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

Ametek Thermox WDG-1200 Insitu User Manual

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

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  • Page 1  ®   ®  Thermox Thermox WDG-1200/1210/Insitu WDG-1200/1210/Insitu User Manual User Manual Thermox Thermox 150 Freeport Road 150 Freeport Road Pittsburgh, P Pittsburgh, 15238 15238 90685VE 90685VE Rev. Rev.
  • Page 2 AMETEK does not guarantee results and suitability should be obtained; otherwise, AMETEK does not guarantee results and assumes no obligation or liability. assumes no obligation or liability.

  • Page 3: Table Of Contents

    Contents Contents Ofces Ofces ................................................Safety Safety Notes Notes ............................................Electrical Electrical Safety Safety .......................................... Grounding Grounding ..................
  • Page 4 Crimped Connector Asse Crimped Connector Assembly Procedure mbly Procedure ...................... 3-20 3-20 Mains Power Supply Plug ................3-22 Mains Power Supply Plug ................3-22  Mains Connect  Mains Connector Assemb Assembly Proced Procedure ....................3-22 3-22 Fitting of Plug Connectors ................3-22 Fitting of Plug Connectors ................3-22 Pre-operational Checks - Final Checks .............3-23 Pre-operational Checks - Final Checks .............3-23...
  • Page 5 CHAPTER CHAPTER Maintenance Maintenance Troubleshooting oubleshooting Fault Identication Numbers ................5-3 Fault Identication Numbers ................5-3 Fault Description ...................5-4 Fault Description ...................5-4 Bench Testing ....................5-7 Bench Testing ....................5-7 In-Situ Probe T In-Situ Probe Testing and Checking esting and Checking ..........................

  • Page 6: Safety Notes

    Safety Notes Safety Notes WARNINGS, CAUTIONS, WARNINGS, CAUTIONS,  and  and NOTES NOTES  contained in this manual emphasize critical  contained in this manual emphasize critical instructions as follows: instructions as follows:  An operating pr  An operating procedure whi ocedure which, if not strictly ob ch, if not strictly observed, may res served, may...

  • Page 7: Environmental Information (Weee)

    AMETEK recommends that you arrange to recycle and to conserve our natural resources, AMETEK recommends that you arrange to recycle this product when it reaches its “end this product when it reaches its “end...
  • Page 8 ARRANTY AND ARRANTY AND CLAIMS CLAIMS e warrant that any equipment of our e warrant that any equipment of our own manufacture or manufactured for us pursuant to our specications own manufacture or manufactured for us pursuant to our specications which shall not be, at the time of which shall not be, at the time of shipment thereof by or for us, free from...
  • Page 9  |  |...

  • Page 10: Chapter 1 Overview

    OVERVIEW OVERVIEW System Features System Features The WDG 1200/1210 Insitu probes are a type of The WDG 1200/1210 Insitu probes are a type of direct insertion oxygen probe direct insertion oxygen probe used to measure the oxygen i used to measure the oxygen in the exhaust of a combustio n the exhaust of a combustion process.

  • Page 11: Sensor

    Sensor Sensor e recommend that all personnel who e recommend that all personnel who will regularly use this analyzer become will regularly use this analyzer become familiar with the following brief explanation of how the analyzer familiar with the following brief explanation of how the analyzer works and the works and the components that make up...
  • Page 12 output signal. output signal.  Because of the high op  Because of the high operating temperatur erating temperature of the cell, combustibl e of the cell, combustible    gases that ar  gases that are present m e present may burn. When this occurs ay burn.

  • Page 13: Problems To Avoid

    Problems to Avoid Problems to Avoid These are some errors to avoid. If they are avoided, your analyzer will operate These are some errors to avoid. If they are avoided, your analyzer will operate with a minimum of maintenance and with a minimum of maintenance and troubleshooting troubleshooting.

  • Page 14: Technical Support

    Support Support AMETEK/Thermox is committed to providing you the best technical support in AMETEK/Thermox is committed to providing you the best technical support in the industry industry. If . If you need service you need service or application assistance, please call AMETEK...
  • Page 15 This page intentionally left blank. This page intentionally left blank. Thermox Thermox WDG-1200/1210 WDG-1200/1210 Insitu Insitu Probes Probes...

  • Page 16: Specifications

    SPECIFICATIONS SPECIFICATIONS WDG 1200/1210/Insitu Probe WDG 1200/1210/Insitu Probe General General 20°C to 800°C/68°F to 1472°F 20°C to 800°C/68°F to 1472°F Flue gas temp: Flue gas temp: Heater temperature: Heater temperature: 750°C ±3°C (1382°F ± 5°F) 750°C ±3°C (1382°F ± 5°F) Pressure: Pressure: ±...
  • Page 17 Dimensions: Dimensions: 152 mm (6”) high 152 mm (6”) high 153 mm (6”) wide 153 mm (6”) wide 130 mm (5.2”) deep 130 mm (5.2”) deep Weight: Weight: 2.7 kg / 6 lb. 2.7 kg / 6 lb. Max Distance between Controller and Probe: Max Distance between Controller and Probe: 150 m 150 m...
  • Page 18 Electrical Data Electrical Data Voltage range: Voltage range: 100-240 VAC 100-240 VAC Frequency: Frequency: 48-62 Hz 48-62 Hz Power: Power: 250 W 250 W Current Rating: Current Rating: 4 A Peak 4 A Peak Over-voltage category: Over-voltage category: CAT II CAT II Fuse rating and characteristics: Fuse rating and characteristics:...
  • Page 19 This page intentionally left blank. This page intentionally left blank. Thermox Thermox WDG-1200/1210 WDG-1200/1210 Insitu Insitu Probes Probes...

  • Page 20: Installation And Start-Up

    INSTALLATION AND START-UP INSTALLATION AND START-UP Only qualied service personnel with knowledge Only qualied service personnel with knowledge of electrical safety of electrical safety techniques should perform the operations in this chapter. There are techniques should perform the operations in this chapter. There are no operator-serviceable components inside the WDG-1200/1210 no operator-serviceable components inside the WDG-1200/1210  Insitu pr...

  • Page 21: Mechanical Installation

    Mechanical Installation Mechanical Installation • • Location Location • • Installing Installing Filter/Flame Filter/Flame Arrestor Arrestor (optional) (optional) • • Mounting Mounting Sensor  Sensor  • • Calibration Calibration Setup Setup Location Location Observe the following guidelines when selecting Observe the following guidelines when selecting an analyzer instal- an analyzer instal- lation location.

  • Page 22: Unpacking The Shipping Protection

    Unpacking the shipping protection Unpacking the shipping protection Remove the Remove the Anti-Shock Anti-Shock rubber rubber cap, see cap, see the pict picture belo below:  Anti-Shock  Anti-Shock Rubber Plug Rubber Plug Unpack Unpack Mullite Mullite ceramic ceramic tube tube below: below: Mullite Tube Mullite Tube...

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

    Fitting a Filter or Shield to the Probe Fitting a Filter or Shield to the Probe Some protection must always be tted to Some protection must always be tted to the probe tip to prevent foreign objects the probe tip to prevent foreign objects from entering the probe and damaging the from entering the probe and damaging the sensor...

  • Page 24: Mounting The Sensor

    Mounting the Sensor  Mounting the Sensor   Ambient temperatur  Ambient temperature in the contr e in the controller ar oller area should be less than ea should be less than   160° F (70°C). 160° F (70°C). NOTE NOTE Mount the probe and its ange to the ange on the process (see Figure Mount the probe and its ange to the ange on the process (see Figure 3-2a and 3-2b).

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

    Mounting the Controller (WDG-1210 Insitu only) Mounting the Controller (WDG-1210 Insitu only) Figure 3-3. Figure 3-3. Model 1210 Insitu Oxygen Probe System Model 1210 Insitu Oxygen Probe System Key Components: Key Components: Model Model 1210 1210 Oxygen Oxygen Probe Probe Mains Mains Power...

  • Page 26: Mounting Guidelines

    Mounting Guidelines Mounting Guidelines Mount th Mount the control e control unit to unit to a at, a at, vertical surface vertical surface at a at a height wh height where the ere the display display is clearly visible and the key panel is clearly visible and the key panel user interface is readily accessible.

  • Page 27: Installing The Controller

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

  • Page 28: Calibration Setup

    Calibration Setup Calibration Setup Figures 3-7a and 3-7b show the Figures 3-7a and 3-7b show the location of the calibration gas inlet port on both location of the calibration gas inlet port on both units. When calibrating the system, connect your calibration gases to this inlet units.

  • Page 29: Electrical Connections

    Electrical Connections Electrical Connections The customer is The customer is responsible for providing all switch cabinets, responsible for providing all switch cabinets, distribution boxes, distribution boxes, fuses and other components for electrical installation as well as fuses and other components for electrical installation as well as the mains power the mains power supply connections.

  • Page 30: Plug Plate Connector Designation - Wdg-1200 Insitu

    Optional Signal Connections Optional Signal Connections The following signal outputs may be connected: The following signal outputs may be connected: • • Current Current Loop Loop • • Calibration Calibration Progress Progress relay relay • • RS485 RS485 Serial Serial Communications Communications •...

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

    Plug Plate Connector Designation - WDG-1210 Insitu Plug Plate Connector Designation - WDG-1210 Insitu PLUG PLATE CONNECTOR DESIGNATIONS (view from underside of probe) PLUG PLATE CONNECTOR DESIGNATIONS (view from underside of probe) 1. Power Supply 1. Power Supply 2. Connections to Automatic Gas Calibration Control Unit (option) 2.

  • Page 32: System Cables

    System Cables System Cables The power supply The power supply must be isolated before any electrical connections must be isolated before any electrical connections are made. are made. Recommendations for Laying Cable Recommendations for Laying Cable • • Mains Mains signal signal cables...

  • Page 33: Cable Recommendations - Wdg-1200 Insitu

    Cable Recommendations - WDG-1200 Insitu Cable Recommendations - WDG-1200 Insitu WDG-1200 Insitu Cable Recommendations WDG-1200 Insitu Cable Recommendations Max. o.d. Max. o.d. No. of No. of Core Core Core Size Core Size Core Core Shielded Shielded Cores Cores Size mm Size mm strands/dia strands/dia...

  • Page 34: Pin Designations - 1200/1210 Insitu

    Pin Designations - 1200/1210 Insitu Pin Designations - 1200/1210 Insitu The following is a list of pin designations for Connectors 1, 2, and 3. The following is a list of pin designations for Connectors 1, 2, and 3. Wire Color  Wire Color ...
  • Page 35 Wire Color Wire Color Wire Color  Wire Color  Outputs/Relay Outputs/Relays  A  A Current Loop -ve Current Loop -ve Red/Blue Red/Blue White* White*  A  A Trigger +ve Trigger +ve Trigger 0V Trigger 0V NOTE: NOTE: wire half duplex) wire half duplex) Normal (for normally open N/O and 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. The following is a list of pin designations for Connectors 4 & 5 - WDG-1210 Insitu Only. Probe Probe Wire Color  Wire Color  ecto Ref.

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

    Probe Connections - WDG-1210 Insitu Only Probe Connections - WDG-1210 Insitu Only Make the connections ensuring the cables are routed Make the connections ensuring the cables are routed correctly as shown in Figure correctly as shown in Figure 3-8. 3-8. Cell +ve Cell +ve Cell -ve...

  • Page 38: Grounding

    Grounding Grounding External grounding External grounding points are provided. points are provided. These should be connected These should be connected to local to local ground. ground. Correct grounding is essen Correct grounding is essential for compliance with EMC regu tial for compliance with EMC regulations.

  • Page 39: Assembly Of Connector Plugs

    Assembly of Connector Plugs Assembly of Connector Plugs The pin designation of each connector is repeated on each individual The pin designation of each connector is repeated on each individual    plu  plug. NOTE NOTE In most cases, complete cable assembl In most cases, complete cable assemblies are supplied with th ies are supplied with...
  • Page 40 Push the p Push the pins into ins into the correct sl the correct slots (7). ots (7). They will They will snap into snap into place when place when posi- posi- tioned correctly (pull & tug to tioned correctly (pull & tug to check).

  • Page 41: Mains Power Supply Plug

    Mains Power Supply Plug Mains Power Supply Plug Ensure there is sufcient clearance to enable connection and disconnec- Ensure there is sufcient clearance to enable connection and disconnec-   tion of the mains connector. tion of the mains connector. NOTE NOTE Mains Connector Assembly Procedure...

  • Page 42: Pre-Operational Checks - Final Checks

    Pre-operational Checks - Final Checks Pre-operational Checks - Final Checks Check that a Check that a  has been securely tted to the  has been securely tted to the blanking plug blanking plug calibration gas con- calibration gas con-  on the probe.  on the probe.

  • Page 43: Chapter 4 User Interface And Calibration

    USER INTERFACE AND CALIBRATION USER INTERFACE AND CALIBRATION Control Panel Control Panel • • Menus Menus displayed displayed 4-character 4-character format. format. • • oxygen oxygen concentration concentration displayed displayed four-digit four-digit oating oating decimal decimal point point format. format. Fault data: Fault data: In addition to gas readi...

  • Page 44: Abbreviatio

    Abbreviations Used on the Control Panel Abbreviations Used on the Control Panel Calibration Calibration fi fi fi fi  TRAC  TRAC Analog track o Analog track or hold during calibrat r hold during calibration  TTNC  TTNC Time to next calibra Time to next calibration tion Thermox...

  • Page 45: Using The Probe For The First Time

    Using the Probe for the First Time Using the Probe for the First Time Before turning on the power supply to Before turning on the power supply to the probe, check the following: the probe, check the following: • • Ensure Ensure that...

  • Page 46: Operational Structure

    Operational Structure Operational Structure The operational structure can be described as a The operational structure can be described as a  that allows access to  that allows access to Menu Spine Menu Spine ve other menus. ve other menus. Befo  Before you can access th you can access the Menu Spi e Menu...

  • Page 47: Probe Display Settings

    Probe Display Settings Probe Display Settings Operational Structure Diagram Operational Structure Diagram CALIBRATION MENU CALIBRATION MENU Display Display Action Action Display Display Action Action O2 Display  O2 Display  ▼ ▼ Conguration Conguration    Menu Menu Auto Cal. Auto Cal. Span Span conc.

  • Page 48: Calibration Screens

    Calibration Screens Calibration Screens Calibration Menu Calibration Menu Ensure that installation of the analyzer is complete (see Ensure that installation of the analyzer is complete (see installation manual) and installation manual) and that the that the SYSTEM SYSTEM  parameters have been  parameters have been set.
  • Page 49 All the options necessary to calibrate the analyzer can All the options necessary to calibrate the analyzer can be accessed using the be accessed using the Cali- Cali- bration bration  menu. The  menu. The Calibration Calibration  menu consists of three  menu consists of three sub-menus: sub-menus:...
  • Page 50 ↵ ↵ ↵ ↵ Span gas concentration (CAL Span gas concentration (CAL COnF  COnF  SgAS) SgAS) OPTIONS OPTIONS Set concentration of span Set concentration of span calibration gas calibration gas o set the o set the concentration of the gas concentration of the gas used to calibrate used to calibrate...
  • Page 51 ↵ ↵ ↵ ↵ Calibration settling time (CAL Calibration settling time (CAL COnF  COnF  SEtL) SEtL) OPTIONS OPTIONS Set time for calibration read- Set time for calibration read- ings to settle ings to settle The period required for the calibration gas to stabilize is The period required for the calibration gas to stabilize is normally two minutes.

  • Page 52: Alarm Screen

    Alarm Screen Alarm Screen Alarm Menu Alarm Menu Display Display Action Action      ▼      ▼  ALARM  ALARM Enter  Enter    value  value The alarm sub-menu has only one option. Access this menu by pressing The alarm sub-menu has only one option. Access this menu by pressing Enter ...
  • Page 53 Analog Outputs Screens Analog Outputs Screens Display Display Action Action      ▼      ▼ ZERO ZERO Enter  Enter    Value  Value ▼ ▼ Display Display Action Action      ▼      ▼ SPAN SPAN Enter Enter Value Value ▼ ▼ Display Display Action Action      ▼      ▼...

  • Page 54: Analog Outputs

    ↵ ↵ Zero setting (AO  Zero setting (AO  ZEro) ZEro) OPTIONS OPTIONS Set zero reading output Set zero reading output To set the minimum O To set the minimum O  concentration of the  concentration of the Analog Output Analog Output RANGE RANGE Range...

  • Page 55: Diagnostics Screens

    Diagnostics Screens Diagnostics Screens Diagnostics Menu Diagnostics Menu Diagnostics Diagnostics  menu consists of three sub-menus:  menu consists of three sub-menus: • • Faults Faults • • Cell Cell status status • • Resistance Resistance test. test. o access these menus, from o access these menus, from Diagnostics Diagnostics...
  • Page 56 Fault list (diAg) Fault list (diAg) OPTIONS OPTIONS View faults View faults To display the fault list, press To display the fault list, press Enter  Enter    when the  when the Diagnos- Diagnos- RANGE RANGE tics tics screen is on view. Each fault is represented by a  screen is on view.

  • Page 57: System ConGuration Screens

    System Conguration Screens System Conguration Screens System Conguration Menu System Conguration Menu All the options necessary to congure the analyzer are All the options necessary to congure the analyzer are accessed using the accessed using the System System Confguration Confguration  ...
  • Page 58 ↵ ↵ Probe type (SySt  Probe type (SySt  Prty) Prty) OPTIONS OPTIONS Set probe type Set probe type To select the probe type: To select the probe type: Press Press Enter  Enter  RANGE RANGE Select a value using the Select a value using the UP and  and DOWN...

  • Page 59: Output Setup

    Output Setup Output Setup System Outputs System Outputs The current loop output can provide one of The current loop output can provide one of two output functions: two output functions: Track  Track  Measurement Measurement output output is t tracked racked during during normal...

  • Page 60: Analog Outputs Menu

    Analog Outputs Menu Analog Outputs Menu o set the o set the analog outputs, you must enter analog outputs, you must enter the password, set the the password, set the maintenance relay maintenance relay, and select the and select the  menu.

  • Page 61: Analog Output Settings

    Analog output settings Analog output settings All the options necessary to set the analyzer All the options necessary to set the analyzer outputs can be accessed using the outputs can be accessed using the Analog Outputs Analog Outputs  menu. The  menu.
  • Page 62 Track Setting Track Setting The analog output may be set to The analog output may be set to track  track    the O  the O  levels or  levels or hold  hold    the last reading  the last reading during calibration. This is set by pressing during calibration.

  • Page 63: Modbus Interface

    Modbus Interface Modbus Interface Serial data bus conguration Serial data bus conguration The serial data bus can The serial data bus can be set to any be set to any of the following four congurations: of the following four congurations: Data Data format:...

  • Page 64: Command Register

    Register Numbers Register Numbers This manual uses Register Numbers as dened This manual uses Register Numbers as dened in the Modbus specications. in the Modbus specications. The rst register number is 1. The rst register number is 1. Modbus packets contai Modbus packets contain Register offsets wh n Register offsets...

  • Page 65: Modbus Rs485 Interface Interface

    Modbus RS485 Interface Modbus RS485 Interface Figure 4-3. Figure 4-3. RS485 Bus topology. RS485 Bus topology. Figure 4-4. Figure 4-4. Two -wire RS485 connection. Two -wire RS485 connection. User Interface / Calibration User Interface / Calibration 4-23 4-23...
  • Page 66 Full Register List Full Register List Nonvolatile (Saved on power down) Nonvolatile (Saved on power down)     Volatile (Lost on power down) Volatile (Lost on power down)  R  Re Ω Ω Status and Calibration Start Status and Calibration Start 4-24 4-24 Thermox...
  • Page 67 The ‘Status and Calibration Start’ register 20 is used both to trigger a The ‘Status and Calibration Start’ register 20 is used both to trigger a calibration calibration and to monitor the inst and to monitor the instrument status. rument status. The meaning of each bit is as sh The meaning of each bit is as shown in the...

  • Page 68: Full

    Zero and Span Calibration Zero and Span Calibration Full (zero and span) calibration may Full (zero and span) calibration may be carried out manually, set to occur auto- be carried out manually, set to occur auto- matically at dened time interv matically at dened time intervals, or triggered from a remote device.
  • Page 69 i splay isplay Action Action D  D       ▼      ▼      ▼      ▼ Conguration Conguration Sub-menu Sub-menu Span Span conc. conc. Enter Enter value value ▼ ▼ Zero Zero conc. conc. Enter Enter value value time time interval interval Enter Enter value value Time Time...

  • Page 70: ConGuration

    Conguration Conguration The ve options available within the The ve options available within the  sub-menu are accessed by  sub-menu are accessed by Confguration Confguration  pressing  pressing  from the  from the  display. Each option is set by pressing  display. Each option is set by pressing Enter Enter Confguration...

  • Page 71: Automatic Calibration

    Automatic Calibration Automatic Calibration  sub-menu has  sub-menu has only one option. Access this option only one option. Access this option Automatic Calibration Automatic Calibration  by pressing  by pressing  from the  from the  display. The  display. The Enter Enter Auto Calibration Auto Calibration Auto Calibration Auto Calibration...

  • Page 72: Manual Calibration

    Manual Calibration Manual Calibration  sub-menu has two options:  sub-menu has two options: Manual Calibration Manual Calibration • • Zero Zero • • Span Span Calibration Calibration  These options are accessed by pressing  These options are accessed by pressing  from the  from the Enter Enter...
  • Page 73 Span Calibration Span Calibration The span calibration reading is checked by connecting the calibration gas via The span calibration reading is checked by connecting the calibration gas via the calibration gas inlet on the probe and pressing the calibration gas inlet on the probe and pressing Enter ...

  • Page 74: Maintenance And Troubleshooting

    MAINTENANCE AND TROUBLESHOOTING MAINTENANCE AND TROUBLESHOOTING The operations in this chapter should be performed only by qualied The operations in this chapter should be performed only by qualied  service  service personnel personnel with with knowledge knowledge electrical electrical safety safety techniques techniques.
  • Page 75 System Fault LED System Fault LED (red) (red) The fault sub-menu is accessed through the The fault sub-menu is accessed through the Diagnostics Diagnostics  menu on the  menu on the Menu Spine Menu Spine If a fault occurs, a fault identication number is displayed. This identication number If a fault occurs, a fault identication number is displayed.

  • Page 76: Fault IdentiCation Numbers

    Fault Identication Numbers Fault Identication Numbers Each fault is identied by a specic number as follows: Each fault is identied by a specic number as follows: (a (a) Heate ter tempe pera ratur ture th the contro trol band (± (±5°C 5°C) 00.0 .02 ...

  • Page 77: Fault Description

    Fault Description Fault Description Key to Key to  column of each fault:  column of each fault: Elements Elements Prob Faul ult re rela late ted pr prob Wiring Wiring Fault Fault related related wiring wiring system system Main ins Faul ult re rela late ted main ins powe...
  • Page 78 (b) Span coefcient out of range (b) Span coefcient out of range 00.10. 00.10. The calculated span coefcient from span calibration cycle is outside the expected The calculated span coefcient from span calibration cycle is outside the expected value range. value range.
  • Page 79 (d) Thermocoupl Thermocouple fault and e fault and heater above maximum limit 40.00. heater above maximum limit 40.00. The analyzer is measuring an The analyzer is measuring an unexpected voltage from the probe thermocouple. unexpected voltage from the probe thermocouple. Ther ermo moco coup...

  • Page 80: Bench Testing

    Bench Testing Bench Testing When the fault has been resolved, the probe should be bench-tested before tting When the fault has been resolved, the probe should be bench-tested before tting it back into the ue. it back into the ue. Allow th Allow the probe to...

  • Page 81: In-Situ Probe

    In-Situ Probe In-Situ Probe esting and esting and Checking Checking In-situ checking will assist with identifying errors or faults associated with the probe. 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 Cell output voltage can be displayed on the user interface using the Diagnostics Diagnostics...
  • Page 82 Measure Measure voltage voltage across across thermocoupl thermocouple (T (T/C) contacts contacts probe. probe. Refer Refer to Table 2. to Table 2.  Mains  Mains power connections on the pr power connections on the probe. obe. High risk of High risk of electric shock ! electric shock ! Cell...
  • Page 83 Table 2 Table 2 gives the voltage that should be present at the gives the voltage that should be present at the probe thermocouple connections probe thermocouple connections (Step (Step accordin according to the temper g to the temperature measu ature measured at Step 5, when the probe has stabili red at Step 5, when the probe has...
  • Page 84  If  If thermocoupl thermocouple voltage is voltage is high, relocate high, relocate prob probe position position   where the ue temperature is 800°C/1272°F or lower. where the ue temperature is 800°C/1272°F or lower. NOTE NOTE Disconnect Disconnect the thermo thermocouple l couple leads from...

  • Page 85: Maintenance

    Maintenance Maintenance Routine Maintenance Schedule Routine Maintenance Schedule Ensure the followin Ensure the following routine maintenance sched g routine maintenance schedule is followed. ule is followed. Failure to do so Failure to do so may invalidate the terms of warranty. may invalidate the terms of warranty.
  • Page 86 This page intentionally left blank. This page intentionally left blank. Maintenance and Troubleshooting Maintenance and Troubleshooting 5-13 5-13...

  • Page 87: Chapter 6 Service And Parts

    SERVICE AND SERVICE AND ARTS ARTS The operations in this chapter should be performed only by quali- The operations in this chapter should be performed only by quali-  ed service personnel wit  ed service personnel with knowledge of electrical s h knowledge of electrical safety techniques.

  • Page 88: Inner Probe Assembly Removal

    Inner Probe Assembly Removal Inner Probe Assembly Removal  Remove power  Remove power before rep before replacing any parts on lacing any parts on the WDG-1200/1210 the WDG-1200/1210  Insitu.  Insitu. Most of the procedures in this Most of the procedures in this chapter require that you rst remove chapter require that you rst remove the inner...
  • Page 89 Slide the Slide the inner probe inner probe assembly out assembly out of the out of the outer protective er protective tube by tube by pulling o pulling its handle. its handle. Process under Pressure Process under Pressure If the process is under pressure, place a blind plate and gasket over the ange If the process is under pressure, place a blind plate and gasket over the ange hole (blind plate and gasket included in insitu accessory kit).

  • Page 90: Cell Replacement

    Cell Replacement Cell Replacement Removing the Cell Removing the Cell Remove the Remove the inner probe inner probe assembly as assembly as described i described in the n the previous s previous section, ection,  Inner  Inner  Probe  Probe Assembly Removal  Assembly Removal ...
  • Page 91 With With the probe the probe oriented in oriented in front of y front of you so th ou so that the cell at the cell assembly end assembly end is on is on your right and the sheet metal your right and the sheet metal plate is on your left, plate is on your left,...

  • Page 92: Fitting The New Cell

    o prevent twisting of the cell o prevent twisting of the cell leads, keep the mark on leads, keep the mark on the left hex nut and the left hex nut and the orientation of the white cell lead the orientation of the white cell lead from being more than one from being more than one quarter turn...
  • Page 93 Unscrew Unscrew the cell the cell assembly assembly from th from the inner e inner probe probe assembly assembly. Slide the Slide the heater, heater, cell clips, cell clips, and cell l and cell leads forward eads forward through the through the end of th end of...
  • Page 94 Using a at blade screwdriver, snap the new retainer clip over the cell clip to Using a at blade screwdriver, snap the new retainer clip over the cell clip to  provide a strong cont  provide a strong contact between the cell clip and th act between the cell clip and the cell.
  • Page 95 Figure 6-4. Figure 6-4. Cell clip with attached cell leads. Cell clip with attached cell leads. Figure 6-5. Figure 6-5. Cell and retainer clip placement. Cell and retainer clip placement. Service and Parts Service and Parts...

  • Page 96: Heater/Thermocouple Replacement

    Heater/Thermocouple Replacement Heater/Thermocouple Replacement Removing Heater (See Figure 6-3) Removing Heater (See Figure 6-3) Remove the Remove the inner probe inner probe assembly as assembly as described i described in the n the previous s previous section, ection,  Inner  Inner Tube Assembly Removal ...

  • Page 97: Spare Parts

    Spare Parts Spare Parts Cell Lead Kits Cell Lead Kits 9” 9” Probe Probe 95382WE 95382WE 18” 18” Probe Probe 95383WE 95383WE 36” 36” Probe Probe 95384WE 95384WE 72” 72” Probe Probe 95385WE 95385WE 108” 108” Probe Probe 95386WE 95386WE Cell, Cell, Zirconia...
  • Page 98 This page intentionally left blank. This page intentionally left blank. 6-12 6-12 Thermox Thermox WDG-1200/1210 WDG-1200/1210 Insitu Insitu Probes Probes...
  • Page 99 DRAWINGS AND CUSTOM INSTRUCTIONS DRAWINGS AND CUSTOM INSTRUCTIONS This appendix provides any custom drawings or instructions you may have This appendix provides any custom drawings or instructions you may have ordered in addition to ordered in addition to the standard WDG-1200/1210 Insitu probes. If you the standard WDG-1200/1210 Insitu probes.
  • Page 100  A-2  A-2 Thermox WDG-1200/1210 Ins Thermox WDG-1200/1210 Insitu Probes itu Probes...

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