EC9820 Service Manual
Contents
1. Event Log Messages ELECTRONIC ZERO An analyzer electronic zero Normal after reset or power ADJUST cycle was initiated failure If not associated with these check zero air supply BACKGROUND CYCLE Background cycle started No action required The value of the result of the previous background is stored here RESET DETECTION Reset button pressed or Unless the reset was not watchdog timer caused initiated by the user no reset action is required AZS CYCLE AZS cycle started No action required CHOPPER WHEEL Indicates that the chopper Check chopper motor ERROR wheel is not operating opto interrupter and correctly chopper wheel DATA LOGGING MEM Occurs if unable to write to Battery failure or system FAIL datalogging memory software error If error persists call Ecotech Customer Service for instructions CONTROL LOOP Occurs when Control Loop No action required RESTARTED has been disabled and then automatically enabled after the main screen has been visible for the last 1 minute CHASSIS TEMP Occurs if chassis No action required THRESHOLD temp varies by 4C then 3 successive backgrounds will be performed each hour VALVE SEQUENCING Occurs when valve No action required RESTARTED sequencing has been disabled and then automatically enabled after the main screen has been visible for the last 1 minute 982076012. GAS PRESSURE Current gas pressure measured from the flow controller GAS FLOW Current gas flow measured from the flow controller 3 4 2 FACTORY DIAGNOSTICS MENU This menu is for pre release factory use only Any modifications made within this menu will alter instrument settings and readings Ecotech Pty Ltd does not guarantee the validity of any results following changes being made within this section 3 5 Pressure amp Flow Calibration The pressure and flow calibrations should be performed whenever a flow or pressure reading becomes suspect when a transducer is replaced or can be performed as an annual maintenance item The pressure and flow transducer calibration may be performed separately or together For both procedures the following equipment is required o Digital Volt Meter o Pressure transducer absolute calibrated in torr o Flowmeter slpm nominal o 1 fitting with hose to suit pressure transducer 3 5 1 Pressure Flow Calibration 3 5 1 1 Setup Note 32 98207601 Rev B CHAPTER 3 MAINTENANCE The EC9820 analyzer should be left running for at least one hour with the pump switched on before this procedure is attempted This will allow the flow block temperature to stabilize to 50 C From the HIDDEN MENU set the FLOW BLOCK TYPE TO STANDARD and press Enter gt 1 Press Reset on the analyzer secondary panel 3 5 1 2 Pressure Calibration 1 From the HIDDEN MENU select the PRESSUR
3. Routine Maintenance Components 3 3 1 Check Particulate Filter The inlet filter prevents particulates from entering the pneumatic components of the EC9820 Contamination of the filter can result in degraded performance of the EC9820 including slow response time erroneous readings temperature drift and various other problems Several factors affect the filter replacement schedule In the springtime for example pollens and dust might accumulate in the filter Man made environmental changes such as construction dust might indicate more frequent change or a climate where dry dusty conditions are normal might dictate more frequent filter replacement than climates with few natural pollutants Determining the schedule for changing the filter is best developed by monitoring the filter at weekly intervals for the first few months then adapting the schedule to fit the specific site 3 3 2 Particulate Filter Replacement Procedure 24 Use Figure 10 as reference when performing the filter replacement procedure 98207601 Rev B CHAPTER 3 MAINTENANCE Za Z LLL Yj YY UH ZA ALLL ZLLZLZ gt gt gt gt gt H ax IATA GO Bite ITA jj A XN LE x A QZ Figure 10 Filter Replacement Procedure 1 Open the front panel to access the service switches and particulate filter Position the Pump switch in the secondary front panel to OFF 2 Completely unthread the filter cap by turning it counterclockwise 3 Pull t
4. periphery of the wheel and generates a signal indicating when the center of each sector is the target of the IR source beam 98207601 Rev B CHAPTER 2 THEORY OF OPERATION Xe Sl ANA SES 7 IN NS A SS PE Figure 8 Gas Filter Correlation Wheel Measurement Cell The IR next enters the multiple pass optical measurement cell where it travels a mirror folded five meter path through the sample gas before exiting the cell See Figure 7 The cell housing is kept at a controlled temperature and the thermistor monitoring this temperature is reported as CELL TEMP on the SYSTEM TEMPERATURES screen This temperature is used for gas law corrections Narrow Bandpass Filter The broadband radiation from the IR source that passes through the gas filter wheel and measurement cell is filtered again by the narrow band pass filter Only the CO2 sensitive portion of the band centered at 4 5 microns passes through the filter The removal of wavelengths sensitive to other gases reduces interference IR Detector The lead selenide IR detector is chilled to 20 C When IR centered at 4 5 microns shines on the detector it changes the current flowing through it This change produces the detected signal 2 1 2 3 Electronics 98207601 Rev B o Preamplifier Board The preamplifier preamp board converts the current from the IR detector to voltage and amplifies it to a waveform containing a reference
5. 2 Voltage Regulator The voltage regulator board regulates and distributes the different voltages needed throughout the system 12 VDC to 5 VDC for the digital circuitry and 12 VDC to 10 volts for analog circuitry An additional 15 VDC supply is present to power the microprocessor display supplies and analog output circuits The voltage regulator also furnishes a 300 msec power extension in the event of power failure to allow the computer to store data before the power failure can affect it 2 1 1 3 Microprocessor The microprocessor board contains a battery backed clock calendar and an onboard 16 bit microprocessor MC68HC12 operating at 16 MHz The microprocessor board is the control center for input and output apparatus such as the 2 inch by 4 inch liquid crystal display LCD keyboard switches the serial ports and the 50 pin I O connector on the rear panel The 50 pin I O connector input accepts control lines from the rear panel and sends status and failure signals to solid state relay drivers Support circuitry for the liquid crystal display includes a 20 V power supply and digitally adjusted potentiometers for contrast level All analog voltages from the sensor assembly are digitized by the analog to digital A D converter for microprocessor use Digital to analog D A conversion of three channels is used to send 0 to 20 mA analog signals to the 50 pin I O connector 98207601 Rev B 98207601 Rev B CHAPTER 2 THEORY OF OPERATI
6. 4 2 TROUBLESHOOTING THE EC9820 ANALYZER cscssssscccececsesssaesecccecsesnsaeceeececsessaaececececsesesaeceseeecseseaaseeeececeeneaeea 39 AZ Preproces Or Pots MEU A A lia ica 40 4 2 2 Flow Control Pots Menu A Series Only ccccscccssccessceessecesscecesecesneecseceeaeecsaecssaeecsaeeeaceceaeeeeaeecsaeecseneeenaeeees 40 4 2 3 Valve Test Men iii dai cada 4 ADA Event LO oi AA vas 0 ante cae ot A ies do op Ta bead A ii 4 ALI AOSTUMENEI TAUSTE AS 44 42 6 System Temperatures a A A a 44 42 7 System Faults dd A dt a oi 45 AS TEST FUNCTION A O Bae Raa RAs Rd 46 EISAOPM E A A A A nb ine IRA PGE 46 98207601 Rev B 1 EC9820 CO ANALYZER SERVICE MANUAL IL PLANA A A Hawai E gods E da te RE 46 ASIA a 46 AJA Use of Diagnostic Modes enren ao da 46 4 4 TROUBLESHOOTING GUIDE ceci 47 A A RI 49 2 98207601 Rev B EC9820 CO ANALYZER SERVICE MANUAL Manual History The scope of this new manual covers the following analyzers O O EC9820 Carbon Monoxide Analyzer 3000 ppm PN 98201000 101 EC9820 Carbon Monoxide Analyzer 1500 ppm PN 98201000 102 EC9820 Carbon Monoxide Analyzer 750 ppm PN 98201000 103 EC9820 Carbon Monoxide Analyzer 3000 ppm PN 98205000 101 Systems EC9820 Carbon Monoxide Analyzer 1500 ppm PN 98205000 102 Systems EC9820 Carbon Monoxide Analyzer 750 ppm PN 98205000 103 Systems This instrument is manufactured by Ecotech P L in Australia and support the new SMD Microprocessor Board Part number 9800006
7. Opening the Front Panel illustration oomooo o 5 Illustrations Correlation Wheel Motor IR Source Optical detectOr ceececcceceeeceeseeeseeeeeeeeeeseeeteensees 15 Replacement ccccscsssssscscscecececsesssensnsseseneeeee 27 Optical Path illustration oococnonnncnnnnnonnnnnccnnoroooo 14 Illustrations Detector Signal Adjustment 26 Optics system COMPONEN S eee esses eeeeeeees 14 Illustrations Gas Filter Correlation Wheel 15 Optodecoder circuit o ooooocnnccnoconoconononcncnnnnnncnnncanccn noo 16 Illustrations Instrument Status and Ranges 44 P Illustrations Instrument Status Ranges 30 33 34 Illustrations IR Detector Replacement 28 Particulate filter maintenance ooncnnnicnncninncnnnnnincns 24 Illustrations Major Components eeeeeeeeeeees 12 Periodic maintenance ce eeeeeseecsseeeeeseceeeeeeeeees 20 Illustrations Opening the Front Panel 5 Pneumatic Diagram illustration oooononinnicnnnnic 13 Illustrations Optical Path 0 eee eeeeeeecseeeeceeeeees 14 Power microprocessor module ec eeeeeeeeeeees 10 98207601 Rev B 49 EC9830 CO ANALYZER SERVICE MANUAL Preamp test function oooocccocnncconcnonocanononncnnonncanonacnnos 46 Preamp Pressure board c ocococcnoccnococoncnonccononnninnninnnnno 16 Preamplifier boardissa 16 Preprocessor board coooocccnccnoccconn
8. The optics of the EC9820 analyzer include an IR source an optical detector a gas filter correlation wheel measurement cell narrow band pass filter IR detector and preamp board as described in the following paragraphs Figure 7 illustrates the optical path o IR Source The IR source is a heated resistor that generates broad band infrared radiation and irradiates the gas filter correlation wheel Pa MOTOR IR SOURCE Wi 7 CORRELATION WHEEL DETECTOR LR BEAM OUT BANDPASS FILTER Figure 7 Illustrated Optical Path o Gas Filter Correlation Wheel The gas filter correlation wheel includes two gas filled sapphire chambers and mask areas As the wheel rotates the IR beam passes through either 1 the reference chamber which is filled with CO removing the CO sensitive wavelengths which are centered at 4 5 microns and passing the CO gt insensitive wavelengths 2 the measure chamber which is filled with nitrogen and passes the CO gt sensitive wavelengths or 3 a mask which blocks the beam When the mask blocks the transmission of IR the detector generates the mask signal used as a zero reference to determine the strengths of the other two signals The differences between signals are used to compute the concentration of CO Figure 8 shows the gas filter correlation wheel The wheel is mounted on a shaft driven by a brushless DC motor o Opto detector A reflective optical detector reacts to timing marks on the
9. defined consists of radiation from the IR source encountering a gas filter wheel alternating between CO N and a mask The radiation passes through a multiple pass measurement cell where the sample gas absorption process occurs then through a narrow band pass filter to limit absorption to optical wavelengths of interest for CO absorption after which it encounters the IR detector where the amount of absorption is measured The N filter in the gas filter correlation wheel is transparent to IR and yields a measure beam that can be absorbed by CO in the measurement cell The CO2 filter in the wheel yields a beam that cannot be further attenuated by the CO in the measurement cell thus it is a reference beam The mask creates a signal used to determine the strength of the other two signals The CO concentration in the measurement cell absorbs the measure beam and does not absorb the reference beam modulating the IR radiation or detector input signal between the gas filters Other gases absorb the reference and measure beams equally and thus do not cause modulation of the detector signal Using this method the system responds specifically to CO The EC9820 analyzer uses the advanced digital Kalman filter This filter provides the best possible compromise between response time and noise reduction for the type of signal and noise present in ambient air analyzers and their application Ecotech s implementation of this filter enhances t
10. dislodged or cables disconnected follow the instructions below 6 98207601 Rev B CHAPTER 1 INSTALLATION 1 1 4 Reinsert Dislodged Boards The bottom edge of the boards must be held in place by the guides The top of the boards must be attached to the metal bulkheads by the plastic or metal studs with spring tips 1 1 5 Cable Connections The cable connectors and the board connectors must be matched securely in place for correct connection The red indicator on each cable must be positioned at the arrowhead mark on the board connector Make the connection by pressing the cable connector into the mating connector until a click is heard Then fold the retainers inward to secure the connection see Figure 3 Figure 3 Cable Connections 98207601 Rev B 7 EC9820 CO ANALYZER SERVICE MANUAL This page is intentionally left blank 8 98207601 Rev B CHAPTER 2 THEORY OF OPERATION 2 0 Theory of Operation 98207601 Rev B Carbon Dioxide absorbs infrared radiation IR at wavelengths near 4 5 microns therefore the presence and the amount of CO can be determined by the amount of absorption of the IR The EC9820 analyzer uses gas filter correlation to compare the detailed IR absorption spectrum between the measured gas and other gases present in the sample being analyzed A highly concentrated sample of the measured gas 1 e CO is the filter for IR transmitted through the analyzer thus gas filter correlation The process further
11. lt 3 ecotech environmen tal monitoring solutions EC9820 Carbon Dioxide Analyser Service Manual www ecotech com EC9820 CO ANALYZER SERVICE MANUAL Table of Contents MANUAL STORY e Se ee 3 SAFETY REQUIREMENTS ed cesa 4 SERVICE AND SPARE PARTS a di 4 IO AAA A A 5 TEL INTA E CHECK o a adi ee 5 JA Remove the Top COVer ni lali 5 SAE PAI A 411 162 200011 AR A ER A A EAE E O EA 6 LAS ANS pect the Components 6 1 A Reinsert DislOd BEd Boards a Aedo A A EEE 7 Fi Cable GCONNECHONS iaa 7 2 0 THEORY QOF OPERATION vise csdcsscsosscsscscascassscscessescececdesectessuccuecveesacdcssececsevesasseassscsitewsecs sesbescasdessscscdassscauuasoose 9 2 INSTRUMENT DESCRIPTION ssssccccd cevevacsceonnchbeavevatenecoastasten stance cesses aver vaterecoves stueteauecbeccdel Seesvessewvesdstecteceteotenteitewees 10 211 Power Microprocessor MOdUle iii ia 10 DED Sensor Module A il Sea aed aaa Beas 12 2 2 OPERATION MODES id ia 16 ZiZ AS Arup MoOdEii A ha A aa 16 De Ded Mea mre MODE A A id N do 18 2 23 AULO ZCTOR OULINES a 18 3 O MAINTENANCE bieissisccssscccisessscsesscvesssosscasicescdsesivetsossoescseses esbacstanessentisessguseed sbdesesossoacecosedessisedeesseotsacbsoses ssbaesseness 20 3 1 MAINTENANCE SCHEDULE hn a cascdevaes sce ide caucecntees a A ody ainda a A iento caida 20 3 2 REPLACEABLE PARIS cdt bd da Lot cb Red E as adidas iria 21 3 2 1 Expected Life Span of Constables sscecczecsesse sects daba 22 3 3 MAINTENANCE PROCEDURES cito ta
12. symptoms persist readings 9 Instrument Reference voltage Perform detector signal check and adjustment stuck in reference adjust 10 Response time Low Flow Check sample flow with flow meter It should be not at specified 0 8 to 1 2 slpm at STP Replace inlet filter SS value filter or orifice if it is not 48 98207601 Rev B CHAPTER 4 TROUBLESHOOTING Symptom 11 Analyzer Possible Cause Preprocessor ID set System Troubleshooting Table Fault Isolation Solution 1 Check J5 connector on Microprocessor ae lays BAD wong 2 Check J4 connector on Preprocessor ANALYZER 3 Reprogram device ID 4 Replace Preprocessor c Illustrations Pneumatic Diagram ocononncnicnicnnnnincnn 13 Illustrations Preprocessor Pots and Ranges 40 Cable Connections illustration oooonooccccncnoncconos 7 Illustrations System Block DiagraM ooonncnn n 11 Correlation wheel cescceseeececeeeeeeneeeeeeeeeeneees 14 Illustrations System Temperatures and Tolerances 44 Correlation wheel replacement cesceeseeeeees 27 Illustrations Valve Test Menu l s 41 Correlation Wheel Motor IR Source Replacement Installation erre 5 GUNNS tratiON 00355 tcc sies acct dec het secs he copies cadenteadescveeees 27 Instrument Status and Ranges illustration 44 D Instrument Status Ranges illustration 30 33 34 Instrument Status screen eee ee
13. the detector cover to the detector assembly 4 Remove the four screws securing the detector assembly to the bench 5 Remove the detector assembly Install the new detector in reverse order of the above steps 3 3 7 Leak Test Procedure This is a test for the pneumatic system of the instrument The display readings will indicate whether the system is leaking 1 Enter the TEST MENU and select OUTPUT TEST MENU then VALVE TEST MENU from these items pick VALVE SEQUENCING and set to OFF 2 Set all valves to CLOSED 3 Press lt Pg Up gt to return to the OUTPUT TEST MENU and choose FLOW CONTROL POTS 4 Turn the Pump Switch on the secondary panel to OFF and verify FLOW 0 00 sLPM If it does not read 0 00 the Flow Control PCA requires recalibration Return the Pump Switch to ON 5 Plug the INLET port on the rear panel 6 Verify GAS FLOW in the FLOW CONTROL POTS screen reads 0 00 If the reading 1s not 0 00 there is a leak somewhere between the valves and the flow block 7 Set VALVE SEQUENCING to ON and then press lt Exit gt Remove the plug from the INLET port 8 Verify that the flow returns to the original setting by observing the INSTRUMENT STATUS menu The actual flow through the analyzer should be checked by turning on the pump and connecting a flow meter to the measure inlet ensure that the analyzer is in SAMPLE MEASURE Actual flow through the analyzer sh
14. 000 SLPM 585 6 TORR VALVE TEST MENU INT VALVE 1 INT VALVE 2 INT VALVE 3 EXT MEASURE EXT ZERO GAS EXT SPAN GAS AUX VALVE 1 AUX VALVE 2 VALVE SEQUENCING Figure 23 Valve Test Menu OPEN CLOSED CLOSED CLOSED CLOSED CLOSED CLOSED CLOSED ON The VALVE TEST MENU see Figure 23 displays the current status of each valve in the instrument This menu can be particularly useful in correcting flow problems in the machine The valves can be opened and closed from this menu thus allowing the operator to determine whether valves are operating correctly Valve sequencing must be on in order for correct gas measurement to be accomplished 4 2 4 Event Log Upon noting a possible operational problem examine the EV ENT LOG menu to determine whether the microprocessor is reporting a system failure or problem 98207601 Rev B 41 EC9820 CO ANALYZER SERVICE MANUAL Should the EVENT LOG indicate an error it will also provide information as to the portion or component of the instrument which is at fault Event Log Messages RAM CHECKSUM Checksum of memory at Battery failure or system FAILURE power down differs from software error If error checksum at restart persists call Ecotech Customer Service for instructions EAROM X DATA ERROR EROM designated X Check pressure board cable Y detected error at location connections and pressure Y
15. 3 4 This manual is current for firmware version 1 18 and above This manual should only be used in conjunction with the EC9820 Carbon Monoxide Analyzer Operation Manual PN 98207600 Rev B April 2007 Ecotech Manual ID MAN 0006 Manual PN 98207601 Current Revision B Date Released April 2007 Description EC9820 Carbon Monoxide Analyzer Service Manual Revision History Rev Date Summary Affected Pages A September New Release for new Microprocessor Board Based All 2005 on original manuals B April 2007 98207601 Rev B Updated specifications language and links within All pdf manual created EC9820 CO ANALYZER SERVICE MANUAL Safety Requirements O To reduce risk of personal injury caused by electrical shock follow all safety notices and warnings in this documentation This equipment should always be used with a protective earth installed The EC9820 is compliant with the requirements of EN61010 1 A2 1995 Safety Requirements for Equipment for Measurement Control and Laboratory Use If the equipment is used for purposes not specified by the manufacturer the protection provided by this equipment may be impaired Replacement of any part should only be carried out by qualified personnel only using parts specified by the manufacturer Always disconnect power source before removing or replacing any components Surfaces marked with a Caution Hot Surface see internationally recognized symbols on
16. 820 analyzer it must be set to 9820 in order to operate correctly The analyzer type will default to 2 if the device type has not been set or cannot be read from the preprocessor board SUB TYPE Allows the user to set the correct Hardware options for this analyzer The options for the EC9820 are STANDARD TRACE amp HIGH LVL GAS NAME Allows the user to set a 3 character name for the primary gas name The name entered here will be used to replace the primary gas name in all screens If the first character is a space then CO will be used as a gas name FLOW BLOCK TYPE Displays the type of flow block installed If the flow block is not connected or calibrated then no type will be displayed Should be set to STANDARD 98207601 Rev B CHAPTER 3 MAINTENANCE 3 4 1 Pressure amp Flow Calibration sub menus The pressure and flow calibration menus allow the user to manually calibrate the pressure transducers and calibrate the flow of the flow controllers The contents of the pressure and flow calibration menus are described below Note that these parameters will vary depending on which flow block type is selected Refer to section 3 5 for further details DESIRED FLOW Desired flow rate that the standard flow block will maintain a constant flow at Note If the flow rate is changed the instrument must be reset in order for the change to take effect FLOW SPAN POINT During the flow calibration of the standard flow block this is wh
17. E CALIBRATION MENU The menu of Figure 15 should be displayed PRESSURE CALIBRATION MENU PRESSURE 1 HIGH 743 0 TORR PRESSURE 1 LOW 530 0 TORR VALVE SEQUENCING ON CONTROL LOOP ENABLED PUMP SPEED COARSE 28 GAS PRESSURE 710 0 TORR GAS FLOW 1 000 SLPM Figure 15 Pressure Calibration Menu for Standard flow block 2 98207601 Rev B Verify the pump is turned off by setting the pump switch to OFF on the secondary panel Allow 30 seconds for the pressure reading to stabilize to ambient pressure on both the calibrated pressure transducer and the analyzer This reading in TORR should be the ambient pressure Set this value as PRESSURE 1 HIGH in the PRESSURE CALIBRATION MENU and then press Enter gt Note To convert from millibar to TORR multiply the pressure by 0 75 Set the CONTROL LOOP TO DISABLED and press Enter gt This will disable the flow control loop Connect the calibrated pressure transducer to the sample inlet on the rear panel of the analyzer Turn the pump ON from the secondary panel 33 EC9820 CO ANALYZER SERVICE MANUAL 7 Setthe PUMP SPEED COARSE to 99 and press Enter gt J 8 Allow approximately 1 minute for the pressure to drop to a stable reading This reading should be typically 100 to 200 torr lower than the ambient pressure depending upon the capacity of the pump 9 Set this reading in TORR as PRESSURE 1 LOW in the PRESSURE CALIBRATIO
18. N MENU and press Enter gt 10 Disconnect the pressure transducer from the inlet and turn the pump OFF 11 To verify that the pressure transducers on the standard flow control board are calibrated view the GAS PRESSURE reading in the PRESSURE CALIBRATION MENU 1t should be at ambient pressure 2 TORR This completes the pressure transducer calibration procedure 3 5 1 3 Flow Calibration 1 From the HIDDEN MENU select the FLOW CALIBRATION MENU The menu of Figure 16 should be displayed FLOW CALIBRATION MENU DESIRED FLOW 1 00 SLPM FLOW CONTROL ZERO 81 FLOW TRANSDUCER DF CANCEL CONTROL LOOP ENABLED VALVE SEQUENCING ON FLOW ZERO FLOW SPAN POINT CANCEL POINT 1 000 SLPM PUMP SPEED COARSE 28 PUMP SPEED FINE 7 GAS PRESSURE 710 0 TORR GAS FLOW 1 000 SLPM Figure 16 Flow Calibration Menu for Standard flow block 2 Verify the pump is turned OFF and the CONTROL LOOP is DISABLED in the FLOW CALIBRATION M 3 Load the linearization ENU table into the flow control board EAROM by setting FLOW TRANSDUCER DF to SET and pressing Enter gt 1 The linearization table contains the follo wing parameters Flow points 0 0 5 1 75 2 5 3 25 3 75 Voltage points 0 0 13 0 91 1 783 2 5 3 478 34 98207601 Rev B 10 11 12 13 CHAPTER 3 MAINTENANCE Connect the calibrated flow meter to the sample inlet on the rear panel of the analyzer With the pump turn
19. ON The microprocessor has electrically erasable ROMs which store the operating program and internally logged data Program upgrades can be easily made through the serial port The Service and Reset switches are located on the front of the board and are accessible when the top is removed or when the front panel is opened The microprocessor also has provisions for USB and optional TCIP connections through the rare panel vy Figure 4 System Block Diagram 11 EC9820 CO ANALYZER SERVICE MANUAL Figure 5 Major Components 2 1 2 Sensor Module The sensor module can be divided into three areas of description pneumatics optics and electronics 2 1 2 1 Pneumatics The pneumatic system continuously supplies sample air to the measurement cell at a rate that allows the sample to be measured before exiting the analyzer The pneumatic system flow is illustrated in Figure 6 The pump causes sample air to be drawn into the sample inlet and through the 5 micron particulate filter During the startup and auto zero cycles the sample port is disconnected and air is pulled into the system from then into the measurement cell This provides the analyzer with a stable reference of zero air to automatically correct for changes in the measurement path 12 98207601 Rev B CHAPTER 2 THEORY OF OPERATION Figure 6 Pneumatic Diagram 2 1 2 1 1 Flow Control 98207601 Rev B o Particulate Filter The particulate filter
20. Rev B 43 EC9820 CO ANALYZER SERVICE MANUAL 4 2 5 Instrument Status INSTRUMENT STATUS GAS FLOW 039 13 GAS PRESSURE 430 800 REF VOLTAGE 3 80 4 20 CONC VOLTAGE O 4 50 ANALOG SUPPLY 11 6 12 2 DIGITAL SUPPLY 4 8 5 2 VERSION 1 11 0002 Figure 24 Instrument Status and Ranges The INSTRUMENT STATUS screen provides information about several critical parameters in the EC9820 If any of the parameters displayed on the INSTRUMENT STATUS screen vary significantly from the values shown in Figure 24 the fault or operational problem is probably related This is also true if one of the parameters is demonstrating a rapid change or is oscillating strongly around the desired setpoint For more information on the operational limits and fault messages refer to the table in section 4 2 7 System Faults Several of the parameters displayed on the INSTRUMENT STATUS screen are affected by the potentiometer settings on the PREPROCESSOR POTS screen If a parameter is out of the normal operating range make note of the parameter value proceed to the applicable menu and examine the pertinent potentiometer settings 4 2 6 System Temperatures 44 SYSTEM TEMPERATURES CELL TEMP 47 CONV TEMP 87 CHASSIS TEMP 2 15 FLOW TEMP 0 45 COOLER TEMP 1 0 1 MIRROR TEMP 47 53 Figure 25 System Temperatures and Tolerances The SYSTEM TEMPERATURES screen provides the temperatures of the measure
21. and lt Select gt for lighter contrast DC power 1 Verify the cable connection from the power supply to the Vreg board 2 Check the Vreg board for correct voltages as listed in the troubleshooting voltages table in section 4 1 above If incorrect voltages are found replace the power supply 3 Check Microprocessor test points listed in the Troubleshooting Voltages table in section 4 1 Display Check the interface cable between the display and J6 on the microprocessor board Bad Display or 1 Replace the front panel display microprocessor board 2 Replace the microprocessor board 3 A bad cable is unlikely but if you suspect it perform a pin for pin continuity test using an ohmmeter 3 Zero Flow Pump failed Replace the pump Filter Check the particulate filter Replace if dirty or plugged Flow control Recalibrate the flow control assembly assembly Pressurized Rx Cell Ensure Sample and Zero inlets are maintained at ambient pressure 4 Noisy or Leaks A leak dilutes the sample stream and causes low unstable readings span readings and noise See the leak test procedure in section 3 3 7 above 47 EC9820 CO ANALYZER SERVICE MANUAL System Troubleshooting Table detector and stable 0 3 C wheel procedure in section 3 3 7 above Symptom Possible Cause Fault Isolation Solution IR source weak or Adjust the detector signal If you are unable to noisy det
22. at the cell temperature is not within the acceptable limits TEMPERATURE A fault is indicated if the cell temperature is below 35 C or above FAILURE 60 C CONVERTER Indicates that the converter temperature is not within the acceptable TEMPERATURE limits A fault is indicated if the converter temperature is below 80 C FAILURE or above 100 C MIRROR Indicates that the mirror temperature is not within the acceptable TEMPERATURE limits A fault is indicated if the mirror temperature is below 35 C or FAILURE above 60 C FLOW BLOCK TEMP Indicates the flow block temperature is not within acceptable limits A fault is indicated if the flow temperature is below 35 C or above 60 C START UP Indicates that the analyzer is in start up mode Usually after power up SEQUENCE ACTIVE or reset 4 3 Test Functions The following lists the available diagnostic modes in the EC9820 under the TEST MENU Not supported 4 3 2 Preamp The preamp test function generates an electronic test signal which is applied to the input of the IR detector preamp This simulates an input from the detector and is then processed as if it were an actual signal This test is used to verify the operation of the detector 4 3 3 Electric The electric test function generates an electronic test signal which is applied to the input of the preprocessor This simulates a reference and measure input to the preprocessor and is the
23. board SERVICE SWITCH Unit taken out of service Return analyzer to service ACTIVATED from front panel using the front panel switch Check display cable connection display board and microprocessor board LCD DISPLAY BUSY LCD constantly busy indicates hardware failure in display A D CONVERSION A D returned busy status Normal at startup If failure 42 requested span to measured span is gt 1 25 ERROR persists replace microprocessor SYSTEM POWER Power removed from No action required FAILURE system SYSTEM POWER Power applied to system No action required RESTORED ZERO POT LIMITED Zero voltage controller Reset analyzer check zero TO 0 OR 99 reached limits before air source voltage reached set point INPUT POT LIMITE Input controller reached Check IR source TO 0 OR 99 limits before reference voltage reached set point ZERO FLOW Instrument flow has gone The pump has failed or a to zero flow obstruction has occurred Replace pump or clear obstruction SPAN RATIO lt 0 75 After AZS cycle ratio of Instrument span has drifted requested span to measured beyond acceptable limits span is lt 0 75 Recalibrate SPAN RATIO gt 1 25 After AZS cycle ratio of Instrument span has drifted beyond acceptable limits Recalibrate 98207601 Rev B CHAPTER 4 TROUBLESHOOTING
24. conoconocononononnninnncnnonns 16 Preprocessor Pots and Ranges illustration 40 Preprocessor Pots Menu ooococccoccnocooncconocnonnninncnnnonns 40 R Replaceable partS ooooncnnonnnocncononononononnccnnonanonnninnnnno 39 Routine Maintenance ooooconccnonconconcnnnononononcnnninnonacnnos 23 S Sensor module sissies eecseicers iesise serrit 12 Service SWIChe Siasea e arie 6 Spare OE 39 System Faults display oooocnccnnccnonnconnconocnncnnccnnonnss 45 System Temperatures and Tolerances illustration 44 System Temperatures screen ssseeseeeeeseeeeeeeereeee 44 T Clio t 11 Theory Of Operation oooccocconocnnononncononnnononononnnnnnnncnnon 9 TroubleshootiN8 cconcocionocnccnoncnononcnnannnnnnnonncnnon 39 47 U US Bici d 11 21 V Valve Test Menu cooconoccnncconccononanonnncnncnanonncnnncnnncnnoos 41 Valve Test Menu illustratiOn oooonoococnnnanccononanos 41 Voltage Regulator board eee ee eeeeeeeeeeeees 10 98207601 Rev B
25. cription Part Number Level Filter element 5 micron consumable 50 each 98000098 1 1 Infrared source 80340371 Filter optical 002 057401 O ring optical filter 025 030410 O ring sapphire window 28000186 Extraction tool minifit connectors 29000141 2 Detector 37000076 Pump 58500037 Window sapphire 883 05 1600 PCA Voltage Regulator 98000056 Display switch assembly 98000057SP PCA Microprocessor SMD 98000063 4 PCA 50 Pin I O 98000066 2 Power supply 115 230 VAC to 12 VDC 98000142 Flow control assembly 98300046SP3 PCA USB Board Assembly 98007502 PCA Preprocessor 98200002SP Preamplifier detector assembly 98300015 Motor correlation wheel 98300032 Reflector optical interrupter 98300033 Valve manifold assembly 98300037 2 Source timing assembly 98200006 Heater thermistor assembly 98300061 Correlation wheel assembly 98200017 Wl_wl wi w low w f wl wo wow wo ww wl wo ww wo wl wf wo fw wo wo wl rv Level 1 General maintenance supplies and expendables such as filters O rings lamps etc Level 2 Critical items that are known from experience to have a higher failure rate such as pumps heaters converters valves and circuit boards Level 3 Other miscellaneous items not included in Level 1 or 2 This level includes other spare parts that are not expected to fail over a given time frame 98207601 Rev B 21 EC9820 CO ANALYZER SERVICE MANUAL Components marked with shading are essential components wh
26. ctronic zero adjust to reset the preprocessor measurement coarse and fine zero adjustment This routine is identical to the electronic zero adjust described in the startup routine After an electronic zero adjust the analyzer will perform a background to incorporate this new baseline value 19 EC9820 CO ANALYZER SERVICE MANUAL 3 0 Maintenance 3 1 Maintenance Schedule The following outlines a periodic maintenance schedule for the EC9820 analyzer This schedule is based on experience under normal operating conditions and may need to be modified to suit specific operating conditions and regulations It is recommended that this schedule be followed in order to maintain reliable long term operation of the analyzer Interval Item Procedure Section Weekly Inlet Particulate Filter Check Replace Service Manual 3 3 1 Event Log System Faults Service Manual 4 2 4 amp 4 2 7 Operation Manual 2 4 Monthly Service Manual 3 3 3 Operation Manual 2 4 Operation Manual 2 3 3 6 Monthly Operation Manual 3 2 1 Year Service Manual 3 3 4 Service Manual 3 3 7 Suggested intervals for normal operation and actual intervals will vary depending upon application The user can refer to this table as a guideline but should develop a maintenance schedule to suit their specific requirements 20 98207601 Rev B CHAPTER 3 MAINTENANCE 3 2 Replaceable Parts EC9820 Analyser Spare Parts Requirements Des
27. e possible cause of the fault Message OUT OF SERVICE ZERO FLOW A series LAMP SOURCE FAILURE CHOPPER WHEEL FAILURE COOLER FAILURE REFERENCE VOLTAGE OUT OF RANGE 12 VOLT SUPPLY FAILURE System Fault Messages Description Failure Limits Indicates the Service switch is in the OFF position Unless the analyzer is being serviced this switch should be in the IN position Indicates that the sample flow is less than 0 1 slpm Indicates that the source voltage is not within the acceptable limits A fault is indicated if the cooler voltage falls below 0 5 volts Indicates that the chopper correlation wheel is not rotating Indicates that the cooler temperature or voltage is not within the acceptable limits A fault is indicated if the cooler voltage is above 1 5 volts Indicates that the reference voltage is not within the acceptable limits A fault is indicated if the reference voltage is below 3 volts or above 4 5 volts Indicates that the 12 volt supply voltage is not within the acceptable limits A fault is indicated if the 12 volt supply voltage is below 11 1 volts or above 14 3 volts 45 EC9820 CO ANALYZER SERVICE MANUAL 4 3 1 Optic System Fault Messages Message Description Failure Limits CELL Indicates th
28. ect operating range 4 2 Troubleshooting the EC9820 Analyzer 98207601 Rev B Because of the sophisticated design of the EC9820 analyzer a significant amount of information about the condition of the system is available on the front panel display You can therefore troubleshoot an operating instrument without opening the front cover The most useful menus in terms of troubleshooting are 39 EC9820 CO ANALYZER SERVICE MANUAL o PREPROCESSOR POTS g VALVE TEST MENU m EVENT LOG m INSTRUMENT STATUS m SYSTEM TEMPERATURES m SYSTEM FAULTS These menus provide information that may indicate a failure or an operational problem If instrument performance appears to have changed dramatically the component that is causing the problem can possibly be determined thereby speeding up the corrective process It may assist the operator to periodically check and record these parameters to establish an operational history of the analyzer In addition information from this section may be requested by the Ecotech Service Support personnel when assistance is required 4 2 1 Preprocessor Pots Menu PREPROCESSOR POTS MEASURE COARSE ZERO 67 50 80 MEASURE FINE ZERO 4 1 99 INPUT 42 REFERENCE GAIN 0 TEST MEASURE 0 REF VOLTAGE VOLTS co PPM CONC VOLTAGE VOLTS Figure 21 Preprocessor Pots and Ranges The PREPROCESSOR POTS screen di
29. ector obtain an acceptable reading replace the source or Cell Heater Mirror A failed temperature control allows the instrument Heater zero to drift with ambient temperature Verify that the cell temperature and mirror temp are 50 39 C 5 Low span Span setting Adjust the span using the calibration procedure in the EC9820 Operation Manual See the zero flow symptom in this table Correlation Wheel Check the preprocessor pots measure coarse zero Leak setting If it is below 50 replace the correlation Leaks A leak dilutes the sample stream and causes low span readings and noise See the leak test procedure in section 3 3 7 above 6 No response to Leaks A leak dilutes the sample stream and causes low span gas span readings and noise See the leak test See the zero flow symptom in this table Correlation Wheel Check the preprocessor pots measure coarse zero Leak setting If it is below 50 replace the correlation wheel Software lockup 1 Observe whether ECOTECH GLOB E on the display is turning on the Microprocessor Board 7 Zero drift procedure in section 3 3 7 above 2 Verify that other menus can be selected 3 Press the Reset button on the secondary panel 4 Check that D5 HEART BEAT LED is flashing A leak dilutes the sample stream and causes low span readings and noise See the leak test 8 Unstable flow Failed pressure Recalibrate flow pressure board Replace board if or pressure board
30. ed off verify that there is no flow Connect a Digital Volt Meter DVM to the FLOW test point on the Flow Control PCA TP1 is the OV connection and pin 5 of the J2 connector is the FLOW test point The Digital Volt Meter should be set to the 2V DC range Adjust the FLOW CONTROL ZERO pot until the DVM reads slightly positive 0 to 0 5 VDC then press lt Enter gt Set the FLOW ZERO POINT to SET and press Enter gt A The GAS FLOW should now read 0 000 SLPM Disconnect the DVM Turn the analyzer pump ON and verify the CONTROL LOOP is still DISABLED From FLOW CALIBRATION MENU use the PUMP SPEED COARSE and PUMP SPEED FINE pots to adjust the measured flow external flowmeter to as close as possible to 1 00 SLPM Note If the analyzer attempts to automatically change the pot position during adjustment then repeat step 9 Record the average measured flow from the flowmeter and enter it into the FLOW SPAN POINT and press Enter gt Set the DESIRED FLOW to 1 00 SLPM and press Enter gt 4 Press Reset on the analyzer and allow the flow to stabilize Verify the flowmeter reading is now 1 0 0 05 SLPM Note After the instrument startup is complete verify the gas pressure is slightly below actual ambient pressure approximately 10 20 torr The gas pressure and gas flow readings may not bet updated during the startup routine This completes the flow transducer calibration procedure 3 6 Preprocessor Device ID Entr
31. eeeeeeeceeneeceeeeeeneees 44 DATA LOGGING a a n i 43 IR detecto inienn nnna eT NE E 15 Detector signal adjustment ooccioninnoninnnncncononnoncnnos 26 IR detector replacement oooonoocnococonoccnoncconcncnnnncnnnoss 28 Detector Signal Adjustment illustration 26 IR SOUL CO ici alate a 14 Diagnostic modes cococcononononononononnnnonononcnnononncncncnonos 46 IR source replacement mococnicinnnnnononincnoncncnnnrorononnnnos 27 E L Electric test function cooooococonccccononononcncnnnnonaononcncn ns 46 AA eE 29 Eyent LOS e e aer as cabo eviuctep aa Nae ENE 42 M x Maintenance periodic 00 ec eeeseeseeeeeseceeeeeeneeeeeees 20 Fan filter elearning adds 25 Maintenance routine cerro 23 Filter maintenance o concnnnonccncnnnninonannncnnanacnnonnanacinos 24 Major Components illustration oococnicninncn 12 Filter narrow DandpaSS coocconnononnonnncononncncononcnncnnons 15 Measurement Cell ooononnnnccionacanononnnnnrananacinonncnanananos 15 Flow Pressure board calibration cccccceee 30 31 Microprocessor board coooooonncnoconoconoccoonconoconocnnccn nono 10 G Motor replacement ooooooconoccnononinocccononononcconononnnaconess 27 N Gas filter correlation wheel ooooonconncnnncnicnnicnnccnonnnns 14 Gas Filter Correlation Wheel illustration 15 Narrow bandpass filter oooooonconicnnncnnnnnnccnncnonnconnconoo 15 I O Illustrations Cable ConnectionS oocococnoncnconcnnononns 7
32. ere the externally measured flow rate is entered FLOW ZERO POINT During the zero flow calibration of the standard flow block this option must be set to set and enter pressed for the zero calibration to take effect Select cancel to abort this operation FLOW TRANSDUCER DF Selecting set loads the factory default calibration curve into the earom on the standard flow control board PRESSURE 1 HIGH Pressure entered during ambient calibration PRESSURE 1 LOW Pressure entered during low pressure calibration VALVE SEQUENCING Turn the valve sequencing on or off Same as in the Valve Test Menu When turned off the appropriate valve sequence will set ready for pressure calibration CONTROL LOOP When ENABLED the microprocessor controls the pump speed via the flow control pots to give the desired flow rate When DISSABLED the user can manually adjust the pump speed using the flow control pots For the standard flow block only 98207601 Rev B 31 EC9820 CO ANALYZER SERVICE MANUAL FLOW CONTROL ZERO This flow control pot is used to manually adjust the zero flow offset voltage during the zero calibration of the standard flow block PUMP SPEED COARSE FINE The two flow control pots PUMP SPEED COARSE amp PUMP SPEED FINE are software controlled pots which control the pumps speed on the standard flow block AMBIENT PRESSURE Current ambient pressure measured from the ISO flow controller
33. es only o Preamp pressure board The pressure flow portion of the board contains an absolute and a gauge pressure transducer to measure cell pressure and detect sample flow 2 2 Operation Modes The analyzer operates in a number of different measurement modes These modes include startup measurement and auto zero modes Following is a description of each of the operating modes 2 2 1 Startup Mode When the instrument is initially powered up several components in the instrument are automatically configured by the microprocessor and an automatic zero is run This process typically takes about 10 minutes Following is a description of the various adjustments made during the startup routine All adjustments are automatically performed by the microprocessor no manual intervention is required During all the startup routines the cell is filled with zero air 2 2 1 1 Reference Self Test The test reference and input potentiometers on the preprocessor are adjusted to ensure response of the reference channel of the preprocessor 16 98207601 Rev B 2 2 2 2 2 2 2 2 98207601 Rev B CHAPTER 2 THEORY OF OPERATION 1 2 Electronic Zero Test The test measure potentiometer on the preprocessor board is adjusted to ensure response of the measurement channel of the preprocessor 1 3 Reference Adjust Reference adjust allows the input pot of the preprocessor to be adjusted for the proper reference voltage level of 4 0 0 1 volt
34. h Firmware Updater menu 2 Connect the 9800 analyzer to the computer using a standard serial cable you can connect to either the Multidrop port on the back of the analyzer or the service port on the front of the analyzer 3 Select Serial Port and the COM Port on the computer from those listed on the Firmware Update screen 36 98207601 Rev B CHAPTER 3 MAINTENANCE W Firmware Update Connect to the analyser via which port type Serial Port Communication Port COMI ha Figure 17 Firmware Update communication settings screenshot 4 Click Next 5 Enter the full path and file name of the firmware sx file you downloaded e g C TEMP V1 03 0001 SX assuming the file was saved to C TEMP W Firmware Update What firmware to do you wish to load C TEMPS 1 03 0008 S Browse Details Firmware 1 03 0008 S Date Friday 9 January 2004 3 31 07 PM Size KB 244 Figure 18 Firmware Update firmware selection screenshot 6 Click Next 7 Tick the boxes as shown in the figure below 98207601 Rev B 37 EC9820 CO ANALYZER SERVICE MANUAL W Firmware Update Select the operations you wish to perform Enter bootloader Erase Flash ROM Erase EEPROM Erase RAM Upload Firmware HHOOASs Run Firmware Previous Figure 19 Firmware Update operations screenshot 8 Ensure the analyzer is switched off using the switch under the front panel 9 Click Start 10 Switch the analy
35. he analyzer s measurement method by making the filter time base variable depending on the change rate of the measured value If the signal rate is changing rapidly the instrument is allowed to respond quickly When the signal is steady a long integration time is used to reduce noise The system continuously analyzes the signal and uses the appropriate filtering time EC9820 CO ANALYZER SERVICE MANUAL 2 1 Instrument Description The instrument is designed in a modular format consisting of a power microprocessor module and a sensor module The power microprocessor module contains the power supply voltage regulators and the system microprocessor The sensor module contains all components necessary to measure the pollutant gas The layout of the instrument is shown in the system block diagrams Figure 4 and major component layout diagrams Figure 5 2 1 1 Power Microprocessor Module 10 The power microprocessor module can be described in three sections the power supply the voltage regulator and the microprocessor 2 1 1 1 Power Supply The power supply is a self contained unit housed in a steel case It is designed to meet UL VDE CSA and other regulatory requirements It converts 99 to 264 VAC 50 60 Hz to 12 VDC power for distribution within the analyzer The power supply also furnishes a 250 msec power extension in the event of power failure to allow the computer to store data before the power failure can affect it 2 1 1
36. he filter plunger out of the body carefully resting it in a secure place The O ring and filter membrane are now exposed inside the filter body 4 Remove inspect and wipe down the O ring Replace the O ring only if damaged 5 Remove discard and replace the old filter membrane 6 Reinstall the O ring over the new membrane reinstall the plunger and hand thread the cap back into place by turning it clockwise Do not use tools 7 Return the Pump to ON 8 Close the front panel 3 3 3 Clean Fan Filter The fan filter is located on the rear of the analyzer If this filter becomes contaminated with dust and dirt it may affect the cooling capacity of the analyzer The fan screen should be cleaned by removing it from the analyzer and blowing it out with compressed air or by cleaning it with mild soapy water and air drying 98207601 Rev B 25 EC9820 CO ANALYZER SERVICE MANUAL 3 3 4 Detector Signal Adjustment The detector signal must be maintained at proper intensity to ensure satisfactory operation of the analyzer If this signal becomes too large or too weak the analyzer will not be able to maintain proper reference and measurement signals resulting in loss of measurement capability To perform the detector signal adjustment Caution If the detector signal is adjusted the analyzer will require recalibration Required equipment Oscilloscope 1 Remove the analyzer cover and connect an oscilloscope to the PAMP2VPP
37. ich need to be kept on hand at all times EC9820 Analyser Spare Parts Requirements Options and Accessories Description Part Number Rack mount kit with slides 98000036 2 Battery power option 12 VDC 98000115 Filter kit particulate sample inlet 5 micron 98000211 1 50 pin connector and shell kit 98000235 1 Valve manifold kit external zero span EZS 98300087 Valve span for external pressurized span source or gas cylinder 98301002 EC9820 Operation Manual 98207600 EC9820 Service Manual 98207601 3 2 1 Expected Life Span of Consumables 22 Component Minimum Typical IR Source 98300049 2 years 98207601 Rev B CHAPTER 3 MAINTENANCE 3 3 Maintenance Procedures 98207601 Rev B Following is a list of routine maintenance procedures which may be required over the life of the analyzer Recommended equipment to perform maintenance o Toolbox o Oscilloscope o Digital multimeter DMM o Computer or remote data terminal and connection cable for RS232 communication a Pressure transducer absolute and connection tubing calibrated in torr o Flowmeter 2 slpm nominal o Wire strippers o Soldering iron o Minifit extraction tool o Orifice removal tool o Assortment of 1 4 and 1 8 tubing and fittings o Test zero air source CO gt free o Test span gas source o Leak tester 23 EC9820 CO ANALYZER SERVICE MANUAL INLET FILTER DETECTOR ADJUSTMENT Figure 9
38. is designed to remove particles larger than 5 microns and to expose the sample to only nonreactive materials of Kynar Teflon and Viton The filtering agent is a 47 mm diameter 5 micron filter Flow Control Module The sample flow rate is monitored by measuring the pressure drop across a calibrated flow restrictor The upstream pressure of this restrictor is the sample cell pressure Mass flow through the restrictor is computed from the upstream and downstream pressures Since the pressure transducers used are temperature sensitive they are mounted in a temperature controlled block Sample Pump The rotary vane type pump is powered by a brushless DC motor Since the pump is working with a very light load it rotates very slowly resulting in very little bearing or vane wear The estimated pump life is in excess of 5 years The Pump speed is controlled by a DC input voltage derived from two digital potentiometers under microprocessor control on the flow control board The pump speed is varied to achieve desired sample flow rate Rear Fan The fan speed is controlled by a variable input voltage derived from a digital potentiometer under microprocessor control on the flow control board The fan speed is controlled to begin operating at about 30 C chassis temperature and increase its speed in a linear fashion until it is at full operating speed about 50 C chassis temperature 13 EC9820 CO ANALYZER SERVICE MANUAL 14 2 1 2 2 Optics
39. loosening the set screw in the side of the wheel body 0 5 mm hex screw Slide the correlation wheel off of the motor shaft 5 Remove the four screws securing the motor to the mounting plate and remove the motor 6 Remove the two screws that fasten the IR source into the source block Remove the IR source from the block 98207601 Rev B 27 EC9820 CO ANALYZER SERVICE MANUAL 7 Using a minifit extraction tool remove the two wires from the source to the electrical connection Remove the IR source and install the new source rewiring the new source in place of the old one 8 Reinstall the IR source 9 Reinstall the motor 10 Reinstall the correlation wheel When securing the correlation wheel to the motor shaft ensure the set screw secures to the flat face of the motor shaft 11 Reassemble the source timing assembly to the optical bench and reinstall the bench in the sensor tub 12 Perform the detector adjustment from earlier in this section Be sure to recalibrate the analyzer 3 3 6 IR Detector Replacement Refer to Figure 13 Figure 13 IR Detector Replacement 1 Turn the analyzer off and disconnect power 2 Disconnect the 1 4 tubing from the measurement cell inlet and outlet and all electrical connections from the bench to the sensor tub Remove the four mounting screws from the bench and remove the bench from the sensor tub 28 98207601 Rev B CHAPTER 3 MAINTENANCE 3 Remove the four screws securing
40. measure allows the cell to be filled with zero air from an external zero air source with external valves selected Processing of the signal is identical to measurement processing the only difference is the source of the sample stream 2 2 2 3 Span Measure Span measure allows the cell to be filled with gas from an external span source Processing of the signal is identical to measurement processing the only difference is the source of the sample stream 2 2 2 4 AZS Cycle The analyzer can be placed in an AZS cycle mode where the sample stream is automatically switched to zero then span then back to sample Further information on the AZS cycles is included in the EC9820 Operation Manual 2 2 3 Auto Zero Routines The EC9820 is an auto zero instrument The analyzer is allowed to periodically sample zero air and correct for the readings obtained 18 98207601 Rev B 2 2 2 2 98207601 Rev B CHAPTER 2 THEORY OF OPERATION 3 1 Background The auto zero function background is performed nightly at midnight unless BACKGROUND iS DISABLED This compensates for drift in the measurement baseline of the analyzer The nightly background routine is identical to the background described in the startup routine 3 2 Electronic Zero Adjust Long term negative drift may occasionally cause the measurement voltage near zero to drift outside the range of the preprocessor measurement channel If this occurs the analyzer will initiate an ele
41. ment cell the chassis temperature and the thermoelectric cooler temperature used to cool the detector Figure 25 contains the nominal values that should be displayed on this screen If any of the parameters are outside the acceptable ranges a significant problem among these components is strongly indicated For more information on the operational limits and fault messages refer to the table in section 4 2 7 System Faults 98207601 Rev B 4 2 7 System Faults 98207601 Rev B CHAPTER 4 TROUBLESHOOTING The SYSTEM FAULTS display provides pass fail indications for various parameters that are continually monitored These parameters must be within acceptable operating ranges in order to display Pass If FAIL is indicated this indicates a major failure in that area If the instrument is in startup mode START will be displayed Note The SYSTEM FAULTS screen only indicates PASS or FAIL for the various analyzer parameters and is meant to indicate major failures Desired operating ranges are indicated in the INSTRUMENT STATUS and SYSTEM TEMPERATURE ranges section If analyzer readings are not within these ranges it could indicate deterioration of certain assemblies within the analyzer or minor failures The following table lists the possible system fault messages that are displayed on the primary screen if a major failure occurs If a fault message is displayed use the troubleshooting guide to find th
42. n processed as if it were an actual signal This test is used to verify the operation of the preprocessor board reference and measure channels 4 3 4 Use of Diagnostic Modes 46 The diagnostic mode is actuated by selecting DIAGNOSTIC MODE ELECTRIC or PREAMP and adjusting the test measure or test reference potentiometer until a response simulated concentration or reference is noted Response to tests will vary depending upon individual analyzer parameters These tests are typically pass fail response or no response 98207601 Rev B CHAPTER 4 TROUBLESHOOTING 4 4 Troubleshooting Guide 98207601 Rev B Use this troubleshooting guide to find the symptom then follow in order the possible causes and fault isolation solutions until the problem is discovered and take the action described If you cannot identify the problem contact Ecotech at the locations given in the front of this manual System Troubleshooting Table Symptom Possible Cause Fault Isolation Solution 1 No display AC power 1 Verify that the line cord is connected instrument dead 2 Check that the power supply fuse is not open The fuse should be 5A 115 v or 3A 230 v 3 Verify that the voltage switch is in the proper position 2 No display Contrast Set or adjust the display contract by maladjusted simultaneously pressing two keys on the front panel as follows Contrast Press Up Arrow A and lt Select gt for darker contrast Down Arrow Y
43. ould be approximately 1 slpm If flow is too low perform the flow calibration in section 3 5 below 3 4 Hidden Menu The new software features of the Ecotech Microprocessor board SMD version provides provisions for a hidden menu This enables the experienced user to access menus for maintenance purposes These menus eliminate the need for a portable computer to perform flow amp pressure calibrations 98207601 Rev B 29 EC9820 CO ANALYZER SERVICE MANUAL 30 To access the hidden menu simultaneously press three keys on the front panel from the primary screen as follows Up arrow A lt Pg Up gt and Enter gt J The following menu will be displayed HIDDEN MENU SERIES A ANALYZER TYPE 9820 SUB TYPE STANDARD FLOW BLOCK TYPE STANDARD GAS NAME PRESSURE CALIBRATION MENU FLOW CALIBRATION MENU FACTORY DIAGNOSTICS MENU Figure 14 Hidden Menu SERIES Allows the user to choose the correct series of analyzer The options are A B amp s The selection must reflect the Hardware to which it is being installed i e for an EC9820 analyzer it must be set to a and for an EC9820B analyzer set to B in order to operate correctly The s option is reserved for special system software ANALYSER TYPE Allows the user to choose the correct analyzer type The options are 9810 9811 9812 9820 9830 9841 9842 amp 9850 The selection must reflect the Hardware to which it is being installed i e for an EC9
44. page 4 sticker may get hot and deliver burns Measure the temperature on the surface before making any contact with it O Equipment Rating o 100 120 220 240V 10 o 50 60 Hz o 250 VA max O O FUSE 5 3 15A T 250V All wiring must be in accordance with local norms and be carried out by experienced personnel Service and Spare Parts For world wide customer service amp spare parts contact ECOTECH Address Phone Fax Email Service Email Spare Parts Web Ecotech Pty Ltd 1492 Ferntree Gully Rd Knoxfield Australia VIC 3180 61 1300 364 946 61 1300 668 763 ecotech O ecotech com au parts ecotech com au www ecotech com au 98207601 Rev B CHAPTER 1 INSTALLATION 1 0 Installation 1 1 Initial Check Verify that the serial number label on the documentation and the serial number s on the analyzer match Check to make certain your instrument arrived undamaged If you find damage report it as described in the preface on the page titled Claims for Damaged Shipments and Shipping Discrepancies in the Operation manual Analyzers are shipped ready to power up Occasionally however rough handling during shipment causes dislodged PC boards disconnected cables or incorrectly positioned switches Verify that your instrument is in operating condition by performing the following procedure 1 1 1 Remove the Top Cover 98207601 Rev B Grasp the front top corners of the front panel and p
45. performed then the analyzer can be placed in sampling environment and proceed sampling 4 Ensure background air is NEVER taken from ambient air in sampling environment this will result in erroneous sample readings 17 EC9820 CO ANALYZER SERVICE MANUAL 2 2 1 6 Sample Fill Measure After the background the analyzer is switched into the sample fill mode where the reaction cell is filled with sample gas and finally to sample measure mode when actual gas measurement begins 2 2 1 7 Quick Start Routine If the analyzer power is removed for less than two minutes the full automatic startup routine is replaced by a quick start routine The analyzer is returned to its last known operating parameters and normal operation is immediately restored This allows the analyzer to rapidly return to measurement mode and keeps data loss to a minimum If power is lost for greater than two minutes a full automatic restart is performed 2 2 2 Measure Modes 2 2 2 1 Sample Measure Sample measure is the standard operating mode of the EC9820 The cell is continuously filled with sample gas via the main valve manifold The IR detector senses the IR signal from the measurement cell This signal is amplified and conditioned by the preprocessor to separate reference and measure signals which are compared to become what is called the concentration voltage This concentration voltage is then used to determine gas concentrations 2 2 2 2 Zero Measure Zero
46. s The reference voltage is proportional to the intensity of the IR signal 1 4 Electronic Zero Adjust Electronic zero adjust sets the preprocessor measurement channel to minimize any electronic or optical offset present at zero First the cell is allowed to fill completely with zero air The preprocessor measure coarse zero and measure fine zero potentiometers are then adjusted until a concentration voltage of just above 0 00 volts is obtained This is the analyzer s coarse zero adjustment Once this is set it is not readjusted until another automatic startup routine is performed or the concentration voltage is sensed to be below 0 1 volts 1 5 Background Background allows the analyzer to sample zero air and measure the level of the concentration voltage This reading is taken as the zero signal level and this is subtracted from any subsequent readings This is the analyzer s fine zero measurement The background is re run nightly at midnight unless background is disabled when manually selected through the CALIBRATION MENU when a temperature change of greater than 4 C is sensed or when another automatic startup routine is performed Note To perform a differential background 1 Ensure that zero air is not connected to zero port otherwise a standard absolute background will be performed 2 Connect the zero port to ambient air outside of sampling area and run background readings 3 Once this background has been
47. splays the potentiometer settings associated with several components variables or signals on the preprocessor board Figure 21 illustrates a typical screen for an instrument that is operating normally The value of the potentiometer settings is somewhat arbitrary and differences in the examples shown here and the values displayed on an operating instrument should not be construed as a definite indicator of a problem Potentiometer settings of 99 and 0 however represent the extreme limits of the potentiometer range and may be reason to suspect a problem except for TEST MEASURE which is zero unless changed by the operator 4 2 2 Flow Control Pots Menu A Series only 40 The FLOW CONTROL POTS screen displays the potentiometer settings associated with several components variables or signals on the A series Flow Control board Figure 22 illustrates a typical test screen for an instrument that is operating normally Like the PREPROCESSOR POTS the value of the potentiometer settings is somewhat arbitrary Potentiometer settings 99 and 0 however represent the 98207601 Rev B CHAPTER 4 TROUBLESHOOTING extreme limits of the potentiometer range and may be reason to suspect a problem FLOW CONTROL POTS FLOW CONTROL ZERO FAN SPEED CONTROL PUMP SPEED FINE PUMP SPEED COARSE GAS FLOW GAS PRESSURE Figure 22 Flow Control Pots Range 4 2 3 Valve Test Menu 81 50 90 16 0 99 85 0 99 62 20 60 1
48. test point J5 14 on the Preprocessor PCA Set the scope for 0 5 v div and 2 msec div Synchronize the scope using the REF test point J5 3 on the Preprocessor PCA 2 The detector adjustment potentiometer is accessible through the hole on the top of the detector cover Use an electronic tweeker to adjust the preamp signal using for 2 volts peak to peak on the smaller signal refer to Figure 11 Figure 11 Detector Signal Adjustment 3 Verify that the two signals on the detector signal differ in amplitude by approximately 15 refer to Figure 11 If they differ by less than 15 the correlation wheel may require replacement 26 98207601 Rev B CHAPTER 3 MAINTENANCE 4 Disconnect the oscilloscope and reinstall the cover If the signal was readjusted the analyzer should be reset and recalibrated after its startup sequence is complete 3 3 5 Correlation Wheel Motor IR Source Replacement Refer to Figure 12 Qs Pa me y K Sa Figure 12 Correlation Wheel Motor IR Source Replacement 1 Turn the analyzer off and disconnect power 2 Disconnect the 1 4 tubing from the measurement cell inlet and outlet and all electrical connections from the bench to the sensor tub Remove the four mounting screws from the bench and remove the bench from the sensor tub 3 Remove the four screws securing the source timing assembly to the optical bench and remove the block from the bench 4 Remove the correlation wheel by
49. ti ci cocdts Sock viens da Geass a a Sea de SAGO Bs Sahu add ASS 23 331 Check Particulate Eta A dsd dee OE 24 3 3 2 Particulate Filter Replacement Procedure oonocncnonncononononnnonanonnnnnnnnnnnnno cono cono cone on nero nono conan ran rn eran cnnncn neo 24 S313 Clean PANE A AAA oleae hese A glued aa a aa ea A cae a e A eE e E E A eats 25 3 3 4 Detector Signal Adjustment srs siisii ieina peace A a ia 26 3 3 5 Correlation Wheel Motor IR Source Replacement 1sccsccesseeseesseescesecesecesecusecesecusecseecaeesseeeseeseeeneensees 27 3 3 0 IR Detector Replacement ous ss scivecss castes AA A A Seanbenees 28 S337 LEALES PO CUE a hee eS Rien ears 29 SZ AJHIDDEN MENU vosconocor iii a AR aid a be 29 3 4 1 Pressure amp Flow Calibration SUbD MEenUsS ocococononononononanonanananonononononononononononnnnononononononononononononona noo nananananons 31 TAL FACTORY DIAGNOSTICS MENU eiiie irii tiio ad 32 3 5 PRESSURE amp FLOW CALIBRATION ccccccccccccssssssscecececeesssseaececececsensaaecececeesessaaececececseseaaeaesececeesesaaececeeeesensaaeeeeees 32 3 Del Pres Sure Flow Cadera a ed 32 3 6 PREPROCESSOR DEVICE ID ENTRY c ccccccccsssssscecececeesensnaececeeecsenseaececececsensaaececececseneaesecececeesessaaeseeeesesensaaeeeeees 35 3T FIRMWARE UPDATE diia 36 4 0 TROUBLESHOOTING esses siiverccsesveseesessducisdenessssuueessstecveseese sess sbusexes Era Ea r do ssdeeseasbsdeveaseseavesnesegetecuseesesre 39 4 1 DCPOWER SUPPLY VOLTAGES incida daa 39
50. ull forward The panel will pop loose and pivot forward See Figure 1 The top cover retaining hardware is then visible as shown in Figure 2 Use a screwdriver to unscrew the two captive screws When the two captive screws are loosened slide the cover backward about 4 inches and lift the top cover straight up GRIP GRIP HERE HERE GLB GA Re Clos Pla TAS Figure 1 Opening the Front Panel EC9820 CO ANALYZER SERVICE MANUAL 1 1 2 Service Switch Opening the front panel allows a view of the secondary panel where four switches are visible The position of the toggle switches for operating mode is DC Power ON Pump ON ServiceIN The Reset switch is not a toggle switch and is only activated when pressed It resets the microprocessor The pump switch is not applicable to the B line instrumentation because the flow is generated through the use of an external pump When in the OUT position the Service switch sets the OUT OF SERVICE bit in the 50 pin I O interface and in the status word from the serial port The OUT position has no other effect on the operation or validity of the data obtained from the analyzer When the Service switch is set from OUT to IN the instrument returns to the normal operating conditions Captive screws SECONDARY PARTICULATE FILTER OPTICAL BENCH Figure 2 The Secondary Panel 1 1 3 Inspect the Components Verify that the components were not damaged in shipping If any PC boards are
51. voltage peak measure voltage peak and the mask voltage valley 15 EC9820 CO ANALYZER SERVICE MANUAL o Preprocessor The preprocessor contains circuitry for sampling the amplitude of the reference and measure pulses a regulator to keep the IR source at constant intensity a heater control and miscellaneous logic to generate test signals The heater circuit controls the adjustable mirror plate in the measurement cell to 50 C o An optodecoder circuit separates detected timing marks on the gas filter correlation wheel into logic signals for comparison of the reference and measure pulse amplitudes Circuitry is included to convert the pulse amplitudes into direct current DC to balance the two detected DC signals for zeroing and to amplify the resultant signal with a programmable gain amplifier under control of the microprocessor The board also contains an EAROM which contains device identification and stored setup parameters A switching regulator is used to step down system 12 volts power to 6 volts for powering the IR source and the detector Peltier cooler All circuitry adjustments are made via the microprocessor controlled digital potentiometers o Flow Control PCA The pressure flow portion of the board contains an absolute and a gauge pressure transducer to measure cell pressure and control sample flow This board also controls the pump speed powers the chassis fan and has a heater control circuit to heat the flow block A seri
52. y 98207601 Rev B This procedure is only required if the microprocessor is not reading the device ID from the preprocessor board or if the preprocessor board has been replaced 35 EC9820 CO ANALYZER SERVICE MANUAL 1 From the HIDDN MENU set the SERIES to A then press Enter gt 2 Set the ANALYSER TYPE to 9820 and press Enter gt 3 Press Reset on the analyzer secondary panel The display should now display 9820 CO ANALYZER 4 You may need to erase memory after this procedure to avoid any problems This completes the analyzer device type programming 3 7 Firmware Update As improvements are made to the EC9800 series analyzers these can be easily passed on to the user by updating the firmware software operating within the Microprocessor board To update your EC9800 Analyzer download the Firmware Updater Software Install this software on a Windows based computer with a COM port To do this run the downloaded file setup exe by double clicking on it then follow the installation screens to install Next download the required software version for your 9800 analyzer from those listed at the bottom of this page e g V1 00 0002 by right clicking on the link and choosing Save Target As and saving the sx file on your computer You will need to select save as type All Files in the download window To update the firmware on the analyzer 1 Run Firmware Updater from the Start Programs Ecotec
53. zer on 11 The Firmware Updater window will show each step as the firmware is uploaded DO NOT turn the analyzer off until the Close button is enabled as shown below and the Analyzer is operating as usual again Firmware Update Connect to Analyser Enter Bootloader OK Erase EAPROM OK Erase EEPROM SKIPPED Erase RAM SKIPPED Upload Firmware OK Verify Upload OK Run Firmware OK Previous Close Figure 20 Firmware Update completion screenshot 38 98207601 Rev B CHAPTER 3 MAINTENANCE 4 0 Troubleshooting 4 1 DC Power Supply Voltages Before consulting the troubleshooting section verify that the DC power supply voltages are present and within the specifications given for each printed circuit board listed in the following table Circuit board illustrations indicating the test points and other component locations immediately follow the Troubleshooting Guide Table 1 Troubleshooting Voltages PCB Supply DVM DVM Response Microprocessor 12V GOOD TP1 PGND TP2 20 0 5 v 10 v TP3 10 0 5 v 20 v TP4 20 40 5 v Voltage Reg TP7 AGND TP9 12 40 5 v TP8 10 0 5 v TP6 10 0 5 v TP4 5 0 25 v Preprocessor 12 v TP2 AGND 12 0 5 v 5 v 5 0 25 v 10 v 10 40 5 v 1 v COOLER 1 40 3 v 6 v SOURCE 6 40 3 v Flow Control TP1 AGND 5 0 25V 4 5 0 25V 12 0 5V The 12V GOOD test point is a 5 volt status output from the power supply to indicate that the Mains supply is within the corr
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