Ametek WDG-V User Manual
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Ametek WDG-V User Manual

Combustion analyzer
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USER MANUAL
WDG-V, WDG-VC, WDG-VCM, WDG-VM
Combustion Analyzer
5000-017-PI rA
PN 9000-133-VE, Rev U

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Summary of Contents for Ametek WDG-V

  • Page 1 USER MANUAL WDG-V, WDG-VC, WDG-VCM, WDG-VM Combustion Analyzer 5000-017-PI rA PN 9000-133-VE, Rev U...
  • Page 2 AMETEK Process Instruments assumes no responsibility or liability for any errors or inaccuracies that may appear in this document. AMETEK Process Instruments is not responsible for any infringement of patents or other rights of third parties that may result from the use of this document. The content of this document is furnished for informational purposes only, is subject to change without notice, and does not represent a commitment or guaranty by AMETEK Process Instruments.

  • Page 3: Table Of Contents

    Contents Safety Notes ..............................vii Electrical Safety ............................vii Grounding ..............................vii Personnel and Equipment Safety Information................viii Important Notice to Users ........................x Warning Labels ...........................xi Environmental Information – WEEE ....................xi OVERVIEW ..........................1-1 Analyzer Operations ..........................1-1 Basic Elements of the Analyzer ....................1-2 Analyzer I/O ..........................1-2 Analyzer Communications ....................
  • Page 4 Communications Between the Analyzer and the PC Configurator Software) ..2-36 Connecting the PC to the Analyzer ..................2-37 Installing the AMEVision Display User Interface (Secondary Communication Option)............................. 2-38 ® PN 9000-133-VE, Rev U iv | Thermox WDG-V / VC / VCM / VM...
  • Page 5 Aftermarket Excellence and Long-Term Commitment to Safety and Quality ....3-2 Requesting Technical Support ....................3-3 Requesting Authorization to Return Equipment ..............3-3 Spare Parts List ............................3-4 WDG-V Analyzer Spare Parts .......................3-4 WDG-V Analyzer Spare Parts .......................3-5 Diagnostics Flowcharts .........................3-6 Thermocouple Checks ........................3-6 Calibration/Aspirator Air Setup Checks ..................3-7...
  • Page 6 Utilisez une alimentation électrique adéquate .............. 5-6 Ne faites pas fonctionner avec les défaillances suspectes ........... 5-6 Mise à la terre CEM (EMC), blindage et protection contre le bruit ......5-6 ® PN 9000-133-VE, Rev U vi | Thermox WDG-V / VC / VCM / VM...

  • Page 7: Safety Notes

    Safety Notes WARNINGS, CAUTIONS, and NOTES contained in this manual emphasize critical instructions as follows: Important information that should not be overlooked. 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: Personnel And Equipment Safety Information

    Avoid Electrical Overload To avoid electrical shock or fire hazard, do not apply a voltage to a terminal that is outside the range specified for that terminal. ® PN 9000-133-VE, Rev U viii | Thermox WDG-V / VC / VCM / VM...
  • Page 9 Ground the Product Follow the grounding instructions provided in the “Installation and Start-Up” chapter of this manual. Before making connections to the input or output terminals of this product, ensure that the product is properly grounded. Use Proper Fuse To avoid fire hazard, use only the fuse type and rating specified for this product. Use Proper Power Source Do not operate this product from a power source that applies more than the voltage specified.

  • Page 10: Important Notice To Users

    C, D and Groups E, F, G or Nonhazardous locations only. The maximum ambient temperature for the analyzer is 60 °C (140 °F). The WDG-V Analyzer and AMEVision Display User Interface is a complex piece of equipment that should only be serviced by a qualified service technician with exper- tise in instrument technology and electrical systems.

  • Page 11: Warning Labels

    Achtung – Heiße Oberfläche 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 environ- ment 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 reaches its “end of life.
  • Page 12 This page intentionally left blank. ® PN 9000-133-VE, Rev U xii | Thermox WDG-V / VC / VCM / VM...

  • Page 13: Overview

    Overview Analyzer Operations Designed for fast response in a wide range of flue gas applications, the analyz- er mounts directly on the combustion process to provide continuous measure- ment of oxygen, or oxygen and combustibles, or oxygen, combustibles, and methane. A sample is drawn from the process stream by means of an air-operated aspira- tor and is immediately returned to the process.

  • Page 14: Basic Elements Of The Analyzer

    All required I/O comes with the analyzer. See “About the Analyzer Electronics” for descriptions. Analyzer Communications The WDG-V is a complete standalone unit. No separate controller is required. The analyzer is configured, calibrated and monitored using the MODBUS RTU interface. Communication with the analyzer is provided via the Display User In- terface, or the WDG-V Configurator Software via PC (standard with each unit).

  • Page 15: How The Oxygen Measuring Cell Works

    How the Oxygen Measuring Cell Works The sensing element is a closed-end tube made from ceramic zirconium oxide stabilized with an oxide of yttrium or calcium. Porous platinum coatings on the inside and outside serve as both a catalyst and as electrodes. At high tempera- tures (generally above 650 °C/1200 °F), oxygen molecules coming in contact with the platinum electrodes near the sensor become ionic.

  • Page 16: Measuring Non-Combustible Gases

    When this occurs, the cell will gener- ate high millivolts and cause the display to indicate less oxygen than is actually in the gas (net oxygen content). 1-4 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 17: Hydrocarbons In The Gas Sample

    Hydrocarbons in the Gas Sample When hydrocarbons are present in the gas sample, a combustion process oc- curs when this gas sample is exposed to the high temperature of the zirconia cell. An indication that hydrocarbons may be present in the gas sample is that the oxygen reading will be lower than expected.

  • Page 18: Analyzer Operations - Wdg-Vcm, Close-Coupled Extractive Flue Gas Analyzer

    Figure 1-2. Typical WDG-V Analyzer configuration. Detectors are very delicate and should be handled with care. 1-6 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 19: Detectors

    The resistance change is inter- preted by the microprocessor and the corresponding reading is displayed. • The AMETEK catalytic methane detector will detect methane gases present in a sample. The sample must, however, contain enough oxygen to fully burn the methane present.

  • Page 20: Flow Sensor

    The flow measurement is updated every 90 seconds. This delay is used to allow the analyzer to effectively auto-zero to prevent false alarms. Figure 1-3. RTD Flow Sensor. 1-8 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 21: Temperature Sensors

    RTD is mounted on the aspirator block. All internal plumbing components are maintained above 200 °C. Heaters There are two main heaters in the WDG-V, the cell heater and box heater. In WDG-VCM units, an additional heater is used for fine temperature control of the combustible block.

  • Page 22: About The Analyzer Electronics

    • Valve controls for Remote Calibration Unit (RCU) Current Outputs There are three (3) analog outputs in the WDG-V. Each analog output can be configured for Mode, Function, and Span, Zero. Mode options include 0–20 mA, 4–20 mA, and NAMUR.

  • Page 23: Alarm Contact Connections

    Alarm Contact Connections The WDG-V Analyzer has five (5) alarm contacts, one (1) Service alarm, one (1) Data Valid alarm, and three (3) configurable process alarms. Standard Alarm Connections Service Alarm Relay This relay is used to determine if there is a problem with the analyzer.

  • Page 24: Communicating With The Analyzer

    WDG-V: • Display User Interface (refer to the AMEVision Display User Interface User Manual, AMETEK PN 9000-165-VE). • WDG-V Configurator Software via PC, provided with each unit (refer to the AMETEK PC Configurator Software User Manual, AMETEK PN 9000-231-VE).

  • Page 25: Flame Arrestors

    Component Function Flame Arrestors The WDG-V Analyzer contains two flame arrestors to prevent it from being an ignition source to the process for short periods of high combustible levels (25 % of LEL – Lower Explosive Limit) in the process. The flame arrestors are not, however, intended to protect the process where the combustibles levels are constantly high.

  • Page 26: Working In This Manual

    Examples of Manual Supplements include a non-standard Measuring Cell, non-standard or optional equipment, analyte-specific applications, or information that is intended to replace similar information in the manual. 1-14 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 27: Installation And Start-Up

    Installation and Start-up This chapter describes how to install the WDG-V Analyzer components and Display User Interface. If you have an Oxygen-only analyzer without the combustibles option, the combustibles and methane options described in this chapter do not apply. The combustibles and methane sections are clearly identi- fied.

  • Page 28: Pre-Installation Requirements

    • The installation location should be free from excessive vibration and the ambient temperature is required to be within the WDG-V specification limits. If the ambient temperature is outside the specified limits or the vi- bration is excessive, contact the AMETEK Sales or Service Department to discuss solutions and special options to address ambient temperatures outside the listed specifications.

  • Page 29: Unpacking And Inspecting The Equipment

    Unpacking and Inspecting the Equipment Remove any packing material from the WDG-V Analyzer shipping crate. Check for damage. If equipment is damaged, notify the carrier and contact AMETEK Service (https://www.ametekpi.com/customersupport/requestsupport) immediately if parts are missing or damage is found, and to verify if damaged parts will require replacement prior to safely installing and operating the analyzer/ equipment.

  • Page 30: Common Operator Errors

    – severe thermal shock can be destructive to either of them. • Always replace the metal cell o-ring when replacing the oxygen cell. 2-4 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 31: Installing The Mechanical Components

    Installing the Mechanical Components This section describes how to mount and connect gases to your WDG-V Ana- lyzer. Installing the Sample Inlet Probe For some applications, you must first connect the sample inlet probe to the analyzer before mounting the analyzer. The same applies if you are installing the probe heater or exhaust tube.

  • Page 32: Standard 1/8" Npt Probe Installation

    (NA for long probes) Probe Inlet Hook TOP VIEW Probe Support 54-1/8"long Assembly replaces bushing for probes Figure 2-1. 5', 6 and 8' WDG-V Probe installation. 2-6 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 33: Ceramic Probe Or Long Probe Installation

    5. Reconnect the Probe Inlet Hook to both the analyzer backplate and the aspirator block and tighten. Backplate Bushing Aspirator Block TOP VIEW Figure 2-2 Probe Inlet Hook WDG-V ceramic probe installation - top view. Installation and Start-Up PN 9000-133-VE, Rev U...

  • Page 34: Probe Heater Installation (Optional)

    3. Route the wires from the probe heater to the electronics enclosure. 4. Remove the electronics box cover and connect the wires to an AC power source. 2-8 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...
  • Page 35 Sample Probe Exhaust Port Inlet Port Probe Heater Port (Remove Plug) Terminal Box Figure 2-3. Port locations on rear of analyzer – front view. Installation and Start-Up PN 9000-133-VE, Rev U...

  • Page 36: Installing The Exhaust Tube (Optional)

    To install the exhaust tube, thread the exhaust tube into the exhaust port on the rear of the analyzer as shown in Figure 2-4. Figure 2-4. Mounting dimensions – Hinged analyzer. 2-10 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 37: Installing The Analyzer

    Methods for Mounting the Analyzer There are three methods for mounting a WDG-V Analyzer to the process. Each method is explained in the following pages. Mounting dimensions for the hinged style enclosure, including the Z-purge option, are provided in Figure 2-5.
  • Page 38 Check Probe Valve 3.64 Figure 2-5. Terminal Box Mounting dimensions and 92.56 Exhaust tube location. A 7/16" wrench is required to open both analyzer doors. 2-12 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 39: Analyzer Flush Mounting (Preferred Method)

    Sensor bolted to mounting plate after plate is welded to wall by customer. Gasket (by Ametek) Mounting plate supplied by Ametek with 2 7/8"OD x 9"long nipple (7.30cm x 22.86cm) welded to wall over 3 3/4"od (9.52cm) hole by customer.

  • Page 40: Customer-Supplied Pipe Nipple Analyzer Mounting

    (supplied by customer) SIDE VIEW Single stud at 12 o'clock position Figure 2-7. Proper orientation for WDG-V Analyzer pipe nipple mounting plate and flange mount. 2-14 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 41: Customer-Supplied Flange Analyzer Mounting

    ORIGINAL ISSUE 06-11-13 ADD MISSING PARTS 10-14-13 tective pipe nipple. If you have a different type of flange, AMETEK supplies a number of flange adapters. CUSTOMERS 3"-300# FLANGE (REDUCING FLANGE IF REQUIRED) CONNECTED TO 2 1/2" MINIMUM SCH 40 PIPE ATTACHED TO WALL BY CUSTOMER.

  • Page 42: Installing The Remote Calibration Unit (Optional)

    RCU. 3. Connect the combustibles span calibration gas to the combustibles span gas inlet on the RCU. For a WDG-V analyzer with RTD-type combustibles detector, the combustibles span calibration gas would also include the methane span calibration concentration.
  • Page 43 Figure 2-9.1. RCU mounting dimensions, Standard (O ) RCU. COMBUSTIBLES (SPAN 2) CALIBRATION GAS INLET 1/4” COMPRESSION FITTING Figure 2-9.2. RCU mounting dimensions, Combustibles RCU. Installation and Start-Up 2-17 PN 9000-133-VE, Rev U...

  • Page 44: Combustibles Rcu Installation

    5. Using appropriate tubing, connect the Aspirator air outlet on the right side of the RCU to the Aspirator air inlet connection on the analyzer. Figure 2-10.1. RCU flow diagram (Single Span). 2-18 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...
  • Page 45 Figure 2-10.2. RCU flow diagram (2 Span), Combustibles. Figure 2-10.3. RCU flow diagram (3 Span), Combustibles and Methane. Installation and Start-Up 2-19 PN 9000-133-VE, Rev U...

  • Page 46: Calibration/Aspirator Air

    If using a WDG-VCM analyzer, you also must have a methane span gas: • 2 % CH , 8 to 10 % O , balance N 2-20 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 47: Z-Purge Connections (Optional)

    Z-Purge Connections (Optional) • Connect instrument air to the analyzer Z-purge inlet. Maintain the pressure and flow as directed on the Z-purge warning label. • You must provide a protective gas supply with an alarm for a loss of pres- sure indication in order to meet regulatory requirements.

  • Page 48: Z-Purge Shut-Down Procedure

    • The WDG-V Analyzer contains two flame arrestors to prevent it from being an ignition source to the process for short periods of high combustible lev- els (25 % of LEL – lower explosive limit) in the process. The flame arrestors are not, however, intended to protect the process where the combustibles levels are always high.

  • Page 49: Aspirator And Manual Calibration Connections

    Connect Aspirator air to the Aspirator air inlet on the analyzer (Figure 2-12). The recommended initial aspirator pressure setting is 3 PSI. This will vary depending on the pressure/vacuum of the process for which the WDG-V is installed. If your system includes the optional Display User Interface, you can use the Flow Sensor output diagnostic screen to set the flow to the ideal rate.

  • Page 50: Calibration Gas Connection

    During normal operations, the calibration gas inlet port should be plugged. 2-24 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 51: Ac Power And Signal Connections

    WDG-V unit to alarm devices • WDG-V unit to current output devices • WDG-V unit to Display User Interface (RS-485 communications) • AC mains supply wiring to Display User Interface This wiring section also provides mandatory EMC grounding, shielding, and noise protection requirements.

  • Page 52: General Wiring And Conduit Requirements

    • Use only the applicable NEMA-approved conduit fittings or cable fittings to maintain the NEMA rating for the analyzer enclosure or WDG-V. If not us- ing a conduit entry, leave the factory NEMA-approved plugs intact. Never leave any holes unplugged.

  • Page 53: Wdg-V Mains Supply Connections

    N – Neutral connection (USA) • Chassis Stud – Equipment ground (protective conductor) Use the 1/2" conduit entry hole in the WDG-V for AC mains supply wiring. Use the chassis stud next to the 1/2" conduit entry hole for equipment ground (protective conductor).

  • Page 54: Emc Grounding, Shielding And Noise Protection

    Capacitor Conduit Nut Conduit Housing Max. Length 2 inches Washer Capacitor Conduit Nut Ring Terminal Figure 2-14.2. EMC Grounding, ground stud Washer method. Ring Terminal 2-28 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 55: Transient And Rfi Interference

    Transient and RFI Interference Transient and RFI interference precautions include: • Although there are transient and noise protectors on all analyzer unit I/O connections (communications, current outputs, analyzer, etc.), this protec- tion is intended to act as a last line of defense against unwanted transient and RFI interference.

  • Page 56: Current Output Connections

    Current Output Connections Standard Current Outputs There are three current outputs on the WDG-V Analyzer. The current output connections are labeled as follows on the Sensor board terminals: Analog Output #1 => +I1- Analog Output #2 => +I2- Analog Output #3 => +I3- The current outputs are referenced as Analog Outputs 1, 2, and 3 in the Display User Interface and PC Configurator Software.
  • Page 57 Figure 2-15. Wiring. Installation and Start-Up 2-31 PN 9000-133-VE, Rev U...

  • Page 58: Alarm Contact Connections

    This section describes how to make wiring connections for any alarm devices you wish to connect to the control unit. Standard Alarm Connections The WDG-V analyzer provides five (5) sets of normally open alarm contacts: Terminal Block ID Description –...

  • Page 59: Remote Calibration Unit Connections (Optional)

    If you have the combustibles option (and a combustibles RCU), you must also make the following connection (see Figure 2-16): COMBUSTIBLE SPAN – WDG-V Terminal S2 to Pin 17 on RCU For a WDG-VCM with hot-wire detector, Remote Calibration Unit connects: METHANE SPAN –...
  • Page 60 Figure 2-16. RCU Connections. 2-34 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 61: Notes About Ducting

    Digital Input to Initiate Remote Calibration Unit The digital input connections on the Wiring board allow you to initiate a remote calibration from a remote location. For this option to work, you must have a remote calibration unit. The system monitors the digital input, and when the switch closes, it sends the system into an automatic calibration.

  • Page 62: Installing The User Interface/Communications Options

    Figure 2-17. Close-up of Dip Switch, Sensor board. The address on the WDG-V analyzer is set using the dip switch on the front of the Sensor board. When connecting a single analyzer, the address is “1”. 321 Switch Address...

  • Page 63: Connecting The Pc To The Analyzer

    For instructions on how to work in the PC Configurator Software to configure and calibrate the analyzer, and to view analyzer status read- ings, refer to the WDG-V PC Configurator Software User Manual. The PC Configurator Software and the AMEVision Display User Inter- face cannot be simultaneously connected to the analyzer.

  • Page 64: Installing The Amevision Display User Interface (Secondary Communication Option)

    The AMEVision Display User Interface is an intuitive remote, color, graphi- cal user interface and communications link that provides easy configuration, calibration, and monitoring of data for up to four (4) WDG-V Analyzers using a single display unit. The interface between the Display User Interface and the WDG-V Analyzer is two-wire MODBUS RTU.
  • Page 65 The Control Unit can be mounted to either a panel or a wall. Refer to the AMEVision Display User Interface User Manual (AMETEK PN 9000-165-VE) for complete installation and operation details. 9.00 228.60 5.97 1.50 2.00 151.58 38.10 50.80 HINGE...

  • Page 66: Setting The Analyzer Address Using The Dip Switch (To Enable Communications Between The Analyzer And The Amevision Display User Interface Unit)

    Display User Interface unit. Each connected analyzer must have a unique address. The address on the WDG-V Analyzer is set using the dip switch on the front of the Sensor board. See Figure 2-17 (and 2-21 for the dip switch).

  • Page 67: Connecting Analyzers To The Amevision Display Unit

    When only one analyzer is connected, set the address to “1”. Connecting Multiple Analyzers Up to four (4) analyzers can be connected to a single AMEVision Display User Interface. The WDG-V Analyzer has extra terminal connections for daisy-chain connections. Figure 2-22..2 Multiple WDG-V Analyzers to the Display User Interface.

  • Page 68: Final Daisy Chain Connection Configuration Setting

    For instructions on how to work from the AMEVision Display User Interface to configure and calibrate the analyzer, and to view analyzer status readings, refer to the AMEVision Display User Interface User Manual (AMETEK PN 9000-165-VE). 2-42 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 69: Customer I/O Connections

    Customer I/O Connections Figure 2-23. Customer I/O Connections. Installation and Start-Up 2-43 PN 9000-133-VE, Rev U...

  • Page 70: Communication Troubleshooting Checks

    (1219.2 me- ters/4000 ft), the devices may need to be moved closer together. 2-44 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 71: Setting The Flow

    The recommended initial aspirator pressure setting is PSI. This will vary depending on the pressure/vacuum of the process for which the WDG-V is installed. If you purchased the AMEVision Display User Interface, you can use the Flow Sensor output diagnostic screen to set the flow to the ideal rate. If...

  • Page 72: Led Status Indicator

    Main Status LED (Light Pipe Visible From the Front) OFF – Power is off. The status LED is NOT directly connected to the WDG-V power supply. In the unlikely event of an error condition, it is possible for the ana- lyzer to be energized with dangerous voltages even though the status LED is off.
  • Page 73 Figure 2-26. Analyzer is in warm-up state or diagnostic state. Figure 2-27. Analyzer has a service alarm and is in need of attention. Installation and Start-Up 2-47 PN 9000-133-VE, Rev U...

  • Page 74: Printed Circuit Board (Pcb) Status Leds

    FORWARD LED – Modbus Communications LED. Toggles upon receipt of a valid Modbus message. This LED will blink rapidly in short bursts when com- municating properly to the Display User Interface. 2-48 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 75: Maintenance And Troubleshooting

    Maintenance and Troubleshooting Remove AC power from the analyzer and allow it to cool for at least 90 minutes before performing any maintenance or troubleshooting activities. Always use gloves when working on the analyzer. This chapter describes Display User Interface and error messages. It also provides troubleshooting assistance.

  • Page 76: Aftermarket Excellence And Long-Term Commitment To Safety And Quality

    Aftermarket Excellence and Long-Term Commitment to Safety and Quality Safety is a core value at AMETEK Process Instruments and is our primary consideration in every decision. We believe all accidents, injuries, and occupa- tional illnesses are preventable. We adhere to the highest design and safety...

  • Page 77: Requesting Technical Support

    Requesting Technical Support To request service support, a call back, or product information we encour- age you to use our Web-to-Case online tool, so we are instantly aware of your request no matter the time zone or day of the week. To do this, follow the link below.

  • Page 78: Spare Parts List

    WDG-V Analyzer Main Processor Board For Hot Wire Combustibles 8000-148-SE Detector Assy, WDG-V Boards and Plate For RTD Combustibles Detector 7000-845-SE *** Assy, WDG-V Boards and Plate For Hot Wire Combustibles Detector 7001-214-SE *** Kit, Combustibles Block w/Nut and Ferrules 7001-226-TE**** Kit, Combustibles/Methane Block w/Nut and Ferrules...
  • Page 79 WDG-V Analyzer Spare Parts Description AMETEK Part No. Figure 0–60 PSI External Air Regulator 39004JE 2-12.1 0–60 Regulator Gauge 37018JE Aspirator Air Solenoid Valve (normally open) 36090JE 2-12.1 Calibration Gas Solenoid Valve (normally closed) 36088JE 2-12.1 Flow Meter 37020JE 2-12.1 0–15 PSI Internal Regulator...

  • Page 80: Diagnostics Flowcharts

    “General Troubleshooting” in this chapter. AMETEK recommends monitoring the Thermocouple millivolts and Cell mil- livolts displayed during troubleshooting as a troubleshooting aid. This infor- mation will be helpful should you need to contact the factory for assistance. Be sure to always include your analyzer model and serial number when contact- ing AMETEK for technical support.

  • Page 81: Calibration/Aspirator Air Setup Checks

    Calibration/Aspirator Air Setup Checks If performing a manual calibration, wait for the reading to stabilize on the display before switching to the next calibration gas. Problem/Possible Cause Corrective Action To check Calibration gas values: Calibration Gas Check From the Calibration Gas Values screen (User Interface), check ...

  • Page 82: Ac Power Checks

    If no voltage is present at terminals FURN on the Sensor board, replace the Sensor board. 3-8 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 83: Process Pressure Checks (Only If Above 2 Psig)

    Process Pressure Checks (only if above 2 PSIG) Problem/Possible Cause Corrective Action Process Pressure set To check that you entered the process pressure correctly, select Process Pressure from the Configuration menu. Also ensure incorrectly that the calibration process pressure equals normal operating process pressure.

  • Page 84: Flow Sensor Alarm Limits Checks

    If resistance is much lower or higher than 8–10 Ω, replace the Flow Sensor. Flow Sensor Heater Element (Red Wire) Flow Sensor Sense Element (Yellow Wire) Figure 3-1. RTD Flow Sensor. 3-10 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 85: Maintenance

    Personnel should be thoroughly familiar with the operation of the WDG-V Analyzer before performing the maintenance and trouble- shooting procedures described in this section. Preventing leaks in the sample system is critical to proper analyzer op- eration.

  • Page 86: General Troubleshooting

    Be sure that the mounting plate or mounting flange gasket on the rear of the analyzer is in place (see “Installing the Analyzer” in Chapter 2 for details on the placement of the gasket). 3-12 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 87: Sniffing For Leaks

    Sniffing for Leaks For processes under vacuum, you can check for leaks by sniffing the fittings with another gas (for example, nitrogen or pure oxygen), being sure to avoid the area over the top of the cell. 1. Use a piece of tygon or plastic tubing with a 1/8” stainless steel nozzle to apply the gas from a cylinder (using stainless steel prevents any problems that might occur with plastic melting the nozzle on hot analyzer compo- nents).

  • Page 88: Internal Wiring Diagram, Standard Analyzer

    Internal Wiring Diagram, Standard Analyzer Figure 3-2.1. Internal Wiring diagram for standard analyzer. 3-14 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 89: Customer Connections Wiring Diagram, Standard Analyzer

    Customer Connections Wiring Diagram, Standard Analyzer Figure 3-2.2. Customer Connections wiring diagram for standard analyzer. PN 9000-133-VE, Rev U Maintenance and Troubleshooting 3-15...

  • Page 90: Cleaning And Replacing Parts

    If replacing the Cell, discard the old Cell and Cell o-ring and retrieve the new Cell with supplied Cell o-ring. Avoid touching the bare Cell. Instead, hold the Cell by one of its hex nuts. 3-16 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...
  • Page 91 6. Place the Cell o-ring on the base of the Cell as shown in Figure 3-3. 7. Insert the new Cell into the Cell housing. Do not touch the bare Cell when reinserting. Tighten the Cell into the Cell housing using the lower hex nut (the upper hex nut is pre-tightened at the factory).

  • Page 92: Replacing The Thermocouple

    7. Attach one new speed nut to each post. 8. Attach the Thermocouple wires to the +TC- terminals on the Sensor board (Yellow wire is positive (+)). 9. Perform an oxygen calibration. 3-18 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...
  • Page 93 Figure 3-4. Thermocouple replacement. PN 9000-133-VE, Rev U Maintenance and Troubleshooting 3-19...

  • Page 94: Replacing The Combustibles / Methane Detectors

    Save the screws from the detector to use when installing the new combustibles detector. 4. Always use a new o-ring when the Methane Detector has been removed. 3-20 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...
  • Page 95 5. Install the new Methane detector in place, aligning the two screws on the block. Be careful not to damage the detector element ends while inserting the assembly. Tighten screws until face is flush with the block and gasket is fully compressed.

  • Page 96: Replacing The Flow Sensor

    6. Route the wires through the top conduit back to the electronics enclosure. 7. Connect the new wires to the Cact terminals. 8. Reopen the process valves and close the enclosure doors. 3-22 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...
  • Page 97 Figure 3-6. Flow sensor replacement. PN 9000-133-VE, Rev U Maintenance and Troubleshooting 3-23...

  • Page 98: Replacing The Furnace

    9. Install the new Furnace assembly in place. 10. Reinstall the Thermocouple, Flow Sensor, and Cell. 11. Reconnect the wires on the Sensor board. Figure 3-7. Furnace Assembly. 3-24 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 99: Replacing The Box Heater

    Replacing the Box Heater There is only one heater in the O version. There are two heaters in the Combustibles/Methane version of the WDG-V. To replace the Box Heater (Figure 3-8): 1. Disconnect heater wires. 2. Remove the speed clip from the mounting tab. Use needle-nose pliers to remove the clip.

  • Page 100: Replacing The Combustibles Block Heater (Only On Combustibles/Methane Units)

    3. Remove the Combustibles Block Heater by sliding it out. 4. Replace the Block Heater. 5. Tighten the hex screw into place. 6. Reconnect the wires on the Sensor board. 3-26 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...
  • Page 101 Figure 3-9. Combustibles Block Heater Replacement. PN 9000-133-VE, Rev U Maintenance and Troubleshooting 3-27...

  • Page 102: Replacing The Sensor Board

    3. Slide the board out until the pegs at the top line up with the holes in the Sensor board plate and drop it down. 4. Replace the Sensor board. 5. Properly tighten the screws. 3-28 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...
  • Page 103 Figure 3-10. Sensor board removal. PN 9000-133-VE, Rev U Maintenance and Troubleshooting 3-29...

  • Page 104: Alarm And Warning Messages

    • Check the associated cables/wiring for proper connections and inspect them for damage (cuts, nicks, burn marks, etc.). • Check the associated components for proper operation and replace faulty parts if necessary. Contact AMETEK to verify operation before removing and replacing parts.
  • Page 105 • Check the Box Heater and Box Temperature RTD wiring for proper connections and inspect them for damage (cuts, nicks, burn marks, etc.). • Check the Box Temperature RTD for a short or open circuit. Replace the RTD if necessary. Contact AMETEK to verify operation before removing the RTD.
  • Page 106 Take appropriate safety precautions, open the Analyzer door, and: • Check the Cell for an open circuit. • Check the Cell for proper operation. Replace the Cell if necessary. Contact AMETEK to verify operation be- fore removing the Cell. Cell Mv Mismatch The Cell Mv measurement does not match the real-time Cell measurement.
  • Page 107 • Check the associated cables for proper connections and inspect them for damage (cuts, nicks, burn marks, etc.). • Check the Thermocouple for a short or open circuit. Replace the Thermocouple if necessary. Contact AMETEK to verify operation before removing the Thermocouple.
  • Page 108 • Check the Cell Thermocouple for a short or open circuit. Replace the Thermocouple if necessary. Contact AMETEK to verify operation before removing the Thermocouple. • Check the Heater for a short or open circuit. Replace the Heater if necessary. Contact AMETEK to verify opera- tion before removing the Heater.
  • Page 109 • Check the Methane Detector for an open circuit. • Check the operation of the electronics and check the wiring for damage or improper connections. • Check the Methane Detector for proper operation. Replace the Detector if necessary. Contact AMETEK to verify operation before removing the Detector.
  • Page 110 • Check the Box Temperature RTD wiring for proper connection and inspect it for damage (cuts, nicks, burn marks, etc.). • Check the Box Temperature RTD for a short or open circuit. Replace the RTD if necessary. Contact AMETEK to verify operation before removing the RTD.

  • Page 111: Warnings

    Trigger Conditions: • Low Cell output. Corrective Action: Take appropriate safety precautions, open the Analyzer door, and: • Replace the ZrO Cell. Contact AMETEK to verify operation and to order a new Cell. PN 9000-133-VE, Rev U Maintenance and Troubleshooting 3-37...
  • Page 112 • Low Combustibles Detector output. Corrective Action: Take appropriate safety precautions, open the Analyzer door, and: Cell. Contact AMETEK to verify operation and to order a new Cell. • Replace the ZrO High Cell Mv The combustible measurement is no longer valid (set to full-scale) due to lack of O Trigger Conditions: •...
  • Page 113 Alarm Condition / Description / Corrective Action Last Comb Calibration Failed The last combustible calibration failed. Trigger Conditions: • Tank Empty. • Bad solenoid. • Insufficient time allowed for calibration. • Bad detector. Corrective Action: • Check the Calibration tank. •...
  • Page 114 Trigger Conditions: • Low Methane Detector output. Corrective Action: Take appropriate safety precautions, open the Analyzer door, and: Cell. Contact AMETEK to verify operation and to order a new Cell. • Replace the ZrO Oxygen Calibration Required Calibration is required.

  • Page 115: Specifications

    Specifications Specifications included in this chapter for the WDG-V, WDG-VC, WDG-VCM, and WDG-VM versions of this analyzer are typical for the ranges listed. For custom ranges/applications refer to accompanying Manual Supplements shipped with the analyzer, or consult with your AMETEK representative.

  • Page 116: Wdg-V Analyzer Specifications

    Calibrate or verify calibration. Store last 10 calibration data. Selectable calibration gas run time and process recovery time. Timed automatic calibration with optional Remote Calibration Unit. 4-2 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...
  • Page 117 Specification Description Calibration Gas Use calibration gases @ 10 PSIG, 3.0 SCFH. Use certified mixtures Requirements only. Span Gas: Instrument air or from 1.0–100 % O balance N (typically, 2 % O , balance , Combustibles, and CH Zero Gas: 2 % O or from 0.1–10 % O , balance N...

  • Page 118: Wdg-Vc Analyzer Specifications

    All static performance characteristics are with operating variables constant. System accuracy referenced to 0.1 to 10 % calibrated range. Response is to calibration gas (without flame arrestors). 4-4 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 119: Wdg-Vcm Analyzer Specifications

    WDG-VCM Analyzer Specifications Specification Description Output Range Oxygen: From 0–1 % to 0–100 % Combustibles: From 0–2,000 PPM to 0–10,000 PPM Methane: From 0–5 % Accuracy Oxygen: ±0.75 % of measured value or ±0.05 % O , whichever is greater Combustibles: ±2 % of full scale output range Methane:...

  • Page 120: Wdg-Vm Analyzer Specifications

    All static performance characteristics are with operating variables constant. System accuracy referenced to 0.1 to 10 % calibrated range. Response is to calibration gas (without flame arrestors). 4-6 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 121: Remote Calibration Unit (Rcu) Specifications

    0 % to 90 %, non-condensing Maximum Altitude: 2000 meters Approvals and Certifications WDG-V Analyzer Directives and Standards ATEX and IECEx Zone 2 II 2 G Ex pz IIC T3 Gc, without pressure switch II 2 G Ex d pz IIB + H...

  • Page 122: Wdg-Vm Analyzer Directives And Standards

    Directive 73/23/EEC Directive 2004/108/EC Remote Calibration Unit (RCU) Directives and Standards Directive 2004/108/EC Low Voltage Directive Directive 73/23/EEC. IEC Installation Category II IEC Pollution Degree 2 4-8 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 123: Wdg-V Analyzer Marking

    WDG-V Analyzer Marking WARNING–PRESSURIZED ENCLOSURE AVERTISSEMENT–ENCEINTE PRESSURISE THIS ENCLOSURE SHALL NOT BE OPENED UNLESS THE AREA IS KNOWN TO BE FREE OF FLAMMABLE MATERIAL OR UNLESS DEVICES WITHIN HAVE BEEN DE-ENERGIZED. CETTE ENCEINTE NE DOIT PAS ÊTRE OUVERTE SAUF SI VOUS SAVEZ QUE LA ZONE NE CONTIENT PAS DE MATÉRIEL INFLAMMABLE OU SI TOUS LES APPAREILS ONT ÉTÉ...
  • Page 124 This page intentionally left blank. 4-10 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 125: French Warnings/Français Adverstissements

    French Warnings/Français Adverstissements NOTES SUR LA SECURITE LES AVERTISSEMENTS, LES PRÉCAUTIONS ET LES NOTES CONTENUS DANS CE MANUEL ATTIRENT L’ATTENTION SUR DES INSTRUCTIONS CRITIQUES COMME SUIT: Une procédure de fonctionnement qui n’est pas strictement suivie peut engendrer une blessure de personne ou une contamination de l’environnement.

  • Page 126: Sécurité Électrique

    électriques et les vérifications de terres. Une utilisation quelconque de l’équipement de manière non spécifiée par le constructeur peut compromettre la protection de la sécurité d’origine fournie par l’équipement. 5-2 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...

  • Page 127: Mise À La Terre

    Note importante aux utilisateurs Il n’y a pas de composant à maintenir à l’intérieur même des composants de l’analyseur WDG-V. Ne pas retirer le capot d’un analyseur WDG-V. Se référer à du personnel qualifié pour la maintenance. Les instructions suivantes s’appliquent à l’unité d’affichage hôte : L’alimentation électrique, les entrées et sorties (E/S) doivent être en accord...
  • Page 128 à l’usine. Vous devriez seulement essayer de réparer ou maintenir cet équipement après avoir reçu une formation d’un représentant AMETEK / Division P&AI. Si vous décidez d’effectuer la mainte- nance de cet analyseur, ayez conscience que des hautes tensions, des hautes températures et d’autres conditions potentiellement à...

  • Page 129: Sommaire De Sécurité Générale

    Sommaire de Sécurité Générale Lisez attentivement les précautions de sécurité suivantes pour éviter de se blesser et d’endommager l’équipement ou tout produit connecté à ce dernier. Utilisez un câblage adéquat Pour éviter les risques de feu, utilisez seulement le câblage spécifié dans le chapitre Installation de ce manuel de l’utilisateur.

  • Page 130: Precautions Aux Dommages De L'analyseur

    Dans un but de compatibilité électromagnétique, en aucune circon- stance vous ne devez laisser l’écran d’un câble déconnecté en une ou deux extrémités (unité de contrôle ou de terrain ou autre appareil). 5-6 | Thermox ® WDG-V / VC / VCM / VM PN 9000-133-VE, Rev U...
  • Page 131 AMETEK Process Instruments delivers worldwide sales and service support through a network of direct and factory-trained global distribution channels. AMETEK Service Assistance Program plans offer coverage up to 24 hours a day, 365 days of the year. As worldwide experts in the manufacture of process analyzers and instrumentation, we have supplied solutions to industry since 1962, providing the widest range of analysis technology available.

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