compliance...
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  • Page 33: Chapter 3 Installation

    InstallatIon The operations in this chapter should be performed only by qualified  service personnel experienced in electrical safety techniques. There are no operator-serviceable components inside the WDG system. Never NOTE service the controller or sensor unless power has been removed from the controller and sensor, and the sensor has been allowed to cool for at least one hour.

  • Page 34: Inspect Shipping Contents

    Inspect shipping Contents Remove any packing material from the sensor and the Series 2000 control unit. Check for damage. If any is found, notify the shipper. 3-2 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 35: Mechanical Installation

    Mechanical Installation This section describes how to mount and connect gases to your WDG-IV 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 For some applications, you must first connect the sample inlet probe ...
  • Page 36 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. Figure 3-1. WDG-IV 1/8 nPt probe installation. 3-4 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 37 Ceramic probe or long probe installation If you ordered a long probe or a ceramic probe, connect the probe to the sensor as follows: 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.

  • Page 38: Probe Heater Installation

    NPT bushing and wires leading out of it. EXHAUST PORT SAMPLE PROBE INLET PORT PROBE HEATER PORT (REMOVE PLUG) TERMINAL BOX Figure 3-3. Port locations on rear of sensor - front view. 3-6 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 39: Exhaust Tube Installation

    Follow the steps below to install the probe heater: 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. Screw the probe heater into the 3/8”...
  • Page 40 Figure 3-4. Mounting dimensions - lift-off sensor. 3-8 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 41 Figure 3-4. Mounting dimensions for the hinged style enclosure, includ- ing the Z-purge option, are provided in Figure 3-5. If the protection nipple provided by AMETEK/Thermox extends past  the inside of the refractory wall on a process that has a gas tempera- ture over 1200 °F (650 °C), the nipple should be cut down before...
  • Page 42 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 3-7). 3-10 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 43 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 number of flange adapters.

  • Page 44: Calibration/Aspirator Air/Z-Purge Connections

    For example, if using an operating range of 0 to 2000 ppm combusti- bles, use 800 ppm CO, 800 ppm H , 1 to 2% CH , 8 to 10% O , balance 3-12 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 45 Always use tubing that is free of oil and dirt. Stainless steel tubing is rec- ommended. Figure 3-8. Z-purge setup. Z-Purge Connections Connect instrument air to the sensor Z-purge inlet. Maintain the pressure and flow as directed on the Z-purge warning label. •...
  • Page 46 1/4” NPT (F) HINGED ENCLOSURE - FRONT VIEW PURGE AIR INLET 1/4” COMPRESSION FITTING CAL GAS INLET PORT INSTRUMENT AIR INLET 1/4” COMPRESSION FITTING 1/4” NPT (F) Figure 3-9. sensor inlet connections. 3-14 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 47 Manual calibration and aspirator air connections If you have a remote calibration unit (RCU), skip the remainder of  this section and proceed to the “RCU Installation Instructions” ap- pendix. NOTE If performing manual calibrations, do the following: Connect aspirator air to the aspirator air inlet on the sensor (see Fig- ure 3-9).
  • Page 48 U-bolt of 3/8” or 1/2” diameter for a 2 1/2” to 4 1/2” pole diameter. Figure 3-11. series 2000, weatherproof wall/pole mount. 3-16 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 49: Weatherproof Wall/Z-Purge Option

    Weatherproof Wall/Z-Purge option Figure 3-19 shows the wall and pole mounting dimensions for the Series 2000 weatherproof Z-purge enclosure. To mount this control unit version, you must also connect instrument air to the Purge Inlet and set the pres- sure and flow as indicated on the warning tag on the control unit. Don’t open the Z-purge enclosure until you verify that the area has been classified as nonhazardous.
  • Page 50 Use 1/4” diameter fasteners to mount the control unit to the wall. 10.38 11.38 26.37 28.90 4 Holes for 1/4" fasteners Figure 3-15. series 2000, general purpose wall mount. 3-18 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 51: Wiring

    Wiring Remove AC mains power from the controller before performing wiring. Connections to the control unit are made through the wiring card (see Figure 3-16). The wiring card is located on the front-bottom of the control unit for all weatherproof versions and for the general purpose wall mount version (see the “Control Unit Mounting”...

  • Page 52: General Wiring And Conduit Requirements

    Follow proper grounding, shielding and noise protection practices as described in this section. • Use twisted-pair cable with an overall braided shield, or twisted-pair cable in rigid metal conduit for all sensor and signal wiring. 3-20 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 53: Control Unit Mains Supply Connections

    • For AC mains supply wiring, use between 12 and 14 American Wire Gauge (AWG) or equivalent metric between 3.3 mm and 2.1 mm . For all signal wiring, use 18 to 22 AWG (0.82 mm to 0.33 mm ). For sensor connections, Figure 3-17 shows the recommended sensor cable types for various WDG-style sensors.
  • Page 54 Keep shields as short as possible. • Ground Stud Method Connect all cable shields for that conduit entry to the grounding stud closest to that conduit entry hole. 3-22 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 55 SHIELD RING METHOD Shield Terminal Ring Quick Disconnet (1/4”) Cable Shield(s) Conduit Housing Max. Length 1 inch Capacitor Conduit Nut GROUND STUD METHOD Cable Shield(s) Conduit Housing Max. Length 2 inches Capacitor Conduit Nut Washer Ring Terminal Figure 3-18. Direct shield grounding methods transient and RFI interference This section describes transient and RFI interference precautions: •...

  • Page 56: Sensor Connections

    Sensor cabling must be twisted pairs in an overall braided shield, or  twisted pairs in rigid metal conduit. Follow all wiring guidelines as specified in Figure 3-17 in the front of this wiring section. NOTE 3-24 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 57 Figure 3-19. sensor board. sensor aC mains supply connections Connections for AC mains supply to the sensor are labeled as follows: L - Line Connection N - Neutral (USA) Chassis Stud -Equipment Ground (Protective conductor) There is no power switch on the sensor, and it must be protected by in- stalling it on a circuit protected line, maximum 15 amperes, with a switch or circuit breaker in close proximity to the sensor and within easy reach of an operator.
  • Page 58 If you have a methane detector, also make the following connections (see Figure 3-27): Control Unit label sensor terminal number CH4 ACT + (one pair) CH4 ACT - CH4 REF + (one pair) CH4 REF - 3-26 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 59 Figure 3-20. sensor connections with all sensor options. Installation | 3-27...

  • Page 60: Remote Sense Setup Wiring For Combustibles

    Ridged metal conduit Same Sensor connections as above Methane Combustibles SERIES 2000 Option Option WIRING BOARD 15 16 13 9 10 Remote Sense Detector Connections Figure 3-21. Remote sense connections for combustibles. 3-28 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 61: Current Output Connections

    Current output Connections standard current outputs Standard current output connections are labeled as follows on the wiring card of the Series 2000 control unit (see Figure 3-21): IOUT1 + and - IOUT2 + and - These current outputs are referenced as current outputs 1 and 2 in soft- ware.

  • Page 62: Alarm Contact Connections

    Oxygen Alarm connections are configurable in software to activate under a variety of user defined conditions, and are labeled as follows: ALARM 3A ALARM 4A ALARM 3B ALARM 4B 3-30 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 63 Power Supply Max. 30v Transient protector Computer dry for inductive contact input loads Load Max. 30VA Figure 3-22. series 2000 alarm contact connections. Installation | 3-31...

  • Page 64: Remote Calibration Unit Connections

    2000 control unit wiring card, and their RCU connections, are as follows (see Figure 3-30): ZERO - 13 on RCU ASPIR - 14 on RCU SPAN1 -15 on RCU VALVE COMMON - 16 on RCU 3-32 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 65 Combustibles remote calibration unit connections If you have the combustibles option (and a combustibles RCU), you must also make the following connection (see Figure 3-23): SPAN2 - 17 on RCU For a WDG-IVCM with RTD-type combustibles detector, you make the following connection: SPAN2 - 17 on RCU For a WDG-IVCM with hot-wire detector, Remote Calibration Unit connects:...

  • Page 66: Rs-485 Communications Connections

    Switch 3 on SW1 of the display module allows you to place a 120 ohm termination resistor into the RS-485 circuit: Switch 3 of SW1 = ON (Termination Resistor In Circuit) 3-34 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 67 Figure 3-24. series 2000 2-wire Rs-485 communication connections. Installation | 3-35...
  • Page 68 The factory default setting is to have Switch 3 OFF with no termination resistor in the circuit. 3-36 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 69 Figure 3-25. series 2000 4-wire Rs-485 communication connections. Installation | 3-37...

  • Page 70: Option Card Installation

    (see Figure 3-26): Remove power from the control unit before working on it. Figure 3-26. Front view of series 2000 control unit. 3-38 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 71: Adding An Option Card

    Open the access door below the display module (hinges down). Pull on the handle of the power supply/keypad module and remove this module from the control unit (it slides out). Note that the power supply/keypad module must be removed before you can remove the display module.
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  • Page 73: Areas Of The Control Unit

    CONTROLLER / USER INTERFACE This chapter includes: Areas of the Control Unit  Setup Key Functions  Analog Range Key Functions  Alarm Key Functions  Areas of the Control Unit Figure 4-1 shows you the various areas of the control unit, including the locations of the power supply/keypad module and display module.

  • Page 74: Selecting Menu Options

    Cancel until all menus disappear from the display and only process read- ings remain. Pressing the Cancel key does not delete any settings you have set  while in that menu. NOTE 4-2 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 75: Automatic Menu Exit Feature

    NOTE Setting up a system password If you have forgotten the correct password, you can call AMETEK/  Thermox and a service password will be provided so that you can ac- cess the Password option and enter a new system password.

  • Page 76: Setup Key

    Select the type of sensor you are using. Communication Define Series 2000 communication parameters. Combustibles Define combustibles scale (% or PPM). Define combustible detector type. This only applies if you purchased a combustibles detector. 4-4 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 77: Display

    Display Define what information should appear on the top three (3) display lines of the control unit. Choices include: Percent oxygen (% O  Cell temperature  Cell millivolts  Thermocouple millivolts (T/C millivolts)  Current date/time  User text ...
  • Page 78 Even though the unit was calibrated at the factory, the analyzer must be calibrated again after installation. Once the analyzer is calibrated and the combustibles signal is in the normal range, the display lines will show the correct reading. 4-6 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 79: Process Pressure

    Process Pressure Define your process pressure and whether your process is operating under a positive or negative pressure. Setting this value corrects oxygen measurements for the defined pressure. Setting up process pressure From the Setup key menu, select Process Pressure. Select Positive Pressure or Negative Pressure.

  • Page 80: System Tests

    System Tests Check the Series 2000 control unit for possible problems and isolate the problem. You may be asked by AMETEK/Thermox personnel to access this menu option to perform system diagnostics. Performing these tests is not required under normal operations.

  • Page 81: Primary Calibration

    Primary Calibration Perform a primary calibration on the zirconium oxide oxygen sensor. You should perform a primary calibration on your system instead of a regular calibration (from the Calibrate key) only when: you replace the zirconium oxide oxygen cell or thermocouple ...
  • Page 82 Only if these checks have been done and the system still can’t be properly calibrated should you perform a primary calibration. 4-10 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 83 Setting up a primary calibration Make sure you have properly entered calibration gas values using the Cal Gas Values option from the Calibrate key before starting your primary calibration. From the Setup key, select Primary Calib. If you have the auto calibration card option (and a remote calibra- tion unit), you will be prompted to select Auto Calibrate, Remote Calibrate, or Manual Calibrate.

  • Page 84: Sensor Config

    Select the sensor you will use with the Series 2000 control unit. If your sensor is not listed in Table 4-3, call the factory for the correct operat- ing temperature for your sensor type. 4-12 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 85: Communication

    Communication Define RS-485 communications parameters between the Series 2000 con- trol unit and a host device. This includes the following: Allows you to define the baud rate that the control unit and the Baud Rate host computer are using to communicate. Choices are 300, 600, 1200, 2400, 4800, and 9600 baud.

  • Page 86: Analog Range Key

    4 to 20 mA Output Filtering Smooth out variations in readings Select Function Define the information the analog output should track: Cell temperature Cell Millivolts Thermocouple Millivolts Combustibles (option) Methane (option) 4-14 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 87: Analog Output Port

    Analog Output Port Before you can define any Analog Range key functions, you must  choose whether they will apply to analog output ports 1 or 2 on the rear of the control unit. If you have the combustibles option, you can NOTE also use analog output ports 3 and 4.

  • Page 88: Set Track/Hold Option

    Separate choices can be made for calibration and verify operations. For calibration operations, select one of the following: Hold during cal Track during cal 4-16 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 89: Set Current Mode

    After you select one of these options, your choice will be confirmed on the display: Out # 1 will TRACK during Calibration Out # 1 will HOLD during Calibration For verify operations, select one of the following: Track during Verify Hold during Verify After you select one of these options, your choice will be confirmed on the display:...

  • Page 90: Output Filtering Option

    The default value is 100 (no filtering). NOTE Type a number between 1 and 100, then press Enter. Note that you should enter 01 to enter 1, 07 to enter 7, 70 for 70, etc. 4-18 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 91: Select Function

    Select Function Select what type of information the analog output port should track. Percent oxygen (% O  Cell temperature  Cell millivolts  Thermocouple millivolts (T/C millivolts)  Combustibles (optional)  Methane (optional)  The combustibles and methane options are available only for current out- puts 3 and 4, and cannot be set for analog output ports 1 or 2.

  • Page 92: Alarm Key

    See the “Wiring” section in the Installation chapter for help on alarm con- nections and how alarms are labeled on the control unit wiring card. 4-20 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 93: Overview Of Alarm Functions

    Overview of Alarm Functions Define whether Alarm 3 activates based on oxygen levels, the start of a calibration, or the start of a verification (Select Function). All other alarms are set to activate based on only a single condition ; for Alarm 4 this condition is levels of oxygen, for Alarms 5 and 6 this condition is high combustible levels (% or PPM scale), for Alarms 7 and 8 this condition is high methane.

  • Page 94: Alarm Set Points

    Enter the Alarm 3 set point value, then press Enter (just press Enter if you don’t want to change the current value). You are prompted to enter the Alarm 4 set point value: Alarm #4= xx %O2 New Value? 4-22 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 95 Enter the Alarm 4 set point value. If you don’t have the combustibles option installed, you are done (press Cancel to exit this menu option). Combustibles Option Alarms If you do have the combustibles option installed, you are prompted to enter the Alarm 5 set point value: Alarm #5= xx yy New Value?

  • Page 96: Alarm Configure

    (energize on alarm) or open on an alarm condition (de-energize on alarm). This menu option applies to all alarms except for the service and watchdog alarms, which are always set to de-energize on alarm (fail-safe). 4-24 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 97: Select Function

    Configuring the relay From the Alarm menu, select Relay Configure. Select De-energize on Alarm or Energize on Alarm. If you select Energize on Alarm, the following message appears: Relays are set to ENERGIZE on Alarm If you select De-energize on Alarm, the following message appears: Relays are set to DE-ENERGIZE on Alarm Select Function...

  • Page 98: Service Alarm

    (hidden keys to the left and right of the Setup key) for a long enough time will cause a watchdog. This will indicate as a beep after the system restarts after releasing the reset keys. 4-26 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 99: Exception Log

    Exception Log The exception log provides a history of the following types of events: • System or error messages • Alarm conditions • Reset conditions • Start of calibrations or verifications Accessing the exception log • From the Alarm menu, select Exception Log. The system displays the most recent exception log entry on line four of the display.
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  • Page 101: Chapter 5 Calibration

    Calibration CALIBRATE KEY Initiate Cal Initiate Verify Cal/Verify Data Cal Gas Value Inject Cal Gas Set Cal Timers Set K Factor Sensitivity Figure 5-1. Calibrate Key menu options. Sensor alarms are disabled during calibrations and the recovery time  after a calibration. You can set whether analog outputs should follow the calibration readings or hold at the last process reading before the NOTE calibration.

  • Page 102: Definitions

    Span and Zero Calibration Gas Definitions This chapter also refers to the terms span and zero calibration gases. The span gas is the high calibration gas. The zero gas is the low calibration gas. 5-2 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 103: Types Of Calibrations

    types of Calibrations The Series 2000 control unit allows you to perform automatic, remote, or manual calibrations. Automatic and remote calibrations require a factory- provided remote calibration unit (RCU) that automatically switches the calibration gases for you; manual calibrations are performed without an RCU, and gases are switched manually.

  • Page 104: Overview

    All other menu functions are temporarily disabled during a calibration or verification. Oxygen, combustibles, and methane alarms are also disabled during a calibration. 5-4 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 105: Initiate Cal And Initiate Verify

    initiate Cal and initiate Verify Perform an automatic, remote, or manual calibration or verification. These menu options function almost identically. See the introduction to this chapter for more information on the difference between a calibration and a verification. Automatic calibrations and verifications can also be set to run at prede- termined frequencies using the cycle times defined in the Set Cal Timers/ Set Auto Timers menu option.
  • Page 106 The system returns to monitoring process readings and the calibration or verify operation is complete. You can view the results of the last cali- bration or verification using the Cal/Verify Data menu option from the Calibrate key menu. 5-6 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 107: Remote Calibrate/Remote Verify

    Remote Calibrate/Remote Verify To initiate a remote calibration or verification, do the following: Enter the calibration gas values to match the span and zero calibration gas cylinders you intend to use to calibrate/verify your system. These values are referred to in this section as setpoint values . Select initiate Cal or initiate Verify from the Calibrate key menu, de- pending on whether you want to perform a calibration or verification.

  • Page 108: Manual Calibrate/Manual Verify

    You are prompted to apply the O span gas to the calibration gas inlet port on the sensor (tubing must be free of oil and dirt): Inject Span Gas ENTER to Continue CANCEL to Abort 5-8 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 109 Press Enter when you have applied the calibration gas. The span display appears (display line 2 will only appear if you have the combustibles op- tion; display line 3 will only appear if you have the combined combustibles and methane option): O2 xx.x % Set xx.x % Cmb y CH4 z...

  • Page 110: Calibration: Hot Wire Type Combustibles Detector

    Cmb yyyy Set yyyy CH4 zzzz Set zzzz Press ENTER to Span Comb 3. Press Enter when the combustibles span gas reading(s) stabilizes on the far left of the display. 5-10 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 111 If you have the methane option, you are also prompted to apply the methane span gas to the calibration gas inlet port of the sensor (tubing must be free of oil and dirt): Inject Meth Span Gas ENTER to Continue CANCEL to Abort Press Enter when you have applied your methane span gas.

  • Page 112: Calibration With Rtd Type Combustibles Detector

    Cmb yyyy Set yyyy CH4 zzzz Set zzzz Press ENTER to Span Comb 3. Press Enter when the Comb & CH4 span gas reading(s) stabilizes on the far left of the display. 5-12 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 113 If you specified a recovery time, the system will display the recovery time remaining: Recovery xx:xx System Calibrating The system returns to monitoring process readings. Be sure to reinsert the 1/4” tube cap on the calibration inlet port on  the sensor once you have completed the manual calibration.

  • Page 114: Cal/Verify Data

    Press Enter to then view the zero gas values. The following then appears on the display: Zero Value: xx % O2 Zero Gas: xx % O2 Zero Drift: xx % O2 5-14 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 115 The term zero value on the display is the value the system read during the calibrate/verify operation, and the term zero gas is the setpoint value entered using the Cal Gas Values option from the Calibrate key menu. Press Enter. The time when the calibration or verification was completed will then ap- pear on the display: End time hr:mm...

  • Page 116: Cal Gas Value

    Enter without entering a value. Combustibles option If you have the combustibles option, you are then prompted to enter the combustibles span gas value: Comb Span = xxxx YY New Value? 5-16 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 117 Enter the combustibles span gas value, then press Enter. If you want to keep the current combustibles span gas value unchanged, press Enter without entering a value. If you have a 3-in-1 analyzer (includes methane), you will also be prompted to enter the methane span gas value: Meth Span = x.xx% New Value? Enter the methane span gas value, then press the Enter key.

  • Page 118: Inject Cal Gas

    Cancel key to end the cycle. CANCEL to quit Then, if you specified a recovery time, the system will display the recov- ery time remaining: Recovery xx:xx 5-18 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 119 Combustibles and Methane option If you have the combustibles option, you will be prompted to press Enter when you have set the pressure and flow for the zero gas: ENTER for next Gas. CANCEL to quit. When you have adjusted the pressure and flow for the zero gas to the desired levels, press Enter.

  • Page 120: Set Cal Timers

    Recovery Duration Define a recovery duration during which time the sensor switches from measuring calibration gas readings to measuring process readings without affecting the ana- log output or triggering of alarms. 5-20 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 121 Set Cal timers - Set auto timers Set the frequencies for automatic calibrations or verifications, including the time when the first calibration or verification should begin. You have the option of setting the cycle in either hours or days. If you schedule a verification and calibration at the same time, the ...
  • Page 122 Select Disable Auto Cal (or Disable Auto Verify) to disable the auto calibration or auto verification cycle. Select Enable Auto Cal (or En- able Auto Verify) to enable the auto calibration or verification cycle. 5-22 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 123 The system will confirm your enabling or disabling selection: Auto Cal is ENABLED Auto Cal is DISABLED and will then exit this menu option. Set Cal timers - Cal Gas Duration Define how long the RCU should apply the span and zero calibration gases to the sensor during an automatic calibration or verification.
  • Page 124 Cal recovery = xx:yy Enter new time: Mn:Sc Enter the recovery time, then press Enter. If you want to use the cur- rently displayed recovery time, press Enter without entering a new value. 5-24 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 125: Set K-Factors

    Set K-Factors This menu option is not used on the WDG IV Series 2000. The de-  fault factor is always set to 1.00. NOTE Sensitivity Select this option to display the Sensitivity (slope). Calibration | 5-25...
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  • Page 127: Chapter 6 Maintenance And Troubleshooting

    MAINTENANCE AND TROUBLESHOOTING The operations in this chapter should be performed only by qualified service personnel experienced in electrical safety techniques. There are no operator-serviceable components inside the WDG system. Never service the controller or sensor unless power has been removed from the controller and sensor, and the sensor has been allowed to cool for at least one hour.

  • Page 128: System Messages

    Indicates that a system verification is in progress. It will appear System Verifying Cal during the entire automatic verification cycle or during the recovery period for a remote or manual verification. 6-2 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 129: Error Messages

    Error Messages Error messages on the control unit display indicate problems with the operation of the analyzer. Use this section to see the types of problems your error message indicates, then go to the “Diagnostic Checks” section at the end of this chapter for help on how to perform diagnostic checks to pinpoint the problem area.

  • Page 130: Span Gas Range Error

    Cell wiring reversed (Cell + and Cell - wires) • Aspirator air not turned off during calibration (WDG-IV only) • Failed cell (primary calibration should be run at this time) • Leak or plug in plumbing 6-4 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 131: Diagnostics Checks

    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”...

  • Page 132: Wiring Checks

    If this fuse is not OK, replace the fuse (1/4 amp, 125 volts, IEC speed type FF). Check the intercon- necting wiring for short circuits before applying power to the control unit. 6-6 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 133 If you do measure 15 volts at Measure across terminals D (+) and 6 (-) on the sensor terminals 2 (-) and 12 (+) of the board. Twelve millivolts should be measured ( this signal sensor board: is a function of ambient temperature and may vary up to 2 millivolts at extreme ambient temperatures ).

  • Page 134: Calibration/Aspirator Setup Checks

    If wiring is correct, replace the Auto Cal Card. 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. 6-8 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 135: Ac Power Checks

    To check if a Verify that no drive signal is present and check for flow on the calibration gas RCU flow meter. If flow is indicated when no solenoids are ener- solenoid is stuck gized, a solenoid is stuck open. Shut off your calibration gases open: (one at a time) until the flow drops to zero.

  • Page 136: Process Pressure Checks

    If this doesn’t work, check for leaks or plugged plumbing. If this doesn’t solve the problem, replace the cell, then run another primary calibration. 6-10 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 137: General Troubleshooting

    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 This check does not apply to Insitu users. Leaks can lead to inaccurate readings, especially if operating under a sig- nificant pressure or vacuum.

  • Page 138: Plugged Plumbing Check

    You will need a new metal O-ring when installing the venturi. 6-12 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 139: Series 2000 Leds

    Series 2000 LEDs This section describes how to interpret information on the LEDs in the Series 2000 controller auto calibration card and combustibles card. Auto Calibration Card LEDs All auto calibration card LEDs denote that the Series 2000 has sent out a 15-volt signal to the RCU to activate the appropriate solenoid.

  • Page 140: Combustibles And Methane Card Leds

    Blinking Green & sensopr enclosure over temperature Blinking RED Blinking Red Switch setup invalid sensor Temperature RTD circuit error (RTD open or shorted) YELLOW Indeterminate error 6-14 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 141: Chapter 7 Service And Parts

    SERVICE AND PARTS The operations in this appendix should be performed only by quali- fied service personnel with a knowledge of electrical safety techniques. There are no operator-serviceable components inside the WDG sys- tem. Never service the controller or sensor unless power has been removed from the controller and sensor, and the sensor has been allowed to cool for one hour.
  • Page 142 Never use pipe dope or any other contaminant that gives off combus- tible vapor on any joints of the sample tubing. Combustible vapor in the sample tubing can lead to erroneous readings. 7-2 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 143 Figure 7-1. Wiring diagram for standard sensor. Service and Parts | 7-3...

  • Page 144: Cell Replacement/Cleaning

    Before performing a primary calibration, first connect power to the  sensor and allow it to heat up and stabilize (approximately one hour). NOTE Perform a primary calibration if you replaced the cell. 7-4 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 145 Figure 7-2. Cell replacement. Service and Parts | 7-5...

  • Page 146: Thermocouple Replacement

    Before performing a primary calibration, first connect power to the  sensor and allow it to heat up and stabilize (approximately one hour). NOTE Perform a primary calibration. 7-6 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 147 TOP VIEW - FURNACE cell housing Thermocouple mounting tab Thermocouple convection loop mounting clamp Compression fitting Figure 7-3. Thermocouple replacement. Service and Parts | 7-7...

  • Page 148: Furnace Replacement

    If you measure a short circuit, loosen the screw that secures the ther- mocouple and relocate slightly until resistance is infinite. 11. Reattach cell clips. 12. Reattach furnace leads (reverse the actions taken in Step 3). 7-8 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 149 CONVECTION LOOP MOUNTING CLAMP CELL ASSEMBLY CELL HOUSING FURNACE UNION FITTING COMPRESSION FITTING Figure 7-4. Furnace replacement. Service and Parts | 7-9...

  • Page 150: Combustibles Detector Replacement

    Connect to terminals W and X. The reference element wires are labeled “R” and “RC” WDG-IVC Connect to terminals H and I on the sensor board. Polarity not required. WDG-IVCM Connect to Y and Z 7-10 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 151 Side View Furnace assembly Ferrule Detector head Combustibles Detector Block Compression Fitting Front View Place Mark @ 12 o'clock flow Sample flow Figure 7-5. Combustibles detector replacement (Hot-Wire). Service and Parts | 7-11...
  • Page 152 Step 1 above. Side View Furnace Assembly Ferrule Detector Head Combustibles Detector Block Compression Fitting Nut Front View Flat must face down flow Sample flow Figure 7-6. Combustibles detector replacement (RTD). 7-12 | Thermox Series 2000 WDG-IV / IVC / IVCM...

  • Page 153: Box Heater Diagram

    Box Heater Diagram Figure 7-7 shows how to wire box heaters using the sensor board. BOX HEATER 115 VOLT CONFIGURATION BOX HEATER 115 VAC BOX HEATER SENSOR BOARD BOX HEATER 230 VOLT CONFIGURATION BOX HEATER 230 VAC BOX HEATER SENSOR BOARD Figure 7-7.

  • Page 154: Replacement Parts List

    P/N 42373JE 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 7-14 | Thermox Series 2000 WDG-IV / IVC / IVCM...
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  • Page 156: Appendix A Serial Communications

    SERIAL COMMUNICATIONS Serial communications for the Series 2000 (ver 3.3 and later) and the IQ based software IQ applies to IQ sensor based products only S2 applies to Series 2000 based products only Communication Protocols Communication with all analyzers through the RS-485 connection uses the following word format: • 8 data bits • 1 stop bit...
  • Page 157 ?? (?? is equivalent to 2 ASCII 3FH hex charac- ters). This makes testing by the programmer easy, but it is strongly NOTE recommended that the integrity check be enabled in the final system. A-2 | Thermox Series 2000 WDG-IV /I VC / IVCM...

  • Page 158: General Serial Communication Commands

    General Serial Communication Commands Read Number (F) This command reads the value of a variable in the analyzer. The data sec- tion of this command is a number from 00-FF. These numbers correspond to the variable you wish to read. The table below provides a list of these variables and their location codes.

  • Page 159: Development Serial Communication Commands

    Due to the nature of EEPROM memory, each location in the memory has a limited number of writes allowed (approximately 10,000). The location character can be used to determine where the data is stored internally to the analyzer and act accordingly. A-4 | Thermox Series 2000 WDG-IV /I VC / IVCM...
  • Page 160 This command is only available via the Series 2000 software  NOTE Command List The following command letters are available: Letter Description Echo Bad Command Acknowledge Read Number Calibrate Write Number Data Format (Series 2000 software only) Read Date and Time Set Date and Time Serial Communications...

  • Page 161: Responses

    Failure Code Description Bad command letter Bad checksum Input overrun in serial communication Parameter out of range Error in receipt of character Cannot calibrate/verify now Internal error Illegal access (read-only variable) A-6 | Thermox Series 2000 WDG-IV /I VC / IVCM...

  • Page 162: Variable Table

    Variable Table The following pages provide a summary of the variable locations, name, and descriptions available. Location Variable Name Description (Hex/Decimal) Access 00/00 Flags3 Read only Various flags (1=true, 0=false) bit 0 – sensor is at operating temperature. bit 1 – Over/under Flag for tuning temperature bit 2 –...
  • Page 163 13 – Future use (used on S2000) bit 14 – WDG type sensor, 0 is HP type sensor bit 15 – combustibles are measure in percent,0 = combustibles are measured in A-8 | Thermox Series 2000 WDG-IV /I VC / IVCM...
  • Page 164 Config_flags System configuration flags (1=true, 0=false) bit 0 – auto verify cycle time is programmed in hours, 0 if in days bit 1 – Auto cal option is installed bit 2 – Combust module is installed bit 3 – Future use bit 4 –...
  • Page 165 0 is hold analog output 4 during verify. bit 14 – analog output 4 set for 0 to 20 ma, 0 is 4 to 20 ma bit 15 – Future use A-10 | Thermox Series 2000 WDG-IV /I VC / IVCM...
  • Page 166 Iout_flags Analog outputs flags (1=true, 0=false) bit 0 – analog output 3 tracks during calibration 0 is hold analog output 3 during calibration bit 1 – analog output 3 tracks during verify 0 is hold analog output 3 during verify. bit 2 –...
  • Page 167 The methane reading Read only 0B/11 Cell_temp The current cell temperature in degrees C Read only 0C/12 Cell_mv The cell millivolts Read only 0D/13 Tc_mv The thermocouple millivolts Read only A-12 | Thermox Series 2000 WDG-IV /I VC / IVCM...
  • Page 168 0E/14 Out1_flg What analog output 1 corresponds to 0 – oxygen 1 – cell temperature 2 – cell temperature thermocouple mv 3 – cell mv 4 – thermocouple mv box temp 5 – combustibles 6 – cell mv methane 7 – AF Ratio 8 –...
  • Page 169 Amount of time oxygen zero gas will flow in MMSS 28/40 Gas3_time Amount of time the combustibles span gas will flow in seconds Amount of time combustibles span gas will flow in MMSS A-14 | Thermox Series 2000 WDG-IV /I VC / IVCM...
  • Page 170 29/41 Recov_time Amount of time for recovery after a calibration in seconds Amount of time for recovery after a calibration in MMSS 2A/42 O2_gas1 Oxygen span gas setpoint value, always in percent 2B/43 O2_gas2 Oxygen zero gas setpoint value, always in percent 2C/44 Co_gas1...
  • Page 171 Mthslope Methane slope during last calibration Read only 5B/91 Cal_cycle Interval between auto cals [1 hour to 90 days] 5C/92 Ver_cycle Interval between auto verifies [1 hour to 90 days] A-16 | Thermox Series 2000 WDG-IV /I VC / IVCM...
  • Page 172 5D/93 Alr1_flg What process alarm is associated with 0 – oxygen oxygen, combustibles, or methane 1 – calibration 2 – verify 3 – in cal/verify 5E/94 Alm_config Configuration for oxygen alarms, high or low. If a bit is 1, that is the condition that the indicated alarm will trip on.
  • Page 173 Which type of calibration the unit is in: 0 – In normal calibration 1 – In verify 2 – In primary cal 3 – In none of the above, normal operation A-18 | Thermox Series 2000 WDG-IV /I VC / IVCM...
  • Page 174 61/97 Alarm_flags Read only Which oxygen alarm has been set and why bit 0 – high oxygen, process alarm bit 1 – low oxygen, process alarm bit 2 – high combustible, process alarm bit 3 – high methane, process alarm bit 4 –...
  • Page 175 Read only 68/104 Cal_temp Last calib temperature 69/105 CJTemp Cold Junction temperature Read only 6A/106 Box_temp Box Temperature Read only 6B/107 Cmb_Kfact Combustible K Factor 6C/108 Mth_Kfact Methane K Factor 6D/109 A-20 | Thermox Series 2000 WDG-IV /I VC / IVCM...
  • Page 176 6E/110 Dig_Input Read only Status of digital inputs(1=closed/on, 0=open/off) bit 0 – CAL 0 bit 0 – Dig In bit 1 – CAL 1 6F/111 70/112 SysTst_Flag System test that was preformed 1-Calibrate A/D 2-Ram Test 4-Test EEPROM 7-Erase Ram 8-Erase EEPROM 9- Test Watchdog 71/113...
  • Page 177 Exception number 18 see Exception Chart Read only 92/146 Excep_19 Exception number 19 see Exception Chart Read only 93/147 Excep_20 Exception number 20 see Exception Chart Read only 94/148 95/149 A-22 | Thermox Series 2000 WDG-IV /I VC / IVCM...
  • Page 178 Exception # Exception Out of Range Power up/Reset High Meth (Alm #3) High Comb (Alm #3) Low O2 (Alm #3) High O2 (Alm #3) High Meth (Alm #2) / METHANE HIGH #8 High Comb (Alm #2) / METHANE HIGH #7 Low O2 (Alm #2) / COMBUSTIBLE HIGH #6 High O2 (Alm #2)

  • Page 179: Sample Program

    Sum = 0 ‘Skip FOR i% = 2 TO LEN(M$) Sum = Sum + ASC(MID$(M$, i%, 1)) NEXT i% ‘Get low byte of checksum Checksum$ = HEX$(Sum MOD 256) END FUNCTION<P255D> A-24 | Thermox Series 2000 WDG-IV /I VC / IVCM...

  • Page 180: Starting/Monitoring A Calibration: An Example

    Starting/Monitoring a Calibration: An Example This section provides an example of how to initiate and then monitor a calibration. Check that no calibration or verification is currently occurring by checking the Calflag variable (Calflag=3). Send the Calibrate command to the IQ analyzer (G00). If an acknowledge is returned (A ...
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  • Page 182 MENU OPTION CHARTS SETUP KEY Functions/Options Menu Options Select info for Display Line 1. Display Select info for Display Line 2. Select info for Display Line 3. Passwords Create a system password select a positive or negative process pressure. Process Pressure Enter process pressure value.
  • Page 183 Alarm 8 calibration cycle) (methane only) * Note: Alarms 1 and 2 are reserved for the watchdog timer and service alarms and are not software-selectable. Table B-4. Alarm Set Point sub-menu. B-2 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 184 CALIBRATE KEY Functions/Options Menu Options start an automatic, remote, or manual calibration Initiate Cal/Initiate Verify or verify View latest calibration and verify data. Cal/Verify Data - cal data - Verify data cal gas Values Enter calibration gas values. Set pressure and flow to RCU gases without Inject Cal Gas performing a calibration.
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  • Page 186 CURRENT OUTPUTS: OTHER APPLICATIONS This appendix describes how to: • Modulate an external power loop using current outputs. • Power current outputs from an external power supply. Powering Current Outputs from an External Power Supply The Series 2000 control unit wiring card contains a set of terminals that can be used to connect an external voltage source to power the standard current outputs: VEXT1, 2 +...
  • Page 187 O2 current output external voltage source described in the previous section. Modulation can also be done in the same manner as IOUT1 or IOUT2. C-2 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 188 Modulation of External Power Loop Using Current Outputs Figure C-1 shows an example of the connection method when you want to produce a modulated current loop from an external power supply and a load device. All current output channels (IOUT1 and IOUT2) can be connected in the same manner as shown in this figure.
  • Page 189 Skip this section if you don’t measure combustibles. NOTE In addition, both of the combustibles current outputs can be used in a modulation scheme using the following: VEXT3+ VEXT4+ VEXT3- VEXT4- C-4 | Thermox Series 2000 WDG-IV / IVC / IVCM...
  • Page 190 DRAWINGS AND CUSTOM INSTRUCTIONS This appendix provides any custom drawings or instructions you may have ordered in addition to the standard WDG analyzer. If you didn’t or- der 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.
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  • Page 192: Setup Parameters

    SERIES 2000 CONTROLLER SETUP PARAMETERS o2 PRoDucTs O2 PRODUCTS INCLUDE CLEAR AREAS ONLY coMB. PRoDucTs COMB. PRODUCTS INCLUDE CLEAR AND SHADED AREAS METHANE PRODUCTS METH. PRODUCTS INCLUDE CLEAR,SHADED,AND BORDERED AREAS PARAMETER DEFAULT SETTINGS CUSTOMER SETTINGS cEM/o2, InsITu sEnsoR conFIguRE o2 WDG-IV, WDG-HPII sEnsoR conFIguRE coMB WDG-IVC, WDG HPIIC...
  • Page 193 2:00 MInuTEs RECOVERY DURATION 4:00 MInuTEs K FAcToR OUTPUT # 1 FUNCTION % OXYGEN cuRREnT MoDE,RAngE 4 To 20 MA = 0-10 TRACK/HOLD CAL VERIFY HOLD,TRACK OUTPUT FILTER # 1 E-2 | Thermox Series 2000 WDG-IV / IVC / IVCM...

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