Ametek Thermox 2000 ATEX Series User Manual
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Ametek Thermox 2000 ATEX Series User Manual

Ametek Thermox 2000 ATEX Series User Manual

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Thermox
Series 2000 ATEX
WDG-HPII and WDG-HPIIC
User Manual
Thermox
150 Freeport Road
PN 90571VE, Rev B
Pittsburgh, PA 15238

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Summary of Contents for Ametek Thermox 2000 ATEX Series

  • Page 1 ® Thermox Series 2000 ATEX WDG-HPII and WDG-HPIIC User Manual Thermox 150 Freeport Road PN 90571VE, Rev B Pittsburgh, PA 15238...
  • Page 2 If the instrument or procedures are used for purposes over and above the capabilities specified herein, confirmation of their validity and suitability should be obtained; otherwise, AMETEK does not guarantee results and assumes no obligation or liability.

  • Page 3: Table Of Contents

    Table of Contents Safety Notes ......................vi Electrical Safety ....................vi Grounding ......................vi Important Notice to Users ................vii Explosion Hazards: .................... vii Environmental Information (WEEE) ............. viii General Safety Summary ................... ix 1 OVERVIEW Basic Elements of the Sensor................1-2 Start Up Checklist .....................
  • Page 4 4 CONTROLLER / USER INTERFACE Areas of the Control Unit ................4-1 Setup Key ......................4-5 Analog Range Key ................... 4-18 Alarm Key ......................4-25 5 CALIBRATION Definitions ......................5-2 Span and Zero Calibration Gas Definitions ..........5-2 Types of Calibrations ..................5-3 Overview ......................

  • Page 5: Safety Notes

    Safety Notes WARNINGS, CAUTIONS, and NOTES contained in this manual emphasize critical instruc- tions as follows: An operating procedure which, if not strictly observed, may result in personal injury or environmental contamination. WARNING An operating procedure which, if not strictly observed, may result in damage to the equipment.

  • Page 6: Important Notice To Users

    AMETEK recommends that all equipment requiring service be sent back to the factory. You should only attempt to repair or service this equipment after receiving training from an AMETEK/P&AI Division training representative.

  • Page 7: 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 product when it reached its “end of life”.

  • Page 8: 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.
  • Page 9 WDG Series analyzers with the suffix Div. 2, O2 Only RCU, O2 & Comb RCU, and O2, Combustibles & Methane RCU also conform to the following safety standard: UL 1604 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...
  • Page 10 WARRANTY AND CLAIMS We warrant that any equipment of our own manufacture or manufactured for us pursuant to our specifications which shall not be, at the time of shipment thereof by or for us, free from defects in material or workmanship under normal use and service will be repaired or replaced (at our option) by us free of charge, provided that written notice of such defect is received by us within twelve (12) months from date of shipment of portable analyzers or within eighteen (18) months from date of shipment or twelve (12) months from date of installation of permanent...

  • Page 11: Overview

    OVERVIEW Designed for applications with high particulate levels in the gas stream, the sensor mounts directly on the combustion process to provide continu- ous measurement of oxygen (HPII), or oxygen and combustibles (HPIIC). Since the sample inlet and return are inside the filter and at the same abso- lute pressure as the process, there is no flow through the filter.

  • Page 12: Basic Elements Of The Sensor

    Basic Elements of the Sensor The WDG-HPII analyzer consists of the following basic systems: The Plumbing • All inlet and outlet tubing (cell housing), the sensing cell, the sensing cell fitting, and the combustibles flow block and detector (for com- bustibles).
  • Page 13 Figure 1-1. Zirconium oxide cell principle of operation. where R and F are constants, T is absolute temperature, and O and O the oxygen partial pressures on either side of the cell. For measuring oxygen in non-combustibles gases, the calibration of an ana- lyzer is obtained from the formula: 20.9% E = A...
  • Page 14 The Combustibles Detector 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 cata- lyzed element changes as the combustible mixture burns.
  • Page 15 Common Operator Errors These are some common errors to avoid; if they are avoided, your analyzer will operate with a minimum of maintenance and troubleshooting. If your process is running and the analyzer is installed on the process, • the analyzer must have power applied to it to prevent plugged plumb- ing and sensor component damage.

  • Page 16: Start Up Checklist

    Start Up Checklist Review the installation chapter before installing this system. • Install the probe tubes (sample and exhaust) and filter assembly to the • rear of the sensor. Install the sensor on the process. The ambient temperature must not •...

  • Page 17: Technical Support

    Technical Support AMETEK/Thermox is committed to providing you the best technical sup- port in the industry. If you need service or application assistance, please call AMETEK at (412) 828-9040, or your local AMETEK/Thermox represen- tative. Before you call the factory for technical support, run test gases and...
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  • Page 19: Specifications

    SPECIFICATIONS Series 2000 Control Unit Display 4-line x 20-character vacuum fluorescent. Selectable displays with pass- word protection, programmable pressure compensation and context- sensitive help. Analog Output Two isolated linear current outputs. One additional output for cumbustibles. Each output can be 4-20mA or 0-20 mA and is fully scal- able.
  • Page 20 Environment Ambient Temp: -10 – 50°C Relative Humidity: 10% to 80%, non-condensing IEC Installation (Overvoltage) Category: II IEC Pollution Degree 2 Max. Altitude: 2000 meters Enclosure Weatherproof NEMA 4 (IP 56). NEMA4X (IP56) Stainless Steel available as option.. Calibration Oxygen cell lifetime extender. Calibrate or verify calibration. Store last cali- bration and verification data.
  • Page 21 Sensor Principle of Operation Zirconium oxide for net oxygen measurement and hot-wire type catalytic detector for combustibles. Output Range Oxygen: From 0-1% to 0-100% Comb: From 0 to 2,000 ppm to 0 to 10,000 ppm or from 0 - 2% to 0 - 5% Accuracy Oxygen: ±0.75% of measured value or ±0.05% oxygen, whichever is greater.
  • Page 22 Enclosure Hinged Stainless Steel NEMA 4X (IP 56) wall mount Power Requirements 104-127 VAC, 740 VA; 207-253 VAC, 1990 VA Calibration Gas Requirements Use calibration gases @ 0.70 kg/cm 0.7 Lmin. Span Gas: Air or from 1.0% to 100% O , balance N &...
  • Page 23 Remote Calibration Unit (RCU): O2 Only RCU O2 & Comb RCU Enclosure NEMA 4X (IP56) Environment AmbientTemperature: -18°C to 70°C Humidity: 0 to 90%, non-condensing Max Altitude: 2000 Meters IEC Installation (Overvoltage) Category: II IEC Pollution Degree 2 Compliance: EMC Compliance: 2004/108/EC Electronics Safety Compliance: 73/23/EEC ATEX Directive 94/9/EC Specifications...
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  • Page 25: Installation

    INSTALLATION The operations in this chapter should only be performed by qualified service personnel experienced with electrical safety techniques. There WARNING are no operator serviceable components inside the WDG-HPII/HPIIC system. Never service the sensor unless power has been removed and it has been allowed to cool for at least one hour.

  • Page 26: Mechanical Installation

    Mechanical Installation This section describes how to perform the mechanical installation portion of your system installation. This includes the following: • Probe and Probe Filter Connection to Sensor • Sensor Mounting • Remote Calibration Unit Mechanical Installation (optional) Observe the following guidelines when selecting an analyzer instal- lation location: CAUTION 1.
  • Page 27 To connect the inlet probe, exhaust tube, and probe filter to the sensor, do the following - see Figure 3-1 for help: Remove all protective plastic caps and plugs from the probe filter and inlet probe. Thread the 1/4" pipe inlet probe into the manifold block on the rear of the sensor.

  • Page 28: Mounting The Sensor

    Mounting the Sensor You must attach the probe, exhaust tube, and probe filter assembly to the sensor before mounting the sensor to the process. NOTE The ambient temperature range for the sensor is -20 to 60 C. Hinged sen- sor mounting dimensions are provided in Figure 3-2. The three methods of mounting the WDG-HPII to the process are as fol- lows: Directly weld the Thermox supplied mounting plate to the process.
  • Page 29 2.88 [7.30] 11.75 [29.85] 9.00 [22.86] INCH 12.25 ALLOW 6" [31.12] CLEARANCE TO OPEN DOOR (15.24cm) 21.50 4.00 [54.61] [10.17] ENCLOSURE RAPID EXCHANGE PROTECTION VENT PURGING SYSTEM MAGNAHELIC GAUGE HINGE SET PRESSURE .15 TO .35 SIDE INCHES OF WATER TERMINAL BOX 19.50 1/2"...
  • Page 30 Flush with process mounting method (Preferred) This section describes how to directly weld the Thermox supplied mount- ing plate to your process so the attached pipe nipple extends completely through the refractory. If you are unable to mount the sensor in this fash- ion, refer to the other mounting methods described below.
  • Page 31 SENSOR BOLTED TO MOUNTING PLATE AFTER PLATE IS WELDED TO WALL BY CUSTOMER GASKET (BY AMETEK) AMETEK SUPPLIED MOUNTING PLATE WITH 2 7/8"OD X 9"LONG NIPPLE (7.30cm X 22.86cm) WELDED TO WALL OVER A 3 3/4"OD (9.52cm) HOLE BY CUSTOMER...
  • Page 32 Customer-supplied pipe nipple mounting method If you can’t mount the sensor to the process directly because the wall is curved sharply, covered with insulation, or obstructed with reinforcing members, you can instead weld the Thermox supplied mounting plate with attached pipe nipple to a pipe nipple that you supply. To do this, follow these steps - see Figure 3-4 for help: Weld a short 3 and 1/2“...
  • Page 33 SENSOR BOLTED TO MOUNTING PLATE AFTER PLATE IS WELDED TO NIPPLE BY CUSTOMER EXHAUST TUBE GASKET (BY AMETEK) AMETEK SUPPLIED MOUNTING PLATE WITH 2 7/8"OD X 9" LONG NIPPLE (7.30cm X 22.86cm) PROCESS WALL FILTER SAMPLING PROBE (INSIDE EXHAUST TUBE)
  • Page 34 Avoid overtightening mounting bolts if using a raised face flange. This will prevent damaging the backplate of the sensor. CAUTION SENSOR BOLTED TO MOUNTING FLANGE GASKET (BY AMETEK) REQUIRES 1" (2.54cm) MIN INSULATION AROUND EXPOSED EXHAUST TUBE PORTION OF NIPPLE...

  • Page 35: Mounting The Sensor To The Process

    Mounting the Sensor to the Process Do the following to mount the sensor to the process: Make sure the gasket provided is on the mounting plate or customer- supplied flange. This gasket keeps the system sealed and leak tight. Make sure that the probe, exhaust tube, insulation sleeve, and probe filter assembly are attached to the sensor - see the “Probe and Probe Filter Connection to Sensor”...

  • Page 36: Calibration

    Calibration Required Calibration Gases and Tubing See “Specifications” for required pressure/flow of calibration gases. NOTE The span gas is the high gas. The zero gas is the low gas. Use dry calibration gases that are free of oil and dirt. Stainless steel tubing is recommended.

  • Page 37: Purging Operation

    • Process pressure is assumed to always be sub-atmospheric (vacuum). • Your sample gas stream must contain no more than 25% of the LEL (lower explosive limit) for all combustible gases in your sample at any time. Otherwise, there is a possibility for the ana- lyzer to be an ignition source for the process.
  • Page 38 Do not exceed “Safe” pressure with the Enclosure Pressure Control Valve. WARNING Operators must follow-step-by-step sequence of the Start-Up instructions Nameplate on the Protection System. With the protective gas supply connected, enclosure power deenergized and alarm system energized (if utilized). Carefully read Start-Up Instruction on system.
  • Page 39 SYSTEM START-UP INSTRUCTIONS ENCLOSURE PRESSURE GAUGE ENCLOSURE PRESSURE CONTROL VALVE STEM RAPID EXCHANGE Figure 3-6. PRESSURE GAUGE Rapid Exchange Purge System. T-BAR VALVE KEY WITH RAPID EXCHANGE CONTROL VALVE STEM PURGE AIR INLET 1/2"NPT (F) SET @ 60PSI MIN. ENCLOSURE Figure 3-7.

  • Page 40: Manual Calibration Connections

    Manual Calibration Connections If you have a Remote Calibration Unit (RCU), skip the remainder of this section and proceed to the “RCU Mechanical Installation” sec- NOTE tion that follows. If you don’t have an RCU, simply connect calibration gases to the calibra- tion gas inlet port on the sensor (see Figure 3-7).

  • Page 41: O2 And Combustibles Rcu Connections

    3.54 4.50 [89.92] [114.23] 18.48 [469.38] 1/4" MOUNTING HOLES 4 PLCS Figure 3-8. 6.29 4.33 [159.86] [110.00] RCU mounting dimensions. 9.45 5.91 [240.00] [150.24] 10.24 [260.01] -Only RCU Connections Make the following calibration gas connections to the RCU (see Figure 3-9): Connect the span calibration gas to the span gas inlet on the RCU.
  • Page 42 COMBUSTIBLE SPAN GAS OPTIONAL COMBUSTIBLES 1/8"NPT (F) MIDRANGE VERIFY SPAN 10 PSI GAS 1/8"NPT (F) 10 PSI METHANE ZERO GAS INLET SPAN GAS 1/8"NPT (F) 1/8"NPT (F) 10 PSI 10 PSI ASPIRATOR AIR OUTLET 1/8" NPT (F) Figure 3-9. RCU Plumbing. ASPIRATOR AIR INLET 1/4"NPT (F) 60 PSI MAX.
  • Page 43 Air regulator Solenoid and gauge Sensor Valve Instrument Plugged Air Inlet Calibration Flowmeter Solenoid Valve Calibration Gas line Figure 3-10. Flow Diagram. 1/4" OD Regulator 1psi factory Solenoid Check set @ Valve Valve O2 zero 10psi Gas Inlet To be kept to a minimum Air regulator...

  • Page 44: Control Unit Mounting

    Control Unit Mounting The Weatherproof Series 2000 Control Unit is availabae with different mounting options: • Panel • Wall/Pole Weatherproof - Panel Mount Figure 3-12 shows the panel mounting dimensions for the Series 2000 weath- erproof enclosure. Use 1/4" diameter fasteners to mount the control unit to the panel.

  • Page 45: Weatherproof - Wall/Pole Mount

    Weatherproof - Wall/Pole Mount Figure 3-13 shows the wall and pole mounting dimensions for the Series 2000 weatherproof enclosure. For wall mount installations, use 1/4" diam- eter fasteners to mount the control unit to a wall. For pole mount installa- tions, the two slots on the backplate of the enclosure can be used to accom- modate a customer supplied U-bolt of 3/8"...

  • Page 46: Wiring

    Wiring Remove AC mains power from the controller and sensor before per- forming wiring. WARNING Connections to the control unit are made through the wiring card (see Figure 3-14). 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 47 If you are considering adding option cards at a later time, such as a combustibles card, you may wish to connect the required intercon- NOTE nect wiring when you first install your analyzer, especially if run- ning the wires over long distances through conduit. TB11 Figure 3-14.
  • Page 48 General Wiring and Conduit Requirements This section describes general wiring and conduit requirements: • Sensor wiring conductors must be rated at a minimum of 80°C. All other wiring conductor ratings should be for the minimum tempera- ture required for the equipment being connected to the analyzer, but not less than 60°C.
  • Page 49 Control Unit Mains Supply Connections Do not run control unit AC mains supply wiring in the same conduit with other AC line power wires. By keeping this wiring separated, CAUTION you prevent transient signals from reaching the control unit. The Series 2000 control unit can operate using between 85 to 250 volts AC, 47 to 63 Hertz.
  • Page 50 EMC grounding, shielding, and noise protection You must use twisted-pair cable in rigid metal conduit or use twisted pair cable with an overall braided shield. All cable shields or conduits connect- ing to the control unit must be chassis grounded. Under no circumstances should you leave cable shields disconnected at one end or both ends of the cable (sensor or control unit or other CAUTION...
  • Page 51 Transient and RFI interference This section describes transient and RFI interference precautions: • Although there are transient and noise protectors on all control unit I/ O connections (communications, current outputs, sensor, etc ...), this protection is intended to act as a last line of defense against unwanted transient and RFI interference.

  • Page 52: Sensor Connections

    Sensor connections This section describes required wiring connections between the control unit and the sensor. Follow the connection instructions for the applicable options for your analyzer. All sensor connections require that you access the sensor board (see Figure 3-16). Sensor AC mains supply connections Connections for AC mains supply to the sensor are to the dry sensor board.

  • Page 53: Standard Sensor Connections

    Standard sensor connections All WDG sensors, regardless of the sensor type, requires that you make the following connections from the control unit to the sensor using twisted pair cable (see Table 3-3). CONTROL UNIT SENSOR TERMINAL LABEL NUMBER Cell + (one pair) Cell - Table 3-3.
  • Page 54 Remote sense setup wiring for combustibles If you do not have the combustibles option, skip this section. NOTE If the distance between the controller and the sensor is over 40 feet, and you are using the combustibles option, you must use the remote sense setup.
  • Page 55 Not actual order of sensor connections Methane Combustibles Option Option SENSOR CARD 15 16 13 14 Overall Braided Shield or Rigid metal conduit SERIES 2000 WIRING CARD Figure 3-16. Sensor connections with all sensor options. Installation 3-31...
  • Page 56 Current output connections Standard current outputs Current output connections are labeled as follows on the wiring card of the Series 2000 control unit (see Figure 3-17): IOUT1+ IOUT1- IOUT2+ IOUT2- These current outputs are referenced as current outputs 1 and 2 in soft- ware (see the Analog Range Key section for help on defining current out- put settings in software).
  • Page 57 OUTPUT DEVICE (COMPUTER OR CHART RECORDER) MAX LOAD RESISTANCE 1200 OHMS Figure 3-17. Current output connections example. These combustibles current outputs are cable of driving up to 1200 ohm loads. Current outputs 3 and 4 are isolated from the control unit as are isolated from current outputs 1 and 2, but not from each other.
  • Page 58 Alarm contact connections This section describes how to make wiring connections for any alarm de- vices you wish to connect to the control unit. Information on how to set up alarms in software is described in the Alarms Key section. Alarm connections The Series 2000 control unit provides six sets of standard alarm contacts, which are labeled as follows (see Figure 3-18):...
  • Page 59 Power Supply Max. 30v Transient protector Computer dry for inductive contact input loads Load Max. 30VA Figure 3-18. Series 2000 alarm connections example. Installation 3-35...
  • Page 60 Combustibles detector alarm connections If you have the combustibles option, two sets of alarm relay contact are available to activate for high combustibles levels, and are labeled as follows (see Figure 3-18). ALARM 5A ALARM 6A ALARM 5B ALARM 6B Loss of Pressurization - Alarm Contact If pressure drops below 0.15”...
  • Page 61 Remote Calibration Unit Connections If you don’t have the remote calibration unit (RCU) option, skip this sec- tion. Oxygen-Only remote calibration unit connections Remote Calibration Unit (RCU) connections on the Series 2000 control unit wiring card, and their RCU connections, are as follows (see Figure 3-21): ZERO - 13 on RCU SPAN1 -15 on RCU VALVE COMMON - 16 on RCU...

  • Page 62: Rs-485 Communications Connections

    Combustibles remote calibration unit connections If you have the combustibles option (and a combustibles RCU) you must also make the following connection (see Figure 3-21.) SPAN2 - 17 on RCU Digital input to initiate Remote Calibration Unit The digital input connections on the wiring card allow you to initiate a remote calibration from a location other than the control unit (see Figure 3-21).
  • Page 63 Figure 3-22. Series 2000, 2-wire RS-485 communication connection. 2-Wire termination resistor The Series 2000 control unit is equipped with a termination resistor that can be used for the last control unit on the network. 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) Installation...
  • Page 64 4-Wire connections The connections used for the RS-485 4-wire communications on the wiring card are labeled as follows: 4WTX+/2W+ 4WTX-/2W- 4WRX+ 4WRX- Connect all control unit 4WTX+, 4WTX-, and all 4WRX+ and 4WRX- con- nections in parallel in a daisy chain fashion. Make the following connec- tions between the host computer and the controller in a daisy chain fash- ion (see Figure 3-23): Host Computer TX- to Controller 4WRX-...
  • Page 65 SW1-1=ON SW1-2=ON SW1-3=ON USE 2 TERMINATION RESISTORS AT HOST SERIES 2000 (EACH 120 ohms) (LAST OR ONLY) SW1-1=OFF SW1-1=OFF SW1-2=ON SW1-2=ON SW1-3=OFF SW1-3=OFF SERIES SERIES HOST 2000 2000 Figure 3-23. Series 2000, 4-wire RS-485 communication connections. Installation 3-41...

  • Page 66: Option Card Installation

    Option Card Installation This section shows you how to add option cards to the control unit. This includes the following option cards: Auto Calibration Card - requires remote calibration unit • This section also shows you how to access the display module and power supply/keypad module on the control unit in case you need to replace these modules or change a component in them (for example, install new software).
  • Page 67 Figure 3-24. Front view of Series 2000 Control Unit. Adding an option card Do the following to add an option card to the Series 2000 control unit: 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).
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  • Page 69: Controller / User Interface

    CONTROLLER / USER INTERFACE This chapter provides a brief overview on how to use the Series 2000 control unit. This includes the following topics: 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 70 Control Unit Display The main control unit display allows you to view different types of information. You define which information to place on the first three lines of the display using the Display option from the Setup key. Note that you can also use the Display menu option to place your own text messages on one of the first three lines.
  • Page 71 Control Unit Keys This section provides an introduction to the main Series 2000 control unit keys. Each of these keys provides you a menu of choices you can select. Setup key - Allows you to set the control unit for your specific appli- cation.
  • Page 72 Exiting Menu Options To cancel out of a specific menu, press the Cancel key. To cancel out of all menus, continue to press the Cancel key until all menus disappear from the display and only process readings remain. Pressing the Cancel key does not delete any settings you have set while in that menu.

  • Page 73: Setup Key

    Setup Key Setup Key Display Passwords Process Pressure System Serial # Primary Calib System Tests Sensor COnfig Communication Combustibles Figure 4-2. Setup Key menu options. The Setup key allows you to do the following: Define what information to place on each display line (Display). Define a system password that limits control unit access to autho- rized personnel (Passwords).
  • Page 74 Perform a primary calibration on the sensor (primary calibration). This is not a typical calibration. A primary calibration is intended to extend the life of your sensor. Do not perform this type of calibration unless specifically instructed to do so. Select the type of sensor you are using (Sensor Configuration).
  • Page 75 Display This menu option allows you to define what information should appear on the top three display lines of your Series 2000 control unit. Choices for each line are as follows: Percent oxygen (% O Cell temperature Cell millivolts Thermocouple millivolts (T/C millivolts) Current date/time User text Turn off (leave display line blank)
  • Page 76 User text can be up to 20 characters long. NOTE In addition, the following keys can be used to help you move quickly to a specific location in the ASCII text table: Pressing the number 1 key scrolls you to the capital letter A. Pressing the number 3 key scrolls you to the capital letter Z.
  • Page 77 You can also use this menu option to disable the password require- ment. If you have forgotten the correct password, you can call AMETEK/ Thermox and a service password will be provided so that you can NOTE access the Password option and enter a new system password.
  • Page 78 Process Pressure This menu option allows you to define your process pressure. It also allows you to define 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 Select Process Pressure from the Setup key menu.
  • Page 79 System Tests This menu allows you to check the Series 2000 control unit for possible problems and to isolate the problem. You may be asked by AMETEK/ Thermox personnel to access this menu option to perform system diag- nostics. Performing these tests is not required under normal operations.
  • Page 80 System Serial # This menu option allows you to view your system serial # and manufac- turing #. You may be asked by AMETEK/Thermox personnel to provide this information upon request. Setting up the serial number Select System Serial # from the Setup menu.
  • Page 81 Primary Calibration The actual furnace temperature set point will vary from unit-to-unit based upon the Primary Calibration which correlates the actual cell response for the desired 695°C cell set point temperature with the actual furnace thermocouple feed back temperature. This is accomplished by applying two known concentrations of oxygen to the analyzer during the primary calibration.
  • Page 82 mary calibration and then attempt a standard calibration again. If you get an excess cal error during primary calibration, then the furnace temperature set point cannot be increased any further to prevent dam- age to the cell housing and/or furnace assembly. Failure limits for standard calibration - +/- 10 mVs of the anticipated mVs for the gas concentration applied (air 0 mV expected).
  • Page 83 If you find that a regular calibration isn’t working correctly, first check that your calibration gas values match the values written on the gas cylinders; also be sure that the correct flow of gases has been set and that the gases are allotted enough time to flow through the sensor.
  • Page 84 Sensor Config. Use this menu to select the sensor you will be using with the Series 2000. When selecting a sensor, use the table below to see the temperature each type of sensor uses. If your type of sensor is not listed, find the operating temperature for your sensor, then choose the sensor below that uses that operating temperature.
  • Page 85 Communication This menu option allows you to define RS-485 communications param- eters between the Series 2000 control unit and a host device. This in- cludes the following: Baud Rate Allows you to define the baud rate that the control unit and the host computer are using to communicate.

  • Page 86: Analog Range Key

    Analog Range Key Analog Range Key Set Current Range Set Track/Hold Figure 4-5. Analog Range Key Set Current menu. Mode Output Filtering Select Function The Series 2000 control unit allows you to direct process readings to either of the two analog output ports on the rear of the control unit. If you have the combustibles option, you can also have process readings directed to the two extra analog output ports that are activated if you have the combustibles option.
  • Page 87 Define what type of information the analog output should track (Select Function). Choices are % O , cell temperature, cell millivolts, and thermocouple millivolts. If you have the combustibles option, you can also track combustibles. Once you select what type of process readings the analog output should track using the Select Function menu option, decide what range of these readings the analog output range will cover (Set Current Range).
  • Page 88 System Password System passwords are created using the Setup key. Please see the “Setup Key” section for information on defining or disabling a system password. NOTE If a system password is enabled, you will be required to correctly enter this password before accessing Analog Range key functions. When you select the Analog Range key, you will be prompted to enter your system password: Enter password...
  • Page 89 Set Current Range This menu option allows you to define the range of readings that the 0- to-20 or 4-to-20 mA (milliamp) output will represent. You can also choose to set a reverse analog output range, so, for example, 0 mA can corre- spond to the high end of the oxygen range, and 20 mA can correspond to the low end of the oxygen range.
  • Page 90 Set Track/Hold Option This menu option allows you to decide what signals to send to the selected analog output port during a calibration or verification. You have the option to either hold the last process reading or track calibration readings. Separate decisions can be made for verify and calibrate opera- tions, so you can hold the last process readings during verifications, but track calibration gas readings during calibrations.
  • Page 91 Out # 1 will HOLD during Verify Set Current Mode The Set Current Mode menu option allows you to define either a 0-to-20 or 4-to-20 mA analog output range for the selected analog output port. This output is dependent on both the range of readings you define (see the “Set Current Range”...
  • Page 92 Type a number between 1 and 100, then press the Enter key. Note that you should enter 01 to enter 1, 07 to enter 7, 70 for 70, etc. The default value is 100 (no filtering). NOTE Select Function The Select Function menu option allows you to select what type of information the analog output port should track.

  • Page 93: Alarm Key

    Alarm Key Alarm Key Alarm Set Points Alarm Configure Figure 4-7. Alarm Key menu. Relay Configure Select Function Exception Log Alarms 1 and 2 are hard wired for the watchdog timer and service alarms and are therefore not software-selectable. NOTE Oxygen and combustibles alarms are all disabled during a primary or regular calibration.
  • Page 94 Define for each oxygen alarm (Alarms 3 and 4) whether the alarm should be a high or low alarm (Alarm Configure). If you have the combustibles option, the combustibles alarms (Alarms 5 and 6) always act as high alarms, and can’t be configured as low alarms. Define whether alarm relays should energize or de-energize on alarm (Relay Configure).
  • Page 95 Function * Select Function Alarm Configure Relay Configure - % O - High O alarm - Cal Start - Low O alarm Alarm 3 - Verify Start - Cal/Verify Start (Only selectable if Select - Energize on alarm Function is % O Alarm 4 Not selectable - High O...
  • Page 96 For example, if the first display line is showing % O values, and a high alarm occurs, an up arrow will appear to the right of the O value. If, for example, you set alarm 3 for a high O alarm and alarm 4 for a high/high O alarm, and the O value exceeds both the high and high/high alarm set...
  • Page 97 Enter the Alarm 5 set point value. Note that combustibles alarms are always high alarms (can’t be set up as a low alarm). You are then prompted to enter the alarm 6 set point value: Alarm #6=xx yy New Value? where xx is the current value and yy is either PPM combustibles or % combustibles, depending on the combustibles scale you are using (see the “Combustibles”...
  • Page 98 Relay Configure All Series 2000 control unit relays are Form A, normally open contacts. You can, however, use the software to set whether your alarms should close on an alarm condition (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).
  • Page 99 Alarm3= Cal/Verify, depending on whether alarm 3 should be associated with % oxygen levels, or with the start of a calibration or verification, or with the start of a calibration or verification (dual function). The control unit automatically exits you from this menu after you make your selection.
  • Page 100 In addition, the control unit reads the watchdog after reset, and beeps for a brief time if the reset was caused by a watchdog condition. Pressing the reset keys simultaneously (hidden keys to the left and right of the Setup key) for a long enough time will in turn cause a watchdog, which will indicate as a beep after the system restarts upon release of the reset keys.

  • Page 101: Calibration

    CALIBRATION Calibrate Key Initiate Cal Initiate Verify Cal/Verify Data Cal Gas Value Inject Cal Gas Set Cal Timers Sensitivity Set K Factor Figure 5-1. Calibrate Key menu options. The Calibrate key allows you to use the Series 2000 control unit to calibrate your analyzer.

  • Page 102: Definitions

    Definitions Calibrations vs. Verifications The Series 2000 control unit software refers to both calibrations and verifications. During a verify operation, the calibration gas readings are taken, and the difference between what the system records for the gas values and their known values is recorded. Internal calibration param- eters are not changed.

  • 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 a RCU, and you switch the gases.

  • Page 104: Overview

    Overview The Calibrate key allows you to do the following (see Figure 5-2 for a summary): Initiate an automatic, remote, or manual calibration or verification. • Although automatic calibrations can be set to run at predetermined frequencies, you can also force the system into an automatic calibra- tion (Initiate Cal and Initiate Verify).
  • Page 105 Calibrate Key Menu Options Functions/Options Initiate Cal/Initiate Verify Start an automatic, remote, or manual calibration or verify. Cal/Verify Data View latest calibration and verify data. - Cal data - Verify data Cal Gas Values Enter calibration gas values. Inject Cal Gas Set pressure and flow of RCU gases without performing a calibration.

  • Page 106: Aborting A Calibration

    Aborting a Calibration If you press the Calibrate key while the system is performing a calibration or verification, you will be provided with the option to abort the calibra- tion or continue the calibration. All other menu functions are temporarily disabled during a calibration or verification.

  • Page 107: Initiate Cal And Initiate Verify

    Initiate Cal and Initiate Verify The Initiate Cal menu option allows you to perform an automatic, remote, or manual calibration. The Initiate Verify menu option allows you to perform an automatic, remote, or manual verification. Because these menu options function almost identically, we discuss them to- gether.

  • Page 108: Auto Calibrate/Auto Verify

    Auto Calibrate/Auto Verify Before you can start an auto calibration or verification, you must do the following: Create auto cal timers to tell the system when to perform the auto- • matic calibrations. Note that by doing this you don’t have to select the Calibrate key later to run the calibration, it does it automatically for you at the frequencies you defined.
  • Page 109 Then the following message will appear on your display: Zero Gas xx:xx System Calibrating During this time, the RCU has switched the solenoid valves and has introduced the zero gas to the sensor. If you have the combustibles option, the following message appears on your display: Comb Span Gas xx:xx System Calibrating...

  • Page 110: 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 calibra- tion gas cylinders you intend to use to calibrate/verify your system (see the “Cal Gas Values” section later in this chapter for help on how to do this).
  • Page 111 You are then prompted to calibrate the zero gases: O2 xx.x % Set xx.x % Cmb yyyy Set 0 Press ENTER to Zero Press the Enter key once the zero gas reading(s) on the left of the display has stabilized. If you don’t have the combustibles option, you only need to wait until the O zero gas value stabilizes.

  • Page 112: Manual Calibrate/Manual Verify

    Manual Calibrate/Manual Verify To perform a manual calibration or verification, follow these steps: Enter the calibration gas values to match the span and zero calibra- tion gases you intend to use to calibrate or verify your system (see the “Cal Gas Values” section later in this chapter for help on how to do this).
  • Page 113 You are then prompted to apply the O zero gas to the calibration inlet port of the sensor: Inject Zero Gas ENTER to Continue CANCEL to Abort Press the Enter key once you have applied this cal gas. The zero gas display then appears (display line 2 will only appear if you have the combustibles option): O2 xx.x % Set xx.x % Cmb yyyy Set 0...
  • Page 114 Press the Enter key once the combustibles span gas reading(s) stabi- lize on the far left of the display. Then, if you specified a recovery time, the system will display the recov- ery time remaining: Recovery xx:xx System Calibrating The system then returns to monitoring process readings. Be sure to reinsert the 1/4"...

  • Page 115: Cal/Verify Data

    Cal/Verify Data This menu option allows you to view the results of the latest calibration or verification. This includes the following: span calibration gas value vs. O span calibration gas reading • Zero calibration gas value vs. zero calibration gas reading •...
  • Page 116 The following then appears on the display: Zero Value: xx % O2 Zero Gas: xx % O2 Zero Drift: xx %O2 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.

  • Page 117: Cal Gas Value

    Cal Gas Value This menu option allows you to enter span and zero calibration gas values to match the calibration gas cylinders you use to calibrate or verify your system. These values will be used for all automatic, remote, or manual calibrations and verifications. span gas - high calibration gas •...
  • Page 118 If you have the combustibles option, you are then prompted to enter the combustibles span gas value: Comb Span = xxxx YY New Value? Enter the combustibles span gas value, then press the Enter key. If you want to keep the current combustibles span gas value un- changed, press the Enter key without entering a value.

  • Page 119: Inject Cal Gas

    Inject Cal Gas This menu option allows you to manually adjust the pressure and flow of your calibration gases (pressure of calibration gas cylinders and flow into sensor) by cycling through the solenoid valves on the RCU. No calibration or verification data is collected while in this menu option. See the “Mechanical Installation”...
  • Page 120 ENTER for next Gas. CANCEL to quit. When you have adjusted the pressure and flow for the zero gas to the desired levels, press the Enter key. The following message will then appear on your display, indicating that the RCU has introduced the combustibles span gas to the sensor: Comb gas is flowing Once you have set the pressure and flow for the span gas, the system prompts you to press the Cancel key to end the cycle:...

  • Page 121: Set Cal Timers

    Set Cal Timers Set Auto Timers Set Time & Date Auto Cal On/Off Cal Gas Duration Recovery Figure 5-2. Duration Set Cal Timers menu options. Set Cal Timers The Set Cal Timers submenu from the Calibrate key allows you to do the following: Set auto timer for desired auto calibration/verification cycle times (Set •...
  • Page 122 Set Cal Timers - Set Auto Timers This menu option allows you to set the frequencies for automatic calibra- tions 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.
  • Page 123 Enter the time you want the first calibration or verification to begin, then press the Enter key. The system uses military time, so to enter 4:00 p.m., you would type 16:00. If, for example, you set the cycle frequency at 8 hours, and specify the first calibration to take place at 4:00 p.m., the next automatic calibration or verification will take place at midnight.
  • Page 124 Set Cal Timers - Auto Cal On/Off This menu option allows you to disable or re-enable the auto calibration or auto-verification cycle. If you know your process will be down for an extended period of time, you may want to temporarily disable the auto- matic calibration or verification cycle.
  • Page 125 You will be prompted to enter the new span gas duration time: O2 Span Time = xx:yy Enter new time: Mn:Sc Enter the new span gas duration time, then press the Enter key. Mn equals minutes and Sc = seconds. As you type the new span gas duration time, it overwrites the Mn:Sc text.
  • Page 126 Set Cal Timers - Recovery Duration This menu option allows you to define a recovery time so the control unit can return to reading process gases after reading calibration gases without affecting the analog outputs or the triggering of alarms. If, for example, your process gas is 6%, and your last calibration gas is 2%, this option gives the system time to recover back to reading the 6% process gas.
  • Page 127 Set K-Factors This menu option allows you to enter K-Factor (Correction Factor) to match the indications obtained from the combustible sensor with gas flowing through the cal port to those obtained when the same gas flows through the inlet probe. Note that care must be taken when applying gas to the inlet port to assure that is does not change the flow from that generated by the aspirator.
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  • Page 129: Maintenance & Troubleshooting

    MAINTENANCE AND TROUBLESHOOTING Use only OEM replacement parts to ensure proper ATEX certifica- tion for your analyzer. NOTE The operations in this chapter should be performed only by qualified service personnel experienced in electrical safety techniques. WARNING 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 130: System Messages

    System Messages Auto Cal Pending This message indicates that an automatic calibration is pending. Once the current calibration or verification is completed, the automatic calibration will begin. This message will only appear if the Auto Calibration option is installed and enabled. Auto Verify Pending This message indicates that an automatic verification is pending.
  • Page 131 Primary Calibration This message appears when the system is performing a primary Calibra- tion (see the Setup key for further information on primary calibration). The message continues to be displayed during the recovery period after the primary calibration. System Calibrating This message indicates that a system calibration is in progress.

  • Page 132: Error Messages

    Error Messages Error messages on the control unit display indicate problems with the op- eration 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 pin- point the problem area.
  • Page 133 Memory is Corrupted This error message indicates that the control unit’s internal EEPROM memory has been corrupted, or a significantly new version of software has been installed in the control unit. Under these conditions, the software will reprogram the EEPROM with the factory default values. You can ac- knowledge this error message by setting or reading any user program- mable value, and this will clear the message from the display.
  • Page 134 Temp Rise Failure This error message indicates that the sensor has failed to increase in tem- perature a minimum of 10 °C in a 60-second time frame during start-up. Once the system reaches the operating set point, this message will only occur if the sensor falls below the set point by 15 °C and fails to recover within 60 seconds.
  • Page 135 Zero Gas Range Error This error message occurs if the calibration zero gas does not read within the software’s allowable limits. Once this error occurs, calibration of the system is aborted. This error indicates one of the following problems: Calibration gas setup problem Process pressure incorrectly entered.

  • Page 136: 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 you see. In addition, if you don’t see an error message, yet feel your readings are inaccurate, you may also want to check the “General Troubleshooting”...
  • Page 137 Thermocouple Checks Open thermocouple Remove power to the control unit and the sensor. Measure across termi- nals “C” and “D” on the sensor board with an ohm meter. If an open is measured, replace the thermocouple. Shorted/Failed thermocouple Check that the thermocouple leads are not shorted to chassis ground. To do this, use an ohm meter to measure between terminal C on the sensor board and chassis ground, and between terminal D on the sensor board and chassis ground.
  • Page 138 the control unit power supply/keypad module. If this fuse is not OK, re- place 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. If you do measure 15 volts at terminals 2 (-) and 12 (+) of the sensor board, measure across terminals D (+) and 6 (-) on the sensor board.
  • Page 139 Calibration Setup Checks Calibration gas check Check that the correct calibration gas values have been entered into the control unit. To do this, select the Cal Gas Value menu option from the Calibrate key on the control unit and check that the cali- bration gas values entered match the analyzed concentration of the cylinders.
  • Page 140 Remote calibration unit (RCU) problem The RCU contains one normally open solenoid-the aspirator air solenoid. All other solenoids are normally closed. Problems with the RCU are usually as follows: Plumbing leaks Solenoids not energizing Plumbing Leak To check for plumbing leaks, disconnect power from the RCU and pres- surize the inlets.
  • Page 141 Calibration gas time inadequate If you are having problems running an auto calibration, you may not have allowed the calibration gases enough time to flow through the sensor and stabilize. To correct this problem, select the Inject Cal Gas option from the Calibrate key menu.
  • Page 142 AC Power Checks Loss/Inadequate AC voltage to the sensor Measure the AC voltage to the sensor board at terminals L1 and L2. Ensure that this voltage is sufficient. Check the measurement technique used by the volt meter (for example, RMS, average, peak, etc.). Specifications are based on RMS measurements.
  • Page 143 Process Pressure Checks To check that you entered the process pressure correctly, select the Process Pressure menu option from the Setup key. Also ensure that the calibration process pressure equals normal operating process pressure. Calibration should only be performed under these conditions for highest accuracy. Cell Checks If the cell fails when you first begin to use the analyzer, it is likely that there is a leak in the sensor plumbing or an improper calibration gas setup, and...

  • Page 144: 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 Leaks can lead to inaccurate readings, especially if operating under a sig- nificant pressure or vacuum.
  • Page 145 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 146 Sensor Board (80471SE) LEDs Two diagnostic LED indicators are on the sensor board. DS1 is located near the relay on the board and DS2 is located near the end of the numbered terminal strip. STATUS FUNCTION INDICATOR Oxygen cell furnace over-temperature shutdown circuit status GREEN Furnace is operating normally...

  • Page 147: Service & Parts

    SERVICE AND PARTS The operations in this appendix should be performed only by qualified service personnel with a knowledge of electrical safety WARNING 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 one hour.
  • Page 148 Warnings The outside of the sensor cover and all sensor assembly components • are extremely hot (up to 500°F, 260°C inside the cover), even after a considerable period from shutdown. Turn off the power to the sensor and control unit when working inside the sensor. Use caution and wear appropriate gloves when handling components! Be extremely careful when performing maintenance on the sensor while •...
  • Page 149 Figure 7-1. Wiring diagram for standard sensor. Service and Parts | 7-3...
  • Page 150 Cell Replacement/Cleaning To replace or clean the cell, do the following (see Figure 7-2): Disconnect power from the sensor and control unit and allow the sensor to cool before replacing parts inside the sensor. CAUTION Remove the sensor cover to expose sensor components. Remove the cell clips.
  • Page 151 Figure 7-2. Cell replacement. Service and Parts | 7-5...
  • Page 152 Furnace 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 To replace the thermocouple, do the following (see Figure 7-3): Remove the sensor cover to expose sensor components.
  • Page 153 Figure 7-3. Furnace thermocouple replacement. Service and Parts | 7-7...
  • Page 154 Box Temperature RTD Replacement Remove power from the sensor and allow it to cool before replacing parts inside the sensor. CAUTION To replace the box temperature thermocouple, do the following (see Figure 7-4): Remove the sensor cover to expose sensor components. Disconnect RTD wires from terminals C and D on the sensor board.
  • Page 155 #8-32 RTD and Screw Loop Clamp #10-32 Screw #8-32 Nut Bracket Splitlock Washer Manifold Block Finned Heater Block Figure 7-4. Box temperature RTD replacement. Service and Parts | 7-9...

  • Page 156: Furnace Replacement

    Furnace Replacement Disconnect power from the sensor and control unit and allow unit to cool before replacing parts inside the sensor. CAUTION To replace the furnace, do the following (see Figure 7-5): Disconnect cell clips. Remove the thermocouple from the furnace (see the “Thermocouple Replacement”...
  • Page 157 Figure 7-5. Furnace replacement. Service and Parts | 7-11...
  • Page 158 Hot-Wire Combustibles Detector Replacement Always use a backup wrench when working on sensor plumbing. NOTE To replace a hot-wire style combustibles detector, do the following (see Figure 7-6): Remove the detector leads from terminals E, F, H and I from the sensor card inside the terminal box.

  • Page 159: Combustibles Detector Replacement

    Figure 7-6. Combustibles detector replacement (Hot-Wire). Service and Parts | 7-13...
  • Page 160 Box Heater Diagram Figure 7-6 shows how to wire box heaters using the sensor board. Box Heater 120 Volt Configuration 120VAC Box Heater Box Heater Sensor Board Box Heater 230 Volt Configuration 230VAC Box Heater Box Heater Sensor Board Figure 7-7. Box heater diagram.
  • Page 161 RCU Solenoid Valve Replacement Figure 7-8 shows the locations of the various solenoid valves. To replace any solenoid valve, do the following: Disconnect wiring at the appropriate terminal block locations. Remove old solenoid valve by turning the knurled ring at the base of the solenoid counter-clockwise.

  • Page 162: Replacement Parts List

    Display 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 Phone: (412) 828-9040 Fax: (412) 826-0399 7-16 | Thermox Series 2000 WDG-HPII / HPIIC - ATEX...

  • Page 163: Appendix A Serial Communications

    SERIAL COMMUNICATIONS Serial communications for the Series 2000 (ver 3.3 and later) and the IQ based software applies to IQ sensor based products only applies to Series 2000 based products only Communication Protocols Communication with all analyzers through the RS-485 connection uses the following word format: •...
  • Page 164 The Start Character is the greater than character (“>”, which is ASCII 3E hex). The Node Address is from 00-FF, and is represented as two hex ASCII characters. Each sensor has a unique node address. Note, however, that the maximum number of sensors that can be connected on the network is 32 and for the gateway, we have limited the valid addresses from 01-32.
  • Page 165 General Serial Communication Commands Normally, we will use these general serial communications 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.
  • Page 166 Development Serial Communication Commands These commands are used during initial serial communication design. Echo (A) The echo command is used to test the serial protocol and line integrity. Any text sent to the analyzer is echoed back to the host. Bad Command (B) Just returns a bad command (error code 01) reply.
  • Page 167 Due to the nature of EEPROM memory, each location in the memory has a limited number of writes allowed (approximately 10,000). The location char- acter can be used to determine where the data is stored internally to the analyzer and act accordingly. This command is only available via the Series 2000 software NOTE Command List...
  • Page 168 Responses An analyzer returns a variety of responses that can be broken into two categories, success and failure. Success All successful responses start with an A. If there is data returned, it will follow the A and have a checksum after it. All responses end with a car- riage return.
  • Page 169 Failure All failure responses start with an N followed by a two hex digit failure code and a carriage return. Failure Failure Code End Character (2 hex ASCII characters) <CR> Failure Codes are as follows: Failure Code Description Bad command letter Bad checksum Input overrun in serial communication Parameter out of range...
  • Page 170 Variable Table The following pages provide a summary of the variable locations, name, and descriptions available. Location (Hex/Decimal) Variable Name Description Access Various flags (1=true, 0=false) 00/00 Flags3 Read only bit 0 – sensor is at operating temperature. bit 1 – Over/under Flag for tuning temperature bit 2 –...
  • Page 171 Location (Hex/Decimal) Variable Name Description Access 01/01 Inf_mess_flag System and error message flags Read only (1=true, 0 = false) bit 0 – No Exception , Future use bit 1 – Future use bit 2 – Future use bit 3 – Future use bit 4 –...
  • Page 172 Location (Hex/Decimal) Variable Name Description Access 02/02 Config_flags System configuration flags (1=true, 0=false) bit 0 – relays energize on alarm. not, they deenergize. Bit 1 – auto calibration time is set, an auto calibration will happen at the set time if the auto calibration is enabled bit 2 –...
  • Page 173 Location (Hex/Decimal) Variable Name Description Access System configuration flags (1=true, Config_flags 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 –...
  • Page 174 Location (Hex/Decimal) Variable Name Description Access Analog outputs flags (1=true, 0=false) 03/03 Iout_flags bit 0 – analog output 1 tracks during calibration 0 is hold analog output 1 during calibration bit 1 – analog output 1 tracks during verify 0 is hold analog output during verify. bit 2 –...
  • Page 175 Location (Hex/Decimal) Variable Name Description Access Analog outputs flags (1=true, 0=false) Iout_flags 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.
  • Page 176 Location (Hex/Decimal) Variable Name Description Access 04/04 Probe_type 0 – Insitu 1 – Cem/02 2 – WDG 3 – HP 4 – EI 20 5 – SA/F A – Insitu B – CEM/O2 C – WDG D – HP E – TM F –...
  • Page 177 Location (Hex/Decimal) Variable Name Description Access What is displayed on line 1 of the 05/05 Line1_flg display 0 – blank line 2 – oxygen 4 – cell temperature 6 – cell mv 8 – thermocouple mv 10 – box temp 12 –...
  • Page 178 Location (Hex/Decimal) Variable Name Description Access 08/08 Oxygen The oxygen reading in percent Read only 09/09 Cmbcomb The combustibles reading Read only 0A/10 Mthcomb The methane reading Read only 0B/11 Cell_temp The current cell temperature in Read only degrees C 0C/12 Cell_mv The cell millivolts...
  • Page 179 Location (Hex/Decimal) Variable Name Description Access 10/16 Out3_flg What analog output 3 corresponds to 0 – oxygen 1 – cell temperature 2 – thermocouple mv 3 – cell mv 4 –box temp 5 – combustibles 6 – methane 10 – combustibles 12 –...
  • Page 180 Location (Hex/Decimal) Variable Name Description Access 12/18 I1_span Analog output 1, 20 ma value 13/19 I1_zero Analog output 1, 0 or 4 ma value 14/20 I2_span Analog output 2, 20 ma value 15/21 I2_zero Analog output 2 , 0 or 4 ma value 16/22 I3_span Analog output 3 , 20 ma value...
  • Page 181 Location (Hex/Decimal) Variable Name Description Access 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...
  • Page 182 Location (Hex/Decimal) Variable Name Description Access 37/55 Ver_zero Oxygen zero gas read during last Read only verify 38/56 O2_zero Zero gas millivolts read during last Read only calibration 39/57 Cal_cgas3 Combustibles span gas setpoint during Read only last calibration 3A/58 Cmbspan Combustibles span value during last Read only...
  • Page 183 Location (Hex/Decimal) Variable Name Description Access 45/69 Cal_h10 Auto calibration hour value 46/70 Cal_h1 Auto calibration hour value 47/71 Cal_m10 Auto calibration minute value 48/72 Cal_m1 Auto calibration minute value 49/73 Ver_h10 Auto verify time hour value 4A/74 Ver_h1 Auto verify time hour value 4B/75 Ver_m10 Auto verify time minute value...
  • Page 184 Location (Hex/Decimal) Variable Name Description Access 5D/93 Alr1_flg What process alarm is associated with 0 – oxygen oxygen, combustibles, or methane 1 – calibration 2 – verify 3 – in cal/verify Configuration for oxygen alarms, high 5E/94 Alm_config or low. If a bit is 1, that is the condition that the indicated alarm will trip on.
  • Page 185 Location (Hex/Decimal) Variable Name Description Access 5F/95 Gas_ctr Which gas is currently flowing to the Read only sensor 0 – span gas flowing 1 – zero gas flowing 2 – combustible span gas 3 – methane span gas (if 3 span value RCU installed) Normal operation 4 –...
  • Page 186 Location (Hex/Decimal) Variable Name Description Access Which oxygen alarm has been set and 61/97 Alarm_flags Read only 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 187 Location (Hex/Decimal) Variable Name Description Access 62/98 Cal_variable The calculated percent value that 0 mv Read only would correspond to with the cell that is currently being used. This value can vary between different cells. is calculated during calibration and used in the oxygen calculations.
  • Page 188 Location (Hex/Decimal) Variable Name Description Access 6E/110 Dig_Input Status of digital inputs(1=closed/on, Read only 0=open/off) bit 0 – CAL 0 bit 0 – Dig In bit 1 – CAL 1 6F/111 System test that was preformed 70/112 SysTst_Flag 1-Calibrate A/D 2-Ram Test 4-Test EEPROM 7-Erase Ram...
  • Page 189 Location (Hex/Decimal) Variable Name Description Access 80/128 Excep_1 Exception number 1 see Exception Chart Read only 81/129 Excep_2 Exception number 2 see Exception Chart Read only 82/130 Excep_3 Exception number 3 see Exception Chart Read only 83/131 Excep_4 Exception number 4 see Exception Chart Read only 84/132 Excep_5...
  • Page 190 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 191 Sample Program This section provides a sample Quick Basic program that reads and writes to the serial port DECLARE FUNCTION Checksum$ (M$) ‘Serial test routine’ Continuously sends a message and prints the string returned ‘Open the communications port OPEN “COM2: 9600,N,8,1 “ FOR RANDOM AS #1 ‘String to be sent T$ = “08”...
  • Page 192 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 check- ing the Calflag variable (Calflag=3). Send the Calibrate command to the IQ analyzer (G00). If an acknowledge is returned (A<cr>), the calibration command is accepted.

  • Page 193: Appendix B Menu Option Charts

    MENU OPTION CHARTS SETUP KEY FUNCTION/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 positive or negative process Process Pressure pressure. Enter process pressure value.
  • Page 194 CALIBRATE KEY MENU OPTIONS FUNCTION/OPTIONS Initiate Cal/Initiate Verify Start an automatic, remote, or manual calibration. Cal/Verify Data View latest calibration and verify data. Cal Gas Values Enter calibration gas values Set pressure and flow of RCU gases without Inject Cal Gas performing a calibration.
  • Page 195 Alarm Key Menu Menu Options Alarm Set Points Alarm 3 Value Alarm 4 Value Alarm 5 Value Alarm 6 Value Alarm Configure High O (for alarms 3 and 4) Low O Relay Configure Energize on Alarm De-energize on Alarm Select Function % Oxygen (for alarm 3) Start of Calibration...
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  • Page 197: Appendix C Current Outputs: Other Applications

    CURRENT OUTPUTS: OTHER APPLICATIONS This appendix describes how to do the following: Modulate 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 198 To determine the minimum external voltage supply required to power the current outputs, use the following formula: VEXTmin = .02 amps (RLoad + Rwires) + 4 volts where: VEXTmin = the minimum external voltage required to power current output circuit RLoad = the load resistance of the current output device Rwires = the resistance of the wires Skip this section if you don’t measure combustibles.
  • Page 199 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 con- nected in the same manner as shown in this figure.
  • Page 200 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-HPII / HPIIC - ATEX...

  • Page 201: Appendix D Drawings And Custom Instructions

    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 order any custom options, the standard Interconnect Drawing is pro- vided. If you did order any special options, the drawings or special instructions provided here supercede any drawing or options provided elsewhere in this manual.
  • Page 202 This page intentionally left blank. D-2 | Thermox Series 2000 WDG-HPII / HPIIC - ATEX...

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