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1. B 4 18 9 cr i Te TAS D El N o7 i i o 1 E e y U 20 23 4 ITEM DESCRIPTION PART ITEM DESCRIPTION PART NUMBER NUMBER 1 Manifold Ass Solenoid 24437 13 Bracket Fan MT3500A7 2 Label English French MT3000A37A 14 Guide Circuit Card 22066 3 Filter Assembly See Page 9 5 15 Bracket Monitor MT3500A6 4 Bumper Rubber 8518 16 Power Supply Assy MT3500A500 5 Grommet Blk Plastic 85716 17 Chassis Subassembly MT3500A600B 6 Switch On Off 28658 18 Bezel w handle MT3500310 7 Fuse 20A 32V 210551 19 Shield Monitor MT3500A340 8 Fuse Holder 210951 20 Knob 86330 9 Pump Sample MT3500A21 21 Bench 7049012901 10 Bracket Pum
2. LEAK TEST A MODE PULL DOWN COMPONENT TYPE STATE ACTIVE PORT PUMP NA ON NA 51 3 WAY DE ENERGIZED NO 52 NC DE ENERGIZED NA Zero Gas Por Port Z A Back Y Panel _ 2 RD NC S2 NC sal S1 MANIFOLD COM Y ean _ _ A Restrictor r n Pet is ea cec tM Bench Assembly A Low on BENCH BP iid D X ducer 1 l D A A Restrictor CAP V EXHAUST PROBE 2 O A i Check D gt Exhaust Valve Back D Panel b VAC PUMP O Check DDD DIN Exhaust 2 9 OD D D Q Q Valve lt j DENOTES PRIMARY FLOW PATH DENOTES OTHER AFFECTED PNEUMATICS Sin SUN ELECTRIC CORPORAT ION One Sun Parkway Crystal Lake linois 600 U S A MODEL MT 3505 0195 REV A we J HINKLE CH BY PULL me LEAK TEST A DOWN DIG 5 3 PAGE 5 7 NOTES Page 5 8 All information
3. 1 RSTOR None 19 LENGTH 066 36 HEXMODE Off 2 SAVE None 20 WIDTH 8 37 AUTO CR On 3 DFALT SUN 21 DEMAND Auto 38 AUTO LF Off 4 TEST None 22 BIN None 39 AUTO FF Off 23 TOP MAR 000 40 PAPROUT On 5 EMUL MT3010 24 BOT MAR 066 41 SLASH 0 On 6 FNT Draft 25 LFT MAR 000 42 QUIET Off 7 PITCH 10 26 MAR 080 43 LF SPD 5 0 8 LPI 6 cowwuNrcarrous 44 DELAY 3 SEC 9 TALICS Of 27 DWNLOAD Off 10 Off HIGH Off 28 INTRFCE Par 1 WIDE Off 29 BAUD 9600 12 SCRIPT Off 30 PARITY None 13 UNDLINE Off 31 DTA BITS 8 14 BLD SHA Off 32 STOP BITS 5 CIR JST Off 33 HNDSHAK DTR 6 LANG PC437 34 DIR Low 7 DIRCIN Bi d 35 IPRIME off 8 GRFICS Uni PAGE 11 1 ACCESSING THE SETUP MENU Press Setup to enter the Setup menu When the Setup menu appears the control panel acts like a one line window over the menu Each line contains a different parameter Turning the Select dial scrolls the menu up or down past the window Each parameter is numbered so you can always tell where you are in the menu Beside each parameter is the current setting
4. CPU BOARD Front Panel Brightness Control 1 1 2 212 13 13 i Vus fr O EXTERNAL u ur 6 6 3 BIT 7 7 BRIGHTNESS o zt tr ut 8 8 5 2 9 9 8 s 10 10 HORIZONTAL DRIVER HIGH 29 BEEN OUTPUT CIRCUITRY VOLTAGE 5 ga 13 13 12 Volts IN 2 14 14 20 15 VIDEO 45 VIDEO VIDEO 16 16 DRIVER OUTPUT VERTICAL SYNC VERTICAL DRIVER OUTPUT CIRCUITRY 19 19 0 0 VIDEO VIDEO DISPLAY DISPLAY RAM RAM VIDEO BOARD COMES WITH MONITOR FIGURE 4 1 TROUBLESHOOTING Not available at time of publication PAGE 44 NOTES PAGE 42 CHAPTER 5 PNEUMATICS GENERAL The pneumatic system associated with the MT 3505 is controlled by two solenoid valves which are in turn controlled via solenoid drivers on the Main CPU Board These solenoid valves operate in four different modes They are 1 Zero Mode 2 Gas Calibration Mode 3 Leak Test Modes and 4 Sample Mode A detailed description of each follows ZERO MODE DRAWING 5 1 PAGE 5 3 To maintain the high accuracy of the MT 3505 the analyzer must continually be zeroed This can be done manually by turning on the Auto Zero function F3 in t
5. 1 14 43 ll 1 12 1l isi ft LU N Ras A L 22 yl 5 WW 12 SUS 7 pros UA 8 No B h NY P J PR 3 N 9 M 1 0 P on Se ITEM DESCRIPTION PART ITEM DESCRIPTION PART NUMBER NUMBER 1 Fitting Brass Nipple 0647030101 8 Nut Filter Bowl 0301094801 2 Nut Brass Seal 0647030201 9 Nut Filter Retaining 0301094601 3 Fitting Brass Elbow 0647030301 10 Bowl Filter 0301094701 4 Fitting Male Brass 113380 11 Plug Filter 06470138 5 Element Primary Filter 0301094401 12 Element Sec Filter 0301094501 6 Fitting Brass Elbow 113680 13 Bracket Filter MT3500A9 7 Fitting Brass Nipple 113480 14 Head Filter 0301094201 PAGE 9 5 DESCRIPTION Adapter Inductive Pickup AntiDilution Exhaust Probe Battery External NO Cell Bench Bezel w handle Board Connector Board Main CPU Board NO O Interface Bowl Filter Bracket Bench Support Bracket CRT Board Bracket Fan Bracket Filter Mounting Bracket Pump Support Bracket Speaker Breaker Circuit Bumper Rubber Bumper Rubber Cable 20 Pin Ribbon Cable 5 Pin Ribbon Cable 9 Pin Ribbon Cable 9 Pin Ribbon Cable O and NO Cell Cap Needle Adapter Cap Sample Probe Case Top Channel O and NO Chassis Subassembly Clamp Cab
6. BACK PANEL CB1 s Tn F1 POWER 20A SWITCH P2 NOT USED 1 Z 412VDC 2 O OS 907 oi ST3 12VDC GND 1 a 12V RTN 3 ST1 12V RTN VCC 45V 2 PGNDS 3 lt 15HPS 4 Q pol JUMPER gt _ P1 15HP gt gt _ F u T lo fv 15V 6 a B vd ono List s MOT AGND 7 dl Lee lj pues ue 3 NEUTRAL N 15V 8 E 1 GND PGND 9 INPUT FILTER FUSE ASSY 77 CHASSIS POWER SUPPLY MT3500A500 SUN ELECTRIC CORPORATION One Sun Parkway Crystal Lake Illinois 60014 U S A MODEL MT 3505 0795 REVB DWG BYeff Hinkle CHK BY TITLI o E AC DISTRIBUTION DWG PAGE 1 1 1 5 CHAPTER AC DC DISTRIBUTION NOTES Effective Page 1 6 2 97 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric Corporation Al manufacturing use reproduction and sales rights are reserved by Sun Electric Corporation and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric Corporation O2 NO DISPLAY S2 INTERFACE PCB CRT PWB P1 1311109 7 615 4 3 2 1
7. Zero Gas Por Port A Back 7 o Panel 777 o 8 Uno S2 a MANIFOLD ZZ Y COM BE a co i A Restrictor n Y gt Y A A cec C M Bench Assembly dE D UT TU A NO N Low x D Flow n g BENCH BP ID W Sensor X ducer D x D UE V oo e Restrictor Ys o A See zer Check o LL IN Exhaust Valve Back D Panel VAC PUMP D D Check DD D oO J T IN Exhaust OQ 2 OQ J OD OD OD Q Valve lt gt DENOTES PRIMARY FLOW PATH DENOTESOTHER AFFECTED PNEUMATICS E CORPORAT ION SAMPLE MODE was COMPONENT TYPE STATE ACTIVE PORT wn MT 3505 0195 REV A PUMP NA ON NA wg J HINKLE 0 8 81 3 WAY DE ENERGIZED NO TME s2 NC DE ENERGIZED NA SAMPLE WE PAGE 5 5 5 11 NOTES Page 5 12 CHAPTER 6 INFRARED GENERAL NOTE The term IR Bench is used throughout this chapter to refer to the Andros 5 Gas Infrared Analyzer There are three key components that make up the Infrared Exhaust Analyzer function They include the CPU Board Andros Infrared Bench and the Pneumatics The Analyzers purpose is to measure the concentrations of Hydrocarbons HC Carbon Dioxide CO2 Carbon Monoxide CO Oxygen O2 and Nitric Oxide NO emitted from the exhaust of an automobile The infrared bench i
8. 11 1 AMT PARALLEL PRINTER ttr tri na Loan e ta red ih a Fe trat i RR Aaa iaei cin 11 1 USING THE SETUP MENU u u EE ETE EIE 11 1 ACCESSING THE SETUP MENU A A i i tenentes 11 2 SELEGTING OPERATIONS 2 aaa 11 2 SERVICE MODE FUNCTIONS IILI cnn cnn cnn cnn cnn rra 11 8 ERROR MES O AGED u tee edipi 11 10 MT3010 SCRIBE Il PARALLEL PRINTER 11 13 INDICATOR LIGELITS s o ce sa u ee ee een 11 13 SELECTING THE POWER ON CONFIGURATION 11 13 CHANGING THE POWER ON CONFIGURATION 11 14 SELECTING THE MENU essent nennen etre nnns 11 14 CHANGING THE MENU MODEL LIU nnne nnne enne 11 14 RUNNING THE SELF TEST IILI nente nne nnne nennen nnne ninia STEARRE 11 14 MT1670A SERIAL PRINTER tinta grana t cttm y Lui o E 11 15 FRONT PANEL CONTROLS AND DISPLAY sess 11 15 BACK PANEL uu c 11 15 PRINTER COMPARTMENT cnn cnn cnn cnn 11 16 TROUBLESHOOTING wes aia u ce De a a ln gies in a e 11 17 FUNCTIONAL BLOCK DIAGRAM conca 11 21 APPENDIX A SOFTWARE PAGE FLOW APPENDIX BGLOSSARY GENERAL B 1 APPENDIX C BOARD CONFIGURATION GENERAL tete er
9. PUMP 51 E NOT NOT lt a lt NOT USED USED THERMO alcia USED TACH COUPLE EP 12 112 1 2 a 1213 J15 123 4 J16 o 8 7 615 4 3 2 1 a 2 1 o o cc of 9 o m a ar P4 P2 lt lt N x 00 od hs IN at 5 t at at O O RXD3 1 gt gt s IN Jo ET 65 5 5 zoo 2 Al Oi Qs lt lt 0000 TXD3 2 5 m m a OFF GND 1 1 GND nam 2 02 CTS3 3 gt voc 2 2 vcc SV J18 J17 ERE IDO J22 J21 J20 J19 RTS3 4 PGNDS 3 3 PGNDS RXD2 5 T 15HPS 4 4 415HPS 3 J9 TXD2 6 O JA sup 5 5 5HP E J13 CTS2 7 z 15V 6 6 415V 8 RTS2 8 LLI AGND 7 7 AGND amp DTR2 9 m 15V 8 8 15V DSR2 10 PGND 9 9 PGND RTS4 11 RXD4 12 N CTS4 13
10. BACK PANEL 3 3 313 TACHI 3i Fata 414 1 COMPARITOR ENGINE COUNTER MT60A08A 515 515 TACH 2 3 SYNC TIMER SIE SIE PROG PLUG WIRE g CPU Board AAA ECC 4 Figure 1 RPM CIRCUITRY PAGE 84 NOTES PAGE 82 CHAPTER 9 PARTS GENERAL This chapter contains parts considered replaceable during field service It includes assemblies subassemblies and piece parts NOTE The following is a breakdown description for the MT3505 serial numbers Serial Number Location Back Panel bottom left hand corner on the Serial Plate Example 1194A0102 11 Month Manufactured 94 Year Manufactured A Serial Revision 0102 Number of Unit Off Production Line Example A95030102 A Serial Revision 95 Year Manufactured 03 Week Manufactured 0102 Number of Unit Off Production Line PARTS BY PICTORIAL The following section is a list of parts in pictorial form PAGE 9 1 ITEM N FRONT BEZEL VIEW o me m il J 4 l f Un En A i la EI oe 2 DESCRIPTION PART ITEM DESCRIPTION PART NUMBER NUMBER Gasket CRT MT16651013 4 Monitor MT3500320 Escutcheon MT3500301 5 Keyboard MT3500A330 Bezel w Handle MT3500310 6 Standoff 15061 7 Grommet 85216 PAGE 9 2 INSIDE VIEW
11. 2 1 pM ies 2 1 gibt cL 2 1 VIDEO ened pnd gig da Bay Devt vend Sea deny dant pnd Dae Bay Bent vin a dey dex gina Ry 2 2 SERIAL PARALLEL VO 2 2 PUMPS ors M 2 2 NODI T 2 2 TACHOMETER itr edem usnu 2 2 THERMOGOUPLE uuu Em 2 2 TROUBLESEQOOT NQG uu u u u o dee ee Uh e a od e tate prd 2 2 FUNCTIONAL BLOCK DIAGPAM IILI II nne sasana nent nnne rnnt nnne 2 3 CHAPTER 3 KEYPAD THEORY OF OPERATION u este He e b e uum 5 Te tie u 2 3 1 TROUBLESHOOTING Z l u u RE HR RE ERE RR ER CREER FRE RAPID s 3 1 CHAPTER 4 VIDEO THEORY OF OPERATION oia 4 1 FUNCTIONAL BLOCK DIAGRAM uuuunsenssenssnnsnnnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 4 1 CHAPTER 5 PNEUMATICS GENERAL coo aiii dario rial 5 1 ZERO MODE D E 5 1 GAS CALIBRATION uu u 1 dt 5 1 LEAK TEST MODES R u rit an Tete AE u htt E a as a u LAC add dla ARR LAORE ARMADA pad ada AULA 5 1 LEAK TEST A MODE ee RE IIT IN AN Mr cant pant tants 5 2 LEAK TEST B MODE e e n atii e CUERO REOR ME FRE L S He sss 5 2 Nadie Pc 5 2 IR CHAPTER 6 INFRARED ciini 6 1 INFRARED THEORY uuu c s ran nn ne Mies pees na Hl Ha nn pa ale Pa pt nah be Pe 6
12. FLA YABA x an an 2 E 2 d I le baal Gas yy A a hex ES J18 30 V AC 1 GND ER 30 V AC a PUMP PUMP DRIVER CIRCUITRY 52 21 SOLD2 AVV 15HP 2 SOLENOID DRIVER CIRCUITRY J22 S1 15HP_ o AAAA Sit s m swi _ TILT O O MERCURY SWITCH SUN ELECTRIC CORPORATION One Sun Parkway Crystal Lake Illinois 60014 U S A MODEL MT 3505 0795 REV B DWG BYJeff Hinkle CHK BY COMP UTER DWG 2 2 PAGE 2 7 A CHAPTER2 COMPUTER NOTES Effective Page 2 8 2 97 CHAPTER 3 KEYPAD THEORY OF OPERATION The keypad is the operator s interface to the MT 3505 s computer It is the only device that the operator has to control the MT 3505 The keypad is a 19 button keypad It is configured in a 3 x 7 matrix with seven active lines and 3 sense lines With these lines the keyboard controller determines which of the keys are pressed This information is then sent to the system controller via control lines The key press is then executed by the CPU For a functional block diagram of the keyboard refer to figure 3 1 below er J12
13. ho ko sa SS e AM menm No CA No T No SUN ELECTRIC CORPORATION BACK PANEL MESES RS232 CONNECTOR WX MT 3505 0395 REV wee J HINKLE OKE SERIAL PRINTER 12 123 NOTES PAGE 11 24 CHAPTER 12 MT 2500 SNAP ON SCANNER GENERAL The MT 2500 Snap on Scanner is an optional analyzer that can be connected to and controlled by the MT 3505 This chapter is not designed to make you familiar with the MT 2500 s operation or to even allow you to troubleshoot the MT 2500 Instead it is designed to tell you how to connect the MT 2500 to the MT 3505 THEORY OF OPERATION The MT 2500 connects to the 25 pin SCANNER port on the back panel of the MT 3505 This SCANNER port is simply a 25 pin serial port which is part of the Connector Board inside the analyzer From the Connector Board the serial information is sent from J1 pins 1 2 3 and 4 on the connector board to J28 pins 1 2 3 and 4 on the CPU board On the CPU board the serial information is processed by Serial Parallel Integrated Circuits and their associated hardware Once the information is processed by these chips the information is sent to the system controller SCANNER SETUP In order to enable the MT 3505 to recognize and control the MT 2500 the
14. NC NC MANIFOLD S2 IT DI we S1 COM i COM LI _ _ Restrictor ETA i sims c mi j eo et URS IN Bench Assembly i I N Low LEE re x Flow BENCH BP E tb Sensor Y X ducer N V oL M d A Restrictor gt Dg N 1 Check IN Exhaust Valve Back Panel VAC PUMP Check IN Exhaust Valve DENOTES PRIMARY FLOW PATH DENOTESOTHER AFFECTED PNEUMATICS SUN ELECTRIC CORPORAT ION CALIBRATION MODE En En COMPONENT TYPE STATE ACTIVE PORT WE MT 3505 0195 REV A PUMP NA OFF NA ma J HINKLE Wg 51 3 WAY DE ENERGIZED NO TRE S2 NC ENERGIZED NC GAS CALIBRATION Dic PAGE 5 2 5 5 NOTES Page 5 6 All information contained or disc losed in this document is considered conf ident ial and proprietary by Sun Electric Corporation A manufacturing use reproduct ion and sales rights ore reserved by Sun Electric Corporation and the informat ion contained herein shal not be used in whole or in part without the express written consent of Sun Electric Corporation
15. X Printer prints garbled text and paper Wrong printer setup or configuration moves erratically y e Ensure Printer and analyzer are set for the same emulation and the same configuration XI Paper does not feed properly Paper is not loaded correctly e Check for proper installation e Check for paper wadding or a paper jam On 80 column printers the tractor select lever is in the wrong position e Forsingle sheets push the lever towards the rear of the printer For pin feed paper push the lever towards the front of the printer XII Printing goes off the right side of the Print width setting is wrong page or does not print all the way M across the page on the 80 column e Change the WIDTH setting in the SETUP menu printers XIII Lines of text print on top of one Automatic line feed mode is off eo column punter e Change AUTO LF setting on the setup menu Paper is not taught between tractor feeder or around platen e Reload paper XIV Printer leaves blank line afterevery Automatic line feed mode is on it needs to be turned off Print ine on pe AMT printer e Change AUTO LF setting in the setup menu PAGE11 18 COMPLAINT XV Carriage does not return to the left margin before printing next line on the AMT printer XVI Printer prints on pin feed perforations on the AMT printer XVII 40 column printer prints garbage CORRECTIVE ACTION Automatic carriage return is off it needs
16. 2 CORRECTING PROGRAMMING ERRORS The printer can notify the user of only one programming error DOWNLOAD ERROR This error occurs when the computer attempts to download a font to the printer but the user has not allocated printer memory to store the font When a download error occurs the printer ignores the downloaded font information and continues printing normally CORRECTIVE ACTION Press lt Ready gt to stop the printing in progress Change the download parameter setting to On Then restart the print job from the beginning PAGE 11 10 3 UNDERSTANDING WARNINGS The printer offers three warnings to notify you of special conditions CHECK TRACTR LVR After a paper park operation this message appears to remind the user to move the paper select lever if the user is going to load a cut sheet into the printer Moving this lever disengages the forms tractor and enables the cut sheet mode If the user forgets to move this lever a paper jam can result since both the cut sheet and pin fed paper will feed into the printer at the same time If the user is not going to load a cut sheet just ignore the message Pressing Ready or moving the paper select lever clears the message CORRECTIVE ACTION If the user is going to load a cut sheet into the printer push the paper select lever towards the back of the printer and press lt Ready gt button TEST IN PROGRESS When the user selects a printer test on the Setup menu this message
17. CHANGING THE POWER ON CONFIGURATION MODE If an Items setting does not match the example below when the LCD shows PRINTOUT use the down arrow key to scroll through the items in the order listed on the printout Then use the left and right arrow keys to change the item s setting Continue this process for any other items that need to be changed To exit from the Power On Configuration Mode press lt MENU gt This saves the changes just made SELECTING THE MENU MODE 1 Turn the printer power ON 2 With the printer OFF LINE press lt MENU gt MENU MODE is displayed on the LCD to confirm this 3 Release MENU PRINT OUT is shown asking if you want to print out the current Menu Mode settings Press the right arrow Pitch or left arrow Font key to begin printout 4 Compare the printout to the one below The settings should match If not refer to Changing The Menu Mode below MENU MODE ITEMS MENU 1 MENU 2 1 FONT DRAFT DRAFT 2 PITCH 10CPI 10CPI 3 LINE SPACE 6LPI 6LPI 4 LEFT MARGIN 0 0 5 RIGHT MARGIN 80 80 6 PAGE LENGTH 66 66 7 TOP MARGIN 1 1 8 BOTTOM MARGIN 2 2 9 SLASHED ZERO OFF OFF 10 DOUBLE HIGH OFF OFF 11 PRINT DIRECTION BI NORMAL NORMAL 12 DEFULT MENU 1 1 CHANGING THE MENU MODE If an Items setting does not match the example above when the LCD shows PRINTOUT use the down arrow key to scroll through the items in the order listed on the printout Then use the left and right
18. Holding down lt Alt gt and turning the Select dial cycles through the possible settings The current setting is displayed wher lt Alt gt is released To leave the Setup menu and redisplay the status message presscSetup again If you display the Setup menu and do not use it for more than one minute the status message will reappear automatically Also pressing any control panel button except lt Alt gt will redisplay the status message Change the current settings as required then save them for use at a later time Specify the power on defaults for the printer to use Print the Setup menu by holding down lt Alt gt and pressing Status SELECTING OPERATIONS RUNNING PRINTER SELF TEST To run the printer self test press and hold lt Alt gt and press lt Test gt BASIC PRINTER OPERATION The first section of the Setup menu is basic printer operations Selecting an operation performs a specific action Unless otherwise specified for MT 3505 operation the settings are identified directly behind the name of the function 1 RSTOR None Restore Printer Settings The first operation on the Setup menu is RSTOR RSTOR is used to restore printer settings to the factory settings or user settings that you saved previously with the SAVE operation When RSTOR is selected the printer clears the data input buffer Selecting NONE can be used to cancel the operation Fctry to restore the factory settings or Usr 1 through Usr 3 to restore the settin
19. Power cable is not plugged into power outlet e Check power cable Power outlet is not supplying voltage e Check receptacle outlet for 110VAC and correct polarity Fuse in Printer is blown e Replace 1 amp fast blo fuse Find the Error message or flashing pattern in the AMT operators manual e Perform the corrective action Printing is in progress e Wait for printing to stop or press lt READY gt to halt printing Printer is not paused e Press lt Ready gt and try again Wrong interface settings are set e Check host analyzer and printer configurations Interface cable is loose defective or wired incorrectly e Check interface cable Replace if defective Printer head gap is too wide e Push the paper head gap lever toward the back of the analyzer Ribbon cartridge is not fully seated in place e Reload ribbon Ribbon is worn e Replace ribbon PAGE11 17 CONPLAINT CORRECTIVE ACTION VII Printing is smearing Printer head gap is too narrow e Pull paper head gap lever towards the front of the printer Ribbon is tangled or folded e Correct problem or replace ribbon Small piece of paper or debris is lodged in front of printhead e Remove obstruction Vill Large portion of characters are not Ribbon is tangled or folded printing Correct problem or replace ribbon IX Characters are missing one or more Printer head gap is too wide dots e Adjust printer paper head lever to correct problem
20. fuel mixture 14 7 1 Rich mixtures are written as a value less than one 0 8 lean mixtures are written as a value greater than one 1 3 A misfire that occurs when the air fuel mixture is too lean to support combustion An air fuel ratio that contains more than the ideal amount of air or less than the ideal amount of fuel The control information prefixed in a message text i e the customers name address phone number A term used to indicate millions of bytes 1 megabyte 1Mb 1 048 576 bytes or 1048 kilobytes 1000k One of the main features of a computer is its ability to store and retrieve information very quickly There are several kinds of memory See RAM ROM EPROM Green keys located on the right of the keyboard used to select one of five analyzer operation categories A computer output device designed to show alphanumeric and or graphics data In personal computing the monitor is usually a TV like video screen An abbreviation for Nitric Oxide which is an Oxide of Nitrogen An abbreviation for Oxides of Nitrogen One of which is Nitric Oxide Nitric Oxide is measured by the MT 3505 A method of transmitting data in which the bits comprising a character are sent at the same time The port used by peripherals to communicate with the host computer in a parallel format Any device that connects to and is controlled by a computer such as a terminal PIXEL PORT PROM RAM RESOLUTION RESPONSE
21. or a malfunctioning carriage home switch CORRECTIVE ACTION First try replacing the ribbon cartridge with another If the error recurs try cleaning the carriage shaft with a soft dry lint free cloth If the error still recurs service must be contacted for repair or replacement EEROM ERROR This error occurs when the printer detects that its non volatile memory is defective or does not contain the correct information REPLACE BATTERY This error occurs when the printer s battery which refreshes the non volatile memory when power is off becomes weak and is not providing reliable operation PAGE 11 12 MT3010 SCRIBE II PARALLEL PRINTER The results and or diagnostic messages of the MT 3505 can also be printed using the MT3010 Scribe Il parallel printer When the printer is activated the print head will travel through its range of motion and will then stop in the center position The power indicator will then light to show that the power is on At that point either the Red P E printer Error light illuminates indicating an error or the On Line indicator will illuminate From any screen pressing lt PRINT gt will print the information on the screen The MT3010 prints at a rate of 250 cps characters per second and can print in near letter quality mode INDICATOR LIGHTS There are four indicator lights used on the MT3010 They are Power On Line Menu and P E for Printer Error or Paper Empty When lit the POWER l
22. 1 CALIBRATION as u ea enge man nn Wan na nn ln Kan He RER havea Vases ann 6 3 FUNCTIONAL BLOCK DIAGRAMS uU IIIa aan nee an a a a a na 6 5 CHAPTER 7 O2 AND NO NO THEORY OF OPERATION UL uu s aaasussusasqassasashassssqskaqpasaqsasqaqasqhasqasaspassasqasasqhasaqasnasasskasq 7 1 O2 THEORY OF OPERATION 3 2 re eet u u xu in fan na ka cen ias 7 1 FUNCTIONAL BLOCK DIAGRBAN l l l l ll li nnne SARRAR RRRA 7 3 CHAPTER8 RPM GENERAL 8 1 THEORY OF OPERATION iiti u u E ER aD MER De ER EA ER Eu ER ADR 8 1 FUNCTIONAL BLOCK DIAGRAM REKAREKA NANENANE n nnne nnne nnns 8 1 CHAPTER 9 PARTS eJ ni 9 1 PARTS BY PIGTORIAL ecc cscs caus vive bows epe ved re pe Ue cus ee E pee re re tous ved ere ae Sa 9 1 FRONT BEZEL VIEW iii 9 2 INSIDE y E u u mu un 9 3 BACK PANEL VIEW uk us ct ui L CEU RE CURED CLAU KA LAO LAE dd 9 4 FETER ASSEMBLY u u dt 9 5 PARTS IN ALPHABETICAL ORDER UI nennen nnne erret nnne nnne tnnt nennen nennen 9 6 PARTS IN NUMERICAL ORDER eere siria er tiras cular ies bene ber apa He Fine uere tied 9 8 CHAPTER 10 THEROMCOUPLE GENERA M 10 1 THEORY OF OPERATION rere kin ede tede 10 1 FUNCTIONAL BLOCK DIAGRAM LLULLU IIIa 10 1 eii i
23. DC Power Manifold Assembly Solenoid Manifold Block O and NO Monitor NO Cell Nut Brass Seal Nut Filter Bowl Nut Filter Element Retaining ORing Filter Sensor Pickup Trigger Plate Oz and NO Mounting Plug Black Plastic Plug Filter Power Supply Assembly Probe Exhaust Pump Sample Restrictor Shield Monitor Spacer Speaker Standoff Bench Standoff CRT Standoff NO O Interface Bd Strip Optional AC Power Switch On OFF Valve Check 85216 85716 85816 51441 22066 MT310047 MT3500A40 MT3500A50 MT3500A10 6105G004ADED 6031C0099901 0301094201 MT310017 MT310020 MT3500A330 86330 MT35002 MT35005 810262 EAL0062C00A EAL0061C00A MT16704A MT3000A37A MT35003A MT35004 MT3000210A 24437 EAA0031C02A MT3500320 7049013001 0647030201 0301094801 0301094601 0301094301 7049000401 MT60A08A EASP033C00A 13740031 06470138 MT3500A500 MT310018 MT3500A21 12779 MT3500A340 04010354 MT3500A1 10 15861 15061 0429003802 EAW0029C00A 28658 12981 4 attached to corners of CRT Side of unit by Power Switch qty 1 On Back Panel qty 4 On CRT sheet metal for Power Supply Wiring Harness Without Flexible Probe Tip With AC Power Line Filter Includes Back Panel Conn amp Harnesses Back Panel Tach Connector and Internal Harness 1 wire Internal Thermocouple Harness 2 wire Internal Thermocouple Harness Primary and Secondary Filter Exhaust Hose Handle and Flexible Probe 25 Feet
24. ERROR MESSAGES PRINTER MESSAGES When a printer message appears in the Select dial control panel find it in this section and perform the corrective action s There are five kinds of messages operating errors programming errors warnings communication errors and printer errors 1 CORRECTING OPERATING ERRORS The printer can notify the user of three operator errors When one of these errors occurs the printer does not lose any buffered data After the user performs the corrective action s printing continues where it left off LOAD PAPER This error occurs when the printer has data to print but no paper is loaded in the printer CLEAR PAPER JAM This error occurs when the printer detects a paper jam while ejecting the current page CORRECTIVE ACTION Carefully remove the jammed paper and press the Ready button PAPER ERROR This error occurs when the printer tries to eject a single sheet or perform a paper park operation but continues to detect paper in the printer CORRECTIVE ACTION If the paper is jammed carefully remove the jammed paper and press the Ready button If the user is just using a very long cut sheet pressForm Feed If the user is using pin fed paper tear off the last printed sheet and then hold down lt Alt gt and press Park If this error occurs with no paper in the printer one of the paper sensors is falsely detecting paper Check for small scraps of paper caught in the front behind or below the platen
25. Replacement Sample Hose No Probe Brightness Adjustment Knob Scanner RS232 Printer etc DC AC Power Connector On AC Power Cord Connector MT3505 Front Panel Adhesive Label Exhaust Probe Warning Label on Handle Electrical Shock Label next to AC Power Input Conn English French Electrical Shock Label Warning on top of Filter Assembly Warning below Tach input connector Might Break This Down into smaller Part Monitor and Monitor Bd mounted on Monitor Shield Between Primary Filter Bowl and 90 Adapter Primary and Secondary Filter Bowl Nut Primary and Secondary Element Retaining Nut Primary and Secondary Filter Bowls Inductive Trigger Pickup with Cable Sheet Metal 2 Plugs Below Cal and Zero Ports on Back Panel Bottom of Secondary Filter Bowl Sheet Metal and Board Flexible Sample Hose with Probe Tip In Pneumatics going to Barometric Pressure Transducer Holds CRT PCB to Sheet Metal with wiring harness 4 between Bezel and Monitor Between Interface Bd and Sheet Metal To Plug In Optional Accessories printer PAGE 9 7 PARTS IN NUMERICAL ORDER PART NUMBER DESCRIPTION EAA0030C01A EAA0030C02A EAA0030C03A EAA0031C01A EAA0031C02A EAL0061C00A EAL0062C00A EAP0041C00A EASP033C00A EASP034C00A EAW0029C00A MT16651013 MT16704A MT3000210A MT3000A37A MT310012 MT310013 MT310017 MT310018 MT310019 MT310020 MT310032 MT310033 MT310047 MT35002 MT3500301 MT3500320 MT3500326 MT35003A MT35004 MT3
26. TITLE NO 02 INTERFACE 7 1 PAGE Crystal Lake Illinois 60014 U S 0195 REVA CHK BY DWG 7 3 NOTES PAGE 74 CHAPTER 8 RPM GENERAL The MT 3505 s RPM circuitry consists of an Inductive Trigger Pickup MT60A08A with cable and an RPM Adapter Cable MT350090 on the outside of the analyzer On the back panel of the analyzer is the TACH connector with the internal RPM harness attached to it The internal RPM wiring harness attaches to the CPU Board which has the engine sync processor and counter timer circuitry on it THEORY OF OPERATION When the spark plug in an automobile fires it has current flowing through its spark plug wire The inductor coil in the trigger pickup assembly senses this current The inductor produces a positive and negative going signal These two signals are sent through pins 3 and 5 of the TACH cables to the back of the analyzer These two signals are routed from the back panel TACH connector to pins 2 and 3 of connector J15 on the CPU Board On the CPU Board the signals are run through a comparator where they are compared and the single output signal is sent to the engine sync processor From the engine sync processor the signal is sent to a counter timer where the signal is changed to a digital signal and processed by the system controller r SSS Saal
27. TYPE STATE ACTIVE PORT PUMP NA OFF NA 51 3 WAY DE ENERGIZED NO 52 NC DE ENERGIZED NA EXHAUST PORT DENOTESOTHERAFFECTED PNEUMATICS Sum SUN ELECTRIC CORPORAT ION One Sun Parkway Crystal Lake linois 600 U S A w MT 3505 0195 REV A we J HINKLE CH BY me LEAK TEST VAC DECAY 5 4 PAGE 5 9 NOTES Page 5 10 All information contained or disc losed in this document is considered conf ident ial and proprietary by Sun Electric Corporation A manufacturing use reproduct ion and sales rights ore reserved by Sun Electric Corporation and the informat ion contained herein shal not be used in whole or in part without the express written consent of Sun Electric Corporation
28. a TXD4 14 oc GND 15 lt TXD1 1 1 TXD1 Go me O o joe 1a CPU BOARD m JD ew 3 8 GND sra 38 E N C 4 4 N C la O N C 5 5 N C J28 20 E INIT 21 O PD1 22 Lu SLIN 23 2 J3 PD2 24 2 PDA 25 1 sp VOND 2 RESSW boe Ia PD5 28 ACK 29 PD7 30 PE 31 RED J11 BUSY 32 1 12V BLK 2 GND 33 POND SLCT 34 GND 35 NC 36 J4 J2 GND 37 NC 38 POWER IN E J12 3 GND 39 o9 2 o lt Sq NC Force lala aoSe683885897r r92 x Eu x ao lt a 9 Z66 6438 Zzuooooooooso 23929 599 7900 225 5 C x S S S x x S s lt x s 132134 5 6 7 89 7121314 J23 1 2 3145 6 7 89 1211110 112131415 FROM KEYPAD KEYBOARD POWER SUN ELECTRIC CORPORATION SUPPLY One Sun Parkway Crystal Lake Illinois 60014 U S A WEL 3505 0795 REV B Jeff Hinkle 8 TITLE DC DISTRIBUTION DIC PAGE 1 2 1 7 CHAPTER AC DC DISTRIBUTION NOTES Effective Page 1 8 2 97 CHAPTER 2 COMPUTER THEORY OF OPERATION The heart of the MT 3505 is a ROM based 80286 Microprocessor driven CPU Board specifically designed for the needs of this analyzer It is mounted on the bottom chassis of the MT 3505 below the Andros Infrared Bench All the Functions of the MT 3505 are
29. amount of fuel Acronym for Read Only Memory A permanent data storage device that once programmed cannot be re programmed The user can only read what is in the ROM he cannot write to it This type of memory is non volatile See also EPROM and PROM Interface between data terminal equipment and data communications equipment employing serial binary data interchange Acronym for Request To Send This is a signal sent by the host computer to determine if the peripheral is ready to receive data Acronym for the Receive data line in serial communications The rate at which the video beam scans the line from the top to the bottom of the screen Higher scan rates work faster to produce sharper images A type of input or output utilizing an established protocol writing and information format so that data is submitted one bit at a time An Input Output port in a computer through which data is transmitted and received one bit at a time In most cases in personal computers serial data is passed through an RS232C serial interface A term describing the ideal air fuel ratio of 14 7 1 Acronym for the Transmitt Data line in serial communications The analyzer adjusts HC CO and NO to a zero point from which all readings are measured The zeroing process uses ambient air introduced into the sample cell through the zero port on the back panel of the analyzer Zeroing may be performed automatically or manually The analyzer retain
30. arrow keys to change the item s setting Continue this process for any other items that need to be changed To exit from the Power On Configuration Mode press lt MENUs This saves the changes just made RUNNING THE SELF TEST To run the printer self test press and hold lt LF gt while turning the printer on PAGE 11 14 MT1670A SERIAL PRINTER The MT1670A is a 40 column dot matrix printer that prints at a rate of eight lines per second It is a Serial printer that hooks directly to the MT 3505 s back panel RS232 connector A display indicates the function of the printer and four touch keys control the functions FRONT PANEL CONTROLS AND DISPLAY LED DISPLAY CONTROL PANEL PAPERFEED TEST ID FORM PRINT BACK PANEL POWER SWITCH FUSE HOLDER RS232 CONNECTOR BNC CONNECTOR A dot in the center of the LED display signals the user that the printer is turned on and that it is ready to print If the printer becomes jammed while printing it will display the letters J A and M in a continual sequence The control panel has four dual function touch keys When the printer is turned on all of the functions listed on the top of the keys are automatically activated except TEST refer to test key below The functions on the bottom of the keys are activated by turning the printer s power switch to the ON position while the ID FORM key is depressed Advances the paper TEST is used to check the character
31. equivalent static dissipative material which provides adequate static and physical protection 6 Avoid any unnecessary contact with internal circuits 7 Avoid setting Board s on static prone insulating surfaces such as paper glass rubber and plastic 8 Beware of friction generated static when a Wearing silk or nylon garments b Walking on carpets C Souffing rubber sole shoes NOTE Relative humidity has a direct bearing on the magnitude of possible static charge buildup the lower the relative humidity the higher the charge and vice versa PAGE ii BASIC ASSEMBLY DESCRIPTIONS The Computer Power Supply Assembly converts primary AC power into the required DC output voltage necessary to operate the CPU along with all of its associated circuitry For a more in depth explanation refer to Chapter 1 The 286 CPU Board is the brain used to control and process all the information collected by the MT 3505 Such functions include but are not limited to the pneumatics speaker peripheral ports keypad Infrared Bench and Monitor It also contains ROM memory used for the system s BIOS Basic Input Output System used to standardize software calls to hardware devices For a more in depth explanation refer to Chapter 2 The Connector Board contains the serial and parallel ports used by the various external peripherals There are no active components on the Connector board It simply provides a medium to interface to external periphera
32. following parameters need to be set in the MT 3505 and MT 2500 1 Turn the MT 3505 to the ON 1 position Press OPTION MENU The analyzer proceeds to the Option Menu Press F5 COMM SETUP The analyzer proceeds to the Communication Setup page Press F1 SCANNER BAUD RATE until the box surrounds the 4800 selection Press F6 RETURN to return to the Option Menu Press GAS ANALYZER to proceed to the Gas Analysis page Hook the MT 2500 s 25 pin Serial Cable to the MT 3505 back panel SCANNER port Press F5 SPLIT SCREEN on the MT 3505 The bottom portion of the MT 3505 screen will prompt O On ID SCANNER NOT DETECTED Check Communications cable connections Analyzer COMM SETUP Scanner communications setup Scanner power PAGE 12 1 SCANNER SETUP Cont NOTE f you have already identified a vehicle the following steps will change it to the demo vehicle 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Turn the power to the MT 2500 on Press Y on the MT 2500 If the MT 3505 s display does not change to display what is showing on the MT 2500 continue to step 11 If it does correspond to the MT 2500 you are ready to use the scanner with the MT 3505 Press Y to select DOMESTIC PRIMARY Press Y to select GENERAL MOTORS Press Y to select ENGINE AND OTHER SYSTEMS Turn the thumbwheel until D is displayed in the Vehicle portion of
33. in case there is a pneumatic related problem with the analyzer The only residual flow in the Gas Calibration Mode would be from the Manifold block to the check valve on the exhaust side of the Vacuum pump If for any reason this check valve fails open the Calibration Gas from the gas bottle will also flow into the pump diluting the gas getting to the bench possibly causing a Gas Calibration Failure Cal Failed LEAK TEST MODES To ensure the sample system is leak free a Leak Test should be performed every week A leak test should also be performed after every probe change filter service or any other servicing of the pneumatic system In the MT 3505 the Leak Test consists of two modes The first mode is Leak Test A Mode which is more symbolically named the Pull Down Mode because it pulls the entire inlet side of the vacuum pump into a vacuum The second mode is Leak Test B Mode or more symbolically named Vacuum Decay Mode because it monitors the vacuum decay of the Leak Test Mode A A more detailed explanation for both modes are described on the next page Page 5 1 LEAK TEST A PULL DOWN MODE DRAWING 5 3 IAGE 5 7 During the Leak Test A Mode the operator must place a Leak Test Cap on the end of the exhaust probe The pump then draws a vacuum on the exhaust probe filtering system the low flow switch and all tubing on the input side of the sampling system During this portion of the Leak Test the low flow sensor threshold is changed to all
34. pin 3 Speaker J28 pin 15 16 Connector Bd 33 35 37 39 VCC 5V 2 J13 pin 2 Bench J23 pin 4 Speaker PGNDS 3 J13 pin 3 Bench 15 HPS 4 J13 pin 4 Bench 15 HP 5 J13 pin 5 Bench J21 pin 2 Solenoid 1 J22 pin 2 Solenoid 2 J11 pin 1 Fan 15V 6 J13 pin 6 Bench AGND 7 J13 pin 7 Bench 15V 8 J13 pin 8 Bench PGND 9 J13 pin 9 Bench J11 pin 2 Fan CHECKOUT CALIBRATION There are no power supply adjustments Therefore there is no need for a calibration procedure To verify that proper DC Voltages are present refer to drawing 1 2 on page 1 7 Effective Page 1 2 2 97 CHAPTER1 AC DC DISTRIBUTION TROUBLESHOOTING Whenever troubleshooting any problem always ensure the power supply is generating the correct voltages Whenever troubleshooting power problems ensure the following e 110 Volts AC is present at P1 across pins and 5 on the power supply board or e 12 Volts DC is present across ST1 and ST3 on the power supply board all DC supplies are present at P2 on the power supply board COMPLAINT CORRECTIVE ACTION I UNIT WILL NOT POWER UP Unplug the unit from the AC wall outlet and plug the unit into the DC FROM AC SOURCE Source Does the unit power up now e Check DC Power Supply Voltages Refer to Page 1 2 e Check AC Power to the Power Supply Board Connector P1 e Check the 2 amp fast blow fuse If blown replace fuse and recheck voltages e Check the Input Filter Fuse Assembly If no AC voltage is getting through it repl
35. printer receives a line that exceeds the maximum print width the excess prints on the next line The user may specify 8 8 5 or 13 6 inches 13 6 only applies to wide carriage printer models therefore it should not be selected 21 DEMAND Auto Turn Demand Document Mode On and Off DEMAND is used to turn demand document mode on and off The demand document mode lets the user remove a pin fed page without wasting the next page When demand document mode is on pressing Ready gt turns printing off and feeds the paper until the bottom edge of the last printed page is at the tear bar You can then tear the page off The display will show DEMND instead of PAUSE PressingeReady gt again causes one of the following actions to occur A If you removed the las printed page the paper reverse feeds to the last top of form the READY message reappears and printing continues at the point where it left off B If you did not remove the last printed page the paper reverse feeds back to its original position the READY message reappears and printing continues at the point where it left off The user can select On to turn the demand document mode on Off to turn the mode off or Auto which causes the printer to present the paper for tear off whenever the printer idle you don t have to presscReady If demand document mode is on and the user does not want the paper presented for tear off just press lt Ready gt twice 22 BIN None Select Sheetfee
36. routed through this Board Below is a discussion of individual circuits and their functions CMOS RAM BATTERY BACKUP The CMOS RAM Random Access Memory is Battery Backed up by the 3 6 volt 110 milliamp Ni Cad Nickel Cadmium Battery It supplies power to the CMOS RAM when the power switch is in the 0 OFF position This allows special setups waveforms Letterhead Communication ports Date and Time to be stored when the power is turned off If this battery was to fail or become weak some if not all of the above setups would be erased SPEAKER The speaker is run by the System Controller Chip U41 82C235 The speaker signal is output on J23 pin 1 and 5 volts VCC powers the speaker on J23 pin 4 KEYPAD The Keypad is controlled by the Keyboard controller U7 80C51SL BG Keypad Sense and Activate lines are transmitted via connector J12 pins 3 through 12 Pins 1 and 2 of that same connector are the Software Reset Lines for the Central Processing Unit For further details and a functional block diagram of the Keypad circuitry please refer to Chapter 3 of this manual TILT CIRCUIT The angle of operation of the MT 3505 is to 30 measured from the front of the analyzer to the back of the analyzer horizontally If the front of the MT 3505 is tilted more than approximately 30 higher than the back the mercury switch SW1 on the CPU board will short between contacts 1 and 2 This Switch is being monitored by the Keyboard Controll
37. set and operation of the printer To activate the TEST function turn the printer s power switch to ON while the TEST key is depressed The printer should then print out all of the letters numbers and other characters available the version of the printer s software identified by date the selected mode of operation MT1665 or RS232 serial and the RS232 baud rate bits per second transmission speed selected NOTE For MT 3505 applications the mode of operation is RS232 ID FORM is used to print a customer vehicle data form This information includes the following fields Customer Vehicle Make Year Odometer Reading and Date Is inactive when hooked to an MT 3505 Turns the printer ON and OFF Contains a 1 amp fuse and a voltage selector that is set for 120 Volt operation For 240 Volt operation use a 3 4 amp fuse and change the voltage selector to the 240 position The RS232 connector is a 25 pin communication port that can be used for interconnecting the printer to the MT 3505 The BNC coaxial connector is used for connecting the printer to the Snap on scope PAGE 11 15 PRINTER COMPARTMENT MODE SWITCH The mode switch is used to set the mode of operation to use the BNC Connector or the RS232 connector on the back panel To use the Serial Printer in a MT 3505 the switch should be set to RS232 NOTE The position of this switch should only be altered when the power switch is OFF 10 POSITION SWITCH The 10 positi
38. the VIN selection and prese Y gt Turn the thumbwheel until 1 is displayed in the Make portion of the VIN selection and prese Y Turn the thumbwheel until M is displayed in the ENGINE portion if the VIN selection and press Y gt Press Y for Automatic Transmission Press Y for Air Conditioned Press Y to Continue Press Y to Continue Press Y for Engine Turn the thumbwheel until the cursor is next to CUSTOM SETUP Press Y Turn the thumbwheel until the cursor is next to COMMUNICATION SETUP Press Y gt Turn the thumbwheel until the cursor is next to OTHER COMMUNICATION 4800 BAUD Press Y gt Press F5 SPLIT SCREEN on the MT 3505 twice The MT 3505 should correspond to the MT 2500 PAGE 12 2 X NOT USED TRANSMIT DATA TXD RECEIVE DATA RXD REQUEST TO SEND RTS CLEAR TO SEND CTS NOT USED GND NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED J28 J1 CTS RTS RXD TXD GND 4 NE ICA al gt gt CPU BOARD MT3500A100 CONNECTOR BOARD MT3500A200 BACK NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED ho c g
39. the gas will be taken and sent to the computer PAGE 6 1 The Sample Tubeis a cylinder that gases flow in and out of The source is located at one end of the tube radiating infrared energy through the tube The gases inside the sample tube absorb the infrared energy as it passes through As the energy exits the tube it passes through an opening that is covered by a concave material This concave material acts as a lens and focuses the energy to a constant location The Filters are located at the end of the sample tube opposite to the source The energy focused by the lens passes through the filters The filters are referred to asBand Pass Filters These filters will only allow the frequency for each of the gases to pass There are 4 filters used in most 3 gas IR benches one each for the three gases HC CO and CC2 and a Reference filter The 3 for the gases allow the particular frequency for each gas to pass through The fourth filter Reference allows all the frequencies except those absorbed by the 3 gases to pass through This gives a known value for the source so that we can determine how much absorption occurs in the sample tube The Detectoris positioned behind the filters It receives the unabsorbed infrared energy This unabsorbed amount is then turned into an analog voltage that is used in calculating the amount of gas inside the sample tube The analog voltage is then processed by the Andros Bench turned into a digital signal and sent
40. the values in the Analyzer Dat Column on the screen with those in Table 6 1 ALLOWABLE RANGE 11 696 12 496 3 8596 4 1596 1940 ppm 2060 ppm 60 ppm of Gas Tag FIGURE 6 1 ALLOWABLE CALIBRATION CHECK RANGES If all readings are within the allowable ranges calibration is not necessary Disconnect the calibration gas hose then press RETURN F6 the Service Screen is displayed If any of the readings are not within the allowable range continue with the next step to calibrate the analyzer Press lt FREEZES gt to unfreeze the gas calibration screen NOTE f the analyzer reverted back to the Service Screen Press GAS CAL F1 then 18 19 20 21 22 23 CALIBRATE F2 Re open the valve on the calibration gas bottle Verify that the output pressure is still 5 10 psi Press CONTINUE F1 Calibration will begin by automatically zeroing CALIBRATION PASSED will be displayed when the calibration is successful Close the valve on the calibration gas bottle and remove the hose from the CAL port Press RETURN lt F6 gt PAGE 64 All information contained or disclosed ih this document is considered confidential and proprietary by Sun Electric Corporation All manufacturing use reproduction and sales rights are reserved by Sun Electric Corporation and the information contained herein shall not be used in whole or in part witho
41. thehexadecimal mode the printer prints the hexadecimal and ASCII representations of every byte it receives The printer does not interpret or execute any control sequences nor does it print any text Hexadecimal mode is useful when you need to view the codes being sent from the host computer to the printer The user can select On to turn the hexadecimal mode on or Off to turn the mode off 37 AUTO CR On Turn Auto Carriage Return Modes On and Off AUTO CR is used to turn the automatic carriage eturn mode on and off In automatic carriage return mode the printer performs a carriage return line feed for each line feed code it receives The user can select On to turn the mode on or Off to turn the mode off 38 AUTO LF Off Turn Automatic Line Feed Mode On and Off AUTO LF is used to turn the automatic line feed mode on and off In the automatic line feed mode the printer performs a carriage return line feed for each carriage return code it receives The user can select On to turn the mode on or Off to turn the mode off PAGE 11 7 39 AUTO FF Off Turn Automatic Form Feed Mode On and Off AUTO FF is used to turn the automatic form feed mode on and off In the automatic form feed mode the printer skips over the perforations of the pin fed paper by setting top and bottom margins to one half inch The user can select On to turn the mode On or Off to turn the mode off For the automatic form feed mode to work correctly the LENGTH parame
42. to J23 pin 4 The Digital Multimeter should read 5 volts e If not Check DC Voltage supplies on connector J4 e If DC Voltage is present at J4 replace CPU Board e If DC voltage is not present refer to chapter 1 Ensure that connector J12 on the CPU Board is seated properly and that the connector is not moved over one pin Press lt RESET gt does the analyzer reset e If yes keyboard controller is fine Replace Keypad e If no replace CPU Board Ensure that the front of the analyzer is less than 30 above the rear of the analyzer e f not Take the proper steps necessary to level the analyzer such that the front of the analyzer is closer to the same height as the rear of the analyzer With a Digital Multimeter measure the resistance between pins 1 and 2 of SW1 on the CPU Board e If the contacts are shorted and the analyzer is level Replace CPU Board Page 2 3 CHAPTER2 COMPUTER COMPLAINT V SOLENOIDS WILL NOT ENERGIZE Page 2 4 CORRECTIVE ACTION Enter the second page of the Service Menu through the Options Menu In this mode you can toggle the solenoids on and off Place the Digital Multimeters Red lead to J22 pin 1 and the Black lead to J22 pin 2 Press lt F2 gt to toggle solenoid 1 to the ZERO Mode The Digital Multimeter should read 12 voltst3 volts f yes replace Solenoid e not Check Power Supply Voltages on J4 e If Voltages are OK replace CPU Board e f not refer to chapter 1 Pla
43. to the CPU board From there the CPU board processes the digital signals and displays them on the monitor Propane Equivalency Factor or P E F PEF is a value used in calculating the amount of Hydrocarbons contained in the calibration gas PEF values will fall between 490 540 The purpose of PEF is to make Propane Gas appear as Hexane Gas during calibrations Hexane is used by the BAR Bureau of Automotive Repair to set standards for the Hydrocarbon s measurement The reason Hexane was chosen is due to its molecular structure It is in the middle of all the Hydrocarbons that are emitted from vehicles Hexane is not practical for customer use due to its instability at different temperatures This is why we use Propane for calibration therefore we need a PEF value to correlate the two readings As mentioned earlier in the text the bench is no more than a molecule counter The atomic structure for Propane C3Hg and Hexane The size of molecules found in Propane is almost exactly half the size of the molecules in Hexane When a sample tube is filled with Propane almost twice as much absorption will occur due to twice as many molecules contained in the tube Remember the bench is counting the number of molecules contained in the tube Therefore we multiply the gas readings of Propane by the PEF amount This makes the Propane appear the same as Hexane An Example of How PEF is used in Gas Calculations Gas Tag Value for Hydrocarbons HC 3
44. used to specify a left margin All subsequent carriage returns cause the printhead to move to the left margin The left margin can be from 0 to 271 character spaces to the right of the far left print position however the user can only select a character space that is to the left of the right margin setting To help the user visualize leftmargin locations as they scroll through the possible settings the printhead moves to the displayed setting The physical location of the left margin setting is unaffected by subsequent pitch changes 26 RGT MAR 085 Set Right Margin PAGE 11 5 RGT MAR is used to specify a right margin When printing reaches the right margin on a line the printer performs a carriage return line feed and continues printing on the next line The right margin is also used in the center and justify modes The right margircan be from 1 to 272 character spaces to the right of the far left print position however the user can only select a character space that is to the right of the left margin setting To help the user visualize the right margin locations as they scroll through the possible settings the printhead moves to the displayed setting The physical location of the right margin on the page is unaffected by subsequent pitch changes SPECIFYING COMMUNICATIONS PARAMETERS The next section on the Setup menu is Communications The communications parameters control data communications between the printer and the host com
45. 00ppm x PEF from the Bench 510 153ppm During a Gas Calibration using a bottle with this value the bench should read 153ppm parts per million Note PEF is only used in the calculation of Hydrocarbons CO and CO2 should equal the amount on the Gas Tag during calibration Gas Tag Valuesare the values that are written on tags located on gas bottles These values indicate the mixture of the HC Hydrocarbons CO Carbon Monoxide CO2 Carbon Dioxide and NO Nitric Oxide in the bottle The Gas Tag Values are written in the MT 3505 software by the operator in the Gas Calibration Screen Each time the bench performs a calibration it reads these values in order to know which gas it is reading and what the correct reading should be when calibrating PAGE 62 Barometric Pressure Barometric Pressureis Atmospheric pressure measured in inches of mercury With different pressures the bench will indicate different gas readings due to the density of the molecules in the sample tube To ensure correct readings the Gas Tag Values are compensated depending on the Barometric pressure reading taken at Calibration Every time a calibration is performed the barometric pressure is read from the transducer located on the IR Bench The pressure is used in a calculation with the Gas Tag Values The values are changed and written to the bench to compensate for the pressure This procedure is performed at the beginning of each Gas Calibration WARM UP Th
46. 10 1 NOTES PAGE 10 2 CHAPTER11 PRINTERS GENERAL There are two types of printers Parallel and Serial that can be used in an MT 3505 In addition there are two different Parallel printers that can be used in the MT 3505 All printers are optional and are described in detail below AMT PARALLEL PRINTER The results and or diagnostic messages of the MT 3505 are printed using the AMT 242 an 85 column bi directional 24 pin dot matrix impact printer When the printer is activated the print head will travel to the far right and then back to the far left of the platen to indicate initialization The LCD window on the front panel will display DRAFT 10 READY From any screen menu an operator can print the desired information by pressing PRINT gt The AMT 242 prints at a rate of up to 240 cps characters per second and can print letter quality in any of eight available character faces Fonts and six character sizes Pitch The printer resolution is 360 x 360 dpi dots per inch The printer also incorporates self diagnostics which will help in isolating a specific printer component for corrective action USING THE SETUP MENU The Setup menu is a list of printer parameters organized into six categories 1 Operations 6 Service Mode 2 Print Modes 3 Page Settings 4 Communication Settings 5 Special Modes OPERATIONS PAGE SETUP SPECIAL MODES
47. 2 Draft Quality 12 Pitch Vertical Adjustment When printing in Draft mode this adjustment will align the forward pass of the print head with the backwards pass of the print head If this is not set to the proper setting the alignment of the lines in a printout will not line up with the left or right margin 58 ADJ DQ17 51 Draft Quality 17 Pitch Vertical Adjustment When printing in Draft mode this adjustment will align the forward pass of the print head with the backwards pass of the print head If this is not set to the proper setting the alignment of the lines in a printout will not line up with the left or right margin 59 ADJ DQ20 50 Draft Quality 20 Pitch Vertical Adjustment When printing in Draft mode this adjustment will align the forward pass of the print head with the backwards pass of the print head If this is not set to the proper setting the alignment of the lines in a printout will not line up with the left or right margin 60 TEARBAR 8 Tearbar Sets the distance from the first printed line to the paper tear bar Aligns the perforation on the paper to the paper tear off bar 61 P SNSR 12 Page Sensor Sets the distance from the top of the form to the first printed line on the paper 62 H SNSR 0 Head Sensor Sets the spacing on the first column of the page with respect to the left perforation 63 SET USR Set User Sets the printer to factory Default settings when changed to DONE PAGE 11 9
48. 211 BUSY PRINTER EN BUSY EN 12 a GND a 13 SLOT Serial SLCT ar 14 AFD Port 35 GND E 15 ERR Drivers 736 N C 7367 6 INIT 37 GND 17 SLIN a N C 788 18 GND 739 GND 7397 19 GND EN N C w 20 GND 21 GND 22 GND CONNECTOR 5 ie 24 GND CPU BOARD BOARD 25 GND EAP0041C00A MT3500A200 SUN ELECTRIC CORPORATI One Sun Parkway Crystal Lake Illinois 60014 U S A MODEL MT 3505 0795 REV B DWG BYJeff Hinkle CHK BY TITLE lO SERIAL AND PARALLEL DWG PAGE 2 1 2 5 CHAPTER2 COMPUTER NOTES Effective Page 2 6 2 97 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric Corporation All manufacturing use reproduction and sales rights are reserved by Sun Electric Corporation and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric Corporation CENTRAL PROCESSING UNIT CPU PGND 412V 2 J11 BLK RED SYSTEM CONTROLLER SERIAL PARALLEL CONTROLLER KEYBOARD CONTROLLER 1 2 3 4 5 6 7 8 9 12 11 10 J12 1 2 3 4 5 6 7 8 9 12 1110
49. 5005 MT350090 MT3500310 MT3500A10 MT3500A110 MT3500A125 MT3500A200 MT3500A21 MT3500A25 MT3500A330 MT3500A340 MT3500A40 MT3500A410 MT3500A50 MT3500A500 MT3500A6 MT3500A60 MT3500A600B MT3500A7 MT3500A700 MT3500A8 MT3500A9 MT60A08A 6031C0099901 6047D0149901 6057D004990 1 PAGE 9 8 Battery External NO Cell Cable O and NO Cell Board NO Interface Filter Assembly Manifold Block O and NO Label Warning Label Model Board Main CPU Plate Oz and NO Mounting Cover and NO Cell Strip Optional AC Power Gasket CRT Label Warning Leadset DC Power Label Warning Screen Water Filter Screen Gas Filter Hose Assembly Exhaust Probe Exhaust AntiDilution Exhaust Probe Hose Exhaust Cap Sample Probe Cap Needle Adapter Handle Sample Probe Label Escutcheon Monitor CRT Label Warning Label Warning Label Adapter Inductive Pickup Bezel w handle Harness Internal Tach Speaker Bracket Speaker Board Connector Pump Sample Bracket Pump Support Keyboard Subassembly Shield Monitor Harness Internal AC Bracket Bench Support Harness Internal DC Power Supply Assembly Bracket CRT Board Fan Chassis Subassembly Bracket Fan Case Top Foot Bracket Filter Mounting Pickup Trigger Harness Int Thermocouple Cable 20 Pin Ribbon Cable 5 Pin Ribbon COMMENTS Below NO O Interface Bd From Behind NO and O Cell Complete Pri amp Sec Filter Assembly Ex
50. 51 28658 28851 51441 62421 84918 85216 85716 85816 86330 113380 113480 113680 210351 210551 210751 210951 810262 04010354 05010003 06470102 06470138 07200002 07390040 13740031 0301094201 0301094301 0301094401 0301094501 0301094601 0301094701 0301094801 0429003802 0647030101 0647030201 0647030301 7049000401 7049012901 7049013001 Cable 9 Pin Ribbon Cable 9 Pin Ribbon Harness Int Thermocouple Bumper Rubber Clamp Hose Restrictor Valve Check Standoff CRT Fitting Plastic Standoff Bench Connector Thermocouple Guide Circuit Card Manifold Assembly Solenoid Clamp Cable Fuse Switch On OFF Breaker Circuit Grommet Strip Cord Power Bumper Rubber Grommet Grommet Black Plastic Grommet Black Plastic Knob Fitting Male Brass Fitting Brass Nipple Fitting Brass Elbow Fuse Fuse Filter AC Line Fuse Holder Label Line Cord Fuse Spacer Grommet Fitting Plastic Tee Plug Filter Channel O and NO Fuse Plug Black Plastic Head Filter ORing Filter Element Primary Filter Element Secondary Filter Nut Filter Element Retaining Bowl Filter Nut Filter Bowl Standoff NO O Interface Bd Fitting Brass Nipple Nut Brass Seal Fitting Brass Elbow O Sensor Bench NO Cell From IR Bench to Main PCB J13 From Power Supply P2 to Main PCB J4 1 wire Internal Thermocouple Harness Back of Analyzer Internal Tubing Clamp In Pneumatics going t
51. CB J14 From IR Bench to Main PCB J13 From Power Supply P2 to Main PCB J4 From For Leak Check For Leak Check Sheet Metal Back and Bottom Sheet Metal Panels For Case Gray Plastic Wiring Harness Hold Down Internal Tubing Clamp Back Panel Thermocouple Connector Sheet Metal Cover Over Both Sensors 75 Micron Filter 8 Micron Filter Black Plate around Monitor Brightness Control Input Filter Fuse Assembly Complete Pri amp Sec Filter Assembly 90 Elbow to Exhaust Sample Hose 90 Elbow off Secondary Filter Housing and Bottom of Primary Filter Bowl Between Primary and Secondary Filter Between Primary Filter and 90 adapter Primary Filter Housing to 90 adapter For Back Panel Gas Calibration Port Bottom Rubber Bumper Screws into it 1 Amp Slo Blo 1 Amp 250 Volt for 240 Volt Testers 2 Amp 250 Volt Fast Blow AC input Connector 20 Amp 32 Volt Holds 20A Fuse Above Power in Conn Gasket around front of CRT O Harness runs through this on Manifold Sheet Metal Grommet Grommet Black Plastic Grommet Black Plastic Grommet Strip Guide Circuit Card Handle Sample Probe Harness Internal AC Harness Internal DC Harness Internal Tach Harness Int Thermocouple Harness Int Thermocouple Head Filter Hose Assembly Exhaust Hose Exhaust Keyboard Subassembly Knob Label Label Label Line Cord Fuse Label Model Label Warning Label Warning Label Warning Label Warning Label Warning Leadset
52. EP NU ETC L ul SENSE 2 zA A ial 3 O SENSE3 A ACTIVE 1 um OF CONTROL Z ACTIVE Aot NC RE LINES O ACTIVES I P ET OPT O O ACTIVE4 ae 1 gt Ye E ACTIVE 5 FA ME 2 ACTIVES si y A YO E O ACTIVE7 o 9 EJ E M nESSW F5 SEL HELP 7 ep y T Ye EV x Prin e Freez ve Reset _ CPU BOARD NE AA uni Figure 1 Keypad Connections Effective 2 97 Page 3 1 CHAPTERS ENTER INFORMATION HERE TROUBLESHOOTING COMPLAINT CORRECTIVE ACTION I PRESSING RESET DOES NOT Remove keyboard connector J12 from the CPU Board Place the RESET THE ANALYZER DMM red and black leads to P12 pins 1 and 2 Press lt RESET gt e If DMM indicates continuity replace CPU Board e If DMM indicates open replace Keypad ONE Effective Page 3 2 2 97 CHAPTER 4 VIDEO THEORY OF OPERATION The MT 3505 s display is a 9 diagonal Cathode Ray Tube The CPU Board is responsible for generating the signals that need to be sent to the Monitor The Monochrome Video Graphics Adapter generates three signals that are sent to the monitor The three signals are Video Vertical Sync and Horizontal Sync The Video RAM receives characters in digital form Each character position is independently capable of displaying characters in inverse video blinking or both Below is a Block Diagram of the Video Circuitry
53. LEVEL and update this appendix as necessary PART DESCRIPTION INSTALLATION INSTRUCTION MT 3505 Unit Setup 0692 2329 01 REVISION B PAGE 1 NOTES PAGE E2 APPENDIX F SCREEN MESSAGE PROMPTS INCLUDING FAULT PROMPTS GENERAL NORMAL MESSAGES Normal messages are those that appear under typical operating conditions They are either informative explain what is happening or instructional tell what to do next Informative messages can tell the operator e how to enter the next function e anaction the analyzer is performing e anaction the analyzer will take Instructional messages usually tell the operator what to do after the analyzer has e performed an action e failed to perform an action failed a test A complete listing of normal messages are as follows AUTO ZERO IN ONE MINUTE e Appears in Exhaust Gas Test e Indicates that the Analyzer is going to perform a Zeroing procedure in one minute e Allows the operator to intervene if desired by pressing lt F3 gt AUTO ZERO OFF ANALYZER WARM UP IN PROGRESS e Appears in Warm up e Indicates that the Analyzer is Warming Up CALIBRATION IN PROGRESS e Appears during Calibration e Indicates that the Analyzer is in Calibration Mode and that Calibration is in progress CALIBRATION PASSED e Appears at the end of a successful Calibration CAP EXHAUST PROBE THEN PRESS CONTINUE e Appears during Leak Test e Prompts the operator to seal the end of
54. Off ITALIC is used to turn the italic mode on and off 10 HIGH Off Turn Double High Mode On and Off HIGH is used to turn the Double High mode on and of In double high mode characters stretch downward to twice their normal height and the LPI setting changes to three lines per inch When the mode is turned off the LPI settings change to six lines per inch 11 WIDE Off Turn Double Wide Mode On and Off WIDE is used to turn double wide mode on and off In double wide mode characters stretch to the right twice their normal width When the user turns on the double wide mode the pitch is set to half its current value When the user turns off double wide the pitch is doubled to its previous value 12 SCRIPT Off Turn Super Subscript Mode On and Off SCRIPT is used to turn on and off the superscript and subscript modes In superscript mode characters shrink to about half their normal size and print above the print line In subscript mode the same small characters print below the normal print line Select Supr to turn the superscript mode on sub to turn the subscript mode on or Off to turn both modes off PAGE 11 3 13 UNDLINE Off Turn Underline Mode On and Off UNDLINE is used to turn the underline mode on and off In underline mode all characters and spaces are underlined 14 BLD SHA Off Turn Bold Shadow Modes On and Off BLD SHA is used to turn on and off the bold shadow modes In bold mode characters are printed twice
55. Oo gt IN Exhaust OD 2 3 Q Q Q lt gt DENOTES PRIMARY FLOW PATH Valve DENOTESOTHER AFFECTED PNEUMATICS Ln E CORPORAT ION ZERO MODE stole los DD USA COMPONENT TYPE STATE ACTIVE PORT wn MT 3505 0195 REV A PUMP NA ON NA weg J HINKLE 81 3 WAY ENERGIZED NC TME s2 NC DE ENERGIZED NONE ZERO WE PAGE 5 1 5 3 NOTES Page 54 All information contained or disc losed in this document is considered conf ident ial and proprietary by Sun Electric Corporation A manufacturing use reproduct ion and sales rights ore reserved by Sun Electric Corporation and the informat ion contained herein shal not be used in whole or in part without the express written consent of Sun Electric Corporation Zero Gas Port nenn Y o o _ Panel
56. R Bp E DATA 6 74 7 DATA 7 DATAO 9 EE ACK ERR 19 19 BUSY DATA1 11 n 22 y POUT 23 23 les SELOUT 26 DATA3 35 AUTOFEED GND 4 6 6 3 45V 25 2 PRIME E 5 5 ERROR DATA5 32 28 28 SELIN GND 36 33 5 E y 6 B 35 GND L 39 DATA7 5 20 19 37 GND 37 21 20 79 ACK 9 22 21 30 GND 39 23 22 BUSY 24 23 32 32 24 PE 25 31 31 25 BACK PANEL 27 PRINTER CONNECTOR 28 29 30 E E MN CPU BOARD 33 In gt 0395 REVA MT3500A100 x a5 HINRLE a PARALLEL PRINTER 11 1 11 21 NOTES PAGE 11 22 P2 NOT USED TRANSMIT DATA TXD RECEIVE DATA RXD REQUEST TO SEND RTS CLEAR TO SEND CTS DATA SET READY DSR GND NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED NOT USED DATA TRANSMIT READY DTR NOT USED 7 NOT USED 73 USED m NOT USED 25 NOT USED J28 DIR J1 DSR CTS RTS RXD TXD GND co s co co Cn apor Zu CPU BOARD CONNECTOR MT3500A100 BOARD MT3500A200 SERIAL PRINTER ola alo ajlelale gt 2 S A OIA
57. SELECTING PRINT MODES Emulation is the most important print mode parameter and must be set to be compatible with the application program 5 EMUL MT3010 Set Printer Emulation EMUL allows a selection for a printer emulation for the printer to use Selecting an Emulation enables the printer to imitate other popular printers When an emulation is selected all current printer settings stay in effect Selections include Epson that causes the printer to imitate Epson LQ 570 and LQ 1070 printers IBM that causes the printer to imitate IBM XL24 and LEXMARK 2390 2391 printers and MT3010 which causes the printer to imitate the Snap on MT3010 printer The only setting which will print properly when working with an MT 3505 is the MT3010 emulation 6 FNT Draft Set Font FNT is used to select a font typestyle such as Roman SanSrf Courier Prestige Script OCR B Orator Draft and HSDraft 7 PITCH 10 Set Pitch PITCH is used to specify how many characters to print per inch You can select 10 12 13 15 17 or 20 Select PS for proportional spacing If the current setting is Other then the software has set the pitch to some nonstandard value 8 LPI 6 Set Number of Lines Per Inch LPI specifies how many lines to print per inch You can select 3 4 6 8 or 12 If the current setting is Other then the software has set the number of lines per inch to some other numerical value 9 ITALICS Off Turn Italics Mode On and
58. TABLE OF CONTENTS INTRODUCTION GENERAL u uu i IMPORTANT GUIDELINES FOR SERVICGING nennen nnne nennen nnne nnne i LOGIC LEVEL DESIGNATIONS uuu u tte tie turni erts a a a a a a i OPEN COELECTOROUTPU iS LL uu l lt ul i li is Susa Ha HE Hin ak Eh ii HANDLING OF MOS IC AND OTHER STATIC SENSITIVE ii BASIC ASSEMBLY DESCRIPTIONS Isa as nre etr nn etri trennen eterne nnns iii CHAPTER 1 AC DC DISTRIBUTION AG DISTRIBUTION cette Ert rt Dt o te OE p D me Rn o p dave o oe RE E E ep oh 1 1 DG DISTRIBUTION l u iS Late UE Heute LAC sie dade LAB LAUS pds tallo ias 1 1 12 VOLPE INPUT SUBPLY u u u ettet ete ted tete Ea p rete eher bene 1 1 INTERNAL DC POWER SUPPLY 1 1 DC VOLTAGE REFERENGE GHAHLT 3 22 metet epe rer peperere raid 1 2 CHECK OUT CALIBRATION 2 2 20522652 ace pang pcan RR cous gang fdas nung anna EAM Dea Rae pees RUM fous Ran Hana RAM Ha Ran 1 2 TROUBLESHOOT Nus eite rettet dede e ERU cole oie leia soleada leed 1 2 FUNCTION BLOCK DIAGRAM III ii e i ets ets its etse tnnt 1 3 CHAPTER 2 COMPUTER THEORY OF OPERATION ntm idas 2 1 CMOS RAM BATTERY BACKUP uunenseessenssensnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nenn 2 1 SPEAKER u gt oil 2 1 KEYPAD
59. TIME REVERSE VIDEO RICH MIXTURE ROM RS 232C RTS RXD SCAN RATE SERIAL SERIAL PORT STOICHIOMETRIC TXD ZEROING printer modem etc Picture element Refers to the smallest single screen element directly addressable by a computer The smaller the pixel size the more pixels to a screen and thus the finer the graphics resolution An Interface on a computer configured as data terminal equipment and capable of attaching a modem or other peripheral for communication with a remote data terminal Acronym for Programmable Read Only Memory a permanent storage device that can be programmed by the device manufacturer supplier or user Acronym for Random Access Memory A volatile type of temporary storage device that can be written to by the user Any data stored in RAM can be directly retrieved simply by entering its address Data stored in RAM is irretrievably lost when power is shut down Refers to either the number of scanning lines on a video display terminal or the number of pixels addressable on the display screen The elapsed time between the generation of the last character of a message at a terminal and the receipt of the first character of the reply It includes terminal delay and network delay A term used to indicate in some video terminals the ability to display black character on a white or green background An air fuel mixture that contains less than an ideal amount of air or more than an ideal
60. ace Input Filter Fuse Assembly e Check AC wall Outlet and check power cable I UNIT WILL NOT POWER UP Unplug the unit from the DC Source and plug the unit into the AC wall FROM DC SOURCE outlet Does the unit power up e Check DC Power Supply Voltages Refer to Page 1 2 e Check DC Power to the Power Supply Board Connector ST1 to ST3 should read 12 volts e Check the 20 amp fuse If blown replace fuse e Check Circuit Breaker e Check DC Source Ill PUMP WILL NOT RUN Ensure that you are in a mode in which the pump should run e Verify 15 VAC from J18 pins 1 to 2 e Verify 15 VAC from J18 pins 2 to If all voltages are OK replace vacuum pump Replace CPU Board IV FAN WILL NOT RUN The fan should be running whenever the unit is powered up If not check the following e Verify 12 Volts across pins 1 and 2 on connector J11 If present replace FAN Verify all voltages at connector J4 If present replace CPU Board e Replace Power Supply Effective 2 97 Page 1 3 CHAPTER1 AC DC DISTRIBUTION NOTES Effective Page 1 4 2 97 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric Corporation All manufacturing use reproduction and sales rights are reserved by Sun Electric Corporation and the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric Corporation
61. allel connectors to hook up a serial printer parallel printer or MT 2500 Scanner For a detailed block diagram of the Serial Parallel I O circuit please refer to drawing 21 page 2 5 PUMP The pump is powered by a 60 volt center tapped AC supply which is generated on the CPU board When the software has determined by operator input that the pump should be turned on 30 volts AC is supplied across pins 1 and 2 and pins 2 and 3 of connector J18 on the CPU board This turns the pump on SOLENOIDS The two solenoids contained in the MT 3505 are both controlled by circuitry on the CPU Board Part of one of the Serial Parallel Controller chips on the CPU board is used as the controlling device to turn the solenoids on and off Solenoid 1 is controlled via connector J22 and Solenoid 2 is controlled via connector J21 on the CPU Board Pin 2 on both connectors is 15 volt HP supply and pin 1 is the controlling signal In order for the solenoids to be energized the controlling circuitry must provide a ground path for the 15 volt HP supply TACHOMETER The entire tachometer circuitry is located on the CPU Board From the back panel TACH connector the RPM signal is routed via a wiring harness to J15 on the CPU Board On the CPU Board the RPM signal is processed digitized and sent to the Central Processing Unit Chip From there the signal is sent to the video circuitry and displayed on the Monitor For a detailed description of the Tachomete
62. appears to notify the user that the printer is executing the test TEST UNAVAILABLE When the user selects the printer test on the Setup menu this message appears to notify the user that the test is not contained on the printer and cannot be executed 4 CORRECTING COMMUNICATION ERRORS The printer can notify the user of three communicatn errors When a communication error occurs printing stops and some or all of the print data is lost After the user performs the corrective action s you must restart the print job from the beginning FRAMING ERROR This error occurs when the baud rate of the printer and the host computer are not the same CORRECTIVE ACTION Change the BAUD and DTA BITS settings on the Setup menu to the computer s baud rate and number of data bits Then presscReady button and restart the print job from the beginning PARITY ERROR This error occurs when the printer using the select parity method detects a data transmission error affecting one or more data bytes CORRECTIVE ACTION Change the PARITY setting on the Setup menu to the host computer s parity method Then press lt Ready gt to re enable printing then restart the print job from the beginning If the printer s parity setting is correct hold down lt Alt gt and press Clear to clear the data input buffer and then lt Ready gt to re enable printing then start the print job from the beginning If the error occurs reset the host computer and the p
63. by the Power Supply 12 VOLT INPUT SUPPLY REFER TO DRAWING 1 1 PAGE 1 5 Since the MT 3505 can be run on a 12 Volt DC supply instead of the AC supply there is a second power supply Leadset The DC leadset connects to a 12 Volt DC supply and provides 12 volts DC across Pin 2 and 3 of the 3 pin 12 Volt input power connector located on the back panel of the analyzer The 12 Volt DC return line runs directly from Pin 3 of the 12 Volt DC input connector to the Male spade lug marked ST1 on the Power Supply Board The 12 Volt DC line is routed first to the 15 Amp Circuit Breaker located on the back panel of the MT 3505 From the Circuit Breaker the 12 Volt DC line is routed to the 32V 20 Amp fuse F1 located above the Input Filter Fuse Assembly on the inside of the back panel From the 20 Amp fuse the 12 Volts DC is routed to the MT 3505 s Power Switch then to the Male spade lug ST3 on the Power Supply Board INTERNAL DC POWER SUPPLY ROUTING beyond the power supply Whether the input to the MT 3505 s power supply is a DC or AC voltage the power supply provides many DC voltages out at connector P2 to the CPU Board J4 The next page has a list of power supply voltages and where they are routed to from the CPU board Effective 2 97 Page 1 1 CHAPTER1 AC DC DISTRIBUTION DC VOLTAGE REFERENCE CHART DC VOLTAGE SIGNAL FROM J4 of CPU PIN NUMBER DESTINATION GND 1 J9 pin 1 2 19 20 Monitor J12 pin 1 Keyboard J13 pin 1 Bench J14 pin 3 Bench J23
64. ce the Digital Multimeters Red lead to J21 pin 1 and the Black lead to J21 pin 2 Press F3 to toggle solenoid 2 to the CAL Mode The Digital Multimeter should read 12 volts 3 volts Follow the steps above for Troubleshooting Effective 2 97 All information contained or disclosed in this document is considered confidential and proprietary by Sun Electric Corporation All manufacturing use reproduction and sales rights are reserved by Sun Electric Corporation ani the information contained herein shall not be used in whole or in part without the express written consent of Sun Electric Corporation P1 2 TXD2 8 RXD2 H 4 RTS2 Serial 5 orsa SCANNER or 7 GND and Drivers J28 Ji Parallel De Controller E P2 E CTS3 E 2 TXD3 E RTS3 LAC 38 RXD3 5 RXD2 E 4 RTS3 ng TXD2 EE 5 RS232 E CTS2 6 DSR3 E RTS2 Em _7 GND 1 Er DTR2 a 20 DTR3 Serial E bord uc Port ar RTS4 zo Drivers RXD4 ETE P3 413 CTS4 ECH 2 RXD4 d4 TXD4 14 3 TXD4 5 GND ER 5 GND AUX CPU System 16 GND A 7 RTS4 Controller ETE AFD ETA 8 CTS4 AB ST8 ECE ERR ELE E PDO gt P4 EN INIT a 1 STE I Serial PD1 zs Z PDO Serial Port a SLIN 8 PDI Drivers 7947 PD2 a 4 PD2 and 5 PD4 5 Parallel ES PD3 cx 76 Pos PD6 gt 7 PD5 Controller La Eie E d ome 29 ACK a 9 PD7 30 PD7 a 10 ACK
65. contained or disc losed in this document is considered conf ident ial and proprietary by Sun Electric Corporation A manufacturing use reproduct ion and sales rights ore reserved by Sun Electric Corporation and the informat ion contained herein shal not be used in whole or in part without the express written consent of Sun Electric Corporation Zero Gas Por Port Z R Back Y Panel _ 2 NC S2 sal S1 Nc z MANIFOLD COM I V N Ld Restrictor Y Bench Assembly XE D O5 NO OW D Flow Ed b Sensor en j x x 2 EXHAUST PROBE 2 O Check D gt Exhaust Valve Back D Panel PUMP O D IN Exh E ans mem DENOTES PRIMARY FLOW PATH LEAK TEST B MODE VAC DECAY COMPONENT
66. cuit boards use Anti Static Bags and Cartons when transporting the circuit boards LOGIC LEVEL DESIGNATIONS Throughout this manual the terms high and low are used Unless otherwise noted the high refers to a TTL logic high level 5V and a low refers to a TTL logic low level OV PAGEi Signals that are active low or active on the falling edge are designated with an asterisk Jollowing the signal name i e TRACK 00 STROBE Typically the text will differentiate between a level sensitive or edge sensitive signal A Functional block may use either an asterisk following the signal name PUMP ON or a bar over the signal s name PUMP ON to indicate that the signal is active low or on the falling edge OPEN COLLECTOR OUTPUTS Some of the outputs are open collector meaning that a pull up resistor is used to pull up the signal to Vcc Usually the pull up resistor is at the signal s destination board The Open Collector outputs are designated on the diagrams with an O C marking at the edge connector The FST should keep in mind the fact that open collector drive may be used A broken wire between the source board and the destination board will cause the source board to appear to be defective the signal will not be pulled up thus it will appear that the source board is not outputting a signal HANDLING OF MOS IC AND OTHER STATIC SENSITIVE DEVICES A majority of integrated circuits are high impedance devices This characteri
67. d permanently in PROM or ROM or Semi permanently in an EPROM These are the yellow keys on the keypad that are used to control analyzer operations or functions related to specific screens They are located on the left side of the keypad and on the right side of the screen These keys are referred to as F keys and are numbered F1 through F6 These keys are variable and depend on the screen or mode in which the analyzer is operating Used to describe system components that function as a result of being soldered into the system rather than being connected through a connector Describes all items in a computer system that are not software circuit boards integrated circuits transistors discrete components etc A measure of frequency or bandwidth The same as cycles per second Input Output Refers to the paths by which information enters a computer system input and leaves the system output Some traditional input device might be a keyboard although some computer systems utilize joysticks a mouse touch Screens or other similar devices The usual output devices on modern computers is a video screen or a printer An electronic or software device used to mate a computer and its peripherals with the outside world A calculator style arrangement of numeric and arithmetic keys This is the input device that allows the operator to control the analyzer A alternate way of expressing air fuel ratio where 1 0 lambda is the ideal air
68. d the tag values in use are those from the factory e Message appears Press F3 Cal Reset Default Cal Values Now In Use FLOW RATE FAULT PRESS HELP THEN F3 MESSAGE HELP MENU e Indicates that the Analyzer detects a Low Flow Condition NOTE This message could also appear when the Sample Probe and Hose are not connected to the Analyzer and a Low Flow condition exists in the Filters or internal components INVALID TIME OR DATE e Appears on the Analyzer Setup Screen e Appears when an invalid time or date is entered LEAK TEST ABORTED e Indicates that there is a leak in the Sampling System e Message Appears Check Probe Cap and verify it is tight Filter Bowls and Sample Hose inlet for leaks Sample Probe Hose for damage or deterioration that could be a source of leaks LEAK TEST FAILED e Appears after a failed Leak Test e Message Appears Check Probe Cap and verify it is tight Filter Bowls and Sample Hose inlet for leaks The Analyzer Pump for operation at the start of the Leak Test TAG VALUES OUT OF RANGE e Appears in Calibration e Indicates that the value entered for the Tag Value on the Calibration Gas is invalid or unusable ZERO FAILURE PRESS HELP THEN F3 MESSAGE HELP MENU e Appears in Zero e Indicates that Zeroing Failed PAGE F4
69. der Bin If the user is using a sheetfeeder option BIN lets the user select a sheetfeeder bin to feed paper from Select None when not using a sheet feeder Front to feed paper from the front or only sheet feeder bin Back to feed paper from the back sheetfeeder bin or Envel to feed from the envelope tray if your printer has it installed 23 TOP MAR 000 Set Top Margin continued TOP MAR is used to specify a top margin On subsequent form feeds paper advances to the top margin you specify The top margin can be from 0 to 181 lines down from the top of form however the user can only select a line that is above the bottom margin setting The physical location of the top margin on the page is unaffected by subsequent changes to line spacing If the user changes the LENGTH page length setting the top margin resets to 0 24 BOT MAR 066 Set Bottom Margin BOT MAR is used to specify a bottom margin After printing on this line the printer performs a form feed operation automatically no printing occurs below the bottom margin The bottom margin can be from 1 to 182 lines down from the top of form however the user can only select a line that is below the top margin setting The physical location of the bottom margin on the page is unaffected by subsequent changes to line sgeing If the user changes the LENGTH page length setting the bottom margin resets to the new page length 25 LFT MAR 000 Set Left Margin LFT MAR is
70. e MT 3505 will allow the operator to read gases during the warm up period It is important to note that if gases are being read during this period they are still drifting and may not be accurate During a Cold Start the IR source temperature stabilizes long before the filter detector assemble which has a much higher thermal mass reaches final temperature This can take up to 14 minutes under worst case conditions During a hot restart caused by a front panel reset the filter detector assembly s thermal mass allows it to regain final temperature very quickly The IR Source however may take one to two minutes to regain the temperature it lost and retrace its steps through the software sequenced startup routine CALIBRATION Calibration should be performed at a minimum interval of at least every 30 days to maintain accuracy To determine if a calibration should be performed before the 30 day interval either follow the procedure below or consult the operators manual NOTE The following procedure assumes that a quad blend gas with 2000 ppm Nitric Oxide NO 1200 ppm Propane HC 4 0 Carbon Monoxide CO and 12 0 Carbon Dioxide CO2 is used 1 Turn the analyzer on and let the analyzer Warm up for a minimum of 30 minutes 2 Press OPTION MENU The Option Screen is displayed 3 Press SERVICE F6 The Service Screen is displayed 4 Press GAS CAL F1 The Gas Calibration Screen is displayed 5 Compare the Tag Val
71. en sent to the Andros Bench The Q NO interface board also passes on the O sensor output to the Andros Bench For a block diagram of the O and NO circuitry refer to drawing 7 1 page 7 3 OXYGEN 0 THEORY OF OPERATION The O content of the exhaust sample from the engine under test is measured by Q Cell The cell outputs a DC voltage in the millivolts range when exposed to atmospheric oxygen Typically the voltage is 11 millivolts 3 millivolts when exposed to atmospheric oxygen 20 896 at sea level As the oxygen content of the exhaust sample decreases the cell s DC output voltage decreases The output of the QCell is very stable throughout its life At the end of a O Cell life the output will begin to ramp up as much as 40 millivolts Therefore if the output is consistently out of specification replacement is recommended The O Cell output is routed to the NO Interface Board at J2 pin 1 signal voltage and J2 pin 2 ground The input and ground signals then go through a filter and are output on pins 1 and 2 of J1 respectively From there the O signal is routed to the Andros Bench for processing PAGE 7 1 NOTES PAGE 72 All information contained or disclosed in thi document is considered confidential and proprietary by Sun Electric Corporation All manufacturing use reproduction and sales rights are reserved by Sun Electric Corporation and the information contained herein shall not be u
72. er When the switch is shorted the keyboard controller tells the system controller that the analyzer has been tilted At that point an error beep will sound This indicates an error has occurred and the message ANGLE TOO STEEP LEVEL ANALYZERvill be displayed FAN The fan is powered by the 15HP volt supply from the power supply assembly Before the 15HP volt supply reaches the fan it goes though a 24 ohm 5 watt sand block resistor Sending the 15HP volt line through the resistor before it gets to the fan cuts down the effective current to the fan Connector J11 pin 1 on the CPU board is the fan power Pin 2 of J11 is the ground for the fan Effective 2 97 Page 2 1 CHAPTER2 COMPUTER VIDEO Video signals to the monitor are generated on the CPU board by the Video chip U3 W86855 Video Display RAM is also stored on the CPU board on Integrated Circuit chips U2 and U3 53C464 The Front panel Brightness pot is also located on the CPU board For an in depth description of the Video circuitry please refer to Chapter 4 of this manual SERIAL AND PARALLEL I PORTS All the controlling components drivers controllers are located on the CPU Board U55 and U56 16C462 are the Serial Parallel controllers Each chip controls two serial ports and one parallel port J28 on the CPU board is the connector through which all the data is transferred to the connector board The connector board mounted on the back panel has all the serial and par
73. es a bias voltage applied to it at all times During shipment this voltage is supplied by the 3 volt Lithium Battery which is permanently mounted on top of the NO cell This battery has a lifetime of 180 days from the date of manufacture If the NO cell is not installed into a analyzer within this 180 days the NO cell will become inoperative When the cell is placed in the analyzer the 6 volt rechargeable sealed Lead Acid battery takes over and supplies power to the NO cell When the analyzer is powered up the rechargeable sealed Lead Acid Battery is being recharged It takes approximately 12 hours of power up time over the period of a month to keep the rechargeable lead acid battery charged The NO Cell is mounted on the back panel of the MT 3505 under the Q NO cover The NO content of the exhaust sample from the engine under test is measured by flowing a small amount of the exhaust sample over the NO Cell The cell outputs a DC voltage when exposed to NO Typically the voltage is 4 4VDG0 22 volts when exposed to the atmosphere As the concentration of NO increases the DC voltage drops When full scale NO 4000ppm is reached the DC voltage should be 2 0 Volts DC 1 0 Volt DC Zero and span calibration of the NO sensor is required periodically to accommodate the unit to unit and unit over time differences in the NO Cell output The O NO Interface Board contains the circuits that support the NO Cell and preamplify its output This output is th
74. es zj ej g J aoe s a3ijg e ejiej e 7 e m NOT USED No ko sa SS e eue mm NOT USED No I NOT USED No M2 NOT USED No CA NOT USED No CA No ES NOT USED No T No PANEL SCANNER CONNECTOR No 2500 SCANNER Eur SUN ELECTRIC CORPORATION One Sun Parkway Crystal Lake Illinois 60014 U S A m MT 3505 0395 REVA Wes J HINKLE CHK BY MT 2500 SCANNER m 123 NOTES PAGE 12 4 APPENDIX A SOFTWARE PAGE FLOW GENERAL This appendix will give a breakdown of the software page flow that is used by the customer and the service technician Directly below the Start Up Screen heading are five boxes These boxes represent the green keys on the front of the keypad All other boxes have function keys in the upper left hand corner These F keys represent the F keys on the keypad SERVICE PAGE The Service page should only be accessed by Authorized SurSERVICE personnel To access the Service Page first enter the service menu by pressing lt OPTION MENU then F6 Once in the service page press lt F5 gt then lt gt and then lt gt gt This will allow you to look at specific parameters of the analyzer PAGE A4 NOTES PAGE A2 GENERAL APPENDIX B GLOSSARY The following i
75. est possible vertical alignment but slows down printing Select Bi d for bidirectional printing or Uni for left to right printing 18 GRFICS Bi d Set Graphics Printing Direction GRFICS is used to specify whether he printer should print graphics in both directions or from left to right only Printing from left to right only provides the highest possible vertical alignment but slows down printing You can select Bi d for bidirectional printing or Uni for left to right printing SELECTING PAGE SETUP PARAMETERS Page Setup parameters lets you specify page size and margins 19 LENGTH 066 Set Page Length LENGTH is used to specify the length of the paper that the user is using in 1 6 inch increments T isetting is especially important since it controls continuous forms feeding The user may select a number from 0 to 182 To determine the correct number to use for your paper multiply the length of the paper in inches by 6 For example if the paper is 11 inches long select 66 11 x 6 66 When setting page length the printer sets the top of form at the current line and clears top and bottom margins If the length is set to 0 the printer does not keep track of lines per page When using singb sheets a form feed control code ejects the page when using pin feed paper a form feed control code performs a carriage return only PAGE 11 4 20 WIDTH 8 5 Set Maximum Print Width WIDTH is used to specify the maximum print width If the
76. gs saved under one of these names 2 SAVE None Save Printer Settings SAVE is used to save the current printer setting in non volatile memory for use at a later time To save the current printer settings hold down lt Alt gt and turn the Select dial to select one of the three users names As soon as Alt is released the printer saves the current printer settings and assigns the user name that is selected RSTOR is used to restore the settings that are saved DFALT is used to make your saved settings the power on default settings None is selected to cancel the operdion or Usr 1 through Usr 3 to save the current settings under one of these names 3 DEFALT Fctry Select Power On Default Settings DFALT is used to select the printer settings to use as the power on default settings Select the factory settings or the settings were saved previously with a SAVE operation The printer keeps that DFALT selection in non volatile memory so it is retained when the printer is off Select Fctry to use the factory settings as the power on defaults or Usr 1 through Us3 to use settings saved under one of these names PAGE 11 2 4 TEST None Run Printer Test TEST allows a variety of printer tests including a sensor check and a memory check If a test fails an error message will appear Select None that is always the default and does not perform any test Sensor that runs the sensor check or Memory that checks the printer memory
77. haust Probe Warning Label on Handle MT3505 Front Panel Adhesive Label With Speaker and Speaker Bracket Sheet Metal Sheet Metal Cover Over Both Sensors To Plug In Optional Accessories printer Gasket around front of CRT Electrical Shock Label next to AC Power Input Conn English French Electrical Shock Label Exhaust Hose Handle and Flexible Probe Flexible Sample Hose with Probe Tip 25 Feet Replacement Sample Hose No Probe For Leak Check For Leak Check Without Flexible Probe Tip Scanner RS232 Printer etc Black Plate around Monitor Brightness Control Monitor and Monitor Bd mounted on Monitor Shield Warning on top of Filter Assembly Warning below Tach input connector DC AC Power Connector From Back Panel to Inductive Pickup Harness Front Panel Bezel with handle Back Panel Tach Connector and Internal Harness with wiring harness Sheet Metal Contains 6049D0039901 Ribbon Cable Sheet Metal With AC Power Line Filter Sheet Metal Includes Back Panel Conn amp Harnesses Sheet Metal and Board Sheet Metal Back and Bottom Sheet Metal Panels For Case Sheet Metal Sheet Metal Bottom Rubber Bumper Screws into it Sheet Metal Inductive Trigger Pickup with Cable 2 wire Internal Thermocouple Harness From Monitor PCB to Main PCB J9 From IR Bench to Main PCB J14 6058D0049901 6058D0169901 6105G004ADED 8518 11582 12779 12981 15061 15680 15861 214348 22066 24437 25857 275
78. he Gas Analyzer Mode or by pressingF4 gt Manual Zero in the Gas Analyzer Mode During the Zero Mode clean air is drawn in from the Zero port on the back of the analyzer and into the manifold The clean air is then drawn through the normally closed port of S1 through the common port and to the pump From the pump the clean air is pushed through the Bench the NO and O manifold and out the port to the atmosphere It is important to note that the vacuum pump is also aspirating moisture from the primary filter bowl at this time as is consistent with any time the pump is running Therefore if for any reason solenoid S1 does not fully energize gases from the filter assembly would be pulled in GAS CALIBRATION MODE DRAWING 5 2 PAGE 5 5 To maintain the accuracy of the MT 3505 gas readings the analyzer may need to be periodically calibrated To determine if a Gas Calibration needs to be performed the operator should consult the User s Manual During a Gas Calibration the pump is off or not running and solenoid S2 is energized Gas from the pressurized calibration gas bottle flows in through the back panel Cal port From the Cal port the calibration gas is forced through a restrictor which is internally molded into the manifold The gas then travels through S2 which is energized the Bench and finally through the NQ and manifold where it is pushed out to the atmosphere As with all pneumatic modes it is important to note any residual flow
79. ibration Page Usage when applicable Calibration when applicable and troubleshooting for the various functions of the Tester NOTE f the Table of Contents does not list a calibration procedure service calibration usage notes etc this indicates that there is no procedure applicable to that function Most Theory of Operation is written around the Functional Block Diagram All Signals and Circuitry that are referred to will be all capitalized i e BUS INTERFACE LOGIC Printed Circuit Boards may be called PCB s CCA Circuit Card Assemblies or just Boards IMPORTANT GUIDELINES FOR SERVICING A ALWAYS verify that the power supply is operating within the specified tolerance at CPU before replacing any Circuit Boards B Verify that the connectors on the boards are fully seated and that the boards are fully seated in their respective backplane In addition verify that a connector keying pin has not come loose and lodged between pins thereby inhibiting proper mating C NEVER remove boards or disconnect a connector with power on D Make sure that you completely understand what the Tester is suppose to do you cannot fix it if it s not broken Refer to the Operator s Manual application notes and the flow diagrams for this type of information E CONSULT the Service Bulletin Binder to see if this problem was identified earlier and instructions provided on how to correct it F Use Wrist Static Straps when handling the cir
80. ight shows that the printer is ON P E light shows that an error condition exists MENU light shows that the printer is in the MENU MODE which allows selection of various settings using the LF FF FONT and PITCH keys down arrow up arrow left arrow and right arrow respectively ON LINE light shows that the printer is ON LINE NOTE The MENU MODE settings will not change the way information from the MT 3505 is printed since information is sent to the printer in graphics format which is not affected by changes in font or pitch NOTE The printer will not print unless the On Line light is illuminated SELECTING THE POWER ON CONFIGURATION MODE 1 With the power switch OFF hold down MENU and turn the power switch ON POWER ON CONFIG is shown on the LCD to confirm this Release lt MENU gt PRINT OUT is shown asking if you want to print out the current configuration Press Right Arrow PITCH or Left Arrow lt FONT gt to begin the printout Compare the printout to the one below These settings should match If not refer to Changing the Power On Configuration Mode Settings POWER ON CONFIGURATION TEMS DATA 1 EMULATION TYPE1 2 CHARACTER SET ITALIC 8 NATIONAL SET USA 4 AUTOMATIC CR OFF 5 AUTOLF OFF CR 6 INPUT BUFFER 20kb 7 ASF OFF 8 IBM 20 COMPR ON 9 INTERFACE PARALLEL 10 BAUD RATE 9600 BPS 11 PARITY NONE 12 DATA BITS 8BITS 13 TEAR OFF MANUAL 14 ALIGNMENT 10 PAGE 11 13
81. ise To change any of the settings release Pitch and Form Feed Then press and hold lt Alt gt while turning the dial Below are all the service modes and there associated function SERVICE MODE 54 ADJ LQ10 52 55 ADJ HQ10 19 56 ADJ DQ10 24 57 ADJ DQ12 42 58 ADJ DQ17 51 59 ADJ DQ20 50 60 TEARBAR 24 61 P_SNSR 46 62 SNSR 0 63 SET USR PAGE 11 8 54 ADJ LQ10 52 Letter Quality 10 Pitch Vertical Adjustment When printing in letter quality mode this adjustment will align the forward pass of the print head with the backwards pass of the print head If this is not set to the proper setting the alignment of the lines in a printout will not line up with the left or right margin 55 ADJ HQ10 19 High Draft Quality 10 Pitch Vertical Adjustment When printing in HDraft mode this adjustment will align the forward pass of the print head with the backwards pass of the print head If this is not set to the proper setting the alignment of the lines in a printout will not line up with the left or right margin 56 ADJ DQ10 24 Draft Quality 10 Pitch Vertical Adjustment When printing in Draft mode this adjustment will align the forward pass of the print head with the backwards pass of the print head If this is not set to the proper setting the alignment of the lines in a printout will not line up with the left or right margin 57 ADJ DQ12 4
82. le Clamp Hose Connector Thermocouple Cord Power Cover and NO Cell CRT Element Primary Filter Element Secondary Filter Escutcheon Fan Filter AC Line Filter Assembly Fitting Brass Elbow Fitting Brass Elbow Fitting Brass Nipple Fitting Brass Nipple Fitting Male Brass Fitting Plastic Fitting Plastic Tee Foot Fuse Fuse Fuse Fuse Fuse Holder Gasket CRT Grommet PAGE 9 6 PARTS IN ALPHABETICAL ORDER PART NUMBER COMMENTS MT350090 MT310019 EAA0030C01A 7049012901 MT3500310 MT3500A200 EAP0041C00A EAA0030C03A 0301094701 MT3500A410 MT3500A6 MT3500A7 MT3500A9 MT3500A25 MT3500A125 28851 8518 84918 6047D0149901 6057D0049901 6058D0049901 6058D0169901 EAA0030C02A MT310033 MT310032 MT3500A700 07200002 MT3500A600B 25857 11582 214348 62421 EASP034C00A MT3500326 0301094401 0301094501 MT3500301 MT3500A60 210751 EAA0031C01A 0647030301 113680 113480 0647030101 113380 15680 06470102 MT3500A8 07390040 27551 210351 210551 210951 MT16651013 05010003 From Back Panel to Inductive Pickup Harness Below NO O Interface Bd Andros 5 Gas Front Panel Bezel with handle Contains 6049D0039901 Ribbon Cable With Speaker and Speaker Bracket Behind NO and O Cell Primary and Secondary Sheet Metal Sheet Metal Sheet Metal Sheet Metal Sheet Metal Sheet Metal 15 Amp Back of Analyzer Bottom of Analyzer From Monitor PCB to Main PCB J9 From IR Bench to Main P
83. ll MT 3505s The Thermocouple circuitry consists of a Temperature Probe MT3500A800 on the outside of the analyzer On the back panel of the analyzer is the TEMP connector with the internal thermocouple harness attached to it The internal thermocouple wiring harness attaches to the CPU Board which has the engine sync processor and counter timer circuitry on it THEORY OF OPERATION The Thermocouple on the outside of the analyzer produces a voltage when hooked to the analyzer This voltage is sent to the back panel TEMP connector From there the internal thermocouple wiring harness routes the signal to J16 pins 2 and 3 of the CPU Board This voltage signal is then sent to a temperature compensation circuit which sets a reference for the thermocouple From there the voltage is sent to a comparator The output of the comparator is then sent to an operational amplifier where the zero and gain calibrations can be performed From the operational amplifier the signal is sent to a counter timer where the signal is changed to a digital signal and processed by the system controller R46 GAIN PANEL Q THERMOCOUPLE z 16 TL TEMP 2 ep COMPARATOR COUNTER J zs TEMP 3 COMP TIMER 4 ENSATION CPU Board y A INS ADS EN A A O s DAA NN vo ERE DON ERA Figure 1 THERMOCOUPLE CIRCUITRY PAGE
84. ls all interpretation of this data is done by the CPU Board For a more in depth explanation refer to Chapter 2 The Keypad is used to allow the operator to input information into the computer It is a Smart Keyboard in that it scans the keys continuously interrupting the CPU to communicate what and when a key is pressed For a more in depth explanation refer to Chapter 3 The monitor which includes the monitor board interprets the signals sent from the CPU board This enables the production of monochrome quality text and high resolution graphic displays on the VDU For a more in depth explanation refer to Chapter 4 The Infrared Bench is an Andros 6241 digital automotive bench which utilizes a single beam NDIR nondispersive infrared measurement technology to provide fully corrected HC CO and C gas concentrations These concentrations are then transferred to the CPU Board For a more in depth explanation refer to Chapter 6 The NO and O2 measurements are performed by cells located on the rear of the analyzer These cells produce a voltage in the presence of Nitric Oxide and Oxygen respectively This voltage is then processed by the Andros Bench For a more in depth explanation refer to Chapter 7 PAGE 3 CHAPTER1 AC DC DISTRIBUTION A WARNING DANGEROUS HIGH VOLTAGES ARE PRESENT IN THIS EQUIPMENT Always use the One Hand Rule keep one hand in a pocket or behind your back when working with AC voltages Alway
85. n A manufacturing use reproduct ion and sales rights ore reserved by Sun Electric Corporation and the informat ion contained herein shal not be used in whole or in part without the express written consent of Sun Electric Corporation Zero Gas Por Port Back Y e Panel N 8 wc S2 ga ade S1 a P COM 7 _ V LT Restrictor n Y T Y M Pett EU I Bench Assembly E A aig filo TI Ing Y Low V Flow A BENCH BP gt Sensor X ducer A l 2 uA dd A 7 Y Restrictor A D v ses Check gt Exhaust A Val alve Back u D Panel PUMP 2 D Check VD
86. o Barometric Pressure Transducer 4 between Bezel and Monitor For Back Panel Gas Calibration Port Back Panel Thermocouple Connector Might Break This Down into smaller Part Gray Plastic Wiring Harness Hold Down 1 Amp 250 Volt for 240 Volt Testers 15 Amp On CRT sheet metal for Power Supply Wiring Harness Bottom of Analyzer 4 attached to corners of CRT Side of unit by Power Switch qty 1 On Back Panel qty 4 Brightness Adjustment Knob Primary Filter Housing to 90 adapter Between Primary and Secondary Filter 90 Elbow off Secondary Filter Housing and Bottom of Primary Filter Bowl 2 Amp 250 Volt Fast Blow AC input Connector 20 Amp 32 Volt Input Filter Fuse Assembly Holds 20A Fuse Above Power in Conn On AC Power Cord Connector Holds CRT PCB to Sheet Metal Harness runs through this on Manifold Sheet Metal Bottom of Secondary Filter Bowl 1 Amp Slo Blo 2 Plugs Below Cal and Zero Ports on Back Panel Primary and Secondary Filter Primary and Secondary Filter Bowls 75 Micron Filter 8 Micron Filter Primary and Secondary Element Retaining Nut Primary and Secondary Primary and Secondary Filter Bowl Nut Between Interface Bd and Sheet Metal Between Primary Filter and 90 adapter Between Primary Filter Bowl and 90 Adapter 90 Elbow to Exhaust Sample Hose Andros 5 Gas PAGE 9 9 NOTES PAGE 9 10 CHAPTER 10 THERMOCOUPLE GENERAL The Thermocouple or Temperature function is optional on a
87. on switch is used to select printer functions The switches are preset at the factory with switches 1 2 3 4 8 9 and 10 open up and switches 5 6 and 7 closed down Dip switches 1 2 3 4 and 10 are not used at the current time Dip switch 5 is used to enable the Customer Vehicle Data Form With this switch in the down position pressing lt ID FORM gt will print the Customer Vehicle Data Form on the paper Dip switches 6 7 and 8 are used to set the communication baud rate With the dip switches set as shown below the printer is configured to print at a baud rate of 2400 baud Dip switch 9 is used by the factory to do testing and should always be set to the Up position To configure the dip switches for use in the MT 3505 set them according to the chart below SWITCH POSITION DESCRIPTION 1 UP OPEN NOT USED 2 UP OPEN NOT USED 3 UP OPEN NOT USED 4 UP OPEN NOT USED 5 DOWN CLOSED CUSTOMER VEHICLE DATA FORM ENABLED 6 DOWN CLOSED BAUD RATE 7 DOWN CLOSED BAUD RATE 8 UP OPEN BAUD RATE 9 UP OPEN FACTORY SERVICE TESTING 10 UP OPEN NOT USED PAGE 11 16 VI TROUBLESHOOTING COMPLAINT Printer does not turn on Error message appears on AMT Select dial control panel Control Panel on AMT printer does not operate Select dial does not move printer paper on the AMT printer Self test prints but printer does not print data sent from the analyzer Printing is too light CORRECTIVE ACTION
88. one on top of the other to produce bold print In shadow mode characters are also printed twice once and then slightly offset to the right to produce shadow print Select Bld to turn the bold mode on Sha to turn the shadow mode on or Off to turn both modes off 15 CTR JST Off Turn Center Justify Modes On and Off CTR JST is used to turn on and off the center and justify modes In the center mode the printer centers each line of text between the margins In the justify mode the printer expands or compresses each line of text as necessary so that it ends at the right margin If the printer must expand a line to over twice its original length or compress a line so that characters overlap the line prints unjustified With both the center and justify modes a carriage return or line feed code in the print marks the end of the line Select Ctr to turn on the center mode Jst to turn on the justify mode or Off to turn both modes off 16 LANG PC437 Set Language LANGi is used to specify a language for the printer to use when printing text When selecting any other language than USA the printer replaces some of the standard ASCII printable characters with alternate characters that are used in a specific language Use PC437 for the setup 17 DIRCTN Bi d Set Text Printing Direction DIRCTN is used to specify whether the printer should print text in both directions or from left to right only Printing only from left to right provides the high
89. operator to continue PRESSURIZE TO 10 PSI MAXIMUM Appears in Calibration e Promotes the operator to set the calibration gas pressure PRINT ABORTED e Appears when the print is canceled PRINTER ERROR PRESS HELP THEN F3 MESSAGE HELP MENU e Appears when the data will not print SCANNER NOT DETECTED e Appears when Scanner screen is in use e Message Appears Check Comm cable connections Check Analyzer Comm Setup Check Scanner Communication Setup Check Scanner Power ZERO REQUIRED PAGE F2 e Indicates the Analyzer requires Zeroing ZERO IN PROGRESS e Appears during Manual and Auto Zero e Indicates that Zeroing is in progress PAGE F3 GENERAL FAULT MESSAGES Fault messages inform the operator of a failure A complete listing of possible Analyzer Fault Messages follows ANALYZER SUBSYSTEM FAULT PRESS HELP THEN F3 MESSAGE HELP MENU e Indicates that the Analyzer has an Internal Malfunction e Appears whenever an Internal Malfunction occurs in the Analyzer ANGLE TOO STEEP LEVEL ANALYZER PRESS SELECT e Indicates the front of the Analyzer has been tilted too high 30 in relation to the back of the Analyzer CAL FAILED e Appears at the end of an unsuccessful Gas Calibration e Message appears Cal Gas Tag Values out of range Change Analyzer tag values to match calibration gas concentrations CALIBRATION FAILURE DEFAULT CAL VALUES NOW IN USE e Indicates the Analyzer has failed Calibration an
90. ow the unit to accurately measure the vacuum draw Once the proper amount of vacuum is sensed the pump shuts off and the analyzer proceeds to the Leak Test B Mode LEAK TEST B VAC DECAY MODE DRAWING 5 4 PAGE 5 9 Leak Test B Mode occurs immediately following Leak Test A Mode The only noticeable difference to an operator would be that the pump shuts off During the Leak Test B Mode the pump shuts off trapping the vacuum drawn in the Leak Test A Mode The computer monitors the low flow sensor to determine if the vacuum that was drawn in the Leak Test A Mode diminishes If the Vacuum diminishes below a predetermined level a Leak Test Failed error message will appear If the leak test passes the analyzer will return back to the first service screen SAMPLE MODE DRAWING 5 5 PAGE 5 11 The Sample Mode is used to read gases from the vehicles exhaust pipe The exhaust gases are drawn through the exhaust probe primary and secondary filter assemblies solenoid S1 and into the vacuum pump From the vacuum pump the exhaust gases are pushed through the check valve bench NQand manifold and out the port to the atmosphere During this mode the low flow sensor is constantly monitoring the amount of vacuum from the vacuum pump to determine if sufficient flow exists If it doesn t a Low Flow condition exists Page 52 All information contained or disc losed in this document is considered conf ident ial and proprietary by Sun Electric Corporatio
91. p MT3500A25 22 Standoff 15861 11 Spacer 04010354 23 Board Main CPU EAP0041C00A 12 Fan MT3500A60 24 Board Connector MT3500A200 PAGE 9 3 BACK PANEL VIEW 10 Q nn 2 1 2 on I iu 5 TO 4 d S J Y N d 44 4 d 47 w 2 22 ITEM DESCRIPTION PART ITEM DESCRIPTION PART NUMBER NUMBER 1 Label Warning MT16704A 12 Bumper Rubber 84918 2 Cover NO and EASP0034C00A 13 Foot MT3500A8 3 Manifold Block NO O EAA0031C02A 14 Harness Internal Tach MT3500A10 4 Channel NO and 07200002 15 Plug Black Plastic 13740031 5 Sensor 7049000401 16 Label Warning MT35004 6 Plate NO and EASP033C00A 17 Grommet Blk Plastic 85816 7 Grommet 05010003 18 Harness Internal DC MT3500A50 8 NO Cell 7049013001 19 Label MT35005 9 Filter Assembly See Page 9 5 20 Breaker Circuit 28851 10 Conn Thermocouple 214348 21 Filter AC Line 210751 11 Label RS232 Printer MT35002 22 Bumper Rubber 8518 PAGE 9 4 FILTER ASSEMBLY
92. p in d E C 1 GPU C 1 INFRARED BENGH ec C 2 APPENDIX D MODEL DIFFERENCES uu D 1 APPENDIX E INSTALLATION INSTRUCTIONS 1 APPENDIX FSCREEN MESSAGE PRONPTS GENERAL NORMAL F 1 GENERAL FAULT MESSAGES tenti b it p te den eg dee AE Pe Re exa a Ded ele naht eR aea enden F 4 INTRODUCTION GENERAL The MT 3505 Emission Analyzer is a highly versatile test instrument used to test exhaust gases When used with other tools and equipment the analyzer can also be used to detect and locate ignition fuel exhaust emission control and engine service problems When exhaust gas concentrations are within limits specified by the vehicle manufacture or the local state or federal government it is generally assumed that the fuel ignition and emission control systems are functioning properly If exhaust gas concentrations exceed those specified limits repairs or adjustments are probably needed Most customer complaints are attributed to a specific function of the MT 3505 not operating properly Therefore the Service Manual is divided into Chapters that provide Theory of Operation Service Cal
93. pers will never need to be moved This section has been included as a means of checking the Infrared bench to determine if a jumper may have fallen off MAIN BOARD Wi OPEN W2 OPEN W3 SHORTED W4 SHORTED W5 OPEN W6 OPEN W7 OPEN W8 OPEN W9 SHORTED W10 OPEN ENHANCED O2 NO BOARD W1 OPEN W2 OPEN W3 SHORTED W4 OPEN W5 OPEN W6 OPEN PAGE C2 APPENDIX D MODEL DIFFERENCES GENERAL At the time of publication there was only one model of the MT 3505 In the future if different models are manufactured this appendix will explain the differences PAGE D4 NOTES PAGE D2 APPENDIX E INSTALLATION INSTRUCTIONS GENERAL Appendix E is reserved for the filing of Installation Instructions When a kit is successfully installed in a analyzer the Installation Instructions should be filled in this appendix in alpha numerical sequence At the bottom of every page of an Installation Instruction is the part number the revision level and the date the instructions were printed For example 0692 2329 01 01 26 95 REV Bs at the bottom of the page 0692 2329 01 is the number of the Installation Instructions REV B is the revision of the Installation Instructions and 01 26 95 is the date they were printed If a subsequent instruction is done the revision level will change to a C and a new date will be applied Every time you receive a new Instruction check the REV
94. puter Before successful communications can occur these parameters must be set to match those of the host computer When you change a communications setting the printer clears the data input buffer 27 DWNLOAD Off Allocating Memory for User Defined Characters DWNLOAD is used to allocate a portion of the printers memory to hold user defined characters that are downloaded from the computer Select ON to allocate eight kilobytes 8 191 bytes of memory for user defined characters or Off to allocate all of the printers memory for a data input buffer 28 INTRFCE Par Select Interface INTRFACE is used to select either the parallel or serial interface port for communication with the host computer The user can select Par for parallel or Ser for serial If the user selects serial you must also set the BAUD PARITY DTA BITS STOP BITS and HNDSHAK parameters to match the serial configuration of the host computer If the user selects parallel these parameters are irrelevant For our applications Par should be selected 29 BAUD 9600 Specify Baud Rate BAUD is used to tell the printer what serial baud rate your computer is using Baud rate is the speed that serial data is transmitted between the computer and the printer The user can select 150 300 600 1200 2400 9600 19200 or 38400 Both the computer and the printer must be set to the same baud rate which is 9600 for the MT 3505 30 PARITY None Specify Parity PARITY is used
95. r circuit and a functional block diagram please refer to Chapter 8 of this manual THERMOCOUPLE As with the Tachometer circuitry the entire Thermocouple circuitry is also located on the CPU Board From the back panel TEMP connector the Temperature signal is routed via a wiring harness to J16 on the CPU Board On the CPU Board the Temperature signal is processed digitized and sent to the Central Processing Unit Chip From there the signal is sent to the video circuitry and displayed on the Monitor For a detailed description of the Thermocouple circuit and functional block diagram please refer to Chapter 12 of this manual Effective Page 2 2 2 97 TROUBLESHOOTING COMPLAINT Il ANALYZER CONTINUES TO LOOSE SETUP PARAMETERS OR STORED WAVEFORMS I SPEAKER NEVER BEEPS Ill NO RESPONSE FROM ANY KEYS ON THE KEYPAD IV ANALYZER TOO STEEP LEVEL ANALYZER MESSAGE ALWAYS DISPLAYED Effective 2 97 CHAPTER2 COMPUTER CORRECTIVE ACTION Ensure that the CMOS Battery is reading 3 6 Volts DC across its terminals If not replace CPU Board Refer to Drawing 2 1 ensure that all voltages are present at the CPU Board connector J4 If not replace Power Supply Enter the Analyzer Setup menu through the Options Menu and ensure that the beeper option is turned on e Toggle Beeper Option to ON by pressing F4 Place the black lead of the Digital Multimeter to Chassis Ground Sheet Metal place the red lead
96. rinter for no parity checking and try again BUFFER OVERFLOW This error occurs when the printer s data input buffer overflows A buffer overflow occurs when the following condition s exist s The printer and the host computer are not using the same handshaking method and or the baud rate exceeds the print speed PAGE 11 11 CORRECTIVE ACTION Change the HNDSHAK setting on the Setup menu to the computers handshaking method The press lt Ready gt to re enable printing and restart the print job from the beginning If the computer or software program does not use handshaking you must reduce the baud rate of the computer and printer to a rate that does not exceed the print speed 5 CORRECTING PRINTER ERRORS The printer can notify the user of four printer errors Printer errors occur when the printer is unable to continue printing due to a malfunctioning printer component MEMORY ERROR This error occurs when the printer logic detects defective memory during a printer memory test Memory tests occur during power up and when the user selects Memory Test on the Setup menu CORRECTIVE ACTION The printer s memory must be replaced If this message appears during the Setup menu memory test the user may be able to clear the message and return to the Setup menu by turning the Select dial CARRIAGE ERROR This error occurs when the printer is unable to index the carriage at the hme position due to a jammed ribbon dirty carriage shaft
97. s an appendix of common terms that may have been used throughout this manual but are pertinent to the MT 3505 Gas Analyzer When reading this manual please refer to this appendix for terms you are uncertain about If you come across a term which you are unfamiliar with and do not find it in this appendix please alert Technical Support in Crystal Lake so they may make the proper adjustments AIR FUEL RATIO ALPHANUMERIC AMBIENT ANALOG SIGNAL ASCII BAUD CRT CTS DOT MATRIX DRIVER EPROM FEATURE KEYS FIELD A Specific quantity of air per one part of fuel by weight such as 14 7 pounds of air to one pound of fuel This may be written as a ratio 14 7 to 1 or 14 7 1 The smaller the quantity of air the richer the fuel mixture The larger the quantity of air the leaner the mixture A set of alphabetic and numeric characters Usually referred to in gas analyzers as ambient air This is the air surrounding the analyzer A continuous electrical signal representing a condition such as temperature or the position of a mouse Unlike a digital signal which is discrete an analog signal can be any frequency or amplitude American Standard Code for information interchange Set of digital codes for all alpha numeric and control codes A measure of the rate at which digital data is transmitted in bits per second typically ranges up to 57 600 baud 57 6k baud Cathode ray tube This is the most common form of a compu
98. s being used to measure HC CO and CO2 concentrations The NO and O2 readings are obtained from a NO and O2 cell mounted on the rear of the analyzer For further information on the O2 and NO functions please refer to chapter 7 of this manual INFRARED THEORY In order to understand the purpose of the MT 3505 you must understand the basic principles of Infrared analyzing The IR Bench is nothing more than a molecule counter It counts the number of molecules of HC CO and CO2 that pass through the bench Each of the gases absorb a different Infrared Frequency This is how an infrared bench measures the concentration of each gas The following figure and text is a breakdown of the components used in an Infrared IR bench jin CHOPPER BLADE SAMPLE TUBE FILTERS DETECTOR E Joh FILLED 7 FIGURE 1 BASIC COMPONENTS OF THE IR BENCH The Sourceis used to emit a broad band of Infrared Light or Energy The source is nothing more than a coil of wire with current flowing through it just like a light bulb The Chopper Bladeis used as a reference or sync pulse to allow the hardware interface of the gas bench to determine the start of a stream of data When the chopper blade is in front of the source it acts much as the dark pulse This provides a reference to the computer to tell it that when the chopper blade drops a sample of
99. s the zeroing data last used except in the Warm up and Standby modes In these modes zeroing is always performed automatically PAGE B3 NOTES PAGE B4 BOARD CONFIGURATION GENERAL The following Appendix shows the jumper settings for the MT 3505 boards CPU APPENDIX C The CPU Board has two different configurations One configuration is for analyzers with six PROMs on the CPU Board the other is for a CPU Board with two PROMs In both configurations the jumpers tell the analyzer what type and size of PROMs are being used CPU BOARD CPU BOARD with 6 PROMs with 2 PROMs JUMPER POSITION POSITION W1 2 amp 3 Shorted 2 amp 3 Shorted W2 2 amp 3 Shorted 2 amp 3 Shorted WS 2 amp 3 Shorted 2 amp 3 Shorted W4 No Jumper 2 amp 3 Shorted W5 No Jumper 2 amp 3 Shorted W6 2 amp 3 Shorted 2 amp 3 Shorted W7 2 amp 3 Shorted 2 amp 3 Shorted W8 2 amp 3 Shorted 2 amp 3 Shorted W9 2 amp 3 Shorted 2 amp 3 Shorted W10 No Jumper No Jumper W11 No Jumper No Jumper W12 2 amp 3 Shorted 2 amp 3 Shorted W13 2 amp 3 Shorted 2 amp 3 Shorted W14 2 amp 3 Shorted 2 amp 3 Shorted W15 2 amp 3 Shorted 2 amp 3 Shorted W16 No Jumper No Jumper W17 No Jumper No Jumper W18 2 amp 3 Shorted 2 amp 3 Shorted PAGE C4 INFRARED BENCH The Infrared Bench has two boards which have jumpers that need to be configured During normal operation these jum
100. s verify that the Analyzer is OFF using the Power Switch on the side of the tester It is also important to ensure the AC power cord is unplugged from the outlet before removing wires from the MT 3505 s power supply board AC DISTRIBUTION REFER TO DRAWING 1 1 PAGE 1 5 AC Power enters the unit via the power cord The power cord plugs into the combination Input Filter Fuse Assembly on one end and the wall outlet on the other end Both the AC Hot line and the AC Neutral line are filtered through the Input Filter portion of the Input Filter Fuse Assembly On the output side of the Input Filter portion of the Input Filter Fuse Assembly the AC Neutral line is routed directly to Pin 3 of P1 on the Power Supply Board The AC Hot line is jumped to the Fuse Assembly portion of the Input Filter Fuse Assembly where it runs though a 2A fast blow fuse After the AC Hot line has passed through the 2A fast blow fuse it is routed to the S1 power switch From the S1 power switch the AC Hot line is routed to Pin 5 of P1 on the Power Supply Board The AC Ground line is routed to the ground post on the Chassis sheet metal DC DISTRIBUTION REFER TO DRAWING 1 2 PAGE 1 7 The DC Distribution portion of this manual has been broken into two sections since the MT 3505 can be run on a 12 Volt DC supply The first portion deals with the 12 volt DC supply that will be use to power the MT 3505 The second portion deals with the DC voltages that are generated
101. sed in whole or in part without the expre written consent of Sun Electric Corporation 7049012901 ANDROS BENCH 31211 Sun OXYGEN CELL 7049 0004 01 c nase 17 O2 CELL NOTUSED 4 FILTERS Pa NOTUSED 4 7 NOT USED 10 9 NOT USED 12 J2 111 2 2 NO SENSOR 1 343 3 NOTEMP jj TEMP RESISTANCE TO VOLTAGE 8 6 CONVERTER 22 NO 99 SENSOR 1919 ASSEMBLY 1212 NO NO 41313 gL NONPUT I SENSOR LINE SENSOR ua WITH 31 NOINPUT pg PRE FILTERS DISCONNECT ER BERE AMPLIFIER RELAY 1919 020 1 e121 2 2323 EY 7 35V 4 24e 7049 0130 01 gi t1210 415v gi REFERENCE L l GROUND A CIRCUIT BATTERY CHARGER V AND 4 412 TO 150 7 NO SENSOR J1 BIAS VOLTAGE 5 SOURCE CONTROL EAA0030C03A Rechargeable Lead Acid Battery EAA0030C01A SUN ELECTRIC CORPORATIC One Sun Parkway Sun MODEL MT 3505 DWG BYJeff Hinkle
102. stic makes them susceptible to damage by electrostatic charges Large electrostatic charges can build up in low humidity environments which if discharged through IC terminals may permanently damage the device To eliminate needless failures use the following techniques when handling any circuit board integrated circuit chip or any other static sensitive device 1 Do not remove the printed circuit board from the static protection packaging until it is ready for use 2 Never remove or insert boards under power 3 The correct procedure for removal of a Board from card rack or main equipment is as follows a Equipment on which the repair is performed must be grounded b Wear wrist strap and connect wrist strap to equipment or any available nearest ground wrist strap ground cord is included in field service kit c Always grasp the Board from two opposite edges using the forefingers d Place removed Board on grounded static dissipative mat part of field service kit when troubleshooting or upgrading software 4 When inserting Boards into a card rack or into main equipment a Remove Board from original packaging on static dissipative material Save all packaging for possible reuse if required to ship defective Board b Install Boards into unit using rules 3A 3B and 3C c Package defective Boards into a shielded bag and then return in a reusable container 5 Package IC chips or any other static sensitive device in conductive foam or an
103. ter display screen It may be a television set or a video monitor or a slightly modified version of these display devices Acronym for Clear To Send This is a signal sent by the peripheral to let the computer know that it is ready to receive commands A means by which printed characters are formed using a matrix or pattern of small dots The pattern is fixed and defined as so many dots wide by so many dots high Typically patterns are 5x7 7x9 7x12 and so on A program that provides communication between a computer and an peripheral devices such as display adapters or a mouse Acronym for Erasable Programmable Read Only Memory a type of computer memory device that can be used to store data within a computer for instant access Can be erased by ultraviolet light and reprogrammed A nonvolatile memory that retains programmed data even when no power is applied See also PROM an ROM These are the Gray Keys located in the center of the keypad that are used to choose items that display on the screen These keys includes T gt J SELECT FREEZE and PRINT The number of character spaces reserved in a data file for a specific piece of data PAGE B4 FIRMWARE FUNCTION KEYS HARD WIRED HARDWARE HERTZ yo INTERFACE KEYPAD LAMBDA LEAN MISFIRE LEAN MIXTURE LETTERHEAD MEGABYTE MEMORY MENU KEYS MONITOR NO NO PARALLEL PARALLEL PORT PERIPHERAL PAGE B2 A computer program or software store
104. ter must be set to the correct page length 40 PAPROUT On Enable and Disable Paper Out Sensing PAPROUT is used to disable paper out detection by the printer s paper out sensors Disabling paper out detection does not affect the printer s ability to load paper The user can select On to enable the mode or Off to disable the mode 41 SLASH 0 On Turn Zero Flashing On and Off SLASH 0 is used to turn zero flashing on and off The user can select Off to specify that the numeral 0 be printed without a slash 0 or On to specify the numeral 0 be printed with a slash The user s selection affects the printing of the numeral 0 in all fonts 42 QUIET Off Turn Quiet Mode On and Off QUIET is used to turn quiet mode on and off In quiet mode the print speed slows down by about 10 in all modes to decrease the amount of noise that is generated The user can select On to turn the mode on or Off to turn the mode off SERVICE MENU FUNCTIONS The Service mode settings are numbered 54 through 63 To access the Service modes enter the printer setup by pressing Setup Once in the setup menu turn the dial clockwise until the numbers do not change With the previous message displayed press and hold lt Pitch gt and Form Feed while turning the dial clockwise This will bring up the Service Menu item number 54 ADJ LQ10 52 To change to any other Service selection continue holding Pitch and Form Feed gt while turning the dial clockw
105. that neither device receives more data than it can handle at any given time The user can specify DTR for DTR hardware method XON for the X ON X OFF software method ETX for the ETX ACK software method D X for both the DTR and X ON X OFF methods D E for both the DTR and ETX ACK methods or None for no handshaking method Both the host computer and the printer must use the same handshaking method For the MT 3505 set this to DTR 34 DTR Low Set DTR Signal Polarity DTR is used to specify the polarity of the Data Terminal Ready signal in the printer s serial interface You can select Low for a signal that goes low to disable data transmission or High for a signal that goes high to disable data transmission For the MT 3505 set this to Low 35 IPRIME Off Enable and Disable IPRIME Signal IPRIME is used to enable and disable the IPRIME signal When enabled the computer can reset the printer by setting the IPRIME signal low for at least 50 microseconds The printer remains in the reset condition until the signal returns high You can select On to enable the IPRIME signal or Off to disable it With most computers and software this signal should be disabled SELECTING SPECIAL MODES The last section on the setup menu is Special Modes These modes let the user invoke a variety of special printing features They are as follows 36 HEXMODE Off Turn Hexadecimal Mode On and Off HEXMODE is used to turn the hexadecimal mode on and off In
106. the Exhaust Probe FROZEN e Appears when FREEZE is pressed HOSE PROBE PURGE IN PROGRESS PRESS F1 TO RESUME TEST e Appears when Exhaust Gas Test is manually or automatically switched off e Indicates the Gas Sampling System is being automatically purged before the Analyzer goes into Standby PAGE LEAK TEST IN PROGRESS e Appears during Leak Test e Indicates that a Leak Test has been initiated and is currently running LEAK TEST PASSED e Appears when the Analyzer successfully passes a Leak Test MEMORY A e Indicates the screen is being saved to Memory A e Indicates the memory column that the screen information was recalled from MEMORY B e Indicates the screen is being saved to Memory B e Indicates the memory column that the screen information was recalled from NO GRAPHS SELECTED e Appears in the Gas Analyzer Screen or split screen when no graphs are selected e Gas Analyzer screen message appears PRESS F6 GRAPH SETUP then follow the on screen instructions e Scanner Split screen messages appears PRESS THE GREEN GAS ANALYZER KEY ONLY 4 GRAPHS CAN BE SELECTED e Appears in Graph Setup screen when more than 4 graphs are selected ONLY FROZEN SCREENS CAN BE SAVED IN MEMORY e Appears when trying to save a screen that has not been frozen PRESS F1 TO TEST EXHAUST GAS e Appears on the Exhaust Gas Test Screen e Indicates that the Analyzer is ready to test exhaust gas PRESS CONTINUE WHEN READY e Prompts the
107. to be turned on e Change the AUTO CR setting in the setup menu Top of form is set incorrectly e Advance paper until the first print line is in front of the printhead then hold Alt and press Park Then press Form Feed gt Setup of the MT 3505 or the printer is incorrect e Confirm the configuration of the dip switches in the paper compartment of the printer Refer to this chapter for the correct settings e Ensure the setup of the printer in the analyzer e Under Option Menu Comm Setup e Printer type should be SERIAL e Printer Baud Rate should correspond to baud rate set by switches on the printer Default is 2400 Baud PAGE 11 19 NOTES PAGE 11 20 reserved by Sunt ion ond id e ni De re CONNECTOR STB BOARD DATA 0 MT3500A200 2 DATA 1 3 DATA 2 4 DATA 3 5 DATA4 PARALLEL J28 STB J1 7 DATA 5 SN PRINTE
108. to tell the printer what parity method your computer is using Parity is a technique that lets the printer check for data transmission errors The user must select None if the host computer does not support parity Odd if the host computer uses odd parity or Even if the host computer uses even parity Both the computer and the printer must be set for the same parity method 31 DTA BITS 8 Specify Number of Data Bits DTA BITS are used to tell the printer how many data bits your computer is sending in each byte The user must select 7 if your computer sends 7 bit bytes 8 if the computer sends 8 bit bytes or 8 if the computer sends 8 bit bytes and you want the printer to ignore the most significant bit MSB For MT 3505 operation the printer should be set to 8 PAGE 11 6 32 STOP BITS 1 Specify Number of Stop Bits STOP BITS are used to tell the printer how many stop bits the host computer is sending in each byte Stpbits are necessary to separate consecutive bytes in the data stream The user must select 1 if the host computer sends one stop bit or 2 if the host computer sends two stop bits For the MT 3505 operation the printer should be set to 1 33 HNDSHAK DTR Specify Handshaking Method HNDSHAK is used to tell the printer what handshaking method the host computer is using Handshaking is a technique that starts and stops data transmission between the host computer and the printer This starting and stopping is important so
109. ues displayed to the Tag Values on the gas bottle Press CHANGE TAG VALUE F1 and change the analyzer tag values to match the concentration on the calibration gas bottle if required 6 Press CHANGE TAG VALUE F1 again Selected tag values are saved NOTE Calibration gas concentrations are checked against the tag values that display on the screen before calibration is performed When calibration gas concentrations do not equal at least 50 of the tag value calibration is not allowed an AL FAILED is displayed This prevents calibration that would result in decreased accuracy 7 Connect the hose from the gas bottle regulator assembly to the CAL port on the back panel of the analyzer 8 Open the valve on the calibration gas bottle Ensure the bottle pressure is at least 25 psi Replace the bottle if the pressure is less than 25 psi PAGE 63 9 10 Adjust the output regulator until 5 10 psi is indicated on the output pressure gauge Press CALIBRATE lt F2 gt NOTE You will not execute the last line of the messagePRESS CONTINUE WHEN READY Atthis 11 12 13 14 17 point in the procedure you are checking thedibration not actually performing a calibration Wait approximately 60 seconds or until the readings stabilize Press FREEZE Data on the screen freezes NOTE After 5 minutes the analyzer will automatically revert back to the Service Screen Close the valve on the calibration bottle Compare
110. ut the express written consent of Sun Electric Corporation BENCH P C BOARD Chopper Motor Interface Chopper x SOURCE M 7 5V Drivers GND 7 5v c _ J19 gt Phase 1 _ Phase 1 Phase 2 Phase 2 IR SOURCE Chopper Motor PIEZO RESO OPTICAL BENCH f ds FROM CPU BOARD J13 B E u ae a 2 sz 2300 0159582 S gt lt lt a 10 9 gt gt a ely Te lt i T e 1123141516071 55 Pl MICRO CONTROLLER T L RS232 cn 2 TO Drivers amp Used 2 Receivers m4 4 CPU 5 co HC co2 Channel Channel Channel Filter Detector Circuits Circuits Circuits Heater Servo 22 oz oo 7 49 Ji ma DETECTOR BENCH BLOCK TEMP SENSOR O HEATER Eun SUN ELECTRIC CORPORATION One Sun Parkway Crystal Lake Illinois 60014 U S A 6 1 wx 3505 0195 REV A mee Jeff Hinkle TITLE INFRARED WG PAGE 6 5 NOTES PAGE 66 CHAPTER 7 O AND NO NITRIC OXIDE NO THEORY OF OPERATION The NO Sensor Assembly has a finite lifetime and is designed to be end user replaceable The NO cell requir

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