27631437

Thermox® Series 2000
WDG-IV, WDG-IVC, WDG-IVCM
User Manual
Thermox
150 Freeport Road
PN 90269VE , Rev. Y Pittsburgh, PA 15238
Offices
USA - Pittsburgh CHINA
150 Freeport Road AMETEK Shanghai (SPL)
Pittsburgh, PA 15238 Room 408, Metro Tower
Ph. 412-828-9040 #30 Tian Yao Qiao Road
Fax 412-826-0399 Shanghai 200030
Ph. 86 21 6426 8111
Fax 86 21 6426 7054
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455 Corporate Blvd. CITIC Building, Room 2305
Newark, DE 19702 19, Jianguomenwai Dajie
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CANADA GERMANY
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Calgary, AB T1Y 7H9 Rudolf-Diesel-Strasse 16
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Fax 403-248-3550 Ph. 49 21 59 91 36 0
Fax 49 21 59 91 3680
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AMETEK
PO Box 17067
Jebel Ali Free Zone
Dubai, UAE
Ph. 971-4-881 2052
Fax 971-4-881 2053
SINGAPORE
AMETEK Singapore Pte. Ltd.
No 43, Changi South Avenue 2, #04-01
Singapore 486164
Ph. 65-64842388
Fax 65-64816588
© 2000 AMETEK
This manual is a guide for the use of the Thermox Series 2000 WDG-IV (IVC / IVCM). 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; otherwise, AMETEK does not guarantee results and assumes no
obligation or liability. This publication is not a license to operate under, or a recommendation to infringe upon, any process patents.
Contents
Offices.......................................................................................................................ii
Safety Notes........................................................................................................... vi
Environmental Information (WEEE)............................................................... viii
General Safety Summary......................................................................................ix
CHAPTER 1 Overview
Sensor Operations............................................................................................... 1-1
Sensor . ................................................................................................................. 1-2
Basic Elements of the Sensor...................................................................... 1-2
The Oxygen Measuring Cell....................................................................... 1-2
Sensor Operations - WDG-IVCM..................................................................... 1-5
Close-Coupled Extrative Flue Gas Analyzer.................................................. 1-5
Hot-Wire Type............................................................................................... 1-5
RTD Type....................................................................................................... 1-6
Detectors............................................................................................................... 1-7
Combustibles................................................................................................. 1-7
Methane......................................................................................................... 1-7
Common Operator Errors................................................................................. 1-8
Start-Up Checklist............................................................................................... 1-9
Technical Support.............................................................................................. 1-10
CHAPTER 2 Specifications
Series 2000 Control Unit..................................................................................... 2-1
Sensor : WDG-IV . .............................................................................................. 2-2
Sensor : WDG-IVC . .......................................................................................... 2-3
Sensor : WDG-IVCM......................................................................................... 2-4
Sensor : WDG-IVC - 0-500 PPM ..................................................................... 2-6
Remote Calibration Unit (RCU)........................................................................ 2-7
CHAPTER 3 Installation
Analyzer Location............................................................................................... 3-1
Inspect Shipping Contents................................................................................ 3-2
Mechanical Installation...................................................................................... 3-3
Sample Inlet Probe Installation.................................................................. 3-3
Probe Heater Installation............................................................................ 3-6
Exhaust Tube Installation............................................................................ 3-7
Sensor Mounting.......................................................................................... 3-7
Calibration/Aspirator Air/Z-Purge Connections................................... 3-12
Weatherproof Wall/Z-Purge Option........................................................ 3-17
Wiring................................................................................................................. 3-19
General Wiring and Conduit Requirements.......................................... 3-20
Control Unit Mains Supply Connections............................................... 3-21
Sensor Connections.................................................................................... 3-24
Contents | iii
Remote Sense Setup Wiring for Combustibles...................................... 3-28
Current Output Connections................................................................... 3-29
Alarm Contact Connections..................................................................... 3-30
Remote Calibration Unit Connections.................................................... 3-32
RS-485 Communications Connections.................................................... 3-34
Option Card Installation.................................................................................. 3-38
Removing Display Module or Power Supply/Keypad Module.......... 3-38
Adding an Option Card............................................................................ 3-39
Removing an Option Card....................................................................... 3-39
CHAPTER 4 Controller/User Interface

Areas of the Control Unit................................................................................... 4-1
Control Unit Display.................................................................................... 4-1
Selecting Menu Options.............................................................................. 4-2
Exiting Menu Options................................................................................. 4-2
Automatic Menu Exit Feature..................................................................... 4-3
On-Line Help................................................................................................ 4-3
System Password.......................................................................................... 4-3
Setup Key.............................................................................................................. 4-4
Display........................................................................................................... 4-5
Process Pressure............................................................................................ 4-7
System Tests................................................................................................... 4-8
System Serial #............................................................................................. 4-8
Primary Calibration...................................................................................... 4-9
Sensor Config.............................................................................................. 4-12
Communication.......................................................................................... 4-13
Combustibles Option................................................................................. 4-13
Analog Range Key............................................................................................. 4-14
Analog Output Port.................................................................................... 4-15
Set Current Range...................................................................................... 4-15
Set Track/Hold Option............................................................................... 4-16
Set Current Mode....................................................................................... 4-17
Output Filtering Option............................................................................ 4-18
Select Function............................................................................................ 4-19
Alarm Key........................................................................................................... 4-20
Overview of Alarm Functions.................................................................. 4-21
Alarm Set Points.......................................................................................... 4-22
Alarm Configure......................................................................................... 4-24
Relay Configure.......................................................................................... 4-24
Select Function............................................................................................ 4-25
Service Alarm.............................................................................................. 4-26
Watchdog Relay.......................................................................................... 4-26
Exception Log.............................................................................................. 4-27
iv | Thermox Series 2000 WDG-IV / IVC / IVCM

Chapter 5 Calibration
Definitions............................................................................................................ 5-2
Calibrations vs. Verifications....................................................................... 5-2
Span and Zero Calibration Gas Definitions............................................. 5-2
Types of Calibrations.......................................................................................... 5-3
Overview.............................................................................................................. 5-4
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
Calibration: Hot Wire Type Combustibles Detector............................... 5-10
Calibration with RTD Type Combustibles Detector............................... 5-12
Cal/Verify Data................................................................................................... 5-14
Cal Gas Value..................................................................................................... 5-16
Inject Cal Gas..................................................................................................... 5-18
Set Cal Timers.................................................................................................... 5-20
Set Auto Timers........................................................................................... 5-21
Set Time and Date...................................................................................... 5-22
Auto Cal On/Off.......................................................................................... 5-22
Cal Gas Duration........................................................................................ 5-23
Recovery Duration..................................................................................... 5-24
Set K-Factors....................................................................................................... 5-25
Sensitivity........................................................................................................... 5-25
Chapter 6 Maintenance and Troubleshooting

System Messages................................................................................................. 6-2
Auto Cal Pending.......................................................................................... 6-2
Auto Verify Pending..................................................................................... 6-2
Calibration Aborted...................................................................................... 6-2
Calibration Required.................................................................................... 6-2
Cal Verify Aborted........................................................................................ 6-2
Power Down Detected................................................................................. 6-2
Primary Calibration...................................................................................... 6-2
System Calibrating....................................................................................... 6-2
System Verifying Cal.................................................................................... 6-2
Error Messages.................................................................................................... 6-3
Cell is Over Temp......................................................................................... 6-3
Combustibles Cal Error............................................................................... 6-3
Excessive Cal Error....................................................................................... 6-3
Memory is Corrupted.................................................................................. 6-3
Methane Cal Error........................................................................................ 6-3
Span Gas Range Error.................................................................................. 6-4
Temp Rise Failure......................................................................................... 6-4
T/C (Thermocouple) Circuit Failure.......................................................... 6-4
Contents | v
Thermocouple Failure................................................................................. 6-4
Zero Gas Range Error.................................................................................. 6-4
Diagnostics Checks............................................................................................. 6-5
Wiring Checks............................................................................................... 6-6
Interconnecting Wiring Problem............................................................... 6-6
Thermocouple Checks................................................................................. 6-6
Shorted/Failed Thermocouple.................................................................... 6-6
Reversed Thermocouple Wires.................................................................. 6-6
Thermocouple Compensation .................................................................. 6-6
Circuit Check................................................................................................. 6-6
Calibration/Aspirator Setup Checks.......................................................... 6-8
AC Power Checks......................................................................................... 6-9
Furnace Checks............................................................................................. 6-9
Process Pressure Checks............................................................................ 6-10
Cell Checks.................................................................................................. 6-10
General Troubleshooting................................................................................. 6-11
Leak Check.................................................................................................. 6-11
Plugged Plumbing Check......................................................................... 6-12
Aspirator Air Not Pulling Sample from Process.................................... 6-12
Series 2000 LEDs................................................................................................ 6-13
Auto Calibration Card LEDs..................................................................... 6-13
Combustibles Card LEDs.......................................................................... 6-13
Combustibles and Methane Card LEDs................................................. 6-14
Sensor Board (80471SE) LEDs.................................................................. 6-14
Chapter 7 Service and Parts

Cell Replacement/Cleaning............................................................................... 7-4
Thermocouple Replacement............................................................................. 7-6
Furnace Replacement......................................................................................... 7-8
Combustibles Detector Replacement............................................................. 7-10
Hot-Wire Combustibles Detector Replacement..................................... 7-10
Box Heater Diagram................................................................................... 7-13
Replacement Parts List..................................................................................... 7-14
Appendix A Serial Communications

Communication Protocols...........................................................................A-1
General Serial Communication Commands............................................A-3
Development Serial Communication Commands..................................A-4
Responses......................................................................................................A-6
Variable Table.......................................................................................................A-7
Sample Program................................................................................................A-24
Starting/Monitoring a Calibration: An Example..........................................A-25
vi |
Appendix B Menu Option Charts
Appendix C Current Outputs: Other Applications

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
| vii
Safety Notes
warnings, cautions, and notes contained in this manual emphasize
critical instructions as follows:
An operating procedure which, if not strictly observed, may result in

personal injury or environmental contamination.
An operating procedure which, if not strictly observed, may result in dam-

age to the equipment.
Important information that should not be overlooked.


NOTE
Electrical Safety
Up to 5 kV may be present in the analyzer housings. Always shut down power
source(s) before performing maintenance or troubleshooting. Only a qualified
electrician should make electrical connections and ground checks.
Any use of the equipment in a manner not specified by the manufacturer may
impair the safety protection originally provided by the equipment.
Grounding
Instrument grounding is mandatory. Performance specifications and safety
protection are void if instrument is operated from an improperly grounded
power source.
Verify ground continuity of all equipment before applying power.
viii | Thermox Series 2000 WDG-IV / IVC / IVCM

Important Notice to Users
No operator serviceable components inside any components of the WDG sys-
tem. Do not remove the cover from any WDG component. Refer servicing to
qualified personnel.
The following applies to the Series 2000 Control unit and the WDG-IV Division
2 Models:
Power, input, and output (I/O) wiring must be in accordance with Class I, Divi-
sion 2 wiring methods [Article 501-4(b) of the National Electric Code, NFPA 70]
and in accordance with the authority having jurisdiction.
WARNING - EXPLOSION HAZARD - SUBSTITUTION OF COM-

PONENTS MAY IMPAIR SUITABILITY FOR CLASS I, DIVISION 2.
WARNING - EXPLOSION HAZARD - WHEN IN HAZARDOUS LO-

CATIONS, TURN OFF POWER BEFORE REPLACING OR WIRING
MODULES.
WARNING - EXPLOSION HAZARD - DO NOT DISCONNECT

EQUIPMENT UNLESS POWER HAS BEEN SWITCHED OFF OR
THE AREA IS KNOWN TO BE NONHAZARDOUS.
THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS I, DIVISION

2, GROUPS A, B, C, AND D OR NONHAZARDOUS LOCATIONS
ONLY.
The maximum ambient temperature for the Series 2000 control unit is 50 °C
(122 °F)
The Series 2000 Control Unit with WDG-IV sensor is a complex piece of equip-
ment that should only be serviced by a qualified service technician with expertise
in instrument technology and electrical systems. 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.
Contents | ix
Environmental Information (WEEE)
This AMETEK product contains materials that can be reclaimed and recycled. In some cases
the product may contain materials known to be hazardous to the environment or human
health. In order to prevent the release of harmful substances into the environment and to
conserve our natural resources, AMETEK recommends that you arrange to recycle this prod-
uct when it reached its “end of life”.
Waste Electrical and Electronic Equipment (WEEE) should never be disposed of in a munici-
pal waste system (residential trash). The Wheelie Bin marking on this product is a reminder
to dispose of the product properly after it has completed its useful life and been removed
from service. Metals, plastics, and other components are recyclable and you can do your
part by doing one of the following steps:
• When the equipment is ready to be disposed of, take it to your local or

regional waste collection administration for recycling.
• In some cases, your “end of life” product may be traded in for credit to-
wards the pur-chase of new AMETEK instruments. Contact your dealer to
see if this program is avail-able in your area.
• If you need further assistance in recycling your AMETEK product, contact
our office listed in the front of the instruction manual.
x | Thermox Series 2000 WDG-IV / IVC / IVCM

General Safety Summary
Review the following safety precautions to avoid injury and prevent damage
to this product or any products connected to it.
Use Proper Wiring

To avoid fire hazards, use only the wiring specified in the Installation Chapter
of this user’s manual.
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.
Ground the Product

Follow the grounding instructions provided in the Installation Chapter of this
user’s manual. Before making connections to the input or output terminals of
this product, ensure that the product is properly grounded.
Do Not Operate without Covers

To avoid electric shock or fire hazard, do not operate this product with covers
or panels removed.
Use Proper Fuse

To avoid fire hazard, use only the fuse type and rating specified for this prod-
uct.
Do Not Operate in Explosive Atmosphere

To avoid injury or fire hazard, do not operate this product in an explosive at-
mosphere unless you have purchased options that are specifically designed for
these environments.
Product Damage Precautions
Use Proper Power Source

Do not operate this product from a power source that applies more than the
voltage specified.
Do Not Operate with Suspected Failures

If you suspect there is damage to this product, have it inspected by qualified
service personnel.
Contents | xi
Declaration of Conformity
Manufacturer’s Name: AMETEK/Thermox®

Manufacturer’s Address: Process & Analytical Instruments Division
150 Freeport Road
Pittsburgh, PA 15238

declares that the products:
Product Names: Thermox WDG series of Flue Gas Analyzers using Series 2000 Controller:
WDG-IV WDG-IVC WDG-IVCM
WDG-HPII WDG-HPIIC
O2 Only RCU
O2 & Comb RCU
O2, Combustibles & Methane RCU
Conform to the following standards:
EMC compliance:
EMC Directive 2004/108/EC
Immunity:
EN 50082-2:1995 Generic - Heavy Industrial Equipment
EN 50082-1:1997 Generic - Residential, Commercial, Light Industrial Equipment
EN 61000-6-2:1999 Generic - Heavy Industrial Equipment
EN 61326:1997 Measuring Equipment (Heavy Industrial)

Emissions:
EN 55011:1998 Class A, ISM Equipment

Safety Compliance:
UL 3101-1 UL Listed Inspection and Measuring Electrical Equipment
CAN/CSA 22.2 No. 1010.1-92 cUL Listed Inspection and Measuring Electrical Equipment
Low Voltage Directive 73/23/EEC:

EN61010-1:1993,
Amendment A2: 1995 Electrical Equipment for Measurement, Controls,
and Laboratory Use
Series 2000 Controller also has the following safety compliance:

UL 1604 UL Listed Process Control Equipment for Use in Hazardous Location
WDG Series analyzers with the suffix Div. 2, O2 Only RCU, O2 & Comb RCU, and O2,
Combustibles & Methane RCU 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
April 2002
xii | Thermox Series 2000 WDG-IV / IVC / IVCM

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 equipment, whichever period is shorter. All equipment requiring
repair or replacement under the warranty shall be returned to us at our factory, or at such
other location as we may designate, transportation prepaid. We shall examine such returned
equipment, and if it is found to be defective as a result of defective materials or workman-
ship, it shall be repaired or replaced as aforesaid. Our obligation does not include the cost of
furnishing any labor in connection with the installation of such repaired or replaced equip-
ment or parts thereof, nor does it include the responsibility or cost of transportation. In ad-
dition, instead of repairing or replacing the equipment returned to us as aforesaid, we may,
at our option, take back the defective equipment, and refund in full settlement the purchase
price thereof paid by Buyer.
The warranty shall not apply to any equipment (or part thereof) which has been tampered
with or altered after leaving our control or which has been replaced by anyone except us,
or which has been subject to misuse, neglect, abuse or improper use. Misuse or abuse of the
equipment, or any part thereof, shall be construed to include, but shall not be limited to,
damage by negligence, accident, fire or force of the elements. Improper use or misapplica-
tions shall be construed to include improper or inadequate protection against shock, vibra-
tion, high or low temperature, overpressure, excess voltage and the like, or operating the
equipment with or in a corrosive, explosive or combustible medium, unless the equipment
is specifically designed for such service, or exposure to any other service or environment of
greater severity than that for which the equipment was designed.
The warranty does not apply to used or secondhand equipment nor extend to anyone other
than the original purchaser from us.
THIS WARRANTY IS GIVEN AND ACCEPTED IN LIEU OF ALL OTHER WARRANTIES,

WHETHER EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION AND WAR-
RANTIES OF FITNESS OR OF MERCHANTABILITY OTHER THAN AS EXPRESSLY SET
FORTH HEREIN, AND OF ALL OTHER OBLIGATIONS OR LIABILITIES ON OUR PART.
IN NO EVENT SHALL WE BE LIABLE UNDER THIS WARRANTY OR ANY OTHER
PROVISION OF THIS AGREEMENT FOR ANY ANTICIPATED OR LOST PROFITS, INCI-
DENTAL DAMAGES, CONSEQUENTIAL DAMAGES, TIME CHANGES OR ANY OTHER
LOSSES INCURRED BY THE ORIGINAL PURCHASER OR ANY THIRD PARTY IN CON-
NECTION WITH THE PURCHASE, INSTALLATION, REPAIR OR OPERATION OF EQUIP-
MENT, OR ANY PART THEREOF COVERED BY THIS WARRANTY OR OTHERWISE. WE
MAKE NO WARRANTY, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION
ANY WARRANTIES OF FITNESS OR OF MERCHANTABILITY, AS TO ANY OTHER MAN-
UFACTURER’S EQUIPMENT, WHETHER SOLD SEPARATELY OR IN CONJUNCTION
WITH EQUIPMENT OF OUR MANUFACTURE. WE DO NOT AUTHORIZE ANY REPRE-
SENTATIVE OR OTHER PERSON TO ASSUME FOR US ANY LIABILITY IN CONNEC-
TION WITH EQUIPMENT, OR ANY PART THEREOF, COVERED BY THIS WARRANTY.
Contents | xiii
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xiv | Thermox Series 2000 WDG-IV / IVC / IVCM

OVERVIEW
Sensor Operations
Designed for fast response in a wide range of flue gas applications, the
sensor mounts directly on the combustion process to provide continuous
measurement of oxygen, or oxygen and combustibles, or oxygen, combus-
tibles and methane.
A sample is drawn from the process stream by means of an air-operated

aspirator and is immediately returned to the process. A portion of this gas
rises past the oxygen measuring cell and combustibles detector and re-
turns to the primary loop. All sample wetted parts are heated to maintain
the sample above the dewpoint of the gas.
Follow these cautions when working on the sensor:
Do not turn on the aspirator until the analyzer has been turned on
and is hot - preferably 24 hours. Also, if you turn off the analyzer or
the process is shut down, turn off the aspirator air to avoid plugging
problems!
Remove AC power from the sensor and control unit and allow the
sensor to cool for at least one hour before performing any maintenance
or troubleshooting activities.
The outside of the sensor cover and all sensor assembly components
are hot during normal operation (up to 500° F, 260° C inside the
cover). Allow sensor components to cool for at least an hour before
working inside the sensor. Use caution and wear appropriate gloves
when handling components or when touching the sensor cover!
Overview | 1-1
Sensor
Basic Elements of the Sensor

The WDG-IV series analyzer consists of the following basic systems:
 The Plumbing
All inlet and outlet tubing (cell housing), the oxygen cell, the oxygen
cell fitting, and the combustibles flow block and detector (for combus-
tibles). Also includes the calibration gas inlet and aspirator assembly,
with the aspirator used to pull the sample into the sensor.
 The Measuring System

The oxygen cell, combustibles detector (RTD or hot-wire type), meth-
ane detector, interconnecting wiring, and control unit.
 The Temperature System

The electrical cell heater (furnace), sensor case heaters, the type “K”
thermocouple (maintains cell operating temperature), and the sensor
board containing cold junction compensation. The sensing cell oper-
ates at a constant temperature. The circuit board in the sensor terminal
box switches power to the furnace from the AC mains connected to
the sensor. This board also provides cold junction compensation to the
thermocouple circuit.
The Oxygen Measuring Cell

The sensing element itself is a closed-end tube or disk made from ceramic
zirconium oxide stabilized with an oxide of yttrium or calcium. Porous
platinum coatings on the inside and outside serve as a catalyst and as
electrodes. At high temperatures (generally above 1200°F/650°C), oxygen
molecules coming in contact with the platinum electrodes near the sensor
become ionic. As long as the oxygen partial pressures on either side of the
cell are equal, the movement is random and no net flow of ions occurs.
If, however, gases having different oxygen partial pressures are on either
side of the cell, a potentiometric voltage is produced (See Figure 1-1).
The magnitude of this voltage is a function of the ratio of the two oxygen
partial pressures. 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% O2), is used for one of the gases.
1-2 | Thermox Series 2000 WDG-IV / IVC / IVCM

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. The oxygen content is then determined from the Nernst equation:
RT O
E= In 1
4F O2
where R and F are constants, T is absolute temperature, and O1 and O2 are

the oxygen partial pressures on either side of the cell.
For measuring oxygen in non-combustibles gases, the calibration of an

analyzer is obtained from the formula:
20.9%
E = A*T*Log AT = 48.0 at 695°C
O2 Unk%
Where A is a constant, T is the cell temperature on an absolute scale (°C +

273) and O2 Unk% is the unknown oxygen concentration of the gas to be
analyzed, and which is calculated by the analyzer.
Overview | 1-3
The cell produces zero voltage when the same amount of oxygen is on
both sides, and the voltage increases as the oxygen concentration of the
sample decreases. The voltage created by the difference in the sample gas
and the reference air is carried by a cable to the microprocessor control
unit, where it is linearized to an output signal.
Because of the high operating temperature of the cell, combustible

 gases that are present may burn. When this occurs, the cell will gener-
NOTE ate high millivolts and cause the display to indicate less oxygen than
is actually in the gas (net oxygen content).
Hydrocarbons
When hydrocarbons are present in the gas sample, a combustion process

occurs 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. For exam-
ple, if a calibration gas cylinder has an oxygen value of 20 PPM and 5 PPM
of hydrogen (balance nitrogen), the oxygen analyzer will read 17.5 PPM
oxygen. The reduction of oxygen is due to the combustion process where
5 PPM of hydrogen will combine with 2.5 PPM of oxygen to form water.
Thus, the oxygen analyzer will read 17.5 PPM rather than the actual 20
PPM oxygen.
The amount of oxygen reduction is dependent on the type of hydrocar-

 bons present in the sample gas.
NOTE

Sensor Operations - WDG-IVCM
Close-Coupled Extrative Flue Gas Analyzer
The WDG-IVCM analyzer is ideal for natural gas-fired power boilers or
for those using gas during start-up and shutdown. With this analyzer, you
can monitor oxygen and combustibles for maximum fuel efficiency. In
addition, the methane detector can be used for purge and lightoff cycles
during start-up and shutdown.
Hot-Wire Type
WDG-IVCM analyzers with hot-wire type combustibles detector (see
Figure 1-2) are used for processes that use natural gas for start-up and oil,
fuel gas or coal for primary fuel. Process gas is drawn into the analyzer’s
primary sample loop by an aspirator and returns to process. Gas enters
the split flow block that is separted by a baffle and contacts the hot-wire
catalytic combustibles and methane detector. It then passes the zirconium
oxide cell, where the oxygen concentration is measured, before returning
to the main sample loop and then back to the process.
CELL HOUSING
ZIRCONIUM OXIDE
OXYGEN CELL
CONVECTION LOOP
RETURN
PPM OR PERCENT
COMBUSTIBLES DETECTOR METHANE DETECTOR
ASPIRATOR BLOCK
RETURN TO
PROCESS
SAMPLE
ASPIRATOR AIR
Figure 1-2. WDG-IVCM with hot-wire type combustibles detector convection loop.
Overview | 1-5
RTD Type
WDG-IVCM analyzer with RTD-wire type combustibles detector (see Fig-
ure 1-3) is used for natureal gas fired boilers (natural gas for start-up and
primary fuel). Process gas is drawn into the analyzer’s primary sample
loop by an aspirator and return to process. Gas enters the RTD-type com-
bustibles detector flow block and contacts RTD-type combustibles detec-
tor. The gas then travels into the hot-wire methane detector flow block
where it contacts the methane sensor. It then passes the zirconium oxide
cell, where the oxygen concentration is measured, before returning to the
main sample loop and then back to the process.
CELL
HOUSING
ZIRCONIUM OXIDE
OXYGEN CELL
CONVECTION
LOOP
RETURN
HOT-WIRE TYPE
METHANE DETECTOR
RTD-TYPE
COMBUSTIBLES DETECTOR
ASPIRATOR BLOCK
RETURN
TO PROCESS SAMPLE
ASPIRATOR AIR
Figure 1-3. WDG-IVCM with RTD-wire type combustibles detector convection loop.

Detectors
Combustibles
The Combustibles Detector is a dual element device. The elements differ
only in that one is coated with a catalyst. The catalyst causes oxidation
to occur at a lower-than-normal temperature. The temperature of the
catalyzed element changes as the combustible mixture burns. The tem-
perature change causes the resistance of the catalyzed element to change.
The resistance change is interpreted by the microprocessor and the corre-
sponding combustibles reading is displayed.
The Thermox catalytic combustibles detector will detect combustible

gases present in a sample. The sample must, however, contain enough
oxygen to fully burn the combustibles present. The combustibles detector
responds to all incompletely burned combustibles gases, such as CO and
H2. We recommend that you use an even mixture of CO and H2 as the
combustibles component within your span gas, although you can also use
all CO if needed.
The combustibles span gas for calibration should be 60 to 80% (ppm

range) or 40 to 60% (percent ranges) of the selected combustibles recorder
output range.
Methane
The Methane Detector is a dual element device. The elements differ only
in that one is coated with a catalyst. The catalyst causes oxidation to occur
at a lower-than-normal temperature. The temperature of the catalyzed
element changes as the mixture burns. The temperature change causes
the resistance of the catalyzed element to change. The resistance change
is interpreted by the microprocessor and the corresponding reading is
displayed.
The Thermox catalytic methane detector will detect methane gases pres-
ent in a sample. The sample must, however, contain enough oxygen to
fully burn the methane present.
The methane span gas should be 2% CH4 with 8 - 10% oxygen present in
the mixture.
Overview | 1-7
Common Operator Errors
If you follow the steps below, your analyzer will operate with a minimum
of maintenance and troubleshooting.
 Connect the air supply to the aspirator air supply inlet but DO NOT
turn on the air until the sensor is at operating temperature. If the ana-
lyzer is turned off or the process is shut down, the aspirator air should
be turned off to avoid plugging problems.
 If your process is running and the analyzer is installed on the pro-

cess, the analyzer must have power applied to it to prevent plugged
plumbing and sensor component damage. The case heaters must be
on if the process is running to maintain sensor plumbing above the
process gas dewpoint.
 Do not use pipe dope or any other contaminant that gives off combus-
tible vapor on any joints of the sample tubing.
 For O2 calibration gases, do not use calibration gases to check Ther-

mox analyzers if they contain a mixture of oxygen and combustibles.
Note, however, that this is acceptable for combustibles span gases
(used only if you purchased the combustibles option).
 Always introduce calibration gases at the recommended flow rate.
 When working on the plumbing inside the sensor cabinet, turn the
power off. The oxygen cell heater has exposed windings and a short
to the plumbing will blow the fuse and could damage the furnace or
thermocouple.
 Caution should be used if performing maintenance on the sensor

while the process is running. Removing any part of the sensor can
allow process gases and gases of high temperature to escape into the
sensor.
 Do not handle the cell excessively. Do not try to clean the cell except
by rinsing. If you need to handle the cell, grasp by touching the seal
fitting at the top; never touch the bare part of the cell.
 Do not remove a cell or type “K” thermocouple that you may want to
use again when the inside of the furnace is still hot - severe thermal
shock can be destructive to either of them.
 Always replace the metal cell O-ring when replacing the oxygen cell.

Start-Up Checklist
 Review the installation chapter in the User ’s Manual.
 Install the sensor on the process.
- If the sensor is on the pipe nipple, insulate the pipe from the process
wall to the mounting flange on the sensor.
- Install the probe.
- Install the probe heater, if required.
- If the sensor is a floor mount configuration, the rear, insulated cover

must be installed and secured so the process sample remains hot.
 This type of sensor requires a clean, dry instrument air supply for the
aspirator. Connect the air supply to the aspirator air supply inlet but
DO NOT turn on the air until the sensor is at operating temperature.
If the analyzer is turned off or the process is shut down, the aspirator
air should be turned off to avoid plugging problems.
 Do not create any additional conduit entries in the enclosure.
 Interconnect the control unit and the sensor per the appropriate inter-
connecting drawing.
- The specified cable must be used in order to insure proper operation

of the systems.
- Keep the interconnecting located in the control unit as short as pos-

sible. A service loop need not be used.
- Maintain the ordered wire pairs per the drawing.
 Connect AC mains supply to the sensor. Make sure that the AC voltage
is within specified limits.
Overview | 1-9
Technical Support
AMETEK/Thermox is committed to providing the best technical support

in the industry. If you need service or application assistance, please call
AMETEK at (412) 828-9040, or your local AMETEK/Thermox representa-
tive.
Before you call the factory for technical support, run test gases and record
the following values (you may be asked by the factory to provide this
information when receiving service):
 Cell millivolts
 Thermocouple millivolts
 Cell temperature
See the “Display” section in the Controller / User Interface chapter for
help on how to display this information on your Series 2000 control unit.
If you need to return equipment, you will be asked to provide the follow-
ing information before obtaining a Return Material Authorization (RMA)
number.
 Billing and shipping address
 Model number
 Serial number
 Purchase order number
 Telephone number
Before returning material, you must get an RMA number from the
 factory.
NOTE

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 for oxygen and one each for combusti-
bles and methane if you purchased those options. Select O2, combustibles
(optional), methane (optional), cell temperature, thermocouple mV or cell
Analog Output
mV. Each output can be 4-20 mA, 0-20 mA, 20-4 mA or 20-0 mA and is
fully scalable. Hold or track during calibration and select degree of damp-
ing. Maximum load 1200 ohms.
Two independent oxygen alarms, each high or low selectable. One alarm
can be allocated to % oxygen, calibrate or verify. Two high combustibles
Alarms
and two high methane alarms (optional). Set relays to energize or de-
energize on alarm.
Contact Rating 1A, 30V max. noninductive load, AC or DC
Watchdog timer and service alarms. System test for A/D, RAM, EEPROM
Diagnostics and keypad. Display Line 4 reserved for full text error and diagnostic mes-
sages. Twenty-entry event log.
Oxygen cell lifetime extender. Calibrate or verify calibration. Store last

calibration and verification data. Selectable calibration gas run time and
Calibration
process recovery time. Timed automatic calibration with optional remote
calibration unit.
Communications RS-485, 2-way addressable.
Ambient Temp: 14 to 122° F (-10 to 50° C)

Relative Humidity: 10% to 80%, non-condensing
Environment IEC Installation Category II
IEC Pollution Degree 2
Max. Altitude: 2000 meters
Power Nominal 115-230 VAC ±10%, 47-63 Hz. max.; 75 VA max.
Requirements
Standard weatherproof NEMA 4 (IP 56) wall/panel mount. Optional GP
(General Purpose) wall mount, GP 19” rack mount, GP panel mount, or
Enclosure stainless steel weatherproof NEMA 4X (IP 56) wall/panel mount. All are
UL Listed for NEC Class I, Division 2 areas. Purged and explosion-proof
versions also available.
Specifications | 2-1
Sensor : WDG-IV
Output Range From 0-1% to 0-100%
Accuracy ± 0.75% of measured value or ± 0.05% oxygen, whichever is greater
Response 90% of a process step change < 6 secs.
< 0.1% of cell output per month (< 0.005% O2 per month with 2% O2
Drift
applied)
Aspirator Air
10 to 20 scfh (4.72 to 9.4 L/min) at 15 to 100 psig (1.05 to 7.04 kg/cm2)
Requirements
Max. Flue Gas Temp / Probe Type / Lengths

1300°F (704°C) 316 SS 36” - 108” (91 cm - 271 cm)
1875°F (1024°C) 310 SS 36” - 108” (91 cm - 271 cm)
3000°F (1649°C) Hexoloy® 24” - 72” (60 cm-182 cm)
Max. Sample 392°F (200°C) standard. High dewpoint sensors are available for
Dewpoint sample dewpoints up to 700°F (371°C).
Sample Pressure ± 10 inch water gauge
Environment
Ambient Temp.: -5°F to 160°F (-20°C to 71°C);
-5°F to 140°F (-20°C to 60°C) with Div. 2 Option
Enclosure
Lift-off NEMA 3R, weather resistant, stainless steel. Optional hinged NEMA 4X (IP56), explo-
sion-proof, purged, and floor mount versions available.
115 VAC, ± 10%, 47-63 Hz, 600VA 230 VAC, ± 10%, 47-63 Hz, 1850
Power Requirements max. (650 VA max. floor mount op- VA max. (1900 VA max. floor mount
tion) option)
Calibration Gas Requirements

Use calibration gases @ 10 PSIG, 1.5 SCFH (0.70 kg/cm2, 0.7 L/min.)
O2 Span Gas: Air or from 1.0 to 100% O2, balance N2
O2 Zero Gas: 2% or from 0.1 to 10% O2, balance N2
System Compliance
EMC Compliance: 2004/108/EC
Safety Compliance: 73/23/EEC
NOTES
1. All static performance characteristics are with operating variables constant.
2. System accuracy referenced to 0.1 to 10% calibrated range.
3. Response is to calibration gas.

Sensor : WDG-IVC
Oxygen From 0-1% to 0-100%
Combustibles From 0-2,000 ppm to 0-10,000 ppm or from 0-1% to 0-5%
Accuracy
Oxygen ± 0.75% of measured value or ± 0.05% oxygen, whichever is greater
Combustibles ± 2% of full scale output range
Response O2 90% of a process step change < 13 secs.
Drift
applied)
Aspirator Air
Requirements

1300°F (704°C) 316 SS 36” - 108” (91 cm - 271 cm)
1875°F (1024°C) 310 SS 36” - 108” (91 cm - 271 cm)
3000°F (1649°C) Hexoloy® 24” - 72” (60 cm-182 cm)
Max. Sample
392°F (200°C)
Dewpoint
Environment
Enclosure
115 VAC, ± 10%, 47-63 Hz, 600VA max. 230 VAC, ± 10%, 47-63 Hz, 1850 VA max.
Power Requirements
(650 VA max. floor mount option) (1900 VA max. floor mount option)

O2 Zero Gas & 2% or from 0.1 to 10% O2, balance N2
Comb Zero Gas:
Comb Span Gas: 60 to 80% (ppm ranges) or 40 to 60% (% ranges) of the selected
comb. recorder output range in certified mixtures of
CO + H2, 3-4% O2, balance N2.
System Compliance
NOTES:
3. Response is to calibration gas (without flame arrestors).
Sensor : WDG-IVCM
Combustibles From 0-2,000 ppm to 0-10,000 ppm
Methane 0 to 5%
Accuracy
Combustibles ± 2% of full scale output range
Methane ±5% of full scale output range
Drift
applied)
Aspirator Air
Requirements

1300°F (704°C) 316 SS 36” - 108” (91 cm - 271 cm)
1875°F (1024°C) 310 SS 36” - 108” (91 cm - 271 cm)
3000°F (1649°C) Hexoloy® 24” - 72” (60 cm-182 cm)
Max. Sample
392°F (200°C)
Dewpoint
Environment
Enclosure
Power Requirements

Calibration Gas Requirements for Hot-Wire Type Combustibles Detector
O2 Comb &
From 0.1 to 10% O2, balance N2
CH4 Zero Gases:
Comb Span Gas: 60 to 80% (ppm ranges) or 40 to 60% (% ranges) of the selected
comb. recorder output range in certified mixtures of
CO + H2, 3-4% O2, balance N2.
CH4 Span Gas 2% CH4, 8% to 10% O2, balance N2
Calibration Gas Requirements for RTD Type Combustibles Detector
Comb & CH4
From 0.1 to 10% O2, balance N2
Span Gases:
Comb Span Gas: Use a combined combustibles and methane span gas containing 60 to
80% of the full scale combustibles operating range in certified mixtures
of CO (or CO + H2), 2% CH4, 8 to 10% O2, balance N2.
System Compliance
NOTES:
3. Response is to calibration gas (without flame arrestors).
Sensor : WDG-IVC - 0-500 PPM
Combustibles From 0-500 ppm to 0-10,000 ppm or from 0-1% to 0-5%
Accuracy
Combustibles ± 25 ppm between 0 to 500 ppm or ±5% of full scale output range
Aspirator Air
Requirements

1300°F (704°C) 316 SS 36” - 108” (91 cm - 271 cm)
1875°F (1024°C) 310 SS 36” - 108” (91 cm - 271 cm)
3000°F (1649°C) Hexoloy® 24” - 72” (60 cm-182 cm)
Max. Sample
392°F (200°C)
Dewpoint
Environment
Enclosure
Hinged, stainless steel, weatherproof NEMA 4X (IP56). Flame arrestors standard. Optional
CENELEC and NEC Class I, Division 2 available.
Power Requirements

O2 , Zero & Comb
2% or from 0.1 to 10% O2, balance N2
Zero Gases:
Comb Span Gas: 80 to 100% of the selected combustibles recorder output range in certi-
fied mixtures of CO + H2, 3-4% O2, balance N2
System Compliance
NOTES
3. Response is to calibration gas (with flame arrestors)

Remote Calibration Unit (RCU)
O2 Only RCU
O2 & Comb. RCU
O2, Combustibles & Methane RCU
Enclosure UL Type 4X (NEMA 4X (IP56)

Environment
Ambient Temperature: -18°C60°C
Humidity: 0 to 90%, non-condensing
Max Altitude: 2000 Meters
IEC Installation Category II
IEC Pollution Degree 2
System Compliance

Installation
The operations in this chapter should be performed only by qualified

 service personnel experienced in electrical safety techniques. There are
NOTE 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. Also, always use gloves when working on the sensor.
Do not turn on the aspirator until the sensor has been turned on and
is hot - preferably 24 hours. If you turn off the analyzer or the process
is shut down, turn off the aspirator air to avoid plugging problems!
Analyzer Location
Observe the following guidelines when selecting an analyzer installation
location:
1. Select a readily accessible position for the analyzer to allow for routine
maintenance. Comfort levels for maintenance personnel should be
considered in placement of the sensor and control interface.
2. The installation location should be free from excessive vibration and

the ambient temperature is required to be within the limits listed in
the specifications. If the ambient temperature is outside the speci-
fied limits or the vibration is excessive, please contact Thermox Sales
or Service Department at (412) 828-9040. We have special options to
address ambient temperatures outside the listed specifications and we
can provide special mounting solutions for excessive vibration installa-
tion locations.
Installation | 3-1
This chapter shows you how to install your Series 2000 controller and
WDG-IV sensor components, and includes the following sections:
• Inspection of Shipping Contents

• Mechanical Installation
• Wiring
• Series 2000 Control Unit Option Card Installation
If you have an oxygen-only analyzer without the combustibles option, the

combustibles and methane options described in this chapter do not apply.
These combustibles and methane sections are clearly identified. Likewise,
if you have the combustibles option, but not the methane option (3-in-1
analyzer), you can skip all sections pertaining to methane.
Inspect Shipping Contents

Remove any packing material from the sensor and the Series 2000 control
unit. Check for damage. If any is found, notify the shipper.

Mechanical Installation
This section describes how to mount and connect gases to your WDG-IV
sensor. This includes the following:
• Sample Inlet Probe Installation
• Probe Heater Installation (optional)
• Exhaust Tube Installation (optional)
• Sensor Mounting
• Remote Calibration Unit Mounting and Plumbing (optional)
Sample Inlet Probe Installation

For some applications, you must first connect the sample inlet probe
 to the sensor before mounting the sensor. The same applies if you are
NOTE installing the probe heater or exhaust tube. Therefore, these subjects
are discussed before the sections on how to mount the sensor to the
process.
The sample inlet probe is how the sample gas gets to the sensor. Aspira-
tor air within the sensor is used to pull process gas from the sample probe
into the sensor. The sample inlet probe is identified by the threads on both
ends.
• Figure 3-1 shows how to install the standard 1/8” NPT probe.
• Figure 3-2 shows how to install a ceramic or long probe.
• Figure 3-3 shows port locations on the rear of the sensor.
You can connect the probe to the sensor before mounting the sensor un-
less the probe is either very long or made of ceramic. In that case you
should mount the sensor first and then install the probe.
Installation | 3-3
Standard 1/8” NPT probe installation
Connect a standard 1/8” NPT sample inlet probe to the sensor as follows:
• If your probe is 4 feet or less, simply screw the probe into the back of
the sample probe port on the rear of the sensor, then mount the sensor
- see Figure 3-1.
Figure 3-1. WDG-IV 1/8 NPT probe installation.

Ceramic probe or long probe installation
If you ordered a long probe or a ceramic probe, connect the probe to the
sensor as follows:
1. Mount the sensor. See the “Sensor Mounting” section later in this
chapter for help. Note, however, that if you are installing the probe
heater or exhaust tube, you must connect these items to the sensor
before mounting the sensor.
2. Remove the sensor enclosure to expose the sensor components.
3. Remove the probe inlet hook from the sensor as shown in Figure 3-2.
To do this, loosen the fitting connecting the inlet hook to the aspirator
block and pull the hook out of the sensor.
4. Unscrew the bushing that was plugged into the sensor inlet port and
discard. The probe comes with its own bushing and fitting.
5. Thread the sensor probe into the sensor inlet port on the sensor
backplate. Do not let the probe hit against the Thermox-provided pipe
nipple as you insert the probe into the process. If inserting a ceramic
probe, you must slowly insert it into a hot process to prevent the
probe from cracking due to thermal shock.
6. Reconnect the probe inlet hook to both the sensor backplate and the
aspirator block and tighten.
Figure 3-2. WDG-IV ceramic probe installation - top view.
Installation | 3-5
Probe Heater Installation
Do not install the probe heater if your sample gas contains a poten-
tially explosive mixture of combustibles; the probe heater can heat the
flue gas to the point of ignition.
The probe heater must be connected to the sensor before mounting the
 sensor to the process.
NOTE
For installations where a standard setup allows the sample gas to cool
below its acid dewpoint before reaching the sensor, you can attach the
optional probe heater to the probe heater port on the backplate of the
sensor to heat the sample gas - see Figure 3-3. This will prevent plugged
plumbing due to condensation of the sample gas. For example, when a
fuel containing only a few thousand parts per million of sulfur is burned
with a high level of excess oxygen (over 4 percent), the resulting sulfuric
acid mist may condense at temperatures as high as 175 °C.
The probe heater comes shipped in an envelope, is 8.5” long, has a 3/8
NPT bushing and wires leading out of it.
EXHAUST PORT
SAMPLE PROBE
INLET PORT
PROBE HEATER PORT

(REMOVE PLUG)
TERMINAL BOX
Figure 3-3. Port locations on rear of sensor - front view.

Follow the steps below to install the probe heater:
1. Remove and discard the plug from the probe heater port as shown in
Figure 3-3. This port is plugged during shipment and should remain
plugged if no probe heater is installed.
2. Screw the probe heater into the 3/8” NPT probe heater port.
3. Route the wires from the probe heater to the sensor board.
4. Remove the sensor terminal box cover and connect the wires from the
probe heater to Terminals “M” and “N” on the sensor board - polarity
is not required.
Exhaust Tube Installation
If installing an exhaust tube, you must connect it to the sensor before

 mounting the sensor to the process.
NOTE
Enclosed in the envelope with the probe heater is a stainless steel exhaust
tube that allows you to extend the aspirator exhaust. The exhaust tube can
be identified by having a thread on only one end of it.
To install the exhaust tube, thread the exhaust tube into the exhaust port
on the rear of the sensor as shown in Figure 3-3.
Sensor Mounting
• The sensor ambient temperature range is -20 °C to 70 °C.
• When installing a probe heater or exhaust tube along with the sensor,
attach it to the back of the sensor before mounting the sensor to the
process.
• If your sensor has a lift-off lid, allow at least 10” (25.4 cm) above the
sensor so you can remove the lid and access sensor components.
Do not open a Z-purge, hinged-sensor enclosure door until you first

verify that the area has been classified as nonhazardous.
Installation | 3-7
Methods for mounting the sensor
There are three methods for mounting a WDG-IV sensor to the process:
• flush with the process,
• using a customer-supplied pipe nipple,
• using a customer-supplied flange.
Each of these methods is explained in the sections that follow. The flush
mount method is preferred because it positions the sensor as close to the
process as possible and minimizes the chances of the sample gas cooling
below its dewpoint.
Figure 3-4. Mounting dimensions - Lift-off sensor.

Mounting dimensions for the lift-off style sensor enclosure are provided
in Figure 3-4. Mounting dimensions for the hinged style enclosure, includ-
ing the Z-purge option, are provided in Figure 3-5.
If the protection nipple provided by AMETEK/Thermox extends past

 the inside of the refractory wall on a process that has a gas tempera-
NOTE ture over 1200 °F (650 °C), the nipple should be cut down before
installation in order to remain flush with the inside wall.
Figure 3-5. Mounting dimensions - Hinged sensor.
Installation | 3-9
Sensor flush mount (Preferred Method)
Weld the 7” x 7 5/8“ (17.78 cm x 19.37 cm) mounting plate supplied with
the sensor to the process wall over a 3 3/4” (9.52 cm) diameter hole as
shown in Figure 3-6. Then bolt the sensor to the mounting plate. This
method positions the sensor as close to the process as possible and mini-
mizes any chance that the sample gas will cool below its dewpoint.
Figure 3-6. WDG-IV sensor flush mount (preferred).
Customer-supplied pipe nipple sensor mounting
If you can’t mount the sensor flush with the process as described in the
previous section (for example, the process wall is curved sharply, covered
with insulation, or obstructed with reinforcing members) you can instead:
1. Weld a short 3 1/2“ diameter pipe nipple to the process wall and make
sure to extend the nipple through the skin of the process (see Figure 3-7).

Sensor bolted to mounting plate after
plate is welded to nipple by customer.
Gasket (by Thermox)
AMETEK supplied mounting plage with 1 7/8”

OD x 9” long nippled (7.30 cm x 22.896 cm)
welded to pipe over 3 3/4” OD (9.52 cm) hole
by custmer
Process Wall
Probe
Length minimum
necessitated by installation
Required 1” (25.4 cm) min. insulation
SIDE VIEW around exposed portion of nipple
Pipe Nipple
(supplied by customer)
Single stud
at “12 o’clock”
position
Proper orientation for

mounting plate and flange
Figure 3-7. Customer-supplied pipe nipple sensor mounting.
2. Weld the 7” x 7 5/8” (17.78 cm x 19.37 cm) supplied plate to the end of
the nipple, taking care to center it over the hole
3. Wrap the nipple with at least 1” (2.54 cm) weatherproof insulation and
heat trace it.
4. Then bolt the sensor to the plate.
If mounting the sensor using this method, you can also install the probe
heater to minimize the possibility of the sample gas cooling below its dew-
point.
Flange sensor mounting method
You can also mount the sensor to a 3” x 300# customer-supplied flange. In

this case, you will not need the AMETEK-supplied mounting plate with
attached protective pipe nipple. If you have a different type of flange,
AMETEK supplies a number of flange adapters.
Installation | 3-11
Calibration/Aspirator Air/Z-Purge Connections
Required calibration gases and tubing
See Chapter 2 for information on calibration gases. The span gas is

 the high gas; the zero gas the low gas.
NOTE
The span gas must be 10 times greater than the zero gas. For example, if
the zero gas is 1% O2, the span gas must be 10% O2 or higher.
O2 Span Gas
Instrument air (20.9%) or from 1.0% to 100% O2.
O2 Zero Gas
From .1 to 10% O2, balance N2
Combustibles Span Gas

If using a WDG-IVC analyzer, you must also have a combustibles span
gas as follows:
• 60 to 80% (ppm range) or 40 to 60% (% range) of the full combustibles

operating range in certified mixtures of CO or CO + H2, with an
equal amount of O2, balance N2.
For example, if using an operating range of 0 to 2000 ppm combus-

tibles, use 800 ppm CO, 800 ppm H2, 1 to 2% O2, balance N2. If using a
0 to 1% combustibles range, use 0.3% CO, 0.3% H2, 1 to 2% O2, balance
N 2.
Combustibles Span Gas for 3-in-1
If using a WDG-IVCM analyzer with RTD-type combustibles detector,

you also must have a combustibles span gas as follows:
• 60 to 80% of the full combustibles operating range in certified mixtures

of CO (or CO + H2), 2% CH4, 8 to 10% O2, balance N2
For example, if using an operating range of 0 to 2000 ppm combusti-

bles, use 800 ppm CO, 800 ppm H2, 1 to 2% CH4, 8 to 10% O2, balance
N 2.

Always use tubing that is free of oil and dirt. Stainless steel tubing is rec-
ommended.
Figure 3-8. Z-purge setup.
Z-Purge Connections
Connect instrument air to the sensor Z-purge inlet. Maintain the pressure
and flow as directed on the Z-purge warning label.
• You must provide a protective gas supply with an alarm for a loss of
pressure indication in order to meet NFPA 496 requirements.
• You must not exceed the maximum temperature rating listed in the
specifications.
• Process pressure is assumed to always be subatmospheric (vacuum)

unless the High-pressure option is installed.
• The WDG-IV sensor contains a flame arrestor to prevent it from being

an ignition source to the process for short periods of high combustible
levels (25% of LEL - lower explosive limit) in the process. The flame
arrestor is not, however, intended to protect the process where the
combustibles levels are always high.
Installation | 3-13
Z-Purge Shutdown Procedure
Hot internal parts are above the ignition temperature of combustible

gases. Power must be disconnected from both the sensor and control
unit for 90 minutes while maintaining purge air flow before the door
is opened, unless the area is demonstrated to be nonhazardous. The Z-
purge apparatus provided by Thermox meets NFPA 496 under certain
conditions.
Power must not be restored after the enclosure has been opened until the
enclosure has been purged for 65 minutes at a pressure of 0.4” of water.
LIFT-OFF ENCLOSURE - FRONT VIEW
CAL GAS INLET

1/4” COMPRESSION FITTING
ASPIRATOR AIR INLET
1/4” NPT (F)
HINGED ENCLOSURE - FRONT VIEW
PURGE AIR INLET

CAL GAS INLET PORT 1/4” COMPRESSION FITTING
1/4” COMPRESSION FITTING INSTRUMENT AIR INLET
1/4” NPT (F)
Figure 3-9. Sensor inlet connections.

Manual calibration and aspirator air connections
If you have a remote calibration unit (RCU), skip the remainder of

 this section and proceed to the “RCU Installation Instructions” ap-
NOTE pendix.
If performing manual calibrations, do the following:
1. Connect aspirator air to the aspirator air inlet on the sensor (see Fig-
ure 3-9). Adjust the aspirator air regulator to the minimum pressure
required to get a response from the analyzer; typically this is 5 psi. Do
not turn on the aspirator until the sensor has been turned on and is
hot -preferably 24 hours.
2. A calibration gas inlet port is provided to allow you to calibrate the

system as shown in Figure 3-9. During calibration, you turn off the
aspirator air supply and inject your calibration gases into the calibra-
tion gas inlet port on the sensor. During normal operations, you plug
this calibration gas inlet port.
• You must provide a protective gas supply with an alarm for a loss of
pressure indication in order to meet NFPA 496 requirements.
• Do not exceed the maximum temperature rating listed on the warning

label on the Z-purge enclosure
Installation | 3-15
Control Unit Mounting
The Series 2000 Control Unit comes with various mounting options.
• The weatherproof enclosure can be mounted to either a panel, a wall,

or to a pole.
• The general purpose enclosure can be mounted as a panel, a rack, or a

wall mount.
Find the section below that corresponds to the type of control unit mount-
ing configuration you ordered, then mount as shown in that section.
Weatherproof - Panel
Figure 3-10 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 3-10. Series 2000, weatherproof panel mount.
Weatherproof - Wall/Pole
Figure 3-11 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” or 1/2” diameter for a 2
1/2” to 4 1/2” pole diameter.
Figure 3-11. Series 2000, weatherproof wall/pole mount.

Weatherproof Wall/Z-Purge Option
Figure 3-19 shows the wall and pole mounting dimensions for the Series
2000 weatherproof Z-purge enclosure. To mount this control unit version,
you must also connect instrument air to the Purge Inlet and set the pres-
sure and flow as indicated on the warning tag on the control unit.
Don’t open the Z-purge enclosure until you verify that the area has
been classified as nonhazardous.
Z-purge shutdown procedure
Remove power from the control unit for one hour while maintaining
purge air flow before door is opened, unless the area is demonstrated to
be nonhazardous.
Z-purge start-up procedure
Do not restore power after the enclosure has been opened until the enclo-
sure has been purged for 1 hour at a pressure of 0.4” of water.
7.50
5.31
5.88 19.05
13.49
14.94
12.00
Flange
30.48
8.00
20.32
Pressure
Gauge
Exhaust
Restriction
1/2” Conduit
Metering Valve Entry (2.22 cm)
Two 3/4” Conduit

Entries (2.70 cm)
Purge Air Inlet
1/8” Compression Fitting
Figure 3-12. Series 2000, weatherproof wall / z-purge.
Installation | 3-17
9.10
12.6 23.11
32.0
5.22
General Purpose - Panel
6.57 13.26
16.69 5.00 Figure 3-13 shows the panel mounting
12.70
dimensions for the Series 2000 general
purpose enclosure. This version can be
10.00 mounted in panels up to 1” thick.
25.40 10-32
3.8 cm (1.5 in.)
10.45 4 places
26.54
Figure 3-13. Series 2000, general purpose panel mount.
12.6
9.10 General Purpose - 19” Rack
23.11
32.0
Figure 3-14 shows the mounting dimen-
1.48
3.76
sions for the Series 2000 general pur-
pose 19” rack mount enclosure. Use #10
5.22 screws to mount the control unit to a rack
13.26 whose holes are spaced per E.I.A. stan-
4.95
12.57 dard RS-310-C (universal spacing).
2.25
5.72
19.00
48.26
Figure 3-14. Series 2000, general purpose rack mount.
7.65
11.5 General Purpose - Wall
29.21
19.43 10.26
26.06
Figure 3-15 shows the mounting dimen-
sions for the 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 3-15. Series 2000, general purpose wall mount.

Wiring
Remove AC mains power from the controller before performing wiring.
Connections to the control unit are made through the wiring card (see
Figure 3-16). 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” Section earlier in this chapter
for help). For the general purpose rack and panel mount versions, the wir-
ing card is located on the rear of the control unit (Figure 3-23 shows the
orientation of the wiring card for general purpose rack and panel mount
versions - for all other versions, the wiring card is 180 degrees from this
view). To access the wiring card for all general purpose versions of the
control unit, unscrew the four screws on the wiring card chassis cover
plate. For the weatherproof versions of the control unit, first open the
front door of the weatherproof enclosure to gain access to the wiring card
shield. Remove the three screws on this shield to gain access to the wiring
card.
Any screw terminals on the wiring card not described in this section
 are reserved for future use.
NOTE
Figure 3-16. Wiring card (rack/panel mount orientation)
Installation | 3-19
This wiring section shows you how to make the following connections:
• AC mains supply wiring to control unit
• AC mains supply wiring to sensor
• Control unit to sensor
• Control unit to remote calibration unit
• Control unit to alarm devices
• Control unit to current output devices
• Control unit to host computer (RS-485 communications)
In addition, this wiring section provides mandatory EMC grounding,

shielding, and noise protection requirements.
If you are considering adding option cards at a later time, such as a

 combustibles card, you may want to connect the required intercon-
NOTE necting wires when you first install your analyzer, especially if run-
ning the wires over long distances through conduit.
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.
• Use only the applicable NEMA-approved conduit fittings or cable

fittings to maintain the NEMA rating for the Series 2000 controller
or sensor enclosure. If not using a conduit entry, leave the factory
NEMA-approved plugs intact. Never leave any holes unplugged.
• Follow all applicable electrical codes for your location.
• Follow proper grounding, shielding and noise protection practices as

described in this section.
• Use twisted-pair cable with an overall braided shield, or twisted-pair

cable in rigid metal conduit for all sensor and signal wiring.

• For AC mains supply wiring, use between 12 and 14 American Wire
Gauge (AWG) or equivalent metric between 3.3 mm 2 and 2.1 mm2. For
all signal wiring, use 18 to 22 AWG (0.82 mm2 to 0.33 mm2 ). For sensor
connections, Figure 3-17 shows the recommended sensor cable types
for various WDG-style sensors.
• Use the conduit entry point closest to the connections you are making.
Do not add any additional conduit entry holes!
• You may use 1” conduit with a 3/4” adapter at the entry to the Series
2000 controller for signal and sensor wiring.
WDG SENSOR TYPE NUMBER OF TWISTED GAUGE OF WIRE

PAIRS NEEDED
22 AWG (to 250 ft)
WDG-IV (O2 ONLY) 4
18 AWG (to 1000 ft)
6 (to 40 ft)
WDG-IVC (COMBUSTIBLES) 8 (40 to 10000 ft - must 18 AWG
use remote sense)
8 (to 40 ft)
WDG-IVCM (COMBUSTIBLES/METHANE) 12 (40 to 10000 ft - must 18 AWG
use remote sense)
Figure 3-17. Required sensor cable wiring (minimum acceptable grades).
Control Unit Mains Supply Connections

Do not run control unit AC mains supply wiring in the same conduit
with other AC line power wires. By keeping this wiring separated,
you prevent transient signals from reaching the control unit.
The Series 2000 control unit can operate using between 85 to 250 volts AC,
47 to 63 Hz. There is no power switch or circuit breaker on the control
unit, and it must be protected by installing it on a circuit-protected line,
maximum 15 amperes, with a switch or circuit breaker in close proximity
to the control unit and within easy reach of an operator. Mark the switch
or circuit breaker as the control unit disconnecting device.
Mains supply connections to the control unit are as follows:
Line - Line connection
Neutral - Neutral connection (USA)
Chassis Stud - Equipment ground (protective conductor)
Installation | 3-21
Use the 1/2” conduit entry hole in the control unit for AC mains supply
wiring. Use the chassis stud next to the 1/2” conduit entry hole for equip-
ment ground (protective conductor).
AC (L) and (N) markings are provided by the terminal block for connec-
tion of AC power. These markings are for reference purposes only, such as
for use on system wiring diagrams, etc. The system/product has or needs
no specific LINE or NEUTRAL connection for any function, safety or oth-
erwise. The (N) terminal is not internally grounded, nor needs to be. The
system will operate normally regardless of what AC input terminal (L or
N) the AC Line or Neutral is connected to, or, if there is a Neutral used at
all (i.e., 208 VAC US power connection).
EMC grounding, shielding, and noise protection
For EMC purposes, under no circumstances should you leave cable

shields disconnected at one end or both ends of the cable (sensor or
control unit or other device).
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.
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 3-25). This shield ring is a stain-
less steel ring with a metal tab. Place the shield ring under the conduit
nut. Crimp the shields from all cables for that conduit entry to a 1/4”
female quick disconnect, then push it onto the tab that sticks out of
the conduit shield ring. Keep shields as short as possible.
• Ground Stud Method

Connect all cable shields for that conduit entry to the grounding stud
closest to that conduit entry hole.

SHIELD RING METHOD
Shield Terminal Ring
Quick Disconnet (1/4”)
Conduit Housing Cable Shield(s)

Max. Length 1 inch
Capacitor
Conduit Nut
GROUND STUD METHOD
Cable Shield(s)
Conduit Housing Max. Length 2 inches
Capacitor Conduit Nut
Nut
Washer
Ring Terminal
Figure 3-18. Direct shield grounding methods
Transient and RFI interference
This section describes transient and RFI interference precautions:
• Although there are transient and noise protectors on all control unit
I/O connections (communications, current outputs, sensor, etc.), this
protection is intended to act as a last line of defense against unwanted
transient and RFI interference.
• Proper installation practices to prevent the introduction of transients

and noise into the system must be followed. Inductive loads connect-
ed to the control unit must have transient suppressors installed at the
Installation | 3-23
inductive loads. Be sure to place the transient suppressor as close to
the load as possible. Examples of transient suppressors include MOVs,
TRANSORBs, and RC snubbers.
• AC mains supply wiring should not be run in the same conduit with
mains supply wiring that feeds heavy inductive loads.
• Avoid running signal wiring in the same cable or conduit with wires
that power inductive loads unless all the cables within the conduit are
shielded, the inductive loads are small, and transient suppressors are
used at the loads.
• Do not run signal lines in the same cable or conduit with high voltage
lines.
• For optimum noise protection, control unit mains supply wiring

should be connected to a circuit separate from any circuit that could
introduce transients into the system. 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.
Sensor Connections
Make sure that power has been removed from the control unit and
sensor before making sensor connections. See Figure 3-25, 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. All sensor connections require that you access
the sensor board (see Figure 3-19).
Sensor cabling must be twisted pairs in an overall braided shield, or

 twisted pairs in rigid metal conduit. Follow all wiring guidelines as
NOTE specified in Figure 3-17 in the front of this wiring section.

Figure 3-19. Sensor board.
Sensor AC mains supply connections
Connections for AC mains supply to the sensor are labeled as follows:
L - Line Connection
N - Neutral (USA)
Chassis Stud -Equipment Ground (Protective conductor)
There is no power switch on the sensor, and it must be protected by in-

stalling it on a circuit protected line, maximum 15 amperes, with a switch
or circuit breaker in close proximity to the sensor and within easy reach of
an operator. Mark the switch or circuit breaker as the sensor disconnecting
device.
AC (L) and (N) markings are provided by the terminal block for connec-
tion of AC power. These markings are for reference purposes only, such as
for use on system wiring diagrams, etc. The system/product has or needs
no specific LINE or NEUTRAL connection for any function, safety or oth-
erwise. The (N) terminal is not internally grounded, nor needs to be. The
system will operate normally regardless of what AC input terminal (L or
N) the AC Line or Neutral is connected to, or, if there is a Neutral used at
all (i.e., 208 VAC US power connection).
Installation | 3-25
Standard sensor connections
All WDG sensors, regardless of the sensor type, require that you make
the following connections from the control unit to the sensor (see Figure
3-27):
ontrol Unit Label Sensor Terminal Number

C
Cell + 1 (one pair)
Cell - 2
Furnace 3 (one pair)

15V COM 4
T/C + 5 (one pair)

T/C - 6
15V SPLY 12 (one pair)

15V SPLY 12
Combustibles connections
If you have a combustibles detector in your sensor, also make the fol-
lowing connections between the control unit wiring card and the sensor
board on the sensor (H2 represents the hydrogen/carbon monoxide style
of combustibles detector. This detector can measure both CO and H2 ) -
refer to Figure 3-27:
Control Unit Label Sensor Terminal Number

H2 Act + 7 (one pair)
H2 Act - 8
H2 REF + 9 (one pair)

H2 REF - 10
Methane connections
If you have a methane detector, also make the following connections (see
Figure 3-27):
Control Unit Label Sensor Terminal Number

CH4 ACT + 13 (one pair)
CH4 ACT - 14
CH4 REF + 15 (one pair)

CH4 REF - 16

Figure 3-20. Sensor connections with all sensor options.
Installation | 3-27
Remote Sense Setup Wiring for Combustibles
If you do not have the combustibles option, skip this section.
If the distance between the controller and the sensor is over 40 feet,
 and you are using the combustibles option, you must use the re-
NOTE mote sense setup. With the remote sense setup, you can obtain the
best accuracy of your combustibles detector readings. See Figure 3-17
for the number of pairs required and the type of wire required.
To use the remote sense setup, you must first set the Remote/Local jump-
ers on the Series 2000 controller wiring card to the Remote Position (see
Figure 3-21). Then you need to make another set of wiring connections
between the control unit wiring card and sensor as shown in Figure 3-21.
(You will end up having two wires connected to each combustible detec-
tor connection on the sensor board.)
Not actual order of

sensor connections
Methane Combustibles
Option Option
Note:
(CH4 REF+)
(CH4 REF-)
(CH4 ACT+)
(CH4 ACT-)
(H2 REF-)
(H2 REF+)
(H2 ACT+)
(H2 ACT-)
SENSOR Connect both standard and

BOARD remote sense detector
connections together at
15 16 13 14 9 10 7 8
sensor screw terminals.
Overall Braided Shield

or Ridged metal conduit
Same Sensor connections

as above
Methane Combustibles
SERIES 2000 Option Option
WIRING BOARD
T/C-
CH4 REF-
H2 REF+
H2 REF-
H2 ACT-
CH4 REF+
H2 ACT+
CH4 ACT+
CH4 ACT-
(CH4 REF-)
(CH4 REF+)
(CH4 ACT+)
(CH4 ACT-)
(H2 REF+)
(H2 REF-)
(H2 ACT+)
(H2 ACT-)
15 16 13 14 9 10 7 8
M
O
R
E
E
T
W5 W6 W7 W8 W9 W10 W11 W12

O
C
A
L
L
+S
+S
+S
+S
-S
-S
-S
-S
Remote Sense Detector

Connections
Figure 3-21. Remote sense connections for combustibles.

Current Output Connections
Standard current outputs
Standard current output connections are labeled as follows on the wiring

card of the Series 2000 control unit (see Figure 3-21):
IOUT1 + and -
IOUT2 + and -
These current outputs are referenced as current outputs 1 and 2 in soft-
ware. Be sure to observe polarity when connecting current output devices
to these terminals.
Current outputs 1 and 2 are capable of driving up to 1200 ohm loads.
The standard control unit with no options provides two current outputs.
These two current outputs (1 and 2) are isolated from the control unit,
but are not isolated from each other. If you have the combustibles option,
current outputs 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
NOTE Power Using Current Outputs” appendix.
Combustibles option current outputs

If you have the combustibles option, the connections for current outputs 3
and 4 on the wiring card allow you to monitor combustibles information.
They are labeled as follows:
IOUT3+ IOUT4+
IOUT3- IOUT4-
These current outputs are referenced as current outputs 3 and 4 in soft-

ware (see Chapter 4 for help on defining current output settings in soft-
ware). Be sure to observe polarity when connecting current output de-
vices to these terminals. These combustibles current outputs are capable
of driving up to 1200 ohm loads.
Current outputs 3 and 4 are isolated from the control unit and are
 isolated from current outputs 1 and 2, but not from each other.
NOTE
These current outputs are only active if you have the combustibles option
card installed in your control unit.
Installation | 3-29
Alarm Contact Connections
This section describes how to make wiring connections for any alarm de-
vices you wish to connect to the control unit. Alarm contact information
is divided for standard alarms and alarms that are available only if you
have the combustibles card installed in your control unit.
Standard alarm connections
The Series 2000 control unit provides four sets of standard alarm contacts,
which are labeled as follows (see Figure 3-29):
ALARM 1A ALARM 2A ALARM 3A ALARM 4A

ALARM 1B ALARM 2B ALARM 3B ALARM 4B
The Watchdog Timer Alarm connections are labeled as follows on the con-
trol unit:
ALARM 1A
ALARM 1B
The watchdog alarm contacts are normally closed during system opera-
tions (deactivated). A watchdog event triggers these alarm contacts to an
open condition. If you have a watchdog event, and the system returns to
normal operations, then the watchdog alarm will reset. The system will
retain in memory the last time the watchdog condition occurred.
The Service Alarm connections are labeled as follows:
ALARM 2A
ALARM 2B
The service alarm contacts are normally closed during system operations
(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

Power
Supply
Max. 30v
Transient
Computer dry protector
contact input for inductive
loads
Load
Max. 30VA
Figure 3-22. Series 2000 alarm contact connections.
Installation | 3-31
Combustibles detector alarm connections
If you have the combustibles option, two sets of alarm relay contacts are
available to activate for high combustibles levels, and are labeled as fol-
lows (see Figure 3-22):
ALARM 5A ALARM 6A
ALARM 5B ALARM 6B
Methane detector option alarm connections
If you have the methane detector option, two sets of alarm relay contacts
are available to activate for high methane levels, and are labeled as follows
(see Figure 3-29):
ALARM 7A ALARM 8A
ALARM 7B ALARM 8B
Remote Calibration Unit Connections

If you don’t have the remote calibration unit (RCU) option, skip this sec-
tion.
Oxygen-only remote calibration unit connections
Oxygen-Only Remote Calibration Unit (RCU) connections on the Series

2000 control unit wiring card, and their RCU connections, are as follows
(see Figure 3-30):
ZERO - 13 on RCU
ASPIR - 14 on RCU
SPAN1 -15 on RCU
VALVE COMMON - 16 on RCU

Combustibles remote calibration unit connections
If you have the combustibles option (and a combustibles RCU), you must
also make the following connection (see Figure 3-23):
SPAN2 - 17 on RCU
For a WDG-IVCM with RTD-type combustibles detector, you make the

following connection:
SPAN2 - 17 on RCU
For a WDG-IVCM with hot-wire detector, Remote Calibration Unit connects:
SPAN2 - 17 on RCU
SPAN3 - 18 on RCU
Remote cal
switch normally
open (dry
contact closure)
Overall braided shield

or rigid metal conduit
All common wires

to pin 16 on RCU
and valve commons
on control unit
Figure 3-23. Series 2000 controller RCU connections.
Installation | 3-33
Digital input to initiate remote calibration unit
The digital input connections on the wiring card allow you to initiate a
remote calibration from a location other than the control unit (see Figure
3-23). For this option to work, you must have a remote calibration unit
and an auto calibration card. The system monitors the digital input, and
when the switch closes, it sends the system into an automatic calibration.
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 -
RS-485 Communications Connections

The Series 2000 control unit has the ability to communicate with other
computers that use the same protocol and have the same hardware inter-
face.
2-wire connections
The connections used for RS-485 2-wire communications on the wiring

card are labeled as follows:
4WTX+/2W+
4WTX-/2W-
Connect all the 2-wire pluses (+) and all the 2-wire minuses (-) in parallel
with all the devices in a daisy chain fashion, including all the control units
on the network and the host computer. In addition, on the host computer
connect the receive and transmit terminal block connections (see Figure
3-24). Be sure to use twisted-pair cable for all connections.
2-wire termination resistor
The Series 2000 control unit is equipped with a termination resistor that
can be used for the last control unit on the network. 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)

Figure 3-24. Series 2000 2-wire RS-485 communication connections.
Installation | 3-35
4-wire connections
The connections used for the RS-485 4-wire communications on the wir-
ing card are labeled as follows:
4WTX+/2W+
4WTX-/2W-4WRX+
4WRX-
Connect all control unit 4WTX+, 4WTX-, and all 4WRX+ and 4WRX- con-
nections in parallel in a daisy chain fashion. Make the following con-
nections between the host computer and the controller in a daisy chain
fashion (see Figure 3-25):
Host Computer TX- to Controller 4WRX-Host
Computer TX+ to Controller 4WRX+
Host Computer RX- to Controller 4WTX-Host
Computer RX+ to Controller 4WTX+
Be sure to use twisted-pair cable for all connections.
4-wire termination resistor
The Series 2000 Control Unit is equipped with termination resistors that
can be used for the last control unit on the network. The switch settings
are:
SW1-1 = ON
SW1-2 = ON
SW1-3 = ON
This provides 120 ohm termination resistors in the RS-485 circuit. See
the “Option Card Installation” section in this chapter for help on how to
remove and access the display module. You may need to experiment to
get optimum performance over long lengths of communications wiring to
see if having a termination resistor on the last control unit of the network
improves communications. Remember, though, only to insert a termina-
tion resistor on the last control unit on the network, and not on all control
units on the network. The factory default setting is to have Switch 3 OFF
with no termination resistor in the circuit.

Figure 3-25. Series 2000 4-wire RS-485 communication connections.
Installation | 3-37
Option Card Installation
This section shows you how to add option cards to the control unit. This
includes the following option cards:
• Combustibles Card - requires combustibles detector in sensor

• Auto Calibration Card - requires remote calibration unit
If you ordered any of these options when you purchased your analyzer,
these option cards will already be installed in the control unit. This section
shows you how to install an option card if you later add that option to the
control unit.
This section also shows you how to access the display module and power
supply/keypad module on the control unit in case you need to replace
these modules or change a component in them (for example, install new
software).
Removing Display Module or Power Supply/Keypad

Module
This section describes how to remove or replace the display module or
power supply keypad module on the control unit (see Figure 3-26):
Remove power from the control unit before working on it.
Figure 3-26. Front view of series 2000 control unit.

1. Open the access door below the display module (hinges down).
2. 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.
3. Pull on the display module handle to then pull out the display module.
4. Reverse these steps to reinstall the display module or power supply/

keypad module.
Should you need to replace fuse F1 on the display module, it is a Littlefuse

type 273 microfuse or equivalent, voltage rating: 125V AC, ampere rating:
50 mA.
Should you need to replace Fuse F1 on the wiring card, it is a Littlefuse

type 273 microfuse or equivalent, voltage rating 125V AC, ampere rating:
250 mA.
Adding an Option Card

Do the following to add an option card to the Series 2000 control unit (this
includes the auto calibration card or the combustibles card):
1. Open the access door below the display module (hinges down).
2. Pull on the handle of the power supply/keypad module and remove

this module from the control unit (it slides out).
3. Insert the option card into any of the three available slots underneath
the display module. Make sure the card is properly seated by pressing
on both sides firmly. If the card is not properly seated, the access door
may not close.
4. Reinstall the power supply/keypad module.
Removing an Option Card

Do the following to remove an option card:
1. Remove the power supply/keypad module.
2. Pull with your left hand on the left of the option card while pulling on
the ejector lever on the right of the option card with your right hand
to remove the option card. The ejector will help apply extra force to
make is easier to release the card.
Installation | 3-39

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 you the various

areas of the control unit, including the
locations of the power supply/keypad
module and display module.
The control unit is operated by press-

ing keys on the keypad and by view-
ing information on the main display.
Figure 4-1. Control unit display and keypad.
Control Unit Display

You can view different types of information on the main control unit
display. The first three lines of the display display user-defined informa-
tion programmed using the Setup key Display option. You can also use the
Display menu option to place your own text messages on one of the first
three lines. The last display line is reserved for system and error messages.
See Alarm Setpoints in the
Alarm Key section for
When there is an alarm condition, alarm information in the form of an Up
details. or Down arrow (corresponding to a high or low alarm) will appear next to
the process reading on that display line.
Controller / User Interface | 4-1

Control Unit Keys
Each of the Control Unit keys provides a menu of choices.
Key Function
Setup Set up the control unit for your specific application.
Calibrate Set calibration parameters and start calibrations.
Analog Range Define parameters that control analog current outputs.
Alarm Define parameters that control the alarm relays.
Help Access control unit on-line help.
Cancel Cancels out of menu options.
Enter Confirm menu choices and values.
Selecting Menu Options

Select a menu option, by pressing the Down arrow key until the arrows are
pointing at the menu option, then press Enter. The selected choice has an
asterisk (*) in front of it.
For example, if you select the Display option from the Setup key, and then select
“Display Line 1”, the current choice on display line 1 will have an asterisk in front
of it (for example, % oxygen).
If all menu options are not able to be listed on the display, there will be a
Down arrow on the far right of the last line of the display. This indicates that
there are more menu options to view. When the Down arrow disappears,
there are no more menu options to display. Conversely, if an Up arrow ap-
pears on the far right of the first line of the display, there are more menu
options available if you press the Up arrow key.
Exiting 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

Automatic Menu Exit Feature
If you don’t press a key after 15 minutes, the system exits the menu you were
in and returns the system to normal operations (exits out of all menus).
On-Line Help
Press the Help key to get a description of the function for the menu options.
Press Help again to exit on-line help and return to the menu options (or press
the Cancel or Enter). For example, to get on-line help for the Passwords op-
tion from the Setup key, select the Setup key, then move the arrow pointers
to Passwords and press Help.
System Password
By default, the system password is disabled. If you don’t want to
 enable a system password, you can skip this section. You can also use
NOTE this menu option to disable the password requirement.
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-
NOTE cess the Password option and enter a new system password.
1. From the menu key menu, select Passwords.

You will be prompted to enter a new system password:
Enter NEW Password
2. Enter a four-digit password. You are prompted to reenter the pass-

word to verify it.
Reenter to Verify
3. Reenter the password.
To later disable or change the system password, you must first enter
 the old password to access this menu option, then change or disable
NOTE the password (0000 disables the password).

Setup Key
SETUP KEY
Display Passwords
Process Pressure System Serial #
System Tests Primary Calib
Sensor COnfig Communication
Combustibles
Figure 4-2. Setup Key menu options.
SETUP KEY
Functions/Options
Menu Options
Display Define what information to place on each display line.
Passwords Create a system password to limit control unit access.
Process Select a positive or negative process pressure.

Pressure Enter process pressure value.
System Tests Perform internal diagnostics on Series 2000.
System Serial # View serial and manufacturing number for the control unit.
Primary
Perform an automatic, remote, or manual primary calibration
Calib
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.
Combustibles Define combustibles scale (% or PPM).

Define combustible detector type.
This only applies if you purchased a combustibles detector.

Display
Define what information should appear on the top three (3) display lines
of the control unit. Choices include:
 Percent oxygen (% O2 )
 Cell millivolts
 Thermocouple millivolts (T/C millivolts)
 Current date/time
 User text
 Turn off (leave display line blank)
 Combustibles (optional)
 Methane (optional)
 Combustibles/Methane (optional)
When you access menus, the menu options can occupy display lines 3
 and 4, and sometimes display line 2. Therefore, place the information
NOTE that is most critical for you to view on the topmost display lines.
Setting up the dIsplay
1. From the Setup menu, select Display.
2. Select Display Line #1, Display Line #2, or Display Line #3, de-
pending on where you want to place the information.
3. Select the type of information you want to place on the display line.
Entering User Text
The Down arrow found on the third line of the display allows you to see
your current position when entering user text. When you first select the
User Text option, this Down arrow moves to above the first position.
To enter text, use the Up and Down arrow keys on the keypad to scroll
through the ASCII text characters. When the letter you want to enter ap-
pears in position, press the Right arrow key to move to the next position.
You can also press the Left arrow key to move back one position in your
text message. When you are finished entering your message, press Enter.
User text can be up to 20 characters long.


NOTE

Use the following keys to move directly to a specific location in the ASCII
text table:
Press this Key Move to this Location

1 capital letter A.
3 capital letter Z.
7 small letter a.
9 small letter z.
5 space character.
0 number zero character.
Combustibles and methane scale shown on display
• If you select to display Combustibles, the display will show % com-

bustibles or PPM combustibles, depending on what you selected for
the Combustibles Option from the Setup key.
• If you select Methane, the display will always show % methane.
Option Full Scale Range

% combustibles 0 to 5 %
PPM combustibles 0 - 10,000 PPM
methane 0 to 5 %
An incorrect combustibles reading is always displayed after the initial

 installation (the information on the combustibles display line wraps
NOTE around to the display line below and over-rides a few characters).
Even though the unit was calibrated at the factory, the analyzer must
be calibrated again after installation. Once the analyzer is calibrated
and the combustibles signal is in the normal range, the display lines
will show the correct reading.

Process Pressure
Define your process pressure and whether your process is operating
under a positive or negative pressure. Setting this value corrects oxygen
measurements for the defined pressure.
Setting up process pressure
1. From the Setup key menu, select Process Pressure.
2. Select Positive Pressure or Negative Pressure.
You are prompted to enter your system process pressure:
Pressure = xxx.x kPa

New Value?
3. Enter your process pressure (up to one decimal point is allowed - for
example, 1.5 kPa), then press the Enter.
• If you select a positive pressure, a plus sign (+) will appear.
• If you select a negative pressure, a negative sign (-) will appear.
The process pressure you entered will now appear on the third display
line.
4. 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.

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.


NOTE
Calibrate A/D Forces an A/D converter calibration. This is automatically

done during system start-up.
Test RAM Checks the functionality of the control unit’s internal Ran-
dom Access Memory (RAM).
Test Keyboard Tests that each key is functioning correctly.
Test EEPROM Tests the electrically erasable programmable read-only
memory.
Module Detect Allows the control unit to check for the presence of option
modules. This test is used to ensure that the control unit is rec-
ognizing any option modules you have installed on the control
unit. This is done automatically during system start-up.
Test Digital In Allows you to test the system digital input.
Erase RAM Allows you to erase all RAM memory locations.
Erase EEPROM Allows you to erase internal EEPROM memory locations
if your control unit is not operating properly. Be careful,
though, because selecting this option will erase all settings
in your control unit and the default values will be reinstalled.
Watchdog Timer Allows you to test that the watchdog timer and alarm circuit
is working properly. (See the “Watchdog Timer” section at
the end of Chapter 7 for more information on the watchdog
timer).
Serial Output Sends the string “Test Message” through the serial port until
stopped by the user. This is used to test communication
settings and wiring.
Read Memory This is used to view internal software variables used for
Location system operation and troubleshooting.
System Serial #
View system serial # and manufacturing #.
Setting up the serial number
1. From the Setup menu, select System Serial # .

2. Select System Serial # or Manufacturing #.
3. The system displays the system serial # or manufacturing #.

Primary Calibration
Perform a primary calibration on the zirconium oxide oxygen sensor. You
should perform a primary calibration on your system instead of a regular
calibration (from the Calibrate key) only when:
 you replace the zirconium oxide oxygen cell or thermocouple
 your system fails a regular calibration due to a deteriorating cell
You should always attempt to perform a regular calibration before

 resorting to a primary calibration for all cases other than when you
NOTE install a new cell.
The Primary Calibration correlates the actual cell response for the desired 695°C
cell set-point temperature with the actual furnace thermocouple feed back tem-
perature. This is done by applying two known concentrations of oxygen to the
analyzer during the primary calibration. The software algorithm then calculates
the actual cell temperature from the cell mV response and increases or decreas-
es the furnace temperature control set point accordingly.
Because of the age of the cell and its characteristics, the control temperatures
should be slightly different. However if you perform a primary calibration incor-
rectly, or if the cell really starts to deteriorate, the actual cell response to calibra-
tion gas will drop off. The primary calibration is a way to extend the life of the
cell. The furnace control temperature can be increased to reduce the atrophy and
extend the cell life as the cell ages and the output starts to drop off its original
factory cal furnace set point temperature. This can be seen in the distribution in
your spreadsheet since the calculated cell temperatures for some of the analyz-
ers are well below 695°C or above by a fair amount. If the cell response goes
out of the limits in Table 4-1, there will be a zero or span gas range error. At this
point, you should perform a primary calibration and then attempt a standard cali-
bration again. If you get an excess cal error during primary calibration, then the
furnace temperature set point cannot be increased any further to prevent dam-
age to the cell housing and/or furnace assembly.
Failure Limits for Standard Calibration
• +/- 10 mVs of the anticipated mVs for the gas concentration applied (air 0
mV expected).
• +/- 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.

Determining temperature
If 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. The corresponding temperature from a Type-K thermocouple should be the
actual furnace set point temperature = 695°C / T/C Ratio (memory location 88).
Use the Type-K table to determine the mV change you have for 273°C and add
this mV change for the actual board temperature. This should be the compensa-
tion voltage measured between D+ and 6- on the sensor board. So for a 50°C
ambient at the board, the voltage should be 11.05 mV (273°C) + 2.02 mV (50°C)
= 13.07 mVs.
If you have a T/C ratio of 0.9, the corresponding furnace temperature set point
should be (695°C / 0.9 = 772°C). If you measure the voltage at terminals C and D
on the sensor board with a 50°C ambient, the voltage should be 32.125 (772°C)
- 2.02 mV (50°C) = 30.1 mV. If you add in the compensation voltage for 50°C, the
voltage at terminals 5 and 6 should be 30.1 mV + 12.05 mV = 42.15 mVs which
should also be the voltage that you measures at T/C+ and T/C - terminals on the
Series 2000 wiring card terminals and also the displayed T/C mV value that you
can set one of the display lines to view in the Setup key - Display menu.
T/C Ratio Adjustment Limits for Primary Calibration
Cell Temp °C Max T/C Ratio Min T/C Ratio

615 1.3 0.7
650 1.24 0.74
695 1.22 0.777
824 1.139 0.861
790 same as 824°C
Table 4-2.
For a cell operating temperature of 695°C, the T/C ratio low limit is .777 and the
high limit is 1.222, which corresponds to a thermocouple indicated temperature
range of 540°C to 848°C.
• If you find that a regular calibration isn’t working correctly, first check that
your calibration gas values match the values written on the gas cylinders;
also be sure that the correct flow of gases has been set and that the gases
are allotted enough time to flow through the sensor. Only if these checks
have been done and the system still can’t be properly calibrated should you
perform a primary calibration.

Setting up a primary calibration
Make sure you have properly entered calibration gas values using the Cal
Gas Values option from the Calibrate key before starting your primary
calibration.
1. From the Setup key, select Primary Calib.
2. If you have the auto calibration card option (and a remote calibra-
tion unit), you will be prompted to select Auto Calibrate, Remote
Calibrate, or Manual Calibrate. If you don’t have the auto calibration
option, the system defaults to a manual calibration, and you will be
prompted to inject span gas into the calibration gas inlet port.
From this point, operations continue as they do for a regular calibration.

Please see the “Initiate Cal/Initiate Verify” section in Chapter 5 for help
on how to perform the calibration.
If you have the combustibles option, during a primary calibration the

 system will not use the combustible span gas to calibrate the system.
NOTE
 When the primary calibration is finished, the system will notify you
that a standard calibration is required by displaying a Calibration
Required message.
 Oxygen readings on the display will not be accurate until the regular
calibration is performed.
 A 15-minute recovery time follows the primary calibration to allow

the cell to stabilize. Perform the regular calibration after this 15 minute
stabilization period,
During the recovery time immediately following the primary calibra-

 tion, you may see some temperature related error messages. You can
NOTE ignore these messages and assume no problem exists. This is because
the cell temperature is adjusted after a primary calibration.

Sensor Config
Select the sensor you will be using with the Series 2000 controller.
When selecting a sensor, use Table 4-3 for the temperature each type of
sensor uses. If your type of sensor is not listed, find the operating tem-
perature for your sensor, then choose the sensor that uses that operating
temperature.
Use caution when selecting the type of sensor used with the Series
2000 Control Unit. Selecting the wrong sensor will damage sensor
components and could invalidate your warranty coverage.

SENSOR OPERATING TEMPERATURE °C

Insitu Probe
Normal Cell Range 615
High Cell mV Range 650
WDG IV or HP Series
3-in-1 (WDG-IVCM) 695

CEM/O2
Table 4-3. Sensor temperatures by analyzer type.
Configurating the sensor
1. From the Setup menu, select Sensor Config.
2. Select the sensor you will use with the Series 2000 control unit. If your
sensor is not listed in Table 4-3, call the factory for the correct operat-
ing temperature for your sensor type.

Communication
Define RS-485 communications parameters between the Series 2000 con-
trol unit and a host device. This includes the following:
Baud Rate Allows you to define the baud rate that the control unit and the
host computer are using to communicate. Choices are 300,
600, 1200, 2400, 4800, and 9600 baud.
Node Address Allows you to define the physical address for the control unit
(between 0 and 255) on a network so the host computer can
identify the control unit if using network communications (see
below). Note that each control unit must be assigned a unique
address; otherwise, communication results will be unpredict-
able.
Enable Serial Allows you to temporarily disable control unit serial communi-
cations.
Combustibles Option
Combustibles Choices are % combustibles or PPM combustibles.
Scale
The % combustibles full scale range is 0 to 5 %.
The PPM combustibles full scale range is 0 - 10,000 PPM.
If you have the methane option, the range is always in % methane (not select-
able), and the full scale range is 0 to 5 %.
If you have a methane detector, the combustibles detector must be used in the
PPM range.
Combustibles Choices are Hot Wire and RTD detector.
Type
If not sure, check your customer configuration sheet, in-
cluded in the front of this manual.

Analog Range Key
ANALOG RANGE KEY
Set Current
Range
Set Track/Hold
Set Current
Mode
Output Filtering
Select Function
Figure 4-3. Analog Range Key menu.
You can direct process readings to either of the two analog output ports
on the rear of the control unit. If you have the combustibles option, you
can also have process readings directed to two additional analog output
ports activated with this option. All functions in this chapter are directed
to a specific analog output port.
ANALOG KEY FUNCTIONS/OPTIONS

Set Current Range Define what information should be sent to the analog
output port during a calibration. For example:
4% O2 = 4 mA
10% O2 = 20 mA
Set Track/Hold Hold output at last process reading during a cal or
verify, or track the calibration readings.
Set Current Mode 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:
% O2
Cell temperature
Cell Millivolts
Thermocouple Millivolts
Combustibles (option)
Methane (option)

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
NOTE rear of the control unit. If you have the combustibles option, you can
also use analog output ports 3 and 4.
Analog output port 1 is labeled I OUT 1; analog output port 2 is labeled I

OUT 2. If you have the combustibles card option, analog output port 3 is
labeled IOUT3 and analog output port 4 is labeled IOUT4. Analog output
ports 3 and 4 can only be used for combustibles or methane sensor options.
Selecting an analog output port
1. Select the Analog Range key.

2. Select Current Output #1 or Current Output # 2. If you have the
combustibles option, you can also select Current Output # 3 or Cur-
rent Output # 4.
You can then select any of the menu options described in the remainder of
this chapter, and they will apply to the analog output port you selected.
Set Current Range

Define the range of readings that the 0-to-20 or 4-to-20 mA output will
represent. You can also choose to set a reverse analog output range. For
example, 0 mA can correspond to the high end of the oxygen range, and
20 mA can correspond to the low end of the oxygen range.
The range of readings the current output represents is also a function of

the type of process readings the analog output port tracks (see the “Select
Function” section later in this chapter for the types of readings the current
output can represent).
See the “Set Current Mode” section for help on choosing either a 0-to-
 20 mA or 4-to-20 mA scale.
NOTE
Setting the current range
1. Select an analog output port.
2. From the Analog Range key menu, select Set Current Range.

You will be prompted to define the new value to correspond to the 20 mA
analog output:
Out # y 20 ma = xx
New Value?
where y is the analog output port, and xx is the present value that the cur-
rent output currently represents (for example, 10 % O2 ). The output port
that appears depends on the analog port you selected.
3. Input the value to correspond to the 20 mA analog output.
You will be prompted to define the value to correspond to the 0 or 4 mA

analog output:
Out # 1 4 ma = xx
New Value?
where xx is the value that the current output currently represents.
4. Input the value to correspond to the 4 (or 0) mA analog output.
Set Track/Hold Option

Define the signals to send to the selected analog output port during a cali-
bration or verification. You have the option to either hold the last process
reading or track calibration readings. Separate decisions can be made for
verify and calibrate operations, so you can hold the last process readings
during verifications, but track calibration gas readings during calibrations.
Setting track or hold
2. From the Analog Range key, select Set Track/Hold.
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

or
Track during cal

After you select one of these options, your choice will be confirmed on the
display:
Out # 1 will TRACK

during Calibration
or
Out # 1 will HOLD
during Calibration
For verify operations, select one of the following:
Track during Verify

or
Hold during Verify
After you select one of these options, your choice will be confirmed on the
display:
Out # 1 will TRACK

during Verify
or
Out # 1 will HOLD
during Verify
Set Current Mode

Define either a 0-to-20 or 4-to-20 mA analog output range for the selected
analog output port. This output is dependent on both the range of read-
ings you define and on the function you track on the analog output.
Setting the current mode
2. From the Analog Range key, select Set Current Mode.
3. Select 4-to-20 mA Mode or 0-to-20 mA Mode. Default selection is 4-to-

20 mA.

The following will then appear on the display:
Out # 1 is set for

4 - 20 ma
or
Out # 1 is set for
0 - 20 ma
Output Filtering Option

Filter out quick transitions in readings to allow a smoother analog output.
Setting output filtering
2. From the Analog Range key, select Output Filtering. You will be
prompted to enter an output filtering value:
[100 =FAST 1 = SLOW

Fltr = XX New #?
where XX is the current filter value.
100 equals no filtering, and 1 equals the highest possible filter value.
 The default value is 100 (no filtering).
NOTE
3. Type a number between 1 and 100, then press Enter. Note that you
should enter 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 (% O2 )
 Cell millivolts
 Thermocouple millivolts (T/C millivolts)
 Combustibles (optional)
 Methane (optional)
The combustibles and methane options are available only for current out-
puts 3 and 4, and cannot be set for analog output ports 1 or 2.
Selecting the function
2. From the Analog Range key, select Select Function.
3. 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” sec-
tion in this chapter for details).

Alarm Key
ALARM KEY
Alarm Set Points
Alarm Configure
Relay Configure
Select Function
Exception Log
Figure 4-4. Alarm Key menu.
Alarms 1 and 2 are hard wired for the Watchdog Timer and Service
 alarms and are not software-selectable.
NOTE
Oxygen, combustibles, and methane alarms are all disabled during a
primary or regular calibration. In addition, alarms are disabled dur-
ing 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.

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). All other alarms are set to activate based on
only a single condition; for Alarm 4 this condition is levels of oxygen, for Alarms 5 and
6 this condition is high combustible levels (% or PPM scale), for Alarms 7 and 8 this
condition is high methane.
*Select Function Alarm Configure Relay Configure
Alarm 3 % O2 High O2 Alarm

ALARM NUMBER
Cal Start Low O2 Alarm Energize on alarm

Verify Start
Cal/Verify Start
Alarm 4 Not selectable De-energize on alarm
(% O2 only)
Alarm 5
Not Selectable
Not selectable (high alarms only)
Alarm 6 (combustibles only)
Alarm 7
Not selectable (Disabled during
(methane only) calibration cycle)
Alarm 8
* The Select Function menu option applies only to Alarm 3. All other alarms are restricted
to activate based on process reading levels.
For oxygen alarms, these values depend on the Alarm
Alarm Set Points Configure menu option for whether they are high or low
alarms.
The exception log provides a history of events, such as
system or error messages, alarm conditions, and the
Exception Log
start of calibrations or verifications.
Alarms 1 and 2 are reserved for Watchdog and Service alarms and are not software-
selectable. They always de-energize on alarm (FAIL SAFE).

Alarm Set Points
Set alarm limits. Use the Alarm Configure menu option to define whether
these limits represent high or low alarms, although certain restrictions
apply (See the “Alarm Configure” section later in this chapter for further
help on defining high/low alarms).
Oxygen, combustibles, and methane alarms are disabled during cali-

 bration cycles.
NOTE
If an alarm triggers, an up or down arrow (depending on whether a high

or low alarm) will appear to the right of the process reading on the dis-
play. For example, if the first display line is showing % O2 values, and a
high alarm occurs, an up arrow will appear to the right of the O2 value. If,
for example, you set alarm 3 for a high O2 alarm and alarm 4 for a high/
high O2 alarm, and the O2 value exceeds both the high and high/high
alarm set points, two up arrows will appear next to the O2 value on the
display.
Defining alarm set point
1. From the Alarm menu, select Alarm Set Points.
Once you select the Alarm Set Points menu option, the system
 alerts you that Alarms 1 and 2 are reserved for the watchdog and ser-
NOTE vice alarms, and are not software selectable. Press Enter to continue
to the configurable alarms.
You will be prompted to define the Alarm 3 set point value (this option
won’t appear if Alarm 3 is set to activate based on the start of a calibra-
tion or verification - see the “Select Function” section in this chapter for
details):
Alarm #3= xx %O2

New Value?
2. Enter the Alarm 3 set point value, then press Enter (just press Enter if
you don’t want to change the current value).
You are prompted to enter the Alarm 4 set point value:
Alarm #4= xx %O2

New Value?

3. Enter the Alarm 4 set point value.
If you don’t have the combustibles option installed, you are done (press
Cancel to exit this menu option).
Combustibles Option Alarms
If you do have the combustibles option installed, you are prompted to

enter the Alarm 5 set point value:
Alarm #5= xx yy
New Value?
where xx is the current value and yy is either PPM combustibles or %

combustibles, depending on the scale you are using.
4. Enter the Alarm 5 set point value. Note that combustibles alarms are
always high alarms (can’t be set up as a low alarm).
Alarm #6= xx yy
New Value?
where xx is the current value and yy is either PPM combustibles or %

combustibles, depending on the combustibles scale you are using.
5. Enter the Alarm 6 set point value. Note that combustibles alarms are
always high alarms. So, for example, Alarm 5 can be high and Alarm 6
can be high/high.
If you don’t have the methane option, you are done (press Cancel key or
Enter to exit this menu option).
Methane Option Alarms
If you do have a methane detector, you are then prompted to enter the
Alarm 7 set point value:
Alarm #7=xx.x % CH4

New Value?
6. Enter the Alarm 7 set point value. Note that methane alarms are al-
ways high alarms.

Alarm #8=xx.x % CH4

New Value?
7. Enter the Alarm 8 set point value. Note that methane alarms are al-
ways high alarms. So, for example, Alarm 7 could be a high alarm, and
Alarm 8 high/high.
8. Press Cancel or Enter to exit this menu option.
Alarm Configure
Define whether alarms should trigger based on a high alarm or a low
alarm condition. If you have the combustibles or methane options, Alarms
5 through 8 always act as high alarms. So, for example, Alarm 5 could be a
high combustibles alarm, and Alarm 6 could be a high/high combustibles
alarm.
Whether Alarm 3 is set high or low only applies if it is set to track

 oxygen levels (% O2). If Alarm 3 is set to trigger at the start of a cali-
NOTE bration or verification, this option does not apply.
Configuring the alarms
1. From the Alarm menu, select Alarm Configure.
2. Define Alarm 3 and Alarm 4 as high or low alarms.
3. Press Cancel to exit this menu option.
Relay Configure
All Series 2000 control unit relays are Form A, normally open contacts.
You can use the software to set whether these alarms should close on
an alarm condition (energize on alarm) or open on an alarm condition
(de-energize on alarm). This menu option applies to all alarms except for
the service and watchdog alarms, which are always set to de-energize on
alarm (fail-safe).

Configuring the relay
1. From the Alarm menu, select Relay Configure.
2. Select De-energize on Alarm or Energize on Alarm.
If you select Energize on Alarm, the following message appears:
Relays are set to

ENERGIZE on Alarm
If you select De-energize on Alarm, the following message appears:
Relays are set to

DE-ENERGIZE on Alarm
Select Function
Select which function Alarm 3 should track.
• % Oxygen
• When the system starts a calibration
• When the system starts a verification
• When the system starts a calibration or a verification (dual function)
When tracking the start of a calibration or verification, the alarm will de-
activate once the calibration or verification has been completed, including
any recovery time you have specified.
Defining the select function
1. From the Alarm menu, select Select Function.
2. Select Alarm3= Oxygen, Alarm3= In Cal., Alarm3= In Verify, or

Alarm3= Cal/Verify, depending on whether Alarm 3 should be associ-
ated with % oxygen levels, or with the start of a calibration or verifi-
cation, or with the start of a calibration or verification, or both (dual
function).
The control unit automatically exits from this menu once you make your
selection.

Service Alarm
The Service Alarm operates as normally closed (service alarm condi-
 tion causes open contacts).
NOTE
The Service Alarm provides an alarm to alert you of possible system prob-
lems that require attention. 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
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” due to such
things as noise spikes or power surges. You can use this relay to activate a
remote indicator to notify you if the watchdog timer times out.
In addition, the control unit reads the watchdog after reset, and beeps for
a brief time if the reset was caused by a watchdog condition. Pressing the
reset keys simultaneously (hidden keys to the left and right of the Setup
key) for a long enough time will cause a watchdog. This will indicate as a
beep after the system restarts after releasing the reset keys.

Exception Log
The exception log provides a history of the following types of events:
• System or error messages
• Alarm conditions
• Reset conditions
• Start of calibrations or verifications
Accessing the exception log
• From the Alarm menu, select Exception Log.
The system displays the most recent exception log entry on line four of
the display. It also displays when the event was recorded on line three.
Line three of the display indicates the order in which events are recorded
into the log, with number 1 being the most recent entry into the log. The
system is able to store the 20 most recent entries in this exception log.
Pressing the Down arrow key shows later exception log entries. Pressing
the Up arrow key shows more recent exception log entries. Press Cancel
at any time to exit this menu option.


Calibration
CALIBRATE KEY
Initiate Cal Initiate Verify
Cal/Verify Data Cal Gas Value
Inject Cal Gas Set Cal Timers
Set K Factor Sensitivity
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
NOTE the calibration readings or hold at the last process reading before the
calibration.
Calibration | 5-1
Definitions
Calibrations vs. Verifications

The Series 2000 control unit software refers to both calibrations and verifi-
cations. During a verify operation, the calibration gas readings are taken,
and the difference between what the system records for the gas values
and their known values is recorded. Internal calibration parameters are
not changed. Verify operations are often used to check that the instru-
ment is running within required tolerances.
On the other hand, during a calibration software, algorithms adjust the

difference between the current readings and the known calibration gas
values until they are equal. In this chapter, when we speak about a calibra-
tion in a general sense, we are referring to either a verification or a calibra-
tion.
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.

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.
• Automatic calibrations allow the system to calibrate itself. You define the
calibration gas values, the time each gas will flow through the sensor,
and the frequencies at which automatic calibrations will be performed
(for example, every four hours, every two days, etc.). The system cali-
brates itself at those predefined times. You can also use a digital input
to activate an automatic calibration (see the “Remote Calibration Unit
Connections” section in the Chapter 2). With the digital input method,
you can only initiate an automatic calibration, not an automatic veri-
fication. You can also start an auto calibration using the keypad - the
calibration gas run times are predetermined.
• For remote calibrations, you define the calibration gas values, but you
interactively determine how long each calibration gas should flow
from the RCU and into the sensor (by pressing a key on the control
unit).
• For a manual calibration, you must physically switch the gases because
you are not using an RCU. However, you still define the calibration
gas values.
Calibration | 5-3
Overview
CALIBRATE KEY
Functions/Options
Menu Options
Start an automatic, remote, or manual cali-
Initiate Cal/Initiate Verify
bration or verify
Although automatic calibrations can be set to run at predetermined frequencies,
you can also force the system into an automatic calibration.
View latest calibration and verify data.
Cal/Verify Data - Cal data
- Verify data
Define calibration/verify gas values to
match known values of calibration gas
Cal Gas Values cylinders.
Enter calibration gas values.
Set pressure and flow to RCU gases with-
Inject Cal Gas
out performing a calibration or verification.
Set control unit time/date.
Set Cal Timers/Set Auto Timers Enable or disable auto cal cycles.
(applies only for auto cal operations
with RCU, except for setting time and Set cal gas times for auto cal/verify opera-
date) tions.
Define recovery durations after a cal/verify.
Set K Factor Enter Value
(not used on WDG-IV Series)
View the Sensitivity (Slope) determined
Sensitivity during calibration for the combustibles
detector in mV/1000 PPM.
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. Oxygen, combustibles, and methane alarms are
also disabled during a calibration.

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. Once you set these cycle times, it won’t be
necessary to select the Initiate Cal or Initiate Verify menu options for an
automatic calibration.
The Auto Calibrate/Auto Verify and Remote Calibrate/Remote Verify se-

lections are only available if you have installed an Auto Calibrate Card in
your Series 2000 control unit and have a Remote Calibration Unit (RCU).
If the Series 2000 control unit detects that these options are not installed,
it will automatically prompt you with a manual calibration or verification
operation when you select either the Initiate Cal or Initiate Verify menu
options.
This chapter section is divided into discussions on automatic, remote, and

manual calibrations or verifications.
Auto Calibrate/Auto Verify

Before you can start an auto calibration or verification:
1. Create auto cal timers to tell the system when to perform the automatic
calibrations.
By doing this you don’t have to select the Calibrate key later to run the calibra-
tion, it does it automatically at the frequencies you defined. This is not required
if initiating the auto calibration using a digital input.
2. Enter the calibration gas values to match the span and zero calibration
gas cylinders you will use to calibrate or verify your system.
3. Define how long you want each calibration gas to flow through the sen-
sor before switching the gases. Remember that with an auto calibration
or verification, the RCU automatically switches the span and zero cali-
bration gases based on the calibration gas duration times you specify.
Be sure to allow enough time for the gases to stabilize when you define
these times. You may want to use the “Inject Cal Gases” option from
the Calibrate menu to determine how long it takes for gases from the
remote calibration unit (RCU) to reach the sensor and stabilize and then
use these times.
4. Define a time period for the system to recover from reading calibration
gas values to reading process gases.
Calibration | 5-5
You can start the auto calibrate cycle as follows:
1. Depending on whether you want to perform a calibration or verifica-

tion, select either the Initiate Cal or Initiate Verify option from the
Calibrate key menu.
2. Select the Auto Calibrate or Auto Verify option. The system will begin
the automatic calibration, and will notify you how long the span gas
will be applied to the sensor from the RCU:
Span Gas xx:xx

System Calibrating
Then the following message will appear on your display:
Zero Gas xx:xx

System Calibrating
During this time, the RCU switched the solenoid valves and introduced
the zero gas to the sensor.
Combustibles and Methane Options
If you have the combustibles option, the following message appears:
Comb Span Gas xx:xx

System Calibrating
During this time, the RCU switched the solenoid valves and introduced
the combustibles span gas to the sensor.
If you set the duration time for the combustibles span gas to 0 from
 the Set Cal Timers menu, you will not see this message.
NOTE
If you have the methane options, the following message appears:
Methane Span Gas xx:xx

System Calibrating
When specified, the system will display the recovery time remaining:
Recovery xx:xx
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.

Remote Calibrate/Remote Verify
To initiate a remote calibration or verification, do the following:
gas cylinders you intend to use to calibrate/verify your system. These
values are referred to in this section as setpoint values.
2. Select Initiate Cal or Initiate Verify from the Calibrate key menu, de-
pending on whether you want to perform a calibration or verification.
3. Select Remote Calibrate or Remote Verify.
The following appears on your display (display line 2 will only appear if
you have the combustibles option; display line 3 will only appear if you
have the methane option):
O2 xx.x % Set xx.x %

Cmb y
CH4 z
Press ENTER to Span
4. Press Enter when the O2 reading on the far left of the first display line
stabilizes. The reading on the far right of the first display line shows the
setpoint value you entered using the Cal Gas Values menu option. This
setpoint value should match the cal gas cylinder value.
If your O2 reading on the far left of the display has stabilized, yet is not near the setpoint
value on the far right of the display, you should check the cal gas value you entered and
ensure that this value matches the cal gas cylinder for that gas in the RCU.
When performing a primary calibration or the first calibration after a

 primary calibration, the reading and the setpoint values often won’t
NOTE match. Once the first regular calibration after a primary calibration is
performed, the readings should match.
You are then prompted to calibrate the zero gases:

Cmb yyyy Set 0
CH4 zzzz Set 0
Press ENTER to Zero
5. Press Enter when the zero gas reading(s) on the left of the display stabi-
lizes. If you don’t have the combustibles option, you only need to wait until
the O2 zero gas value stabilizes. If you have the combustibles option, wait
until all readings stabilize. The reading on the far right of the first display
line shows the setpoint value you entered for the O2 zero gas using the Cal
Gas Values menu option. This O2 zero gas setpoint value should match
the cal gas cylinder for the O2 zero gas connected to your RCU.
Calibration | 5-7
If you have the combustibles option, you are also prompted to calibrate
the combustibles span gas:
O2 xx.x %
Cmb yyyy Set yyyy
CH4 zzzz Set zzzz
Press ENTER to Span
6. Press Enter when the combustibles span gas reading(s) stabilizes on

the far left of the display. If you have the methane option with RTD-type
combustibles detector, combustibles and methane are handled simultane-
ously using a single calibration gas. If you have the methane option with
the Hot-wire type combustibles detector, the combustibles and methane
are handled separately using two calibration gases.
Then, if you specified a recovery time, the system will display the recov-
ery time remaining:
Recovery xx:xx
System Calibrating
The system returns to monitoring process readings.
Manual Calibrate/Manual Verify

Verify the type of combustibles detector (Hot Wire or RTD type) in-
stalled on the unit before proceeding. Specific instructions are given
for the Hot Wire and the RTD type.
To perform a manual calibration or verification, follow these steps:
gases you intend to use to calibrate or verify your system.
2. Select Initiate Cal or Initiate Verify from the Calibrate key menu, de-
pending on whether you want to perform a calibration or verification.
3. Select Manual Calibrate or Manual Verify.

You are prompted to apply the O2 span gas to the calibration gas inlet port
on the sensor (tubing must be free of oil and dirt):
Inject Span Gas

ENTER to Continue
CANCEL to Abort

4. Press Enter when you have applied the calibration gas. The span display
appears (display line 2 will only appear if you have the combustibles op-
tion; display line 3 will only appear if you have the combined combustibles
and methane option):

Cmb y
CH4 z
Press ENTER to Span
5. Press Enter when the O2 reading on the far left of the first display line
stabilizes. The reading on the far right of the first display line shows the
setpoint value you entered using the Cal Gas Values menu option. This
setpoint value should match the cal gas cylinder for the O2 span gas.
If your O2 reading on the far left of the display has stabilized, yet is not near the setpoint
value on the right of the display, you should check the cal gas value you entered and
ensure that this value matches the cal gas cylinder for the gas you applied to the cal gas
inlet port of the sensor.
You are then prompted to apply the O2 zero gas to the calibration inlet
port of the sensor:
Inject Zero Gas

ENTER to Continue
CANCEL to Abort
6. Press Enter when you have applied this cal gas.
Separate instructions are given for Hot Wire-type and RTD-type

 combustibles detector. Verify the type of detector used on the sensor
NOTE and proceed accordingly.
Calibration | 5-9
Calibration: Hot Wire Type Combustibles Detector
If you have a Hot Wire-type detector, the zero gas display appears:

Cmb yyyy Set 0
CH4 zzzz Set 0
Press ENTER to Zero
Display line 2 will only appear if you have the combustibles option;
 display line 3 will only appear if you have the combined combustibles
NOTE and methane option.
lizes. The reading on the far right of the first display line shows the setpoint
value you entered for the O2 zero gas using the Cal Gas Values menu
option. This O2 zero gas setpoint value should match the cal gas cylinder
for the O2 zero gas.

You are also prompted to apply the combustibles span gas to the calibra-
tion gas inlet port of the sensor (tubing must be free of oil and dirt):
Inject Comb Span Gas

ENTER to Continue
CANCEL to Abort
2. Press Enter when you have applied this calibration gas. You are prompted
to calibrate the combustibles span gas.
If you are calibrating a WDG-IVCM analyzer with a Hot-wire type

catalytic detector, you must have a separate combustibles span and
methane span calibration gas - see the “Mechanical Installation” sec-
tion in Chapter 3 for recommended calibration gases.
O2 xx.x %
Cmb yyyy Set yyyy
CH4 zzzz Set zzzz
Press ENTER to Span Comb
3. Press Enter when the combustibles span gas reading(s) stabilizes on the
far left of the display.

If you have the methane option, you are also prompted to apply the
methane span gas to the calibration gas inlet port of the sensor (tubing
must be free of oil and dirt):
Inject Meth Span Gas

ENTER to Continue
CANCEL to Abort
4. Press Enter when you have applied your methane span gas. You are
prompted to calibrate the methane span gas.
O2 xx.x %\Cmb yyyy Set yyyy

CH4 zzzz Set zzzz
Press ENTER to Span Meth
5. Press Enter when the methane span gas reading stabilizes on the far left
of the display.
If you specified a recovery time, the system will display the recovery time
remaining:
Recovery xx:xx
System Calibrating
The system then returns to monitoring process readings.
Be sure to reinsert the 1/4” tube cap on the calibration inlet port on
 the sensor once you have completed the manual calibration. This pre-
NOTE vents air from getting into the sample gas line during normal opera-
tions.
Calibration | 5-11
Calibration with RTD Type Combustibles Detector
If you are calibrating a 3-in-1 sensor with the RTD combustibles de-
 tector, your combustibles span calibration gas must include methane.
NOTE
On RTD-type detector, the zero gas display then appears:

Cmb yyyy Set 0
CH4 zzzz Set 0
Press ENTER to Zero
Display line 2 will only appear if you have the combustibles option;
 display line 3 will only appear if you have the combined combustibles
NOTE and methane option.
lizes. The reading on the far right of the first display line shows the setpoint
value you entered for the O2 zero gas using the Cal Gas Values menu
option. This O2 zero gas setpoint value should match the cal gas cylinder
for the O2 zero gas.
If you have the Comb. & CH4 span gas option, you are also prompted
to apply the Comb. & CH4 span gas to the calibration gas inlet port of
the sensor (tubing must be free of oil and dirt):
Inject Comb Span Gas

ENTER to Continue
CANCEL to Abort
2. Press Enter when you have applied this calibration gas. You are prompted
to calibrate the Comb & CH4 span gas.
O2 xx.x %
Cmb yyyy Set yyyy
CH4 zzzz Set zzzz
Press ENTER to Span Comb
3. Press Enter when the Comb & CH4 span gas reading(s) stabilizes on the
far left of the display.

If you specified a recovery time, the system will display the recovery time
remaining:
Recovery xx:xx
System Calibrating
Be sure to reinsert the 1/4” tube cap on the calibration inlet port on
 the sensor once you have completed the manual calibration. This pre-
NOTE vents air from getting into the sample gas line during normal opera-
tions.
Calibration | 5-13
Cal/Verify Data
View the results of the latest calibration or verification. This includes the
following:
• O2 span calibration gas value vs. O2 span calibration gas reading

• Zero calibration gas value vs. zero calibration gas reading
• Span calibration gas drift
• Zero calibration gas drift
Span Gas and Zero Gas Refer to the calibration gas values entered
using the Cal Gas Values menu option. These
values are fixed.
Span Value or Zero Value Value the system reads from the cal gas.
Span Drift or Zero Drift Difference between the entered calibration gas
value and the calibration gas values read by
the system.
Both the latest calibration and verification data will be stored in

 memory.
NOTE
1. From the Calibrate key menu, select Cal/Verify Data.
2. Select Calibration Data or Verify Data, depending on whether you

want to see the latest calibration or verification results.
The display then shows the span gas calibration data:
Span Value: xx % O2
Span Gas: xx % O2
Span Drift: xx % O2
The term span value on the display is the value the system read during
the calibrate/verify operation, and the term span gas is the setpoint value
entered using the Cal Gas Values option from the Calibrate key menu.
3. Press Enter to then view the zero gas values.
The following then appears on the display:
Zero Value: xx % O2
Zero Gas: xx % O2
Zero Drift: xx % O2

The term zero value on the display is the value the system read during
the calibrate/verify operation, and the term zero gas is the setpoint value
entered using the Cal Gas Values option from the Calibrate key menu.
4. Press Enter.
The time when the calibration or verification was completed will then ap-
pear on the display:
End time hr:mm

End date mm/dd/yr
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.
Calibration | 5-15
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.
• O2 span gas - high calibration gas
• Zero gas - low calibration gas
• Combustibles span gas (optional)
• Methane span gas (optional)
The O2 span gas value you enter must be higher than the O2 zero gas
 value.
NOTE
1. From the Calibrate key menu, select Cal Gas Value.
You are prompted to enter the span gas value:
Span Gas = xx.xx% O2

New Value?
2. Enter the span gas value, then press Enter. You can also include a
decimal point (for example, 20.9% O2 ). If you want to keep the current
span gas value unchanged, press Enter without entering a value.
You are prompted to enter the zero gas value:
Zero Gas = xx.xx% O2

New Value?
3. Enter the zero gas value, then press Enter. You can enter up to two
decimal points (for example, 2.00% O2 ). If you want to keep the cur-
rent zero gas value unchanged, press Enter without entering a value.
Combustibles Option
If you have the combustibles option, you are then prompted to enter
the combustibles span gas value:
Comb Span = xxxx YY

New Value?

4. Enter the combustibles span gas value, then press Enter. If you want
to keep the current combustibles span gas value unchanged, press
Enter without entering a value.
5. If you have a 3-in-1 analyzer (includes methane), you will also be

prompted to enter the methane span gas value:
Meth Span = x.xx%

New Value?
6. Enter the methane span gas value, then press the Enter key. If you
want to keep the current methane span gas value unchanged, press
the Enter key without changing the value.
Calibration | 5-17
Inject Cal Gas
Manually adjust the pressure and flow of your calibration gases (pressure
of calibration gas cylinders and flow into sensor) by cycling through the
solenoid valves on the RCU. No calibration or verification data is collected
while in this menu option. See the “Mechanical Installation” section in
Chapter 2 for recommended calibration gas pressure and flow require-
ments.
This menu option requires that an auto cal card and RCU are in-
 stalled.
NOTE
1. Connect the span and zero gas cylinders to the RCU.
2. From the Calibrate key menu, select the Inject Cal Gas menu option.
The following message will appear on your display, indicating that the
RCU has introduced the span gas to the sensor:
Span gas is flowing
You will be prompted to press Enter when you have manually set the
pressure and flow for the span gas:
ENTER for next Gas.

CANCEL to quit.
3. When you have adjusted the pressure and flow for the span gas to the
desired levels, press Enter.
RCU has now switched the solenoid valves and has introduced the zero
gas to the sensor:
Zero gas is flowing
4. Adjust the pressure and flow for the zero gas to the desired levels. If
you don’t have the combustibles option, press the Cancel key to end
the cycle.
CANCEL to quit
ery time remaining:
Recovery xx:xx

Combustibles and Methane Option
If you have the combustibles option, you will be prompted to press Enter
when you have set the pressure and flow for the zero gas:
ENTER for next Gas.

CANCEL to quit.
5. When you have adjusted the pressure and flow for the zero gas to the
RCU has introduced the combustibles span gas to the sensor:
Comb gas is flowing
Once you have set the pressure and flow for the span gas, the system
prompts you to press the Cancel key to end the cycle:
CANCEL to quit
If you have the methane option, you will be prompted to press Enter
when you have set the pressure and flow for the zero gas:
ENTER for next Gas.

CANCEL to quit.
6. When you have adjusted the pressure and flow for the zero gas to the
RCU has introduced the combustibles span gas to the sensor:
Methane gas is flowing
Once you have set the pressure and flow for the span gas, the system
prompts you to press the Cancel key to end the cycle:
CANCEL to quit
7. Press the Cancel key to end the cycle.
ery time remaining:
Recovery xx:xx
Calibration | 5-19
Set 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.
Set Time and Date Set the current time and date.
Auto Cal On/Off Enable or disable the auto calibration cycle.
Cal Gas Duration Define how long cal gases should flow through the sen-
sor during automatic calibrations or verifications.
Recovery Duration Define a recovery duration during which time the sensor
switches from measuring calibration gas readings to
measuring process readings without affecting the ana-
log output or triggering of alarms.

Set Cal Timers - Set Auto Timers
Set the frequencies for automatic calibrations or verifications, including
the time when the first calibration or verification should begin. You have
the option of setting the cycle in either hours or days.
If you schedule a verification and calibration at the same time, the

 verification will be performed first.
NOTE
1. From the Set Cal Timers menu, select Set Auto Timers.
2. Select Auto Cal Cycle if defining an automatic calibration cycle. Select

Auto Verify Cycle if defining an automatic verification cycle.
3. Select Set Cycle in DAYS or Set Cycle in HOURS, depending on

whether you want to set the frequency of calibrations or verifications
in days or hours.
If you are setting the auto timers for the first time, the Series 2000
 software will automatically prompt you to enter the current time and
NOTE date.
You will be prompted to enter the frequency for the calibration or verifica-
tion cycle (either in days or hours, depending on what you selected:
Cal Cycle = 01 days

New Value = xx
4. Enter the number of days (or hours) for the automatic calibration or
verify cycle. As you enter the values, they overwrite the XXs on the
display. To enter 1 day or 1 hour, enter 01; otherwise, the system will
assume you are entering 10 days (or hours).
You will be prompted to enter the time of day when the first calibra-
tion of the cycle should begin:
Cal time is YY:YY

Enter new time Hr:Mn
5. Enter the time you want the first calibration or verification to begin,
then press Enter. The system uses military time, so to enter 4:00 p.m.,
you would type 16:00. If, for example, you set the cycle frequency at
8 hours, and specify the first calibration to take place at 4:00 p.m., the
next automatic calibration or verification will take place at midnight.
Calibration | 5-21
Set Cal Timers - Set Time and Date
Set the date or time for the internal control unit clock.
Make sure the current time and date are correct before setting any
 auto cal/auto verify parameters.
NOTE
1. From the Set Cal Timers menu, select Set Time & Date.
You are prompted to enter the new time:
The time is: YY:YY

Enter new time Hr:Mn
2. Enter the new time, then press Enter. As you type the new time, it
overwrites the Hr: Mn text. The Series 2000 control unit uses military
time so 16:00 equals 4:00 p.m., and 04:00 equals 4:00 a.m. If the current
time is correct, press Enter without changing the value.
You are then prompted to enter the correct date:
The date is: YY/XX/ZZ

Enter date: Mo/Da/Yr
3. As you type the new date, it overwrites the mo/da/yr text on the
display. Enter the month, the day, the year, then press Enter. If the
current date is correct, press Enter without changing the value.
Set Cal Timers - Auto Cal On/Off

Disable or re-enable the auto calibration or auto-verification cycle. If you
know your process will be down for an extended period of time, you may
want to temporarily disable the automatic calibration or verification cycle.
When the process is back on-line, you can re-enable the auto calibration or
verification cycle and retain all your timer settings.
1. From the Set Cal Timers menu, select Auto Cal On/Off.
2. Select Auto Cal On/Off or select Auto Verify On/Off, depending on

whether you want to enable or disable the auto verify or auto calibrate
cycle.
3. 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.

The system will confirm your enabling or disabling selection:
Auto Cal is ENABLED

or
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. You can
also set a calibration gas duration time to 0 if you don’t want to include it
in your automatic calibration sequence.
To find out how long it takes for your calibration gases to reach the sen-
sor and stabilize, select the Inject Cal Gas menu option and time the gas
stabilization period. Then use this time frame as your calibration gas dura-
tion (we suggest that you also add a buffer to this time frame to be certain
that the gas has stabilized).
1. From the Set Cal Timers menu option, select Cal Gas Duration.
You will be prompted to enter the new span gas duration time:
O2 Span Time = xx:yy

Enter new time: Mn:Sc
2. Enter the new span gas duration time, then press Enter. Mn equals
minutes and Sc = seconds. As you type the new span gas duration
time, it overwrites the Mn:Sc text. If you want to use the currently
displayed time, press Enter without entering a new value.
At this point, you will be prompted to enter the zero gas duration time:
O2 Zero Time = xx:yy

3. Enter the new zero gas duration time, then press Enter. Mn equals
minutes and Sc = seconds. As you type the new zero gas duration
time, it overwrites the Mn:Sc text. If you want to use the currently
displayed time, press Enter without entering a new value.
Calibration | 5-23
Combustibles and Methane Options
You will be prompted to enter the new combustibles span gas duration time:
Comb Span Time = xx:yy

Enter the new combustibles span gas duration time, then press Enter. You
can set this calibration gas time to 0 if you don’t want to include it in your
automatic calibration sequence. If you want to use the currently displayed
time, press Enter without entering a new value.
You will be prompted to enter the new methane span gas duration time:
Meth Span Time = xx:yy

Enter the new methane span gas duration time, then press Enter. You
can set this methane gas time to 0 if you don’t want to include it in your
automatic calibration sequence. If you want to use the currently displayed
time, press Enter without entering a new value.
Set Cal Timers - Recovery Duration

Define a recovery time so the control unit can return to reading process
gases after reading calibration gases without affecting the analog outputs
or the triggering of alarms.
This menu option also can be used to prevent triggering of alarms if, for
example, your low alarm is set to activate if readings fall below 3%, and
your calibration gas is 2%.
This menu option applies to all automatic, remote, and manual cali-
 brations and verifications.
NOTE
1. From the Set Cal Timers menu, select Recovery Duration.
You will be prompted to enter a calibration recovery duration:
Cal recovery = xx:yy

2. 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.

Set K-Factors
This menu option is not used on the WDG IV Series 2000. The de-
 fault factor is always set to 1.00.
NOTE
Sensitivity
Select this option to display the Sensitivity (slope).
Calibration | 5-25

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. Also, always use gloves when working on the sensor.
This chapter describes Series 2000 control unit system and error messages.
It also provides troubleshooting assistance. System and error messages
appear on the fourth line of the display at three second intervals until the
condition is corrected or has ended. If there is more than one message, the
messages will alternate on the display at three second intervals. These sys-
tem and error messages are listed in this chapter alphabetically to make
them easier to locate.
System or error messages will not appear on the display when you are
 using the control unit keys to access menu functions.
NOTE
Maintenance and Troubleshooting | 6-1

System Messages
Message Explanation
Indicates that an automatic calibration is pending. Once the current
calibration or verification is complete, the automatic calibration will
Auto Cal Pending
begin. This message will only appear if the Auto Calibration option
is installed and enabled.
Indicates that an automatic verification is pending. Once the current

calibration or verification is complete, the automatic verification will
Auto Verify Pending
begin. This message will only appear if the Auto Calibration option
is installed and enabled.
Indicates that the calibration has been aborted by the user, or the
Calibration Aborted calibration failed because the span gas or zero gas was out of
range.
Once you complete a primary calibration, this message is displayed

to inform you that a regular calibration is required (after a primary
calibration is performed, you must always then perform a regular
Calibration Required
calibration). This message will not clear from the display by remov-
ing and restoring power to the control unit. If you see this message,
select the Calibrate key and perform a calibration.
The verification was successfully aborted by the system at your

Cal Verify Aborted
request.
The system detected that power was removed, such as from a

power outage. Acknowledge this system message by setting or
Power Down Detected reading any user-programmable value. This will clear the message
from the display. This message will not clear by removing and restor-
ing power to the unit.
Appears when the system is performing a Primary Calibration (see

the Setup key for further information on primary calibration). The
Primary Calibration
message continues to be displayed during the recovery period after
the primary calibration.
Indicates that a system calibration is in progress. It will appear

System Calibrating during the entire automatic calibration cycle or during the recovery
period of a remote or manual calibration.
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.

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. Note that you should always perform the
easiest checks first. Only perform the more difficult checks if the easiest
checks don’t locate the problem.
Message Explanation
Cell is Over Temp Indicates that the sensor temperature is 30°C or more over its cor-
rect operating temperature. The software shuts off the furnace until
the temperature returns to a normal operating range.
If this message soon goes away, it indicates that the temperature
has returned to an acceptable range. If there is a problem with the
sensor temperature control system, you will see another error mes-
sage after this message appears.
Combustibles Cal Error Indicates that the combustibles detector calibration failed because
of an abnormally low signal. Once this error occurs, calibration of
the system is aborted. This message indicates a problem either with
your calibration setup or the combustibles detector.
Excessive Cal Error If a primary calibration cannot correct the sensor temperature within
the software’s allowable limits, this message displays to indicate the
primary calibration has failed. This message could indicate one of
the following problems:
• Calibration gas setup problem
• Process pressure incorrectly entered
• Failed cell
• Leak or plug in plumbing
Memory is Corrupted Indicates that the control unit’s internal EEPROM memory has
been corrupted, or a significantly new version of software has been
installed in the control unit. Under these conditions, the software will
reprogram the EEPROM with the factory default values. You can
acknowledge this error message by setting or reading any user pro-
grammable value, and this will clear the message from the display.
This message will not clear by removing and restoring power to the
unit.
If you receive this message, you should reset your control unit to
the values required for your application, including Setup key param-
eters, Calibrate key parameters, etc...
Methane Cal Error Indicates that the methane detector calibration failed because of
an abnormally low signal. Once this error occurs, calibration of the
system is aborted. This message indicates a problem either with
your calibration setup or the methane detector.

Span Gas Range Error Occurs if the calibration span gas does not read within the soft-
ware’s allowable limits. Once this error occurs, calibration of the
system is aborted.
This message could indicate one of the following problems:
• Process pressure incorrectly entered
• Aspirator air not turned off during calibration (WDG-IV only)
• Failed cell
• Cell wiring reversed (Cell + and Cell - wires)
• Leak in plumbing
• Plugged plumbing
Temp Rise Failure Indicates that the sensor has failed to increase in temperature a
minimum of 10°C in a 60-second time frame during start-up. Once
the system reaches the operating set point, this message will only
occur if the sensor falls below the set point by 15°C and fails to
recover within 60 seconds. The problems that can cause this error
are as follows:
• AC line power problem at the sensor
• Open furnace
• Over-temperature protection circuit trip on the sensor board
• Sensor board failure
• Loss of furnace drive signal
• Interconnecting wiring problem
T/C (Thermocouple) This message appears when the control unit recognizes a sudden
Circuit Failure drop in temperature (greater than 100 °C). The thermocouple circuit
failure message can be the result of one of the following problems:
• Shorted thermocouple
• Faulty interconnecting wiring
• Control unit display module failure
• Sensor board failure
If this message is soon followed by a “Thermocouple Failure” message, see that message for
troubleshooting instructions.
Thermocouple Failure This error message occurs when the indicated sensor temperature
falls below -70°C. This error message can be the result of one of
the following:
• Open thermocouple
• Faulty interconnecting wiring
• Control unit display module failure
Zero Gas Range Error Occurs if the calibration zero gas does not read within the software’s
allowable limits. Once this error occurs, calibration of the system is
aborted. This error indicates one of the following problems:
• Process pressure incorrectly entered.
• Cell wiring reversed (Cell + and Cell - wires)
• Aspirator air not turned off during calibration (WDG-IV only)
• Failed cell (primary calibration should be run at this time)
• Leak or plug in plumbing

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” section that follows. We recom-
mend that the thermocouple millivolts and cell millivolts be displayed
during troubleshooting as a troubleshooting aid (see the “Display” section
in Chapter 4 for help on how to display these items). This information will
be helpful should you need to contact the factory for assistance. Be sure to
always include your analyzer model and serial number when calling the
factory for technical support.
Diagnostic checks are broken down as follows:
 Wiring Checks
 Thermocouple Checks
 Calibration/Aspirator Setup Checks
 AC Power Checks
 Furnace Checks
 Process Pressure Checks
 Cell Checks
Exercise care when working on the sensor. Turn off power, allow the
unit to cool, and wear gloves.

Wiring Checks
Make sure all wiring connections between the control unit
and the sensor are terminated to the proper locations and
Interconnecting Wiring Problem are seated properly. This includes ensuring that sets of
wires are not reversed, and that the cable is not damaged
or melted.
Open thermocouple
Remove power to the control unit and the sensor. Measure
Thermocouple Checks across terminals “C” and “D” on the sensor board with an
ohm meter. If an open is measured, replace the thermo-
couple.
Check that the thermocouple leads are not shorted to

chassis ground by using an Ohm meter to measure be-
tween terminal C on the sensor board and chassis ground,
and between terminal D on the sensor board and chassis
ground. If shorted, replace the thermocouple.
To verify that the interconnecting cable for the thermocou-
ple is not shorted together, remove the thermocouple wires
Shorted/Failed Thermocouple from terminals C and D on the sensor board and measure
across terminals 5 and 6 on the sensor board. If shorted,
correct the interconnecting problem.
To verify the operation of the thermocouple itself, remove
the thermocouple from the sensor and heat its ceramic tip
to a known temperature. Measure the millivolt output with
a proper temperature indicating meter (type K thermocou-
ple). If the thermocouple reads inaccurately, replace it.
First, have one of the control unit display lines show the
sensor cell temperature. If the thermocouple leads are
reversed, the displayed temperature will be decreasing as
the sensor warms up (this will usually happen at start-up
Reversed Thermocouple Wires or after you replace a thermocouple). This indicates that
the thermocouple wiring is reversed. If you just replaced a
thermocouple, check the leads from the thermocouple to
the sensor board: yellow wire connects to terminal C (+),
red wire connects to terminal D (-).
Using a volt meter, measure across terminals 2 (-) and 12

(+) on the sensor board. If approximately 15 volts is not
present, check that interconnecting wiring is correct. If in-
terconnecting wiring is correct, check across 15V Sup and
Thermocouple Compensation 15V Com on the control unit for approximately 15 volts. If
15 volts is not present, check fuse F1 on the wiring card.
Circuit Check
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.

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). The circuit
compensates to absolute zero (0°K) so 273°C is 11 mV
and 25°C board temperature is 1 mV that results in the 12
mVs added from the compensation circuit.
If you don’t measure this voltage, replace the sensor
board.
For a furnace temperature set point for a 615°C oxygen
cell temperature, the furnace thermocouple output would
be about 27 mVs (take memory location 88 which is the
T/C Ratio calculated during the primary - thermal calibra-
tion and divide the cell temperature by this value to come
up with the furnace temperature set point).
The cell thermocouple compensation circuit on the 80471SE,

 80485SE, 80467SE and 80505SE sensor boards is different in
comparison to the 80418SE sensor board that was supplied with
NOTE
Series 2000 based systems prior to 1996 (CE Marked Systems).
Sensor Board The 80418SE used the 40.2-ohm resistor on the display
80418SE (prior to 1996) module to sense the current sourced from the AD592. The
CE Marked Systems compensation current produces a voltage drop across the
resistor on the display module and then adds this voltage
to the raw T/C mVs sensed at the T/C + and - connections
at the wiring board and at the sensor board.
Sensor Boards The change was implemented on later sensor board
80471SE 80467SE designs (80471SE, 80485SE, 80467SE and 80505SE)
80485SE 80505SE due to the confusion caused by seeing a display that was
approximately 12 mVs higher than the voltage measured
at the terminals on the wiring board.

Calibration/Aspirator Setup Checks
Calibration Gas Check
To check calibration gas  Check that the correct calibration gas values have been en-
values: tered into the control unit.
Select the Cal Gas Value  Check that the calibration gas cylinders are turned on and are
menu option from the Cali- not empty.
brate key on the control unit Check for the proper flow rate and proper delivery pressure
and check that the calibra- 
of calibration gases when the remote calibration unit has
tion gas values entered been activated (see the Inject Cal Gas menu option from the
match the analyzed concen- Calibrate key chapter for help).
tration of the cylinders.
Calibration Line Check Ensure that your calibration line is not contaminated with such
things as pipe dope, cutting fluid, oil, or solvents. All these
The best calibration gas to contaminants produce hydrocarbon vapors that interfere with
use for this check is an O2 the proper calibration of your analyzer, resulting in lower than
zero calibration gas. expected oxygen readings. To test for contaminated lines, you
must temporarily bypass your current calibration line with a clean
calibration line (directly from cylinder to the sensor calibration
inlet port, using a flow meter to set the proper flow) and compare
the response with that from the possibly contaminated line.
Aspirator Not Turned OFF WDG-IV only
during Calibration
Verify that the aspirator air is turned off during calibration (man-
 ual or through the RCU). If the problem is with the RCU, refer to
NOTE
the next section, “Remote Calibration Unit Problem.”
Remote Calibration Unit The RCU contains one normally open solenoid-the aspirator air
(RCU) Problem solenoid. All other solenoids are normally closed. Problems with
the RCU are usually as follows:
Plumbing Leak To check for plumbing leaks, disconnect power from the RCU
and pressurize the inlets. Apply a leak detecting liquid along
the base of the solenoids and any plumbing fittings. Repair any
leaks found.
Solenoid Not The solenoid drive signal is a 12 VDC signal. This is used to
Energizing close the aspirator solenoid and open the appropriate calibra-
tion gas solenoid. To test a solenoid valve, select Inject Cal Gas
from the Calibrate key menu to energize that solenoid. Verify
that the solenoid drive signal is present. The aspirator air sole-
noid is closed when the drive signal is applied. Other solenoids
are open when the drive signal is applied (cal gas flowing). With
the drive signal present, verify the proper flow. If no signal is
present, check the interconnecting wiring between the control
unit and the RCU.
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.

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. This identifies the
defective solenoid valve (replace the solenoid valve, being sure
that the solenoid O-ring seals are properly positioned).
Calibration Gas If you are having problems running an auto calibration, you
Time Inadequate
If performing a manual calibration, ensure that you are waiting for the
 reading to stabilize on the display before switching to the next calibra-
tion gas. You should wait a minimum of two minutes.
NOTE
AC Power Checks
Loss/Inadequate AC Voltage Measure the AC voltage to the sensor board at terminals L1
to the Sensor and L2. Ensure that this voltage is sufficient. Check the mea-
surement technique used by the Volt meter (for example, RMS,
average, peak, etc.). Specifications are based on RMS mea-
surements.
Furnace Checks
Open Furnace Disconnect power to the control unit and the sensor. With Ohm
meter, measure across Terminals “R” and “S” on the sensor
board. The resistance of the furnace should be:
32 ohms (±10%)
If the furnace resistance is not within allowable tolerances,
replace the furnace.
Loss of AC Power Verify the correct line voltage at L1 and L2 of the sensor board.
to the Furnace
With line voltage present, check the voltage at terminals R and
S on the sensor board. If voltage is present and the system is
not heating, remove power and check the furnace resistance
(see “Furnace Checks” section). If no voltage is present at ter-
minals R and S on the sensor board, check for the DC furnace
drive signal at terminals 3 (+) and 4 (-) at the sensor board.
The furnace drive is a 15 VDC pulse train, and depending on
the frequency of the pulse train, the measured voltage will be
between 5 and 15 VDC. If this furnace drive signal is present,
reset the power to the control unit and see if this solves the
problem. If this doesn’t solve the problem, replace the sensor
board.
If the furnace drive signal is Check the interconnecting wiring. If the interconnecting wiring is
not present: correct, check across FURNACE and 15V COM on the control
unit wiring card for the furnace drive signal. If the signal is not
present, check fuse F1 on the wiring card. If this fuse is OK, re-
place the control unit power supply/keypad module. If this fuse
is not OK, replace the fuse (1/4 amp, 125 volts, IEC speed type
FF). Check the interconnecting wiring for short circuits before
applying power to the control unit.

Process Pressure Checks
To check that you entered the process pressure correctly, select Process Pressure from the
Setup key. Also ensure that the calibration process pressure equals normal operating process
pressure. Calibration should only be performed under these conditions for highest accuracy.
Cell Checks
It is likely that there is a leak in the sensor plumbing
or an improper calibration gas setup, and there is not
a problem with the cell itself (see the “Leak Check”
If the cell fails when you first begin
section later in this chapter for help on how to check
to use the analyzer:
for leaks; see the “Calibration/Aspirator Air Checks”
section earlier in this chapter for help on checking
your calibration gas setup).
First check by running a known calibration gas to veri-

If the analyzer has been operating
fy the analyzer’s response. If the analyzer responds to
for some time and you feel the oxy-
the calibration gas correctly, it indicates either leaking
gen reading is inaccurate:
or plugged plumbing.
This may indicate a problem with the cell. Before

replacing the cell, put the analyzer through a primary
If your analyzer doesn’t respond
calibration and see if this improves the response of
properly to the calibration gas:
the analyzer. 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.

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.
• Check that all compression fitting and pipe thread connections are
leak tight.
• Be sure that the mounting plate or mounting flange gasket on the rear
of the sensor is in place (see the “Sensor Mounting” section in Chapter
2 for details on the placement of the gasket).
Sniffing for Leaks
For processes under vacuum you can check for leaks by sniffing the fit-
tings with another gas (for example, nitrogen or pure oxygen), being sure
to avoid the area over the top of the cell.
1. Use a piece of tygon or plastic tubing with a 1/8” stainless steel nozzle
to apply the gas from a cylinder (using stainless steel prevents any
problems that might occur with plastic melting the nozzle on hot sen-
sor components).
2. Monitor the response from the cell. When the cell millivolt reading
changes, it indicates a leak in that area of the plumbing (the vacuum
of the process pulls in the gas).
3. If not convenient to view the control unit display, you can also apply a
volt meter to terminals 1 and 2 on the sensor board (Cell + and Cell -)
to see if the cell millivolts change, indicating a leak.
Pressurizing for Leaks
1. Remove the sensor from the process (after allowing sensor to cool)
and pressurize it with 5 lbs. of air, plugging any exiting ports, the inlet
probe, and exhaust tube holes. Then go over the sensor fittings with a
leak detector fluid.

2. If you see bubbles, it indicates a leak. If using this method be sure to
prevent the liquid from reaching the furnace. If the furnace does get
wet, allow it sufficient time to thoroughly dry.
The WDG-IV style sensor has intentional leaks in the aspirator air
 inlet fitting and the screw in the back of the aspirator block. If you are
NOTE having problems and your process is under positive pressure, these
intentional leaks will need to be sealed.
Plugged Plumbing Check

Exercise care when working on the sensor. Allow the unit to cool and
wear gloves.
This check does not apply to Insitu users.
1. Examine the inlet and exhaust for plugging problems. When possible,
rod out the probe and exhaust.
2. If this doesn’t solve the problem, disassemble the analyzer to locate

the plug. Clean the plumbing using hot water and a bottle brush.
3. When assembly is complete, check for leaks using a leak detecting

liquid.
Aspirator Air Not Pulling Sample from Process

This check only applies for WDG-IV users.
1. To check the aspirator vacuum level, remove the inlet hook and turn
off the aspirator air.
2. Attach a vacuum gauge to the aspirator inlet and apply aspirator air.
The aspirator should pull 2 to 3 inches WC at 5 psig. If the aspirator
doesn’t pull a vacuum, disassemble sensor plumbing and clean the
nozzle and venturi in the back of the aspirator.
You will need a new metal O-ring when installing the venturi.

Series 2000 LEDs
This section describes how to interpret information on the LEDs in the
Series 2000 controller auto calibration card and combustibles card.
Auto Calibration Card LEDs

All auto calibration card LEDs denote that the Series 2000 has sent out a
15-volt signal to the RCU to activate the appropriate solenoid. LEDs are
clearly labeled on the auto calibration card - 1 is on the far right of the
card as you look at it.
LED Process When Lit:

1 In Calibration System is in calibration. This LED remains on for
the entire calibration cycle, then turns off during
the calibration recovery time.
2 O2 span O2 span gas solenoid is energized and the O2
span gas should be flowing into the sensor.
3 O2 Zero O2 zero gas solenoid is energized and the zero
gas should be flowing through the sensor.
4 Combustibles Span Combustibles span gas solenoid is energized
and the combustibles span gas should be flow-
ing into the sensor.
5 through 12 - Not used
Combustibles Card LEDs

Combustibles alarm relays are labeled on the wiring card and in soft-
 ware as Alarms 5 & 6. LED number 1 is on the far right of the card as
NOTE you look at it; LED number 2 is to the left of LED 1. All LEDs denote
an Alarm relay is energized (contact closed).
LED Alarm When Lit:

1 Combustibles 1 Combustibles Alarm #1 relay is energized (contact closed).
This corresponds to Alarm 5 in software.
This corresponds to Alarm 6 in software.

Combustibles and Methane Card LEDs
Alarm relays for combustibles are labeled on the wiring card and in
 software as Alarm 5 & 6 and for methane they are labeled Alarm 7
NOTE & 8. LEDs are clearly labeled on the combustibles and methane card.
1 is on the far right of the card as you look at it. All LEDs denote an
Alarm relay is energized (contact closed).
LED Alarm When Lit:

Corresponds to Alarm 5 in software.
3 Methane 1 Methane Alarm #1 relay is energized (contact closed).
4 Methane 2 Methane Alarm #2 relay is energized (contact closed).
Sensor Board (80471SE) LEDs

Two diagnostic LED indicators are on the sensor board. DS1 is located
near the relay on the board and DS2 is located near the end of the num-
bered terminal strip.
LED STATUS FUNCTION

INDICATOR
DS1 Oxygen cell furnace over-temperature shutdown circuit status
GREEN Furnace is operating normally
OFF Over temperature shut-down has been activated
OFF No 15 Volt DC power provided to sensor board from
control unit
DS2 Sensor enclosure internal temperature monitor
OFF Oxygen-only system (no RTD and SW1) all position
to “ON”
Blinking GREEN Sensor enclosure not at setpoint temperature
GREEN Sensor enclosure over temperature
Blinking Green & Sensopr enclosure over temperature
Blinking RED
Blinking Red Switch setup invalid
RED Sensor Temperature RTD circuit error (RTD open or
shorted)
YELLOW Indeterminate error

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 WDG sys-
tem.
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 one hour.
This chapter is divided into the following sections:
• Cell Replacement
• Thermocouple Replacement
• Furnace Replacement
• Combustibles Detector Replacement (optional)
• Box Heater Wiring
• RCU (Remote Calibration Unit) Solenoid Valve Replacement
• Replacement Parts List
See the Installation chapter for help on how to remove or replace Series
2000 control unit modules or option cards.
You can clean the outside of the sensor or controller (or Remote Calibra-
tion Unit) using normal household or commercial general purpose clean-
ers, cloths, or sponges. You can also use water. Always turn off power
before attempting to clean the enclosure.
A wiring diagram for a standard sensor is provided in Figure 7-1. This

figure shows the locations of all wiring connections on the sensor. If your
sensor requires different wiring, this is provided in an appendix.
Service and Parts | 7-1

Warnings
• If you turn off the analyzer or the process is shut down, turn off the
aspirator air to avoid plugging problems.
• The outside of the sensor cover and all sensor assembly components
are extremely hot (up to 500°F (260°C) inside the cover), even after a
considerable period from shutdown. Turn off the power to the sen-
sor and control unit when working inside the sensor. Use caution and
wear appropriate gloves when handling components.
• Be extremely careful when performing maintenance on the sensor

while the process is running, especially if the process is under signifi-
cant positive pressure. Removing any part of the sensor plumbing can
allow process gases and gases of high temperature to escape into the
sensor.
Cautions
• Always use a backup wrench when working on sensor plumbing. This

helps to prevent damaging welds and distorting sensor plumbing.
• Never use pipe dope or any other contaminant that gives off combus-
tible vapor on any joints of the sample tubing. Combustible vapor in
the sample tubing can lead to erroneous readings.

Figure 7-1. Wiring diagram for standard sensor.

Cell Replacement/Cleaning
Disconnect power from the sensor and control unit and allow the sen-
sor to cool before replacing parts inside the sensor.
Use Figure 7-2:
1. Remove the sensor cover to expose sensor components.
2. Remove the cell clips.
3. While holding the top of the cell housing with a backup wrench,
loosen the lower hex nut (not the top hex nut), then remove the entire
cell assembly.
Loosening the cell may require a good deal of torque.


NOTE
4. If cleaning the cell, wash with water or alcohol. Dry the cell thoroughly
before reinstalling. Always use a new cell O-ring.
If replacing the cell, discard the old cell and cell O-ring and retrieve
the new cell with supplied cell O-ring. Avoid touching the bare cell.
Instead, hold the cell by one of its hex nuts.
5. Place the cell O-ring on top of the cell housing as shown in Figure 7-2.
6. Insert the new cell into the cell housing. Do not touch the bare cell
when reinserting. Tighten the cell into the cell housing using the low-
er hex nut (the upper hex nut is pre-tightened at the factory). The cell
O-ring provides a seal for the system. Make sure it is evenly crushed
when tightening the cell.
Before performing a primary calibration, first connect power to the

 sensor and allow it to heat up and stabilize (approximately one hour).
NOTE
7. Perform a primary calibration if you replaced the cell.

Figure 7-2. Cell replacement.

Thermocouple Replacement
The tip of the thermocouple is positioned in the furnace so that it is

 near, but not touching, the cell housing or the furnace heater coil.
NOTE
Use Figure 7-3:
1. Remove the sensor cover to expose sensor components.
2. Disconnect thermocouple wires from terminals C and D on the sensor

board.
3. Remove the screw from the thermocouple mounting tab (save the
screw for installing the new thermocouple).
4. Pull the thermocouple straight up and remove it from the furnace.
5. Insert the new thermocouple into the slot in the top of the furnace.
It should go in freely; if necessary, wiggle a little to position without
forcing it in. The thermocouple should be near, but not touching, the cell
housing or furnace heater coil.
6. Put the screw back into the thermocouple mounting clamp. This se-
cures the thermocouple to the furnace
7. Attach the thermocouple wires to terminals C and D on the sensor

board, observing polarity (yellow wire to terminal C, red wire to ter-
minal D).
8. Disconnect the furnace wires from sensor board terminals R and S.

Using an Ohm meter, check for short circuits of the heater coil to the
metal thermocouple sheath. Check that neither furnace lead is short
circuited to the metal furnace cover. The resistance should be infinite.
If you measure a short circuit, loosen the screw that secures the ther-
mocouple and relocate slightly until resistance is infinite.
Before performing a primary calibration, first connect power to the

 sensor and allow it to heat up and stabilize (approximately one hour).
NOTE
9. Perform a primary calibration.

TOP VIEW - FURNACE
1 Cell housing
2 Thermocouple mounting tab
3 Thermocouple
4 Convection loop mounting clamp
5 Compression fitting
Figure 7-3. Thermocouple replacement.

Furnace Replacement
Disconnect power from the sensor and control unit and allow unit to
cool before replacing parts inside the sensor.
Use Figure 7-4:
1. Disconnect cell clips.
2. Remove the thermocouple from the furnace (see the “Thermocouple

Replacement” section in this chapter for help).
3. Disconnect the furnace leads from terminals R and S on the sensor

board.
4. Loosen the compression fitting on the underside of the cell housing

and the union fitting on the convection loop return. To prevent strip-
ping threads on any of the fittings, we suggest that you loosen each in
turn at small increments - don’t completely loosen the one fitting and
then try to loosen the other fitting.
5. While holding the furnace in one hand, remove the convection loop
mounting clamp. Be sure to save the mounting clamp for when you
install the new furnace.
6. Gently pull the cell housing out of the furnace and remove the fur-
nace.
7. Slip the new furnace onto the cell housing and attach the cell housing
using the convection loop mounting clamp.
8. Remount the cell housing (reverse the actions taken in Step 4).
9. Reinstall the thermocouple (reverse the actions taken in Step 2).
10. Using an Ohm meter, check for short circuits of the heater coil to the
metal thermocouple sheath. Check that neither furnace lead is short
circuited to the metal furnace cover. The resistance should be infinite.
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).

CONVECTION LOOP
CELL ASSEMBLY MOUNTING CLAMP
CELL HOUSING
FURNACE
UNION FITTING
COMPRESSION FITTING
Figure 7-4. Furnace replacement.

Combustibles Detector Replacement
 Always use a backup wrench when working on sensor plumbing.

NOTE
Hot-Wire Combustibles Detector Replacement

Use Figure 7-5:
1. WDG-IVC
Remove the detector leads from terminal strips E, F, H, and I on the
sensor board.
WDG-IVCM
Remove the detector leads from terminal strips W, X, Y, and Z.
2. Loosen the compression fitting nut that holds the combustible detector
in place and remove the detector from its housing. Save the nut from
the detector to use when installing the new combustibles detector.
3. It is very important to orient the new combustibles detector correctly

inside the combustibles detector block (sample flow path must contact
both detector leads at the same time).
Place a mark on the edge of the combustibles detector at the 12 o’clock

position after you have determined the correct orientation (Figure
7-5). Place detector elements in detector block vertically.
4. Install the new combustibles detector with nut and ferrules. Be ex-
tremely careful not to damage the detector elements when installing.
Ensure that the mark you made in Step 3 is in the 12 o’clock position
to ensure proper orientation of the combustibles detector in the com-
bustibles detector block.
5. Reconnect the detector leads to the sensor board.
The active element wires are labeled “A” and “AC”.

WDG-IVC Connect to terminals E and F on the sensor board.
Polarity not required.
WDG-IVCM Connect to terminals W and X.
The reference element wires are labeled “R” and “RC”
WDG-IVC Connect to terminals H and I on the sensor board.
Polarity not required.
WDG-IVCM Connect to Y and Z

Side View
Furnace assembly
Ferrule
Detector head
Combustibles
Detector
Block
Compression
Fitting
Nut
Front View
Place Mark
@ 12 o'clock
flow
Sample
flow
Figure 7-5. Combustibles detector replacement (Hot-Wire).

RTD Combustibles Detector Replacement
Use Figure 7-6:
1. Remove the detector leads from terminal strips E, F, H, and I on the

sensor board.
2. Loosen the compression fitting nut that holds the combustible detec-
tor in place and remove the detector from the combustible detector
block.
3. It is very important that you orient the new combustibles detector cor-
rectly inside the combustibles detector block (sample flow path must
contact both detector leads at the same time). To do this, ensure that
the flat part of the combustibles detector is facing down (see Figure 7-6
for correct orientation).
4. Install the new combustibles detector with nut and ferrules. Be ex-
tremely careful; do not damage the detector elements when install-
ing. Ensure the proper orientation of the combustibles detector in the
combustibles detector block.
5. Reconnect the detector leads to the sensor board by reversing the ac-
tions taken in Step 1 above.
Side View Furnace Assembly
Ferrule
Detector Head
Combustibles
Detector Block
Compression
Fitting Nut
Front View
Flat must
face down
flow
Sample
flow
Figure 7-6. Combustibles detector replacement (RTD).

Box Heater Diagram
Figure 7-7 shows how to wire box heaters using the sensor board.
BOX HEATER 115 VOLT CONFIGURATION
HTR
BOX HEATER
115 VAC
L HTR
N HTR
BOX HEATER
HTR
SENSOR BOARD
BOX HEATER 230 VOLT CONFIGURATION
HTR
BOX HEATER
230 VAC
NC
L
N NC
BOX HEATER
HTR
SENSOR BOARD
Figure 7-7. Box heater diagram.

Replacement Parts List
Sensor
Furnace Assembly P/N 70409SE
Type “K” Thermocouple P/N 71697KE
Methane Detector Kit P/N 70987TE
Combustibles Detector Kit (hot wire) P/N 70986TE
Combustibles Detector Kit (RTD) P/N 71504TE
Sensor Board P/N 80471SE
Zirconium Oxide Cell P/N 71063SE
Remote Calibration Unit (RCU)

Air Regulator P/N 39003JE
Regulator Gauge P/N 37013JE
Aspirator Air Solenoid Valve P/N 36022JE
Oxygen Span Gas Solenoid Valve P/N 36034JE
Calibration Gas Solenoid Valve P/N 36023JE
Flow Meter (O2-Only RCU) P/N 37030JE
Flow Meter (Combustibles RCU) P/N 37020JE
Control Unit
Display Module P/N 90219VE
Power Supply/Keypad Module P/N 90253VE
Auto Calibration Card P/N 80436SE
Combustibles Card (WDG-IVC) P/N 80461SE
Combustibles Card (WDG-IVCM) - RTD type P/N 80449SE
Combustibles Card (WDG-IVCM) - Hot Wire type P/N 80561SE
Backplane Assembly P/N 80439SE
Wiring Card (WDG-IV) P/N 80457SE
Wiring Card (WDG-IVC) P/N 80445SE
Wiring Card (WDG-IVCM) P/N 80466SE
Processor Board P/N 80440SE
Display 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


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
• No Parity
In addition, the baud rate is fixed at 9600bps.
The communication protocol is a basic master/slave, command/response

protocol. The master initiates each communication transfer. There is one
master on the communication line, but there can be multiple sensors act-
ing as slaves. Up to 32 sensors can be connected on one network.
Start Character Node Address Command Letter Data Checksum End Character
“>” (ASCII charac- 2 Hex ASCII char- (See Command (n characters - 2 hex ASCII char- Carriage Return
ter 3E Hex) acters (00 to FF) Section for list of depends on com- acters (sum of all (ASCII character
commands) mand) preceding charac- 0D Hex)
ters except the “>”
character)
Serial Communications | A-1

Command Message Format
The command message format is as follows:
Where:
The Start Character is the greater than character (“>”, which is ASCII 3E
hex).
The Node Address is from 00-FF, and is represented as two hex ASCII char-
acters. Each sensor has a unique node address. Note, however, that the
maximum number of sensors that can be connected on the network is 32
and for the gateway, we have limited the valid addresses from 01-32.
The Command Letter is from ASCII A-Z (upper case only).
Data is a string of characters whose meaning depends on the command

(see below) and where the number of characters returned also depends
on the command. Limit is 20 characters.
The Checksum is the sum of all the preceding characters (excluding the >
character) - modulo 256 or the characters “??” (?? is equivalent to 2 ASCII
3F hex characters).
The End Character is a carriage return (equivalent to ASCII character 0D

hex).
The system disables any checking of the checksum if the checksum

 character is equal to ?? (?? is equivalent to 2 ASCII 3FH hex charac-
NOTE ters). This makes testing by the programmer easy, but it is strongly
recommended that the integrity check be enabled in the final system.
A-2 | Thermox Series 2000 WDG-IV /I VC / IVCM

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. If a variable is selected beyond the end
of the table, an error will be returned. The value returned is followed by a
text string for the units, where applicable.
Example:
Request Oxygen with the following string: >FEF0836 
Returned string: A20.9 %O2D4 
Write Number (H)
This command sets a value in the analyzer. The data section of this com-
mand is a two-digit hex number (00-FF) to point to the location to write
from the variable table, followed by the value of the variable. A simple
acknowledge is returned if the command was accepted.
Read Date and Time (M)
This command is used to read the dates and times stored in the analyzer.
The data consists of a single digit where 0 is used to read the current date
and time, 1 is used to read the date and time of the last calibration, 2 is
used to read the date and time of the last verification, and 3 is used to
read the date and time of the last step function. Date and time is returned
as mm/dd/yy hh:mm in 24 hour (military) time.
Set Date and Time (N)
This command is used to set the analyzer’s current date and time. The
data string is of the form: mm/dd/yy hh:mm in 24 hour (military) time.
Leading zeroes are required, for example: 03/18/93 20:02.
Calibrate (G)
This command is used to do calibration or verify on the analyzer. The

data string consists of a single digit where 00 is used to do a secondary cal,
01 is used to do a verify, and 02 is used to do a primary cal.
Example:
>01G00??  - perform a secondary cal.

Development Serial Communication Commands
These commands are used during initial serial communication design.
Echo (A)
The echo command is used to test the serial protocol and line integrity.
Any text sent to the analyzer is echoed back to the host.
Bad Command (B)
Just returns a bad command (error code 01) reply.
Acknowledge (C)
Returns a simple acknowledge. This command can also be used later to

check that the IQ sensor is on-line and ready to communicate.
Data Format (J)
This command is used to check how data is output through the serial link.
For each variable that is accessible through the Read Number and Write
Number commands, a string is returned that describes the format of the
number. This response data consists of three characters:
Format Access Location
Where Format is:

F Float
H Hexadecimal
U Unsigned decimal
Access is as follows:
r read only
w write only
b read/write
Location is:
r RAM
e EEPROM
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.

This command is only available via the Series 2000 software

NOTE
Command List
The following command letters are available:
Letter Description
A Echo
B Bad Command
C Acknowledge
F Read Number
G Calibrate
H Write Number
J Data Format (Series 2000 software only)
M Read Date and Time
N Set Date and Time

Responses
An analyzer returns a variety of responses that can be broken into two
categories, success and failure.
Success
All successful responses start with A. If there is data returned, it will fol-
low the A and have a checksum after it. All responses end with a carriage
return ( ).
Success End
A 
Success Data Checksum End Character
A (n characters) (2 hex ASCII characters) 
Examples:
A
Simple acknowledge
AFF0050
Acknowledge with data
Failure
All failure responses start with a N followed by a two hex digit failure code
and a carriage return ( ).
Failure Failure Code End Character

N (2 hex ASCII characters) 
Failure Code Description

01 Bad command letter
02 Bad checksum
03 Input overrun in serial communication
05 Parameter out of range
08 Error in receipt of character
09 Cannot calibrate/verify now
0A Internal error
0B Illegal access (read-only variable)

Variable Table
The following pages provide a summary of the variable locations, name,
and descriptions available.
Location Variable Name Description

(Hex/Decimal) Access
00/00 Flags3 Various flags (1=true, 0=false) Read only
bit 0 – sensor is at operating temperature.

bit 1 – Over/under Flag for tuning
temperatureS2
bit 2 – inject cal gas active.
S2
bit 3 – Auto Cal is occurring
S2
bit 4 – Auto Verify is occurring
S2
bit 5 – in a menu
S2
bit 6 – No limit msg.
bit 7 – calibrate or verify is not
S2
permitted.
01/01 Inf_mess_flag System and error message flags (1=true, 0 = Read only
false)
S2 IQ
bit 0 – No Exception , Future use
bit 1 – Future use
bit 4 – Power Down Detected
bit 5 – Watchdog Failure
IQ
bit 6 – Detector B Fault
IQ
bit 7 – Detector A Fault
bit 8 – Combustble cal error

bit 9 – Methane cal error
bit 10 – Warming up
IQ
bit 11 – RTC Not Running
IQ
bit 12 – Box Under Temp
IQ
bit 13 – Box Over Temp
IQ
bit 14 – Furnace Circuit Open
IQ
bit 15 – Furnace Over Temp
bit 16 – Temp Rise Failure

bit 17 – Cell is Over Temp
bit 18 – Zero Gas Range Error
bit 19 – Span Gas Range Error
bit 20 – Primary Calibration
bit 21 – Memory is Corrupted
bit 22 – Excessive Cal Error
bit 23 – Calibration Required
bit 24 – Thermocouple Failure

bit 25 – T/C Circuit Failure
bit 26 – Cal Verify Aborted
bit 27 – Calibration Aborted
bit 28 - System Verifying Cal
bit 29 - System Calibrating
bit 30 – Auto Verify Pending
bit 31 – Auto Cal Pending

IQ
02/02 Config_flags System configuration flags (1=true, R/W
0=false)
bit 0 – relays energize on alarm. If not,

they deenergize.
Bit 1 – auto calibration time is set, an
auto calibration will happen at the set
time if the auto calibration is enabled
bit 2 – auto calibration timer is enabled,
since this is enabled, an auto calibration
will occur at the auto calibration time.
bit 3 – real time clock is set.
bit 4 – Step Function enabled (only for
RSS)
bit 5 – auto verify time is set, an auto
verify will happen at the set time if the
auto verify is enabled.
bit 6 – auto verify timer is enabled, if
this is enabled an auto verify will occur
at the auto verify time.
bit 7 – auto calibration cycle is
programmed in hours, 0 if in days
bit 8 – auto verify cycle time is

bit 9 – 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
PPM

S2
Config_flags System configuration flags (1=true, R/W
0=false)
bit 0 – auto verify cycle time is

bit 1 – Auto cal option is installed
bit 2 – Combust module is installed
bit 5 – RTD type combustible detector, 0=
Hot wire detector
bit 6 – WDG type sensor, 0 is HP type
sensor
bit 7 – combustibles are measure in
percent,0 = combustibles are measured in
PPM
bit 8 – relays energize on alarm. If not,

they deenergize.
bit 9 – auto calibration time is set, an
auto calibration will happen at the set
time if the auto calibration is enabled
bit 10 – auto calibration timer is enabled,
since this is enabled, an auto calibration
will occur at the auto calibration time.
(0=true, 1=false)
bit 11 – real time clock is set.
bit 12 – Step Function enabled (only for
RSS)
bit 13 – auto verify time is set, an auto
verify will happen at the set time if the
auto verify is enabled.
bit 14 – auto verify timer is enabled, if
this is enabled an auto verify will occur
at the auto verify time. (0=true, 1=false)
bit 15 – auto calibration cycle is

IQ
03/03 Iout_flags Analog outputs flags (1=true, 0=false) R/W
bit 0 – analog output 1 tracks during

calibration
0 is hold analog output 1 during
calibration
verify
0 is hold analog output during verify.
calibration
calibration
verify
bit 6 – analog output 2 set for 0 to 20 ma,
0 is 4 to 20 ma.

calibration
calibration
verify
0 is hold analog output 3 during verify.
bit 10 – analog output 3 set for 0 to 20
ma, 0 is 4 to 20 ma
calibration
calibration.
verify
ma, 0 is 4 to 20 ma

S2
Iout_flags Analog outputs flags (1=true, 0=false) R/W

calibration
calibration
verify
0 is 4 to 20 ma
calibration
calibration.
verify
0 is 4 to 20 ma

calibration
calibration
verify
bit 10 – Analog output 1 is set to 0-20, 0=
Output 1 is set to 4-20ma
calibration
calibration
verify
ma, 0 is 4 to 20 ma.
IQ
04/04 Probe_type 0 – Insitu R/W
IQ
1 – Cem/02
IQ
2 – WDG
IQ
3 – HP
IQ
4 – EI 20
IQ
5 – SA/F
S2
A – Insitu
S2
B – CEM/O2
S2
C – WDG
S2
D – HP
S2
E – TM
S2
F – 3-in-1

05/05 Line1_flg What is displayed on line 1 of the display R/W
0 – blank line
2 – oxygen
4 – cell temperature
6 – cell mv
8 – thermocouple mv
10 – box tempIQ
12 – combustibles
14 – methane
16 – methane and combustibles
IQ
18 – combustible voltages
IQ
20 – methane voltages
22 – time and date
S2
24 – user text
IQ
AF Ratio
IQ
26 – WOBBE
0 – blank line
2 – oxygen
6 – cell mv
IQ
10 – box temp
12 – combustibles
14 – methane
IQ
IQ
S2
24 - user text
IQ
AF Ratio
IQ
26 - WOBBE
0 – blank line
2 – oxygen
6 – cell mv
IQ
10 – box temp
12 – combustibles
14 – methane
IQ
IQ
S2
24 - user text
IQ
AF Ratio
IQ
26 – WOBBE
08/08 Oxygen The oxygen reading in percent Read only

09/09 Cmbcomb 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

0E/14 Out1_flg What analog output 1 corresponds to R/W
0 – oxygen
IQ
S2
IQ
thermocouple mv
IQ
3 – cell mv
S2
IQ
box temp
IQ
5 – combustibles
6 – cell mvS2
IQ
methane
IQ
7 – AF Ratio
IQ
8 – WOBBE
0F/15 Out2_flg What analog output 2 corresponds to R/W
0 – oxygen
IQ
S2
IQ
thermocouple mv
IQ
3 – cell mv
S2
IQ
box temp
IQ
5 – combustibles
S2
6 – cell mv
IQ
methane
IQ
7 – AF Ratio
IQ
8 – WOBBE
10/16 Out3_flg What analog output 3 corresponds to R/W
IQ
0 – oxygen
IQ
IQ
IQ
3 – cell mv
IQ
4 –box temp
IQ
5 – combustibles
IQ
6 – methane
S2
10 – combustibles
S2
12 – methane
IQ
7 – AF Ratio
IQ
8 – WOBBE
11/17 Out4_flg What analog output 4 corresponds to R/W
IQ
0 – oxygen
IQ
IQ
2 –thermocouple mv
IQ
3 – cell mv
IQ
4 –box temp
IQ
5 – combustibles
IQ
6 – methane
IQ
7 – AF Ratio
IQ
8 – WOBBE
S2
10 – combustibles
S2
12 – methane

12/18 I1_span Analog output 1, 20 ma value R/W
13/19 I1_zero Analog output 1, 0 or 4 ma value R/W
14/20 I2_span Analog output 2, 20 ma value R/W
15/21 I2_zero Analog output 2 , 0 or 4 ma value R/W
16/22 I3_span Analog output 3 , 20 ma value R/W
18/24 I4_span Analog output 4 , 20 ma value R/W
1A/26 I_filt1 Filter value for analog output 1 R/W

1B/27 I_filt2 Filter value for analog output 2 R/W
1C/28 I_filt3 Filter value for analog output 3 R/W
1D/29 I_filt4 Filter value for analog output 4 R/W
1E/30 Alm3_value alarm setpoint for process alarmIQ R/W

Oxygen alarm setpoint for Alarm #3S2 Value
is always in percent
1F/31 Alm4_value alarm setpoint for Alarm #2IQ R/W
S2
Oxygen alarm setpoint for Alarm #4 Value
is always in percent
S2
20/32 Alm5_value Combustibles PPM alarm #5 setpoint R/W
IQ
Alarm #3 setpoint
S2
21/33 Alm6_value Combustibles PPM alarm #6 setpoint R/W
S2
22/34 Alm5_percent Combustibles percent alarm #5 setpoint R/W
S2
23/35 Alm6_percent Combustibles percent alarm #6 setpoint R/W
S2
24/36 Alm7_percent Methane percent alarm #7 setpoint R/W
S2
25/37 Alm8_percent Methane percent alarm #8 setpoint R/W
26/38 Gas1_time Amount of time oxygen span gas will flow in R/W
IQ
seconds
Amount of time oxygen span gas will flow in
S2
MMSS
27/39 Gas2_time Amount of time oxygen zero gas will flow in R/W
IQ
seconds
Amount of time oxygen zero gas will flow in
S2
MMSS
28/40 Gas3_time Amount of time the combustibles span gas R/W
IQ
will flow in seconds
Amount of time combustibles span gas will
S2
flow in MMSS

29/41 Recov_time Amount of time for recovery after a R/W
IQ
calibration in seconds
Amount of time for recovery after a
S2
calibration in MMSS
2A/42 O2_gas1 Oxygen span gas setpoint value, always in R/W
percent
2B/43 O2_gas2 Oxygen zero gas setpoint value, always in R/W
percent
S2
2C/44 Co_gas1 Combustibles PPM span gas setpoint value R/W
IQ
Combustibles span gas setpoint
2D/45 Co_percent_gas Combustibles percent span gas setpoint R/W
S2
value
2E/46 Me_percent_gas Methane percent span gas setpoint value R/W
2F/47 Cal_cgas1 Oxygen span gas setpoint for last Read only
calibration
30/48 Cal_span Oxygen span gas reading for last Read only
calibration
31/49 Ver_cgas1 Oxygen span gas setpoint for last verify Read only
32/50 Ver_span Oxygen span gas reading from last verify Read only
33/51 O2_span Oxygen span gas millivolts during last Read only
calibration
34/52 Cal_cgas2 Oxygen zero gas setpoint value for last Read only
calibration
35/53 Cal_zero Oxygen zero gas reading from last Read only
calibration
36/54 Ver_cgas2 Oxygen setpoint value used during last Read only
verify
37/55 Ver_zero Oxygen zero gas read during last verify Read only
38/56 O2_zero Zero gas millivolts read during last Read only
calibration
39/57 Cal_cgas3 Combustibles span gas setpoint during last Read only
calibration
3A/58 Cmbspan Combustibles span value during last Read only
calibration
3B/59 Ver_cgas3 Combustibles span gas setpoint for last Read only
verify
3C/60 Vcmbspan Combustibles span gas read during last Read only
verify
3D/61 Cmbzero Combustibles zero gas read during last Read only
calibration
3E/62 Vcmbzero Combustibles zero gas read during last Read only
verify
3F/63 Cal_cgas4 Methane span gas setpoint during last Read only
calibration
40/64 Mthspan Methane span value read during last Read only
calibration
41/65 Ver_cgas4 Methane span gas setpoint for last verify Read only
42/66 Vmthspan Methane span value during last verify Read only
43/67 Mthzero Methane zero value during last calibration Read only
44/68 Vmthzero Methane zero value during last verify Read only

45/69 Cal_h10 Auto calibration hour value R/W
46/70 Cal_h1 Auto calibration hour value R/W
47/71 Cal_m10 Auto calibration minute value R/W
48/72 Cal_m1 Auto calibration minute value R/W
49/73 Ver_h10 Auto verify time hour value R/W
4A/74 Ver_h1 Auto verify time hour value R/W
4B/75 Ver_m10 Auto verify time minute value R/W
4C/76 Ver_m1 Auto verify time minute value R/W
4D/77 Pressure Process pressure. R/W
4E/78 Optemp The cell temperature setpoint Read only
4F/79 Optemp_range Operating temperature for sensor, 0 is R/W
IQ
normal, 1 is high, 2 is RM CEM
50/80 Cmbref Reference voltage reading for Combustibles Read only
channel
51/81 Cmbact Active voltage reading for Combustibles Read only
channel
52/82 Cmbgnd Ground reading for Combustibles channel Read only
53/83 Mthref Reference voltage reading for the Methane Read only
channel.
54/84 Mthact Active voltage reading for Methane channel Read only
55/85 Mthgnd Ground reading for Methane channel Read only
56/86 AT Cell slope Read only
57/87 AT_ratio Cell slope used during last calibration. Read only
58/88 Tc_ratio Cell/thermocouple compensation multiplier Read only
59/89 Cmbslope 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 R/W
days]
5C/92 Ver_cycle Interval between auto verifies [1 hour to R/W
90 days]

5D/93 Alr1_flg What process alarm is associated with R/W
S2
0 – oxygen
IQ
oxygen, combustibles, or methane
1 – calibration
2 – verify
3 – in cal/verify
IQ
5E/94 Alm_config Configuration for oxygen alarms, high or R/W
low. If a bit is 1, that is the condition
that the indicated alarm will trip on.
IQ
bit 0 – high oxygen, process alarm
IQ
bit 1 – low oxygen, process alarm
IQ
bit 2 – high combustible, process alarm
IQ
bit 3 – high methane, process alarm
IQ
bit 4 – high oxygen, alarm #2
IQ
bit 5 – low oxygen, alarm #2
IQ
bit 6 – high combustible, alarm #2
IQ
bit 7 – high methane, alarm #2
IQ
IQ
IQ
IQ
bit 13 –Future use
S2
Alm_config Configuration for oxygen alarms, high or R/W
low. If a bit is 1, that is the condition
that the indicated alarm will trip on.

bit 5 –Future use
bit 6 – Oxygen Alarm #3. 0=Low, 1=High
bit 7 – Oxygen Alarm #4. 0=Low, 1=High


5F/95 Gas_ctr Which gas is currently flowing to the Read only
sensor
0 – span gas flowing

1 – zero gas flowing
2 – combustible span gas
3 – methane span gas (if 3 span value RCU
IQ
installed)
S2
- Normal operation
4 – Step func. Process gas flowing (1st
time)
5 – Step func. Span gas flowing
6 – Step func. Zero gas flowing
7 – Step func. Process gas flowing (2nd
time)
0x80 – User Aborted Cal (set from abort to
recovery completed)
0x81 – Recovery Period (if in a cal or
verify) per loc 60/95.
– Normal operation (if not in a
cal or verify) per loc 60/95.
60/96 Calflag Which type of calibration the unit is in: Read only
0 – In normal calibration
1 – In verify
2 – In primary cal
3 – In none of the above, normal operation

IQ
61/97 Alarm_flags Which oxygen alarm has been set and why 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 13 - Out of Range, for SA/F sensor
bit 14 - Future use
bit 15 - Future use
S2
Alarm_flags Which oxygen alarm has been set and why Read only

bit 4 – high combustion, alarm #5
bit 5 – high combustion, alarm #6

bit 13 - Future use
bit 14 - Future use
bit 15 - Future use

62/98 Cal_variable The calculated percent value that 0 mv Read only
would correspond to with the cell that is
currently being used. This value can vary
between different cells. It is calculated
during calibration and used in the oxygen
calculations.
63/99 Option_flags Option flags (1=true, 0=false) Read only
bit 0 – combustible detector installed

IQ
bit 1 – Data module installed
S2
Dual current output installed
bit 2 – 2 span value RCU IQ
S2
auto cal option installed
bit 3 – Methane detector installed IQ
3-in-1 option installed S2
bit 4 – Dig – ma module installed IQ
IQ
bit 5 – HART module installed
IQ
bit 6 – RS485 module installed
IQ
bit 7 – 3 span value RCU
S2
Invalid option module
64/100 Tspan_mv Cell mv value measured with the span gas Read only
flowing during last calibration.
65/101 Tzero_mv Cell mv value measured with the zero gas R/W
flowing during calibration.
66/102 Mthvalue Read only
67/103 M_store Read only
68/104 Cal_temp Last calib temperature R/W
69/105 CJTemp Cold Junction temperature Read only
6A/106 Box_temp Box Temperature Read only
6B/107 Cmb_Kfact Combustible K Factor R/W
IQ
6C/108 Mth_Kfact Methane K Factor R/W
6D/109

6E/110 Dig_Input Status of digital inputs(1=closed/on, Read only
0=open/off)
IQ S2
bit 0 – CAL 0 bit 0 – Dig In
IQ
bit 1 – CAL 1
6F/111
70/112 SysTst_Flag System test that was preformed R/W
1-Calibrate A/D
2-Ram Test
4-Test EEPROM
7-Erase Ram
8-Erase EEPROM
9- Test Watchdog
71/113 Passw Current password R/W
IQ
72/114 BoxCtl Value that corresponds to the box set point R/W
0 – 230 C
1 – 270 C
2 – 360 C
3 – Full on control
73/115 InjectGas Turn on gas for inject cal gas menu R/W
0 - Span gas
1 - Zero gas
2 - Comb gas
3 - Methane gas (if 3 span value RCU
installed)
4 - Process gas
74/116 Node_Addr The current node address R/W
75/117 Read only
76/118 Cmbsens Combust sensitivity associated with the Read only
last calibration
77/119 Mthsens Methane sensitivity associated with the Read only
last calibration
78/120 AFRatio The calculated A/F ratio Read only
79/121 AFRatio_CalSP The zero cal gas A/F ratio set point R/W
7A/122 Wobbe The calculated WOBBE value Read only
7B/123 Wobbe_SP The WOBBE Factor R/W
7C/124 Gas4_time Amount of time the methane span gas will R/W
IQ
flow (in seconds)
7D/125 AFRatio_CalSP2 The A/F Ratio set point at low end R/W
7E/126 XSO2Low_SP The XS O2 set point at low end R/W
7F/127 SW Version Current software version # Read only

80/128 Excep_1 Exception number 1 see Exception Chart Read only
8A/138 Excep_11 Exception number 11 see Exception Chart Read only
8B/139 Excep_12 Exception number 12 see Exception Chart Read only
8C/140 Excep_13 Exception number 13 see Exception Chart Read only
8D/141 Excep_14 Exception number 14 see Exception Chart Read only
8E/142 Excep_15 Exception number 15 see Exception Chart Read only
8F/143 Excep_16 Exception number 16 see Exception Chart Read only
94/148
95/149

Exception # Exception
IQ
2D Out of Range
2C Power up/Reset
2B High Meth (Alm #3)IQ
IQ
2A High Comb (Alm #3)
IQ
29 Low O2 (Alm #3)
IQ
28 High O2 (Alm #3)
IQ S2
27 High Meth (Alm #2) / METHANE HIGH #8
IQ S2
26 High Comb (Alm #2) / METHANE HIGH #7
IQ S2
25 Low O2 (Alm #2) / COMBUSTIBLE HIGH #6
IQ S2
24 High O2 (Alm #2) / COMBUSTIBLE HIGH #5
IQ S2
23 High Meth (Proc Alm) / OXYGEN HIGH #4
IQ S2
22 High Comb (Proc Alm) / OXYGEN Low #4
IQ S2
21 Low O2 (Proc Alm) / OXYGEN HIGH #3
IQ S2
20 High O2 (Proc Alm) / OXYGEN LOW #3
1F Auto Cal Pending
1E Auto Verify Pending
1D System Calibrating
1C System Verifying Cal
1B Calibration Aborted
1A Cal Verify Aborted
19 T/C Circuit Failure
18 Thermocouple Failure
17 Calibration Required
16 Excessive Cal Error
15 Memory is Corrupted
14 Primary Calibration
13 Span Gas Range Error
12 Zero Gas Range Error
11 Cell is Over Temp
10 Temp Rise Failure
IQ
0F Furnace Over Temp
IQ
0E Furnace Circuit Open
IQ
0D Box Over Temp
IQ
0C Box Under Temp
0B Future use
0A Warming up
09 Methane cal error
08 Combustible cal error
IQ
07 Detector A Fault
IQ
06 Detector B Fault
05 Watchdog Failure
04 Power Down Detected
03 Future use
02 Future use
01 Future use
S2 IQ
00 No Exception , Future use
Table A-1.
Exception Table.
Exception Chart

Sample Program
This section provides a sample Quick Basic program that reads and writes
to the serial port
DECLARE FUNCTION Checksum$ (M$)

‘Serial test routine’ Continuously sends a message and prints the string
returned
CLS
‘Open the communications port
OPEN “COM2: 9600,N,8,1 “ FOR RANDOM AS #1
‘String to be sent
T$ = “08”
‘Address of the analyzer
Address% = 0
‘Build the message
M$ = “>” + HEX$(Address%) + “F” + T$
M$ = M$ + Checksum$(M$)
‘Continue sending message until key pressed
‘ (Assumes that analyzer is connected)
WHILE (INKEY$ = “”)
PRINT #1, M$
LINE INPUT #1, A$
‘Show results
PRINT “Sent......”; M$
PRINT “Returned...”; A$
PRINT
WEND
CLOSE #1
STOP
FUNCTION Checksum$ (M$)
DIM Sum AS LONG
Sum = 0
‘Skip FOR i% = 2 TO LEN(M$)
Sum = Sum + ASC(MID$(M$, i%, 1))
NEXT i%
‘Get low byte of checksum
Checksum$ = HEX$(Sum MOD 256)
END FUNCTION<P255D>

Starting/Monitoring a Calibration: An Example
This section provides an example of how to initiate and then monitor a
calibration.
1. Check that no calibration or verification is currently occurring by

checking the Calflag variable (Calflag=3).
2. Send the Calibrate command to the IQ analyzer (G00).
3. If an acknowledge is returned (A  ), the calibration command is ac-

cepted. If not accepted, the sensor may not be at a proper operating
temperature or may already be performing a system calibration.
4. Read the Gas_ctr variable to determine the position in the calibration

cycle. Use this variable to determine when to activate solenoids (if not
controlling solenoids using the IQ analyzer).
5. Read the Cal_flag variable to determine when the cal cycle is finished
(Calflag=3).
6. Read the calibration values (for example, cal_span and cal_zero vari-
ables).


Menu Option Charts
SETUP KEY
Functions/Options
Menu Options
Select info for Display Line 1.
Display Select info for Display Line 2.
Select info for Display Line 3.
Passwords Create a system password
Select a positive or negative process pressure.
Process Pressure
Enter process pressure value.
System Tests Perform internal diagnostics on Series 2000.
View serial number for Series 2000.
System Serial #
View manufacturing number for Series 2000.
Primary Calibration Perform an automatic, remote, or manual primary calibration.
Sensor Configuration Select sensor type.
Communications Define communications parameters.
Define combustibles scale (% or PPM).
Combustibles
Define combustible detector type.
Table B-1. Setup Key Menu
ANALOG KEY
Functions/Options
Menu Options
Set Current Range Range of readings that the analog output represents (for
example:
4% O2 = 4 mA
10% O2 = 20 mA)
Set Track/Hold Hold output at last process reading during a cal or verify
Set Current Mode 0 to 20 mA
4 to 20 mA
Output Filtering Smooth out variations in readings
Select Function % O2
Cell temperature
Cell Millivolts
Thermocouple Millivolts
Combustibles (option)
Methane (option)
Table B-2. Analog Range Key menu.
Menu Option Charts | B-1

ALARM KEY
Functions/Options
Menu Options
Alarm Set Points Alarm 3 Value
Alarm 4 Value
Alarm 5 Value
Alarm 6 Value
Alarm 7 Value
Alarm 8 Value
Alarm Configure High O2
(for Alarms 3 and 4) Low O2
Relay Configure Energize on Alarm
De-energize on Alarm
Select Function % Oxygen
( Alarm 3) Start of Calibration
Start of Verify
Start of Calibration or Verify
Exception Log N/A
Table B-3. Alarm Key menu.
FUNCTION
*Select Function Alarm Configure Relay Configure
Alarm 3 % O2 High O2 Alarm
Cal Start Low O2 Alarm Energize on alarm
Verify Start
Cal/Verify Start
Alarm 4 Not selectable De-energize on alarm
ALARM NUMBER
(% O2 only)
Alarm 5
Not Selectable
Not selectable (high alarms only)
Alarm 6 (combustibles only)
Alarm 7
Not selectable (Disabled during

Alarm 8 calibration cycle)
(methane 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 Series 2000 WDG-IV / IVC / IVCM

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 Enter calibration gas values.
Set pressure and flow to RCU gases without
Inject Cal Gas
performing a calibration.
Set control unit time/date.
Set Cal Timers Enable or disable auto cal cycles.
(applies only for auto cal operations with
RCU, except for setting time and date) Set cal gas times for auto cal/verify operations.
Define recovery durations after a cal/verify.
Set K Factor (not used on WDG-IV Series) Enter Value
View the Sensitivity (Slope) determined dur-
Sensitivity ing calibration for the combustibles detector in
mV/1000 PPM.
Table B-5. Calibrate Key menu.
Menu Option Charts | B-3

B-4 | Thermox Series 2000 WDG-IV / IVC / IVCM

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 +
VEXT1, 2 -
Jumper JP2 on the Series 2000 control unit display module is used to allow
you to define which power source to use. If JP2 is in (factory default), the
control unit uses the internal supply to power the current output circuits. If
you try to use an external voltage at this time, the system will use whichever
voltage is higher - control unit voltage is normally about 28 volts. If the JP2
jumper is removed, the external voltage source must be used to power the
current output circuits. The external voltage source must be no greater than
30 volts DC. See the “Option Card Installation” section in the Installation
Chapter for information on how to access or remove the display module.
Current Outputs: Other Applications | C-1

To determine the minimum external voltage supply required to power the
current outputs, use the following formula:
VEXTmin = .02 amps (RLoad + Rwires) + 4 volts
where:
VEXTmin = the minimum external voltage required to power current

output circuit
RLoad = the load resistance of the current output device
Rwires = the resistance of the wires
 Skip this section if you don’t measure combustibles.

NOTE
In addition, both of the combustibles current outputs have external volt-

age options:
VEXT3+ VEXT4+
VEXT3- VEXT4-
Jumper JP1 on the combustibles card allows you to define which power
source to use for current output 4. Jumper JP2 on the combustibles card
allows you to define which source to use to power current output 3. If the
jumper is in (factory default), the control unit uses its own power supply
to power the current output circuits. If you try to use an external voltage
at this time, the system will use whichever voltage is higher - control unit
voltage is normally about 28 volts. If the jumper is removed, the external
voltage source must be used to power the current output circuits. The
external voltage source must be 30 volts DC or less.
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 Series 2000 WDG-IV / IVC / IVCM

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.
IOUT1 and IOUT2 must share the same power supply if both of these chan-
nels are used, or two power supplies can be “ORed” together using a diode
from each power supply positive terminal (diode anode to power supply) to
the VEXT1,2+ terminal. The power supply minuses would be tied together
and connected to one side of the both loads. The other side of one of the
loads would be connected to IOUT1+ terminal, and the other side of the
other load would be connected to the IOUT2+ terminal.
For each current output channel used in a current loop modulation ap-
plication, the jumpers should be removed for that channel.
OPTIONAL
EXTERNAL LOOP POWER SUPPLY
OUTPUT DEVICE MAX VOLTAGE 30 VOLTS DC
(COMPUTER OR CHART RECORDER)
MAX LOAD RESISTANCE 1200 OHMS
Figure C-1. Modulation of external power supply.
Current Outputs: Other Applications | C-3

Skip this section if you don’t measure combustibles.

NOTE
In addition, both of the combustibles current outputs can be used in a

modulation scheme using the following:
VEXT3+ VEXT4+
VEXT3- VEXT4-
C-4 | Thermox Series 2000 WDG-IV / IVC / IVCM

Drawings and Custom Instructions
This appendix provides any custom drawings or instructions you may

have ordered in addition to the standard WDG analyzer. If you didn’t or-
der any custom options, the standard Interconnect Drawing is provided.
If you did order any special options, the drawings or special instructions
provided here supercede any drawing or options provided elsewhere in
this manual.
Drawings and Custom Instructions | D-1

D-2 | Thermox Series 2000 WDG-IV / IVC / IVCM

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

CEM/O2, INSITU
SENSOR CONFIGURE O2 WDG-IV, WDG-HPII
SENSOR CONFIGURE COMB WDG-IVC, WDG HPIIC
SENSOR CONFIGURE METHANE WDG-IVCM
SENSOR NODE ADDRESS 0

BAUD RATE 9600
ENABLE SERIAL ENABLED
COMBUSTIBLE TYPE HOTWIRE

COMBUSTIBLE TYPE RTD
COMBUSTIBLE SCALE PPM
PROCESS PRESSURE 0.00 PSIG
O2 SPAN GAS SETPOINT 20.90%

O2 ZERO GAS SETPOINT 2%
COMB SPAN GAS SETPOINT 1600 PPM
METHANE GAS SETPOINT 2.00%
AUTO CAL CYCLE TIME 8:00

AUTO CAL CYCLE FREQ 1 DAY
AUTO VERIFY CYCLE TIME 9:00
AUTO VERIFY CYCLE FREQ 1 DAY
AUTO CAL/VERIFY DAYS/HRS DAYS,DAYS
AUTO CAL ENABLE/DISABLE ENABLED
AUTO VER ENABLE/DISABLE ENABLED
Sensor Default Settings | E-1

PARAMETER DEFAULT SETTINGS CUSTOMER SETTINGS
CEM/O2, INSITU
SENSOR CONFIGURE O2 WDG-IV, WDG-HPII
SENSOR CONFIGURE COMB WDG-IVC, WDG HPIIC
SENSOR CONFIGURE METHANE WDG-IVCM
SENSOR NODE ADDRESS 0

BAUD RATE 9600
ENABLE SERIAL ENABLED
COMBUSTIBLE TYPE HOTWIRE

COMBUSTIBLE TYPE RTD
COMBUSTIBLE SCALE PPM
PROCESS PRESSURE 0.00 PSIG
O2 SPAN GAS SETPOINT 20.90%

O2 ZERO GAS SETPOINT 2%
COMB SPAN GAS SETPOINT 1600 PPM
METHANE GAS SETPOINT 2.00%
AUTO CAL CYCLE TIME 8:00

AUTO CAL CYCLE FREQ 1 DAY
AUTO VERIFY CYCLE TIME 9:00
AUTO VERIFY CYCLE FREQ 1 DAY
AUTO CAL/VERIFY DAYS/HRS DAYS,DAYS
AUTO CAL ENABLE/DISABLE ENABLED
AUTO VER ENABLE/DISABLE ENABLED
O2 SPAN GAS DURATION 2:00 MINUTES

O2 ZERO GAS DURATION 2:00 MINUTES
COMB SPAN GAS DURATION 2:00 MINUTES
RECOVERY DURATION 4:00 MINUTES
K FACTOR 1
OUTPUT # 1 FUNCTION % OXYGEN
CURRENT MODE,RANGE 4 TO 20 MA = 0-10
TRACK/HOLD CAL VERIFY HOLD,TRACK
OUTPUT FILTER # 1 100
E-2 | Thermox Series 2000 WDG-IV / IVC / IVCM

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Thermox® Series 2000

WDG-IV, WDG-IVC, WDG-IVCM

USA - Delaware AMETEK Beijing

USA - Texas FRANCE

MIDDLE EAST – Dubai

CHAPTER 4 Controller/User Interface

iv | Thermox Series 2000 WDG-IV / IVC / IVCM

Chapter 6 Maintenance and Troubleshooting

Chapter 7 Service and Parts

Appendix A Serial Communications

Appendix C Current Outputs: Other Applications

Appendix D Drawings and Custom Instructions

Appendix E Series 2000 Controller Setup Parameters

An operating procedure which, if not strictly observed, may result in

An operating procedure which, if not strictly observed, may result in dam-

Important information that should not be overlooked.

Verify ground continuity of all equipment before applying power.

viii | Thermox Series 2000 WDG-IV / IVC / IVCM

WARNING - EXPLOSION HAZARD - SUBSTITUTION OF COM-

WARNING - EXPLOSION HAZARD - WHEN IN HAZARDOUS LO-

WARNING - EXPLOSION HAZARD - DO NOT DISCONNECT

THIS EQUIPMENT IS SUITABLE FOR USE IN CLASS I, DIVISION

• When the equipment is ready to be disposed of, take it to your local or

x | Thermox Series 2000 WDG-IV / IVC / IVCM

Use Proper Wiring

Avoid Electrical Overload

Ground the Product

Do Not Operate without Covers

Use Proper Fuse

Do Not Operate in Explosive Atmosphere

Product Damage Precautions

Use Proper Power Source

Do Not Operate with Suspected Failures

Manufacturer’s Name: AMETEK/Thermox®

Conform to the following standards:

Low Voltage Directive 73/23/EEC:

Series 2000 Controller also has the following safety compliance:

Manufacturer’s Address in Europe:

xii | Thermox Series 2000 WDG-IV / IVC / IVCM

THIS WARRANTY IS GIVEN AND ACCEPTED IN LIEU OF ALL OTHER WARRANTIES,

xiv | Thermox Series 2000 WDG-IV / IVC / IVCM

A sample is drawn from the process stream by means of an air-operated

Follow these cautions when working on the sensor:

Basic Elements of the Sensor

 The Measuring System

 The Temperature System

The Oxygen Measuring Cell

1-2 | Thermox Series 2000 WDG-IV / IVC / IVCM

where R and F are constants, T is absolute temperature, and O1 and O2 are

For measuring oxygen in non-combustibles gases, the calibration of an

Where A is a constant, T is the cell temperature on an absolute scale (°C +

Because of the high operating temperature of the cell, combustible

When hydrocarbons are present in the gas sample, a combustion process

The amount of oxygen reduction is dependent on the type of hydrocar-

1-4 | Thermox Series 2000 WDG-IV / IVC / IVCM

1-6 | Thermox Series 2000 WDG-IV / IVC / IVCM

The Thermox catalytic combustibles detector will detect combustible

The combustibles span gas for calibration should be 60 to 80% (ppm

 If your process is running and the analyzer is installed on the pro-

 For O2 calibration gases, do not use calibration gases to check Ther-