Ametek CEM/Humox User Manual
  1. Manuals
  2. Brands
  3. Ametek Manuals
  4. Measuring Instruments
  5. CEM/Humox
  6. User manual

Ametek CEM/Humox User Manual

Moisture in flue gas analyzer
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Thermox
CEM/Humox -
®
Moisture in Flue Gas Analyzer
User Manual
Thermox
150 Freeport Road
Pittsburgh, PA 15238
PN 90486VE, Rev. K

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the CEM/Humox and is the answer not in the manual?

Questions and answers

Related Manuals for Ametek CEM/Humox

Summary of Contents for Ametek CEM/Humox

  • Page 1 Thermox CEM/Humox - ® Moisture in Flue Gas Analyzer User Manual Thermox 150 Freeport Road Pittsburgh, PA 15238 PN 90486VE, Rev. K...

  • Page 2: Offices

    © 2001 AMETEK This manual is a guide for the use of the Thermox CEM/Humox 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, confirmation of their validity and suitability should be obtained;...

  • Page 3: Table Of Contents

    Table of Contents OFFICES ....................ii Safety Notes ..................vii Environmental Information (WEEE) ............ ix CHAPTER 1 OVERVIEW Basic Elements of the Sensor .............. 1-2 Common Operator Errors ..............1-5 Technical Support ................1-6 CHAPTER 2 SPECIFICATIONS Control Unit ..................2-1 Sensor ....................
  • Page 4 Wiring Checks ............... 6-8 Thermocouple Checks ............6-9 Calibration ................6-11 AC Power Checks ............... 6-13 Furnace Checks ..............6-12 Process Pressure Checks ............ 6-13 Cell Checks ................. 6-13 General Troubleshooting ..............6-14 Leak Check ................6-14 iv | Thermox CEM/Humox Analyzer...
  • Page 5 CHAPTER 7 SERVICE AND PARTS Cell Replacement/Cleaning ..............7-4 Thermocouple Replacement..............7-6 Furnace Replacement ................7-8 Parts Replacement ................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 Series 2000 Controller and O2 Only RCU also have the following safety compliance: UL 1604 UL Listed Process Control Equipment for Use in Hazardous Location Manufacturer’s Address in Europe: AMETEK Precision Instruments Europe GmbH Rudolf-Diesel-Strasse 16 D-40670 Meerbusch, Germany Mark Coppler Compliance Engineer July 2001 vi | Thermox CEM/Humox Analyzer...

  • Page 7: 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 8 Switched Off or the Area is Known to be Non-Hazardous. All input and output wiring must be in accordance with Class I, Division 2 wiring methods (NEC Sec 501.4(b) or CEC 18-152) and in accordance with the authority having jurisdiction. viii | Thermox CEM/Humox Analyzer...

  • 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 hu- man 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 OTHER MANUFACTURER’S EQUIPMENT, WHETHER SOLD SEPARATELY OR IN CONJUNCTION WITH EQUIPMENT OF OUR MANUFACTURE. WE DO NOT AUTHORIZE ANY REPRESENTATIVE OR OTHER PERSON TO ASSUME FOR US ANY LIABILITY IN CONNECTION WITH EQUIPMENT, OR ANY PART THEREOF, COVERED BY THIS WARRANTY. x | Thermox CEM/Humox Analyzer...

  • Page 11: Chapter 1 Overview

    OVERVIEW The CEM/Humox - Moisture in Flue Gas Analyzer is designed to measure net oxygen and moisture content in flue gas and process applications. The O and moisture data is used to improve efficiency, identify water or tube leaks, correct emissions, assure product quality, or minimize stack corrosion.

  • Page 12: Basic Elements Of The Sensor

    Basic Elements of the Sensor The CEM/Humox analyzer consists of the following basic system. The Plumbing All inlet and outlet tubing (cell housing), the sensing cell, and the sensing cell fitting. The Measuring System The sensing cell, interconnecting wiring, and the control unit.
  • Page 13 tion of the ratio of the two oxygen partial pressures. If the oxygen partial pres- sure of one gas is known, the voltage produced by the cell indicates the oxygen content of the other gas. A reference gas, usually air (20.9% O ), is used for one of the gases.
  • Page 14 = 20.9% O dry / 10 (dry cell mV/AT) AT - Cell logarithmic slope (ideally 48 mV per decade for T = 695°C) A - Constant (.0496 mV/decade/°K) T - Temperature (°K)(°C + 273) 1-4 | Thermox CEM/Humox Analyzer...

  • Page 15: Common Operator Errors

    Common Operator Errors These are some common errors to avoid; if they are avoided, your analyzer will operate with a minimum of maintenance and troubleshooting. If your process is running and the analyzer is installed on the process, the ana- ...

  • Page 16: Technical Support

    Technical Support AMETEK/Thermox is committed to providing the best technical support in the in- dustry. 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 fol-...

  • Page 17: Chapter 2 Specifications

    SPECIFICATIONS Control Unit Display Four line x 20 character vacuum fluorescent. Displays combinations of percent moisture, oxygen (wet or dry), time and date, cell temperature (wet or dry), cooler temperature, user programmable text, thermocouple mV (wet or dry) or cell mV (wet or dry).
  • Page 18 Enclosure Standard 19” rack mount Optional: GP (general purpose) wall mount, GP panel mount, weatherproof NEMA 4 (IP 56) wall/panel mount, and stainless steel weath- erproof NEMA 4X (IP 56) wall/panel mount. All are UL Listed for NEC Class I, Division 2 areas.

  • Page 19: Sensor

    Sensor Operating Range Oxygen: 0.1% to 100% Moisture: 5% to 85% by volume Accuracy Oxygen: ± 0.75% of reading or 0.1% absolute Moisture: ± 3% of reading or ± 1%, whichever is greater Response Time Less than 4 seconds at 2 scfh over one decade Max.
  • Page 20 This page intentionally left blank. 2-4 | Thermox CEM /Humox Analyzer...

  • Page 21: Chapter 3 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 CEM/Humox sys- tem. Never service the sensor unless power has been removed and it has been allowed to cool for at least one hour.

  • Page 22: Mounting The Wet And Dry Cem/O Sensors

    CEM system. The other part, still wet and uncondi- tioned, goes directly to the other CEM/O analyzer to provide the wet reading. Both sensors should measure the same sample without a time delay that could affect the accuracy of the reading. 3-2 | Thermox CEM/Humox Analyzer...

  • Page 23: Sample Gas Requirements/Connection

    Sample Gas Requirements/Connection Figure 3-1 shows the inlet and outlet ports on the CEM/O sensor. The sample gas should be clean and dry. If the sample contains any condensing moisture, the entire sample line should be heat traced. The sensor may operate at a steady internal pressure up to 20 WC (5 kPa). Outlet restrictions that raise the pressure beyond this level may cause false or unstable readings.

  • Page 24: Calibration Setup

    Figure 3-2 . PROCESS/CAL CONTROL VALVE SAMPLE PROCESS GASES OTHER GAS CEM/O2 ANALYZER(S) SERIES 2000 CONTROL VACUUM TO PULL SAMPLE Figure 3-2. Cal/Process gas setup example (no RCU). 3-4 | Thermox CEM/Humox Analyzer...

  • Page 25: Control Unit Mounting

    Control Unit Mounting The Series 2000 Control Unit comes with different packaging options: • The weatherproof enclosure can be mounted to either a panel, a wall, or to a pole. • The general purpose enclosure can be mounted as a panel, a rack, or a wall mount.
  • Page 26 Z-Purge Start-up Procedure: Power shall not be restored after the enclosure has been opened until the enclosure has been purged for 1 hour at a pressure of 0.4” of water. Figure 3-5. Series 2000, weatherproof wall/Z-purge. 3-6 | Thermox CEM/Humox Analyzer...
  • Page 27 General Purpose - Panel Figure 3-6 shows the panel mount- ing dimensions for the Series 2000 general purpose enclosure. This ver- sion can be mounted in panels up to 1” thick. Figure 3-6. Series 2000, general purpose panel mount. General Purpose - 19” Rack Figure 3-7 shows the mounting di- mensions for the Series 2000 general purpose 19”...

  • Page 28: Wiring

    Remove the three screws on this shield to gain access to the wiring card. Figure 3-9. Wiring card (rack/panel mount orientation). 3-8 | Thermox CEM/Humox Analyzer...

  • Page 29: General Wiring And Conduit Requirements

    Any screw terminals on the wiring card not described in this section  are reserved for future use. NOTE This wiring section shows you how to make the following connections: • AC mains supply wiring to control unit • AC mains supply wiring to sensor •...

  • Page 30: Control Unit Mains Supply Connections

    NOTE These markings are for reference purposes only such as for use on sys- tem wiring diagrams etc. The system/product has or needs no specific LINE or NEUTRAL connection for any function, safety or otherwise. 3-10 | Thermox CEM/Humox Analyzer...
  • Page 31 The (N) terminal is not internally grounded, nor needs to be. The system will operate normally regardless of what 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.
  • Page 32 As an example, do not run motors, blowers, or air condition- ers using the same mains supply circuit or conduit as the control unit’s mains supply circuit or conduit. 3-12 | Thermox CEM/Humox Analyzer...
  • Page 33 Sensor connections This section describes required wiring connections between the control unit and the sensor. Follow the connection instructions for the applicable options for your analyzer. All sensor connections require that you access the sensor board (see Fig- ure 3-12). Sensor cabling must be twisted pairs in rigid metal conduit or in an ...
  • Page 34 15 amperes, with a switch or circuit breaker in close proximity to the sensor and within easy reach of an operator. Mark the switch or circuit breaker as the sensor disconnecting device. 3-14 | Thermox CEM/Humox Analyzer...
  • Page 35 Standard sensor connections Make these connections from the control unit to the Dry Sensor Board (see Figure 3-13): CONTROL UNIT LABEL DRY SENSOR TERMINAL NUMBER Cell + (one pair) Cell - Furnance (one pair) 15V COM T/C + (one pair) T/C - 15V SPLY Figure 3-13.
  • Page 36 If you intend to power current outputs from an external power supply,  see the “External Powering and Modulation of External Power Using Current Outputs” appendix. NOTE Figure 3-15. Current output connections example. 3-16 | Thermox CEM/Humox Analyzer...
  • Page 37 Alarm contact 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 Alarms Key section. Alarm connections The Series 2000 control unit provides six sets of standard alarm contacts, which are labeled as follows (see Figure 3-16): ALARM 1A/1B through ALARM 6A and 6B...
  • Page 38 Figure 3-16. Series 2000 alarm connections example. 3-18 | Thermox CEM/Humox Analyzer...

  • Page 39: Rs-485 Communications Connections

    RS-485 Communications Connections The Series 2000 control unit has the ability to communicate with other computers that use the same protocol and have the same hardware interface. See the “Serial Communications” Appendix in the back of this manual for information on the RS- 485 serial communications protocol.
  • Page 40 Figure 3-17. Series 2000, 2-wire RS-485 communication connection. 3-20 | Thermox CEM/Humox Analyzer...
  • Page 41 4-Wire connections The connections used for the RS-485 4-wire communications on the wiring card are labeled as follows: 4WTX+/2W+ 4WTX-/2W- 4WRX+ 4WRX- Connect all control unit 4WTX+, 4WTX-, and all 4WRX+ and 4WRX- connections in parallel in a daisy chain fashion. Make the following connections between the host computer and the controller in a daisy chain fashion (see Figure 3-18): Host Computer TX- to Controller 4WRX- Host Computer TX+ to Controller 4WRX+...
  • Page 42 Figure 3-18. Series 2000, 4-wire RS-485 communication connections. 3-22 | Thermox CEM/Humox Analyzer...
  • Page 43 Removing display module or power supply/keypad module This section describes how to remove or replace the display module or power sup- ply keypad module on the control unit (see Figure 3-19): 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 44 3-24 | Thermox CEM/Humox Analyzer...

  • Page 45: Chapter 4 Controller / User Interface

    CONTROLLER / USER INTERFACE This chapter provides a brief overview on how to use the Series 2000 control unit. This includes the following topics: Areas of the Control Unit  Setup Key Functions  Analog Range Key Functions  Alarm Key Functions ...
  • Page 46 (corresponding to a high or low alarm) will appear next to the process reading on that display line. See “Alarm Setpoints” in the Alarm Key section for details. Figure 4-1. Front view of Series 2000 Control Unit. 4-2 | Thermox CEM/Humox Analyzer...
  • Page 47 Control Unit Keys This section provides an introduction to the main Series 2000 control unit keys. Each of these keys provides you a menu of choices you can select. Setup key - Allows you to set the control unit for your specific application. ...
  • Page 48 Enter key). For example, to get on-line help on the 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/Humox Analyzer...

  • Page 49: Setup Key

    Setup Key Display Passwords Wet Process Press Dry Process Press System Serial # System Tests Figure 4-2. Primary Calib Communication Setup Key menu options. Cooler Temp Setup Key The Setup key allows you to do the following: Define what information to place on each display line (Display). ...
  • Page 50 Cooler temperature  Cell temperature (wet or dry)  Cell millivolts (wet or dry)  Thermocouple millivolts (T/C millivolts) (wet or dry)  Current date/time  User text  Turn off (leave display line blank)  4-6 | Thermox CEM/Humox Analyzer...
  • Page 51 When you access menus, menu options can occupy display lines 3  and 4, and sometimes display line 2. Therefore, we recommend that you place the information that is most critical for you to view on the NOTE topmost display lines. Select Display from the Setup menu.
  • Page 52 NOTE If no one at your site can remember the correct password, you can call AMETEK/Thermox and a service password will be provided to you so you can access this Password option and enter a new system password. Select Passwords from the Setup key menu.
  • Page 53 Dry Process Pressure This menu option allows you to define your dry process pressure. It also allows you to define whether your process is operating under a positive or negative pressure. Setting this value corrects dry oxygen measurements for the defined pressure. Select Dry Process Press from the Setup key menu.
  • Page 54 If the correct pressure has been entered into the system, press the Enter key without entering a new value to exit this menu option. If the pressure was incor- rectly entered, you can reenter it at this point. 4-10 | Thermox CEM/Humox Analyzer...
  • Page 55 System Tests This menu 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 56 System Serial # This menu option allows you to view your system serial # and manufacturing #. You may be asked by AMETEK/Thermox personnel to provide this information upon request. Select System Serial # from the Setup menu. Select System Serial # or Manufacturing #.
  • Page 57 Based upon the age of your cell and its characteristics, the control temperatures should be slightly different. However if you incorrectly perform a primary calibra- tion or if the cell really starts to deteriorate, the actual cell response to calibration gas will drop off.
  • Page 58 During the recovery time immediately following the primary calibra- tion, you may see some temperature related error messages. You can ignore these messages and assume no problem exists. This is because after a primary calibration, the cell temperature is adjusted. 4-14 | Thermox CEM/Humox Analyzer...
  • Page 59 This menu allows you to select the External cooler temperature for the dry O correction • Internal - not applicable for the CEM/Humox. Please select External • External - the controller will prompt you to enter the control temperature for the external cooler control.

  • Page 60: Analog Range Key

    Define what information should be sent to the analog output port during a  calibration. Decide whether to hold the output at the last process reading taken before the start of calibration or track the calibration readings (Set Track/Hold). 4-16 | Thermox CEM/Humox Analyzer...
  • Page 61 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 Func-  tion). Choices are percent moisture, oxygen (dry or wet), cell temperature (wet or dry), cell millivolts (wet or dry), and thermocouple millivolts (wet or dry).
  • Page 62 Enter password Enter the four digit system password. To protect the identification of the pass- word, the numbers you enter will not be displayed. You will then be able to access Analog Range key functions. 4-18 | Thermox CEM/Humox Analyzer...
  • Page 63 Select an Analog Output Port Before you can define any Analog Range key functions, you must first choose whether they will apply to analog output ports 1, 3, or 4 on the wiring card of the control unit. Analog output port 1 is labeled I OUT 1; analog output port 3 is labeled I OUT 3, and analog output port 4 is labeled I OUT 4 on the wiring card.
  • Page 64 Out # y 4 ma = xx New Value? where xx is the value that the current output currently represents. Type the value to correspond to the 4 (or 0) mA analog output. 4-20 | Thermox CEM/Humox Analyzer...
  • Page 65 Set Track/Hold This menu option allows you to decide what signals to send to the selected analog output port during a calibration or verification. You have the option to either hold the last process reading or track calibration readings. Separate decisions can be made for verify and calibrate operations, so you can, for example, hold the last process readings during verifications, but track calibration gas readings during calibrations.
  • Page 66 Select Output Filtering from the Analog Range key after selecting an analog output port. You will be prompted to enter an output filtering value: [100 = FAST 1 = SLOW] Fltr = XX New #? 4-22 | Thermox CEM/Humox Analyzer...
  • Page 67 where XX is the current filter value. Note that 100 equals no filtering, and 1 equals the highest possible filter value. 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).

  • Page 68: Alarm Key

    Define whether alarm relays should energize or deenergize on alarm (Relay  Configure). The selection you make using the Relay Configure menu option applies to all alarms except the watchdog and service alarms, which always deenergize on alarm. 4-24 | Thermox CEM/Humox Analyzer...
  • Page 69 Define alarm set point values (Alarm Set Points). Whether these act as high or  low alarms is defined using the Alarm Configure menu option. View exception log data (Exception Log). The exception log provides a history  of events, such as system or error messages, alarm conditions, and the start of calibrations or verifications.
  • Page 70 Alarm #4 = xx New Value? Enter the alarm 4 set point value. You are then prompted to enter the alarm 5 set point value: Alarm #5 = xx New Value? Enter the alarm 5 set point value. 4-26 | Thermox CEM/Humox Analyzer...
  • Page 71 You are then prompted to enter the alarm 6 set point value: Alarm #6 = xx New Value? Enter the alarm 6 set point value. Press the Cancel key or the Enter key to then exit this menu option. Alarm Configure This menu option allows you to define whether alarms should trigger based on a high alarm or a low alarm condition, and also to select what reading to track.
  • Page 72 If you select Energize on Alarm, the following message will appear: Relays are set to ENERGIZE on Alarm If you select Deenergize on Alarm, the following message will appear: Relays are set to DEENERGIZE on Alarm 4-28 | Thermox CEM/Humox Analyzer...
  • Page 73 Select Function This menu option allows you to select the type of reading that Alarm 3 should track: % Moisture/% Oxygen  When the system starts a calibration  When the system starts a verification  When the system starts a calibration or verification (dual function). ...
  • Page 74 (hidden keys to the left and right of the Setup key) for a long enough time will in turn cause a watchdog, which will indicate as a beep after the system restarts upon release of the reset keys. 4-30 | Thermox CEM/Humox Analyzer...
  • Page 75 Exception Log The exception log provides a history of the following types of events: System or error messages  Alarm conditions  Reset conditions  Start of calibrations or verifications  Choose Exception Log from the Alarm menu. The system shows you the most recent exception log entry on line four of the display, and shows when this event was recorded on line three.
  • Page 76 This page intentionally left blank 4-32 | Thermox CEM/Humox Analyzer...

  • Page 77: Chapter 5 Calibrate Key

    Calibrate Key Initiate Cal Initiate Verify Cal Gas Value Cal/Verify Data Set Cal Timers Inject Cal Gas Figure 5-1. Bias Adjustment Calibrate Key menu options. CALIBRATE KEY The Calibrate key allows you to use the Series 2000 control unit to calibrate your analyzer.

  • Page 78: Definitions

    Span vs. Zero Gas This chapter also refers to the terms span and zero calibration gases. The span gas is the high calibration gas. The zero gas is the low calibration gas. 5-2 | Thermox CEM/Humox Analyzer...

  • Page 79: Types Of Calibrations

    Types of Calibrations The Series 2000 control unit allows you to perform manual calibrations only. The CEM Humox does not support automatic or remote calibration since the Remote Calibration Unit cannot be connected to the Series  2000. All references to remote or automatic calibration in this manual NOTE should be ignored.

  • Page 80: Overview

    Information in this chapter is presented to you in the order in which the menu options appear in the Calibrate key menu, from top to bottom. Where applicable, calibration and verification operations have been consolidated. 5-4 | Thermox CEM/Humox Analyzer...

  • Page 81: Aborting A Calibration

    CALIBRATE KEY MENU FUNCTION OPTIONS Initiate Cal/Initiate Verify Start an automatic, remote or manual calibration Cal/Verify Data View latest calibration and verify data Cal Gas Values Enter calibration gas values Inject Cal Gas Set pressure and flow on RCU gases without per- forming a calibration Set Cal Timers - Set Control unit time/date.

  • Page 82: Enter A Password

    Enter password • Enter the four digit system password. To protect the identification of the pass- word, the numbers you enter will not be displayed. You will then be allowed to access Calibrate key functions. 5-6 | Thermox CEM/Humox Analyzer...

  • Page 83: Initiate Cal And Initiate Verify

    Initiate Cal and Initiate Verify The Initiate Cal menu option allows you to perform a manual calibration. The Initiate Verify menu option allows you to perform a manual verification. Because these menu options function almost identically, we will discuss them together. See the introduction to this chapter for more information on the difference between a calibration and a verification.
  • Page 84 Also, when performing a primary calibration or the first calibration after a primary calibration, the reading and the setpoint values often won’t match. Once the first regular calibration after a primary calibration is performed, the readings should match. 5-8 | Thermox CEM/Humox Analyzer...
  • Page 85 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: D O2 xx.xx Set xx.xx W O2 xx.xx...

  • Page 86: Cal/Verify Data

    Cal Gas Values option from the Calibrate key menu. Press the Enter key to then view the dry cell zero gas values. The following then appears on the display: Zero Value: xx % DO2 Zero Gas: %DO2 Zero Drift: %DO2 5-10 | Thermox CEM/Humox Analyzer...
  • Page 87 The term zero value on the display is the value the system read during the calibrate/verify operation, and the term zero gas is the setpoint value entered using the Cal Gas Values option from the Calibrate key menu. Press the Enter key. You are then prompted with the calibration data for the wet oxygen cell.

  • Page 88: Cal Gas Value

    Enter the zero gas value, then press the Enter key. You can enter up to two decimal points (for example, 2.00% O ). If you wish to keep the current span gas value unchanged, press the Enter key without entering a value. 5-12 | Thermox CEM/Humox Analyzer...

  • Page 89: Chapter 6 Maintenance And Troubleshooting

    MAINTENANCE AND TROUBLESHOOTING 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 CEM-Humox system. Never service the controller or sensor unless power has been removed from the controller and sensor, and the sensor has been allowed to cool for at least one hour.

  • Page 90: System Messages

    You can acknowledge this system message by setting or reading any user programmable value, and this will clear the message from the display. This message will not clear by removing and restoring power to the unit. 6-2 | Thermox CEM/Humox Analyzer...

  • Page 91: Primary Calibration

    Primary Calibration This message appears when the system is performing a primary Calibration (see the Setup key for further information on primary calibration). The message continues to be displayed during the recovery period after the primary calibration. System Calibrating This message indicates that a system calibration is in progress. It will appear during the entire automatic calibration cycle or during the recovery period of a remote or manual calibration.

  • Page 92: Error Messages

    Calibration has failed. This message could indicate one of the following problems: Calibration gas setup problem  Process pressure incorrectly entered  Failed cell  Leak or plug in plumbing  6-4 | Thermox CEM/Humox Analyzer...

  • Page 93: Memory Is Corrupted

    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 the factory default values.

  • Page 94: Temp Rise Failure (Wet Or Dry Cell)

    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/Humox Analyzer...

  • Page 95: Thermocouple Failure (Wet Or Dry Cell)

    Thermocouple Failure (Wet or Dry Cell) This error message occurs when the indicated wet or dry sensor temperature falls 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 ...

  • Page 96: Diagnostics Checks

    This includes ensuring that sets of wires are not reversed, and that the cable is not damaged or melted. See the “Wiring” section in the Installation chapter for correct sensor  interconnecting wiring connections. NOTE 6-8 | Thermox CEM/Humox Analyzer...

  • Page 97: Thermocouple Checks

    Thermocouple Checks Open thermocouple Remove power to the control unit and the sensor. Measure across terminals “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 98 The change was implemented on later sensor board designs (80471SE, 80485SE, 80467 SE and 80505SE) due to the confusion caused by seeing a display that was approximately 12 mVs higher than the voltage measured at the terminals on the wiring board. 6-10 | Thermox CEM/Humox Analyzer...

  • Page 99: Calibration

    Calibration Calibration gas check Check that the correct calibration gas values have been entered into the control  unit. To do this, select the Cal Gas Value menu option from the Calibrate key on the control unit and check that the calibration gas values entered match the analyzed concentration of the cylinders.

  • Page 100: Ac Power Checks

    F1 on the wiring card. If this fuse is OK, replace the control unit power supply/keypad module. If this fuse is not OK, replace the fuse (1/4 amp, 125 volts, IEC speed type FF). Check the interconnecting wiring for short circuits before ap- plying power to the control unit. 6-12 | Thermox CEM/Humox Analyzer...

  • Page 101: Process Pressure Checks

    Process Pressure Checks To check that you entered the process pressure correctly, select the Process Pressure menu option from the Setup key. Also ensure that the calibration process pressure equals normal operating process pressure. Calibration should only be performed under these conditions for highest accuracy. Cell Checks If the cell fails when you first begin to use the analyzer, it is likely that there is a leak in the sensor plumbing or an improper calibration gas setup, and there is not...

  • Page 102: General Troubleshooting

    1 and 2 on the sensor board (Cell + and Cell -) to see if the cell millivolts change, indicating a leak. 6-14 | Thermox CEM/Humox Analyzer...

  • Page 103: Chapter 7 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 CEM/Humox system. Never service the controller or sensor unless power has been removed from the controller and sensor, and the sensor has been al- lowed to cool for one hour.
  • Page 104 • Never use pipe dope or any other contaminant that gives off combustible vapor on any joints of the sample tubing. Combustible vapor in the sample tubing can lead to erroneous readings. 7-2 | Thermox CEM/Humox Analyzer...
  • Page 105 THIS PAGE INTENTIONALLY LEFT BLANK. Service and Parts...

  • Page 106: Cell Replacement/Cleaning

    Before performing a primary calibration, first apply power to the sensor and allow it to heat up and stabilize (approximately one hour).  NOTE Perform a primary calibration if you replaced the cell. (See the “Primary Cali- bration” in the Setup Key section for help.) 7-4 | Thermox CEM/Humox Analyzer...
  • Page 107 Figure 7-1. Cell replacement. Service and Parts...

  • Page 108: Thermocouple Replacement

    Before performing a primary calibration, first apply power to the sensor  and allow it to heat up and stabilize (approximately one hour). NOTE Perform a primary calibration. (See “Primary Calibration” in the Setup Key section for help.) 7-6 | Thermox CEM/Humox Analyzer...
  • Page 109 Top View - Furnace Cell housing Thermocouple mounting clamp Thermocouple Convection loop Compression mounting clamp fitting Figure 7-2. Thermocouple replacement. Service and Parts...

  • Page 110: Furnace Replacement

    The resistance should be infinite. If you measure a short circuit, loosen the screw that secures the thermocouple and relocate slightly until resistance is infinite. 11. Reattach cell clips. 12. Reattach furnace leads (reverse the actions taken in step 3 (polarity not required). 7-8 | Thermox CEM/Humox Analyzer...
  • Page 111 Convection loop mounting clamp Cell housing Thermocouple Furnace Union fitting Compression fitting Figure 7-3. Furnace replacement. Service and Parts...

  • Page 112: Parts Replacement

    P/N 80517SE 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: 412.828.0399 www.thermox.com 7-10 | Thermox CEM/Humox Analyzer...

  • Page 113: 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 114 ?? (?? is equivalent to 2 ASCII 63 characters). This makes testing by the programmer easy, but it is strongly recommended NOTE that the integrity check is enabled in the final system. A-2 | Thermox CEM/Humox Analyzer...
  • Page 115 General Serial Communication Commands This section provides general serial communication commands. Programming com- mands and Factory setup commands are provided later in this chapter. Normally, you will use these general serial communications commands. Read Number (F) This command allows you to read the value of a variable stored in the Series 2000 Controller.
  • Page 116 Due to the nature of EEPROM memory, each location in the memory has a limited number of writes allowed (approximately 10,000). The location character can be used to determine where the data is stored internally to the Series 2000 Controller and act accordingly. A-4 | Thermox CEM/Humox Analyzer...
  • Page 117 Command List This section provides the command letters you can use. Letter Description Echo Bad Command Acknowledge Read Number Calibrate Write Number Data Format Read Date and Time Set Date and Time Serial Communications...
  • Page 118 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 carriage return. Sucess <CR> Sucess Data Checksum End Character (ncharacters) (2hexASCII <CR> characters) Examples: A <CR> Simple acknowledge AFF0050<CR> Acknowledge with data A-6 | Thermox CEM/Humox Analyzer...
  • Page 119 Failure All failure responses start with a N followed by a two hex digit failure code and a carriage return. Failure Failure Code End Character (2 hex ASCII characters) <CR> Failure Codes are as follows: Failure Code Description Bad command letter Bad checksum Input overrun in serial communication Parameter out of range...
  • Page 120 24 - Future use bit 25 - Future use bit 26 - Future use bit 27 - Low oxygen bit 28 - Power down detected bit 29 - Warming up bit 30 – Reserved bit 31 – Reserved A-8 | Thermox CEM/Humox Analyzer...
  • Page 121 02h/002d Config_flags System configuration flags (1=true, 0=false) Read and Write bit 0 - relays energize on alarm. If not, they deen- ergize. bit 1 - auto calibration time is set, an auto calibra- tion will happen at the set time if the auto calibra- tion is enabled bit 2 - auto calibration timer is enabled, since this is enabled, an auto calibration will occur at the auto...
  • Page 122 Dry Oxygen setpoint value used during last verify Read only 37h/055d Dry_Ver_zero Dry Oxygen zero gas read during last verify Read only 38h/056d Dry_O2_zero Dry Zero gas millivolts read during last calibration Read only 39h/057d Reserved A-10 | Thermox CEM/Humox Analyzer...
  • Page 123 3Ah/058d Reserved 3Bh/059d Reserved 3Ch/060d Reserved 3Dh/061d Reserved 3Eh/062d Reserved 3Fh/063d Reserved 40h/064d Reserved 41h/065d Reserved 42h/066d Reserved 43h/067d Reserved 44h/068d Reserved 45h/069d Cal_h10 Auto calibration time 10 hour value Read and Write 46h/070d Cal_h1 Auto calibration 1 hour value Read and Write 47h/071d Cal_m10...
  • Page 124 Same as Alm3_flg 87h/135d Alm6_flg Configuration for alarm 6, high or low. If a bit is 1, Read and Write that is the condition that the indicated alarm will trip on. Same as Alm3_flg A-12 | Thermox CEM/Humox Analyzer...
  • Page 125 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 126 Use this variable to determine when to activate solenoids (if not controlling solenoids using the Series 2000 control unit). Read the Calflag variable to determine when the cal cycle is finished (Calflag=3). 6. Read the calibration values (for example, wet_cal_span and wet_cal_zero vari- ables). A-14 | Thermox CEM/Humox Analyzer...

  • Page 127: 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 DRY process pressure. Dry Process Pressure Enter process pressure value.
  • Page 128 High sensor alarm % O2 Wet Low sensor alarm % O2 Dry * Note: Alarms 1 and 2 are reserved for the watchdog timer and service alarms and are not software-selectable. Figure B-3. Alarm Key menu options. B-2 | Thermox CEM/Humox Analyzer...
  • Page 129 CALIBRATE KEY MENU FUNCTION OPTIONS Initiate Cal/Initiate Verify Start an automatic, remote or manual calibration Cal/Verify Data View latest calibration and verify data Cal Gas Values Enter calibration gas values Inject Cal Gas Set pressure and flow on RCU gases without per- forming a calibration Set Cal Timers - Set Control unit time/date.
  • Page 130 This page intentionally left blank. B-4 | Thermox CEM/Humox Analyzer...

  • Page 131: Appendix C Current Outputs: Other Applications

    CURRENT OUTPUTS: OTHER APPLICATIONS This appendix describes how to do the following: • Modulate external power loop using current outputs. • Power current outputs from an external power supply. Powering Current Outputs from an External Power Supply The Series 2000 control unit wiring card contains a set of terminals that can be used to connect an external voltage source to power the standard current outputs: VEXT1, 2 + VEXT1, 2 -Jumper...
  • Page 132 To determine the minimum external voltage supply required to power the current outputs, use the following formula: VEXTmin = .02 amps (RLoad + Rwires) + 4 volts where: VEXTmin = t h e m i n i m u m e x t e r n a l v o l t a g e r e q u i r e d t o p o w e r current output circuit RLoad = the load resistance of the current output device Rwires = the resistance of the wires...
  • Page 133 Modulation of External Power Loop Using Current Outputs Figure C-1 shows an example of the connection method when you want to produce a modulated current loop from an external power supply and a load device. All cur- rent output channels (IOUT1 and IOUT2) can be connected in the same manner as shown in this figure.\ IOUT1 and IOUT2 must share the same power supply if both of these channels are used, or two power supplies can be “ORed”...
  • Page 134 OPTIONAL Figure C-1. Modulation of external power supply. C-4 | Thermox CEM Humox Analyzer...

  • Page 135: 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 customer options, the standard Interconnect drawing is provided. If you ordered special options, the drawings or special instructions provided here supersede any drawings or options provided elsewhere in the manual.
  • Page 136 This page intentionally left blank. D-2 | Thermox CEM/Humox Analyzer...

Table of Contents