Ametek Thermox WDG-V User Manual
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Ametek Thermox WDG-V User Manual

Combustion analyzer with pneumatic blow back
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AMETEK/Thermox
®
WDG-V, WDG-VC, WDG-VCM
Combustion Analyzer with
Pneumatic Blow Back
User Manual
Thermox
150 Freeport Road
Pittsburgh, PA 15238
PN 9000-250-VE Rev B

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Summary of Contents for Ametek Thermox WDG-V

  • Page 1 AMETEK/Thermox ® WDG-V, WDG-VC, WDG-VCM Combustion Analyzer with Pneumatic Blow Back User Manual Thermox 150 Freeport Road Pittsburgh, PA 15238 PN 9000-250-VE Rev B...

  • Page 2: Offices

    © 2018 AMETEK This manual is a guide for the use of the AMETEK/Thermox WDG-V (VC / VCM) with Blow Back. 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 ......................ix Electrical Safety ....................ix Grounding .......................ix Important Notice to Users ................x Environmental Information (WEEE) ............xi General Safety Summary ................xii Product Damage Precautions ..............xiii Declaration of Conformity ............xiv Warranty and Claims ..............xv CHAPTER 1 Specifications Sensor : WDG-V ....................
  • Page 4 Remote Calibration Unit (RCU) Connections ........3-26 Oxygen-Only Remote Calibration Unit Connections ......3-26 Combustibles Remote Calibration Unit Connections ......3-26 Digital Input to Initiate Remote Calibration Unit ....... 3-27 Notes About Ducting ................3-28 iv | Thermox WDG-V / VC / VCM with Blow Back...
  • Page 5 CHAPTER 4 AMEVision Display User Interface or Communications Purpose ........................ 4-1 Setting the Analyzer Address ..............4-3 Connecting a Single WDG-V Sensor to the AMEVision ....... 4-4 Connecting Multiple WDG-V Sensors to the AMEVision ....4-4 Troubleshooting ................... 4-6 WDG-V PC Configurator Software ..............4-7 Overview ......................
  • Page 6 Notes sur la Sécurité ..................B-1 Sécurité électrique ....................B-2 Mise à la terre ......................B-2 Note importante aux utilisateurs ..............B-3 Sommaire de Sécurité Générale ...............B-4 Utilisez un câblage adéquat ...............B-4 Evitez les surcharges électriques ...............B-4 vi | Thermox WDG-V / VC / VCM...
  • Page 7 Mettez à la terre l’analyseur ..............B-4 Ne pas faire fonctionner sans capot ............B-4 Utilisez des fusibles adéquats ..............B-4 Ne faites pas fonctionner en atmosphère explosible ......B-4 Precautions aux Dommages de L’Analyseur ..........B-5 Utilisez une alimentation électrique adéquate ........B-5 Ne faites pas fonctionner avec les défaillances suspectes .....B-5 Prenez des précautions en levant l’instrument ........B-5 Utilisez des vêtements adaptés ..............B-5 | vii...
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  • Page 9: Safety Notes

    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 dam- age to the equipment.

  • Page 10: Important Notice To Users

    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. x | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 11: 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...

  • Page 12: General Safety Summary

    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. xii | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 13: Product Damage Precautions

    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.

  • Page 14: Declaration Of Conformity

    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 xiv | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 15: Warranty And Claims

    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...
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  • Page 17: Chapter 1 Specifications

    SPECIFICATIONS Sensor : WDG-V Oxygen: From 0-1% to 0-100% Combustibles: From 0-2,000 ppm to 0-10,000 ppm or from 0-1% Output Range: to 0-5% Methane: From 0-1% to 0-5% Oxygen: ±0.75% of measured value or ±0.05% O2, whichever is greater Accuracy: Combustibles: ±2% of full scale output range Methane: ±5% of full scale output range 90% of a step change <...
  • Page 18 System accuracy referenced to 0.1 to 10% calibrated range. Response is to calibration gas. Specifications for combustibles and methane apply only to those versions equipped for measuring these gases. 1-2 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 19: Sensor : Wdg-Vc

    Sensor : WDG-VC 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 20: Sensor : Wdg-Vcm

    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 (without flame arrestors). 1-4 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 21: 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), Div II 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...
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  • Page 23: Chapter 2 System Overview

    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, 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 24: Sensor

    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 with Blow Back...

  • Page 25: The Oxygen Measuring Cell

    The Oxygen Measuring Cell The sensing element itself is a closed-end tube made from ceramic zirconi- um 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.

  • Page 26: Hydrocarbons

    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 hydro-  carbons present in the sample gas. NOTE 2-4 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 27: Sensor Operations - Wdg-Vcm

    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.

  • Page 28: Detectors

    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 with Blow Back...

  • Page 29: Methane

    The resistance change is interpreted by the microprocessor and the corresponding reading is displayed. The AMETEK/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.

  • Page 30: Flow Sensor

    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. 2-8 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 31: Troubleshooting

    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.

  • Page 32: Temperature Sensors

    There are three main heaters in the WDG-V, the cell heater the sensor box heater and the blow back box heater. In CM units, an additional heater is used for fine temperature control of the combustible block. 2-10 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 33: Cell Heater

    Cell Heater The Oxygen Cell Heater is a 300W coil heater encompassing the cell hous- ing 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.
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  • Page 35: Electronics

    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 (e.g., power, I/O) are directly con- nected to the main electronics.

  • Page 36: Alarm Contacts

    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 AM- ETEK’s remote calibration unit (RCU). See Wiring Section for interface details. 2-14 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 37: Communications Interface

    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.

  • Page 38: Start-Up Checklist

    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. 2-16 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 39: Common Operator Errors

    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 ana- lyzer is turned off or the process is shut down, the aspirator air should be turned off to avoid plugging problems.

  • Page 40: 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 • 2-18 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 41: Chapter 3 Installation Guide

    INSTALLATION GUIDE 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 NOTE the sensor has been allowed to cool for at least one hour. Also, always use gloves when working on the sensor.

  • Page 42: Analyzer Location

    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 with Blow Back...

  • Page 43: Mechanical Installation

    Mechanical Installation This section describes how to mount and connect gases to your WDG-V sensor. This includes the following: • Sample Inlet Probe Installation (Wall/Flange Mount) • Sample Inlet Probe Installation (Floor Mount) • Exhaust Tube Installation (optional) • Sensor Mounting (Wall/Flange Mount) •...

  • Page 44: Pressure Adjustments (Wall/Flange Mount)

    Figure 3-3. Pressure adjustment regulators. Adjust sensor flow using the Aspirator - Regulator 1. Adjust the blow back pressure using the Blow Back -Regulator 2. Minimum instrument air supply pressure = 80 psi. 3-4 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 45: Sample Inlet Probe Installation (Floor Mount)

    Alarms if temperature goes out of range. Resettable Over-Temp Switch Prevents damage to internal components. Using a 3”-150# mounting flange and nipple supplied by AMETEK (shown in Figure 3-4a) mount the analyzer to the process stack. Consult the factory for other floor mount configurations.

  • Page 46: Pressure Adjustments (Floor Mount)

    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. 3-6 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 47: Sensor Mounting (Wall/Flange Mount)

    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 instal-...
  • Page 48 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 dew- point. 3-8 | Thermox WDG-V / VC / VCM with Blow Back...
  • Page 49 Figure 3-8. 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: Weld a short 3 1/2”...

  • Page 50: Sensor Mounting (Floor Mount)

    Mount the sensor to a 3”x 150# customer-supplied flange. 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 variety of flange adapters. 3-10 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 51: Calibration/Aspirator Air

    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% O , the span gas must be 10% O or higher.

  • Page 52: Manual Calibration And Aspirator Air Connections

    (preferably 24 hours from a cold start; 1 hour after a restart). See page 5-1 for further detail. • The blow back pressure regulator should be set to 80 psi. 3-12 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 53: Remote Calibration Unit Mechanical Installation

    Calibration Gas Connection A calibration gas inlet port is provided to allow you to calibrate the system as shown in Figure 3-8. During calibration, you turn off the aspirator air supply and inject your calibration gases into the calibration gas inlet port on the sensor.

  • Page 54: Standard Rcu

    - note the orienta- tion of the valve. Connect the aspirator air outlet on the RCU to the aspirator air inlet connection on the sensor. 3-14 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 55: Combustibles Rcu

    Combustibles RCU Figure 3-15 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 con- taminants in the calibration gas plumbing. The ambient temperature range for the combustibles RCU is -20°...
  • Page 56 Figure 3-16. RCU flow diagram - Single Span. Figure 3-17. RCU flow diagram - -Span Combustibles 3-16 | Thermox WDG-V / VC / VCM with Blow Back...
  • Page 57 Figure 3-18. RCU flow diagram - 3-Span Combustibles and Methane. Installation Guide | 3-17...
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  • Page 59: Wiring

    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 ...

  • Page 60: Wdg-V Mains Supply Connections

    Mark the switch or circuit breaker as the control unit disconnecting device. 3-20 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 61: Emc Grounding, Shielding, And Noise Protection

    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 wir- ing.

  • Page 62: Transient And Rfi Interference

    Be sure to place the transient suppressor as close to the load as possible. Examples of transient suppressors include MOVs, TRANSORBs, and RC snubbers. 3-22 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 63: Current Output Connections

    • 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.
  • Page 64 Figure 3-20. Wiring 3-24 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 65: Alarm Contact Connections

    Alarm Contact Connections This section describes how to make wiring connections for any alarm de- vices you want 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 Service Alarm...

  • Page 66: Remote Calibration Unit (Rcu) Connections

    COMBUSTIBLE SPAN - WDG-V Terminal S2 to Pin 17 on RCU For a WDG-VCM with hot-wire detector, Remote Calibration Unit con- nects: • METHANE SPAN - SWDG-V Terminal S3 to Pin 18 on RCU 3-26 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 67: Digital Input To Initiate Remote Calibration Unit

    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 3-21. RCU connections. Digital Input to Initiate Remote Calibration Unit The digital input connections on the wiring card allow you to initiate a re- mote calibration from a remote location.

  • Page 68: Notes About Ducting

    Enclosure Maximum Overpressure The user should limit the pressure as specified by the manufacturer. 3-28 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 69: Chapter 4 Amevision Display User Interface Or Communications

    AMEVISION DISPLAY USER INTERFACE OR COMMUNICATIONS Purpose The AMEVision Display User Interface provides a remote, color, graphi- cal 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.
  • Page 70 Color 1/4 VGA Navigation Buttons Number Pad Enter/Menu Help Cancel/Escape Figure 4-1. AMEVision Display User Interface Reference the AMEVision Display User Interface manual for more infor- mation. 4-2 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 71: Setting The Analyzer Address

    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.

  • Page 72: Connecting A Single Wdg-V Sensor To The Amevision

    Figure 4-4. Multiple WDG-V Sensors to the AMEVision Display User Inter- face  Each analyzer must have a unique address (reference address setting section). NOTE 4-4 | Thermox WDG-V / VC / VCM with Blow Back...
  • Page 73 AMEVision Display User Interface or Communications | 4-5...

  • Page 74: Troubleshooting

    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 with Blow Back...

  • Page 75: Wdg-V Pc Configurator Software

    WDG-V PC Configurator Software Overview The WDG-V PC Configurator Software provides a convient way to con- figure, calibrate and monitor a single WDG-V analyzer. The interface between the configurator software and the WDG-V sensor is two-wire MODBUS RTU. Operation instructions for the PC Configurator software are found in ...
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  • Page 77: Chapter 5 Troubleshooting

    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.

  • Page 78: General Troubleshooting

    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. 5-2 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 79: Plugged Plumbing Check

    Plugged Plumbing Check Exercise care when working on the sensor. Allow the unit to cool and wear gloves. Examine the inlet and exhaust for plugging problems. When possible, rod out the probe and exhaust. If this doesn’t solve the problem, disassemble the analyzer to locate the plug.

  • Page 80: Diagnostics 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. 5-4 | Thermox WDG-V / VC / VCM with Blow Back...
  • Page 81 Thermocouple Checks Remove power to the sensor. Measure across terminals Open Thermocouple “+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.
  • Page 82 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. 5-6 | Thermox WDG-V / VC / VCM with Blow Back...
  • Page 83 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 84 If your analyzer doesn’t respond This may indicate a problem with the cell. Before re- properly to the calibration gas: placing the cell, check for leaks or plugged plumbing. 5-8 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 85: Alarm And Warning Messages

    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 The PCB temperature sensor has failed Bad Electronics Failure Cell Temperature Control A critical overtemperature condition has Shorted, open, or Bad occurred T/C or Failed Temperature...
  • Page 86 The flow sensor failed (open) Bad flow sensor or circuit Cell T/C Measurement Mis- The Redundant temperature measurement Bad T/C or circuit match does not match the real time meas 5-10 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 87: Warnings

    WARNINGS Cell Life Nearing Its End The ZrO cell is nearing its end of life. This Low cell output is based on calibration history. Comb Detector Life Nearing The combustible detector sensitivity is near Low detector output Its End its end of life. This is based on calibration history.
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  • Page 89 SERVICE AND PARTS The operations in this appendix should be performed only by qualified service personnel with a knowledge of electrical safety techniques. Never service the sensor unless power has been removed from the sen- sor, and the sensor has been allowed to cool for one hour. This chapter is divided into the following sections: •...

  • Page 90: Cautions

    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. 6-2 | Thermox WDG-V / VC / VCM with Blow Back...
  • Page 91 Figure 8-1a. Wiring diagram for sensor. Service and Parts | 6-3...
  • Page 92 Figure 8-1b. Customer wiring diagram for sensor. 6-4 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 93: Cell Replacement/Cleaning

    Cell Replacement/Cleaning Disconnect power from the sensor and control unit and allow the sen- sor to cool before replacing parts inside the sensor. Use Figure 8-2: Open the sensor cover to expose sensor components. Remove the cell clips. 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.
  • Page 94 HOLD CELL HOUSING USING 7/8" OR 1" WRENCH (23mm or 26mm) TURN HEX NUT COUNTER CLOCKWISE USING A CELL CLIPS 7/8" WRENCH (23mm) Figure 8-2. Cell replacement. CELL REPLACEMENT 6-6 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 95: Thermocouple Replacement

    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: Open the sensor door to expose sensor components. Disconnect thermocouple wires from terminals +TC- on the sensor board.
  • Page 96 Figure 8-3. Thermocouple replacement 6-8 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 97: Combustibles/Methane Detector Replacement

    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: Disconnect the combustible detector (Black and Brown) wires on the sensor board. Loosen the two 4.0 mm hex screws that holds the combustible detector in place and remove the detector from its housing.
  • Page 98 • 7. Reconnect the detector leads to the sensor board. Figure 8-4. Combustibles detector replacement 6-10 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 99: Flow Sensor Replacement

    Flow Sensor Replacement Flow Sensor Replacement Use Figure 8-5: Disconnect the flow sensor Red wires (Heater) and the Yellow wires (Sense) on the sensor board. Loosen the nut that connects the heater block and the flow sensor. 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.
  • Page 100 Figure 8-5. Flow sensor replacement • 6-12 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 101: Furnace Replacement

    Furnace Replacement Furnace Replacement Use Figure 8-6: Disconnect cell furnace wires. Remove the Thermocouple assembly from the furnace. Remove the Cell. 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. Remove the Furnace assembly.

  • Page 102: Heater Replacement

    Remove the box heater by sliding it out. Replace the box heater Attach a new speed nut to the post. Reconnect the wires on the sensor board. 6-14 | Thermox WDG-V / VC / VCM with Blow Back...
  • Page 103 Figure 8-7. Box Heater Replacement Service and Parts | 6-15...

  • Page 104: Combustible Block Heater Replacement (Only On Combustible/Methane Units))

    Loosen the 4.0 mm hex screw. Remove the combustible block heater by sliding it out. Replace the box heater Tighten the hex screw into place. Reconnect the wires on the sensor board. 6-16 | Thermox WDG-V / VC / VCM with Blow Back...
  • Page 105 Figure 8-8. Combustible Block Heater Replacement • Service and Parts | 6-17...

  • Page 106: Electronics Replacement

    Slide the board out until the pegs at the top line up with the holes in the electronics board plate and drop it down. Replace the electronics board. Properly tighten the screws. 6-18 | Thermox WDG-V / VC / VCM with Blow Back...
  • Page 107 Figure 8-9. Electronics Board Removal • Service and Parts | 6-19...

  • Page 108: Recommended Maintenance Schedule

    Recommended Maintenance Schedule Calibration Check calibration and/or recalibrate the analyzer every 90 days. 6-20 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 109: Replacement Parts List

    Replacement Parts List Sensor Assy, Furnace, WDG-V, 120 VAC 7000-719-SE Assy, Furnace, WDG-V, 240 VAC 7000-720-SE Kit, WDG-V Replacement Thermocouple For O Cell Furnace 7000-839-TE Combustibles Detector Kit - Hot Wire Detector 7000-816-TE ** Methane Detector Kit 7000-814-TE WDG-V Sensor Main Processor Board For Hot Wire Comb. Detector 8000-148-SE Assy, WDG-V Boards and Plate For Hot Wire Comb.

  • Page 110: Remote Calibration Unit (Rcu)

    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 6-22 | Thermox WDG-V / VC / VCM with Blow Back...

  • Page 111: Chapter 7 Customer Modbus Map

    CUSTOMER MODBUS MAP Sensor Register Name Data Type Description Host System Alarm Int 32 System alarms reported by the AMEVision Read Only Display User Interface Software Oxygen Float Oxygen concentration in percentage Writable Combustibles Float Combusitble concentration in ppm Writable Methane Float Methane concetration in percentage...
  • Page 112 3 Blowback history post BLOBAKPOSTFLW4 float … flow 4 Blowback history post BLOBAKPOSTFLW5 float … flow 5 unsigned long BLOBAKTRIGCNT Blowback trigger count Number of blowback events (32-bit) 7-2 | Thermox WDG-V / VC / VCM with Blow Back...
  • Page 113 Register Parameter ID Name Data Type Description Notes 0 - IDLE, Current state 1 - Charging, BLOBACKSTATUS Blowback status unsigned Char of a blowback 2 - Discharging, event 3 - Recovery Resistance value Blowback RTD Resis- of the blowback BBRTDRES float tance temperature sen-...
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  • Page 115: Appendix A Pc Software User Guide

    APPENDIX A PC SOFTWARE USER GUIDE WDG-V Configurator Software The WDG-V PC Configurator software comes standard with the purchase of the analyzer. It allows the user to configure the sensor and to calibrate the analyzer to the user process and provides real-time status and diag- nostic conditions as well as basic analyzer information.

  • Page 116: Home Screen

    The Status Bar at the bottom of the screen displays the current status of the analyzer. When there is an alarm condition, alarm information is displayed on the Status Bar which turns RED for FAIL; YELLOW for WARM-UP and DIAGNOSTICS; and GREEN for NORMAL. A-2 | Thermox WDG-V Series Analyzers...

  • Page 117: Pc Configurator Menu Buttons

    At the bottom left and right of the screen are displayed: • ON Time (time in hours that the analyzer is on since the last power- • TOTAL Time (cumulative number of hours the analyzer has been on in all sessions) PC Configurator Menu Buttons There are six menu buttons on the left-hand side of the screen that allow the user to set-up and monitor analyzer functions.
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  • Page 119: Configuration Button

    Configuration Button TABS OPTIONS Combustibles, Methane, Blow Back, Flow Sen- OPTIONS sor, Auto Calibration ANALOG OUTPUT AOut1, AOut2, AOut3 PROCESS ALARMS Relay 1, Relay 2, Relay 3 DATE/TIME 24-Hour Clock SENSOR NAME 9 Characters Maximum PROCESS PRESSURE kPa, PSI Configuration_Options Blowback ...
  • Page 120 Auto Calibration is not a standard feature of the WDG-V Analyzer. Do not select Auto Calibration unless your analyzer is equipped with a Remote Calibration Unit (RCU). Figure 4. HOME screen with Combustibles and Methane options activated. Configuration_Analog Output Figure 5. Configuration_Analog Output screen. A-6 | Thermox WDG-V Series Analyzers...
  • Page 121 You can direct process readings to any of the three analog output ports. Each of the outputs can be configured for: • Function • Mode • Span and Zero Ranges • Track or Hold while calibrating Function Cell mV Combustibles Methane Mode 0-20 mA...

  • Page 122: Configuration_Process Alarms

    , Combustibles, Methane, Disable • High Limit • Low Limit • Alarm: Energize/Deenergize When you have entered the information for each function, click the button at the bottom of the screen to apply the values. A-8 | Thermox WDG-V Series Analyzers...

  • Page 123: Configuration_Date / Time

    Configuration_Date / Time Figure 7. Configuration_Date/Time screen. The analyzer date and time can be set manually by clicking on the cal- endar for the date and entering the time in 24-Hour time format in the boxes. Alternately, the time can be retrieved from the computer clock by clicking on the PC DATE/TIME button.

  • Page 124: Configuration_Process Pressure

    (kPa, PSI) will modify the numerical value to reflect the change. When you have entered the numerical value and selected the unit of mea- sure, click the button at the bottom of the screen to apply the value. A-10 | Thermox WDG-V Series Analyzers...

  • Page 125: Configuration_Blow Back

    Configuration_Blow Back Figure 10. Configuration_Blow Back screen. Defines the Blow Back trigger options. Options include: Manual Only Blow Back type Timer Flow Timer and Flow. Defines how often the Blow Back is triggered ( in Interval hours ). Defines how long the data valid relay remains open Recovery Time after a Blow Back event is complete.
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  • Page 127: Calibration Button

    Calibration Button Use the Calibration Menu to configure the sensor for calibration, perform the calibration, and view the calibration history. TABS OPTIONS Set gases to calibrate. Set gas values CALIBRATION and timers. Perform a manual calibra- tion now. CALIBRATION HISTORY Plots the history of gases calibrated.

  • Page 128: Types Of Calibrations

    RCU and into the sensor by clicking to accept the values when the gas is stable. The gases, however, are automatically switched on/off using the RCU. Do not select Remote Calibration unless you have this option. A-14 | Thermox WDG-V Series Analyzers...

  • Page 129: Calibration_Set Gases To Calibrate

    Calibration_Set Gases to Calibrate Figure 11. Calibration_Set Gases to Calibrate screen. This screen will come up when you first initiate a calibration so you can select the gases to calibrate. If O is selected for calibration, it will be the first gas calibrated and the zero gas will be calibrated next, then combustibles and methane. If combustibles is the first gas selected for calibration, zero gas will be calibrated first, then combustibles and methane.
  • Page 130 This must be checked. This date and time must be later than Next Calibrations Date/Time the Calibration Date and Time. When you have completed this screen, click on the button to enter the values. A-16 | Thermox WDG-V Series Analyzers...

  • Page 131: Calibration_Set Cal Gas Values And Timers

    Calibration_Set Cal Gas Values and Timers Figure 14. Configuration_Cal Gas Values and Timers screen. Use this menu to set and save the calibration gas values. These values will be used when calibrating the sensor. This menu provides a way for the user to select the values before calibrating the analyzer. However, if the values are not set here, they can still be set during the calibration process under the Calibration tab.
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  • Page 133: Perform A Manual Calibration

    Perform a Manual Calibration Figure 15. Calibration_Set Gases to Calibrate screen. CALIBRATION Click the button. Select the gases to be calibrated, or choose the “All” option. Click the NEXT button to continue. Figure 16. Calibration_Set Cal Gas Values and Timers screen. Enter the calibration gas values for the gases you have selected. Minimum and maximum values are noted on the screen aside of each entry field.
  • Page 134 The screen displays the status of the O span gas. When the Status is READY ACCEPT , click the button to accept the values and continue the calibration or click on the Abort button to abort the calibration. A-20 | Thermox WDG-V Series Analyzers...
  • Page 135 Figure 18. Calibration_O Span Gas Calibration screen. You are prompted to Inject the O Zero Gas to the calibration inlet port of the sensor. Click the button when you have applied this gas. Figure 19. Calibration_Inject O Zero Gas screen. The system will calibrate the O and combustibles zero gas.
  • Page 136 When all gases have calibrated, the screen displays the Calibration Results that include % drift as well as recovery time. If the calibration is success- ful, a large green checkmark will be displayed. If it is not, a large red displayed. A-22 | Thermox WDG-V Series Analyzers...
  • Page 137 Figure 23. Calibration_Calibration Results screen. PC Configurator Software | A-23...
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  • Page 139: Perform An Automatic Calibration

    Perform an Automatic Calibration Scheduled Auto Calibration Configuration Auto Cal Config Click on tab. Figure 24. Calibration_Auto Cal Configuration screen. Define how long you want each calibration gas to flow through the sensor before switching the gases. Calibration Gas Duration The RCU automatically switches the span and zero calibration gases based on the calibration gas duration times you specify.

  • Page 140: On-Demand Auto Calibration

    Calibration Click on the button. The Set Calibration Type screen appears (Figure 25). From the drop- down menu, select the type of calibration you want to perform: NEXT Manual, Remote or Auto. Click Figure 25. Calibration_Set Calibration Type screen. A-26 | Thermox WDG-V Series Analyzers...
  • Page 141 Figure 26. Calibration_Set Gases to Calibrate screen. NEXT Set the Gases to Calibrate. Click Figure 27. Calibration_Set Gas Values and Timers screen. Enter the calibration gas values for the gases you have selected. Minimum and maximum values are noted on the screen aside of each entry field. These gas values match the span and zero calibration gas cylinders you use to calibrate your system.
  • Page 142 Figure 29. Calibration_Zero Gas Auto Calibration screen. The screen displays the Gas Value, Cal Gas and Time Remaining. The process will advance to the next gas to be calibrated. To abort the cali- bration, click on the Abort button. A-28 | Thermox WDG-V Series Analyzers...
  • Page 143 Figure 30. Calibration_Combustibles Gas Auto Calibration screen. The screen displays the Gas Value, Cal Gas and Time Remaining. The process will advance to the next gas to be calibrated. To abort the cali- bration, click on the Abort button. When all gases have calibrated, the screen displays the Calibration Results that include % drift as well as recovery time.
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  • Page 145: Perform A Remote Calibration

    Perform a Remote Calibration The functions for remote calibration will only be visible if you have an RCU and you have configured your sensor for Automatic Calibration on the Configuration_Options tab. Using the Remote Cal Unit (RCU), the user manually accepts the gas val- ACCEPT ues when each gas is stable by clicking on the button.
  • Page 146 The system will calibrate the O and combustibles zero gas. When the ACCEPT readings have stabilized (READY), click the button to accept the values and continue the calibration or click on the Abort button to abort the calibration. A-32 | Thermox WDG-V Series Analyzers...
  • Page 147 Figure 35. Calibration_Zero Gas Calibration screen. If your analyzer is equipped with the Combustibles option, you are then prompted to Inject the Combustible Span Gas to the calibration inlet port of the sensor. Click the button when you have applied this gas. Figure 36. Calibration_Inject Combustible Span Gas Calibration screen. The system will calibrate the combustibles span gas. When the read- ACCEPT ings have stabilized and the Status is READY, click the button to accept the values and continue the calibration or click on the...
  • Page 148 When all gases have calibrated, the screen displays the Calibration Results that include % drift as well as recovery time. If the calibration is success- ful, a large green checkmark will be displayed. If it is not, a large red displayed. Figure 38. Calibration_Calibration Results screen. A-34 | Thermox WDG-V Series Analyzers...

  • Page 149: Diagnostics Button

    Diagnostics Button Diagnostics are used to help determine the overall health of the sensor as well as for basic troubleshooting in the unlikely event that there is a prob- lem with the analyzer. The display screens give visibility to how the ana- lyzer is running and where glitches might occur.

  • Page 150: Oxygen Cell

    Figure 40. Diagnostics_Oxygen Cell screen. Cell Age in days Estimated Cell Life in months AT Value Cell Resistance Ohms Calculated Cell Temp degrees Celsius Cell Millivolts Millivolts Cell Temperature degrees Celsius A-36 | Thermox WDG-V Series Analyzers...

  • Page 151: Combustible Detector

    Combustible Detector This screen displays the information you need to determine the health of the combustibles detector and to determine if and when it needs to be replaced. Figure 41. Diagnostics_Combustible Detector screen. Detector Age in days Estimated Detector Life in months Sensitivity mV/kppm Active Element Voltage Volts Reference Element Voltage...

  • Page 152: Methane Detector

    Reference Element Voltage Volts I/O - Inputs and Outputs Diagnostics Mode is turned on when changes are made on this menu so that the system does not accidentally trigger an auto calibration while troubleshooting. Figure 43. Diagnostics_I/O screen. A-38 | Thermox WDG-V Series Analyzers...

  • Page 153: Inject Gas

    This screen displays the Outputs available and the Set Values and Get Values (real-time values) and allows you to control the outputs directly. You can access the Set Value fields to change these values and to Open or Close the Output Relays. It also displays the status of the Contact Input on the sensor board interface.

  • Page 154: Blow Back

    There are three utility options: • Parameter Management • About • Upgrade Firmware Parameter Management This screen is used to save or restore sensor user parameters or return the sensor parameters to factory default. Figure 47. Utilities_Parameter Management screen. A-40 | Thermox WDG-V Series Analyzers...

  • Page 155: Upgrade Firmware

    SAVE User Parameters Saves the sensor’s current parameters. Saves previously user-saved sensor param- RESTORE User Parameters eters. RESTORE Factory Defaults Reverts to the factory default parameters. About This screen provides information on Firmware and Hardware revisions, Configurator Software revisions as well as the analyzer serial number. Figure 48. Utilities_About screen.
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  • Page 157: Appendix B French Warnings / Avertissements Français

    FRENCH WARNINGS / FRANÇAIS AVERTISSEMENTS NOTES SUR LA SECURITE LES AVERTISSEMENTS, LES PRÉCAUTIONS ET LES NOTES CONTE- NUS DANS CE MANUEL ATTIRENT L’ATTENTION SUR DES INSTRUC- TIONS 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.

  • Page 158: Sécurité Électrique

    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 with Blow Back...

  • Page 159: Note Importante Aux Utilisateurs

    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...

  • Page 160: Sommaire De Sécurité Générale

    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 with Blow Back...

  • Page 161: Precautions Aux Dommages De L'analyseur

    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...
  • Page 162 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 with Blow Back...
  • Page 163 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...
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