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Ametek Thermox WDG Insitu User Manual

With series 2000 control unit
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WDG Insitu
with Series 2000 Control Unit
User Manual
Thermox
150 Freeport Road
PN 90271VE, Rev. U
Pittsburgh, PA 15238

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  • Page 1 WDG Insitu with Series 2000 Control Unit User Manual Thermox 150 Freeport Road PN 90271VE, Rev. U Pittsburgh, PA 15238...

  • Page 2: Offices

    © 2012 AMETEK This manual is a guide for the use of the Thermox WDG Insitu. Data herein has been verified and validated and is believed adequate for the intended use of this instrument. If the instrument or procedures are used for purposes over and above the capabilities specified herein, confirmation of their validity and suitability should be obtained;...

  • Page 3: Table Of Contents

    Contents OFFICES ......................... ii Safety Notes ......................v Electrical Safety ......................v Grounding ......................v Environmental Information (WEEE) ...............vii OVERVIEW Sensor ........................1 Basic Elements of the Sensor ................ 3 The Oxygen Measuring Cell ................. 3 Common Operator Errors ................... 5 Start-Up Checklist ....................6 Technical Support ....................
  • Page 4 CONTROLLER / USER INTERFACE Areas of the Control Unit ..................1 Control Unit Display ..................1 Selecting Menu Options ................2 Exiting Menu Options ................... 2 Automatic Menu Exit Feature ............... 3 On-Line Help ....................3 System Password .................... 3 Setup Key ........................
  • Page 5 Cal Gas Value ....................... 12 Inject Cal Gas ....................... 13 Set Cal Timers ...................... 14 Set Cal Timers - Set Auto Timers ..............14 Set Cal Timers - Set Time and Date ............15 Set Cal Timers - Auto Cal On/Off ............... 16 Set Cal Timers - Cal Gas Duration .............
  • Page 6 Serial Communications Communication Protocols ................1 Command Message Format ................2 General Serial Communication Commands ..........3 Development Serial Communication Commands ........4 Responses......................6 Variable Table ......................7 Sample Program ....................24 Starting/Monitoring a Calibration: An Example ..........25 Menu Option Charts Current Outputs: Other Applications Powering Current Outputs from an External Power Supply ......

  • Page 7: Safety Notes

    Safety Notes WARNINGS, CAUTIONS, and NOTES contained in this manual emphasize criti- cal instructions as follows: An operating procedure which, if not strictly observed, may result in personal injury or environmental contamination. An operating procedure which, if not strictly observed, may result in damage to the equipment.
  • Page 8 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. If you decide to service this equipment be aware that high voltages, high temperatures, and other potentially hazardous conditions may arise.

  • Page 9: 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 sub- stances into the environment and to conserve our natural resources, AMETEK recommends that you arrange to recycle this product when it reached its “end of...
  • Page 10 WDG Insitu probes with the suffix Div. 2, Series 2000 Controller and O2 -Only RCU, O2 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 11 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 perma-...
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  • Page 13: Overview

    OVERVIEW Sensor The WDG Insitu is a direct-insertion-type oxygen probe where the zirco- nium oxide cell is directly placed in the stream of the products of combus- tion. This patented insitu is designed for applications where the flue gas temperature does not exceed 1250 °F (675 °C), and where combustibles measurements are not required.
  • Page 14 Cell Heater / Thermocouple Cell Housing Metal O-ring Ceramic Rings Negative Lead w/Cell Clip (blue insulation on ange end) Positive Lead w/Cell Clip (white insulation on ange end) Center HTR/TC in Center of Spider Inner Tube Set Screw Spider 1/16” Socket Head Flange Heater ALIGNMENT SPIDER DETAIL...

  • Page 15: Basic Elements Of The Sensor

    Sensor Basic Elements of the Sensor The WDG-IV series analyzer consists of the following basic systems: The Plumbing  All inlet and outlet tubing (cell housing), the oxygen cell, the oxygen cell fitting, and the combustibles flow block and detector (for combus- tibles).
  • Page 16 Figure 1-1. Zirconium oxide cell principle of operation. Since the voltage of the cell is temperature dependent, the cell is main- tained at a constant temperature. Some newer high temperature insitu models use the heat from the process to heat the sensor, and the process temperature is continuously measured and used in the software calcula- tion.

  • Page 17: Common Operator Errors

    The cell produces zero voltage when the same amount of oxygen is on both sides, and the voltage increases as the oxygen concentration of the sample decreases. The voltage created by the difference in the sample gas and the reference air is carried by a cable to the microprocessor control unit, where it is linearized to an output signal.

  • Page 18: Start-Up Checklist

    Start-Up Checklist Review the Installation chapter (Chapter 3).  Install the sensor on the process  If the sensor is on a pipe nipple, insulate the pipe from the process wall to the mounting flange of the sensor. Install the control unit. ...

  • Page 19: Technical Support

    Technical Support AMETEK/Thermox is committed to providing the best technical support in the industry. If you need service or application assistance, please call AMETEK at (412) 828-9040, or your local AMETEK/Thermox representa- tive. Before you call the factory for technical support, run test gases and record...
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  • Page 21: Specifications

    SpecificationS Series 2000 control Unit Four-line x 20-character vacuum fluorescent. Displays combinations of oxy- gen, ppm combustibles, methane, time and date, cell temperature, user-pro- Display grammable text, thermocouple mV or cell mV. Password protection, program- mable pressure compensation and context-sensitive help are also provided. Two isolated linear current outputs.
  • Page 22 Sensor Direct sensing insitu probe suitable for applications where the flue gas Principle of temperature does not exceed 1250°F (677°C) and where combustibles Operation measurement is not required. Zirconium oxide for net oxygen mea- surement. Output Range From 0-1% to 0-100% Accuracy ±...

  • Page 23: Remote Calibration Unit (Rcu)

    Remote calibration Unit (RcU) o2 only RcU enclosure UL Type 4X (NEMA 4X ) environment Ambient Temperature: -18°C to 60°C (-0.4 to 140°F) Humidity: 0 to 90%, non-condensing Max Altitude: 2000 Meters IEC Installation Category II IEC Pollution Degree 2 System compliance EMC Compliance: 2004/108/EC Safety Compliance: 73/23/EEC...
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  • Page 25: Installation

    InstallatIon The operations in this chapter should be performed only by quali-  fied service personnel experienced in electrical safety techniques. There are no operator-serviceable components inside the WDG NOTE 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 26: Installing The Filter/Flame Arrestor (Optional)

    Installing the Filter/Flame arrestor (optional) If you didn’t order a filter or flame arrestor, skip this section. If you ordered just the flame arrestor option with no filter, the flame arrestor comes assembled onto the end of the probe and no steps are required to install it. If you ordered the filter with a flame arrestor, the flame arrestor comes installed inside the filter.

  • Page 27: Sensor Mounting

    sensor Mounting The ambient temperature in the junction box should be lower than 160°F (70°C). If you purchased the Division 2 option, the maximum ambient temperature range is 140°F (60°C). If the ambient temperature is greater than this, consult the fac- tory.
  • Page 28 Figure 3-2. Insitu senor mounting. 3-4 | Thermox Series 2000 WDG Insitu Analyzer...
  • Page 29 Figure 3-3. Division 2 option mounting. WDG INSITU FLUE GAS ANALYZER Figure 3-4. Division 2 option connections. Installation and Start-Up | 3-5...
  • Page 30 Figure 3-5. WDG Insitu cal gas inlet. Figure 3-6. RCU mounting dimensions with Z-Purge. 3-6 | Thermox Series 2000 WDG Insitu Analyzer...

  • Page 31: Gas Requirements And Connections

    Gas Requirements and Connections Use calibration gases at 10 PSIG. Use 3 SCFH for shorter probes and 6 SCFH for six- and nine-foot probes. Span Gas Instrument air (20.9%) or from 1.0% to 100% O , balance N Zero Gas From 0.1 to 10% O , balance N (2% is recommended).
  • Page 32 Figure 3-7. RCU calibration connections with Z-Purge. Figure 3-8. RCU flow diagram. 3-8 | Thermox Series 2000 WDG Insitu Analyzer...

  • Page 33: Control Unit Mounting

    Control Unit Mounting The Series 2000 Control Unit comes with various mounting options. • The weatherproof enclosure can be mounted to either a panel, a wall, or to a pole. • The general purpose enclosure can be mounted as a panel, a rack, or a wall mount.
  • Page 34 Weatherproof Wall/Z-Purge option Figure 3-11 shows the wall and pole mounting dimensions for the Series 2000 weatherproof Z-purge enclosure. To mount this control unit version, you must also connect instrument air to the Purge Inlet and set the pressure and flow as indicated on the warning tag on the control unit.
  • Page 35 9.10 12.6 23.11 32.0 General Purpose - Panel 5.22 6.57 13.26 5.00 Figure 3-12 shows the panel mounting 16.69 12.70 dimensions for the Series 2000 general purpose enclosure. This version can be mounted in panels up to 1” thick. 10.00 10-32 25.40 3.8 cm (1.5 in.)

  • Page 36: Wiring

    Wiring Remove AC mains power from the controller before performing wiring. Connections to the control unit are made through the wiring card (see Figure 3-15). 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 37: General Wiring And Conduit Requirements

    This wiring section shows you how to make the following connections: • AC mains supply wiring to control unit • AC mains supply wiring to sensor • Control unit to sensor • Control unit to remote calibration unit • Control unit to alarm devices •...

  • Page 38: Control Unit Mains Supply Connections

    • For AC mains supply wiring, use between 12 and 14 American Wire Gauge (AWG) or equivalent metric between 3.3 mm and 2.1 mm . For all signal wiring, use 18 to 22 AWG (0.82 mm to 0.33 mm ). For sensor connections, Figure 3-16 shows the recommended sensor cable types for various WDG- style sensors.
  • Page 39 or NEUTRAL connection for any function, safety or otherwise. The (N) terminal is not internally grounded, nor needs to be. The system will operate normally re- gardless of what AC input terminal (L or N) the AC Line or Neutral is connected to, or, if there is a Neutral used at all (i.e., 208 VAC US power connection).
  • Page 40 SHIELD RING METHOD Shield Terminal Ring Quick Disconnet (1/4”) Cable Shield(s) Conduit Housing Max. Length 1 inch Capacitor Conduit Nut GROUND STUD METHOD Cable Shield(s) Conduit Housing Max. Length 2 inches Capacitor Conduit Nut Washer Ring Terminal Figure 3-17. Direct shield grounding methods 3-16 | Thermox Series 2000 WDG Insitu Analyzer...
  • Page 41 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 con- nections (communications, current outputs, sensor, etc.), this protection is intended to act as a last line of defense against unwanted transient and RFI interference.

  • Page 42: Sensor Connections

    sensor Connections Make sure that power has been removed from the control unit and sensor before making sensor connections. See Figure 3-18, Sensor Board. This section describes required wiring connections between the control unit and the sensor. Follow the connection instructions for the applicable options for your analyzer.
  • Page 43 sensor aC mains supply connections Connections for AC mains supply to the sensor are labeled as follows: L - Line Connection N - Neutral (USA) Chassis Stud -Equipment Ground (Protective conductor) There is no power switch on the sensor, and it must be protected by installing it on a circuit protected line, maximum 15 amperes, with a switch or circuit breaker in close proximity to the sensor and within easy reach of an operator.
  • Page 44 Figure 3-19. sensor connections. 3-20 | Thermox Series 2000 WDG Insitu Analyzer...

  • Page 45: Current Output Connections

    Current output Connections standard current outputs Standard current output connections are labeled as follows on the wiring card of the Series 2000 control unit (see Figure 3-20): IOUT1 + and - IOUT2 + and - These current outputs are referenced as current outputs 1 and 2 in software. Be sure to observe polarity when connecting current output devices to these termi- nals.

  • Page 46: Alarm Contact Connections

    alarm Contact Connections Follow general EMC grounding and shielding requirements for all wiring as described in the “General Wiring Requirements” section of this chapter. This section describes how to make wiring connections for any alarm devices you want to connect to the control unit. Information on how to set up alarms in software is described in the Controller/User Interface chapter.
  • Page 47 ALARM 3A ALARM 4A ALARM 3B ALARM 4B Figure 3-21. series 2000 alarm connections example. Installation and Start-Up | 3-23...

  • Page 48: Remote Calibration Unit Connections

    Remote Calibration Unit Connections If you don’t have the remote calibration unit (RCU) option, skip this section. Remote Calibration Unit (RCU) wiring connections between the Series 2000 control unit wiring card and the RCU are as shown in Figure 3-22. ZERO 13 on RCU SPAN1...
  • Page 49 Digital input to initiate remote calibration unit The digital input connections on the wiring card allow you to initiate a remote calibration or verification from a location other than the control unit. For this option to work, you must have a remote calibration unit and an auto calibration card.

  • Page 50: Communications Connections

    Rs-485 Communications Connections The Series 2000 control unit has the ability to communicate with other computers that use the same protocol and have the same hardware interface. See the Serial Communication Appendix for information on the RS-485 serial communications protocol. 2-wire connections The connections used for RS-485 2-wire communications on the wiring card are labeled as follows:...
  • Page 51 Figure 3-23. series 2000 2-Wire Rs-485 communications connections. Installation and Start-Up | 3-27...
  • Page 52 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 connections between the host computer and the controller in a daisy-chain fashion (see Figure 3-24): Host Computer TX- to Controller 4WRX-...
  • Page 53 Figure 3-24. series 2000 4-wire Rs-485 communication connections. Installation and Start-Up | 3-29...

  • Page 54: 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: • Combustibles Card - requires combustibles detector in sensor • Auto Calibration Card - requires remote calibration unit If you ordered any of these options when you purchased your analyzer, these option cards will already be installed in the control unit.

  • Page 55: Adding An Option Card

    Open the access door below the display module (hinges down). Pull on the handle of the power supply/keypad module and remove this mod- ule from the control unit (it slides out). Note that the power supply/keypad module must be removed before you can remove the display module. Pull on the display module handle to then pull out the display module.

  • Page 56: Sensor Wiring Schematic

    sensor Wiring schematic Figure 3-26 provides and overall sensor wiring schematic for the WDG Insitu. Figure 3-26. sensor wiring schematic. 3-32 | Thermox Series 2000 WDG Insitu Analyzer...

  • Page 57: Controller / User Interface

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

  • Page 58: Selecting Menu Options

    Control Unit Keys Each of the Control Unit keys provides a menu of choices. Function Setup Set up the control unit for your specific application. Calibrate Set calibration parameters and start calibrations. Analog Range Define parameters that control analog current outputs. Alarm Define parameters that control the alarm relays.

  • Page 59: Automatic Menu Exit Feature

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

  • Page 60: Setup Key

    Setup Key Setup Key Display Password Process System Serial # Pressure Primary System Tests Calibrate Sensor Config Communication Figure 4-2. Setup Key menu options. SETUP KEY Functions/Options Menu Options Display Define what information to place on each display line. Passwords Create a system password to limit control unit access.

  • Page 61: Display

    Display Define what information should appear on the top three (3) display lines of the control unit. Choices include: Percent oxygen (% O  Cell temperature  Cell millivolts  Thermocouple millivolts (T/C millivolts)  Current date/time  User text ...

  • Page 62: Process Pressure

    Use the following keys to move directly to a specific location in the ASCII text table: Press this Key Move to this Location capital letter A. capital letter Z. small letter a. small letter z. space character. number zero character. Process Pressure Define your process pressure and whether your process is operating under a positive or negative pressure.

  • Page 63: System Tests

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

  • Page 64: Primary Calibration

    Primary Calibration Perform a primary calibration on the zirconium oxide oxygen sensor. You should perform a primary calibration on your system instead of a regular calibration (from the Calibrate key) only when: you replace the zirconium oxide oxygen cell or thermocouple ...
  • Page 65 Determining temperature f you take the displayed cell temperature and divide it by the T/C Ratio in memo- ry location 88, you will have the actual furnace set point control temperature. You can use a Type-K table to measure the voltage on terminals C and D on the sensor board, and add the appropriate amount of mVs for the board ambi- ent.
  • Page 66 Setting up a primary calibration Make sure you have properly entered calibration gas values using the Cal Gas Values option from the Calibrate key before starting your primary calibration. From the Setup key, select Primary Calib. If you have the auto calibration card option (and a remote calibra- tion unit), you will be prompted to select Auto Calibrate, Remote Calibrate, or Manual Calibrate.

  • Page 67: Sensor Config

    Sensor Config Select the sensor you will be using with the Series 2000 controller. When selecting a sensor, use Table 4-3 for the temperature each type of sensor uses. If your type of sensor is not listed, find the operating tem- perature for your sensor, then choose the sensor that uses that operating temperature.

  • Page 68: Communication

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

  • Page 69: Analog Range Key

    Analog Range Key ANALOG RANGE KEY Set Current Range Set Track/Hold Set Current Mode Output Filtering Select Function Figure 4-3. Analog Range Key menu. You can 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 two additional analog output ports activated with this option.

  • Page 70: Analog Output Port

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

  • Page 71: Set Current Range

    Set Current Range Define the range of readings that the 0-to-20 or 4-to-20 mA output will represent. You can also choose to set a reverse analog output range. For example, 0 mA can correspond to the high end of the oxygen range, and 20 mA can correspond to the low end of the oxygen range.

  • Page 72: Set Track/Hold Option

    Set Track/Hold Option Define the signals to send to the selected analog output port during a cali- bration 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 operations, so you can hold the last process readings during verifications, but track calibration gas readings during calibrations.

  • Page 73: Set Current Mode

    Set Current Mode 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 read- ings you define and on the function you track on the analog output. Setting the current mode Select an analog output port.

  • Page 74: Select Function

    Select Function Select what type of information the analog output port should track. Percent oxygen (% O  Cell temperature  Cell millivolts  Thermocouple millivolts (T/C millivolts)  Selecting the function Select an analog output port. From the Analog Range key, select Select Function. Select the function you want the analog output port to track.

  • Page 75: Alarm Key

    Alarm Key ALARM KEY Alarm Set Points Alarm Configure Relay Configure Select Function Exception Log Figure 4-4. Alarm Key menu. Alarms 1 and 2 are hard wired for the Watchdog Timer and Service  alarms and are not software-selectable. NOTE Oxygen alarms are all disabled during a primary or regular calibra- tion.

  • Page 76: Overview Of Alarm Functions

    Overview of Alarm Functions Define whether Alarm 3 activates based on oxygen levels, the start of a calibration, or the start of a verification (Select Function). Alarm 4 is set to activate based on levels of oxygen. Select Function Alarm Configure Relay Configure Alarm 3 High O...
  • Page 77 Defining alarm set point From the Alarm menu, select Alarm Set Points. Once you select the Alarm Set Points menu option, the system  alerts you that Alarms 1 and 2 are reserved for the watchdog and ser- vice alarms, and are not software selectable. Press Enter to continue NOTE to the configurable alarms.

  • Page 78: Alarm Configure

    Alarm Configure Define whether alarms should trigger based on a high alarm or a low alarm condition. Whether Alarm 3 is set high or low only applies if it is set to track  oxygen levels (% O ). If Alarm 3 is set to trigger at the start of a cali- bration or verification, this option does not apply.

  • Page 79: Select Function

    Select Function Select which function Alarm 3 should track. • % Oxygen • When the system starts a calibration • When the system starts a verification • When the system starts a calibration or a verification (dual function) When tracking the start of a calibration or verification, the alarm will de- activate once the calibration or verification has been completed, including any recovery time you have specified.

  • Page 80: Watchdog Relay

    Watchdog Relay During normal system operation, the Watchdog Relay operates as  normally closed (system failure causes open contacts). NOTE The Watchdog Alarm relay de-energizes when the system watchdog timer times out. The watchdog timer will time out and cause the control unit to reset itself to prevent the control unit from becoming “lost”...

  • Page 81: Calibration

    CALIBRATION Calibrate Initiate Cal Initiate Verify Cal/Verify Data Cal Gas Value Inject Cal Set Cal Timers Figure 5-1. Calibrate Key menu options. All oxygen alarms are disabled during calibrations or verifications  and the recovery time after a calibration or verification. You can set whether analog outputs should follow the calibration readings or hold NOTE at the last process reading before the calibration using the Analog...

  • Page 82: Definitions

    Definitions Calibrations vs. Verifications The Series 2000 control unit software refers to both calibrations and verifi- cations. 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 parameters are not changed.

  • Page 83: Types Of Calibrations

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

  • Page 84: Overview

    Overview CALIBRATE KEY Functions/Options Menu Options Start an automatic, remote, or manual cali- Initiate Cal/Initiate Verify bration or verify Although automatic calibrations can be set to run at predetermined frequencies, you can also force the system into an automatic calibration. View latest calibration and verify data.

  • Page 85: Initiate Cal And Initiate Verify

    Initiate Cal and Initiate Verify Perform an automatic, remote, or manual calibration or verification. These menu options function almost identically. See the introduction to this chapter for more information on the difference between a calibration and a verification. Automatic calibrations and verifications can also be set to run at prede- termined frequencies using the cycle times defined in the Set Cal Timers/ Set Auto Timers menu option.

  • Page 86: Remote Calibrate/Remote Verify

    Select the Auto Calibrate or Auto Verify option. The system will begin the automatic calibration, and will notify you how long the span gas will be applied to the sensor from the RCU: Span Gas xx:xx System Calibrating Then the following message will appear on your display: Zero Gas xx:xx System Calibrating During this time, the RCU switched the solenoid valves and introduced...
  • Page 87 When performing a primary calibration or the first calibration after a  primary calibration, the reading and the setpoint values often won’t match. Once the first regular calibration after a primary calibration is NOTE performed, the readings should match. You are then prompted to calibrate the zero gases: O2 xx.x % Set xx.x % Press ENTER to Zero Press Enter when the zero gas reading(s) on the left of the display stabi-...

  • Page 88: 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 calibration gases you intend to use to calibrate or verify your system. Select Initiate Cal or Initiate Verify from the Calibrate key menu, de- pending on whether you want to perform a calibration or verification.
  • Page 89 If you specified a recovery time, the system will display the recovery time remaining: Recovery xx:xx System Calibrating The system then returns to monitoring process readings. Be sure to reinsert the 1/4” tube cap on the calibration inlet port on ...

  • Page 90: Cal/Verify Data

    Cal/Verify Data 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 • Span calibration gas drift •...
  • Page 91 The term zero value on the display is the value the system read during the calibrate/verify operation, and the term zero gas is the setpoint value entered using the Cal Gas Values option from the Calibrate key menu. Press Enter. The time when the calibration or verification was completed will then ap- pear on the display: End time hr:mm...

  • Page 92: Cal Gas Value

    Cal Gas Value 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 93: Inject Cal Gas

    Inject Cal Gas Manually adjust the pressure and flow of your calibration gases (pressure of calibration gas cylinders and flow into sensor) by cycling through the sole- noid valves on the RCU. No calibration or verification data is collected while in this menu option.

  • Page 94: Set Cal Timers

    Set Cal Timers SET CAL TIMERS KEY Set Auto Timers Set Time & Date Aut Cal On/Off Cal Gas Duration Recovery Duration Figure 5-2. Set Cal Timers menu options. Sub-Menu Function Set Auto Timers Set auto timer for desired auto calibration/verification cycle times.

  • Page 95: Set Cal Timers - Set Time And Date

    From the Set Cal Timers menu, select Set Auto Timers. Select Auto Cal Cycle if defining an automatic calibration cycle. Select Auto Verify Cycle if defining an automatic verification cycle. Select Set Cycle in DAYS or Set Cycle in HOURS, depending on whether you want to set the frequency of calibrations or verifications in days or hours.

  • Page 96: Set Cal Timers - Auto Cal On/Off

    Set the date or time for the internal control unit clock. Make sure the current time and date are correct before setting any  auto cal/auto verify parameters. NOTE From the Set Cal Timers menu, select Set Time & Date. You are prompted to enter the new time: The time is: YY:YY Enter new time Hr:Mn...

  • Page 97: Set Cal Timers - Cal Gas Duration

    Auto Cal is ENABLED Auto Cal is DISABLED and will then exit this menu option. Set Cal Timers - Cal Gas Duration Define how long the RCU should apply the span and zero calibration gases to the sensor during an automatic calibration or verification. You can also set a calibration gas duration time to 0 if you don’t want to include it in your automatic calibration sequence.
  • Page 98 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. This menu option also can be used to prevent triggering of alarms if, for example, your low alarm is set to activate if readings fall below 3%, and your calibration gas is 2%.

  • Page 99: Maintenance And Troubleshooting

    MAINTENANCE AND TROUBLESHOOTING The operations in this chapter should be performed only by qualified service personnel experienced in electrical safety techniques. There are no operator-serviceable components inside the WDG Insitu- 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 100: System Messages

    System Messages Message Explanation Indicates that an automatic calibration is pending. Once the current calibration or verification is complete, the automatic calibration will Auto Cal Pending begin. This message will only appear if the Auto Calibration option is installed and enabled. Indicates that an automatic verification is pending.

  • Page 101: Error Messages

    Error Messages Error messages on the control unit display indicate problems with the operation of the analyzer. Use this section to see the types of problems your error message indicates, then go to the “Diagnostic Checks” section at the end of this chapter for help on how to perform diagnostic checks to pinpoint the problem area.
  • Page 102 Temp Rise Failure Indicates that the sensor has failed to increase in temperature 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 103: Diagnostics Checks

    Diagnostics Checks This section shows you how to check different sensor areas for possible problems. See the “Error Messages” section for help on what checks you should perform based on the error message displayed. If you don’t see an error message, yet feel your readings are inaccurate, you may also want to check the “General Troubleshooting”...

  • Page 104: Wiring Checks

    Wiring Checks Make sure all wiring connections between the control unit and the sensor are terminated to the proper locations and Interconnecting Wiring Problem are seated properly. This includes ensuring that sets of wires are not reversed, and that the cable is not damaged or melted.
  • Page 105 If you do measure 15 volts at Measure across terminals D (+) and 6 (-) on the sensor terminals 2 (-) and 12 (+) of the board. Twelve millivolts should be measured ( this signal sensor board: is a function of ambient temperature and may vary up to 2 millivolts at extreme ambient temperatures ).

  • Page 106: Calibration/Aspirator Setup Checks

    Calibration/Aspirator Setup Checks Calibration Gas Check Check that the correct calibration gas values have been en- tered into the control unit. To check calibration gas  Check that the calibration gas cylinders are turned on and are values: not empty. Select the Cal Gas Value Check for the proper flow rate and proper delivery pressure ...
  • Page 107 Calibration Gas Time If you are having problems running an auto calibration, you Inadequate may not have allowed the calibration gases enough time to flow through the sensor and stabilize. To correct this problem, select Inject Cal Gas from the Calibrate key menu. Turn on each calibration gas and determine how long it takes for each gas to stabilize on the control unit display.

  • Page 108: Ac Power Checks

    AC Power Checks Loss/Inadequate AC Voltage Measure the AC voltage to the sensor board at terminals L1 to the Sensor and L2. Ensure that this voltage is sufficient. Check the mea- surement technique used by the Volt meter (for example, RMS, average, peak, etc.).
  • Page 109 First check by running a known calibration gas to veri- If the analyzer has been operating fy the analyzer’s response. If the analyzer responds to for some time and you feel the oxy- the calibration gas correctly, it indicates either leaking gen reading is inaccurate: or plugged plumbing.

  • Page 110: General Troubleshooting

    General Troubleshooting Your system may pass calibrations, yet still seem to be reading incorrect oxygen levels. If this is the case, you may want to check the following: Leak Check This check does not apply to Insitu users. Leaks can lead to inaccurate readings, especially if operating under a sig- nificant pressure or vacuum.

  • Page 111: Plugged Plumbing Check

    If you see bubbles, it indicates a leak. If using this method be sure to prevent the liquid from reaching the furnace. If the furnace does get wet, allow it sufficient time to thoroughly dry. The WDG-IV style sensor has intentional leaks in the aspirator air ...

  • Page 112: Series 2000 Leds

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

  • Page 113: Sensor Board (80471Se) Leds

    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 num- bered terminal strip. STATUS FUNCTION INDICATOR Oxygen cell furnace over-temperature shutdown circuit status GREEN Furnace is operating normally Over temperature shut-down has been activated...
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  • Page 115: Service And Parts

    SERVICE AND PARTS The operations in this appendix should be performed only by quali- fied service personnel with a knowledge of electrical safety techniques. There are no operator-serviceable components inside the WDG sys- tem. Never service the controller or sensor unless power has been removed from the controller and sensor, and the sensor has been allowed to cool for one hour.

  • Page 116: Inner Probe Assembly Removal

    Inner Probe Assembly Removal Most of the parts replacement procedures in this chapter require that you first remove the inner probe assembly. Ensure that power is removed from both the sensor and the control unit and allow the sensor to cool for at least one hour. Remove the insitu probe cover by twisting it off.
  • Page 117 After removing the inner probe assembly, inspect the gasket for dam-  age. If it is damaged, replace the gasket. NOTE 8 - 32 Nut Flange Handle 8 - 32 Screw Chasis Ground Wire 10 - 32 Screw Sensor Board FRONT VIEW Protective Tube Inner Probe Assembly...

  • Page 118: Cell Replacement

    Cell Replacement Disconnect power from the sensor and control unit and allow the sen- sor to cool before replacing parts inside the sensor. Removing the Cell Remove the inner probe assembly. Mark the position of the U-bolt in relation to the heater by drawing a line on either side of the U-bolt on the top of the heater.
  • Page 119 Orient the probe in front of you so that the cell assembly end is on your right and the sheet metal plate is on your left. Rotate both the sheet metal plate (handle end of the probe) and the left hex nut coun- terclockwise at the same time until the left hex nut becomes unthread- ed from the inner probe assembly.
  • Page 120 Cell Heater / Thermocouple Cell Housing Metal O-ring Ceramic Rings Negative Lead w/Cell Clip (blue insulation on ange end) Positive Lead w/Cell Clip (white insulation on ange end) Center HTR/TC in Center of Spider Inner Tube Set Screw Spider 1/16” Socket Head Flange Heater ALIGNMENT SPIDER DETAIL...
  • Page 121 Replacing the Cell Thread the new cell assembly into the inner probe assembly until handtight. Use a magic marker to mark the left hex nut with the same orientation mark as the mark on the inner probe assembly. For example, if the mark on the inner probe assembly is positioned at 3 o’clock, place a mark at 3 o’clock on the left hex nut of the cell assem- bly.
  • Page 122 11. Locate the cell clip associated with the blue cell wire. Wiggle the wire back and forth to determine the correct wire. Snap the cell clip to the cell, placing it on the side of the white band opposite from where the white wire cell clip is positioned.
  • Page 123 Figure 7-5. Cell and retainer clip placement. (Inset) Retaining clip detail. 18. Slide the heater into the inner probe assembly until the marks you placed on the heater in Step 2 of the removal section align with the U-bolt. Tighten the U-bolt using a 3/8” nut driver. 19.

  • Page 124: Heater/Thermocouple Replacement

    Heater/Thermocouple Replacement Disconnect power from the sensor and control unit and allow the sen- sor to cool before replacing parts inside the sensor. Remove the inner probe assembly and the cell. Slide the heater and cell leads out of the inner probe assembly. Mark the location of the spiders on the heater assembly with a magic marker.

  • Page 125: Sensor Board Replacement

    Sensor Board Replacement To replace the sensor board, follow these instructions. Ensure that power has been removed from the control unit and sen- sor. Disconnect all wires from the sensor board. Remove the two screws holding the triacs to the case (upper right corner of the board).

  • Page 126: Rcu Solenoid Valve Replacement

    RCU Solenoid Valve Replacement Figure 7-7 shows the location of the zero and span solenoid valves on the -only remote calibration unit. O2 Span Port 2 Solenoid Valve Port 1 Aspirator Solenoid Valve Zero Solenoid Valve Figure 7-7. Solenoid valves on O -only RCU.

  • Page 127: Parts Replacement List

    80440SE Display 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 Service and Parts | 7-13...
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  • Page 129: Serial Communications

    SERIAL COMMUNICATIONS Serial communications for the Series 2000 (ver 3.3 and later) and the IQ based software IQ applies to IQ sensor based products only S2 applies to Series 2000 based products only Communication Protocols Communication with all analyzers through the RS-485 connection uses the following word format: • 8 data bits • 1 stop bit...

  • Page 130: Command Message Format

    Command Message Format The command message format is as follows: Where: 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 char- acters. 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 131: General Serial Communication Commands

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

  • Page 132: Development Serial Communication Commands

    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 133 This command is only available via the Series 2000 software  NOTE Command List The following command letters are available: Letter Description Echo Bad Command Acknowledge Read Number Calibrate Write Number Data Format (Series 2000 software only) Read Date and Time Set Date and Time Serial Communications...

  • Page 134: Responses

    Responses An analyzer returns a variety of responses that can be broken into two categories, success and failure. Success All successful responses start with . If there is data returned, it will fol- low the and have a checksum after it. All responses end with a carriage return (...

  • Page 135: Variable Table

    Variable Table The following pages provide a summary of the variable locations, name, and descriptions available. Location Variable Name Description (Hex/Decimal) Access 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 136 System configuration flags (1=true, 02/02 Config_flags 0=false) bit 0 – relays energize on alarm. If 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 137 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 – Future use bit 4 –...
  • Page 138 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 139 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. bit 2 –...
  • Page 140 What is displayed on line 1 of the display 05/05 Line1_flg 0 – blank line 2 – oxygen 4 – cell temperature 6 – cell mv 8 – thermocouple mv 10 – box temp 12 – combustibles 14 – methane 16 –...
  • Page 141 What analog output 1 corresponds to 0E/14 Out1_flg 0 – oxygen 1 – cell temperature 2 – cell temperature thermocouple mv 3 – cell mv 4 – thermocouple mv box temp 5 – combustibles 6 – cell mv methane 7 – AF Ratio 8 –...
  • Page 142 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 17/23 I3_zero Analog output 3 , 0 or 4 ma value...
  • Page 143 29/41 Recov_time Amount of time for recovery after a calibration in seconds Amount of time for recovery after a calibration in MMSS 2A/42 O2_gas1 Oxygen span gas setpoint value, always in percent 2B/43 O2_gas2 Oxygen zero gas setpoint value, always in percent 2C/44 Co_gas1...
  • Page 144 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 4C/76 Ver_m1...
  • Page 145 What process alarm is associated with 5D/93 Alr1_flg 0 – oxygen oxygen, combustibles, or methane 1 – calibration 2 – verify 3 – in cal/verify Configuration for oxygen alarms, high or 5E/94 Alm_config low. If a bit is 1, that is the condition that the indicated alarm will trip on.
  • Page 146 Which gas is currently flowing to the 5F/95 Gas_ctr 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 147 Which oxygen alarm has been set and why 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 148 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. It is calculated during calibration and used in the oxygen calculations. Option flags (1=true, 0=false) 63/99 Option_flags...
  • Page 149 Status of digital inputs(1=closed/on, 6E/110 Dig_Input 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 8-Erase EEPROM 9- Test Watchdog 71/113...
  • Page 150 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 Exception number 5 see Exception Chart...
  • Page 151 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 152: Sample Program

    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 153 Starting/Monitoring a Calibration: An Example This section provides an example of how to initiate and then monitor a calibration. Check that no calibration or verification is currently occurring by checking the Calflag variable (Calflag=3). Send the Calibrate command to the IQ analyzer (G00). If an acknowledge is returned (A ...
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  • Page 155: Menu Option Charts

    MENU OPTION CHARTS SETUP KEY Functions/Options Menu Options Select info for Display Line 1. Display Select info for Display Line 2. Select info for Display Line 3. Passwords Create a system password Select a positive or negative process pressure. Process Pressure Enter process pressure value.
  • Page 156 ALARM KEY Functions/Options Menu Options Alarm Set Points Alarm 3 Value Alarm 4 Value Alarm Configure High O2 (for Alarms 3 and 4) Low O2 Relay Configure Energize on Alarm De-energize on Alarm Select Function % Oxygen ( Alarm 3) Start of Calibration Start of Verify Start of Calibration or Verify...
  • Page 157 CALIBRATE KEY Functions/Options Menu Options Start an automatic, remote, or manual calibration Initiate Cal/Initiate Verify or verify View latest calibration and verify data. Cal/Verify Data - Cal data - Verify data Cal Gas Values Enter calibration gas values. Set pressure and flow to RCU gases without Inject Cal Gas performing a calibration.
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  • Page 159: Current Outputs: Other Applications

    CURRENT OUTPUTS: OTHER APPLICATIONS This appendix describes how to: • Modulate an external power loop using current outputs. • Power current outputs from an external power supply. Powering Current Outputs from an External Power Supply The Series 2000 control unit wiring card contains a set of terminals that can be used to connect an external voltage source to power the standard current outputs: VEXT1, 2 +...
  • Page 160 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 ...

  • Page 161: Modulation Of External Power Loop Using Current Outputs

    Modulation of External Power Loop Using Current Outputs Figure C-1 shows an example of the connection method when you want to produce a modulated current loop from an external power supply and a load device. All current output channels (IOUT1 and IOUT2) can be connected in the same manner as shown in this figure.
  • Page 162  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 Insitu Analyzer...

  • Page 163: Drawings And Custom Instructions

    DRAWINGS AND CUSTOM INSTRUCTIONS This appendix provides any custom drawings or instructions you have ordered. If you didn’t order any cutome options, the standard Intercon- nect drawing is provided. If you ordered special options, the drawings or special instructions pro- vided here supercede any drawings or options provided elsewhere in the manual.
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  • Page 165: Series 2000 Controller Setup Parameters

    SENSOR DEFAULT SETTINGS SERIES 2000 CONTROLLER SETUP PARAMETERS O2 PRODUCTS O2 PRODUCTS INCLUDE CLEAR AREAS ONLY COMB. PRODUCTS COMB. PRODUCTS INCLUDE CLEAR AND SHADED AREAS METHANE PRODUCTS METH. PRODUCTS INCLUDE CLEAR,SHADED,AND BORDERED AREAS PARAMETER DEFAULT SETTINGS CUSTOMER SETTINGS SENSOR CONFIGURE O2 CEM/O2, INSITU, WDG-IV, WDG-HPII SENSOR CONFIGURE COMB WDG-IVC, WDG HPIIC...
  • Page 166 PARAMETER DEFAULT SETTINGS CUSTOMER SETTINGS O2 SPAN GAS DURATION 2:00 MINUTES O2 ZERO GAS DURATION 2:00 MINUTES COMB SPAN GAS DURATION 2:00 MINUTES RECOVERY DURATION 4:00 MINUTES K FACTOR OUTPUT # 1 FUNCTION % OXYGEN CURRENT MODE,RANGE 4 TO 20 MA = 0-10 TRACK/HOLD CAL VERIFY HOLD,TRACK OUTPUT FILTER # 1...

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