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

Ametek Thermox CEM/O2 User Manual

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Thermox
CEM/O2 Oxygen Analyzer
User Manual
Thermox
P/N 90275VE REV. R
150 Freeport Road
Pittsburgh, PA 15238

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  • Page 1 ® Thermox CEM/O2 Oxygen Analyzer User Manual Thermox P/N 90275VE REV. R 150 Freeport Road Pittsburgh, PA 15238...

  • Page 2: Offices

    © 2012 AMETEK This manual is a guide for the use of the Thermox CEM/O2 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, confirmation of their validity and suitability should be obtained;...

  • Page 3: Table Of Contents

    Table of Contents OFFICES ......................... ii Safety Notes ......................v Electrical Safety ......................v Grounding ......................v Environmental Information (WEEE) ...............vii CHAPTER 1 Overview Sensor Operations ....................1-1 Sensor ........................1-2 Basic Elements of the Sensor ..............1-2 The Oxygen Measuring Cell ..............1-2 Common Operator Errors ................1-4 Start-up Checklist ....................1-5 Technical Support ....................1-6 Return of Equipment ..................1-6...
  • Page 4 Aborting a Calibration ..................5-4 Initiate Cal and Initiate Verify ................5-5 Auto Calibrate/Auto Verify .................5-5 Remote Calibrate/Remote Verify ...............5-7 Manual Calibrate/Manual Verify ...............5-8 Cal/Verify Data ....................5-9 Cal Gas Value ....................5-11 Inject Cal Gas ....................5-12 Cal Timers ......................5-13 iv | Thermox CEM/O2 Analyzer...
  • Page 5 Set Cal Timers - Set Time and Date ............5-14 Set Cal Timers - Auto Cal On/Off ............5-14 Set Cal Timers - Cal Gas Duration ............5-15 Set Cal Timers - Recovery Duration ............5-16 Configure Verify ....................5-17 CHAPTER 6 Maintenance and Troubleshooting System Messages ....................6-2 Auto Cal Pending ..................6-2 Auto Verify Pending ..................6-2...
  • Page 6 Powering Current Outputs from an External Power Supply ....C-1 Modulation of External Power Loop Using Current Outputs ....C-3 APPENDIX D Drawings and Custom Instructions APPENDIX E SERIES 2000 Controller Setup Parameters Sensor Default Settings ..................E-1 vi | Thermox CEM/O2 Analyzer...

  • Page 7: Safety Notes

    Safety Notes WARNINGS, CAUTIONS, and NOTES contained in this manual emphasize criti- cal 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 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. If you decide to service this equipment be aware that high voltages, high temperatures, and other potentially hazardous conditions may arise.

  • 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 sub- stances into the environment and to conserve our natural resources, AMETEK recommends that you arrange to recycle this product when it reached its “end of...
  • Page 10 Series 2000 Controller and O2 -Only RCU, O2 also conform to the following safety standard: 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 Compliance Engineer July 2001 x | Thermox CEM/O2 Analyzer...
  • 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...
  • Page 12 This page intentionally left blank. xii | Thermox CEM/O2 Analyzer...

  • Page 13: Chapter 1 Overview

    OVERVIEW Sensor Operations The sample flows through the sensor plumbing because of convective mo- tive force. The sample in the vertical cell housing is heated to 695°C, while the sample in the return vertical tube is at about 250°C. This temperature difference generates a density difference, which circulates the gas through the system.

  • Page 14: Sensor

    If the oxygen partial pressure 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. 1-2 | Thermox CEM/O2 Analyzer...
  • Page 15 Figure 1-1. Zirconium oxide cell principle of operation. Since the voltage of the cell is temperature dependent, the cell is main- tained at a constant temperature. Some newer high temperature insitu models use the heat from the process to heat the sensor, and the process temperature is continuously measured and used in the software calcula- tion.

  • Page 16: Common Operator Errors

    Always replace the metal O-ring when replacing the oxygen cell.  Allow at least one hour after closing the sensor door for readings to  stabilize. Allow more time after a cold startup. 1-4 | Thermox CEM/O2 Analyzer...

  • Page 17: Start-Up Checklist

    Start-up Checklist Review the installation chapter and installation drawing, which is  provided in this packet and also in the User’s Manual. 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 ...

  • Page 18: Technical Support

    Technical Support AMETEK/Thermox is committed to providing you the best technical sup- port in the industry. If you need service or application assistance, please call AMETEK at (412) 828-9040, or your local AMETEK/Thermox represen- tative. Before you call the factory for technical support, run test gases and...

  • Page 19: Chapter 2 Specifications

    SpecificationS Series 2000 control Unit Four-line x 20-character vacuum fluorescent. Displays combinations of oxy- gen, ppm combustibles, methane, time and date, cell temperature, user-pro- Display grammable text, thermocouple mV or cell mV. Password protection, program- mable pressure compensation and context-sensitive help are also provided. Two isolated linear current outputs.

  • Page 20: Sensor

    2% or from 0.1 to 10% O , balance N System Compliance EMC Compliance: 2004/108/EC Safety Compliance: 73/23/EEC NOTES All static performance characteristics are with operating variables constant. System accuracy referenced to 0.1 to 10% calibrated range. 2-2 | Thermox CEM/O2 Analyzer...

  • Page 21: Remote Calibration Unit (Rcu)

    Remote Calibration Unit (RCU) O2 Only RCU Enclosure UL Type 4X (NEMA 4X (IP56) Environment Ambient Temperature: -18°C to 60°C Humidity: 0 to 90%, non-condensing Max Altitude: 2000 Meters IEC Installation Category II IEC Pollution Degree 2 System Compliance EMC Compliance: 2004/108/EC Safety Compliance: 73/23/EEC Specifications...
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  • Page 23: Chapter 3 Installation And Start-Up

    INSTALLATION AND START-UP The operations in this chapter should be performed only by qualified  service personnel experienced in electrical safety techniques. There are no operator-serviceable components inside the CEM O2 system. NOTE 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: Mechanical Installation

    10.0 25.4 6.75 6.00 17.0 15.3 12.0 20.0 30.5 Mount 12.75 Vertically 32.39 Outlet 1/4" Compression tube fitting 1.25 .31" dia. 3.00 Holes for Inlet 1/4" fasteners 1/4" Compression tube fitting Figure 3-1. Sensor mounting. 3-2 | Thermox CEM/O2 Analyzer...

  • Page 25: 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 condens- ing moisture, the entire sample line should be heat traced. The sensor may operate at a steady internal pressure up to 20” WC (5 kPa).

  • Page 26: Remote Calibration Mechanical Installation (Optional)

    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” section that follows). 3-4 | Thermox CEM/O2 Analyzer...

  • Page 27: Factory-Provided Remote Calibration Unit Setup

    Factory-Provided Remote Calibration Unit Setup This section shows how to use the optional factory-provided Remote Cali- bration Unit (RCU) to connect your zero and span calibration gases, and to switch between the sample and calibration gases. See the “Wiring” section in the Installation chapter for help on how to ...
  • Page 28 Sensor Control Valve Sample Gas Calibration Solenoid Gas line Valve 1/4" OD O2 span gas Calibration Regulator Solenoid Flowmeter Zero Valve Calibration To be kept to a minimum Remote Calibration Figure 3-5. RCU flow diagram. 3-6 | Thermox CEM/O2 Analyzer...
  • Page 29 RCU calibration setup example 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.

  • Page 30: Control Unit Mounting

    Weatherproof - Panel Figure 3-9 shows the panel mounting dimen- sions for the Series 2000 weatherproof enclo- sure. Use 1/4” diameter fasteners to mount the control unit to the panel. Figure 3-9. Series 2000, weatherproof panel mount. 3-8 | Thermox CEM/O2 Analyzer...

  • Page 31: Weatherproof Wall/Z-Purge Option

    Weatherproof - Wall/Pole Figure 3-10 shows the wall and pole mounting dimensions for the Series 2000 weatherproof enclosure. For wall mount installations, use 1/4” diameter fasteners to mount the control unit to a wall. For pole mount installations, the two slots on the backplate of the enclosure can be used to accommodate a customer- supplied U-bolt of 3/8”...
  • Page 32 Series 2000 general pur- pose 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 1/4" fasteners Figure 3-13. Series 2000, general purpose wall mount. 3-10 | Thermox CEM/O2 Analyzer...

  • Page 33: Wiring

    Wiring Remove AC mains power from the controller before performing wiring. Connections to the control unit are made through the wiring card (see Figure 3-23). 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 34 Figure 3-14. Wiring card. 3-12 | Thermox CEM/O2 Analyzer...

  • Page 35: 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 36: Control Unit Mains Supply Connections

    You must use twisted-pair cable in rigid metal conduit or use twisted pair cable with an overall braided shield. All cable shields or conduits connect- ing to the control unit must be chassis grounded. 3-14 | Thermox CEM/O2 Analyzer...
  • Page 37 EMC grounding method • Shield Ring Method Connect all shields for that conduit entry (other than power) to a sup- plied shield terminal ring (see Figure 3-16). This shield ring is a stain- less steel ring with a metal tab. Place the shield ring under the conduit nut.
  • Page 38 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. 3-16 | Thermox CEM/O2 Analyzer...

  • Page 39: Sensor Connections

    Sensor Connections Make sure that power has been removed from the control unit and sensor before making sensor connections. See Figure 3-14, Sensor Board. This section describes required wiring connections between the control unit and the sensor. Follow the connection instructions for the applicable options for your analyzer.
  • Page 40 Control Unit Label Sensor Terminal Number Cell + (one pair) Cell - Furnace (one pair) 15V COM T/C + (one pair) T/C - 15V SPLY (one pair) 15V SPLY 3-18 | Thermox CEM/O2 Analyzer...
  • Page 41 Figure 3-19. Sensor connections. Installation and Start-up 3-19...

  • Page 42: Current Output Connections

    3 and 4 are also isolated from the control unit and from current outputs 1 and 2. If you intend to power the current outputs from an external power  supply, see the “External Powering and Modulation of External Power Using Current Outputs” appendix. NOTE 3-20 | Thermox CEM/O2 Analyzer...
  • Page 43 Figure 3-20. Current output connections example. Installation and Start-up 3-21...

  • Page 44: Alarm Contact Connections

    (deactivated). A service alarm event triggers these alarm contacts to an open condition. Oxygen Alarm connections are configurable in software to activate under a variety of user defined conditions, and are labeled as follows: ALARM 3A ALARM 4A ALARM 3B ALARM 4B 3-22 | Thermox CEM/O2 Analyzer...
  • Page 45 Figure 3-21. Series 2000 alarm connections example. Installation and Start-up 3-23...

  • Page 46: 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 - 3-24 | Thermox CEM/O2 Analyzer...
  • Page 47 Figure 3-22. Series 2000 controller RCU connections. Installation and Start-up 3-25...

  • Page 48: 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) 3-26 | Thermox CEM/O2 Analyzer...
  • Page 49 Figure 3-23. Series 2000 2-wire RS-485 communication connections. Installation and Start-up 3-27...
  • Page 50 The factory default setting is to have Switch 3 OFF with no termination resistor in the circuit. 3-28 | Thermox CEM/O2 Analyzer...
  • Page 51 Figure 3-24. Series 2000 4-wire RS-485 communication connections. Installation and Start-up 3-29...

  • Page 52: Option Card Installation

    This section describes how to remove or replace the display module or power supply keypad module on the control unit (see Figure 3-25): Remove power from the control unit before working on it. Figure 3-25. Front view of series 2000 control unit. 3-30 | Thermox CEM/O2 Analyzer...

  • Page 53: Adding An Option Card

    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). Note that the power supply/keypad module must be removed before you can remove the display module.
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  • Page 55: Chapter 4 Controller / User Interface

    CONTROLLER / USER INTERFACE This chapter includes: Areas of the Control Unit  Setup Key Functions  Analog Range Key Functions  Alarm Key Functions  Areas of the Control Unit Figure 4-1 shows the various areas of the control unit, including the loca- tions of the power supply/keypad module and display module.

  • Page 56: Selecting Menu Options

    To exit a menu, press Cancel. To exit out of all menus, continue to press Cancel until all menus disappear from the display and only process read- ings remain. Pressing the Cancel key does not delete any settings you have set  while in that menu. NOTE 4-2 | Thermox CEM/O2 Analyzer...

  • Page 57: Automatic Menu Exit Feature

    NOTE 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 that you can ac- cess the Password option and enter a new system password.

  • Page 58: Setup Key

    This is not a typical calibration. A primary calibration is intended to extend the life of your sensor. Do not perform this type of calibration unless specifically instruct- ed to do so. Sensor Config Select the type of sensor you are using. Communication Define Series 2000 communication parameters. 4-4 | Thermox CEM/O2 Analyzer...

  • Page 59: Display

    Display Define what information should appear on the top three (3) display lines of the control unit. Choices include: Percent oxygen (% O  Cell temperature  Cell millivolts  Thermocouple millivolts (T/C millivolts)  Current date/time  User text ...

  • Page 60: Process Pressure

    The process pressure you entered will now appear on the third display line. If the pressure that has been entered is correct, press Enter to exit this menu option. If the pressure was entered incorrectly, you can reenter it at this point. 4-6 | Thermox CEM/O2 Analyzer...

  • Page 61: System Tests

    System Tests Check the Series 2000 control unit for possible problems and isolate the problem. You may be asked by AMETEK/Thermox personnel to access this menu option to perform system diagnostics. Performing these tests is not required under normal operations.

  • Page 62: Primary Calibration

    • +/- 5 mVs of the anticipated mVs for the gas concentration applied (2% O2 applied, 48 mV expected at 695°C cell temp) as referenced to the actual span gas mV reading. Table 4-1. 4-8 | Thermox CEM/O2 Analyzer...
  • Page 63 Determining temperature f you take the displayed cell temperature and divide it by the T/C Ratio in memo- ry location 88, you will have the actual furnace set point control temperature. You can use a Type-K table to measure the voltage on terminals C and D on the sensor board, and add the appropriate amount of mVs for the board ambi- ent.
  • Page 64 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 NOTE the cell temperature is adjusted after a primary calibration. 4-10 | Thermox CEM/O2 Analyzer...

  • Page 65: Sensor Config

    Sensor Config Select the operating temperature for the CEM/O sensor.. Configurating the sensor From the Setup menu, select Sensor Config. Select the operating temperature for the CEM/O sensor. Under normal conditions, select 695°C because it provides a slightly longer cell life than the higher temperature does. Use 812°C only for applications where condensation of the sample gas could occur at 695°C.

  • Page 66: Analog Range Key

    Define analog output range: 0 to 20 mA 4 to 20 mA Output Filtering Smooth out variations in readings Select Function Define the information the analog output should track: Cell temperature Cell Millivolts Thermocouple Millivolts 4-12 | Thermox CEM/O2 Analyzer...

  • Page 67: Analog Output Port

    Analog Output Port Before you can define any Analog Range key functions, you must  choose whether they will apply to analog output ports 1 or 2 on the rear of the control unit. NOTE Analog output port 1 is labeled I OUT 1; analog output port 2 is labeled I OUT 2.

  • Page 68: Set Track/Hold Option

    You can choose to either hold process readings or track calibration readings on the analog output port. Separate choices can be made for calibration and verify operations. For calibration operations, select one of the following: Hold during cal Track during cal 4-14 | Thermox CEM/O2 Analyzer...

  • Page 69: Set Current Mode

    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: Hold during Verify Track during Verify After you select one of these options, your choice will be confirmed on the display:...

  • Page 70: Output Filtering Option

    01 to enter 1, 07 to enter 7, 70 for 70, etc. Select Function Select what type of information the analog output port should track. Percent oxygen (% O  Cell temperature  Cell millivolts  Thermocouple millivolts (T/C millivolts)  4-16 | Thermox CEM/O2 Analyzer...
  • Page 71 Selecting the function Select an analog output port. From the Analog Range key, select Select Function. Select the function you want the analog output port to track. The Series 2000 control unit then prompts you with the Set Current Range menu option to choose the range of readings that the 0-to-20 mA or 4-to-20 mA analog output represents (see the “Set Current Range”...

  • Page 72: Alarm Key

    In addition, alarms are disabled during start-up until the sensor reaches its proper operating temperature. See the “Wiring” section in the Installation chapter for help on alarm con- nections and how alarms are labeled on the control unit wiring card. 4-18 | Thermox CEM/O2 Analyzer...

  • Page 73: Overview Of Alarm Functions

    Overview of Alarm Functions Define whether Alarm 3 activates based on oxygen levels, the start of a calibration, or the start of a verification (Select Function). Alarm 4 activates only on levels of oxygen (high or low alarm). Select Function Alarm Configure Relay Configure Alarm 3...

  • Page 74: Alarm Set Points

    You are prompted to enter the Alarm 4 set point value: Alarm #4= xx %O2 New Value? Enter the Alarm 4 set point value. If you don’t have the combustibles option installed, you are done (click Cancel to exit this menu option). 4-20 | Thermox CEM/O2 Analyzer...

  • Page 75: Alarm Configure

    Alarm Configure Define whether alarms should trigger based on a high alarm or a low alarm condition. Whether Alarm 3 is set high or low only applies if it is set to track  oxygen levels (% O ). If Alarm 3 is set to trigger at the start of a cali- bration or verification, this option does not apply.

  • Page 76: Select Function

    Events that can trigger the service alarm to activate are: • Error condition (detected by software) • System operational variance (such as an over-temperature or under- temperature condition) • Calibration failure • Verification failure • Control unit power failure 4-22 | Thermox CEM/O2 Analyzer...

  • Page 77: Watchdog Relay

    Watchdog Relay During normal system operation, the Watchdog Relay operates as  normally closed (system failure causes open contacts). NOTE The Watchdog Alarm relay de-energizes when the system watchdog timer times out. The watchdog timer will time out and cause the control unit to reset itself to prevent the control unit from becoming “lost”...
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  • Page 79: Chapter 5 Calibration

    CALIBRATION Calibrate Initiate Cal Initiate Verify Cal/Verify Data Cal Gas Value Inject Cal Set Cal Timers Figure 5-1. Calibrate Key menu options. Sensor alarms are disabled during calibrations and the recovery time  after a calibration. You can set whether analog outputs should follow the calibration readings or hold at the last process reading before the NOTE calibration.

  • Page 80: Definitions

    Span and Zero Calibration Gas Definitions 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/O2 Analyzer...

  • Page 81: Types Of Calibrations

    Types of Calibrations The Series 2000 control unit allows you to perform automatic, remote, or manual calibrations. Automatic and remote calibrations require a factory- provided remote calibration unit (RCU) that automatically switches the calibration gases for you; manual calibrations are performed without an RCU, and gases are switched manually.

  • Page 82: Aborting A Calibration

    Pressing the Calibrate key while the system is performing a calibration or verification, displays the option to abort the calibration or continue the calibration. All other menu functions are temporarily disabled during a calibration or verification. The oxygen alarm is disabled during a calibra- tion. 5-4 | Thermox CEM/O2 Analyzer...

  • Page 83: Initiate Cal And Initiate Verify

    Initiate Cal and Initiate Verify Perform an automatic, remote, or manual calibration or verification. These menu options function almost identically. See the introduction to this chapter for more information on the difference between a calibration and a verification. Automatic calibrations and verifications can also be set to run at prede- termined frequencies using the cycle times defined in the Set Cal Timers/ Set Auto Timers menu option.
  • Page 84 The system returns to monitoring process readings and the calibration or verify operation is complete. You can view the results of the last cali- bration or verification using the Cal/Verify Data menu option from the Calibrate key menu. 5-6 | Thermox CEM/O2 Analyzer...

  • Page 85: Remote Calibrate/Remote Verify

    Remote Calibrate/Remote Verify To initiate a remote calibration or verification, do the following: Enter the calibration gas values to match the span and zero calibration gas cylinders you intend to use to calibrate/verify your system. These values are referred to in this section as setpoint values . Select Initiate Cal or Initiate Verify from the Calibrate key menu, de- pending on whether you want to perform a calibration or verification.

  • Page 86: Manual Calibrate/Manual Verify

    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 Enter when you have applied this cal gas. 5-8 | Thermox CEM/O2 Analyzer...

  • Page 87: Cal/Verify Data

    Cal/Verify Data View the results of the latest calibration or verification. This includes the following: • span calibration gas value vs. O span calibration gas reading • Zero calibration gas value vs. zero calibration gas reading • Span calibration gas drift •...
  • Page 88 If the date or time has not been set, random characters will appear instead of the time and date when the calibration or verification was completed. If this occurs, reset the control unit’s time and date. 5-10 | Thermox CEM/O2 Analyzer...

  • Page 89: Cal Gas Value

    Cal Gas Value Enter span and zero calibration gas values to match the calibration gas cylinders you use to calibrate or verify your system. These values will be used for all automatic, remote, or manual calibrations and verifications. • span gas - high calibration gas •...

  • Page 90: Inject Cal Gas

    Adjust the pressure and flow for the zero gas to the desired levels. Press the Cancel key to end the cycle. CANCEL to quit Then, if you specified a recovery time, the system will display the recov- ery time remaining: Recovery xx:xx 5-12 | Thermox CEM/O2 Analyzer...

  • Page 91: Cal Timers

    Cal Timers SET CAL TIMERS KEY Set Auto Timers Set Time & Date Aut Cal On/Off Cal Gas Duration Recovery Duration Figure 5-2. Set Cal Timers menu options. Sub-Menu Function Set Auto Timers Set auto timer for desired auto calibration/verification cycle times.

  • Page 92: Set Cal Timers - Set Time And Date

    Select Disable Auto Cal (or Disable Auto Verify) to disable the auto calibration or auto verification cycle. Select Enable Auto Cal (or En- able Auto Verify) to enable the auto calibration or verification cycle. 5-14 | Thermox CEM/O2 Analyzer...

  • Page 93: Set Cal Timers - Cal Gas Duration

    The system will confirm your enabling or disabling selection: Auto Cal is ENABLED Auto Cal is DISABLED and will then exit this menu option. Set Cal Timers - Cal Gas Duration Define how long the RCU should apply the span and zero calibration gases to the sensor during an automatic calibration or verification.

  • Page 94: Set Cal Timers - Recovery Duration

    You will be prompted to enter a calibration recovery duration: Cal recovery = xx:yy Enter new time: Mn:Sc Enter the recovery time, then press Enter. If you want to use the cur- rently displayed recovery time, press Enter without entering a new value. 5-16 | Thermox CEM/O2 Analyzer...

  • Page 95: Configure Verify

    Configure Verify Define the verify gas value and the acceptable range of readings for a verify. From the Calibrate Key menu, select Configure Verify. Enter the verify gas value, then press Enter. If you want to keep the current verify gas value unchanged, press Enter without entering a value.
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  • Page 97: Chapter 6 Maintenance And Troubleshooting

    MAINTENANCE AND TROUBLESHOOTING The operations in this chapter should be performed only by qualified service personnel experienced in electrical safety techniques. There are no operator-serviceable components inside the WDG 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 98: System Messages

    Indicates that a system verification is in progress. It will appear System Verifying Cal during the entire automatic verification cycle or during the recovery period for a remote or manual verification. 6-2 | Thermox CEM/O2 Analyzer...

  • Page 99: Error Messages

    Error Messages Error messages on the control unit display indicate problems with the operation of the analyzer. Use this section to see the types of problems your error message indicates, then go to the “Diagnostic Checks” section at the end of this chapter for help on how to perform diagnostic checks to pinpoint the problem area.
  • Page 100 Calibration gas setup problem • Process pressure incorrectly entered. • Cell wiring reversed (Cell + and Cell - wires) • Failed cell (primary calibration should be run at this time) • Leak or plug in plumbing 6-4 | Thermox CEM/O2 Analyzer...

  • Page 101: Diagnostics Checks

    Diagnostics Checks This section shows you how to check different sensor areas for possible problems. See the “Error Messages” section for help on what checks you should perform based on the error message displayed. If you don’t see an error message, yet feel your readings are inaccurate, you may also want to check the “General Troubleshooting”...

  • Page 102: Wiring Checks

    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 intercon- necting wiring for short circuits before applying power to the control unit. 6-6 | Thermox CEM/O2 Analyzer...
  • Page 103 If you do measure 15 volts at Measure across terminals D (+) and 6 (-) on the sensor terminals 2 (-) and 12 (+) of the board. Twelve millivolts should be measured ( this signal sensor board: is a function of ambient temperature and may vary up to 2 millivolts at extreme ambient temperatures ).

  • Page 104: Calibration Setup Checks

    If wiring is correct, replace the Auto Cal Card. If the solenoid drive signal is present, it indicates a problem with one of the solenoid valves. Replace the solenoid valve, being sure that the solenoid O-ring seals are properly positioned. 6-8 | Thermox CEM/O2 Analyzer...

  • Page 105: Ac Power Checks

    To check if a Verify that no drive signal is present and check for flow on the calibration gas RCU flow meter. If flow is indicated when no solenoids are ener- solenoid is stuck gized, a solenoid is stuck open. Shut off your calibration gases open: (one at a time) until the flow drops to zero.

  • Page 106: Process Pressure Checks

    If this doesn’t work, check for leaks or plugged plumbing. If this doesn’t solve the problem, replace the cell, then run another primary calibration. 6-10 | Thermox CEM/O2 Analyzer...

  • Page 107: General Troubleshooting

    General Troubleshooting Your system may pass calibrations, yet still seem to be reading incorrect oxygen levels. If this is the case, you may want to check the following: Leak Check This check does not apply to Insitu users. Leaks can lead to inaccurate readings, especially if operating under a sig- nificant pressure or vacuum.

  • Page 108: Series 2000 Leds

    O span gas should be flowing into the sensor. Zero zero gas solenoid is energized and the zero gas should be flowing through the sensor. 4 through 12 - Not used 6-12 | Thermox CEM/O2 Analyzer...

  • Page 109: Chapter 7 Service And Parts

    SERVICE AND PARTS The operations in this appendix should be performed only by quali- fied service personnel with a knowledge of electrical safety techniques. There are no operator-serviceable components inside the CEM/O 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 110: Cell Replacement/Cleaning

    Before performing a primary calibration, first connect 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. 7-2 | Thermox CEM/O2 Analyzer...
  • Page 111 Figure 7-1. Cell replacement. Service and Parts | 7-3...

  • Page 112: Thermocouple Replacement

    Before performing a primary calibration, first connect power to the  sensor and allow it to heat up and stabilize (approximately one hour). NOTE Perform a primary calibration. 7-4 | Thermox CEM/O2 Analyzer...
  • Page 113 TOP VIEW - FURNACE Cell housing Thermocouple mounting tab Thermocouple Convection loop mounting clamp Compression fitting Figure 7-2. Thermocouple replacement. Service and Parts | 7-5...

  • Page 114: Furnace Replacement

    If you measure a short circuit, loosen the screw that secures the ther- mocouple and relocate slightly until resistance is infinite. 11. Reattach cell clips. 12. Reattach furnace leads (reverse the actions taken in Step 3). 13. Calibrate the system. 7-6 | Thermox CEM/O2 Analyzer...
  • Page 115 Convection loop mounting clamp Cell housing Thermocouple Furnace Union fitting Compression fitting Figure 7-3. Furnace replacement. Service and Parts | 7-7...

  • Page 116: Parts Replacement List

    P/N 42373JE 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 7-8 | Thermox CEM/O2 Analyzer...

  • Page 117: Appendix A Serial Communications

    SERIAL COMMUNICATIONS Serial communications for the Series 2000 (ver 3.3 and later) and the IQ based software IQ applies to IQ sensor based products only S2 applies to Series 2000 based products only Communication Protocols Communication with all analyzers through the RS-485 connection uses the following word format: • 8 data bits • 1 stop bit...

  • Page 118: Command Message Format

    ?? (?? is equivalent to 2 ASCII 3FH hex charac- ters). This makes testing by the programmer easy, but it is strongly NOTE recommended that the integrity check be enabled in the final system. A-2 | Thermox CEM/O2 Analyzer...

  • Page 119: General Serial Communication Commands

    General Serial Communication Commands Read Number (F) This command reads the value of a variable in the analyzer. The data sec- tion of this command is a number from 00-FF. These numbers correspond to the variable you wish to read. The table below provides a list of these variables and their location codes.

  • Page 120: Development Serial Communication Commands

    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 analyzer and act accordingly. A-4 | Thermox CEM/O2 Analyzer...
  • Page 121 This command is only available via the Series 2000 software  NOTE Command List The following command letters are available: Letter Description Echo Bad Command Acknowledge Read Number Calibrate Write Number Data Format (Series 2000 software only) Read Date and Time Set Date and Time Serial Communications...

  • Page 122: Responses

    (2 hex ASCII characters)  Failure Code Description Bad command letter Bad checksum Input overrun in serial communication Parameter out of range Error in receipt of character Cannot calibrate/verify now Internal error Illegal access (read-only variable) A-6 | Thermox CEM/O2 Analyzer...

  • Page 123: Variable Table

    Variable Table The following pages provide a summary of the variable locations, name, and descriptions available. Location Variable Name Description (Hex/Decimal) Access Various flags (1=true, 0=false) 00/00 Flags3 Read only bit 0 – sensor is at operating temperature. bit 1 – Over/under Flag for tuning temperature bit 2 –...
  • Page 124 12 – Future use (used on S2000) bit 13 – Future use (used on S2000) bit 14 – WDG type sensor, 0 is HP type sensor bit 15 – combustibles are measure in percent,0 = combustibles are measured in A-8 | Thermox CEM/O2 Analyzer...
  • Page 125 System configuration flags (1=true, Config_flags 0=false) bit 0 – auto verify cycle time is programmed in hours, 0 if in days bit 1 – Auto cal option is installed bit 2 – Combust module is installed bit 3 – Future use bit 4 –...
  • Page 126 13 – analog output 4 tracks during verify 0 is hold analog output 4 during verify. bit 14 – analog output 4 set for 0 to 20 ma, 0 is 4 to 20 ma bit 15 – Future use A-10 | Thermox CEM/O2 Analyzer...
  • Page 127 Analog outputs flags (1=true, 0=false) Iout_flags bit 0 – analog output 3 tracks during calibration 0 is hold analog output 3 during calibration bit 1 – analog output 3 tracks during verify 0 is hold analog output 3 during verify. bit 2 –...
  • Page 128 The combustibles reading Read only 0A/10 Mthcomb The methane reading Read only 0B/11 Cell_temp The current cell temperature in degrees C Read only 0C/12 Cell_mv The cell millivolts Read only 0D/13 Tc_mv The thermocouple millivolts Read only A-12 | Thermox CEM/O2 Analyzer...
  • Page 129 What analog output 1 corresponds to 0E/14 Out1_flg 0 – oxygen 1 – cell temperature 2 – cell temperature thermocouple mv 3 – cell mv 4 – thermocouple mv box temp 5 – combustibles 6 – cell mv methane 7 – AF Ratio 8 –...
  • Page 130 Amount of time oxygen zero gas will flow in seconds Amount of time oxygen zero gas will flow in MMSS 28/40 Gas3_time Amount of time the combustibles span gas will flow in seconds Amount of time combustibles span gas will flow in MMSS A-14 | Thermox CEM/O2 Analyzer...
  • Page 131 29/41 Recov_time Amount of time for recovery after a calibration in seconds Amount of time for recovery after a calibration in MMSS 2A/42 O2_gas1 Oxygen span gas setpoint value, always in percent 2B/43 O2_gas2 Oxygen zero gas setpoint value, always in percent 2C/44 Co_gas1...
  • Page 132 Combustibles slope during last calibration Read only 5A/90 Mthslope Methane slope during last calibration Read only 5B/91 Cal_cycle Interval between auto cals [1 hour to 90 days] 5C/92 Ver_cycle Interval between auto verifies [1 hour to 90 days] A-16 | Thermox CEM/O2 Analyzer...
  • Page 133 What process alarm is associated with 5D/93 Alr1_flg 0 – oxygen oxygen, combustibles, or methane 1 – calibration 2 – verify 3 – in cal/verify Configuration for oxygen alarms, high or 5E/94 Alm_config low. If a bit is 1, that is the condition that the indicated alarm will trip on.
  • Page 134 Which type of calibration the unit is in: 60/96 Calflag Read only 0 – In normal calibration 1 – In verify 2 – In primary cal 3 – In none of the above, normal operation A-18 | Thermox CEM/O2 Analyzer...
  • Page 135 Which oxygen alarm has been set and why 61/97 Alarm_flags Read only bit 0 – high oxygen, process alarm bit 1 – low oxygen, process alarm bit 2 – high combustible, process alarm bit 3 – high methane, process alarm bit 4 –...
  • Page 136 Read only 67/103 M_store Read only 68/104 Cal_temp Last calib temperature 69/105 CJTemp Cold Junction temperature Read only 6A/106 Box_temp Box Temperature Read only 6B/107 Cmb_Kfact Combustible K Factor 6C/108 Mth_Kfact Methane K Factor 6D/109 A-20 | Thermox CEM/O2 Analyzer...
  • Page 137 Status of digital inputs(1=closed/on, 6E/110 Dig_Input Read only 0=open/off) bit 0 – CAL 0 bit 0 – Dig In bit 1 – CAL 1 6F/111 System test that was preformed 70/112 SysTst_Flag 1-Calibrate A/D 2-Ram Test 4-Test EEPROM 7-Erase Ram 8-Erase EEPROM 9- Test Watchdog 71/113...
  • Page 138 Exception number 17 see Exception Chart Read only 91/145 Excep_18 Exception number 18 see Exception Chart Read only 92/146 Excep_19 Exception number 19 see Exception Chart Read only 93/147 Excep_20 Exception number 20 see Exception Chart Read only 94/148 95/149 A-22 | Thermox CEM/O2 Analyzer...
  • Page 139 Exception # Exception Out of Range Power up/Reset High Meth (Alm #3) High Comb (Alm #3) Low O2 (Alm #3) High O2 (Alm #3) High Meth (Alm #2) / METHANE HIGH #8 High Comb (Alm #2) / METHANE HIGH #7 Low O2 (Alm #2) / COMBUSTIBLE HIGH #6 High O2 (Alm #2)

  • Page 140: Sample Program

    DIM Sum AS LONG Sum = 0 ‘Skip FOR i% = 2 TO LEN(M$) Sum = Sum + ASC(MID$(M$, i%, 1)) NEXT i% ‘Get low byte of checksum Checksum$ = HEX$(Sum MOD 256) END FUNCTION<P255D> A-24 | Thermox CEM/O2 Analyzer...
  • Page 141 Starting/Monitoring a Calibration: An Example This section provides an example of how to initiate and then monitor a calibration. Check that no calibration or verification is currently occurring by checking the Calflag variable (Calflag=3). Send the Calibrate command to the IQ analyzer (G00). If an acknowledge is returned (A ...
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  • Page 143: Appendix B Menu Option Charts

    MENU OPTION CHARTS SETUP KEY Functions/Options Menu Options Cell Temperature Cell Millivolts Display Thermocouple Millivolts User Text Date/Time Turn Off Passwords Create a system password Select a positive or negative process pressure. Process Pressure Enter process pressure value. System Tests Perform internal diagnostics on Series 2000.
  • Page 144 Alarm 4 Not selectable De-energize on alarm (% O only) * Note: Alarms 1 and 2 are reserved for the watchdog timer and service alarms and are not software-selectable. Table B-4. Alarm Set Point sub-menu. B-2 | Thermox CEM/O2 Analyzer...
  • Page 145 CALIBRATE KEY Functions/Options Menu Options Start an automatic, remote, or manual calibration Initiate Cal/Initiate Verify or verify View latest calibration and verify data. Cal/Verify Data - Cal data - Verify data Cal Gas Values Span Gas; Zero Gas Set pressure and flow to RCU gases without Inject Cal Gas performing a calibration.
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  • Page 147: Appendix C Current Outputs: Other Applications

    CURRENT OUTPUTS: OTHER APPLICATIONS This appendix describes how to: • Modulate an 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 +...
  • Page 148 To determine the minimum external voltage supply required to power these circuits, use the same formula as provided for the O2 current output external voltage source described in the previous section. Modulation can also be done in the same manner as IOUT1 or IOUT2. C-2 | Thermox CEM/O2 Analyzer...

  • Page 149: Modulation Of External Power Loop Using Current Outputs

    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 current output channels (IOUT1 and IOUT2) can be connected in the same manner as shown in this figure.
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  • Page 151: 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 cutome options, the standard Intercon- nect 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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  • Page 153: Appendix E Series 2000 Controller Setup Parameters

    SENSOR DEFAULT SETTINGS SERIES 2000 CONTROLLER SETUP PARAMETERS O2 PRODUCTS O2 PRODUCTS INCLUDE CLEAR AREAS ONLY COMB. PRODUCTS COMB. PRODUCTS INCLUDE CLEAR AND SHADED AREAS METHANE PRODUCTS METH. PRODUCTS INCLUDE CLEAR,SHADED,AND BORDERED AREAS PARAMETER DEFAULT SETTINGS CUSTOMER SETTINGS SENSOR CONFIGURE O2 CEM/O2, INSITU, WDG-IV, WDG-HPII SENSOR CONFIGURE COMB WDG-IVC, WDG HPIIC...
  • Page 154 DEENGERIZE RELAYS ON ALARM ALARM 1 WATCHDOG ALARM 2 SERVICE ALARM 3 10% O2 HIGH ALARM 4 1% O2 LOW ALARM 5 1000 PPM COMB ALARM 6 2000 PPM COMB ALARM 7 2% METHANE ALARM 8 3% METHANE E-2 | Thermox CEM/O2 Analyzer...

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