Ametek Thermox CEM O2/TM User Manual
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Ametek Thermox CEM O2/TM User Manual

Oxygen analyzer
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Thermox
CEM O2/TM
Oxygen Analyzer
User Manual
Thermox
150 Freeport Road
P/N 90496VE Rev. G
Pittsburgh, PA 15238

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  • Page 1 ® Thermox CEM O2/TM Oxygen Analyzer User Manual Thermox 150 Freeport Road P/N 90496VE Rev. G Pittsburgh, PA 15238...

  • Page 2: Offices

    © 2001 AMETEK This manual is a guide for the use of the Thermox CEM O2/TM Oxygen Analyzer. 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, confir- mation of their validity and suitability should be obtained;...

  • Page 3: Table Of Contents

    Table of Contents OFFICES ......................... ii Safety Notes ......................vi Electrical Safety .....................vi Grounding ......................vi Electromagnetic Compatibility (EMC) .............vii Environmental Information (WEEE) ..............ix ChAPTER 1 OVERVIEW Sensor Operations ....................1-1 Common Operator Errors ................1-4 Startup Checklist ....................1-5 Technical Support ....................1-6 ChAPTER 2 SPECIFICATIONS Control Unit ......................2-1 Sensor ........................2-3 Remote Calibration Unit (RCU) ...............2-4...
  • Page 4 Cal Gas Value ....................5-16 Inject Cal Gas ....................5-17 Set Cal Timers ....................5-19 Configure Verify ....................5-25 ChAPTER 6 MAINTENANCE AND TROUblEShOOTING System Messages ....................6-2 Error Messages....................6-4 Diagnostic Checks ....................6-8 General Troubleshooting .................6-17 Auto Calibration Card LEDs ................6-18 iv | Thermox CEM O2/TM...
  • Page 5 ChAPTER 7 SERVICE AND PARTS Warnings! ......................7-2 Cell Replacement/Cleaning ................7-4 Thermocouple Replacement ................7-6 Furnace Replacement ..................7-8 Parts Replacement List ..................7-10 APPENDIx A SERIAl COMMUNICATIONS APPENDIx b MENU OPTION ChARTS APPENDIx C CURRENT OUTPUTS: OThER APPlICATIONS APPENDIx D DRAWINGS AND CUSTOM INSTRUCTIONS Contents | v...

  • Page 6: Safety Notes

    Grounding Instrument grounding is mandatory. Performance specifications and safety protection are void if instrument is operated from an improperly grounded power source. Verify ground continuity of all equipment before applying power. vi | Thermox CEM O2/TM...

  • Page 7: Electromagnetic Compatibility (Emc)

    Electromagnetic Compatibility (EMC) Read and follow the recommendations in this section to avoid performance variations or dam- age to the internal circuits of this equipment when installed in harsh electrical environments. The various configurations of this Analyzer should not produce, or fall victim to, electromag- netic disturbances as specified in the European Union’s EMC Directive.
  • 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.

  • 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 substances into the environment and to conserve our natural resources, AMETEK recommends that you arrange to recycle this product when it reached its “end of life”.
  • Page 10 Series 2000 Controller and the PPM RCU also conform to the following safety standarrd: 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 July 2001 Compliance Engineer x | Thermox CEM O2/TM...
  • 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 permanent equipment,...
  • Page 12 This page intentionally left blank. xii | Thermox CEM O2/TM...

  • Page 13: Chapter 1 Overview

    OVERVIEW Sensor Operations The sample flows through the sensor plumbing because of a convective motive force. The sample in the vertical call housing is heated to 615°C, while the sample in the return vertical tube is at about 250°C. This tem- perature difference generates a density difference, which circulates the gas through the system.
  • Page 14 The oxygen content is then determined from the Nernst equation: where R and F are constants, T is absolute temperature, and O and O are the oxygen partial pressures on either side of the cell. 1-2 | Thermox CEM O2/TM...
  • Page 15 For measuring oxygen in non-combustibles gases, the zirconium oxide sensor can be modeled using the Nernst equation and the equation given below: 20.9% E = A * T * Log AT = 44.0 at 615°C Unk% Where A is a constant, T is the cell temperature on an absolute scale (°C + 273) and O Unk% is the unknown oxygen concentration of the gas to be analyzed(calculated by the analyzer).

  • Page 16: Common Operator Errors

    Allow at least one hour after closing the sensor door for readings to  stabilize. Allow more time after a cold start-up. If calibrating in the PPM range, calibration gas should be in cylinders  made of aluminum, not carbon steel. 1-4 | Thermox CEM O2/TM...

  • Page 17: Startup Checklist

    Startup Checklist Review the Installation chapter (Chapter 3) and installation drawing  (Appendix D). Install the sensor on the process. The ambient temperature must not  exceed 50°C (122°F). Install the control unit. The ambient temperature must not exceed  50°C (122°F).

  • Page 18: 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...

  • Page 19: Chapter 2 Specifications

    SpecificationS control Unit Display 4 line x 20 character vacuum fluorescent. Displays combinations of oxygen (0.1 PPM O to 100%, auto-ranging), time and date, cell temperature, user programmable text, thermocouple mV or cell mV. Password protection, programmable pressure compensation and context-sensitive help are also provided.
  • Page 20 Timed automatic calibra- tion with optional remote calibration unit. Power Requirements Nominal 115-230 VAC ±10%, 47-63 Hz, 75 VA max. System Compliance EMC Directive 2004/108/EC Low Voltage Directive 73-23/EEC 2-2 | Thermox CEM O2/TM...

  • Page 21: Sensor

    Sensor Operating Range 1 PPM O to 100% O Accuracy Percent: ±0.75% of measured value or ±0.05% O , whichever is greater PPM: ± 2% of reading or 0.5 PPM O absolute, whichever is greater. Response Time < 10 seconds at 1.0 l/min (2 scfh) to 90% of 2-decade step change. Repeatability Percent: ±...

  • Page 22: Remote Calibration Unit (Rcu)

    Indoor/Outdoor; UL Type 4X (NEMA 4X) (IP56) Envoironment: Ambient Temperature: -18° C to 50° C (0° F to 122° F) Humidity: 0 to 90%, non-condensing Max Altitude: 2000 Meters IEC Installation (Overvoltage) Category: II IEC Pollution Degree 2 2-4 | Thermox CEM O2/TM...

  • Page 23: Chapter 3 Installation

    INSTAllATION The operations in this chapter should only be performed by qualified service personnel experienced with electrical safety techniques. There are no operator serviceable components inside the system, and an operator should not attempt to open the sensor or controller cover for any reason. Qualified service personnel should 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 24 Remove any packing material from the sensor and check for damage. If any is found, notify the shipper. Mechanical Installation This section describes how to perform the mechanical installation portion of your system installation. This includes the following: • Mounting the Sensor • Sample Gas Requirements/Connections • Calibration Setup • Remote Calibration Unit Mechanical Installation (optional) 3-2 | Thermox CEM O2/TM...

  • Page 25: Mounting The Sensor

    Mounting the Sensor The CEM O2/TM sensor enclosure is a NEMA 12 rated polyurethane coated carbon steel cabinet that you mount to a wall. Figure 3-1 provides wall mounting dimensions for the sensor. Provide at least six inches clear- ance above the sensor so you can later replace the cell. The cell is replaced by lifting it through the top of the sensor enclosure.

  • Page 26: Sample Gas Requirements/Connection

    See the “Customer Supplied Remote Calibration Initia- tion” section at the end of this section for help on how to use Series 2000 calibration signals to control calibrations. 3-4 | Thermox CEM O2/TM...

  • Page 27: Remote Calibration Mechanical Installation (Optional)

    Remote Calibration Mechanical Installation (Optional) You can use the Series 2000 control unit to automatically switch between calibration and sample gases. To do this, you can use either the optional factory-provided remote calibration unit (see the “Factory-Provided Re- mote Calibration Unit Setup” section below), or the signals from the con- trol unit to create your own remote calibration sequence using your own control valves to switch between the process and calibration gases (see the “Customer-Supplied Remote Calibration Initiation”...
  • Page 28 9.25 23.49 6.29 15.98 Inches Centimeters in bottom of box. Flowmeter 1/4" mounting holes .64cm (2 places) 4.33 2.19 5.56 11.00 Z Purge option Figure 3-3. RCU mounting dimensions. 3-6 | Thermox CEM O2/TM...
  • Page 29 Do the following to plumb the RCU (see Figure 3-4): Connect the zero gas to the zero gas inlet on the RCU. Connect the span gas to the span gas inlet on the RCU. Connect tubing between the calibration gas outlet on the RCU and the control valve used to switch between the process gas and your calibra- tion gases.
  • Page 30 Figure 3-6 shows an example of a calibration setup using the factory-pro- vided RCU. SAMPLE GAS O2 CAL PROCESS/CAL GASES CONTROL VALVE O2 CAL REMOTE GASES CALIBRATION UNIT OTHER GAS CEM/O2 ANALLYZER(S) SERIES 2000 CONTROL VACUUM TO PULL SAMPLE Figure 3-6. RCU calibration setup example. 3-8 | Thermox CEM O2/TM...

  • Page 31: Customer Supplied Remote Calibration Initiation

    Customer Supplied Remote Calibration Initiation You can also use the Series 2000 control unit signals to create your own remote calibration initiation sequence as described below. These signals allow you to control the valves you use to switch between the process gas and the calibration gases.

  • Page 32: Control Unit Mounting

    U-bolt of 3/8” or 1/2” diameter for a 2-1/2” to 4-1/2” pole diameter. Figure 3-9. Series 2000, weatherproof wall/pole mount. 3-10 | Thermox CEM O2/TM...
  • Page 33 Weatherproof Wall/Z-Purge Option Figure 3-10 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 pres- sure and flow as indicated on the warning tag on the control unit. Z-Purge Shutdown Procedure: Hot internal parts are above the igni- tion temperature of combustible gases.
  • Page 34 Series 2000 general purpose wall enclosure. Use 1/4” diameter fasteners to mount the control unit to the wall. 10.38 11.38 26.37 28.90 4 Holes for Figure 3-13. 1/4" fasteners Series 2000, general purpose wall mount. 3-12 | Thermox CEM O2/TM...

  • Page 35: Wiring

    Wiring Remove AC mains power from the controller and sensor before per- forming wiring. Connections to the control unit are made through the wiring card (see Figure 3-14). The wiring card is located on the front, bottom of the control unit for all weatherproof versions and for the general purpose wall mount version (see the “Control Unit Mounting”...
  • Page 36 • Control unit to alarm devices • Control unit to current output devices • Control unit to host computer (RS-485 communications) In addition, this wiring section provides mandatory EMC grounding, shielding, and noise protection requirements. 3-14 | Thermox CEM O2/TM...

  • Page 37: General Wiring And Conduit Requirements

    General Wiring and Conduit Requirements This section describes general wiring and conduit requirements: • Sensor wiring conductors must be rated at a minimum of 80°C. All other wiring conductor ratings should be for the minimum tempera- ture required for the equipment being connected to the analyzer, but not less than 60°C.

  • Page 38: Control Unit Mains Supply Connections

    Chassis Stud - Equipment ground (protective conductor) Use the 1/2” conduit entry hole in the control unit for AC mains supply wiring. Use the chassis stud next to the 1/2” conduit entry hole for equip- ment ground (protective conductor). 3-16 | Thermox CEM O2/TM...
  • Page 39 EMC Grounding, Shielding, and Noise Protection For EMC purposes, under no circumstances should you leave cable shields disconnected at one end or both ends of the cable (sensor or control unit or other device). You must use twisted-pair cable in rigid metal conduit or use twisted pair cable with an overall braided shield.
  • Page 40 As an example, do not run mo- tors, blowers, or air conditioners using the same mains supply circuit or conduit as the control unit’s mains supply circuit or conduit. 3-18 | Thermox CEM O2/TM...

  • Page 41: Sensor Connections

    Sensor Connections Follow all general grounding and shielding requirements as described in the “General Wiring Requirements” section at the beginning of this Wiring section. Also make sure that AC mains power has been removed from the control unit and sensor before making sensor con- nections.
  • Page 42 AC input terminal (L or N) that AC Line or Neutral is connected to, or, if there is a Neutral used at all (i.e. 208 VAC US power connection). Figure 3-18. Sensor connections. 3-20 | Thermox CEM O2/TM...
  • Page 43 There is no power switch on the sensor, and it must be protected by in- stalling 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: Current Output Connections

    This section describes how to make wiring connections for any alarm devices you wish to connect to the control unit. Information on how to set up alarms in software is described in the Controller/User Interface Chapter. 3-22 | Thermox CEM O2/TM...
  • Page 45 Figure 3-20. Current output connections example. Installation 3-23...
  • Page 46 ALARM 3A ALARM 4A ALARM 3B ALARM 4B See the Alarm Key section for complete information on all alarms, includ- ing what they can track and how they operate. 3-24 | Thermox CEM O2/TM...
  • Page 47 Figure 3-21. Series 2000 standard alarm connections. Installation 3-25...

  • Page 48: Remote Calibration Unit Connections

    The switch you connect to this digital input must be a normally open switch. Digital input connections are labeled as follows on the wiring card: DIGIN + DIGIN - 3-26 | Thermox CEM O2/TM...
  • Page 49 Figure 3-22. Series 2000 controller RCU connections. Installation 3-27...

  • Page 50: Rs-485 Communications Connections

    Switch 3 on SW1 of the display module allows you to place a 120 ohm termination resistor into the RS-485 circuit: Switch 3 of SW1 = On (Termination Resistor In Circuit) 3-28 | Thermox CEM O2/TM...
  • Page 51 Figure 3-23. Series 2000, 2-wire RS-485 communications connections. Installation 3-29...
  • Page 52 The fac- tory default setting is to have Switch 3 OFF with no termination resistor in the circuit. 3-30 | Thermox CEM O2/TM...
  • Page 53 Figure 3-24. Series 2000, 4-wire RS-485 communications connections. Installation 3-31...

  • Page 54: Option Card Installation

    Should you need to replace Fuse F1 on the wiring card is a Littlefuse type 273 microfuse or equivalent, voltage rating 125V AC, ampere rating: 250 mA. See the beginning of this Wiring section for the location of the wiring card on the controller. 3-32 | Thermox CEM O2/TM...
  • Page 55 Figure 3-25. Front view of Series 2000 control unit. Adding an Option Card Do the following to add an option card to the Series 2000 control unit: Open the access door below the display module (hinges down). Pull on the handle of the power supply/keypad module and remove this module from the control unit (it slides out).
  • Page 56 This page intentionally left blank. 3-34 | Thermox CEM O2/TM...

  • Page 57: Chapter 4 Controller / User Interface

    CONTROllER / USER INTERFACE Series 2000 User Interface This chapter provides a brief overview on how to use the Series 2000 con- trol unit. This includes the following topics: Areas of the Control Unit  Password Restrictions  Control Unit Display ...

  • Page 58: Areas Of The Control Unit

    For menu options to change system settings in which a password is required, you must first enter the password to access that menu’s func- tions. See the Setup Key section of this chapter for help on how to create a system password. 4-2 | Thermox CEM O2/TM...

  • Page 59: Control Unit Display

    Control Unit Display The main control unit display allows viewing of different types of infor- mation. You define which information to place on the first three lines of the display by using the Display option from the Setup Key. Note that you can also use the Display menu option to place your own text messages on one or more of the first three lines.

  • Page 60: Selecting Menu Options

    Passwords option from the Setup Key, you would select the Setup Key, then move the arrow pointers to the Passwords option and press the Help Key. You would then receive on-line help on the Password option. 4-4 | Thermox CEM O2/TM...

  • Page 61: Setup Key

    Setup Display Password System Process Tests Pressure System Primary Serial # Calibrate Sensor Communications Configuration Remote Switch Configuration Remote Switch Configuration Figure 4-2. Setup Key Menu Options Setup Key The Setup Key (Figure 4-2) allows you to do the following: Define what information to place on each display line (Display).
  • Page 62 Primary Calibration bration. Sensor Configuration Select sensor type. Communications Define communications parameters. Define wheather digital input should start an automatic Remote Sensor Configuration calibration or an automatic verify. Figure 4-3. Overview of Setup Key functions. 4-6 | Thermox CEM O2/TM...
  • Page 63 Display This menu option allows you to define what information should appear on the top three display lines of your Series 2000 control unit. Choices for each line are as follows:  Cell temperature  Cell millivolts  Thermocouple millivolts (T/C millivolts) ...
  • Page 64 PPM scale. hydrocarbon upset condition If the system detects that the oxygen level is 0, and you have selected Hydrocarbon Upset from the Setup/Sensor Config option, the system will display hydrocarbon upset condition information. 4-8 | Thermox CEM O2/TM...
  • Page 65 You can also use this menu option to disable the password requirement. 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 you can access this option and enter a new system password.
  • Page 66 If the correct pressure has been entered into the system, press the En- ter Key without entering a new value to exit this menu option. If the pressure was incorrectly entered, you can reenter it at this point. 4-10 | Thermox CEM O2/TM...
  • Page 67 This menu option allows you to check the Series 2000 control unit for possible problems and to isolate where the problem might be. You may be asked by AMETEK/Thermox personnel to access this menu option to perform system diagnostics. ...
  • Page 68 System Serial # This menu option allows you to view your system serial # and manufac- turing #. You may be asked by AMETEK/Thermox personnel to provide this information upon request. Setting Up the Serial Number Select System Serial # from the Setup menu.
  • Page 69 Primary Calibration The actual furnace temperature set point will vary from unit-to-unit based upon the Primary Calibration which correlates the actual cell response for the desired 615°C cell set point temperature with the actual furnace thermocouple feed back temperature. This is accomplished by applying two known concentrations of oxygen to the analyzer during the primary calibration.
  • Page 70 Perform a primary calibration on your system rather than a regular calibration (from the Calibrate Key) in the following cases: When you replace your zirconium oxide oxygen cell.  When your system fails a regular calibration.  4-14 | Thermox CEM O2/TM...
  • Page 71 You should always try to do a regular calibration before resorting to a  primary calibration in all cases except when you install a new cell. If a regular calibration doesn’t work correctly, see the Calibration Checks NOTE section in the Maintenance and Troubleshooting chapter for possible calibration setup problems affecting the calibration.
  • Page 72 You may need to reenter your alarm setpoints and configura- NOTE tion. Once a hydrocarbon upset condition is reached (and assuming you select- ed Hydrocarbon Upset), the display switches from displaying the oxygen reading to displaying a hydrocarbon condition text message. 4-16 | Thermox CEM O2/TM...
  • Page 73 Communication This menu option allows you to define RS-485 communications param- eters between the Series 2000 control unit and a host device. This includes the following: Baud Rate This parameter allows you to define the baud rate that the control unit and the host computer are using to communicate.

  • Page 74: Analog Range Key

    Define analog output range as 0 to 20 mA or 4 to 20 mA (Set Current  Mode). Define what type of information the analog output should track  (Select Function). Choices are O readings, cell temperature, cell mil- livolts, and thermocouple millivolts. 4-18 | Thermox CEM O2/TM...
  • Page 75 Once you select what type of process readings the analog output  should track using the Select Function menu option, decide what range of these readings the analog output range will cover (Set Cur- rent Range). Decide whether to enable output filtering, and if enabled, how much ...
  • Page 76 Select either Current Output #1 or Current Output # 2. You can then select any of the menu options described in the remainder of this chapter, and they will apply to your selected analog output port. 4-20 | Thermox CEM O2/TM...
  • Page 77 Set Current Range Option This menu option allows you to define the range of readings that the 0-to-20 or 4-to-20 mA (milliamp) output will represent. You can also choose to set a reverse analog output range, so for example, 0 mA can cor- respond to the high end of the oxygen range, and 20 mA can correspond to the low end of the oxygen range.
  • Page 78 After you select one of these options, your choice will be confirmed on the display: Out # 1 will TRACK during Calibration Out # 1 will HOLD during Calibration For verify operations, select one of the following: 4-22 | Thermox CEM O2/TM...
  • Page 79 Hold during verify Track during verify After you select one of these options, your choice will be confirmed on the display: Out # 1 will TRACK during Verify Out # 1 will HOLD during Verify Set Current Mode Option The Set Current Mode menu option allows you to define either a 0-to-20 or 4-to-20 mA analog output range for the selected analog output port.
  • Page 80 Type a number between 1 and 100, then press the Enter Key. Note that you should enter 01 to enter 1, 07 to enter 7, 70 for 70, etc.  The default value is 100 (no filtering). NOTE 4-24 | Thermox CEM O2/TM...
  • Page 81 Select Function Option The Select Function menu option allows you to select what type of infor- mation the analog output port should track. Choices are as follows: • Oxygen • Cell temperature • Thermocouple millivolts (T/C mv) • Cell millivolts (cell mv) Selecting the function Choose Select Function from the Analog Range menu after selecting an analog output port.

  • Page 82: Alarm Key

    The Alarm Key allows you to set control unit alarm information. This includes the following: • Define whether Alarm 3 activates based on oxygen levels, the start of a calibration or the start of a verification. (Select Function). 4-26 | Thermox CEM O2/TM...
  • Page 83 • Define for each oxygen alarm (Alarms 3 and 4) whether the alarm should be a high or low alarm (Alarm Configure). If you selected Hy- drocarbon Upset under the Sensor Config. option from the Setup Key, Alarm 4 is fixed as both a high oxygen alarm and as a hydrocarbon upset condition alarm.
  • Page 84 Setup/Sensor Con- calibration cycle and fig. menu option) during system alarm condition) * Note: Alarms 1 and 2 are reserved for the watchdog timer and service alarms and are not software-selectable. Figure 4-7. Alarm Key overview. 4-28 | Thermox CEM O2/TM...
  • Page 85 Alarm Set Points This menu option allows you to set your alarm limits. Whether these limits represent high or low alarms is defined using the Alarm Configure menu option, although certain restrictions apply (see the “Alarm Config- ure” section. Also, if you select Hydrocarbon Upset as the Sensor Config. option from the Setup Key menu, Alarm 4 is fixed as both a high alarm and the alarm that triggers during a hydrocarbon upset condition.
  • Page 86 Configuring the alarms Select Alarm Configure from the Alarm menu. Define Alarm 3 and Alarm 4 as high or low alarms. Press the Cancel Key to then exit this menu option. 4-30 | Thermox CEM O2/TM...
  • Page 87 Relay Configure All Series 2000 control unit relays are Form A—normally open contacts. You can, however, use the software to set whether your alarms should close on an alarm condition (energize on alarm) or open on an alarm condition (de-energize on alarm). This menu option applies to all alarms, except for the service and watchdog alarms, which are always set to de- energize on alarm (fail-safe).
  • Page 88  pending on whether Alarm 3 should be associated with oxygen levels, or with the start of a calibration or verification. The control unit automatically exits you from this menu after you make your selection. 4-32 | Thermox CEM O2/TM...

  • Page 89: Service Alarm

    Service Alarm The service alarm operates as normally closed (service alarm condi-  tion causes open contacts). NOTE The service alarm provides an alarm that alerts you of possible system problems that require attention. Events that can trigger the service alarm to activate are as follows: Error condition (detected by software) ...

  • Page 90: Exception Log

    Pressing the Down Arrow Key shows later exception log entries. Press- ing the Up Arrow Key shows more recent exception log entries. Press the Cancel Key at any time to exit this menu option. 4-34 | Thermox CEM O2/TM...

  • Page 91: Chapter 5 Calibration

    CAlIbRATION Calibrate Initiate Cal Initiate Verify Cal/Verify Data Cal Gas Value Inject Cal Set Cal Timers Figure 5-1. Configure Calibrate Key menu Verify options. The Calibrate key allows you to use the Series 2000 control unit to cali- brate your analyzer. The Series 2000 control unit provides features that make calibrating your analyzer easy and even includes a way for the system to periodically calibrate itself.

  • Page 92: Definitions

    RCU and into the sensor by pressing a key on the control unit. Manual Calibration You must physically switch the gases because you are not using an RCU. However, you still define the calibration gas values. 5-2 | Thermox CEM O2/TM...

  • Page 93: Overview

    Overview The Calibrate key allows you to do the following (see Figure 5-2) : • Initiate an automatic, remote, or manual calibration or verification. Although automatic calibrations can be set to run at predetermined frequencies, you can also force the system into an automatic calibra- tion (Initiate Cal and Initiate Verify). • View previously collected calibration or verify data (Cal/Verify Data).

  • Page 94: Aborting A Calibration

    Enter Password Enter the four digit system password. To protect the identification of the password, the numbers you enter will not be displayed. You will then be allowed to access Calibrate key functions. 5-4 | Thermox CEM O2/TM...

  • Page 95: Initiate Cal

    Initiate Cal The Initiate Cal menu option allows you to perform an automatic, re- mote, or manual calibration. The Auto Calibrate and Remote Calibrate selections are only available if you have installed an Auto Calibrate card in the Series 2000 control unit and have a Remote Calibration Unit (RCU). If the Series 2000 control unit detects that these options are not installed, it will automatically prompt you with a manual calibration operation when you select the Initiate Cal menu option.
  • Page 96 Recovery xx:xx The system then returns to monitoring process readings, and the calibration is complete. You can view the results of the last calibration using the Cal/Verify Data menu option from the Calibrate key menu. 5-6 | Thermox CEM O2/TM...
  • Page 97 Remote Calibrate Enter the calibration gas value to match the zero calibration gas cylin- der you intend to use to calibrate your system (Cal Gas Values). This value is referred to in this section as the set point value. Select Initiate Cal from the Calibrate key menu. Select Remote Calibration.
  • Page 98 The reading on the far right of the first display line shows the set point value you entered using the Cal Gas Values menu option. This O zero gas set point value should match the cal gas cylin- der for the O span gas. 5-8 | Thermox CEM O2/TM...
  • Page 99 You are then prompted to apply the O zero gas to the calibration inlet port of the sensor: Inject Zero Gas ENTER to Continue CANCEL to Abort Press the Enter key once you have applied this cal gas. The Zero gas display then appears: O2 xx.x Set xx.x Press ENTER to Zero...

  • Page 100: Initiate Verify

    • Define a time period for the system to recover from reading the verify gas to reading process gases (Set Cal Timers/Recovery Duration). Then you can start the auto verify as follows: Select the Initiate Verify option from the Calibrate key menu. 5-10 | Thermox CEM O2/TM...
  • Page 101 Select Auto Verify. The system will begin the automatic verify, and will notify you how long the verify gas will be applied to the sensor from the RCU: Span/Verify Gas xx:xx System Verifying Cal Then the system will display the recovery time remaining: Recovery xx:xx System Verifying Cal The system then returns to monitoring process readings, and the verify...
  • Page 102 You are then prompted to apply the verify gas to the calibration gas inlet port on the sensor (tubing must be free of oil and dirt): Inject Span\Vrfy Gas ENTER to Continue CANCEL to Abort Press the Enter key once you have applied this verify gas. 5-12 | Thermox CEM O2/TM...
  • Page 103 The verify display then appears: O2 xx.x Set xx.x Press ENTER to Verify Press the Enter key once the O reading on the far left of the first display line stabilizes. The reading on the far right of the first display line shows the set point value you entered using the Configure Verify menu option.

  • Page 104: Cal/Verify Data

    Cal Gas Values option from the Calibrate key menu. Press the Enter key to view the zero gas values. 5-14 | Thermox CEM O2/TM...
  • Page 105 The following appears on the display: Zero Value: xx Zero Gas: xx Zero Drift: xx The term zero value on the display is the value the system read during the calibrate/verify operation, and the term zero gas is the set point value entered using the Cal Gas Values option from the Calibrate key menu.

  • Page 106: Cal Gas Value

    Zero Gas = xx New Value? Enter the zero gas value, then press the Enter key. If you wish to keep the current zero gas value unchanged, press the Enter key without entering a value. 5-16 | Thermox CEM O2/TM...

  • Page 107: Inject Cal Gas

    Inject Cal Gas This menu option requires that an auto cal card and RCU are in-  stalled. NOTE This menu option allows you to manually adjust the pressure and flow of your calibration gas (pressure of calibration gas cylinders and flow into sensor) by cycling through the solenoid valves on the RCU.
  • Page 108 CANCEL to quit Press the Cancel key to end the cycle. Then, if you specified a recovery time, the system will display the recov- ery time remaining: Recovery xx:xx The system then returns to monitoring process readings. 5-18 | Thermox CEM O2/TM...

  • Page 109: Set Cal Timers

    Set Cal Timers Set Auto Timers Set Time & Date Auto Cal On/Off Cal Gas Duration Recovery Duration Figure 5-3. Set Cal Timers menu options Set Cal Timers The Set Cal Timers submenu from the Calibrate key allows you to do the following: • Set auto timer for desired auto calibration/verification cycle times (Set Auto Timers).
  • Page 110 As you enter the values, they overwrite the XXs on the display. To enter 1 day or 1 hour, enter 01; otherwise, the system will assume you are entering 10 days (or hours). 5-20 | Thermox CEM O2/TM...
  • Page 111 You will then be prompted to enter the time of day when the first calibra- tion of the cycle should begin: Cal time is YY:YY Enter new time Hr: Mn Enter the time you wish the first calibration or verification to begin, then press the Enter key.
  • Page 112 Select Enable Auto Cal (or Enable Auto Verify) to enable the auto calibration or verification cycle. The system will confirm your enabling or disabling selection: Auto Cal is ENABLED Auto Cal is DISABLED and will then exit this menu option. 5-22 | Thermox CEM O2/TM...
  • Page 113 Set Cal Timers - Cal Gas Duration This menu option allows you to define how long the RCU should apply the span and zero calibration gases to the sensor during an automatic calibration or verification. For a verification, the system uses the span gas inlet for the verify gas.
  • Page 114 Cal Recovery = xx:yy Enter new time: Mn:Sc Enter the recovery time, then press the Enter key. If you wish to use the currently displayed recovery time, press the Enter key without entering any text. 5-24 | Thermox CEM O2/TM...

  • Page 115: Configure Verify

    Configure Verify The Configure Verify menu option allows you to define the verify gas value and the acceptable range of readings for a verify. To set your verify gas value and acceptable verify range, do the following: Select Configure Verify from the Calibrate Key menu. Select whether you wish to enter the verify gas using a percent or PPM scale.
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  • Page 117: Chapter 6 Maintenance And Troubleshooting

    MAINTENANCE AND TROUblEShOOTING The operations in this chapter should be performed only by qualified service personnel with a knowledge of electrical safety techniques. There are no operator-serviceable components inside the CEMO system. An operator should never remove the cover from the controller or sensor.

  • Page 118: System Messages

    This message will not clear from the display by removing or restoring power to the control unit. Cal Verify Aborted This message notifies the operator that the verification was successfully aborted by the system. 6-2 | Thermox CEM O2/TM Analyzer...
  • Page 119 Power Down Detected The system detected that the power was removed. For example, a power outage would cause this message to display. You can acknowledge this system message by setting or reading any user-programmable value and this will clear the message from the display. The message will not clear by removing and restoring power to the unit.

  • Page 120: Error Messages

    Incorrect flow rates between calibration gases  Process pressure incorrectly entered  Failed cell (primary calibration should be run at this time)  Leak or plug in plumbing  Cell lead wires polarity reversed  6-4 | Thermox CEM O2/TM Analyzer...
  • Page 121 Memory is Corrupted This error message indicates that the control unit’s internal EEPROM memory has been corrupted or a significantly new version of software has been installed in the control unit. Under these conditions, the software will reprogram the EEPROM with factory defaults. You can acknowledge this error message by setting or reading any user-programmable value and this will clear the message from the display.
  • Page 122 Shorted thermocouple  Faulty interconnecting wiring  Control unit display module failure  Sensor board failure  If this message is soon followed by a “Thermocouple Failure” message, see that message for troubleshooting instructions. 6-6 | Thermox CEM O2/TM Analyzer...
  • Page 123 Thermocouple Failure This error message occurs when the indicated sensor temperature fall below -70° C. This error message can be the result of one of the following: Open thermocouple  Faulty interconnecting wiring  Control unit display module failure  Verify Failure This error message occurs if the verify gas does not read within the range you defined.

  • Page 124: Diagnostic Checks

    This includes ensuring that sets of wires are not reversed and that the cable is not damaged. See the “Wiring” section in the Installation chapter for cor- rect interconnecting wiring connections. 6-8 | Thermox CEM O2/TM Analyzer...
  • Page 125 Thermocouple Checks Open thermocouple Disconnect power to the control unit and the sensor. Measure across ter- minals “C” and “D” on the sensor board with an ohm meter. If an open is measured, replace the thermocouple. Shorted/failed thermocouple Check that the thermocouple leads are not shorted to chassis ground. To do this, use an ohm meter to measure between terminal C on the sensor board and chassis ground, and between terminal D on the sensor board and chassis ground.
  • Page 126 27 mVs (take memory location 88 which is the T/C Ratio calculated during the primary - thermal calibration and divide the cell temperature by this value to come up with the furnace temperature set point). 6-10 | Thermox CEM O2/TM Analyzer...
  • Page 127 Note: The cell thermocouple compensation circuit on the 80471SE, 80485SE, 80467SE and 80505SE sensor boards is different in compari- son to the 80418SE sensor board that was supplied with Series 2000 based systems prior to 1996 (CE Marked Systems). The 80418SE uses the 40.2-ohm resistor on the display module to sense the current sourced from the AD592.
  • Page 128 The best calibration gas to use for this check is O zero calibration gas. 6-12 | Thermox CEM O2/TM Analyzer...
  • Page 129 Remote Calibration Unit (RCU) problem Problems with the RCU are usually as follows: Vacuum check  Plumbing leaks  Solenoids not energizing  Vacuum Check Perform a vacuum check as follows: Connect a digital volt meter across the connections labeled 1 and 2 on the sensor board.
  • Page 130 (one at a time) until the flow drops to zero. This identifies the defective solenoid valve (replace the solenoid valve being sure that the solenoid O-ring seals are properly positioned). 6-14 | Thermox CEM O2/TM Analyzer...
  • Page 131 Calibration Gas Time Inadequate If you are having problems running an auto calibration, you may not have allowed the calibration gases enough time to flow through the sensor and stabilize. To correct this problem: Select the Inject Cal Gas option from the Calibrate Key menu. ...
  • Page 132 If the analyzer responds to the calibra- tion gas correctly, it indicates either leaking or plugged plumbing on the sample gas line. 6-16 | Thermox CEM O2/TM Analyzer...

  • Page 133: General Troubleshooting

    If your analyzer doesn’t respond properly to the calibration gas, then it may indicate a problem with the cell. Before replacing the cell, put the analyzer through a primary calibration. If this does not work, check the following: Check the proper flow rate and pressure of the gases. ...

  • Page 134: Auto Calibration Card Leds

    O2 span gas should be flowing into the sensor. Zero When lit indicates that the O zero gas solenoid is energized and the zero gas should be flowing through the sensor. 4 through 12 - not used. 6-18 | Thermox CEM O2/TM Analyzer...

  • Page 135: Chapter 7 Service And Parts

    SERVICE AND PARTS The operations in this chapter should only be performed by qualified service personnel with a knowledge of electrical safety techniques. There are no operator serviceable components inside the CEMO2/TM system, and an operator should never remove analyzer component covers.

  • Page 136: Warnings

    • Never use pipe dope or any other contaminant that gives off combus- tible vapor on any joints of the sample tubing. Combustibles in the sample can lead to less than accurate readings. 7-2 | Thermox CEM O2/TM...
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  • Page 138: Cell Replacement/Cleaning

    (approximately one hour). NOTE 11. Perform a primary calibration if you replaced the cell. (See the Primary Calibration section in the Setup Key chapter for help.) 7-4 | Thermox CEM O2/TM...
  • Page 139 Figure 7-1. Cell replacement. Service and Parts...

  • Page 140: Thermocouple Replacement

    After replacing the thermocouple, apply power to the sensor and allow  it to heat up and stabilize (approximately one hour). NOTE Perform a calibration on the system. 7-6 | Thermox CEM O2/TM...
  • Page 141 Cell housing Thermocouple mounting clamp Thermocouple Convection loop Compression mounting clamp fitting Top View - Furnace Figure 7-2. Thermocouple replacement. Service and Parts...

  • Page 142: Furnace Replacement

    Check that neither furnace lead is short circuited to the metal furnace cover. 11. Reattach cell clips. 12. Reattach furnace leads (reverse the actions taken in step 3). Polarity is not important. 13. Calibrate the system. 7-8 | Thermox CEM O2/TM...
  • Page 143 Figure 7-3. Furnace replacement. Service and Parts...

  • Page 144: Parts Replacement List

    P/N 25370JE 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 www.thermox.com 7-10 | Thermox CEM O2/TM...

  • Page 145: Appendix A Serial Communications

    SERIAl COMMUNICATIONS Communication Protocol Communicating to the Series 2000 control unit through the RS-485 serial port requires the following communication parameter settings: 8 data bits 1 stop bit No Parity In addition, the baud rate on the Series 2000 control unit must match the baud rate of the host device.
  • Page 146 Command Message Format Start Character Node Address Command Data Checksum End Character letter “>” (ASCII deci- 2 hex Ascii (See com- (n characters 2 hex ASCII Cariage return mal character 6) characters mands sec- - depends on characters (ASCII decimal (00-FF) tion for list of command)
  • Page 147 General Serial Communication Commands This section provides general serial communication commands. Program- ming commands and Factory setup commands are provided later in this chapter. Normally, you will use these general serial communications com- mands. Read Number (F) This command allows you to read the value of a variable stored in the Series 2000 Controller.
  • Page 148 Read Date and Time (M) This command is used to read the dates and times stored in the Series 2000 Controller. The data consists of a single digit where 0 is used to read the current date and time, 1 is used to read the date and time of the last calibration, and 2 is used to read the date and time of the last verification.
  • Page 149 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 Series 2000 Controller is echoed back to the host. bad Command (b) Just returns a bad command (error code 01) reply.
  • Page 150 Command list This section provides the command letters you can use. Command letter Description Echo Bad Command Acknowledge Read Number Calibrate Write Number Data Format Read Date and Time Set Date and Time Figure A-1. Serial communication commands list. A-6 | Thermox CEM/O2 TM...
  • Page 151 Responses The Series 2000 Controller returns a variety of responses that can be bro- ken into two categories, success and failure. Success All successful responses start with an A. If there is data returned, it will follow the A and have a checksum after it. All responses end with a car- riage return.
  • Page 152 Failure Codes are as follows: Failure Code Description Bad command letter Bad checksum Input overrun in serial communica- tion Parameter out of range Error in receipt of a character Cannot calibrate/verify now Internal error Illegal access (read-only version) Figure A-2. Failure code list.
  • Page 153 Variable Table Figure A-3 provides a summary of the variable locations, names, and de- scriptions available. If you need access to more advanced variables, please call AMETEK. Location Name Description Read/Write *Format Flags_3 (see Table A-4) Read Only H (1 byte)
  • Page 154 Description Read/Write Format sensor at op.temp. over/under temp inject cal gas active Read Only 1 = true 0 = false auto cal is active auto verify is active reserved reserved cal/verify not permitted Figure A-4. Flags_3 variable table. A-10 | Thermox CEM/O2 TM...
  • Page 155 Description Read/Write Format temperature rise failure cell is over temperature zero gas range error span gas range error primary calibration memory is corrupted excessive cal error Read only 1 = true 0 = false calibration required thermocouple failure thermocouple compensation failure verify aborted calibration aborted system verifying...
  • Page 156 Description Read/Write Format relays energize on alarm 1 = true, 0 = false auto cal time is set 1 = true, 0 = false cal timer enabled 1 = false, 0 = true real time clock is set 1 = true, 0 = false Reserved auto verify time is set 1 = true, 0 = false...
  • Page 157 Description Read/Write * Format track/hold output #1 during cal 1=track, 0 = hold track/hold output #1 1 = track, 0 = hold current mode select for output #1 1 = 0 - 20 mA 0 = 4 - 20 mA Reserved track/hold output #2 during verify 1 = track, 0 = hold...
  • Page 158 Sample Program This section provides a sample Quick Basic program that reads and writes to the serial port: DECLARE FUNCTION Checksum$ (M$) ‘Serial test routine ‘ Continuously sends a message and prints the string returned ‘Open the communications port OPEN “COM2:9600,N,8,1 “FOR RANDOM AS #1 ‘String to be echoed T$ = “Test message”...

  • Page 159: Appendix B 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 160 Auto Cal On/Off Auto Cal On/Off Auto Verify On/Off Cal Gas Duration Span Gas Time (Verify gas time if verifying) Zero Gas Time Recovery Duration Enter Recovery Time Figure b-3. Calibrate Key/Set Cal Timers sub-menu. B-2 | Thermox CEM O2/TM...
  • Page 161 AlARM KEY FUNCTIONS/OPTIONS MENU OPTIONS Alarm Set Points Alarm 3 Value Alarm 4 Value Alarm Configure High O Alarm (For Alarms 3 And 4) Low O Alarm Relay Configure Energize On Alarm De-Energize On Alarm Select Function (applies to Alarm 3 only) Start of Calibration Start of Verify Exception Log...
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  • Page 163: Appendix C Current Outputs: Other Applications

    CURRENT OUTPUTS: OThER APPlICATIONS This appendix describes how to do the following: • Power current outputs from an external power supply. • Modulate external power loop using current outputs. 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 + VEXT1, 2 -Jumper...
  • Page 164 IOUT1+ terminal, and the other side of the other load would be connected to the IOUT2+ terminal. For each current output channel used in a current loop modulation applica- tion, the jumpers should be removed for that channel. C-2 | Thermox CEM O2/TM...
  • Page 165 OPTIONAL OUTPUT DEVICE EXTERNAL LOOP (COMPUTER OR POWER SUPPLY CHART RECORDER) MAX VOLTAGE MAX LOAD RESISTANCE 30 VOLTS DC 1200 OHMS Figure C-1. Modulation of external power supply. Current Outputs: Other Applications...
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  • Page 167: Appendix D 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 cutom options, the standard Interconnect 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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