Ametek 5000 Manual
Moisture analyzer
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Summary of Contents for Ametek 5000
- Page 1 AMETEK Western Research 5000 Moisture Analyzer Essential Health & Safety Requirements Process Instruments 455 Corporate Blvd. Newark, DE 19702 PN 500088003, Rev E...
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Page 2: Offices
© 2000 AMETEK This manual is a guide for the use of the Model 5000 Moisture Analyzer (Single Point). 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
SPECIAL WARNINGS AND INFORMATION FOR USE IN HAZARDOUS LOCATIONS ......................8 5000 CONTROLLER ................8 5000 Field Unit ..................8 When 5000 System includes EEx Sample System Components ....8 Special Conditions for safe use: ............8 Warning Labels ...................... 9 Specifications ....................... 10 Utility Requirements .................. - Page 4 Filter Frit (PN 560503901) Replacement ........... 50 Dryer or Trap Refilling ................. 50 Leak Testing ....................51 Valve Operation and Heater Cycling ............51 Oven Temperature Adjustment ..............52 Moisture Generator Temperature Adjustment ........52 4 | 5000 Moisture Analyzer...
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Page 5: About This Document
About This Document This document primarily describes the essential health and safety requirements for the compo- nents that make up the Model 5000 Moisture Analyzer intended for use in explosive atmosphere locations. These sections are described below. The procedures and information discussed in this document include only abbreviated steps to install, operate, and perform maintenance on the Model 5000 Moisture Analyzer. -
Page 6: Warnings
(blocked in) from the process. If the Sample System Enclosure is heated, the components within it will be hot; take precau- tions to avoid burning yourself. WARNING Verify ground continuity of all equipment before applying power. WARNING 6 | 5000 Moisture Analyzer... -
Page 7: Cautions
The sample gas may contain highly toxic and corrosive substances. Proper personal protective equipment including fresh air breathing apparatus, eye protection, and skin protection MUST BE worn when installing the sample tap and/or opening the lid for inspection or maintenance. WARNING If sampe gases contain highly toxic and corrosive compounds, analyzed sample must be re- turned to the process or vented to a safe area. -
Page 8: Special Warnings And Information For Use In Hazardous Locations
To reduce the risk of ignition of hazardous atmospheres, conduit runs must have a sealing fit- ting connected within 18 inches of the enclosure. WARNING When 5000 System includes EEx Sample System Components Special Conditions for safe use: The special conditions for safe use give in the European certificates mentioned in the manufac- turer technical file are still relevant. -
Page 9: Warning Labels
Warning Labels These symbols may appear on the instrument in order to alert you of existing condi- tions. PROTECTIVE CONDUCTOR TERMINAL CAUTION - Risk of electric shock CAUTION - Refer to accompanying documents CAUTION - Hot Surface Essential Health & Safety Requirements | 9... -
Page 10: Specifications
• System Alarm • Concentration Alert • Range or Verification Alert (Contacts rated 30 VAC / 60 VDC, 50 VA maximum, 1A maximum, resistive) Allowable Inlet Pressure 207 to 690 kPa gauge (30 to 100 PSIG) | 5000 Moisture Analyzer... -
Page 11: Operating Pressure
Operating Pressure 103 kPa gauge (15.0 PSIG) Gas Flow Requirements 250 mL/min each at 103 kPa gauge (15 PSIG) for sample, reference, and moisture generator. Approvals and Certifications UL/CSA General Safety Requirements Controller: UL/CSA Class I, Division 2, Groups ABCD, T4 ATEX, Zone 1, Ex db IIC, T6 Gb -12˚C ≤... -
Page 12: Analyzer Markings
Analyzer Markings The Model 5000 Moisture Analyzer will be marked with a corresponding label to indicate its ATEX certification. Figure 1. 5000 Field Unit ATEX Label. Figure 2. 5000 Controller ATEX Label. | 5000 Moisture Analyzer... -
Page 13: Special Conditions To Certification
Special Conditions of Certification Specific Conditions of Safe Use - There is no intention for any adjustments or repair to be made on the flame- path joints - All unused openings in protected enclosures must be fitted with blanking ele- ments with protection types and IP ratings compatible with the respective enclosure - All cable glands used must not invalidate the specific characteristics of the... - Page 14 This page intentionally left blank. | 5000 Moisture Analyzer...
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Page 15: Installation
• Zone 1. The Model 5000 analyzer system is typically installed with the field unit near the sample tap (normally in a hazardous area) and the 5000 controller located in a control room. The controller is suitable for installation in NEC Class 1 ; Groups A, B, C & D; Division 2 areas. -
Page 16: Field Unit Installation
The unit should be protected from direct exposure to weather and located so that the ambient temperature specifications will not be exceeded. Figure 2. Installation / dimensional layout for Model 5000 field unit (Zone1) 16 | 5000 Single-Point Moisture Analyzer... -
Page 17: Controller Installation
Controller Installation Mount the controller indoors in desired location and bolt in place. Figures 3-2a through 3-2d show installation dimensions for all controller mounting configurations. Figure 3a. Surface Mounted Model 5000 controller. Essential Health & Safety Requirements... - Page 18 Figure 3b. 19 inch (~48.26 cm) rack Mount Model 5000 controller. 18 | 5000 Single-Point Moisture Analyzer...
- Page 19 Figure 3c. Through-panel mounted Model 5000 controller. Essential Health & Safety Requirements...
- Page 20 Figure 3d. Surface mounted Model 5000 controller in NEMA 4X enclosure. 20 | 5000 Single-Point Moisture Analyzer...
- Page 21 Figure 3e. Model 5000 Zone 1 Controller Casting. Essential Health & Safety Requirements...
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Page 22: Electrical Connections
Supplemental information may appear in the Customer Drawing (CD) package. The 5000 Field Unit is fused internally with a 1-Amp fuse for nominal 230 VAC applica- tions, and 2-Amp for 100 and 115 VAC. The rupture speed is either a type M or T (slow blow). -
Page 23: Installation Requirements
• Do not substitute parts as this may impair the analyzer’s suitability for Class I, Division 2 use. • If a specific procedure requires the unit to be energized, a hot work permit may be required; check with your safety consultant. •... -
Page 24: Nec Division 1 And 2
• An AC power source of adequate current rating is available at both locations. 1. Unscrew and remove the lid from 5000 Field Unit. 2. Connect controller signal and alarm outputs to user recording equip- ment as shown in the CD package. - Page 25 4. Instrument grounding is mandatory. Performance specifications and safety features are void if the unit is operated from an improperly grounded source. Check ground integrity to all portions of the analyz- er before power up. See Fig. 3-3 for proper internal grounding instruc- tions.
- Page 26 Figure 5. Interconnecting wiring diagram for 5000 field unit and 5000 controller. 26 | 5000 Single-Point Moisture Analyzer...
- Page 27 Figure 6. Model 5000 controller back panel connections. Essential Health & Safety Requirements...
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Page 28: Sample System
Figure 3-6. The sample gas, or gases to be monitored by the analyzer may be toxic, corrosive, and / or flammable. AMETEK strongly recommends that trained service personnel use proper protective equipment including air breathing apparatus, eye protection, and... -
Page 29: Sample Pressure, Temperature, And Flow Rate
Sample Pressure, Temperature, and Flow Rate A pressure reducer/regulator should be installed near the sample tap. Variations in flow of 10 percent will not affect instrument accuracy. Nominal sample pressure to the system should be 520 kPa (75 PSI) gauge with a minimum pressure of 200 kPa (30 PSI) gauge. Temperature of the incoming sample gas should not exceed the analyzer cell tempera- ture of 60 °C (140 °F). -
Page 30: Conditioned Sample Gas Used As Reference
(OPTIONAL) TO VENT Figure 8. Sample system using conditioned sample gas as reference. MOLECULAR SUPER-ACTIVATED SIEVE DRYER MOLECULAR SIEVE DRYER (<1 ppm) (OPTIONAL) VENT TO APPROPRIATE AREA REFERENCE 30 | 5000 Single-Point Moisture Analyzer FIELD SAMPLE UNIT CONTAMINANT TRAP (OPTIONAL) -
Page 31: Separate Gas Source Used As Reference
SAMPLE CONTAMINANT SHUTOFF TRAP VALVE Separate Gas Source Used As Reference (OPTIONAL) PROBE Configure sample system as shown in Figure 3-7b. Standard and optional conditioning PRESSURE SHUTOFF components (dryers, contaminant traps) should be strapped in the upright position to SAMPLE REDUCER VALVE SOURCE... -
Page 32: Gas Connections To Analyzer
4. Connect vent line to analyzer inch exhaust port fitting. 5. Vent the line to appropriate area. Consult plant safety personnel for appropriate venting guidelines. NOTE 32 | 5000 Single-Point Moisture Analyzer... -
Page 33: Troubleshooting And Maintenance
TROUBLESHOOTING AND MAINTENANCE Any troubleshooting or maintenance to this analyzer that requires access to the inte- rior of the components must be performed only by qualified service personnel . There are no operator-level serviceable parts, expendables, or maintenance needs inside this WARNING analyzer. -
Page 34: Computer Operating Properly Alarm
• internal power failure • software problems, or • extreme electronic interference. When activated, the COP alarm generates a system reset but retains software configura- tion parameters. You do not have to reconfigure the system. 34 | 5000 Single-Point Moisture Analyzer... -
Page 35: System Tests Menu
System Tests Menu Numerous self-test routines can be run periodically or used to assist in troubleshooting the analyzer. Press the Test/Config key and enter the Level 1 or higher password. Scroll down to System Tests Menu and press Enter. Select a test from the following list and then follow directions displayed on screen. - Page 36 At the “Number Key to Toggle?” prompt, enter the number of the relay to test (1 through 8). Press Enter to begin test or Cancel to quit. Selected valve contacts will toggle to energized (= 36 | 5000 Single-Point Moisture Analyzer...
- Page 37 Relay 6 has opposite logic. It will be energized when logic=0 and de-energized when logic=1 NOTE Test Watchdog Verifies function of the Computer Operating Properly (watchdog) alarm by introducing an anomaly in the computer logic which should activate the alarm. If functioning properly, a system reboot will occur and the display will return to normal operating screen.
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Page 38: Scheduled Maintenance
• Replace or refill the trap’s activated charcoal. • Replace the super dryer. • Refill the moisture generator with distilled or deionized water (>12 Mohms resistivity). • Replace scrubber cartridge ( use only with acid gas option). See Ap- pendix B. 38 | 5000 Single-Point Moisture Analyzer... -
Page 39: System Inspection
System Inspection Inspection and maintenance should be done only by qualified personnel. WARNING 1. With Snoop PN 202887000 or a soap solution, check the sample line ® for leaks. 2. Verify that flowmeters, regulators, valves, gauges, and filters are in good condition and securely mounted. -
Page 40: Troubleshooting
Check and, if necessary, set oven and moisture generator operating temperatures. Contaminated sample cell crystal Read cell frequency If cell frequency input is >3500 Hz, replace the cell. Contaminated dryer Substitute with known good Replace or re-activate dryer. dryer. 40 | 5000 Single-Point Moisture Analyzer... - Page 41 Troubleshooting Guide for 5000 Analyzer Possible Cause Isolation Procedure Corrective Action Analyzer Reads High Incorrect flow rate Check, and if necessary, reset flow rate. Incorrect back pressure Check, and if necessary, reset back pressure. Incorrect operating parameters Check all values against Calibration Data Sheet.
- Page 42 Replace and/or refill dryer. Memory Is Corrupted Faulty RAM or RAM battery Replace battery. To ensure correct moisture operation, refer to “Display Reads Low in Calibrate or Operate Modes,” or “Moisture Generator Output Incorrect.” NOTE 42 | 5000 Single-Point Moisture Analyzer...
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Page 43: Field Unit Electronics
Field Unit Electronics Power Distribution • The AC supply is applied through circuit breaker CB1 and thermal cutout S2 to the primary of transformer T1. • The T1 secondary (35 VAC) is connected directly to rectifier and regu- lator circuits on the electronic control board. •... -
Page 44: Solenoid Control
U1 and U2 and rc filters. Except for their frequencies, the two oscillators function alike. U2A-1/-2 and U2F-13/-12 provide positive feedback to sustain the Y (Reference) and Y (Measure) nominal oscillations at 8.982500 MHz and 8.982000 MHz, respectively. 44 | 5000 Single-Point Moisture Analyzer... - Page 45 U2B/C and U2E/D amplify the outputs. Assuming a dry Y frequency of 8.982000 MHz, (L2 energized) and a Y frequency of 8.982500 MHz, low pass filter C9 develops a difference frequency of 500 Hz (DF ). This frequency is amplified to produce a square-wave voltage of 0 to 12 at 500 Hz applied to the controller processor.
- Page 46 33, 34, 35 40 (2 PL) 41 (5 PL) Figure 12. Field Unit parts replacement. 46 | 5000 Single-Point Moisture Analyzer...
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Page 47: Field Unit
Field Unit Numbers in parentheses refer to find numbers in Figure 12. The Field Unit may contain flammable or toxic process gas. Remove the lid in a well- ventilated area only after electrical power is shut off and the surrounding area in WARNING known to be non-hazardous. -
Page 48: Moisture Generator Sample/Reference Valve Assy
7. Connect the solenoid wires to TB2. 8. Connect and tighten the tubing nuts. 9. Do a leak test and re-install the lid. 10. Apply the power to the system, allow it to warm up, and resume op- eration. 48 | 5000 Single-Point Moisture Analyzer... -
Page 49: Electronics Control Board
Electronics Control Board 1. Shut off system power and sample and reference gas flows at their sources. 2. Carefully remove the lid and set it aside. 3. Disconnect the plugs from J1 and J2. 4. Remove the two screws (22), pull the board slightly forward to clear the bracket, and pull the board from its connector. -
Page 50: Filter Frit (Pn 560503901) Replacement
6. Fill the dryer with new molecular sieve (dried), or fill the trap with new activated charcoal. 7. Install the fill plug and snubber. 8. Do the following to the superactivated dryer: Attach the bottom fitting to a flowmeter with a valve. 50 | 5000 Single-Point Moisture Analyzer... -
Page 51: Leak Testing
Carefully place the cylinder in an oven with a source of dry gas < 0.1 PPM (known good superactivated dryer) connected to the top fitting. Make sure that one end fitting is open before applying heat to the cylinder. If the sieve is moisture-laden and the fittings are capped, the cylinder could explode when heated. -
Page 52: Oven Temperature Adjustment
5. Remove the DVM and connect the moisture generator plug to J2. 6. Re-install the lid. 7. Apply power to the system and allow it to warm up. 8. If necessary, repeat the procedure until no further adjustment is re- quired to maintain 60 °C. 52 | 5000 Single-Point Moisture Analyzer...