The document discusses a combustion analyzer system that provides precise measurement of oxygen, combustibles, and methane to ensure safe operation of burner management systems. The system includes a combustion analyzer sensor that measures these components with high accuracy and reliability. It also includes an HMI interface that enables remote calibration and diagnostics to monitor the sensor's performance. The system offers several configuration options and is designed to provide an additional layer of safety in industrial combustion applications.

1. A New Standard of Excellence

2. PREVENTION IS SO EASY...
LIVING THROUGH A DISASTER IS NOT
The reliable identification of low combustion oxygen in a fired heater or boiler has
always been critical to the effectiveness of the Burner Management System for
proper control and safety.
Low emission burners and aggressive firing control points to achieve increased
efficiency and emission reductions have driven the industry to tighter control
measures. But tighter control measures also hold a greater potential for combustion
damage. Reducing the risk of a combustion event has become a priority and has
led to the implementation of Safety Instrumented Systems (SIS). This additional
layer of safety is added to the Basic Process Control System.
The WDG-V has been designed to provide an additional layer of safety with the
measurement of excess O2
, Combustibles and Methane. These measurements are
used to ensure the safe operation of the Burner Management System.
The WDG-V Combustion Analyzer is designed to provide the complete solution
for combustion process control and process control safety applications. The
WDG-V Combustion Analyzer has built-in redundancy and diagnostics to monitor
performance and health as well as provide the statistical data needed to implement
predictive and proactive maintenance programs. In control and safety applications,
it is critical that the analyzer is always operational.
Precise control of low O2
setpoints with confidence
CO detection for control interlocks and safety shutdown
Predictive diagnostics
SIL 2 capable for SIS implementation of IEC 61508/61511 into
the burner management system

3. WDG-V COMBUSTION ANALYZER SENSOR
RANGES: O2
0-1% to 0-100%
COMBUSTIBLES 0-1000ppm with overrange
0-2000ppm to 0-5%
HYDROCARBONS 0-1% to 0-5%
RESPONSE: O2
90% < 11sec with
Flame Arrestors
ANALOG OUTPUT: (3) 4-20 mA
ALARM OUTPUT: (5) Dry Contact
PROCESS CONNECTION: 2”, 3” or 4” Flange
AMBIENT TEMPERATURE: -25°C to 65°C
DIGITAL INTERFACE: MODBUS RTU, Configuration Software
ENCLOSURE: Class I, Div II, Gp B, C, D / ATEX Zone 2, T3, IP65
POWER REQUIREMENT: 115 VAC, ±10%, 47-63 Hz, 740 VA
230 VAC, ±10%, 47-63 Hz
DIMENSIONS (LxWxD): 44.45 x 31.75 x 19.8 cm (17.5” x 12.5” x 7.8”)
WEIGHT: 20 kg (44 lbs.)
AMEVISION HMI
COMMUNICATION: 2 Wire MODBUS
DISPLAY: 4.2” Color 1/4W VGA with GUI
KEYPAD: Alpha Numeric Membrane
ENCLOSURE: Div 2, Zone 2, IP65 (NEMA 4X)
POWER REQUIREMENT: 115 VAC or 230 VAC
OUTPUTS: 2 or 4 Wire MODBUS RTU-
Configurable, Ethernet-RJ45
connection with Web Server
DIMENSIONS (LxWxD): 22.9 x 22.9 x 13.3 cm (9” x 9” x 5.25”)
WDG-V COMBUSTION ANALYZER SYSTEM
REMOTE CALIBRATION UNIT (RCU)
GAS CAPABLE: Aspirator Air (Span)
Optional Span O2
Zero O2
Combustible Span
Hydrocarbon Span
ENCLOSURE: IP65, NEMA 4X
Class I, Div 2; ATEX Zone 2
POWER REQUIREMENT: None (Supplied from Analyzer)
CONSTRUCTION: 316SS, Hard Piped
DIMENSIONS (LxWxD): 26 x 31.2 x 13.3 cm (10.25” x 12.28” x 5.25”)

4. # COMPONENT SENSOR ENHANCEMENTS
1 Enclosure The Sensor enclosure size and weight has been reduced by over 30% and features a
hinged door IP65 enclosure as standard. Lightweight, high “R” value blanket
insulation inside the enclosure insures sensor temperature stability throughout wide
ambient temperature cycles.
2 Sensor Heater Block High output single cartridge heater with improved thermal transfer radiant block
maintains internal sensor and enclosure temperature to 235°C with only a 30% duty
cycle leaving added capacity for extreme temperature environments.
3 Aspirator Block New Aspirator block design with increased orifice sizes reduce chances of particulate
interference. Instrument Air or Nitrogen drive gas consumption is reduced by over
20% while directing more process convective flow to the sensors. Analyzer response
time with sensor flame arresters is improved to levels of analyzers without flame
arresters installed.
4 Combustible Sensor Combustible and Hydrocarbon detectors are installed in a thermally controlled flow
block of substantial mass, independent of enclosure temperature, insuring precise
temperature stability of detectors, reducing the effects of thermal drift.
5 Flame Arrestors Flame arrestors are incorporated into the convection flow loop so that they may be
inspected or replaced in minutes. An upstream arrestor “cartridge” installed in the
combustible flow sensor block can be inspected or replaced in minutes without
disassembly of sensor piping.
6 Flow Sensor A flow sensor is incorporated into the sensor piping to detect and alarm when sensor
flow is reduced or stopped to insure the sample transport integrity to the
measurement sensors from inlet probe tip to exhaust port.
7 Zirconia Cell Furnace New cell furnace design reduces the size and susceptibility to vibration and
environmental effects. Redundant thermocouples for cell temperature measurement
improves reliability of the measurement. The re-orientation of the cell furnace
parallel to the combustible sensor block efficiently utilizes cell furnace heat for
maintaining combustible detector temperature stability.
8 Sensor Terminal
Enclosure
Modular snap in terminal strips with laser etched labels simplify wire connections.
Recessed electronics and bottom conduit connections eliminate problems due to
conduit stress, moisture egress, and improve the reliability and integrity of the sensor
connection in high radiant heat areas.

5. • Sample Flow Verification
• Calibration History
• Cell & Detector Trending
• ‘End of Life’ Prediction of
Zirconium Oxide cell &
combustible detector with
Warning
• Stability Indicator during
the Calibration Process
• Analog Output Verification
• Individual Controls of
Analog Outputs, Relays
• Time Stamped Alarm/
Event Log
• Trend Data Logging &
Access by USB Port
• Redundant Cell, Enclosure
& Electronics Temperature
Monitoring
Enables the convenience of site
calibration and communication
with the analyzer
• MODBUS RS485
• TCP/IP Ethernet
• USB Port
• 4.2” colorVGA display
AME
VISION
Display Unit Interface
DIAGNOSTICS & AMEVISION HMI

6. © 2013, by AMETEK, Inc.
All rights reserved. Printed in the U.S.A.
F-0409 Rev. 3 (1013)
150 Freeport Road, Pittsburgh, PA 15238
Ph. +1-412-828-9040, Fax +1-412-826-0399
www.ametekpi.com
CONFIGURATION 2: STAND ALONE SENSOR WITH AMEVISION HMI
CONFIGURATION 1: SENSOR - STAND ALONE, BPCS OR LOGIC
SOLVER COMMUNICATION
CONFIGURATION 3: MULTI-SENSOR with AMEVISION HMI