Ametek Thermox WDG-1200 Insitu User Manual
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Ametek Thermox WDG-1200 Insitu User Manual

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Thermox
®
WDG-1200/1210/Insitu
User Manual
Thermox
150 Freeport Road
Pittsburgh, PA 15238
Rev. L
PN 90685VE

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Summary of Contents for Ametek Thermox WDG-1200 Insitu

  • Page 1 Thermox ® WDG-1200/1210/Insitu User Manual Thermox 150 Freeport Road Pittsburgh, PA 15238 Rev. L PN 90685VE...

  • Page 2: Offices

    If the instrument or procedures are used for purposes over and above the capabilities specified herein, confirmation of their validity and suitability should be obtained; otherwise, AMETEK does not guarantee results and assumes no obligation or liability.

  • Page 3: Table Of Contents

    Contents Offices ........................ii Safety Notes ......................vi Electrical Safety ..................... vi Grounding ......................vi CHAPTER 1 Overview System Features ....................1-1 Sensor .........................1-2 Problems to Avoid ....................1-4 Technical Support ....................1-5 CHAPTER 2 Specifications WDG 1200/1210/Insitu Probe ................2-1 CHAPTER 3 Installation and Start-Up Unpacking ......................3-1 Mechanical Installation ..................3-2 Location ......................3-2...
  • Page 4 Crimped Connector Assembly Procedure ...........3-20 Mains Power Supply Plug ................3-22 Mains Connector Assembly Procedure ..........3-22 Fitting of Plug Connectors ................3-22 Pre-operational Checks - Final Checks .............3-23 CHAPTER 4 User Interface and Calibration Control Panel .......................4-1 Abbreviations Used on the Control Panel ............4-2 Using the Probe for the First Time ..............4-3 Warm Up Procedure ..................4-3 Operational Structure ..................4-4...
  • Page 5 CHAPTER 5 Maintenance and Troubleshooting Fault Identification Numbers ................5-3 Fault Description ...................5-4 Bench Testing ....................5-7 In-Situ Probe Testing and Checking ..............5-8 Bench Testing ....................5-12 Maintenance ....................5-13 Routine Maintenance Schedule ............5-13 Essential Maintenance Tools ..............5-13 CHAPTER 6 Service and Parts Inner Probe Assembly Removal ................6-2 Process under Pressure ................6-3 Cell Replacement ....................6-4 Removing the Cell ..................6-4...

  • Page 6: Safety Notes

    Safety Notes WARnInGs, cAuTIons, and noTEs contained in this manual emphasize critical instructions as follows: An operating procedure which, if not strictly observed, may result in personal injury or environmental contamination. An operating procedure which, if not strictly observed, may result in damage to the equipment.
  • Page 7 Environmental Information (WEEE) This AMETEK product contains materials that can be reclaimed and recycled. In some cases the product may contain materials known to be hazardous to the environment or human health. In order to prevent the release of harmful substances into the environment and to conserve our natural resources, AMETEK recommends that you arrange to recycle this product when it reaches its “end of life.”...
  • Page 8 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...
  • Page 9 | ix...

  • Page 10: Chapter 1 Overview

    overview System Features The WDG 1200/1210 Insitu probes are a type of direct insertion oxygen probe used to measure the oxygen in the exhaust of a combustion process. The zirco- nium oxide cell is placed directly in the stream of the products of combustion. The probe is designed for applications in which the flue gas temperature does not exceed 1472°F (800°C), and where combustibles measurements are not required.

  • Page 11: Sensor

    Sensor We recommend that all personnel who will regularly use this analyzer become familiar with the following brief explanation of how the analyzer works and the components that make up the analyzer. The oxygen Measuring Cell The sensing element itself is a closed-end tube or disk made from ceramic zir- conium oxide stabilized with an oxide of yttrium or calcium.
  • Page 12 output signal. Because of the high operating temperature of the cell, combustible  gases that are present may burn. When this occurs, the cell will generate high millivolts and cause the display to indicate less oxygen NOTE than is actually in the gas (net oxygen content). Figure 1-1.

  • Page 13: Problems To Avoid

    Problems to Avoid These are some errors to avoid. If they are avoided, your analyzer will operate with a minimum of maintenance and troubleshooting. • Do not use pipe dope or any other contaminant that gives off combustible vapor which may cause erroneous measurements on any joints of the sample tubing.

  • Page 14: Technical Support

    Technical Support AMETEK/Thermox is committed to providing you 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 representative. Before you call the factory for technical support, run test gases and record the...
  • Page 15 This page intentionally left blank. 1-6 | Thermox WDG-1200/1210 Insitu Probes...

  • Page 16: Chapter 2 Specifications

    specifications WDG 1200/1210/insitu probe General 20°C to 800°C/68°F to 1472°F Flue gas temp: Heater temperature: 750°C ±3°C (1382°F ± 5°F) Pressure: ± 2 psig (± 13.8 kPa) Probe material: 310L Stainless steel Case material: Powder-coated aluminum Mechanical Data WDG 1200/Inistu Probe Length and Weight: Overall length of probe: Approximate Weight: 0.457 m / 18”...
  • Page 17 Dimensions: 152 mm (6”) high 153 mm (6”) wide 130 mm (5.2”) deep Weight: 2.7 kg / 6 lb. Max Distance between Controller and Probe: 150 m (500 ft) calibration Gas Zero Gas: 1 % O in nitrogen recommended (0.1% to 10% possible) Span Gas: 20.9 % O recommended...
  • Page 18 electrical Data 100-240 VAC Voltage range: Frequency: 48-62 Hz Power: 250 W Current Rating: 4 A Peak Over-voltage category: CAT II 3.15A (T) Fuse rating and characteristics: External earth bonding: 6 mm female thread Relay rating: Single pole changeover 2 A at 30 VAC/ Isolation switch rating Miniature Circuit Breaker or Fused Switched Isolator with 5A fuse fitted...
  • Page 19 This page intentionally left blank. 2-4 | Thermox WDG-1200/1210 Insitu Probes...

  • Page 20: Chapter 3 Installation And Start-Up

    InstallatIon and start-up Only qualified service personnel with knowledge of electrical safety techniques should perform the operations in this chapter. There are no operator-serviceable components inside the WDG-1200/1210 Insitu probe. Never service the Insitu probe unless power has been removed from the probe and it has been allowed to cool for at least one hour.

  • Page 21: Mechanical Installation

    Mechanical Installation • Location • Installing the Filter/Flame Arrestor (optional) • Mounting the Sensor • Calibration Setup location Observe the following guidelines when selecting an analyzer instal- lation location. The installation location should be free from excessive vibration. The ambi- ent temperature must be within the limits listed in the specifications chapter in this manual.

  • Page 22: Unpacking The Shipping Protection

    unpacking the shipping protection 1. Remove the Anti-Shock rubber cap, see the picture below: Anti-Shock Rubber Plug 2. Unpack the Mullite ceramic tube as below: Mullite Tube 3. Put the Mullite Tube into the probe, as below: 4. Fit the filter or shield to the end of the probe as shown below Installation and Start-up...

  • Page 23: Fitting A Filter Or Shield To The Probe

    Fitting a Filter or shield to the probe Some protection must always be fitted to the probe tip to prevent foreign objects from entering the probe and damaging the sensor. Never use the probe without protection on the tip..  NOTE The protector can be a mesh screen, flame arrestor, ceramic filter or stainless steel filter, depending on the application.

  • Page 24: Mounting The Sensor

    Mounting the sensor Ambient temperature in the controller area should be less than  160° F (70°C). NOTE Mount the probe and its flange to the flange on the process (see Figure 3-2a and 3-2b). Insulate the pipe nipple with at least 1” (2.54 cm) thick weather- proof insulation.

  • Page 25: Mounting The Controller (Wdg-1210 Insitu Only)

    Mounting the Controller (WdG-1210 Insitu only) Figure 3-3. Model 1210 Insitu oxygen probe system Key Components: Model 1210 Oxygen Probe 8. Mains Power Supply Input to Control 2. Oxygen Control Unit (required) Unit 3. Remote Calibration Unit (optional) 9. Signal Outputs/Relays (customer 4.

  • Page 26: Mounting Guidelines

    Mounting Guidelines Mount the control unit to a flat, vertical surface at a height where the display is clearly visible and the key panel user interface is readily accessible. There should be a minimum of 150 mm (6”) clearance below to enable both the electrical connections and signal cable connections to be made.

  • Page 27: Installing The Controller

    Installing the Controller All dimensions are given in millimeters/inches. Figure 3-5. Control unit dimensional Information. Mounting the Control unit The Control Unit is mounted to a vertical, flat surface using the four (4) 7mm (0.28”) mounting holes as seen in Figure 3-5. Figure 3-6.

  • Page 28: Calibration Setup

    Calibration setup Figures 3-7a and 3-7b show the location of the calibration gas inlet port on both units. When calibrating the system, connect your calibration gases to this inlet port. Figure 3-7a. Calibration Gas port WdG-1200 Insitu. Calibration Gas Port Figure 3-7b.

  • Page 29: Electrical Connections

    Electrical Connections The customer is responsible for providing all switch cabinets, distribution boxes, fuses and other components for electrical installation as well as the mains power supply connections. The use of a circuit breaker or an isolations switch and a 5A (max) ...

  • Page 30: Optional Signal Connections

    optional signal Connections The following signal outputs may be connected: • Current Loop • Calibration in Progress relay • RS485 Serial Communications • Alarms relay • System OK relay Normal (for normally open N/O and normally closed N/C) is defined ...

  • Page 31: Plug Plate Connector Designation - Wdg-1210 Insitu

    plug plate Connector designation - WdG-1210 Insitu pluG platE ConnECtor dEsIGnatIons (view from underside of probe) 1. Power Supply 2. Connections to Automatic Gas Calibration Control Unit (option) 3. Customer I/O 4. Power Supply connection to measurement probe 5. Signal Connections from measurement probe (cell, thermocouple, heater) Ensure dust covers are fitted to any unused connectors.

  • Page 32: System Cables

    system Cables The power supply must be isolated before any electrical connections are made. recommendations for laying Cable • Mains and signal cables should be laid separately. If cable crossings cannot be avoided they should be made at an angle of 90°. •...

  • Page 33: Cable Recommendations - Wdg-1200 Insitu

    Cable recommendations - WdG-1200 Insitu WdG-1200 Insitu Cable recommendations Max. o.d. no. of Core Core size Core ref. description shielded Cores size mm strands/dia size awg Mains Supply 16/0.2 Calibration 7/0.2 Outputs/Relays 7/0.2 Cables 1 and 3 are supplied with the analyzer. Cable 2 is supplied with the re- mote calibration unit.

  • Page 34: Pin Designations - 1200/1210 Insitu

    pin designations - 1200/1210 Insitu the following is a list of pin designations for Connectors 1, 2, and 3. Wire Color Connector ref. Insert arrangements Function option 1 option 2 1.Mains Power Ground Green/Yel- Green/Yel- Line Black1 Orange Neutral Black2 Black not used none...
  • Page 35 Wire Color Wire Color Connector ref. Insert arrangements Function 3. Outputs/Relays Current Loop -ve Red/Blue White* Current Loop +ve Brown White ** Calibration White*** Trigger +ve Calibration Orange White**** Trigger 0V RS485 Shield Green/Red Yellow* RS485 B (two Red/Brown Yellow** NOTE: wire half duplex) Normal (for normally open N/O and normal-...
  • Page 36 the following is a list of pin designations for Connectors 4 & 5 - WdG-1210 Insitu only. probe Wire Color Connector ref. Insert arrangements description Con- option 1 option 2 nect 4. Mains Supply Ground Earth/Ground Yellow/ Yellow/ Green Green Heater Live/Line Black1 Heater Neutral/Return...

  • Page 37: Probe Connections - Wdg-1210 Insitu Only

    probe Connections - WdG-1210 Insitu only Make the connections ensuring the cables are routed correctly as shown in Figure 3-8. Cell +ve Cell -ve Thermocouple +ve Thermocouple -ve Cold junction +ve Cold junction -ve Heater Live/Line Heater Neutral/Return Not Used Earth/Ground Ground Stud Figure 3-8.

  • Page 38: Grounding

    Grounding External grounding points are provided. These should be connected to local ground. Correct grounding is essential for compliance with EMC regulations. Ground Point Ground Point Ground Point Calibration Gas Port Ground Point Installation and Start-up 3-19...

  • Page 39: Assembly Of Connector Plugs

    assembly of Connector plugs The pin designation of each connector is repeated on each individual  plug. NOTE In most cases, complete cable assemblies are supplied with the analyzer. If cus- tom cables must be assembled, it will be necessary to terminate the cables using the following procedure: pluG ConnECtor assEMBlY KEY 1.
  • Page 40 5. Push the pins into the correct slots (7). They will snap into place when posi- tioned correctly (pull & tug to check). Fit pins to all slots, regardless of cable connections made. Follow the ‘Pin Designations’ correctly.  NOTE 6.

  • Page 41: Mains Power Supply Plug

    Mains power supply plug Ensure there is sufficient clearance to enable connection and disconnec-  tion of the mains connector. NOTE Mains Connector assembly procedure Remove approximately 15mm / 0.6” of the cable’s outer cover to expose the inner cores. Thread the exposed cores through the cable clamp.

  • Page 42: Pre-Operational Checks - Final Checks

    pre-operational Checks - Final Checks Check that a blanking plug has been securely fitted to the calibration gas con- nector on the probe. If the blanking plug is not fitted, air leaking into the probe via the  connector can cause measurement errors. In a pressurised flue, gases venting to atmosphere through the connector could cause cor- NOTE rosion of the test gas tube.

  • Page 43: Chapter 4 User Interface And Calibration

    User Interface and calIbratIon control Panel • Menus are displayed in a 4-character format. • The oxygen concentration is displayed in four-digit floating decimal point format. Fault data: In addition to gas readings and system configuration, comprehensive diagnostics information can be accessed in the event of system malfunction. figure 4-1. control Panel Mode Key Used to move through the menu options. Return Key Used to enter values and select options. Up/Down Keys Used to select values ready to enter. Heater OK This indicator flashes when the heater is functioning corrrectly.

  • Page 44: Abbreviations Used On The Control Panel

    abbreviations Used on the control Panel ALAR Alarm Analog output AUTO Automatic calibration BASE Analog Output 0-20 4-20mA etc. Calibration EMF of cell CELT Temperature of cell Cold junction compensation temperature CONF Configuration Cal time interval DIAG Diagnostics DPNG Damping Faults PRAD Probe address...

  • Page 45: Using The Probe For The First Time

    Using the Probe for the first time Before turning on the power supply to the probe, check the following: • Ensure that a blanking plug has been fitted to the calibration gas connector on the probe. Air can enter the probe through this connector and cause high O readings. In a pressurized flue, gases venting to atmosphere can cause corro- sion of the test gas tube. • Ensure installation has been completed including any optional equipment, for example, a remote calibration unit. • Check that all of the connections have been completed. Warm Up Procedure After a short period the Heater OK LED will begin to flash, indicating the heater is operating. Until the probe has reached working temperature the probe will default to a reading of 20.90. The System OK LED will light when the probe has reached working tempera- ture, this usually takes about 20 minutes. System OK LED (Green) Heater OK LED (Flashes Green) System Fault LED (Red if fault occurs) figure 4-2.

  • Page 46: Operational Structure

    operational structure The operational structure can be described as a Menu Spine that allows access to five other menus. Before you can access the Menu Spine, you must enter a pass- word and set the maintenance relay. Scroll through the Menu Spine by pressing F1 to display the five available menus: Calibration Diagnostics Alarms System Configuration Analog Outputs Each of these menus is accessed by pressing Enter when it is displayed on the Menu Spine. Each of the main menus allows access to a sub-menu with options. Password The password may consist of up to four digits ranging from 0 to 9999. Enter the correct password to change any of the analyzer settings. Without a password, analyzer settings can only be viewed and not altered or stored. Maintenance relay option The maintenance relay option must be set to YES to activate or NO to deactivate it, and then entered before the Menu Spine can be viewed. Set the maintenance relay by pressing the UP and DOWN keys accordingly. The maintenance relay is...

  • Page 47: Probe Display Settings

    Probe display settings operational structure diagram calIbratIon MenU Display Action Display Action O2 Display ▼ configuration Menu auto cal. Span gas conc. Value Zero gas conc. Value Manual cal. Menu Cal time interval Value Zero Value Time to next cal Value Span Value Cal settling time...

  • Page 48: Calibration Screens

    calibration screens calibration Menu Ensure that installation of the analyzer is complete (see installation manual) and that the SYSTEM parameters have been set. If the analyzer is in maintenance mode the two outer decimal points displayed will flash; during calibration, all four will flash. The following information is required: • Span gas concentration • Zero gas concentration If the automatic calibration option is selected, the following settings are also needed: • Time until first calibration • Time necessary for the calibration gas flow to stabilize • Time interval between calibrations ▼ Display Action CONFIGURATION Sub-menu Span gas conc. Enter value Zero gas conc. Enter value ▼ Cal time interval Enter value Time to next cal Enter value...
  • Page 49 All the options necessary to calibrate the analyzer can be accessed using the Cali- bration menu. The Calibration menu consists of three sub-menus: • Configuration • Automatic Calibration • Manual Calibration. To access these menus, from the Calibration menu, press Enter. Use the F1 key to scroll through the menus. Each option within the sub-menu is set by pressing Enter, selecting the appropriate value using the UP and DOWN keys, and press- ing Enter again. The value is set and the display will scroll on to the next option. User Interface / Calibration...
  • Page 50 ↵ ↵ Span gas concentration (CAL COnF SgAS) OPTIONS Set concentration of span calibration gas To set the concentration of the gas used to calibrate the span of the analyzer: RANGE Press enter 5 to 25 % O Select a value using the UP and doWn keys Press enter again.
  • Page 51 ↵ ↵ Calibration settling time (CAL COnF SEtL) OPTIONS Set time for calibration read- ings to settle The period required for the calibration gas to stabilize is normally two minutes. If using long lengths of piping the RANGE time may need to be extended. To enter the settling time: 30 to 1600 sec Press enter Select a value using the UP and doWn keys...

  • Page 52: Alarm Screen

    alarm screen alarm Menu Display Action ALARM enter value The alarm sub-menu has only one option. Access this menu by pressing enter from the alarm display. The option is set by selecting a value using the UP and doWn keys and pressing enter again.

  • Page 53: Analog Outputs Screens

    analog outputs screens Display Action ZERO enter Value ▼ Display Action SPAN Enter Value ▼ Display Action DAMPING Enter value ▼ Display Action BASE Enter value ▼ Display Action TRACK analog outputs Menu All the options necessary to set analyzer outputs can be accessed using the Analog Outputs menu. The Analog Outputs menu consists of five sub-menus: • Zero • Span •...
  • Page 54 ↵ Zero setting (AO ZEro) OPTIONS Set zero reading output To set the minimum O concentration of the analog output RANGE range: 0 to 20 % Press enter Select a value using the UP and doWn keys DEFAULT Press enter again. ↵...

  • Page 55: Diagnostics Screens

    diagnostics screens diagnostics Menu The Diagnostics menu consists of three sub-menus: • Faults • Cell status • Resistance test. To access these menus, from the Diagnostics display, press Enter. To scroll through the menu, press F1. Each option within the sub-menu can be viewed by pressing Enter. Display Action FAULT LIST Display ▼ Display Action EMF OF CELL Display Cell temperature Display ▼ Cold junction temp. Display Display Action RESISTANCE TEST Display User Interface / Calibration 4-13...
  • Page 56 Fault list (diAg) OPTIONS View faults To display the fault list, press enter when the diagnos- RANGE tics screen is on view. Each fault is represented by a NOT APPLICABLE particular number and can be identified using the Fault DEFAULT Table in Chapter 5.

  • Page 57: System Configuration Screens

    system configuration screens system configuration Menu All the options necessary to configure the analyzer are accessed using the System Configuration menu. The System Configuration menu consists of five sub- menus: • Probe type • Baud setting • Negative readings • Probe address • Revision number. These sub-menus are accessed by pressing Enter from the System Configura- tion display. Scroll through the menus pressing F1. Each option within the sub-menu can be set by pressing Enter, selecting the appropriate value using the UP and DOWN keys and pressing Enter again. The value will be set and the display scrolls on to the next option. Display Action Probe type. Enter value ▼ Display Action Baud Enter value ▼ Display Action Negative reading ▼...
  • Page 58 ↵ Probe type (SySt Prty) OPTIONS Set probe type To select the probe type: Press enter RANGE Select a value using the UP and doWn keys 673 to 1172 Press enter again. DEFAULT NOTE: The default setting corresponds to the Model 1023 1200/1210 probe.

  • Page 59: Output Setup

    output setup system outputs The current loop output can provide one of two output functions: Track Measurement output is tracked during normal reading and calibration operations. Hold Measurement output is held at the last reading prior to calibration, and resumes after the final calibration settling period. Output Held Analog Outputs Set to ‘HOLD’ (’NO’ selected) Span Level Analog Outputs Set to ‘TRACK’ (’YES’ selected) Zero Level ACTIVATED DEACTIVATED Setting Time Calibration in Progress Relay During Automatic Calibration ACTIVATED DEACTIVATED Calibration in Progress Relay...

  • Page 60: Analog Outputs Menu

    analog outputs Menu To set the analog outputs, you must enter the password, set the maintenance relay, and select the Analog Outputs menu. From menu spine ▼ Display Action ZERO Enter value ▼ Display Action SPAN Enter value ▼ Display Action DAMPING Enter value ▼ Display Action BASE Enter value ▼ Display Action TRACK 4-18 | Thermox WDG-1200/1210 Insitu Probes...

  • Page 61: Analog Output Settings

    analog output settings All the options necessary to set the analyzer outputs can be accessed using the Analog Outputs menu. The Analog Outputs menu consists of five sub-menus: • Zero • Span • Damping • Base • Track. To access these sub-menus, from the Analog Outputs display, press Enter. To scroll through the menu, press F1. Each option within the sub-menu is set by pressing Enter, selecting the appropriate value using the UP and DOWN keys, and pressing Enter again. The value will be set and the display scrolls on to the next option. Zero reading This is the reading to be output when the analyzer measures at the zero cali- brated value.
  • Page 62 track setting The analog output may be set to track the O levels or hold the last reading during calibration. This is set by pressing enter, selecting Yes to track or no to hold using the UP and doWn keys, and then pressing enter again. 4-20 | Thermox WDG-1200/1210 Insitu Probes...

  • Page 63: Modbus Interface

    Modbus Interface serial data bus configuration The serial data bus can be set to any of the following four configurations: code baud rate Parity stop bits 1200 1200 Even 4800 4800 Even 9600 9600 Even 96nP 9600 None Data format: Modbus RTU The default setting is 1200. To chnage the serial data setting: Press F1. Use the up arrow until the display reads 417 and press Enter. Press Enter again and F1 four times until the display shows: SYSt. Press Enter and F1 until the display shows: bAud. Press Enter and use the up and down arrows to change the baud code. When correct, press and hold Enter until the display flashes. Proceed to next section. slave address and floating Point format The default slave address is 11. To change the slave address, first set the baud rate as in previous section, then: Press F1. The display shows: PrAd.

  • Page 64: Register Numbers

    register numbers This manual uses Register Numbers as defined in the Modbus specifications. The first register number is 1. Modbus packets contain Register offsets which are one less than register Numbers and start at offset 0. data types Integer variable Single register. registers numbers for Instrument readings (integer value) address Variable scaling Reading 1000 Cell Temperature ( command register address Variable scaling Status and Calibration Start To start the calibration sequence, write the value 1 to register 30. Maintenance status register address Variable scaling Maintenance State The value of Register 19 is 1 when the Maintenance Relay is on; otherwise it is 4-22 | Thermox WDG-1200/1210 Insitu Probes...

  • Page 65: Modbus Rs485 Interface

    Modbus rs485 Interface Figure 4-3. RS485 Bus topology. Figure 4-4. Two -wire RS485 connection. User Interface / Calibration 4-23...

  • Page 66: Full Register

    full register list nonvolatile (saved on power down) register Variable scaling Password Cal Span Gas Cal Zero Gas Cal Time Interval Settling Time Alarm Limit 1000 Probe Address Analog O/P Zero Analog O/P Span Analog O/P Damping Analog O/P Base Probe Type Baud Rate Zero Coefficient...
  • Page 67 The ‘Status and Calibration Start’ register 20 is used both to trigger a calibration and to monitor the instrument status. The meaning of each bit is as shown in the table below: Meaning Start Calibration. 0 (LSB) Write “1” to start calibration Zero Calibration acknowledged Span Calibration acknowledged 3 to 9 Not used Failed in Calibration Cold Junction Error Cell too hot Zero Coefficient out of range Span Calibration out of range Temperature out of range 15 (MSB) (±...

  • Page 68: Zero And Span Calibration

    Zero and span calibration Full (zero and span) calibration may be carried out manually, set to occur auto- matically at defined time intervals, or triggered from a remote device. To set the calibration options you must enter the password, set the maintenance relay, and select the Calibration menu. Configuration of calibration parameters must be completed as shown overleaf before full calibration is carried out. The following information is required: • Span gas concentration • Zero gas concentration • Time until first calibration • Time necessary for the calibration gas flow to stabilize • Time interval between calibrations access to calibration Menu from Menu spine oxygen concentration The oxygen concentration measured by the probe is displayed first and will take no longer than 20 minutes to stabilize after connect- ▼...
  • Page 69 isplay Action Configuration Sub-menu Span gas conc. Enter value ▼ Zero gas conc. Enter value Cal time interval Enter value Time to next cal Enter value Cal settling time Enter value Display Action aUto cal. enter or F1 ▼ Display Action ManUal cal Sub-menu...

  • Page 70: Configuration

    configuration The five options available within the Configuration sub-menu are accessed by pressing Enter from the Configuration display. Each option is set by pressing Enter, selecting an appropriate value using the UP and DOWN keys, and press- ing Enter again. configuration sub-Menu You must set the five sub-menu options in order for the analyzer to perform ▼ zero and span calibrations. These options configure the analyzer for span and zero calibration gas concentrations, calibration intervals, timing of cali- bration intervals, and time allowed for readings to settle during calibration.

  • Page 71: Automatic Calibration

    automatic calibration The Automatic Calibration sub-menu has only one option. Access this option by pressing Enter from the Auto Calibration display. The Auto Calibration option is selected by pressing Enter, selecting YES using the UP key and press- ing Enter again. automatic calibration sub-Menu If selected, the analyzer will perform a zero calibration first and then a span calibration. The calibration gases will be allowed to flow automatically from the calibration gas unit. To bypass this option, press f1. ▼...

  • Page 72: Manual Calibration

    Manual calibration The Manual Calibration sub-menu has two options: • Zero • Span Calibration These options are accessed by pressing Enter from the Manual Calibration display. Both options are initiated by connecting the appropriate calibration gas, pressing Enter, waiting for the reading to settle, and then pressing Enter to con- tinue, or pressing F1 to bypass the option. To avoid possible errors which can be introduced by separate zero  and span calibration, the zero and span MUST be calibrated to- gether. NOTE Manual calibration Zero and span calibration are performed manually from this sub-menu ▼...
  • Page 73 span calibration The span calibration reading is checked by connecting the calibration gas via the calibration gas inlet on the probe and pressing enter. The reading displayed will need approximately 120 seconds to settle. ▼  Recommended span calibration gas concentration is 20.90% O (i.e., ambient air).

  • Page 74: Chapter 5 Maintenance And Troubleshooting

    maintenance and troubleshooting The operations in this chapter should be performed only by qualified service personnel with knowledge of electrical safety techniques. There are no operator-serviceable components inside the WDG-1200/1210 Insitu probe. Never service the probe unless power has been removed from the probe and it has been allowed to cool for one hour.
  • Page 75 System Fault LED (red) The fault sub-menu is accessed through the Diagnostics menu on the Menu Spine. If a fault occurs, a fault identification number is displayed. This identification number refers to possible faults on the Fault Identification Table (Table 1). If no fault has been identified by the analyzer, then a zero (0.00) will be displayed.

  • Page 76: Fault Identification Numbers

    Fault identification numbers Each fault is identified by a specific number as follows: Heater temperature out of the control band (±5°C) 00.02 span coefficient out of range 00.10 Zero coefficient out of range 3.00 thermocouple fault and heater above maximum limit 40.00 Cold junction temperature fault 600.0 Failed in calibration 7000 The Fault Identification Number may represent a multiple fault, in which case the individual identification numbers are added together. Use the table below as a quick reference for faults listed above.

  • Page 77: Fault Description

    Fault description Key to Elements column of each fault: Probe Fault is related to probe Wiring Fault is related to wiring of system Mains Fault is related to mains power supply Fault is related to Remote Calibration unit For all actions referring to the Remote Calibration Unit refer to the  relevant operating manual. NOTE (a) heater temperature out of control band 00.02. The probe temperature has not increased/decreased or is too high during the warm up period.
  • Page 78 (b) span coefficient out of range 00.10. The calculated span coefficient from span calibration cycle is outside the expected value range. cause element action 1. Poor wiring, contacts Wiring Check wiring and clean contacts. dirty. 2. span gas concentration Probe Check calibration configuration settings. not entered correctly. 3. span gas not flowing Check gas pipework and valves.
  • Page 79 (d) thermocouple fault and heater above maximum limit 40.00. The analyzer is measuring an unexpected voltage from the probe thermocouple. cause element action 1. thermocouple open circuit. Probe Check probe wiring. 2. thermocouple wired in reverse polarity. Wiring Check connections. 3. thermocouple failed (very unlikely event). Probe Replace heater - thermocouple assembly. (e) cold junction temperature fault 600.0. The analyzer is reading an unexpected voltage from starting, or correctly complet- ing, an auto calibration cycle.

  • Page 80: Bench Testing

    bench testing When the fault has been resolved, the probe should be bench-tested before fitting it back into the flue. 1. Allow the probe to operate in air for about 20 minutes in order to achieve tem- perature stability. 2. Periodically check the cell EMF reading after the initial stabilizing time has expired.

  • Page 81: In-Situ Probe Testing And Checking

    in-situ Probe testing and checking In-situ checking will assist with identifying errors or faults associated with the probe. Cell output voltage can be displayed on the user interface using the Diagnostics menu as an alternative to the following manual checks. After any corrections the system must be fully calibrated.
  • Page 82 Measure the voltage across the thermocouple (T/C) contacts at the probe. Refer to Table 2. Mains power connections on the probe. High risk of electric shock ! 1. Cell +ve 2. Cell -ve 3. t hermocouple +ve 4. t hermocouple -ve 5. Cold junction +ve 6. Cold junction -ve 7. H eater live/line 8. H eater Neutral/Return...
  • Page 83 Table 2 gives the voltage that should be present at the probe thermocouple connections (Step 6), according to the temperature measured at Step 5, when the probe has stabilized at 750°C/ 1382°F. table 2 - thermocouple v. ambient temperature for a probe at 750°c/1382°F ambient temperature: ambient temperature: (°c)
  • Page 84 If the thermocouple voltage is high, relocate the probe to a position  where the flue temperature is 800°C/1272°F or lower. NOTE 7. Disconnect the thermocouple leads from the thermocouple (TC) terminals and check the thermocouple for open or short circuit. A short circuit usually indicates a wiring fault rather than a faulty ...

  • Page 85: Maintenance

    maintenance routine maintenance schedule Ensure the following routine maintenance schedule is followed. Failure to do so may invalidate the terms of warranty. Every Month Perform a complete calibration (unless automatic calibration is enabled). Every 6 months comPonent Procedure action Ceramic Filter Visual inspection.
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  • Page 87: Chapter 6 Service And Parts

    Service and PartS The operations in this chapter should be performed only by quali- fied service personnel with knowledge of electrical safety techniques. There are no operator-serviceable components inside the system. Never service the controller or Insitu probe unless power has been removed from the controller and the probe has been allowed to cool for one hour.

  • Page 88: Inner Probe Assembly Removal

    inner Probe assembly removal Remove power before replacing any parts on the WDG-1200/1210 Insitu. Most of the procedures in this chapter require that you first remove the inner probe assembly (see Figure 6-1). 1. Ensure that power is removed from the control unit and allow the sensor to cool for one hour.

  • Page 89: Process Under Pressure

    6. Slide the inner probe assembly out of the outer protective tube by pulling on its handle. Process under Pressure If the process is under pressure, place a blind plate and gasket over the flange hole (blind plate and gasket included in insitu accessory kit). •...

  • Page 90: Cell Replacement

    cell replacement removing the cell 1. Remove the inner probe assembly as described in the previous section, Inner Probe Assembly Removal. 2. Mark the position of the U-bolt relative to the heater by drawing a line on either side of the U-bolt on the top of the heater. This will help you mark the correct heater position to show how far the heater should be placed into the inner probe assembly during reassembly.
  • Page 91 5. With the probe oriented in front of you so that the cell assembly end is on your right and the sheet metal plate is on your left, rotate both the sheet metal plate (handle end of probe) and the left hex nut counterclockwise at the same time until the left hex nut becomes unthreaded from the inner probe assem- bly.

  • Page 92: Fitting The New Cell

    To prevent twisting of the cell leads, keep the mark on the left hex nut and the orientation of the white cell lead from being more than one quarter turn from each other (see Step 2). Turning them together will prevent this from occurring.
  • Page 93 2. Unscrew the cell assembly from the inner probe assembly. 3. Slide the heater, cell clips, and cell leads forward through the end of the inner probe assembly until the cell clips are exposed. 4. Slide the new metal O-ring over the heater and cell clips assembly so it is po- sitioned at the end of the inner probe assembly.
  • Page 94 12. Using a flat blade screwdriver, snap the new retainer clip over the cell clip to provide a strong contact between the cell clip and the cell. The retainer clip is concave; place the pointed end away from the cell. 13.
  • Page 95 Figure 6-4. cell clip with attached cell leads. Figure 6-5. cell and retainer clip placement. Service and Parts...

  • Page 96: Heater/Thermocouple Replacement

    Heater/thermocouple replacement removing Heater (See Figure 6-3) 1. Remove the inner probe assembly as described in the previous section, Inner Tube Assembly Removal. 2. Remove the cell as described in the Cell Replacement section above under the Removing the Cell subsection. 3.

  • Page 97: Spare Parts

    Spare Parts Cell Lead Kits For 9” Probe 95382WE For 18” Probe 95383WE For 36” Probe 95384WE For 72” Probe 95385WE For 108” Probe 95386WE Cell, Zirconia Electrochemical 71785SE Filter & Flame Arrestor Assembly 71863SE Filter Deflector, Insitu 71764SE Filter, Ceramic, 5 Micron 71849SE Filter, Ceramic, 5 Micron w/shield 71862SE...
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  • Page 99: Appendix A Drawings And Custom Instructions

    drawings and custom instructions This appendix provides any custom drawings or instructions you may have ordered in addition to the standard WDG-1200/1210 Insitu probes. If you didn’t order any custom options, the standard Interconnect Drawing is provided. If you did order any special options, the drawings or special instructions provided here supersede any drawings or options provided elsewhere in this manual.
  • Page 100 A-2 | Thermox WDG-1200/1210 Insitu Probes...

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