Ametek LAND Genesis WDG-1200 User Manual
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Ametek LAND Genesis WDG-1200 User Manual

Insitu oxygen probes
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Genesis WDG-1200/1210
Insitu Oxygen Probes
User Guide
Publication Nº 805712
Language: English
Issue 14
21 April 2017
Copyright © 2017 LAND Instruments International

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  • Page 1 Genesis WDG-1200/1210 Insitu Oxygen Probes User Guide Publication Nº 805712 Language: English Issue 14 21 April 2017 Copyright © 2017 LAND Instruments International...
  • Page 2 IMPORTANT INFORMATION - PLEASE READ Health and Safety Information Read all of the instructions in this booklet - including all the WARNINGS and CAUTIONS - before using this product. If there is any instruction which you do not understand, DO NOT USE THE PRODUCT.
  • Page 3 Web: www.landinst.com For further details on all AMETEK Land offices, distributors and representatives, please visit our websites. Return of Damaged Goods IMPORTANT If any item has been damaged in transit, this should be reported to the carrier and to the supplier immediately.
  • Page 4 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes...

  • Page 5: Table Of Contents

    User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Contents Overview System Features Sensor Problems to Avoid Technical Support Specifications WDG 1200/1210/Insitu Probe Installation and start-up Unpacking Mechanical Installation Electrical Connections 3-10 Pre-operational Checks - Final Checks 3-22 User Interface and Calibration Control Panel Abbreviations Used on the Control Panel Using the Probe for the First Time...
  • Page 6 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes...

  • Page 7: Overview

    User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Overview 1.1 System Features The WDG 1200/1210 Insitu probes are a type of direct insertion oxygen probe used to measure the oxygen in the exhaust of a combustion process. The zirconium oxide cell is placed directly in the stream of the products of combustion. The probe is designed for applications in which the flue gas temperature does not exceed 1472°F (800°C), and where combustibles measurements are not required.

  • Page 8: Sensor

    Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes 1.2 Sensor We recommend that all personnel who will regularly use this analyzer become familiar with the following brief explanation of how the analyzer works and the components that make up the analyzer. The Oxygen Measuring Cell The sensing element itself is a closed-end tube or disk made from ceramic zirconium oxide stabilized with an oxide of yttrium or calcium.
  • Page 9 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Figure 1-1 Zirconium oxide cell principle of operation. Three Simple Systems in the Analyzer • The Mechanical System: The inner and outer pipes, mounting flange, and terminal case. • The Measuring System: The sensing cell, interconnecting wiring, and integrated user interface. • The Temperature System: The electrical zirconium oxide cell heater with internal type “K”...

  • Page 10: Problems To Avoid

    1.4 Technical Support AMETEK/LAND is committed to providing you the best technical support in the industry. If you need service or application assistance, please call AMETEK at +44 01246 417691, or your local AMETEK/LAND representative. Before you call the factory for technical support, run test gases and record the...

  • Page 11: Specifications

    User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Specifications 2.1 WDG 1200/1210/Insitu Probe General Flue gas temp: 20°C to 800°C/68°F to 1472°F Heater temperature: 750°C ±3°C (1382°F ± 5°F) Pressure: ± 2 psig (± 13.8 kPa) Probe material: 310 Stainless steel Case material: Powder-coated aluminum Mechanical Data...
  • Page 12 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Controller Data - WDG 1210/Insitu only Dimensions: 152 mm (6 in) high 153 mm (6 in) wide 130 mm (5.2 in) deep 2.7 kg / 6 lb. Weight: Max Distance between Controller and Probe: 150 m (500 ft) Calibration Gas Zero Gas: 1 % O...
  • Page 13 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Electrical Data Voltage range: 100-240 VAC Frequency: 48-62 Hz Power: 250 W Current Rating: 4 A Peak Over-voltage category: CAT II Fuse rating and characteristics: 3.15A (T) External earth bonding: 6 mm female thread Relay rating: Single pole changeover 2 A at 30 VAC/ Isolation switch rating...
  • Page 14 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Page 2 - 4...

  • Page 15: Installation And Start-Up

    User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Installation and start-up WARNING Only qualified service personnel with knowledge of electrical safety techniques should perform the operations in this chapter. There are no operator-serviceable components inside the WDG-1200/1210 Insitu probe. Never service the Insitu probe unless power has been removed from the probe and it has been allowed to cool for at least one hour.

  • Page 16: Mechanical Installation

    Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes 3.2 Mechanical Installation • Location • Installing the Filter/Flame Arrestor (optional) • Mounting the Sensor • Calibration Setup Location CAUTION Observe the following guidelines when selecting an analyzer installation location. The installation location should be free from excessive vibration. The ambient temperature must be within the limits listed in the specifications chapter in this manual. If the ambient temperature is outside the specified limits or the vibration is excessive, please contact LAND Sales or Service Department at +44...
  • Page 17 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Unpacking the shipping protection Remove the Anti-shock rubber cap, see the picture below: Anti-shock rubber cap Unpack the Mullite ceramic tube, as below: Mullite tube Put the Mullite tube into the probe, as below: Fit the filter or shield to the end of the probe, as described below.
  • Page 18 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Fitting a Filter or Shield to the Probe Some protection must always be fitted to the probe tip to prevent foreign objects from entering the probe and damaging the sensor. CAUTION Never use the probe without protection on the tip. The protector can be a mesh screen, flame arrestor, ceramic filter or stainless steel filter, depending on the application. The example below shows a ceramic filter with stainless steel protector. Once the packing material has been removed, screw the filter or screen onto the end of the probe tube as shown. Loosen the filter protector and slide it over the filter. Extend the protector approximately 1/2 in (1.27 cm) past the tip of the filter.
  • Page 19 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Mounting the Sensor NOTE Ambient temperature in the controller area should be less than 160° F (70°C). Mount the probe and its flange to the flange on the process (see Figure 3-2a and 3-2b). Insulate the pipe nipple with at least 1 in (2.54 cm) thick weatherproof insulation. If the pipe nipple is over 4 in (10.16 cm) long, it should be heat traced.
  • Page 20 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Mounting the Controller (WDG-1210 Insitu only) Figure 3-3 Model 1210 Insitu Oxygen Probe System Key Components: Model 1210 Oxygen Probe Mains Power Supply Input to Control Unit Oxygen Control Unit (required) Signal Outputs/Relays Remote Calibration Unit (optional) (customer connections) Span Calibration Gas (typically 20.9%...
  • Page 21 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Mounting Guidelines Mount the control unit to a flat, vertical surface at a height where the display is clearly visible and the key panel user interface is readily accessible. There should be a minimum of 150 mm (6 in) clearance below to enable both the electrical connections and signal cable connections to be made. Ensure that there is an accessible route for connection to the measurement probe and the remote calibration unit.
  • Page 22 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Installing the Controller All dimensions are given in millimetres/inches. Figure 3-5 Control Unit Dimensional Information Mounting the Control Unit The Control Unit is mounted to a vertical, flat surface using the four (4) 7mm (0.28 in) mounting holes as seen in Figure 3-5. Figure 3-6 Mounting Details Page 3 - 8...
  • Page 23 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Calibration Setup Figures 3-7a and 3-7b show the location of the calibration gas inlet port on both units. When calibrating the system, connect your calibration gases to this inlet port. Calibration Gas Port Figure 3-7a Calibration Gas Port...

  • Page 24: Electrical Connections

    Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes 3.3 Electrical Connections The customer is responsible for providing all switch cabinets, distribution boxes, fuses and other components for electrical installation as well as the mains power supply connections. NOTE A suitable switch or circuit breaker must be provided close to the probe to allow the electrical power supply to be disconnected.
  • Page 25 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Optional Signal Connections The following signal outputs may be connected: • Current Loop • Calibration in Progress relay • RS485 Serial Communications • Alarms relay • System OK relay NOTE Normal (for normally open N/O and normally closed N/C) is defined as the analyzer in measurement mode (not in calibration or maintenance) indicating no faults or alarms.
  • Page 26 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Plug Plate Connector Designation - WDG-1210 Insitu PLUG PLATE CONNECTOR DESIGNATIONS (view from underside of probe) 1. Power Supply 2. Connections to Automatic Gas Calibration Control Unit (option) 3. Customer I/O 4. Power Supply connection to measurement probe 5.
  • Page 27 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Cable Preparation Check the mains power supply cable specification for mains power supply voltage and capacity (see below for full specification). Setting the supply voltage in the system units Isolate the equipment power supply before beginning adjustment. WARNING The PROBE CONTROLLER mains power supply voltage used is auto- switching for 100 to 240VAC, 50/60Hz. No adjustment is necessary. The REMOTE CAL UNIT mains power supply must be selected - refer to the RCU user manual.
  • Page 28 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Cable Recommendations - WDG-1200 Insitu WDG-1200 Insitu Cable Recommendations Max. o.d. No. of Core Core Size Core Ref. Description Shielded Cores Size mm strands/dia Size awg Mains Supply 16/0.2 Calibration 7/0.2 Outputs/Relays 7/0.2 Cables 1 and 3 are supplied with the analyzer.
  • Page 29 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Cable Recommendations - WDG-1210 Insitu WDG-1210 Insitu Cable Recommendations Max. o.d. No. of Core Core Size Core Ref. Description Shielded Cores Size mm strands/dia Size awg Mains Supply 24/0.2 Calibration 7/0.2 Outputs/Relays 7/0.2 Probe Power 24/0.2 Interconnect...
  • Page 30 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Wire Colour Connector Ref Insert Arrangements Function Cable A Cable B 3. Outputs/Relays Current Loop -ve Red/Blue White* Current Loop +ve Brown White** Calibration Trigger +ve White*** Calibration Trigger 0V Orange White**** RS485 Shield Green/Red Yellow* RS485 B (two wire half duplex)
  • Page 31 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Probe Connections - WDG-1210 Insitu Only Make the connections ensuring the cables are routed correctly as shown in Figure 3-8. Cell +ve Cell -ve Thermocouple +ve Thermocouple -ve Cold junction +ve Cold junction -ve Heater Live/Line Heater Neutral/Return Not Used...
  • Page 32 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Grounding External grounding points are provided. These should be connected to local ground. Correct grounding is essential for compliance with EMC regulations. Ground Point Calibration Gas Port Ground Point Ground Point Calibration Gas Port Ground Point Page 3 - 18...
  • Page 33 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Assembly of Connector Plugs NOTE The pin designation of each connector is repeated on each individual plug. In most cases, complete cable assemblies are supplied with the analyzer. If custom cables must be assembled, it will be necessary to terminate the cables using the following procedure: PLUG CONNECTOR ASSEMBLY KEY 1.
  • Page 34 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Push the pins into the correct slots (7). They will snap into place when positioned correctly (pull & tug to check). Fit pins to ALL slots, regardless of cable connections made. NOTE Follow the ‘Pin Designations’ correctly. Screw the pin/socket receptacle and connector (7) into the cable housing (5).
  • Page 35 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Mains Power Supply Plug NOTE Ensure there is sufficient clearance to enable connection and disconnection of the mains connector. Mains Connector Assembly Procedure Remove approximately 15mm / 0.6 in of the cable’s outer cover to expose the inner cores. Thread the exposed cores through the cable clamp. Select the correct rubber sealing washer for the cable diameter and thread the cable through the washer.

  • Page 36: Pre-Operational Checks - Final Checks

    Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes 3.4 Pre-operational Checks - Final Checks Check that a blanking plug has been securely fitted to the calibration gas connector on the probe. NOTE If the blanking plug is not fitted, air leaking into the probe via the connector can cause measurement errors. In a pressurised flue, gases venting to atmosphere through the connector could cause corrosion of the test gas tube. In a negative pressure flue, air leakage can cause high O reading errors. Page 3 - 22...

  • Page 37: User Interface And Calibration

    User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes User Interface and Calibration 4.1 Control Panel • Menus are displayed in a 4-character format. • The oxygen concentration is displayed in four-digit floating decimal point format. Fault data: In addition to gas readings and system configuration, comprehensive diagnostics information can be accessed in the event of system malfunction. Figure 4-1 Control Panel Mode Key Used to move through the menu options.

  • Page 38: Abbreviations Used On The Control Panel

    Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes 4.2 Abbreviations Used on the Control Panel ALAR Alarm Analog output AUTO Automatic calibration BASE Analog Output 0-20 4-20mA etc. Calibration EMF of cell CELT Temperature of cell Cold junction compensation temperature CONF Configuration Cal time interval DIAG...

  • Page 39: Using The Probe For The First Time

    User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes 4.3 Using the Probe for the First Time Before turning on the power supply to the probe, check the following: • Ensure that a blanking plug has been fitted to the calibration gas connector on the probe. Air can enter the probe through this connector and cause high O2 readings. In a pressurized flue, gases venting to atmosphere can cause corrosion of the test gas tube.
  • Page 40 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Operational Structure The operational structure can be described as a Menu Spine that allows access to five other menus. Before you can access the Menu Spine, you must enter a password and set the maintenance relay. Scroll through the Menu Spine by pressing F1 to display the five available menus: Calibration Diagnostics...

  • Page 41: Probe Display Settings

    User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes 4.4 Probe Display Settings Operational Structure Diagram CALIBRATION MENU Display Action Display Action O2 Display Configuration Menu Auto Cal. Span gas conc. Value Zero gas conc. Value Manual Cal. Menu Cal time interval Value Zero Value...
  • Page 42 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Calibration Screens Calibration Menu Ensure that installation of the analyzer is complete (see installation manual) and that the SYSTEM parameters have been set. If the analyzer is in maintenance mode the two outer decimal points displayed will flash; during calibration, all four will flash. The following information is required: •...
  • Page 43 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes All the options necessary to calibrate the analyzer can be accessed using the Calibration menu. The Calibration menu consists of three sub-menus: Configuration • • Automatic Calibration • Manual Calibration To access these menus, from the Calibration menu, press Enter. Use the F1 key to scroll through the menus.
  • Page 44 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes ↵ ↵ Span gas concentration (CAL COnF SgAS) OPTIONS Set concentration of span calibration gas To set the concentration of the gas used to calibrate the span of the analyzer: RANGE Press Enter 5 to 25 % O Select a value using the UP and DOWN keys DEFAULT...
  • Page 45 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes ↵ ↵ Calibration settling time (CAL COnF SEtL) OPTIONS Set time for calibration readings to settle The period required for the calibration gas to stabilize is normally two minutes. If using long lengths of piping the RANGE time may need to be extended.
  • Page 46 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Alarm Screen Alarm Menu Display Action ALARM Enter value The alarm sub-menu has only one option. Access this menu by pressing Enter from the alarm display. The option is set by selecting a value using the UP and DOWN keys and pressing Enter again.
  • Page 47 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Analog Outputs Screens Display Action ZERO Enter Value Display Action SPAN Enter Value Display Action DAMPING Enter value Display Action BASE Enter value Display Action TRACK Analog Outputs Menu All the options necessary to set analyzer outputs can be accessed using the Analog Outputs menu.
  • Page 48 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes ↵ Zero setting (AO ZEro) OPTIONS Set zero reading output To set the minimum O concentration of the Analog Output RANGE 0 to 20 % Range: Press Enter DEFAULT Select a value using the UP and DOWN keys Press Enter again.
  • Page 49 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Diagnostics Screens Diagnostics Menu The Diagnostics menu consists of three sub-menus: • Faults • Cell status • Resistance test To access these menus, from the Diagnostics display, press Enter. To scroll through the menu, press F1. Each option within the sub-menu can be viewed by pressing Enter.
  • Page 50 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Fault list (diAg) OPTIONS To display the fault list, press Enter when the View faults Diagnostics screen is on view. Each fault is RANGE represented by a particular number and can be NOT APPLICABLE identified using the Fault Table in Chapter 5.
  • Page 51 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes System Configuration Screens System Configuration Menu All the options necessary to configure the analyzer are accessed using the System Configuration menu. The System Configuration menu consists of five sub-menus: • Probe type • Baud setting • Negative readings • Probe address • Revision number These sub-menus are accessed by pressing Enter from the System Configuration display.
  • Page 52 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes ↵ Probe type (SySt Prty) OPTIONS To select the probe type: Set probe type Press Enter RANGE 673 to 1172 Select a value using the UP and DOWN keys DEFAULT Press Enter again. NOTE: The default setting corresponds to the Model 1200/1210 probe.
  • Page 53 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Output Setup System Outputs The current loop output can provide one of two output functions: Track Measurement output is tracked during normal reading and calibration operations. Hold Measurement output is held at the last reading prior to calibration, and resumes after the final calibration settling period.
  • Page 54 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Analog Outputs Menu To set the analog outputs, you must enter the password, set the maintenance relay, and select the Analog Outputs menu. From menu spine Display Action ZERO Enter value Display Action SPAN Enter value Display...
  • Page 55 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Analog output settings All the options necessary to set the analyzer outputs can be accessed using the Analog Outputs menu. The Analog Outputs menu consists of five sub-menus: • Zero • Span • Damping • Base • Track To access these sub-menus, from the Analog Outputs display, press Enter.
  • Page 56 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Track Setting The analog output may be set to track the O levels or hold the last reading during calibration. This is set by pressing Enter, selecting YES to track or NO to hold using the UP and DOWN keys, and then pressing Enter again. Page 4 - 20...
  • Page 57 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Modbus Interface Serial data bus configuration The serial data bus can be set to any of the following four configurations: Code Baud Rate Parity Stop Bits 1200 1200 Even 4800 4800 Even 9600 9600 Even 96nP 9600 None Data format: Modbus RTU The default setting is 1200. To chnage the serial data setting: Press F1.
  • Page 58 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Register Numbers This manual uses Register Numbers as defined in the Modbus specifications. The first register number is 1. Modbus packets contain Register offsets which are one less than register Numbers and start at offset 0. Data Types Integer variable Single register. Registers Numbers for Instrument Readings (integer value) Address Variable Scaling Reading 1000 Cell Temperature ( Command Register Address Variable...
  • Page 59 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Modbus RS485 Interface Figure 4-3. RS485 Bus topology. Figure 4-4. Two -wire RS485 connection. Page 4 - 23...
  • Page 60 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Full Register List Nonvolatile (Saved on power down) Register Variable Scaling Password Cal Span Gas Cal Zero Gas Cal Time Interval Settling Time Alarm Limit 1000 Probe Address Analog O/P Zero Analog O/P Span Analog O/P Damping Analog O/P Base Probe Type...
  • Page 61 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes The ‘Status and Calibration Start’ register 20 is used both to trigger a calibration and to monitor the instrument status. The meaning of each bit is as shown in the table below: Meaning Start Calibration.
  • Page 62 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Zero and Span Calibration Full (zero and span) calibration may be carried out manually, set to occur automatically at defined time intervals, or triggered from a remote device. To set the calibration options you must enter the password, set the maintenance relay, and select the Calibration menu. Configuration of calibration parameters must be completed as shown overleaf before full calibration is carried out.
  • Page 63 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes isplay Action Configuration Sub-menu Span gas conc. Enter value Zero gas conc. Enter value Cal time interval Enter value Time to next cal Enter value Cal settling time Enter value Display Action AUTO CAL. Enter or F1 Display Action...
  • Page 64 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Configuration The five options available within the Configuration sub-menu are accessed by pressing Enter from the Configuration display. Each option is set by pressing Enter, selecting an appropriate value using the UP and DOWN keys, and pressing Enter again. Configuration Sub-Menu You must set the five sub-menu options in order for the analyzer to perform zero and span calibrations.
  • Page 65 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Automatic Calibration The Automatic Calibration sub-menu has only one option. Access this option by pressing Enter from the Auto Calibration display. The Auto Calibration option is selected by pressing Enter, selecting YES using the UP key and pressing Enter again.
  • Page 66 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Manual Calibration The Manual Calibration sub-menu has two options: • Zero • Span Calibration These options are accessed by pressing Enter from the Manual Calibration display. Both options are initiated by connecting the appropriate calibration gas, pressing Enter, waiting for the reading to settle, and then pressing Enter to continue, or pressing F1 to bypass the option.
  • Page 67 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Span Calibration The span calibration reading is checked by connecting the calibration gas via the calibration gas inlet on the probe and pressing Enter. The reading displayed will need approximately 120 seconds to settle. NOTE: Recommended span calibration gas concentration is 20.90% O (i.e.
  • Page 68 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Page 4 - 32...

  • Page 69: Maintenance And Troubleshooting

    User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Maintenance and Troubleshooting CAUTION The operations in this chapter should be performed only by qualified service personnel with knowledge of electrical safety techniques. There are no operator-serviceable components inside the WDG- 1200/1210 Insitu probe. Never service the probe unless power has been removed from the probe and it has been allowed to cool for one hour.
  • Page 70 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes System Fault LED (red) The fault sub-menu is accessed through the Diagnostics menu on the Menu Spine. If a fault occurs, a fault identification number is displayed. This identification number refers to possible faults on the Fault Identification Table (Table 1). If no fault has been identified by the analyzer, then a zero (0.00) will be displayed. From menu spine Display Action FAULT LIST Display Page 5 - 2...
  • Page 71 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Fault Identification Numbers Each fault is identified by a specific number as follows: Heater temperature out of the control band (±5°C) 00.02 (b) Span coefficient out of range 00.10 Zero coefficient out of range 3.00 (d) Thermocouple fault and heater above maximum limit 40.00 Cold junction temperature fault 600.0 Failed in calibration 7000 The Fault Identification Number may represent a multiple fault, in which case the individual identification numbers are added together. Use the table below as a...
  • Page 72 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Fault Description Key to Elements column of each fault: Probe Fault is related to probe Wiring Fault is related to wiring of system Mains Fault is related to mains power supply Fault is related to Remote Calibration Unit NOTE For all actions referring to the Remote Calibration Unit refer to the relevant operating manual.
  • Page 73 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes (b) Span coefficient out of range 00.10. The calculated span coefficient from span calibration cycle is outside the expected value range. CAUSE ELEMENT ACTION 1. Poor wiring, contacts dirty. Wiring Check wiring and clean contacts. 2. Span gas concentration not entered Probe Check calibration configuration correctly. settings.
  • Page 74 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes (d) Thermocouple fault and heater above maximum limit 40.00. The analyzer is measuring an unexpected voltage from the probe thermocouple. CAUSE ELEMENT ACTION 1. Thermocouple open circuit. Probe Check probe wiring. 2. Thermocouple wired in reverse polarity. Wiring Check connections.
  • Page 75 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Bench Testing When the fault has been resolved, the probe should be bench-tested before fitting it back into the flue. Allow the probe to operate in air for about 20 minutes in order to achieve temperature stability. Periodically check the cell EMF reading after the initial stabilizing time has expired.

  • Page 76: In-Situ Probe Testing And Checking

    Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes 5.2 In-Situ Probe Testing and Checking In-situ checking will assist with identifying errors or faults associated with the probe. Cell output voltage can be displayed on the user interface using the Diagnostics menu as an alternative to the following manual checks. After any corrections the system must be fully calibrated.
  • Page 77 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Measure the voltage across the thermocouple (T/C) contacts at the probe. Refer to Table 2. WARNING Mains power connections on the probe. High risk of electric shock ! 1. Cell -ve 2. Cell +ve 3.
  • Page 78 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Table 2 gives the voltage that should be present at the probe thermocouple connections (Step 6), according to the temperature measured at Step 5, when the probe has stabilized at 750°C/ 1382°F. Note: older probes operated at 700°C (1292°F).
  • Page 79 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes NOTE A flue temperature greater than 750°C (1382°F) will result in a higher thermocouple reading. The Genesis WDG-1200/1210 will function correctly in flue temperatures up to 800°C (1472°F). Disconnect the thermocouple leads from the thermocouple (TC) terminals and check the thermocouple for open or short circuit. NOTE A short circuit usually indicates a wiring fault rather than a faulty thermocouple..

  • Page 80: Maintenance

    Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes 5.3 Maintenance Routine Maintenance Schedule Ensure the following routine maintenance schedule is followed. Failure to do so may invalidate the terms of warranty. Every Month Perform a complete calibration (unless automatic calibration is enabled). Every 6 months COMPONENT PROCEDURE...

  • Page 81: Service And Parts

    User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Service and Parts WARNING The operations in this chapter should be performed only by qualified service personnel with knowledge of electrical safety techniques. There are no operator-serviceable components inside the system. Never service the controller or Insitu probe unless power has been removed from the controller and the probe has been allowed to cool for one hour.

  • Page 82: Inner Probe Assembly Removal

    Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes 6.1 Inner Probe Assembly Removal CAUTION Remove power before replacing any parts on the WDG-1200/1210 Insitu. Most of the procedures in this chapter require that you first remove the inner probe assembly (see Figure 6-1). Ensure that power is removed from the control unit and allow the sensor to cool for one hour.
  • Page 83 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Process under Pressure If the process is under pressure, place a blind plate and gasket over the flange hole (blind plate and gasket included in insitu accessory kit). • Place the blind plate and gasket over the 8-32 stud on top of the flange hole. • Insert the two 8-32 x 1/4 in long screws from the insitu accessory kit into the two remaining holes. Tighten using a flat blade screwdriver.

  • Page 84: Cell Replacement

    Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes 6.2 Cell Replacement Removing the Cell Remove the inner probe assembly as described in the previous section, Inner Probe Assembly Removal. Mark the position of the U-bolt relative to the heater by drawing a line on either side of the U-bolt on the top of the heater.
  • Page 85 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes With the probe oriented in front of you so that the cell assembly end is on your right and the sheet metal plate is on your left, rotate both the sheet metal plate (handle end of probe) and the left hex nut counterclockwise at the same time until the left hex nut becomes unthreaded from the inner probe assembly.
  • Page 86 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes To prevent twisting of the cell leads, keep the mark on the left hex nut and the orientation of the white cell lead from being more than one quarter turn from each other (see Step 2). Turning them together will prevent this from occurring. NOTE If you don’t have two people and the probe is long (making it impossible to turn both ends at the same time), turn the left hex nut one quarter...
  • Page 87 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Find the cell clip that belongs with the white cell wire (slide the wire forward and back to determine this). Rotate the cell assembly so the mark on the left hex nut is aligned to where the cell clip is welded to the cell lead. Take the white cell clip and snap onto the cell, placing it between the white band on the cell and the open end of the cell.
  • Page 88 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes NOTE If you don’t have two people and the probe is long, you may find it difficult to turn both ends at the same time. In this case, turn the left hex nut one quarter turn, then turn the heater one quarter turn until the left hex nut is threaded into the inner probe assembly.
  • Page 89 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Fig. 6-5 Cell and retainer clip placement Page 6 - 9...

  • Page 90: Heater/Thermocouple Replacement

    Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes 6.3 Heater/Thermocouple Replacement Removing Heater (See Fig. 6-3) Remove the inner probe assembly as described in the previous section, Inner Tube Assembly Removal. Remove the cell as described in the Cell Replacement section above under the Removing the Cell subsection.

  • Page 91: Spare Parts

    User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes 6.4 Spare Parts Spare Probes for use with WDG1200 OR WDG1210 Part Number WDG-1200 Probe 9" (0.22m) 805654 WDG-1200 Probe 18" (0.45m) 805655 WDG-1200 Probe 36" (0.9m) 805660 WDG-1200 Probe 72" (1.8m) 805661 WDG-1200 Probe 108"...
  • Page 92 Genesis WDG-1200/1210 User Guide Insitu Oxygen Probes Probe Spares (Genesis 1200/1210 WDG probes) Part Number Heater/Thermocouple - 9" 805684 Heater/Thermocouple - 18" 805685 Heater/Thermocouple - 36" 805686 Heater/Thermocouple - 72" 805687 Heater/Thermocouple - 108" 805688 Inner Probe - Std. 9" 805689 Inner Probe - Std.
  • Page 93 User Guide Genesis WDG-1200/1210 Insitu Oxygen Probes Appendix - Drawings and Custom Instructions This appendix provides any custom drawings or instructions you may have ordered in addition to the standard WDG-1200/1210 Insitu probes. If you didn’t order any custom options, the standard Interconnect Drawing is provided. If you did order any special options, the drawings or special instructions provided here supersede any drawings or options provided elsewhere in this manual.
  • Page 96 Manufacturers address in Europe Land Instruments International Dronfield, S18 1DJ Tel: +44 (0) 1246 417691 Email:land.combustion@ametek.co.uk Web: www.landinst.com...

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