Ametek WDG-V HP Series User Manual

Combustion analyzer

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USER MANUAL

WDG-V HP Series Combustion Analyzer

PN 10270-11-5, Rev A

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Summary of Contents for Ametek WDG-V HP Series

Page 1 USER MANUAL WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 2 AMETEK Process Instruments assumes no responsibility or liability for any errors or inaccuracies that may appear in this document. AMETEK Process Instruments is not responsible for any infringement of patents or other rights of third parties that may result from the use of this document. The content of this document is furnished for informational purposes only, is subject to change without notice, and does not represent a commitment or guaranty by AMETEK Process Instruments.
Page 3 Contents Safety Notes ..............................vii Electrical Safety ............................vii Grounding ..............................vii Personnel and Equipment Safety Information................viii Important Notice to Users ........................x Warning Labels ...........................xi Environmental Information – WEEE ....................xi Special Conditions for Safe Use ....................xii Hazardous Location Limitations ..................xii Electromagnetic Compatibility (EMC) ..................xiii Supplier’s Declaration of Conformity ..................
Page 4 Interface Unit) ........................2-46 Connecting Analyzers to the AMEVision Display User Interface ......2-47 Connecting a Single Analyzer ...................2-47 Connecting Multiple Analyzers .................2-48 Final Daisy Chain Connection Configuration Setting .........2-49 ® PN 10270-11-5, Rev A iv | Thermox WDG-V HP Series Combustion Analyzer...
Page 5 Standard Purge Start-Up (with or without External Pressure Switch) ................ 2-55 Rapid Purge Start-Up ........................2-59 Tips to Ensure Proper Initial and Continued Operation of the WDG-V HP Series Analyzer..............................2-63 MAINTENANCE AND TROUBLESHOOTING .................3-1 Aftermarket Excellence and Long-Term Commitment to Safety and Quality ....3-3 Spare Parts..............................3-4...
Page 6 WDG-V HP Series Analyzer, North American Rating Labels, 115 VAC and 230 VAC ...............................4-8 Analyzer Purge Markings ........................4-9 WDG-V HP Series Rapid Purge Warning Label and Component Layout Drawing ...4-9 WDG-V HP Series Standard Purge Warning Label and Component Layout Drawing ............................4-11 FRENCH WARNINGS/FRANÇAIS ADVERSTISSEMENTS ............5-1...
Page 7 Safety Notes WARNINGS, CAUTIONS, and NOTES contained in this manual emphasize critical instructions as follows: Important information that should not be overlooked. 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 Avoid Electrical Overload To avoid electrical shock or fire hazard, do not apply a voltage to a terminal that is outside the range specified for that terminal. ® PN 10270-11-5, Rev A viii | Thermox WDG-V HP Series Combustion Analyzer...
Page 9 Ground the Product Follow the grounding instructions provided in the “Installation and Start-Up” chapter of this manual. Before making connections to the input or output terminals of this product, ensure that the product is properly grounded. Use Proper Power Source Do not operate this product from a power source that applies more than the voltage specified.
Page 10 You should only attempt to repair or service this equipment after receiving training from an AMETEK/P&AI Divi- sion training representative. If you decide to service this equipment be aware that high voltages, high temperatures, and other potentially hazardous conditions may arise.
Page 11 Achtung – Heiße Oberfläche 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 environ- ment or human health. In order to prevent the release of harmful substances into the environment and to conserve our natural resources, AMETEK recommends that you arrange to recycle this product when it reaches its “end of life".
Page 12 Special Conditions for Safe Use The WDG-V HP Series Analyzer is designed to be used in Category 3 hazardous loca- tions where explosive gases may be present. Protection against explosion is provided via enclosure purging and pressurization. There are four (4) rules that must always be followed: •...
Page 13 The various configurations of the WDG-V HP Series Analyzers should not produce, or fall victim to, elec- tromagnetic disturbances as specified in the European Union’s EMC Directive. Strict compliance to the EMC Directive requires that certain installation techniques and wiring practices are used to prevent or minimize erratic behavior of the Analyzer or its electronic neighbors.
Page 14 Pittsburgh, Pennsylvania, USA 15238 Tel: 1-412-828-9040 ametekpi.com FCC Compliance Statement (WDG-V HP Series Combustion Analyzers subject to Part 15): This device complies with Part 15 of the FCC Rules. Operation is subject to the follow- ing two conditions: (1) This device may not cause harmful interference, and (2) This device must accept any interference received, including interference that may cause undesired operation.
Page 15 Special Warnings and Information Equipment Used in Hazardous Locations Refer to Specifications in this document for details about the suitability of this equip- ment in hazardous locations. This analyzer must not be commissioned until a person trained in the area of evaluating equipment for use in hazardous classified locations has confirmed that this equipment and its installation are in compliance with the requirements for the area.
Page 16 This page intentionally left blank. ® PN 10270-11-5, Rev A xvi | Thermox WDG-V HP Series Combustion Analyzer...
Page 17 About the Analyzer The WDG-V HP Series Combustion Analyzer is a flue gas analyzer, designed for high particulate flue gas applications. The analyzer uses convection as a mo- tive force and mounts directly to the combustion process to provide continu-...
Page 18 Basic Elements of the Analyzer The WDG-V HP Series Analyzer consists of the following basic systems: • Plumbing All inlet and outlet tubing, Oxygen Cell Housing, and the Combustibles Flow Block. Also includes the Calibration Gas Inlet. • Measuring System The Oxygen Cell, Combustibles Detector, and Methane Detector.
Page 19 How the Oxygen Cell Works The sensing element is a closed-end tube made from ceramic zirconium oxide stabilized with an oxide of yttrium or calcium. Porous platinum coatings on the inside and outside serve as both a catalyst and as electrodes. At high tempera- tures (generally above 650 °C/1200 °F), oxygen molecules coming in contact with the platinum electrodes near the sensor become ionic.
Page 20 When this occurs, the Cell will gener- ate high millivolts and cause the display to indicate less oxygen than is actually in the gas (net oxygen content). 1-4 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 21 Hydrocarbons in the Gas Sample When hydrocarbons are present in the gas sample, a combustion process oc- curs when this gas sample is exposed to the high temperature of the Zirconia Cell. An indication that hydrocarbons may be present in the gas sample is that the oxygen reading will be lower than expected.
Page 22 Process gas enters and replenishes the gas inside the Filter by diffusion only. Thus, the filter never becomes plugged, making it ideal for high particu- late applications. Figure 1-2. WDG-V HP Analyzer Sensor Enclosure layout. 1-6 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 23 . You should attempt to match your Calibration gas with a mixture of CO and H that most closely matches the combustibles mix in your process. AMETEK recommends using an even mixture of CO and H as the com- bustibles component within your Span Calibration gas.
Page 24 RTD, see Figure 1-2), which is mounted on a bracket in the lower- left area of the enclosure. All internal plumbing components are maintained above 200 °C. 1-8 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 25 Heaters There WDG-V HP uses two main heaters. Component Function Oxygen Cell Furnace The Oxygen Cell Heater (Figure 1-3) is a 300 W coil heater en- Heater compassing the Cell Housing and providing precision heat to the Oxygen Cell. Box Heater The Box Heater is a 350 W cartridge heater located in the alu- minum Box Heater Block at the bottom of the Sensor Enclosure (Figure 1-2).
Page 26 The WDG-V HP Sensor board also has the following I/O available: • One (1) RS-485, 2 wire, MODBUS RTU interface (57.6 Kbaud), HART® Option available. • Valve controls for the optional Remote Calibration Unit (RCU). 1-10 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 27 Auto calibration must be selected in the Configuration menu. • RCU Interface: The WDG-V HP has five (5) solenoid valve drivers that are com- patible with AMETEK’s Remote Calibration Unit (RCU). See “Remote Calibration Unit Connections” in Chapter 2 for wiring/interface details.
Page 28 It provides real-time status, diagnostic conditions, and basic analyzer information. Refer to the PC Configurator Software Manual (AMETEK Part No. 9000-231-VE) for a complete description of how to navigate through the software while configuring or calibrating the analyzer, or simply viewing analyzer data.
Page 29 These reminders indicate related information about the topic, certain actions that Leak in the Sample System“ in are necessary before continuing with the current procedure, or information that is Chapter 3. recommended by AMETEK. See example at left.   User Interface Navigation icon:...
Page 30 This page intentionally left blank. 1-14 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 31 Installation and Start-up This chapter describes how to install the WDG-V HP Analyzer, optional equip- ment, and the AMEVision Display User Interface (or PC Configuration Soft- ware). If you have an Oxygen-only analyzer without the Combustibles op- tion, the Combustibles and methane options described in this chapter do not apply.
Page 32 Read this entire section before beginning installation of the analyzer. Failure to do so, and/or use of the WDG-V HP Series Analyzer in a man- ner not specified in this manual, may impair the protection against fire, electrical shock, and personal injury originally provided by this equipment.
Page 33 If equipment is damaged, notify the carrier and contact AMETEK Aftermarket support (https://www.ametekpi.com/customersupport/requestsupport) im- mediately if parts are missing or damage is found, and to verify if damaged parts will require replacement prior to safely installing and operating the analyzer/equipment.
Page 34 WDG-V HP specifica- tion limits. If the ambient temperature is outside the specified limits or the vibration is excessive, contact the AMETEK Sales or Service Depart- ment to discuss solutions and special options to address ambient tem- peratures outside the listed specifications.
Page 35 Always install the analyzer in a location that is as free as possible from vibrations. • The WDG-V HP Series Analyzer is rated for outdoor operation with IP65 / NEMA 4X enclosure: - General Purpose: Ambient -25 °C to +65 °C (-13 °F to 149 °F).
Page 36 Figure 2-1. WDG-V HP Series Analyzer mounting dimensions. 2-6 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 37 Installing the Analyzer and Inlet Probe Review this entire procedure before installing the WDG-V HP Analyzer to help you determine all installation considerations. To install the WDG-V HP Series Analyzer on the process: 1. Identify the mounting method to use for the WDG-V HP. •...
Page 38 If the pipe nipple provided by AMETEK extends past the inside wall of a process duct that has a gas temperature over 650 °C (1200 °F), cut down the nipple before installation so it is flush with the inside wall. c. Weld the AMETEK-supplied mounting plate to the process wall.
Page 39 Insert the AMETEK-supplied pipe nipple (attached to the supplied mounting plate) into the pipe nipple. If the pipe nipple provided by AMETEK extends past the inside wall of a process duct that has a gas temperature over 650 °C (1200 °F), cut down the nipple before installation so it is flush with the inside wall.
Page 40 To prepare the process duct for the installation of the WDG-V HP: a. Mount the analyzer to a 3" x 300# customer-supplied flange (Figure 2-4). In this case, you will not need the AMETEK-supplied mounting plate. b. Mount the analyzer to the process duct as described in Step 3 (fol- low the procedure to install the analyzer with the Probe installed, or without the Probe installed).
Page 41 3. The WDG-V HP Analyzer can be installed with or without its Sample Inlet Probe connected, depending on the length of the Inlet Probe and the amount of room on the platform. This step includes both methods. Install the Sample Inlet Probe and Probe Filter on the WDG-V HP •...
Page 42 Align the three (3) studs on the mounting plate with the three (3) holes in the analyzer's backplate and mount the WDG-V HP to the mounting plate studs. 2-12 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 43 Enclosure door until you first verify that the area has been classified as nonhazardous. To install the WDG-V HP Series Analyzer on the process duct and then install the Sample Inlet Probe and Probe Filter: a. On the WDG-V HP Analyzer, open the Sensor Enclosure door, then lift the door upward to release its hinges and remove it to allow full access to the internal assemblies.
Page 44 Take care not to twist, pull, or damage the wiring leading from the Furnace into the Electronics Enclosure. Figure 2-6.1. Furnace/Detector Block removal, disconnecting the tubing. 2-14 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 45 b. Remove the four (4) nuts and washers from the Manifold Block mounting plate inside the Sensor Enclosure (Figure 2-6.2). Set the nuts and washers aside. Leave the Manifold Block gasket on the studs. c. Remove all protective plastic caps and plugs from the Probe Filter and Sample Inlet Probe.
Page 46 Replace the washers and nuts on the studs and tighten them to secure the Manifold Block to the backplate. Figure 2-6.3. Installing the Inlet Probe/ Manifold Block Assembly. 2-16 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 47 h. In the Sensor Enclosure, lift the Furnace/Detector Block off the hook and lower it while aligning the respective fittings/tubings. Take care not to twist, pull, or damage the wiring leading from the Cell Furnace into the Electronics Enclosure. Make the connection on each tubing (hand tighten). After the Fur- nace/Detector Block is secured, tighten the connections using two wrenches to avoid twisting the tubing.
Page 48 If using a WDG-VM HP or WDG-VCM HP Analyzer, you must also have a Methane Span gas: 2 % CH , 8–10 % O , balance N 2-18 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 49 Manual Calibration Connections If your system uses the optional Remote Calibration Unit (RCU), skip the remainder of this section and proceed to the section “Installing the Remote Calibration Unit (Optional)". Calibration Gas Connection A Calibration Gas Inlet port on the analyzer (see Figure 2-6.1) is provided to allow you to calibrate the system.
Page 50 Purge Connection Options and Requirements AMETEK provides two purge options, one for North American Class I Division 2 and one for ATEX/IECEx Zone 2 applications. • Connect Instrument Air to the analyzer Purge Inlet (Figures 2-7.1 and 2-7.2). Maintain the pressure and flow as directed on the Z-purge warning label.
Page 51 .XXX ANGLES AMETEK ENERGY & PROCESS INSTRUMENTS REPRODUCTION PROHIBITED WITHOUT 150 FREEPORT RD CUSTOMER AMETEK SHEET METAL .010 0-30' PERMISSION BY AMETEK E & PI DIVISION PITTSBURGH, PA 15238 U.S.A. MACHINING .005 0-15' 3/30/2023 WDGV DRAWN BY ALL OTHERS .015...
Page 52 TOLERANCES (UNLESS SPECIFIED) FABRICATION .XXX ANGLES AMETEK ENERGY & PROCESS INSTRUMENTS REPRODUCTION PROHIBITED WITHOUT 150 FREEPORT RD SHEET METAL .010 0-30' PERMISSION BY AMETEK E & PI DIVISION PITTSBURGH, PA 15238 U.S.A. MACHINING .005 0-15' 3/30/2023 WDGV DRAWN BY ALL OTHERS .015...
Page 53 2. Optional: If using a Span gas other than Instrument Air, you must purchase the optional alternate Span gas kit (AMETEK Part No. 76942TE). For this option, connect the alternate O Span gas to the alternate O Span Gas Inlet.
Page 54 WITH FITTINGS 50 PSI MAX (3.5KG/CM ) ZERO MINIATURE CHECK SOLENOID REGULATOR VALVE VALVE FACTORY SET 1/2 PSI @ 10PSI Figure 2-9.2. RCU flow diagram, Standard (Oxygen). 2-24 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 55  alternate Span Gas Inlet. The Aspirator Air Outlet on the right side is not used with the WDG-V HP Series. Cap 2. Connect the O Zero Calibration gas to the O Zero Calibration Gas Inlet this outlet with supplied cap.
Page 56 VALVE CALIBRATION GAS VALVE FACTORY SET 1/2 PSI @ 10PSI OUTLET TO SENSOR PLUMB TO 1/4"OD TUBING WITH FITTINGS Figure 2-10.2. RCU flow diagram (2 Span), Combustibles. 2-26 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 57 O Span Gas Inlet. The Aspirator Air Outlet on the right side is not used with the WDG-V HP Series. Cap 2. Connect the O Zero Calibration gas to the Zero Calibration Gas Inlet port this outlet with supplied cap.
Page 58 CALIBRATION GAS VALVE FACTORY SET 1/2 PSI @ 10PSI OUTLET TO SENSOR PLUMB TO 1/4"OD TUBING WITH FITTINGS Figure 2-11.2. RCU flow diagram (3 Span), Combustibles and Methane. 2-28 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 59 AC Mains Power and Signal Connections Remove AC mains power from the AMEVision and Remote Calibration Unit (RCU) – if used – before beginning wiring. Connections to the analyzer unit are made on the Sensor board, in the Elec- tronics Enclosure (see Figures 2-12.1 and 2-12-2 for entry ports and Sensor board location).
Page 60 Figure 2-12.1. Conduit entry, Calibration gas port, and ground stud locations. Figure 2-12.2. WDG-V HP Analyzer Electronics Enclosure layout. 2-30 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 61 Connecting I/O Signals, Relay Contacts, and AC Power Current Output Connections Standard Current Outputs There are three (3) current outputs on the WDG-V HP Analyzer. The current output connections are labeled as follows on the Sensor board (Figure 2-13.1) terminals: Analog Output #1 =>...
Page 62 Figure 2-13.1. Customer and Modbus wiring, Sensor board. 2-32 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 63 Alarm Contact Connections Standard Alarm Connections The WDG-V HP Series Analyzer provides five (5) sets of Normally Open alarm contacts: Terminal Block ID Description Relay – Service Alarm – Data Valid Alarm ALM1 – Process Alarm 1 (Configurable) ALM2 –...
Page 64 AC line power wires. By keeping this wiring separated, you prevent transient signals from reaching the analyzer. The WDG-V HP Series Analyzer can operate using between 115 VAC, ±10 % or 230 VAC, ±10 %. There is no power switch or circuit breaker on the analyzer,...
Page 65 Figure 2-13.2. AC/Internal Wiring, Sensor board. Installation and Start-Up 2-35 PN 10270-11-5, Rev A...
Page 66 Cable Shield(s) Conduit Housing Max. Length 2 inches Capacitor Conduit Nut Washer Capacitor Conduit Nut Ring Terminal Figure 2-14.2. EMC Grounding, ground stud Washer method. Ring Terminal 2-36 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 67 Transient and RFI Interference Transient and RFI interference precautions include: • Although there are transient and noise protectors on all analyzer I/O con- nections (communications, current outputs, analyzer, etc.), this protection is intended to act as a last line of defense against unwanted transient and RFI interference.
Page 68 Auto-Calibration. The switch used to connect to this digital input must be a Normally Open switch. Digital input connections are labeled CIN on the Sensor board (see Figure 2-15). 2-38 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 69 Overall braided shield or rigid metal conduit COM. COMB. ZERO ASP. SPAN SPAN SPAN REMOTE CAL UNIT Remote cal switch normally open (dry contact closure) Figure 2-15. RCU Connections, Sensor board. Installation and Start-Up 2-39 PN 10270-11-5, Rev A...
Page 70 Enclosure Maximum Overpressure The user should limit the pressure as specified by the manufacturer. 2-40 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 71 If you are using the PC Configurator Software to communicate with the WDG-V HP Analyzer, install the software on a PC, as instructed in the PC Con- figurator Software Manual (AMETEK Part No. 9000-231-VE), and then continue with setting the analyzer address, below.
Page 72 The address on the WDG-V HP Analyzer is set using the dip switch on the front of the Sensor board. When connecting a single analyzer, the address is “1”. 321 Switch Address 1 = ON (UP) 0 = OFF (DOWN) 2-42 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 73 Connecting the PC to the Analyzer Use the optional USB-to-RS-485 converter (Part No. 1000-724-JE) to connect between the analyzer and the PC. Once the analyzer has been connected to the PC, use the PC Configurator Soft- ware to set up parameters and calibrate the unit. For instructions on how to work in the PC Configurator Software to configure and calibrate the analyzer, and to view analyzer status read- ings, refer to the PC Configurator Software User Manual.
Page 74 When installing the AMEVision Display User Interface Unit follow the instructions in this manual (but also refer to the AMEVision Display User Interface User Manual, AMETEK Part No. 9000-165-VE), and then continue with setting the analyzer address, below. Mount the AMEVision Display User Interface on a wall.
Page 75 9.00 228.60 5.97 1.50 2.00 151.58 38.10 50.80 HINGE DISPLAY SIDE 10.00 12.00 304.80 9.14 232.19 KEYPAD 1.44 1.44 36.48 36.48 (3) 3/4" (2.70cm) CONDUIT ENTRIES 2.58 1.58 65.53 40.13 1.44 (2) 1/2" (2.22cm) 36.48 CONDUIT ENTRIES Figure 2-19. AMEVision dimension, installation.
Page 76 2-22 for the dip switch. 321 Switch Address Figure 2-20. Dip Switch, Sensor board, used 1 = ON (UP) to enable communications with 0 = OFF (DOWN) the AMEVision Display Unit. 2-46 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 77 Connecting Analyzers to the AMEVision Display User Interface Figure 2-21.1 Single WDG-V HP Analyzer to the AMEVision Display User Interface. Connecting a Single Analyzer When only one analyzer is connected, set the address to “1”. Installation and Start-Up 2-47 PN 10270-11-5, Rev A...
Page 78 Figure 2-21.2 Multiple WDG-V HP Analyzers to the AMEVision Display User Interface. Each analyzer must have a unique address. See “Setting the Analyzer Address Using the Dip Switch”. 2-48 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 79 For instructions on how to work from the AMEVision Display User Interface to configure and calibrate the analyzer, and to view analyzer status readings, refer to the AMEVision Display User Interface User Manual (AMETEK Part No. 9000-165-VE). Installation and Start-Up 2-49...
Page 80 Customer I/O Connections Figure 2-22. Customer I/O Connections. 2-50 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 81 Communication Troubleshooting Checks The interface between the WDG-V HP and the AMEVision Display User Inter- face is simple and robust. However, if you experience any connectivity issues, here are some of the possible causes. No Communications Possible Cause Corrective Action Polarity reversed Check the wiring for proper polarity.
Page 82 YELLOW – Analyzer is in warm-up state or diagnostic state. RED – Analyzer has a Service alarm and is in need of attention. Figure 2-23.1. Analyzer is in normal operating mode. 2-52 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 83 Figure 2-23.2. Analyzer is in warm-up state or diagnostic state. Figure 2-23.3. Analyzer has a Service alarm and is in need of attention. Installation and Start-Up 2-53 PN 10270-11-5, Rev A...
Page 84 FORWARD LED – Modbus Communications LED. Toggles upon receipt of a valid Modbus message. This LED will blink rapidly in short bursts when com- municating properly with the AMEVision Display User Interface. 2-54 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 85 For North American Class I Division 2 and ATEX/IECEx Zone 2 applica- tions, AMETEK provides two purge options (Standard Purge and Rapid Purge) that can be used with the WDG-V HP Series Analyzer. Standard Purge Start-Up (with or without External Pressure Switch)
Page 86 Figure 2-24.1. Standard Purge system, WDG-V HP Series shown. 2-56 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 87 SUPPLIED BY SUPPLIED BY CUSTOMER AMETEK MARKED SERVICE VALVE ADJACENT TO ENCLOSURE GAUGE ALARM PRESSURIZED PROTECTIVE GAS SUPPPLY ENCLOSURE WITH AN ALARM WITH INDICATOR ALARM PROTECTIVE ACTUATOR SUPPLY MARKED REGULATOR WDG-V HP ADJACENT TO ENCLOSURE Figure 2-24.2. Standard purge setup.
Page 88 8. Wait for the Enclosure Pressure Gauge to return to a “Safe” pressure and en- ergize the protected enclosure(s) power using the local disconnect switch. 9. Ensure the Enclosure Pressure Indicator maintains a “Safe” pressure before leaving the system unattended. 2-58 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 89 Rapid Purge Start-Up “Safe” pressure, for purposes of this manual, is defined as 0.15" to 0.35" of water column. If the Regulator is in the locked position, you will need to adjust it. To do this, pull the handle to the outward position then carefully insert the T-bar Valve Key (supplied with system) to align valve stem tip of both valves.
Page 90 9. Wait for the Enclosure Pressure Gauge to return to a “Safe” pressure and en- ergize the protected enclosure(s) power using the local disconnect switch. 10. Ensure the Enclosure Pressure Indicator maintains a “Safe” pressure before leaving the system unattended. 2-60 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 91 Figure 2-25.1. Rapid Purge system, WDG-V HP Series shown. Installation and Start-Up 2-61 PN 10270-11-5, Rev A...
Page 92 Figure 2-25.2. Rapid purge flow diagram. 2-62 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 93 Tips to Ensure Proper Initial and Continued Operation of the WDG-V HP Series Analyzer Review and follow these points to ensure your analyzer will continue to oper- ate at peak efficiency, with a minimum of maintenance and troubleshooting: • If your process is running and the analyzer is installed on the process, the analyzer must have power applied to it to prevent plugged plumbing and analyzer component damage.
Page 94 This page intentionally left blank. 2-64 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 95 Maintenance and Troubleshooting This chapter describes how to access the AMETEK customer support/after mar- ket pages online to request technical support and authorization on returning equipment, and lists spare parts required for general and continued operation. This chapter also includes Diagnostic Flowcharts which can be used to check...
Page 96 PC Configurator and Web Interface software will display alarms on the bottom Status bar. 3-2 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 97 Aftermarket Excellence and Long-Term Commitment to Safety and Quality Our goal is to make your experience with our products exceptional. We stand behind our analyzers with a broad service offering that provides a sense of security long after the initial purchase has been made. We commit to fulfilling your service needs with speed, quality, and professional consideration.
Page 98 Sensor Assembly includes Sensor board, Main Processor board, and mounting plate. The Block Heater and RTD are not included. Includes heat plate, heater, push nut, and dowel pin. 3-4 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 99 2-11.2 0–69 kPa (0–10 PSI) Internal Regulator 37070JE 2-12.1 Miscellaneous Spare Parts Description AMETEK Part No. Figure WDG-V HP Series Combustion Analyzer User Manual 10270-11-5 — AMEVision Display User Interface User Manual 9000-165-VE — WDG-V PC Configurator Software Manual 9000-231-VE —...
Page 100 Diagnostic Flowcharts. AMETEK recommends monitoring the Thermocouple millivolts and Cell mil- livolts displayed during troubleshooting as a troubleshooting aid. This infor- mation will be helpful should you need to contact the factory for assistance. Be sure to always include your analyzer model and serial number when contact- ing AMETEK for technical support.
Page 101 Calibration gases when the Remote Calibration Unit has been activated (see the “Inject Gas” diagnostic section in the AMEVision Display User Interface User Manual – AMETEK Part No. 9000-165-VE – for more information). If using the PC Configurator Software, view the Cal Gas Values ...
Page 102 Figure 3-1. AC/Internal Wiring, Sensor board. 3-8 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 103 Remote Calibration Unit The RCU contains one (1) Normally Open solenoid for Aspirator (RCU) Problem Air, however, this is not used for the WDG-V HP Series. All other solenoids are Normally Closed. Problems with the RCU are usu- ally as follows:...
Page 104 Furnace resistance. If no voltage is present at terminals FURN on the Sensor board, replace the Sensor board. Contact AMETEK Aftermarket support to verify proper operation. Process Pressure Checks (only if above 14 kPa/2 PSIG)
Page 105 Oxygen Cell Checks Possible Cause/ Condition Corrective Action If the Oxygen Cell fails It is likely that there is a leak in the analyzer plumbing or an when you first begin to improper Calibration gas setup, and there is not a problem with use the analyzer the Cell itself (see “Leak Check”...
Page 106 Clean the plumbing using hot water and a bottle brush. • When assembly is complete, check for leaks using a leak de- tecting liquid. 3-12 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 107 Maintenance Maintenance personnel should be thoroughly familiar with the opera- tion of the analyzer, and the AMEVision Display User Interface (or PC Configurator Software) before performing the maintenance proce- dures described in this chapter. Safety Considerations Before working on the analyzer, read the entire procedure you will be performing to learn how to safely perform maintenance on and troubleshoot the WDG-V HP Analyzer.
Page 108 Calibration Check calibration and/or recalibrate the analyzer every 90 days. Refer to the Calibration section in Chapter 2. 3-14 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 109 Cleaning and Replacing Parts This section discusses how to prepare the analyzer for maintenance/service, the analyzer components that can be cleaned or replaced, and how to prepare the analyzer for normal operation following maintenance/service. Figure 3-2.1. WDG-V HP Analyzer Sensor Enclosure layout.
Page 110 Safely Powering Down the WDG-V HP Series Analyzer to Perform Maintenance This section describes how to safely prepare the analyzer and power it down before performing maintenance/service procedures on it. Before powering down the analyzer read and follow the Warnings and Cautions under “Safety Considerations,”...
Page 111 Safe Start-up Procedure for the WDG-V HP Series Analyzer After Maintenance This procedure assumes all maintenance or service on the analyzer has been completed as described in the maintenance procedures described later in this chapter. Hazardous Locations Before proceeding, test the area around the analyzer for explosive gases and proceed only when the area is found to be safe.
Page 112 2. If not already done, open the Sensor and Electronics enclosures and allow the components to cool before working on the analyzer. 3. Remove the Cell Clips. 3-18 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 113 – including an adequate warm-up period and calibra- tion – as described under “Safe Start-up Procedure for the WDG-V HP Series Analyzer After Maintenance” earlier in this chapter.
Page 114 5. Install the new Thermocouple, aligning the tab with the two mounting tabs on the plate. Take care to avoid damaging the ceramic tip while inserting the new Thermocouple. 3-20 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 115 – including an adequate warm-up period and calibra- tion – as described under “Safe Start-up Procedure for the WDG-V HP Series Analyzer After Maintenance” earlier in this chapter.
Page 116 Reference element – GREEN wires connect to Cref. RTD Combustibles Detectors (special order only): Active element – WHITE wire with RED stripe connects to Cact. Reference element – Solid WHITE wire connects to Cref. 3-22 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 117 – including an adequate warm-up period and calibra- tion – as described under “Safe Start-up Procedure for the WDG-V HP Series Analyzer After Maintenance” earlier in this chapter.
Page 118 – including an adequate warm-up period and calibra- tion – as described under “Safe Start-up Procedure for the WDG-V HP Series Analyzer After Maintenance” earlier in this chapter.
Page 119 Replacing the Cell Furnace Assembly Figure 3-6. Cell Furnace Assembly replacement. To replace the Cell Furnace Assembly (Figures 3-1 and 3-6): 1. Take all necessary steps to safely prepare the analyzer and power it down before performing this procedure. See “Safely Powering Down the WDG-V HP Series Analyzer to Perform Maintenance”...
Page 120 – including an adequate warm-up period and calibra- tion – as described under “Safe Start-up Procedure for the WDG-V HP Series Analyzer After Maintenance” earlier in this chapter.
Page 121 Replacing the Box Heater Cartridge There is only one (1) heater cartridge in the O -only version of the WDG-V HP. There are two (2) heaters in the Combustibles/Methane version. Figure 3-7. Box Heater cartridge replacement. To replace the Box Heater Cartridge (Figures 3-1 and 3-7): 1.
Page 122 – including an adequate warm-up period and calibra- tion – as described under “Safe Start-up Procedure for the WDG-V HP Series Analyzer After Maintenance” earlier in this chapter.
Page 123 – including an adequate warm-up period and calibra- tion – as described under “Safe Start-up Procedure for the WDG-V HP Series Analyzer After Maintenance” earlier in this chapter.
Page 124 (3) pegs on the right side of the Sensor board align with the larger keyhole slots on the Electronics Plate, then pull the Sensor board/Electronics Plate assembly outward to remove it. 3-30 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 125 – including an adequate warm-up period and calibra- tion – as described under “Safe Start-up Procedure for the WDG-V HP Series Analyzer After Maintenance” earlier in this chapter.
Page 126 AMEVision Display User Interface (or PC Configurator Software) before performing troubleshooting proce- dures described in this chapter. AMETEK recommends that you have the required spare parts available before powering down the analyzer to replace the parts. 3-32 | Thermox ®...
Page 127 • Use the user interface control diagnostics to confirm the operation of the analog output. • Check for a failed or faulty read-back circuit. • If any of these checks do not correct the alarm condition, contact AMETEK Aftermarket support. Box Temp High The temperature within the Sensor Enclosure (referred to as Box temperature) is four (4) degrees °C or higher...
Page 128 • If the wires are damaged, or the Box RTD or Box Heater Cartridge are found to have a short or open circuit, re- place the part(s). See “Replacing the Box RTD” or “Replacing the Box Heater Cartridge” in this chapter to replace these parts. 3-34 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 129 • If the Sensor board is found to be damaged, replace it. See “Replacing the Sensor Board” in this chapter to replace the Sensor board. Contact AMETEK Aftermarket support to verify operation before removing and replacing parts. Cell Over Temp The Oxygen Cell temperature within the furnace is four (4) degrees °C or higher above the setpoint.
Page 130 • If the wires are damaged, or a short or open circuit is found, replace the Cell Furnace Thermocouple. See “Re- placing the Cell Furnace Thermocouple” in this chapter to replace this part. 3-36 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 131 Alarm Condition / Description / Corrective Action Cell Temp Rise Failure Cell Heater failed to heat the Cell. Trigger Conditions: • Faulty Cell Furnace Assembly AC wiring connection (FURN on the Sensor board). • Faulty Cell Furnace Thermocouple connection. • Faulty Cell Furnace Heater. •...
Page 132 “Replacing the Combustibles and Methane Detectors” in this chapter to replace these parts. • If the Sensor board is found to be faulty, replace the board. See “Replacing the Sensor Board” in this chapter to replace the board. 3-38 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 133 Alarm Condition / Description / Corrective Action Methane Detector Open (applicable only to WDG-VCM HP and -VM HP Analyzers) Methane Detector is open or not connected. Trigger Conditions: • Faulty Methane Detector. • Faulty Sensor board or wiring. Corrective Action: Take appropriate safety precautions, open the Sensor and Electronics enclosure doors, and: •...
Page 134 Cell is found to have exceeded its end of life, is nearing its end of life, or has a Low Cell Output, re- place the Oxygen Cell. See “Cleaning and Replacing Parts in Oxygen Cell” in this chapter to replace these parts. 3-40 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 135 Warning Condition / Description / Corrective Action Comb Calibration Required Combustibles Calibration is required. Trigger Conditions: • Last Calibration failed. • Unit has never been calibrated. Corrective Action: From the AMEVision Display User Interface or PC Configurator Software: • View the Calibration Results screen to check if it has displayed the message “X Failed!”. If so, restart the Combustibles Calibration and allow sufficient time for it to complete its cycle.
Page 136 • Check the Calibration gas solenoid for proper operation. If the solenoid if found to be faulty, replace the sole- noid. Contact AMETEK Aftermarket support to verify operation before removing and replacing parts. • Check the Methane Detector for proper operation. If it is found to be faulty, replace the Detector. See “Replac- ing the Combustibles and Methane Detectors”...
Page 137 • Check the Calibration gas solenoid for proper operation. If the solenoid if found to be faulty, replace the sole- noid. Contact AMETEK Aftermarket support to verify operation before removing and replacing parts. • Allow sufficient time to allow the Span Calibration gas to flow through the O Sensor and to stabilize.
Page 138 Cal Gas Duration setting, and enter a longer duration. Perform the following: • Restart the Calibration and allow sufficient time for it to complete its cycle. 3-44 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 139 For custom ranges/applications refer to accom- panying Manual Supplements shipped with the analyzer, or consult with your AMETEK representative. WDG-V HP Series Analyzer Specifications The components measured by your analyzer depend on the version ordered. Use the specifications as they apply to your analyzer.
Page 140 227 mm (8.9") with doors closed Weight: Approximately 40 kg (88 lb), entire system (may vary, depending on system configuration and options selected) Enclosure Hinged NEMA 4X (IP65) 4-2 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 141 Specification Description Calibration Gas Use Calibration gases @ 69 kPa (10 PSIG), 1.4 L/minute (3.0 SCFH). Requirements Use certified mixtures only. Span Gas: Instrument air, or from 1.0–100 % O balance N (typically, 20.9 % O , balance Zero Gas, Combustibles Zero Gas, and Methane Zero Gas: 2 % O or from 0.1–10 % O , balance N...
Page 142 AMEVision unit’s specifications. Refer to the AMEVision Display User Interface User Manual (AMETEK Part No. 9000-165-VE) for its specifications. WDG-V HP Series Analyzer Directives and Standards IECEx IECEx ETL 23.0047X:...
Page 143 Remote Calibration Unit (RCU) Directives and Standards IECEx ETL 22.0027X Ex ec IIC T4 Gc -20 °C ≤ Ta ≤ 70 °C IEC 60079-0:2017 IEC 60079-7:2017 ATEX ETL23ATEX0152X: II 3 G Ex ec IIC T4 Gc Directive 2014/34/EU using the following standards: EN IEC 60079-0: 2018 EN IEC 60079-7: 2015/A1:2018 Directive 2014/30/EU...
Page 144 WDG-V HP Series Analyzers Standards Conforms to the following standards: • Electrical Equipment for Measurement, Control, and Laboratory Use; Part 1: General Requirements [UL Standard 61010-1:2012 Ed.3+R:19Jul2019] • Safety Requirement For Electrical Equipment for Measurement, Control, and Laboratory Use: Part 2-010: Particular Requirements For Laboratory Equipment For the Heating Of Materials [UL Standard 61010-2-010: 2015 Ed.3]...
Page 145 WDG-V HP Analyzer Markings WDG-V HP Analyzer, Rapid Purge Labels, 115 VAC and 230 VAC WDG-V HP Analyzer, Standard Purge Labels, 115 VAC and 230 VAC PN 10270-11-5, Rev A Specifications...
Page 146 WDG-V HP Series Analyzer, North American Rating Labels, 115 VAC and 230 VAC 4-8 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 147 This section includes the marking labels and component layout drawings for Rapid Purge and Standard Purge analyzer systems, and a layout drawing for analyzers with the optional external pressure switch. WDG-V HP Series Rapid Purge Warning Label and Component Layout Drawing PN 10270-11-5, Rev A...
Page 148 Figure 4-1. Rapid Purge system, WDG-V HP Series shown. 4-10 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 149 WDG-V HP Series Standard Purge Warning Label and Component Layout Drawing PN 10270-11-5, Rev A Specifications 4-11...
Page 150 Figure 4-2. Standard Purge system, WDG-V HP Series shown. 4-12 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 151 Figure 4-3. Optional external pressure switch, standard WDG-V HP Series Purged Analyzer shown. PN 10270-11-5, Rev A Specifications 4-13...
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Page 153 French Warnings/Français Adverstissements NOTES SUR LA SECURITE LES AVERTISSEMENTS, LES PRÉCAUTIONS ET LES NOTES CONTENUS DANS CE MANUEL ATTIRENT L’ATTENTION SUR DES INSTRUCTIONS CRITIQUES COMME SUIT: Une procédure de fonctionnement qui n’est pas strictement suivie peut engendrer une blessure de personne ou une contamination de l’environnement.
Page 154 électriques et les vérifications de terres. Une utilisation quelconque de l’équipement de manière non spécifiée par le constructeur peut compromettre la protection de la sécurité d’origine fournie par l’équipement. 5-2 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 155 Mise à la terre La mise à la terre de l’instrument est obligatoire. Les spécifications de performance et la protection de sécurité sont invalides si le fonctionnement de l’instrument est effectué depuis une alimentation électrique à la terre impropre. Vérifiez la continuité de la terre de tout équipement avant d’alimenter électriquement.
Page 156 à l’usine. Vous devriez seulement essayer de réparer ou maintenir cet équipement après avoir reçu une formation d’un représentant AMETEK / Division P&AI. Si vous décidez d’effectuer la mainte- nance de cet analyseur, ayez conscience que des hautes tensions, des hautes températures et d’autres conditions potentiellement à...
Page 157 Sommaire de Sécurité Générale Lisez attentivement les précautions de sécurité suivantes pour éviter de se blesser et d’endommager l’équipement ou tout produit connecté à ce dernier. Utilisez un câblage adéquat Pour éviter les risques de feu, utilisez seulement le câblage spécifié dans le chapitre Installation de ce manuel de l’utilisateur.
Page 158 Dans un but de compatibilité électromagnétique, en aucune circon- stance vous ne devez laisser l’écran d’un câble déconnecté en une ou deux extrémités (unité de contrôle ou de terrain ou autre appareil). 5-6 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 159 APPENDIX A Packaging/Shipping the WDG-V HP Series Combustion Analyzer When shipping a WDG-V/-VC/-VCM/-VM HP Analyzer back to AMETEK for ser- vice, or for any other reason, it is important to package the analyzer properly, to avoid damaging it. If possible, reuse the original shipping package. If this is not an option, follow...
Page 160 Anything that can move will smash other fragile objects in the box and potentially crush packing material. If you can hear things rattling around or shifting, open the package and repack it. A-2 | Thermox ® WDG-V HP Series Combustion Analyzer PN 10270-11-5, Rev A...
Page 161 Cold (Non-Powered) Installations Many processes contain gasses that will condense on surfaces that are not sufficiently heated. Do not introduce process gas into an analyzer or sample conditioning system unless all wetted surfaces have warmed up to their de- sign temperature. This may take several hours after applying power. Exposing analyzers or sample systems to process gas while cold/unpowered may result in corrosion and/or plugging of components exposed to the gas.
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Page 163 AMETEK Process Instruments delivers worldwide sales and service support through a network of direct and factory-trained global distribution channels. AMETEK Service Assistance Program plans offer coverage up to 24 hours a day, 365 days of the year. As worldwide experts in the manufacture of process analyzers and instrumentation, we have supplied solutions to industry since 1962, providing the widest range of analysis technology available.

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