PROCESS INSTRUMENTS

®
ATEX II 3 G WDG-IV Series
THERMOX
Close-coupled aspirated analyzers for measurement of oxygen,
combustibles and methane in flue gas streams up to 1648°C.
The WDG-IV series analyzers mount directly on the combustion process and
are designed for direct measurement in high temperature flue gas applications
such as fired heaters and furnaces, but are equally at home on boilers and
other lower temperature applications These analyzers are suitable for gas
streams up to 704°C using the standard 316SS probe/filter assembly. Flue gas
temperatures up to 1648°C can be measured using optional high temperature
probes. For corrosive gas streams, sample wetted parts in Hastelloy® or Inco-
nel® are available. The analyzers can be provided with separate control unit
(Series 2000) or integral on-board electronics (Smart Sensors) and are offered
in a range of mounting styles. Optional combustibles and methane detectors
are available for optimal control of the combustion process.

ATEX II 3 G MODELS
SERIES 2000 BASED SMART SENSOR VERSIONS
WDG-IV Oxygen WDG IV/IQ Oxygen
WDG-IVC Oxygen and Combustibles WDG IVC/IQ Oxygen and Combustibles
WDG-IVCM Oxygen, Combustibles & Methane WDG IVM/IQ Oxygen and Methane
WDG IVCM/IQ Oxygen, Combustibles & Methane

SENSOR SECTION Environment:

Principle of Operation: Zirconium oxide for net oxygen Ambient Temp.: -20°C to 60°C
measurement and hot-wire type catalytic detectors for both Relative Humidity: 10% to 90%, non-condensing
combustibles and methane. Enclosure: NEMA 4X (IP65) hinged stainless steel wall
Output Range: mount; optional floor mount.
Oxygen: From 0-1 to 0-100% Calibration Gas Requirements: For sensors without flame
Combustibles: From 0-2,000 ppm to 0-10,000 ppm or from arresters use calibration gases @ 10 PSIG, 1.5 SCFH (0.7 L/min.)
0-2% to 0-5% For sensors with flame arresters use calibration gases @ 10 PSIG,
Methane: 0-2% to 0-5% 2 SCFH (1 L/min.)
Accuracy: Note: Flame arresters are standard in all certified Div. 2 and ATEX
Oxygen: ± 0.75% of measured value or ±0.05% O2, which-
analyzers
ever is greater
Combustibles: ± 2% of full scale output range O2 Span Gas: Air or from 1.0% to 100% O2, balance N2
Methane: ± 5% of full scale output range O2, Comb. & CH4 Zero Gases: From 0.1 to 10% O2
Response: (2% recommended), balance N2
Oxygen: 90% of a step change < 30 secs. Comb. Span Gas: 800 ppm CO, 800 ppm H2, 2 to 4%
Aspirator Air Requirements: 4.72 to 9.4 L/min. at 1.05 to O2, balance N2 (for a 0 - 2000 ppm combustibles range)
7.04 kg/cm2
CH4 Span Gas: 2% CH4, 8% to 10% O2, balance N2
Max. Flue Gas Temp. / Probe Material / Lengths:
SYSTEM COMPLIANCE:
704°C / 316 SS / 91 cm - 274 cm
EMC Compliance: 2004/108/EC
1024°C / 310 SS / 91 cm - 274 cm
Electronics Safety Compliance: 73/23/EEC
1648°C / Hexoloy® / 60 cm - 182 cm
ATEX Directive 94/9/EC
Max. Sample Dewpoint: 200°C
Sample Pressure: Subatmospheric TYPE APPROVAL (LCIE 05 ATEX 6140 X and LCIE 05 ATEX 6140 X / 02)
Hand Held IQ Link II 3 G Ex iL IIC T4 Gc -20°C ≤ Ta ≤ 70°C
Purge Flow During Rapid Exchange Period: Wall Mount IQ Link II 3 G Ex nA IIC T4 Gc -20°C ≤ Ta ≤ 70°C
340 L/min. Series 2000 Control Unit II 3 G Ex nA IIC T3 Gc -10°C ≤ Ta ≤ 50°C
Purge Flow During Normal Operation: 30.2 WDG... II 3 G Ex pZ IIC T3 Gc -20°C ≤ Ta ≤ 60°C
L/min.

[Link]
 INTERFACE OPTIONS
The choice of smart sensors or discrete sensor and control unit combinations offers flexibility NEMA 4X
THERMOX ®
to suit application and site requirements. Stainless Steel
IQ analyzers incorporate all the necessary intelligence for operation and to provide analog
outputs and alarms directly from the sensor. User access is via a handheld or wall mount IQ
Link™ communicator. For installations where a separate control unit is preferred, the Series
2000 can be located up to 304m from the sensor.
NEMA 4

SERIES 2000 CONTROL UNIT

Display: Four-line x 20-character
vacuum fluorescent.
Analog Output: Two isolated linear cur-
rent outputs. One additional output each
for combustibles and methane (options).
Handheld IQ Link and Wall Mount IQ Link
Alarms: Two independent oxygen Series 2000 Control Unit
alarms, each high or low selectable. Two
high combustibles alarms (optional). Two Calibration: Oxygen cell lifetime
extender. Calibrate or verify calibration. be easily rewired depending on plant
high methane alarms (optional). One needs. With optional HART® protocol,
loss of purge alarm (on sensor). Store last calibration and verification
a universal controller can be used in lieu
Environment: data. Selectable calibration gas run time
of or in addition to the IQ Links. Device
Ambient Temp.: -10°C to 50°C and process recovery time.
descriptions are registered with the
Humidity: 10% to 80%, non-condensing Diagnostics: Watchdog timer and ser- HART foundation.
Communications: RS-485, 2-way vice alarms. System test for A/D, RAM, Interface:
addressable. EEPROM, and keypad. Display line 4 Handheld: RS-232 plug in 213 cm cable,
Enclosure: Weatherproof NEMA 4 (IP reserved for full text error and diagnostic general purpose enclosure.
65). NEMA 4X (IP 65) stainless steel messages. Twenty-entry event log.
Wall Mount: RS-232, max. distance
available as option. Analog Output: Each output can be 1524 cm, NEMA 4X (IP65) enclosure.
4-20 mA or 0-20 mA and is fully scal- Environment:
COMMON FEATURES able. Hold or track during calibration and Operating Temp.: -20°C to 70°C
Display: Selectable displays with pass- select degree of damping. Humidity: 5% to 80% (non-condensing)
word protection, programmable pressure Display: Four-line by 20-character LCD
compensation and context-sensitive IQ VERSIONS Analog Output: One isolated linear
help. output. One additional output for com-
Handheld or dedicated wall mount IQ
Alarms: One alarm can be assigned bustibles and one for methane. Max.
Links provide a local interface to the
as oxygen, in calibrate or in verify. Set load 1000 ohms.
Thermox line of Smart Sensors using
relays to energize or de-energize on RS-232 communications. The IQ links Alarms: One dry contact alarm. One ad-
alarm. SPST type. Contact rating 0.5 A, are used to set up and display system ditional alarm for combustibles and one
30 V, 10 VA max. non inductive load, AC parameters, initiate calibrations, and for methane (options). One loss of purge
or DC. perform system tests and troubleshoot- alarm (on sensor).
ing. The handheld link can be plugged Communications: RS-485, 2-way
into any Thermox IQ Analyzer. The addressable or HART.
dedicated wall mount version is hard
wired to a specific analyzer but can

RELIABLE AND EASY TO SERVICE CONTROLLED 2

TEMPERATURE 695°C
AIR
All models use zirconium oxide REFERENCE
SIDE
for net oxygen measurement and
2

REFERENCE
ELEMENT catalytic detectors for combustibles
ZIRCONIA

SAMPLE
and methane. The sample path GAS SIDE
is through large internal diameter PLATINUM
ELECTRODES
tubing with no restrictions allowing
CATALYTIC
unobstructed sample flow through
the analyzer. The oxygen cell and
1500

SENSOR
Reducing
Cell Millivolts

Oxidizing

catalytic detectors are designed for

Net Excess Fuel

CATALYTIC
Net Excess Oxygen
Sub-stoichiometric
Lambda > 1
Lambda < 1

ELEMENT 0

COMBUSTIBLES
10 % Oxygen 0 % Combustibles 10

SENSOR long life in demanding applications.

HOUSING
All parts are easy to reach and can
be replaced using standard tools
without having to remove the ana-
FLUE GAS FLOW lyzer from the flange.

Catalytic Detector Zirconium Oxide Cell

2
 THERMOX ®
CLOSE-COUPLED ASPIRATED TECHNIQUE

Case heaters maintain the internal sample wetted parts

above the acid dew point of the flue gas. A sample is
drawn into the analyzer by means of an air or nitrogen op- O2 CELL & FURNACE

erated aspirator and returned immediately to the process.

This is the primary or fast loop. A convection loop contain- COMBUSTIBLES & METHANE
DETECTOR OPTION
ing the zirconium oxide oxygen cell is mounted at right
angles to the primary loop. Due to the natural convection
generated by the temperature difference between the cell FLAME ARRESTERS

location (695°C) and the return leg (approximately 215°C),

a portion of the sample rises into the convection loop, past
the detectors and oxygen cell then back to the primary
CONVECTION
loop. The controlled conditions of the convection loop LOOP FLOW
ASPIRATOR

are ideally suited to catalytic combustibles and methane

EXHAUST
detectors which benefit from a constant temperature and SAMPLE
constant flow environment. PROBE
INLET
CAL GAS PRIMARY LOOP FLOW
INLET

SENSOR DETAILS
2

1
1
4
5 3

6
18

16
7 8

17
9
14
11

10
12
15

13

1 Insulated SS Enclosure 7 Combustibles Detector (option) 13 Aspirator Air Regulator & Gauge
2 Vent 8 Methane Detector (option) 14 Purge Enclosure and Terminal Box
3 Oxygen Cell (zirconia) 9 Flame Arresters 15 Plug-in Connector (IQ only)
4 Furnace (cell heater) 10 Inlet Hook 16 Flange or Mounting Plate
5 Thermocouple 11 Aspirator Block 17 Process Wall
6 Cell Housing 12 Case Heater 18 Sample Probe

3
ATEX II 3 G WDG-IV SERIES
WALL MOUNT SENSOR (STANDARD MOUNT)
DIMENSIONS IN CENTIMETERS

THERMOX ®
APPROX WEIGHT: 31.75 KG
10.17 59.07 35.56

Enclosure Rapid Exchange

Protection Vent Purging System

Hinge Magnahelic Gauge

Gasket (by Thermox)
Side
Thermox supplied mounting plate
External welded to wall by customer. Flange
CL Probe Location

Terminal Box Ground

adapters are available.
Stud
54.61
Process Wall

IQ Link Connector
(IQ Version Only)

Probe

9.53 Aspirator Air

Inlet 1/4” NPT (F)
17.15
CL Probe Location 14.69
Calibration Gas Inlet FLOOR MOUNT SENSOR
1/4” Compression Fitting APPROX. WEIGHT: 43.09 KG
(Plug during normal operation)

SERIES 2000 CONTROL UNIT

NEMA 4 / NEMA 4X (CUTOUT: 31.18 cm H X 27.31 cm W)
APPROX WEIGHT: 12.7 KG

Plate for
Wall/Pipe
mount
Shroud and mounting
plate assembly
29.85

IQ Link
Connector

Gasket (by Thermox)

3"-150# flange and nipple
welded to top of duct
by customer

Dia. (4 places) Hardware supplied

by Thermox Requires 1" (2.54cm) min. insulation
around exposed portion of nipple
Process wall
25.4
Probe

WALL MOUNT IQ LINK MODEL POWER REQUIREMENTS

APPROX WEIGHT: 4.53 KG WDG-IV, WDG-IVC, WDG-IVCM 104-127 / 207-253 Vac, 700 / 1950 VA
19.68 WDG-IV, WDG-IVC, WDG-IVCM (Floor Mount) 104-127 / 207-253 Vac, 750 / 2000 VA
WDG IV/IQ, WDG IVC/IQ,
104-127 / 207-253 Vac, 740 / 1990 VA
Thermox WDG IVM/IQ, WDG IVCM/IQ
WDG IV/IQ, WDG IVC/IQ,
104-127 / 207-253 Vac, 790 / 2040 VA
WDG IVM/IQ, WDG IVCM/IQ (Floor Mount)
10.16 18.34
IQ LINK Hand-Held IQ Link 9 - 15 Vdc, 0.1 A
.74Ø
4 PL Wall Mount IQ Link 104 - 253 Vac, 8 VA
PROCESS & ANALYTICAL INSTRUMENTS DIVISION Series 2000 Control Unit 104 - 253 Vac, 30 VA

18.42
NOTE:
21.59 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.

SALES, SERVICE AND MANUFACTURING:

USA - Pennsylvania
150 Freeport Road, Pittsburgh PA 15238 • Tel: +1-412-828-9040, Fax: +1-412-826-0399
USA - Delaware
455 Corporate Blvd., Newark DE 19702 • Tel: +1-302-456-4400, Fax: +1-302-456-4444
150 Freeport Road, Pittsburgh, PA 15238 Canada - Alberta
2876 Sunridge Way N.E., Calgary AB T1Y 7H2 • Tel: +1-403-235-8400, Fax: +1-403-248-3550
Ph. +1-412-828-9040, Fax +1-412-826-0399
[Link] WORLDWIDE SALES AND SERVICE LOCATIONS:
USA - Houston, Texas FRANCE
Tel: +1-713-466-4900, Fax: +1-713-849-1924 Tel: +33 1 30 68 89 20, Fax: +33 1 30 68 89 99
GERMANY
BRAZIL Tel: +49 21 59 91 36 0, Fax: +49 21 59 91 3639
Tel: +55 19 2107 4100
INDIA
CHINA Tel: +91 80 6782 3200, Fax: +91 80 6782 3232
© 2015, by AMETEK, Inc. Beijing / Tel: +86 10 8526 2111, Fax: +86 10 8526 2141 SINGAPORE
All rights reserved. Printed in the U.S.A. Chengdu / Tel: +86 28 8675 8111, Fax: +86 28-8675 8141 Tel: +65 6484 2388, Fax: +65 6481 6588
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One of a family of innovative process analyzer solutions from AMETEK Process Instruments.
Specifications subject to change without notice.