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Ametek Thermox CG1000 User Manual

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Thermox
CG1000 Oxygen Analyzer
®
User Manual
Thermox
150 Freeport Road
PN 90291VE, Rev. S
Pittsburgh, PA 15238

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Summary of Contents for Ametek Thermox CG1000

  • Page 1 Thermox CG1000 Oxygen Analyzer ® User Manual Thermox 150 Freeport Road PN 90291VE, Rev. S Pittsburgh, PA 15238...

  • Page 2: Offices

    If the instrument or procedures are used for purposes over and above the capabilities specified herein, confir- mation of their validity and suitability should be obtained; otherwise, AMETEK does not guarantee results and assumes no obligation or liability. This publication is not a license to operate under, or a recommendation to infringe upon, any process patents.

  • Page 3: Table Of Contents

    Contents OFFICES ........................ii General Safety Summary ................... vii CHAPTER 1 Overview Basic Elements of the Sensor ................1-1 The Oxygen Measuring Cell ................1-2 Hydrocarbons ....................1-3 Proper Sensor Operations ................1-4 Technical Support ....................1-5 CHAPTER 2 Specifications CHAPTER 3 Installation Inspect Shipping Contents ................
  • Page 4 System Messages ....................6-2 Error Messages ....................6-3 Diagnostic Checks ....................6-5 General Troubleshooting .................. 6-8 CHAPTER 7 Parts Replacement Cell Replacement ....................7-2 Removing the Cell ..................7-2 Installing the New Cell ................7-4 iv | Thermox CG1000 Oxygen Analyzer...
  • Page 5 Furnace Replacement ..................7-6 Removing the Old Furnace................ 7-6 Installing the New Furnace ............... 7-7 Replacing the Pump ..................7-9 Replacing the Transformer ................7-11 Replacing the Backplane Board ..............7-12 Replacing Display/Keypad Modules ............. 7-14 APPENDIX A Serial Communications Communication Protocol ..................A-1 General Serial Communication Commands ..........A-3 Development Serial Communication Commands........A-4...
  • Page 6 Grounding Instrument grounding is mandatory. Performance specifications and safety pro- tection are void if instrument is operated from an improperly grounded power source. Verify ground continuity of all equipment before applying power. vi | Thermox CG1000 Oxygen Analyzer...
  • Page 7 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

    Use Proper Power Source: Do not operate this products from a power source that applies more than the voltage specified. • Do Not Operate With Suspected Failures: If you suspect there is damage to this products, have it inspected by qualified service personnel. viii | Thermox CG1000 Oxygen Analyzer...
  • Page 9 Listed Inspection and Measuring Electrical Equipment Low Voltage Directive 73/23/EEC: EN61010-1:1993, Amendment A2: 1995 Electrical Equipment for Measurement, Controls, and Laboratory Use Manufacturer’s Address in Europe: AMETEK Precision Instruments Europe GmbH Rudolf-Diesel-Strasse 16 D-40670 Meerbusch, Germany Mark Coppler Compliance Engineer...
  • Page 10 Process photometric analyzers, process moisture analyzers, and sampling systems are warranted to perform the intended measurement, only in the event that the customer has supplied, and AMETEK has accepted, valid sample stream composition data, process conditions, and electrical area classification prior to order acknowledgment. The photometric light sources are warranted for ninety (90) days from date of shipment.

  • Page 11: Chapter 1 Overview

    OVERVIEW Follow these safety precautions when working on the sensor: Disconnect AC power from the analyzer before performing any main- tenance or troubleshooting. The furnace and furnace insulation cover are hot during normal oper- ation (up to 500°F/260°C inside the furnace insulation cover). Allow analyzer components to cool for at least an hour before working inside the analyzer.

  • Page 12: The Oxygen Measuring Cell

    The oxygen content is then determined from the Nernst equation: where R and F are constants, T is absolute temperature, and O and O are the oxygen partial pressures on either side of the cell. Figure 1-1. Zirconium oxide cell principle of operation. 1-2 | Thermox CG1000 Oxygen Analyzer...

  • Page 13: Hydrocarbons

    For measuring oxygen in non-combustibles gases, the calibration of an analyzer is obtained from the formula: AT = 48.0 at 695°C 20.9% E = A * T * Log Unk% AT = 54.4 at 824°C Where A is a constant, T is the cell temperature on an absolute scale (°C + 273) and O Unk% is the unknown oxygen concentration of the gas to be analyzed, and which is calculated by the analyzer.

  • Page 14: Proper Sensor Operations

    - severe thermal shock can be destructive to either of them. • Calibrate the flow sensor using nitrogen as your carrier gas. • Do not pressurize the external flow meter when calibrating the inter- nal flow sensor. • Wait one hour between performing a thermal and regular calibration. • Allow calibration gases to stabilize before proceeding to the next step of a calibration. • Do not overtighten compression fittings when servicing the analyzer. 1-4 | Thermox CG1000 Oxygen Analyzer...

  • Page 15: 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, you should run test gases...
  • Page 16 This page intentionally left blank. 1-6 | Thermox CG1000 Oxygen Analyzer...

  • Page 17: Chapter 2 Specifications

    SPECIFICATIONS Control Unit 4 line x 20 character vacuum fluorescent. Displays combinations of oxy- gen (0.1 ppm O to 100%, autoranging), time and date, cell temperature, Display user programmable, text, thermocouple mV, cell mV, flow, and pressure. Password protection and context-sensitive help are also provided. Two isolated linear current outputs.
  • Page 18 Use calibration gases @ 150 sccm (limit is 50 to 200 sccm) Zero Gas: From 0.1 to 10% O , balance N Span Gas: One decade above zero gas (10 times greater) recommended. System Compliance EMC Compliance: 2004/108/EC Safety Compliance: 73/23/EEC 2-2 | Thermox CG1000 Oxygen Analyzer...

  • Page 19: Chapter 3 Installation

    INSTALLATION This chapter shows you how to install your CG1000 oxygen analyzer. It includes the following: Inspect Shipping Contents  Mechanical Installation  Wiring  No operator serviceable components are inside the CG1000. Never open the analyzer cover. Refer servicing to qualified personnel. Inspect Shipping Contents Remove any packing material from the CG1000 analyzer.

  • Page 20: Mechanical Installation

    Maximum sample temperature is 70°C (160°F). Combustibles in the sample can burn with available oxygen to pro-  vide lower-than-expected oxygen levels. be aware of this, especially if measuring oxygen in the low ppm ranges. NOTE 3-2 | Thermox CG1000 Oxygen Analyzer...

  • Page 21: Flow Connections

    Flow Connections If your carrier gas is helium, the sample gas must flow through the analyzer at a rate between 150 and 200 sccm (standard cubic centimeters per min- ute). For all other carrier gases (nitrogen, carbon dioxide or argon), the flow rate must be between 125 and 175 sccm.
  • Page 22 Use the same flow rate during both calibrations and normal opera- tions. any pressure variations of the sample gas can lead to flow varia- tions greater than 25 sccm can cause analyzer readings to fluctuate. 3-4 | Thermox CG1000 Oxygen Analyzer...

  • Page 23: Calibration Setup

    Calibration Setup Figure 3-1 shows the location of the inlet port on the CG1000. When cali- brating your system, connect your calibration gases upstream of this inlet port as shown in Figure 3-4. You might find it easier to insert a switching valve before the inlet ...
  • Page 24 (for example, if zero gas is 10 ppm, the span gas must be 100 ppm or higher). • Span gas - from 10 ppm to 1000 ppm. • Zero gas - from 1 ppm to 100 ppm. 3-6 | Thermox CG1000 Oxygen Analyzer...

  • Page 25: Ppm Measurement Suggestions

    PPM Measurement Suggestions This section provides help on how to use the CG1000 in the low ppm ranges: Gas Sample Bypass - A good practice in the measurement of ppm gas con- centrations (during calibration or initial start-up) is to provide a bypass on the gas sample inlet to the analyzer.

  • Page 26: Wiring

    If JP2 is in (factory default), the analyzer uses the internal supply to power the current output circuits. If you try to use an exter- nal voltage at this time, the system will use whichever voltage is higher 3-8 | Thermox CG1000 Oxygen Analyzer...

  • Page 27: Alarm Contact Connections

    -CG1000 voltage is normally about 28 volts. If the JP2 jumper is removed, the external voltage source must be used to power the current output circuits. The external voltage source must be no greater than 30 volts DC. 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:...

  • Page 28: Rs-485 Communications Connections

    2-Wire Switch Settings: SWITCH # ON/OFF SW1 – 1: N/A for 2-Wire Termination Resistor SW1 – 2: Sets type of RS485 communication SW1 – 3: Termination Resistor SW1 – 4: Not used 4-Wire Switch Settings: 3-10 | Thermox CG1000 Oxygen Analyzer...

  • Page 29: Termination Resistor

    SWITCH # ON/OFF SW1 – 1: Termination Resistor SW1 – 2: Sets type of RS485 communication SW1 – 3: Termination Resistor SW1 – 4: Not used Termination Resistor The CG1000 is equipped with a termination resistor that can be used for the last CG1000 on the network.

  • Page 30: Select 50/60 Hertz Operation For Pump

    AC line frequency. 60 Hz operation SW1 switch sets to 60 Hz position 50 Hz operation SW1 switch sets to 50 Hz position 3-12 | Thermox CG1000 Oxygen Analyzer...

  • Page 31: Chapter 4 Controller / User Interface

    CONTROLLER / USER INTERFACE This chapter shows you how to set up your system for operations and also provides an introduction on how to use the software and keypad keys. The following topics are included: System Start-up  Set-up Key ...

  • Page 32: Password Restrictions

    The CG1000 system also includes an auto ranging feature. If the oxygen reading falls below 0.5% O , the display switches to the ppm scale. Other- wise, the system always displays readings using the percent scale. 4-2 | Thermox CG1000 Oxygen Analyzer...

  • Page 33: Keypad Keys

    Keypad Keys Each of these keys includes a list of menu options you can select. Control Unit Key Function Setup Set the control unit for your specific application. Calibrate Set calibration parameters and start calibrations. Alarm Define parameters that control the alarm relays. Analog Range Define parameters that control analog current outputs.

  • Page 34: On-Line Help

    (or press Cancel or Enter). For example, to get on-line help on the Passwords option from the Setup Key, select the Setup Key, then move the arrow pointers to the Passwords option and press the Help Key. 4-4 | Thermox CG1000 Oxygen Analyzer...

  • Page 35: Setup Key

    Setup Key SETUP KEY Display Passwords System Tests System Serial # Primary Calib Communications Pump Carrier Gas Figure 4-1. Setup Key menu options. Setup Key Menu Function/Options Display Select info for Display Lines 1, 2 and 3 Passwords Create a system password System Tests Perform internal diagnostics View Serial Number and manufacturing num-...
  • Page 36 Left Arrow Key to move back one position in your text message. When you are finished entering your message, press Enter. Use these keys to quickly move to a location in the ASCII text table: Number Key Character 0 (zero) space 4-6 | Thermox CG1000 Oxygen Analyzer...
  • Page 37 Auto ranging feature for oxygen readings If you select to display oxygen on one of the display lines and the oxygen reading falls below 0.5% O , the display switches from the percent scale to the PPM scale. Controller / User Interface...

  • Page 38: System Password

    This menu option is also used to disable a password when it is no longer required. Setting Up a System Password If you have forgotten the password, you can call AMETEK/Thermox  and a service password will be provided so you can access this option and enter a new password.

  • Page 39: System Tests

    System Tests Check for possible problems and isolate them. Also used to perform system diagnostics for service personnel.  Performing these tests is not required under normal operations. NOTE Forces an A/D converter calibration. This is auto- Calibrate A/D matically done during system start-up. Checks the functionality of the control unit’s inter- Test RAM nal Random Access Memory (RAM).

  • Page 40: Primary Calibration

    Wait an additional 45 minutes, then perform a regular calibration During the recovery time immediately following the primary calibration, you may see temperature-related error messages. Ignore these messages. The cell temperature is adjusted after a primary calibration. 4-10 | Thermox CG1000 Oxygen Analyzer...

  • Page 41: Communication

    Communication Defines RS-485 communications parameters between the control unit and a host device. This includes the following: Define the baud rate that the control unit and the host com- Baud Rate puter are using to communicate. Choices are 300, 600, 1200, 2400, 4800, and 9600 baud. Define the physical address for the control unit (between 0 and 255) on a network so the host computer can iden- tify the control unit if using network communications (see Node Address...

  • Page 42: Cal Flow Sensor

    Step 5 above. Adjust mech flow rate Enter to continue Adjust the flow until it stabilizes at 150 sccm on the mechanical flow meter, then press the Enter key. 4-12 | Thermox CG1000 Oxygen Analyzer...
  • Page 43 The system will then calibrate the flow sensor: Calculating ratio At this time, you can remove the mechanical flow meter from the outlet port of the CG1000. After calibrating the flow sensor, the system will return you to the previous menu. Run a regular calibration.

  • Page 44: Analog Range Key

    Define the type of information the analog output should track. Select Function Cell Temperature Thermocouple Millivolts Cell Millivolts Table 4-2. Overview of Analog Range key functions. 4-14 | Thermox CG1000 Oxygen Analyzer...

  • Page 45: Analog Output Port

    Analog Output Port Before you can define any Analog Range Key functions, you must  choose whether it will apply to Analog Output Port 1 or 2 on the front of the control unit. Analog Output Port 1 is labeled I OUT 1; Analog NOTE Output Port 2 is labeled I OUT 2.

  • Page 46: Set Track/Hold Option

    Separate choices can be made for calibration and verify operations. For calibration operations, select one of the following: Hold during cal Track during cal Select one of these options, your choice will be confirmed on the display: 4-16 | Thermox CG1000 Oxygen Analyzer...

  • Page 47: Set Current Mode Option

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

  • Page 48: Output Filtering Option

    The Series 2000 control unit prompts you with the Set Current Range menu option where you can choose the range of readings that the 0 to 20 mA or 4 to 20 mA analog output represents (see the Set Current Range section in this chapter for details). 4-18 | Thermox CG1000 Oxygen Analyzer...

  • Page 49: Alarm Key

    Alarm Key ALARM KEY Alarm Set Points Alarm Configure Relay Configure Select Function Exception Log Figure 4-3. Alarm Key menu options. Alarms 1 and 2 are hard wired for the watchdog and service alarms  and are therefore not selectable in software. NOTE Alarm Key Menu Functions/Options...

  • Page 50: Overview Of Alarm Functions

    Once you select the Alarm Set Points menu option, the system alerts  you that Alarms 1 and 2 are reserved for the watchdog and service alarms, and are not software selectable. Press Enter to continue to the NOTE configurable alarms. 4-20 | Thermox CG1000 Oxygen Analyzer...

  • Page 51: Alarm Configure

    2. Select whether you want to enter the Alarm 3 set point using a percent or PPM value. This option won’t appear if Alarm 3 is not set to activate based on an O reading, but is set to activate on the start of a calibra- tion or verification.

  • Page 52: Relay Configure

    Select Alarm 3= O2/Flow, Alarm 3= In Cal, or Alarm 3= In Verify, depending on whether Alarm 3 should be associated with oxygen levels, flow rate, or with the start of a calibration or verification. The CG1000 automatically exits this menu after you make your selection. 4-22 | Thermox CG1000 Oxygen Analyzer...

  • Page 53: Service Alarm

    Service Alarm The service alarm operates as normally closed (service alarm condi-  tion causes open contacts). NOTE The service alarm provides an alarm that alerts you of possible system problems that require attention. Events that can trigger the service alarm are: • Error condition (detected by software) • System operational variance (such as an over-temperature or under- temperature condition) •...
  • Page 54 20 most recent entries in this exception log. Pressing the Down Arrow Key shows later exception log entries. Pressing the Up Arrow Key shows more recent exception log entries. Press Cancel at any time to exit this menu option. 4-24 | Thermox CG1000 Oxygen Analyzer...
  • Page 55 CALIBRATON CALIBRATE KEY Initiate Cal Initiate Verify Cal/Verify Data Cal Gas Value Configure Verify Set Clock Figure 5-1. Calibrate Key menu options. Oxygen alarms are disabled during calibrations, including the recov-  ery time after a calibration. For analog outputs, you can set whether they should follow the calibration readings or hold at the last process NOTE reading (see Chapter 4).

  • Page 56: Calibration

    Set Clock Set analyzer time/date. Define recovery duration after a cal/verify. Table 5-1. Overview of Calibrate Key functions. Aborting a Calibration You can cancel a calibration or verification at any time by pressing Cancel. 5-2 | Thermox CG1000 Oxygen Analyzer...

  • Page 57: Initiate Cal

    Initiate Cal Perform a calibration. If you replaced a cell, or your cell has failed a regular calibration  because of a deterioration, you will need to perform a primary calibra- tion rather than a regular calibration. See the Primary Calibration NOTE section in Setup Key Chapter 4 for help.
  • Page 58 Cal Gas Values menu option. The O zero gas setpoint value should match the cal gas cylinder for the O zero gas. 5-4 | Thermox CG1000 Oxygen Analyzer...
  • Page 59 If you have a pump on your system you will be prompted to adjust the flow rate so the system can calibrate the pressure sensor. Leave the calibration flow on. Adjust the flow rate to the same value as you did for the span and zero gases.

  • Page 60: Initiate Verify

    Configure Verify menu option. This setpoint value should match the cal gas cylinder for the verify gas. 5-6 | Thermox CG1000 Oxygen Analyzer...
  • Page 61 If your O reading on the far left of the display has stabilized, yet is  not near the setpoint value on the right of the display, you may want to check the verify gas value you entered and ensure that this value NOTE matches the cal gas cylinder for the verify gas you applied to the cali- bration inlet port on the back of the analyzer.

  • Page 62: Cal/Verify Data

    “span gas” is the setpoint value entered using the Cal Gas Values option from the Cali- brate key menu. Press Enter to then view the zero gas values. 5-8 | Thermox CG1000 Oxygen Analyzer...

  • Page 63: Verify Data

    Zero Value: xx Zero Gas: xx Zero Drift: xx 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 Cali- brate key menu.

  • Page 64: Cal Gas Value

    Enter the zero gas value: Zero Gas = xx New Value? Press Enter. If you want to keep the current zero gas value un- changed, press Enter without entering a value. 5-10 | Thermox CG1000 Oxygen Analyzer...

  • Page 65: Configure Verify

    Configure Verify Define the verify gas value and the acceptable range of readings for a verify. To set your verify gas value and acceptable verify range, follow these steps: From the Calibrate key menu, select Configure Verify. Select whether you want to use a % or ppm gas for the verify opera- tion.

  • Page 66: Set Clock

    From the Set Clock menu option, select Recovery Duration. Cal Recovery = xx:yy Enter new time: Mn:Sc Enter the recovery time, then press Enter. If you want to use the cur- rently displayed recovery time, press Enter without entering any text. 5-12 | Thermox CG1000 Oxygen Analyzer...
  • Page 67 MAINTENANCE AND TROUBLESHOOTING The operations in this chapter should be performed only by qualified service personnel with a knowledge of electrical safety techniques. There are no operator-serviceable components inside the CG1000 system. An operator should never remove the cover from the controller or sensor. Never service the controller or sensor unless power has been discon- nected from the controller and the sensor, and the sensor has been al- lowed to cool for at least one hour.

  • Page 68: System Messages

    The system is performing a Primary Calibration. The message con- Primary Calibration tinues to be displayed during the one-hour recovery period after the primary calibration. System Calibrating System calibration is in progress. System verification is in progress. System Verifying Cal 6-2 | Thermox CG1000 Oxygen Analyzer...

  • Page 69: Error Messages

    Error Messages Error messages on the analyzer display indicate problems with the opera- tion of the analyzer. Identify the type of problem indicated by the error message and go to “Diagnostic Checks” at the end of this chapter for help on how to pinpoint the problem.
  • Page 70 Zero Gas Range Error - Calibration gas setup problem - Incorrect flow rates between span and calibration gas - Failed cell (primary calibration should be run at this time) - Leak or plug in plumbing 6-4 | Thermox CG1000 Oxygen Analyzer...

  • Page 71: Diagnostic Checks

    Diagnostic Checks Display the thermocouple millivolts and cell millivolts during trou-  bleshooting as a troubleshooting aid. You may need this information if you need to contact the factory for assistance. Be sure to always NOTE include your analyzer model and serial number when calling the fac- tory for technical support.
  • Page 72 The best of your analyzer leading to lower- calibration gas to use for this check is O zero calibration gas. than-expected oxygen readings. 6-6 | Thermox CG1000 Oxygen Analyzer...
  • Page 73 Loss / Inadequate AC Voltage to the Sensor Measure the AC voltage to the backplane board at J4 Pins 1 and 4. Ensure that this voltage is sufficient. AC Power Checks Check the measurement technique used by the volt meter (for example, RMS, average, peak, etc.).

  • Page 74: General Troubleshooting

    Cell + and Cell - connections on the backplane board to see if the cell millivolts change, indicating a leak. Do not spray gas on the reference side of the cell. 6-8 | Thermox CG1000 Oxygen Analyzer...

  • Page 75: Chapter 7 Parts Replacement

    PARTS REPLACEMENT The operations in this chapter should be performed only by quali- fied service personnel. There are no operator-serviceable components inside the CG1000, and an operator should never open the cover of the analyzer. This appendix shows you how to replace system parts and is divided into the following sections: •...

  • Page 76: Cell Replacement

    Always use a backup wrench when working on sensor plumbing. Disconnect the L-shaped exhaust tubing that connects to the T-fitting of the inlet tube assembly by loosening the Swagelok nut. Always use a backup wrench when working on sensor plumbing. 7-2 | Thermox CG1000 Oxygen Analyzer...
  • Page 77 Figure 7-1. U-Tube. 10. Remove the elbow fitting from the end of the inlet tube assembly by loosening the Swagelok nut. Use a backup wrench. 11. Remove the inlet tube (Figure 7-2) from the furnace by turning the T- fitting on the inlet tube assembly counterclockwise until you can pull the assembly out of the furnace.

  • Page 78: Installing The New Cell

    The contact cell clip must stay near the open end of the cell and must not touch the white band of the cell. The O-ring must be posi- tioned on the white band. 7-4 | Thermox CG1000 Oxygen Analyzer...
  • Page 79 Insert the inlet tube into the analyzer and then push the Swagelok nut on the end of the T-fitting through the opening in the front of the analyzer chassis (beside the flow knob). This will provide room so that you can swing the cell past the analyzer chassis and insert it into the furnace (see Step 7 ).

  • Page 80: Furnace Replacement

    7. Loosen the captive screw on the furnace L-bracket until the furnace is loosened from the L-bracket. 8. Pull the furnace straight out and remove it from the analyzer. 7-6 | Thermox CG1000 Oxygen Analyzer...

  • Page 81: Installing The New Furnace

    Installing the New Furnace 1. Retrieve the new furnace and thermocouple assembly (PN 72691SE). If replacing just the thermocouple, also do the following (Figure 7-4): Figure 7-4. Thermocouple assembly. Retrieve an anti-seize and lubricating compound (for example, NEVER  SEEZ catalog number NSB-4 from Bostik Chemical Group). Apply the anti-seize compound to the inside diameter of the Swagelok body.
  • Page 82 Polarity not required when reconnecting these wires. Reconnect the cell assembly as described in the “Cell Replacement” section. Reattach the power plug to the analyzer. 10 Turn on the analyzer. 11 Recalibrate the analyzer. 7-8 | Thermox CG1000 Oxygen Analyzer...

  • Page 83: Replacing The Pump

    Replacing the Pump Removing the Old Pump Remove the analyzer top cover. Remove both tubes that connect to the pump. Push the gray ring on the pump fitting towards the pump so as to free the tubes. Remove the fitting from the top of the pump by turning the fitting counterclockwise.
  • Page 84 (longer length tubing) should go into the hole with the arrow pointing away from the hole. Place the top cover back on the analyzer. Reattach the power plug to the analyzer. 10. Turn on the analyzer. 11. Recalibrate the analyzer. 7-10 | Thermox CG1000 Oxygen Analyzer...

  • Page 85: Replacing The Transformer

    Replacing the Transformer Disconnect the power cord from the analyzer when servicing sys- tem components. High voltages are present inside the analyzer when power is applied. The furnace insulation cover and furnace are extremely hot, even after power has been removed from the analyzer. Use caution and wear ap- propriate gloves if removing the furnace insulation cover to access the furnace.

  • Page 86: Replacing The Backplane Board

    10. Slide the backplane board over to the right until the screws are disen- gaged, then remove the backplane board from the analyzer. 11. Retrieve the new backplane board (PN 80464SE). 12. Reverse the above steps to install the new backplane board. 13. Recalibrate the analyzer. 7-12 | Thermox CG1000 Oxygen Analyzer...
  • Page 87 Figure 7-5. CG1000 main components. Parts Replacement 7-13...

  • Page 88: Replacing Display/Keypad Modules

    If you are replacing the display module, when you receive the new module, you must also remove jumpers AI2, AI3, and AI4 before installing the display module. You can leave jumper AI5 in place. 7-14 | Thermox CG1000 Oxygen Analyzer...

  • Page 89: Appendix A Serial Communications

    SERIAL COMMUNICATIONS Communication Protocol Communication with all analyzers through the RS-485 connection uses the following word format:  8 data bits  1 stop bit  No Parity In addition, the baud rate is fixed at 9600bps. The communication protocol is a basic master/slave, command/response protocol.
  • Page 90 ?? (?? is equivalent to 2 ASCII 3FH hex charac- ters). This makes testing by the programmer easy, but it is strongly NOTE recommended that the integrity check be enabled in the final system. A-2 | Thermox CG1000 Oxygen Analyzer...

  • Page 91: General Serial Communication Commands

    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 92: Development Serial Communication Commands

    Due to the nature of EEPROM memory, each location in the memory has a limited number of writes allowed (approximately 10,000). The location character can be used to determine where the data is stored internally to the analyzer and act accordingly. A-4 | Thermox CG1000 Oxygen Analyzer...

  • Page 93: Command List

    Command List The following command letters are available: Letter Description Echo Bad Command Acknowledge Read Number Calibrate Write Number Data Format (Series 2000 software only) Read Date and Time Set Date and Time Responses An analyzer returns a variety of responses that can be broken into two categories, success and failure.
  • Page 94 Failure Codes are as follows: Failure Code Description Bad command letter Bad checksum Input overrun in serial communication Parameter out of range Error in receipt of a character Cannot calibrate/verify now Internal error Illegal access (read-only variable) A-6 | Thermox CG1000 Oxygen Analyzer...

  • Page 95: Variable Table

    Variable Table The following pages provides a summary of the variable locations, names, and descriptions available. Command Variable Name Format DATA FORMAT Letter Flags_3 0 – Sensor at op.temp 1 – Over/Under temp 2 – Inject Cal Gas Active 3 – Reserved 4 –...
  • Page 96 2 – 0 = 4 – 20 ma 1 = 0 – 20 ma 1 – 0 = holds during verify 1 = tracks during verify 0 – 0 = holds during cal 1 = tracks during cal A-8 | Thermox CG1000 Oxygen Analyzer...
  • Page 97 Command Variable Name Format DATA FORMAT Letter Probe_type Display Line 0 – Blank line 2 – Oxygen 4 – Cell Temperature 6 – Cell Millivolts 8 – T/C Millivolts 10 – Current Time & Date 12 – User Text 14 – Flow Display Line Same as Command letter 05 Display Line...
  • Page 98 Alarm 3 SP FLOAT In % (See command 1E for ppm) Alarm 4 SP FLOAT In % (See command 1F for ppm) Flow FLOAT Hi_flow_set FLOAT Flow High Alarm SP Lo_flow_set FLOAT Flow Low Alarm SP A-10 | Thermox CG1000 Oxygen Analyzer...

  • Page 99: Appendix B Menu Option Charts

    MENU OPTION CHARTS Setup Key Menu Setup Key Menu Menu Options Cell Millivolts Flow Date/Time Display Thermocouple Millivolts Cell Temperature User Text Pressure Turn Off Password Enter password System Tests Various Serial # System Serial # Manufacturing # Primary Calibrate Perform a primary calibration regular Sensor Configure...

  • Page 100: Calibrate Key Menu

    (for Alarms 3 and 4) Low Flow Energize on alarm Relay Configure De-Energize on alarm Select Function Start of Calibration (applies to Alarm 3 only) Start of Verify Exception Log Table B-3. Alarm Key menu. B-2 | Thermox CG1000 Oxygen Analyzer...

  • Page 101: Analog Range Key Menu

    Analog Range Key Menu Analog Range Key Menu Menu Options 20 mA Set Current Range 0 or 4 mA Hold output at last process reading during calibration Set Track/Hold Track calibration readings during calibration 4 to 20 mA Set Current Mode 0 to 20 mA Enter output filter value Output Filtering...
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