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EC9852 Service Manual

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1. th 14 IN 53 tel e eme Cm LA gt lt cH e E C S gt lt d r Y eg al en N JN V N Po A gt lt L Sie Figure 7 Pneumatic Diagram Hydrocarbon Kicker A kicker is placed in the pneumatic system of the 9852 analyzer before the fluorescence cell to remove hydrocarbons that might interfere with the measurement of SO The kicker is composed of a Silastic membrane within a Teflon tubing jacket Sample is pulled through the internal membrane at 0 75 slpm while zero air is pulled through the outer jacket at 1 5 2 3 slpm in the opposite direction Because of the counter propagating flows and differential partial pressures between the two flow channels hydrocarbon interferents diffuse through the membrane and are carried away in the exhaust flow Consequently the interference by hydrocarbons in the SC measurement process is minimized Zero Air Scrubber The charcoal scrubber is used to provide a clean SO2 free zero air supply for the automatic zero function of the instrument and for the kicker jacket flow 98527601 Rev C CHAPTER 2 THEORY OF OPERATION 2 1 2 1 1 Flow Control D 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 restric
2. 4 3 Test Functions The following lists the available diagnostic modes in the EC9852 under the TEST MENU 4 3 1 Optic The optic test function turns on a small incandescent light bulb in the exhaust arm of the reaction cell The glow from this light simulates the glow of the normal fluorescent reaction of SO in the cell which is then detected by the PMT as if it were an actual signal This test is used to verify the operation of the PMT 4 3 2 Preamp The preamp test function generates an electronic test signal which is applied to the input of the PMT Preamp This simulates an input from the PMT and is then processed as if it were an actual signal This test is used to verify the operation of the PMT Preamp 4 3 3 Electric The electric test function generates an electronic test signal which is applied to the input of the preprocessor This simulates an input to the preprocessor and is then processed as if it were an actual signal This test is used to verify the operation of the Preprocessor PCA reference and measure channels 98527601 Rev C 57 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL 4 3 4 Use of Diagnostic Modes The diagnostic modes are actuated by selecting DIAGNOSTIC MODE OPTIC Or PREAMP Or ELECTRIC and adjusting the TEST MEASURE potentiometer until a response simulated concentration is noted Response to tests will vary depending upon individual analyzer parameters These tests are typically pas
3. Set the DESIRED FLOW to 0 50 SLPM and press Enter gt Press Reset on the analyzer and allow the flow to stabilize Verify the flowmeter reading is now 0 50 0 05 SLPM Note 98527601 Rev C CHAPTER 3 MAINTENANCE 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 Entry 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 1 From the HIDDN MENU set the SERIES to A or B depending on which analyzer it is Then press Enter gt 2 Set the ANALYZER TYPE to 9852 and press Enter gt 4 3 Press Reset on the analyzer secondary panel The display should now display 9852 SO2 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
4. eee 15 Illustrations Preprocessor Pots and Ranges 59 Illustrations Routine Maintenance Components 26 Illustrations Rx Cell Cleaning oconnonionncnnnninnnnnnnn 41 62 Illustrations Rx Cell PMT Housing Removal 38 Illustrations Rx Cell PMT Housing Separation 39 Illustrations System Block Daeram eee 12 Illustrations System Temperatures and Tolerances 63 Illustrations UV Lamp Replacement 35 Illustrations Valve Test Menu cccccceceeeeees 60 IEN 5 Instrument Status Ranges illustration 46 50 51 53 54 62 Instrument Status screen 62 K Kicker hydrocarbon ccooooonoccconcconoccconononnccnonancnnccnnno 16 L Lamp Driver board cooconocnconcccnnconcnnconcnnonononannnnnnonacnnos 18 Lamp mamntenamnce 34 Lamp EE 17 Leak checa 45 Lenses UV praderas setos 17 M Maintenance periodic oocoocnocnnoccnoconononononncnnnonnnonnnnos 22 Maintenance routine ooooonnnonnnononncononnnncnnonnnononnnncnnns 25 Major Components illustration ooooncncncnn mmn 13 Measure MOdES eeecessseceeeceeseecesneeeeeceeeeeesaeeeee 20 Microprocessor board 10 Modes of operaton 19 O Opening the Front Panel OGlfustraton eee 5 Optic test function ooooocncococcnnnononononanncnonancnnncnnonccnnos 65 Optical bandpass Dlter seee 17 Optics system Components cooooooccoccconcconccononnnonnninnnnns 17 Orifice Removal illustration ooncnnonicnocnncconcnnnnnon 34
5. 98527601 Rev C UV Lamp The UV lamp generates broad band UV light which is used to irradiate the measurement cell UV Bandpass Filter The 214nm UV bandpass filter limits the UV light within the cell to 214nm which is the frequency of interest for SO fluorescent spectroscopy UV Grade Lenses Two UV grade fused silica lenses are present in the optical path The first is a plano convex lens which is used to focus the UV light inside the measurement cell The second is a bi convex lens which focuses the fluorescent light from the SO reaction onto the cathode of the PMT Optical Bandpass Filter The colored glass optical filter limits the light reaching the PMT to the frequency of interest for the photon emitted during the SO reaction 15 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL 16 Photomultiplier Tube PMT The cooled PMT detects the amount of 350 nm light proportional to the concentration of SO present in the measurement cell The PMT is connected to an integrated High Voltage Power Supply HVPS Preamp UV Reference Detector The UV detector is a solid state photo diode that monitors the intensity of the UV light entering the measurement cell This signal is used to compensate for variations in the UV lamp signal 2 1 2 3 Electronics D Reference Detector Preamplifier This circuit board is housed within the box labeled Reference Detector in Figure 5 The circuit board s function is to convert the current si
6. the leak is in the span gas line 10 Return to the VALVE TEST MENU Close INT VALVE 3 and open INT VALVE 1 for normal operation 11 Set VALVE SEQUENCING ON and then press EXIT Remove the plugs from the INLET and AUXILIARY ports and from the zero air scrubber port 12 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 should be approximately 0 5 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 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 GH The following menu will be displayed 38 98527601 Rev C 98527601 Rev C CHAPTER 3 MAINTENANCE HIDDEN MENU SERIES A ANALYZER TYPE 9852 SUB TYPE STANDARD FLOW BLOCK TYPE STANDARD GAS NAME Se PRESSURE CALIBRAT
7. Hecotech environmental moni itoring solutions EC9852 Sulfur Compounds Analyser so TRS TS Service Manual www ecotech com FRONT MATTER Table of Contents MANUAL HISTORY E E do bocce cseaeeea E ltda dd decai Lia dad aaa Aa aia cbt 3 SAPETY REQUIREMENTS tia 4 SERVICE AND SPARE PARTS poe ea a REE EE ds seen ieasea e e R Ea 4 1 0 INSTALLATION RE 5 Te CINITIAL CHECK EE 5 T A REMOVE the Top EE J A RIESA AE AN I eds 5 LLB Anspect the Components oscan nnsa eree eaae riadas ae EERE SEESE Eea anaaga 6 LRA Reins rt Dislod sg d Boards iii dd Sos ids E E E a E O E A OEE 7 ETS Cable EE 7 2 0 THEORY OF OPERATION WEE 9 2 1 INSTRUMENT DESCRIPTION ciao ri ts ii Ande hee Ace de 10 2 1 1 Power Microprocessor Mod le diusta i a ia i cra rra rana rnn nn nero AS 10 21 2 Sensor Module vi enrii nianie a ria E AARNE EE EESO ri EROE ENS ENa PEDEN EAEE ES EIR S ETAY 13 2 2 OPERATION MODES eebe E E ee ENEE 17 Eelere ER Seeerei ege ae ea a a tata 17 SE Ee leg EE a 18 2213 ALO LEO AUN acc 19 3 0 MAINTENANCE DEE 20 3 1 MAINTENANCE SCHEDUL Eene o a a eet ee See Eed 20 3 2 REPLACEABLE PARTS coi id dada 21 3 2 1 Expected Life Span of Consumables oocniccinonononnnononnonnnnnonncnnnono nn none on nono aran anno nn cre ron non anar nana r ranma rnnan acne 22 3 31MAINTE ANCE PROCEDURES 24 a aid 22 3 31 Check Particulate EE 23 3 3 2 Particulate Filter Replacement Procedure ooooocnocononinncnononononncnnonnonnnnn corona nono rn nono arca aran cre
8. P Particulate filter maintenance ceseeeeseeeees 27 Periodic mauntenance 22 Photomultiplier ube 18 PME e eeneg rer ee SE aia 18 PMT cooler replacement oooocnocccconccononconccnonnninnncnnno 42 PMT desiccant pack replacement ee 36 PMT high voltage supply and preamplifier 18 PMT housing removal occcicnicnocnccconcnonaccnnncanonacinos 37 Pneumatic Diagram illustration 0 0 0 0 15 Power microprocessor module n 9 Preamp test function coooconocnncnoncconaccononononannnonnonacnnos 65 Preamp Pressure board A 18 Preprocessor board c oooocnnccnnccconoconoconcconocanonnninnninnnnns 18 Preprocessor Pots and Ranges illustration 59 Preprocessor Pots Men 59 98527601 Rev C EC9852 SULFUR COMPOUND ANALYZER SERVICE MANUAL Q Quick start edel deed terest 20 R Reaction cell cleanmng 41 Reaction cell removal 37 Reference adjust oia ee ege 19 Reference detector UN 18 Replaceable parts 23 Routine Maintenance ccoooccooccconcnoonnconnnononoconnninnnacnno 25 Routine Maintenance Components illustration 26 Rx Cell Cleaning illustration oooocoonncnncnnncnncninnnnns 41 Rx Cell PMT Housing Removal illustration 38 Rx Cell PMT Housing Separation illustration 39 S Sample fill measure oooncnncnnnnnononononcononoconcononanancnann 20 Sample Measure violin nice 20 Scrubber maintenance ccooccnooccnonnnoonncnonononnninononinoss 30 Scrubber Zero alr oooooc
9. all Sulfur compound including Dimethyl disulfide Dimethyl sulfide and Methyl mercaptan into SO This conversion allows the analysis of Total Sulfur and Total Reduced Sulfur TRS The HTO converts all Sulfur compounds into SO which are then measured TS reading An SO measurement is then taken and subtracted from the TS measurement to find the Total amount of Sulfur compounds that were reduced to SO TRS The cycling of these two measurements occurs over an extended length of time This measurement process means results are susceptible to temporary inaccuracy when fluctuation in concentrations of sample air occurs These instruments are most suited to stable environments where sample air does not vary dramatically over short periods of time 2 1 Instrument Description The instrument consists 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 2 1 1 Power Microprocessor Module 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
10. area If the instrument is in startup mode START will be displayed Note The SYSTEM FAULTS screen only indicates PASS or FAIL of the various analyzer parameters and is meant to indicate major failures Desired operating ranges are indicated in the INSTRUMENT STATUS and SYST EM TEMPERATURES ranges section If analyzer readings are not within these ranges certain assemblies within the analyzer or minor failures it could indicate deterioration of 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 the possible cause of the fault System Fault Messages Message Description Failure Limits OUT OF SERVICE Indicates the Service switch is in the OUT position Unless the analyzer is being serviced this switch should be in the IN position ZERO FLOW Indicates that measured flow has gone below 0 05 SLPM LAMP FAILURE Indicates that the lamp current is not within the acceptable limits In the EC9852 a fault is indicated if the lamp current is below 20 mA or above 50 mA COOLER FAILURE Indicates that the cooler temperature or voltage is not within the acceptable limits In the EC9852 a fault is indicated if the cooler temperature is above 15 C or below 0 C R
11. blowing it out with compressed air or by cleaning it with mild soapy water and air drying 3 3 4 Zero Air Scrubber The zero air supply is critical to the operation of the EC9852 Poor zero air can result in numerous problems such as inaccurate measurements near zero and span drift The quality of the zero air system should be checked by challenging the analyzer with a known good zero air source such as commercially available Ultra Zero Air or a known good charcoal scrubber To check the zero air system perform the following Required equipment Test zero air supply 1 From the CALIBRATION MENU place the analyzer in CAL MODE ZERO This will allow the analyzer to sample zero air from the zero air scrubber Allow to sample for approximately 15 minutes 2 Record the front panel SO reading as the initial value Note This value should be 0 000 0 001 ppm If it is not a background should be initiated by choosing CALIBRATION MENU and BACKGROUND START then press lt Enter gt to re establish the zero baseline The background will require approximately 15 minutes to complete 3 Connect the challenge zero air to the Sample inlet of the analyzer Be sure the inlet pressure is maintained at ambient pressure 4 From the CALIBRATION MENU select CAL MODE MEASURE and press lt Enter gt This will allow the analyzer to sample the challenge zero air Allow to sample for 5 minutes 5 Record the front panel S
12. canister 3 Unscrew the canister cap and remove the plastic insert metal screen and felt pad Pour the charcoal out of the canister 4 Refill the canister with charcoal see the Replaceable Parts list for the part number 5 Replace the felt pad metal screen plastic insert and canister lid 6 Reconnect the Teflon tube to the canister and secure the canister with the strap 27 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL Figure 10 Charcoal Replacement Procedure 28 98527601 Rev C CHAPTER 3 MAINTENANCE 3 3 5 UV Lamp Proper operation of the UV lamp is essential to the EC9852 The UV lamp should be periodically checked to see if it is operating within acceptable parameters and may require periodic realignment to maintain sufficient UV light for analyzer operation Following are procedures to check align and replace the UV lamp assembly Warning The Lamp Driver PCA can generate in excess of 1000 volts Exercise extreme care when working in the vicinity of the Lamp Driver Caution If the UV lamp is adjusted the analyzer will require recalibration 3 3 5 1 UV Lamp Alignment 98527601 Rev C Required equipment Oscilloscope 1 Turn the analyzer on and allow the UV lamp to warm up and stabilize about 15 minutes 2 Connect an oscilloscope to Preprocessor J5 3 REFX2 and TP1 AGND Adjust the scope for 0 5 V division and 20 msec division 3 Remove the UV lamp access cover and remove the two ca
13. for the last 1 minute Occurs when valve sequencing has been disabled and then automatically enabled after the main screen has been visible for the last 1 minute Action Instrument span has drifted beyond acceptable limits Recalibrate Instrument span has drifted beyond acceptable limits Recalibrate Normal after reset or power failure If not associated with these check zero air supply No action required Unless the reset was not initiated by the user no action is required No action required Battery failure or system software error If error persists call Ecotech Customer Service for instructions No action required No action required 53 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL 4 2 5 Instrument Status INSTRUMENT STATUS GAS FLOW 0 375 0 625 GAS PRESSURE 690 760 REF VOLTAGE E 23 S527 CONC VOLTAGE 0 0 4 2 ANALOG SUPPLY 11 6 12 DIGITAL SUPPLY GN WE HIGH VOLTAGE 700 720 LAMP CURRENT 34 36 VERSION 1 18 0012 TRS Figure 26 Instrument Status Ranges If any of the parameters displayed on the INSTRUMENT STATUS screen vary significantly from the values shown in Figure 26 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 tab
14. nana onnrnnan arias 25 3 3 3 Clean Fan Filter A EEN sabsalisesbssdeaadscaceoassacdeesdieteeseseseddecdscavess eE Neuen 26 3 3 4 Ler Air eebe eerste RAN 26 3 30 GV LAMP A easesuatessistiscess aadaasushit E Caahnhig sousessaseabissdeesses 29 3 3 6 PMT Desiccant Pack Replacement csccesccesecsseeneenceeseeenseseceseesceeeeeesecesecesecsecuaecaaecseeeseeeaeeeseeeeeeneeenees 31 33 7 Rx CelUPMT Housing Removal mia ie ee REENEN 32 3 3 0 Rx Te 34 3 3 9 PMT EE 35 3 3 10 Leak Test Procedure cccccccccccccccssescecesssesecusscecesssececssssecsesceecessseeecsssseceenseeeceeseeecnssseceesseeceesseeeensssaeeeenaees 37 3 4 HIDDEN MENUS e E S te tases 38 3 4 1 Pressure Flow Calibration sub menus nono nonnonnnna no nono nnonnnnn no nn nrnnononn nono nnnnccnanns 40 3 5 PRESSURE amp FLOW CALIBRATION ccccsscceessscecesssececseseeceesceeceesaececseneececsueeecsesaeeecssseceesaeeecsesaececeeseecessesecsenaess 41 3 5 1 Pressure Flow Calibration ccccccccccccccccccsescecececssusussceesecseussaececececsesessecececsesenaseceeeceeseesaeceeececsesnsaeaeeececes 42 3 6 PREPROCESSOR DEVICE ID ENTRY cccccsssseceessececssscecesssccecsesaececsensecseaeeecsesaececsaeecsssaeeecsesaeeecseasecessesecnenaees 45 3 PFIRMWARE UPDATE e nidad pibe 45 AIM ON 49 4 1 DCE POWER SUPPEY VOLTAGES 0 aa 49 4 2 TROUBLESHOOTING THE EC9852 ANALYZER cccesssscecsessececsescecessnececsesaececseseecsesaeeecsesaeeeceeseeeesueeecneaeeeeseeeeeess 49 4 21 Preprocessor E 50
15. port To do this run the downloaded file setup exe by double clicking on 1t 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 eg V1 00 0002 by right clicking on the link and choosing Save Target As and saving the sx file on your 98527601 Rev C 45 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL 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 Ecotech 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 pl Firmware Update Connect to the analyser via which port type Serial Port Communication Port COM Figure 19 Firmware Update communication settings screenshot 4 Click Next 5 Enter the full path and file name of the firmware sx file you downloaded eg C TEMP V1 03 0001 SX assuming the file was saved to C TEMP 46 98527601 Rev C CHAPTER 3 MAINTENANCE Firmware Update What firmware to do you wish to load C TEMPSV 1 03 0008 S Browse r Details F
16. the Rx cell bulkhead Loosen the captive screws that secure the PMT housing to the chassis two screws secure to the side of the chassis and two screws secure to the bottom of the chassis Refer to Figure 12 Gently swing the kicker housing forward and out of the way of the UV lamp housing Grasp the Rx cell and PMT assembly by the top cross brace and gently lift it straight up out of the analyzer To separate the Rx cell from the PMT housing remove the three screws that secure the Rx cell to the PMT housing Refer to Figure 13 Gently pull the Rx cell straight away from and PMT housing assembly 98527601 Rev C CHAPTER 3 MAINTENANCE 9 To reconnect the Rx cell to the PMT housing align the base of the Rx cell with the groove in the PMT housing mounting bracket and slide it gently into place against the PMT housing 10 Reinstall the three screws to secure the PMT housing to the Rx cell assembly and alternately tighten these screws to pull the Rx cell squarely into the PMT housing 11 Reassemble the Rx cell PMT housing assembly and reinstall into the analyzer Figure 12 Rx Cell PMT Housing Removal Figure 13 Rx Cell PMT Housing Separation 98527601 Rev C 33 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL 3 3 8 Rx Cell Cleaning The Rx cell cleaning procedure should be performed when zero values begin to drift when the analyzer can no longer accomplish an electronic zero adjust or can be performed as an
17. 1 Rev C 51 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL 4 2 4 Event Log Upon noting a possible operational problem examine the EVENT LOG menu to determine whether the microprocessor is reporting a system failure or problem 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 PCA cable Y detected error at location Y connections and Pressure PCA SERVICE SWITCH Unit taken out of service Return analyzer to service ACTIVATED from front panel using the front panel switch LCD DISPLAY BUSY LCD constantly busy Check display cable indicates hardware failure in connection Display PCA display and Microprocessor PCA SYSTEM POWER Power removed from system No action required FAILURE SYSTEM POWER Power applied to system No action required RESTORED HIGH VOLTAGE POT High voltage adjustment Check Preprocessor PCA LIMITED TO 99 exceeds range PMT or high voltage module LAMP ADJUST ERROR Lamp Adjust Pot reached Check UV lamp Lamp limit before 35 mA lamp Driver PCA or Preprocessor curr
18. 2 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 electronic zero adjust to reset the preprocessor measurement zero adjustment This routine is identical to the electronic zero adjust described in the startup routine After an electronic zero adjust the analyzer will always perform a background to fine adjust for the new baseline value 98527601 Rev C 19 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL 3 0 Maintenance 3 1 Maintenance Schedule The following outlines a periodic maintenance schedule for the EC9852 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 Weekly Monthly 3 Monthly 6 Monthly 1 Year Interval Item Procedure Section 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 Service Manual 3 3 3 Operation Manual 3 3 Operation Manual 2 3 3 Operation Manual 3 3 Service Manual 3 3 4 Service Manual 3 3 6 Operation Manual 3 4 Service Manual 3 3 5 Service Manual 3 3 10 Flow Calibration C
19. 4 2 2 Flow Control Pots Menn 50 4 2 3 Valve Test Menn ee EEE rE TE E NEA EEN AEE TEE E ANE sodgeadvaasesstoedeeacdesdeusessaedcedtieeds 51 KE EE 52 ADS TEE 54 4 2 0 SYstemTemperdlures EE ee EEN eeh ee ER 54 4 2 7 System Faults seee A e EES lA iaa 56 98527601 Rev B 1 EC9852 SO ANALYZER SERVICE MANUAL AB TEST FUNCTIONS amp ed deeg det 57 K RSO M EE 57 AID PLEGINP a E RE r ENEA EA RE E EEN 57 E AE EE E 57 4 34 Use of Diagnostic MOGES ir rapena oe aee e tas eege edd ETES EE 58 4 4 TROUBLESHOOTING GUIDE EAO E E E E E E E E 58 INDEX A ON 62 2 98527601 Rev B FRONT MATTER Manual History The scope of this new manual covers the following analyzers o EC9852 H gt S SO Analyzer PN 98521000 115 o EC9852 TRS SO Analyzer PN 98521000 105 Both of the instruments are Manufactured by Ecotech P L in Australia and sup port the new SMD Microprocessor Board Part number 98000063 4 This manual is current for firmware version 1 34 and above This manual should only be used in conjunction with EC9852 Sulfur Compound Analyzer SO2 H2S and SOY TS Analyzer Operation Manual PN 98527600 Rev C May 2009 Ecotech Manual ID MAN 0026 Manual PN 98527601 Current Revision C Date Released August 2009 Description EC9852 Sulfur Compound Analyzer Service Manual Revision History Rev Date Summary Affected Pages A June 2005 Initial Release All A 1 October 2005 Updates for External H2S converter added various B Decembe
20. C 41 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL 3 5 1 Pressure Flow Calibration 3 5 1 1 Setup Note The EC9852 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 stabilise to 50 C From the HIDDEN MENU set the FLOW BLOCK TYPE TO STANDARD and press Enter gt 4 Press Reset on the analyzer secondary panel 3 5 1 2 Pressure Calibration 1 From the HIDDEN MENU select the PRESSURE CALIBRATION MENU The menu of Figure 17 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 0 500 SLPM Figure 17 Pressure Calibration Menu for Standard flow block 2 Verify the pump is turned off by setting the pump switch to OFF on the secondary panel 3 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 4 Set the CONTROL LOOP TO DISABLED and press Enter gt This will disable the flow control loop 42 98527601 Rev C CHAPTER 3 MAI
21. EFERENCE Indicates that the reference voltage is not within the acceptable VOLTAGE OUT OF limits In the EC9852 a fault is indicated if the reference voltage is RENGA below 1 volts or above 4 volts CONVERTER Indicates that the converter temperature is not within the acceptable E Se e SE UBE limits A fault is indicated if the converter temperature is below E 250 C or above 350 C 98527601 Rev C CHAPTER 4 TROUBLESHOOTING System Fault Messages Message Description Failure Limits 12 VOLT SUPPLY Indicates that the 12 volt supply voltage is not within the acceptable FAILURE limits A fault is indicated if the 12 volt supply voltage is below 11 1 volts or above 14 3 volts HIGH VOLTAGE Indicates that the high voltage is not within the acceptable limits A FAILURE fault is indicated if the high voltage reading differs by greater than 25 of the expected value as determined from the high voltage pot setting CELL TEMPERATURE Indicates that the cell temperature is not within the acceptable limits FAILURE A fault is indicated if the cell temperature is below 35 C or 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 SEQUENCE ACTIVE up orreset
22. ION MENU FLOW CALIBRATION MENU Figure 16 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 1 e for a EC9852 analyzer it must be set to A and for a EC9852B analyzer set to B in order to operate correctly The s option is reserved for special system software ANALYZER TYPE Allows the user to choose the correct analyzer type The options are 9810 9811 9812 9820 9830 9841 9842 9850 amp 9852 The selection must reflect the Hardware to which it is being installed 1 e for a EC9852 analyzer 1t must be set to 9852 in order to operate correctly The analyzer type will default to 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 EC9852 are H2S SCRUBBER TS 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 O3 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 This field should always be left as STANDARD 39 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL 3 4 1 Pressure Flow Calib
23. MENU 98527601 Rev C 43 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL 44 10 11 12 13 Load the linearization table into the flow control board EAROM by setting FLOW TRANSDUCER DF to SET and pressing Enter gt The linearization table contains the following 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 Connect the calibrated flow meter to the sample inlet on the rear panel of the analyzer With the pump turned 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 J 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 0 50 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
24. NTENANCE 5 Connect the calibrated pressure transducer to the sample inlet on the rear panel of the analyzer 6 Turn the pump ON from the secondary panel 7 Setthe PUMP SPEED COARSE to 99 and press Enter gt 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 CALIBRATION 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 it 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 18 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 POINT CANCEL FLOW SPAN POINT 1 000 SLPM PUMP SPEED COARSE 28 PUMP SPEED FINE 7 GAS PRESSURE 710 0 TORR GAS FLOW 1 000 SLPM Figure 18 Flow Calibration Menu for Standard flow block 2 Verify the pump is turned OFF and the CONTROL LOOP is DISABLED in the FLOW CALIBRATION
25. O reading as the challenge value 6 Compare the initial SO value and the challenge value They should agree within 0 002 ppm If the initial value is more positive than the challenge value the zero air scrubber should be recharged or replaced 98527601 Rev C CHAPTER 3 MAINTENANCE 7 Disconnect the challenge zero air and reconnect the sample line to the Sample inlet of the analyzer Verify the analyzer is in the Sample Measure mode The life span of a zero air scrubber system is typically dependent upon the amount of SO the system is required to scrub The user should closely monitor the performance of the zero air system after initial installation and note when the zero air begins to degrade This interval can then be used as the baseline for establishing a zero air maintenance schedule If the instrument uses the Ecotech Zero Air Scrubber part number 98415105 1 the following replacement schedule can be used as a starting point for development of this schedule Average Ambient SO Concentration Charcoal Replacement Interval 0 to 30 ppb 12 Months 3 3 4 1 Charcoal Scrubber Replacement Procedure 98527601 Rev C Use Figure 10 as a reference when replacing the charcoal l Open the Front Panel to access the service switches and the scrubber canisters Position the Pump Switch on the secondary panel to OFF Ze Remove the Kynar nuts and Teflon tubing from the canister Disengage the nylon restraining strap on the scrubber
26. Orifice 20 mil 3 Extraction tool filter and orifice 3 Service kit pump 3 Lamp driver assembly 3 PCA Preprocessor 3 98100039 3 9830037 3 983000465P1 1 98412028 3 5P__ 3 epes 3 985200362 3 98527601 Rev C 21 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL EC9852 Analyzer Spare Parts Requirements Heater and thermistor assembly 98520039 HVPS and preamplifier assembly photomultiplier 98520067 2 SP 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 Components marked with shading are essential components which need to be kept on hand at all times EC9852 Analyzer 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 EC9852 Operation Manual 98527600 EC9852 Service Manual 98527601 Reaction cell maintenance kit 98520061 KIT2 Valve manifold kit external zero span EZS 98300087 3 2 1 Expected Life Span of Consumables 3 3 Maintenance Proce
27. Sample Measure mode when actual gas measurement begins This is followed by the Gas 2 Sample fill mode and then the Gas 2 measurement cycle 2 2 1 5 Quick Start Routine If the analyzer power is removed for less than two minutes the full auto 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 auto restart is performed 2 2 2 Measure Modes 2 2 2 1 Sample Measure Sample measure is the standard operating mode of the EC9852 The cell is continuously stream switching between the SO and the TS H S streams at 8 minute intervals SO2 SAMPLE FILL CELL FILLING WITH S02 SO2 SAMPLE MEASURE SO2 MEASUREMENT IN PROCESS GAS 2 SAMPLE FILL CELL FILLING WITH H2S H amp S TS CONVERTED TO S02 GAS 2 SAMPLE MEASURE SO2 MEASUREMENT IN PROCESS The PMT senses the fluorescent signal in the Rx cell and this signal is amplified conditioned by the preprocessor to become what is called concentration voltage This concentration voltage is then used to determine gas concentrations The UV lamp is also monitored so the measurement reading can be compensated for fluctuations in lamp output A full measurement cycle consists of both the SO
28. 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 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 V 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 98527601 Rev C 2 1 98527601 Rev C CHAPTER 2 THEORY OF OPERATION 1 3 Microprocessor The microprocessor board contains a battery backed clock calendar and an onboard 16 bit microprocessor MC68HC12 operating at 16MHz 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 th
29. and GAS 2 measurement routines After each full measurement cycle the two measurements are processed to determine the GAS 1 SO and GAS 2 concentrations which are then compared to determine the raw TRS H2S concentration 98527601 Rev C CHAPTER 2 THEORY OF OPERATION 2 2 2 2 Zero Measure Zero measure allows the cell to be filled with zero air from an external zero air source 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 a span source from an external source with the external valve manifold 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 For further information on the AZS cycles refer to the EC9852 Operation Manual 2 2 3 Auto Zero Routines The EC9852 is an auto zero instrument The analyzer is allowed to periodically sample zero air and correct for the readings obtained 2 2 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 2
30. annual periodic maintenance item 1 Remove the Rx cell PMT housing assembly from the analyzer refer to section 3 3 6 above 2 Remove the bulkhead end cap from the Rx cell Refer to Figure 14 Figure 14 Rx Cell Cleaning 3 Using a lint free cloth such as a Kimwipe thoroughly wipe and clean the inside of the Rx cell and bulkhead end cap using a high purity isopropyl alcohol and allow to air dry Caution Ensure hands and fingers do not make contact with the inside of the Rx cell or end cap during cleaning Finger oils will fluoresce and result in an artificially high zero signal After cleaning there should be no lint oils or residue present in the Rx cell 4 Reinstall the end cap using a new O ring part number 025 030810 5 Reinstall the Rx cell PMT assembly in the analyzer 34 98527601 Rev C CHAPTER 3 MAINTENANCE 3 3 9 PMT Cooler Replacement Caution Because the PMT is extremely sensitive to light it is essential that before opening the PMT assembly to make sure that the analyzer is switched off In addition even when the analyzer is switched off is very important to cover the PMT at all times so that no direct light reaches its window 1 Remove the Rx cell PMT housing assembly from the analyzer and separate the Rx cell from the PMT housing refer to section 3 3 8 above 2 Remove the desiccant access cap and disconnect the electrical connector 3 Remove the 12 screws that secure the PMT housing
31. ay be bad If the pot is not at 99 try restarting the instrument If the problem continues call the Service Response Center 60 98527601 Rev C 98527601 Rev C CHAPTER 4 TROUBLESHOOTING Symptom 9 Instrument stuck in reference adjust 10 Response time High voltage not at specified value 11 PMT voltage does not reach 700 V 10 V 12 Analyzer displays BAD TD ANALYZER System Troubleshooting Table Possible Cause Low flow Kicker damaged Bad Microprocessor or Preprocessor PCA Preprocessor ID set wrong Fault Isolation Solution Check sample flow with flowmeter It should be 0 6 to 0 7 slpm STP Bypass kicker or replace orifice if it is not Perform leak test If there are no leaks bypass the kicker and re test the response time If the rise time corrects itself replace the kicker If not check the gas delivery system flow and particulate filter Replace the HVPS Preamp module Check that D5 HEART BEAT LED is flashing on the Microprocessor Board Check Display connection Replace the Microprocessor or Preprocessor PCA 1 Check JS connector on Microprocessor 2 Check J6 connector on Preprocessor 3 Reprogram device ID 4 Replace Preprocessor 61 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL INDEX A Auto Zero routines cocococonnnonccnnonanonanonccinonanananoncc ss 21 AZS cycle mode SEENEN E 20 B Backg
32. ccess cap may be easier if the Rx cell PMT housing is removed from the analyzer Refer to section 3 3 6 98527601 Rev C 31 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL 32 6 Remove the old desiccant packs and replace with new Do not attempt to dry and reuse the old packs Inspect the inside of the PMT housing by touch or with an inspection mirror to check for moisture inside the housing If moisture is detected inside the housing the desiccant pack replacement interval should be decreased Reinstall the desiccant cap by gently twisting and pressing the cap back into the PMT housing It may help to apply a small amount of lubricant to the O ring on the desiccant cap Secure with two screws Caution Do not attempt to insert the desiccant cap into the PMT housing by using the screws to pull the cap into place This will damage the PMT housing Reconnect power and restart the analyzer 3 3 7 Rx Cell PMT Housing Removal 1 Ds Turn the analyzer off and disconnect power Remove the UV lamp access cover and remove the two captive screws that secure the kicker to the UV lamp housing Refer to Figure 8 Gently move the kicker forward away from the Rx cell Disconnect the 1 8 tubing from the Rx cell inlet and the 1 4 tubing line from the Flow Control inlet top fitting Refer to Figure 12 Disconnect J1 J2 and J4 from the Preprocessor PCA and disconnect the PMT housing fan power cable the front connector from
33. ccnnnocccononcnononancnnonnnnnononnnnonnnnns 16 Sensor Mod le 0 0 0 eeeeeceeeeececeessececseeeeessseeeeneeees 14 Serial Port 6 10 55 Service switches ooocooococononoconoconnnoonnccononoonncnonononnnooo 6 SPAN MEASUTC e ee er ae pen EEEE PEE EEES EKSE 20 S Pale Parts EE Ee 23 ee 19 98527601 Rev C System Faults display ooococoicnncnoonnnnonccncononanancnnon 64 System Temperatures and Tolerances illustration 63 System Temperatures screen oconccnocnconoconcnonccnninncnnos 63 T MEP igi A Sine 10 Theory of Operation oooooconoccconncncnncnncnncnononannncnnonacnnonos 9 Droublesbootng 58 66 U US Buin 10 23 UV bandpass llenos iii 17 UN grade lenses ern et 17 Ulead irte 17 UV lamp maintenance cocococcccconocononcnnncnnonannncnnonacnnos 34 UV Lamp Replacement illustration 0 0 0 35 UV reference detector scrissi denesi iier 18 H Valve Test Menu seniman o rae r REA 60 Valve Test Menu illustration ooooooncnoncconnninnnccns 60 Voltage Regulator board AA 10 Z Zero alt SCrUDbER caca 16 Zero MEASUIE aber e ies e 20 63
34. cover to the heatsink and lift the cover off the heatsink It may be necessary to loosen the crossbar or mounting bracket to remove the PMT housing cover 4 Disconnect the HVPS Preamp from the PMT and remove the PMT from its housing Refer to Figure 15 Figure 15 Cooler Replacement Important Note the orientation of the red and black cooler wires as they relate to the PMT housing heatsink The new cooler must be installed in the same way 98527601 Rev C 35 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL 36 10 11 12 13 From the underside of the heatsink remove the two screws that secure the PMT cold block to the heatsink and remove the cold block Refer to Figure 15 Remove the cooler from the heatsink and disconnect the cooler from the electrical connector Note If corrosion or moisture is detected inside the PMT housing assembly then the desiccant replacement interval should be reduced replace the desiccant more often Clean the cooler facings of the heatsink and PMT cold block and recoat with a thin layer of heatsink compound Dow Corning 340 or equivalent Install the new cooler in place on the PMT housing being careful to align it in the notch on the PMT cold block Ensure the orientation of the red black wires on the cooler are red on the right and black on the left when viewed from the wire side of the cooler Place the PMT cold block and cooler on the heatsink and secure with the screws
35. dures Following is a list of routine maintenance procedures which may be required through the life of the analyzer Recommended equipment to perform maintenance 22 98527601 Rev C CHAPTER 3 MAINTENANCE Toolbox Oscilloscope Digital multimeter DMM Computer or remote data terminal and connection cable for RS232 communi cation Pressure transducer absolute and connection tubing calibrated in torr Flowmeter 2 slpm nominal Wire strippers Soldering iron Minifit extraction tool Orifice removal tool Assortment of 1 4 and 1 8 tubing and fittings Test zero air source Test span gas source Leak tester LU UU 0 LU UU UU DUU UU Figure 8 Routine Maintenance Components 3 3 1 Check Particulate Filter The inlet filter prevents particulates from entering the pneumatic components of the EC9852 Contamination of the filter can result in degraded performance of the EC9852 including slow response time erroneous readings temperature drift and various other problems 98527601 Rev C 23 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL Several factors affect the filter replacement schedule In the springtime for example the filter might accumulate pollens and dust 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 po
36. e See section 3 3 10 Converter H2S 1 Verify the molycon concverter is 305 to Molycon 325 C 2 Verify that the efficiency of the molycon converter is higher than 9685 See the EC984152 Operation Manual 3 Replace Service the molyconconverter Converter HTO 1 Verify the converter is 795 to 805 C 2 Verify that the efficiency of the converter is higher than 85 See the EC9852 Operation Manual 3 Service the converter Leaks A leak dilutes the sample stream and causes low span readings and noise See section 3 3 10 No flow Check the INSTRUMENT STATUS MENU and verify flow 6 No response to Software lockup 1 Observe whether ECOTECH GLOBE on the span gas display is turning 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 on the Microprocessor Board Leak A leak dilutes the sample stream and causes low span readings and noise See section 3 3 10 Charcoal saturated Replace the charcoal 7 Zero drift Failed cell control The cell temperature SYSTEM TEMPERATURES heater screen should be 50 5 C Reference voltage Perform UV lamp check and adjustment INSTRUMENT STATUS screen not at 2 5 V 8 Unstable flow High voltage won t Check to see if the high voltage adjust or pressure reach 700 V potentiometer is at 99 If it is the high voltage readings 10 V power supply m
37. e analog to digital A D converter for microprocessor use Digital to analog D A conversion of three channels is used to send O to 20 mA analog signals to the 50 pin I O connector 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 vv Figure 4 System Block Diagram 11 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL PART ICULATE FILTER CHARCOAL CANISTER CHARCOAL CANISTER HIGH VOLTAGE POWER SUPPLY amp PMT HOUSING INLET PORTS F PUMP FAN KICKER amp LAMP FLUORESCENCE HOUSING CELL VALVES PRE PROCESSOR BOARD FLOW CONTROL BOARD MODULE REFERENCE DETECTOR FAN VOLTAGE REGULATOR BOARD MICROPROCESSOR BOARD S BATTERY POWER SUPPLY FRONT Figure 5 Major Components REAR FRONT REAR Figure 6 Major Components H2S with external converter 12 98527601 Rev C CHAPTER 2 THEORY OF OPERATION 2 1 2 Sensor Module 2 1 98527601 Rev C T
38. e connection see Figure 3 Figure 3 Cable Connections EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL This page is intentionally left blank 8 98527601 Rev C CHAPTER 2 THEORY OF OPERATION 2 0 Theory of Operation 98527601 Rev C The EC9852 Sulfur Compound analyzer is based on classical fluorescence spec troscopy principles Sulfur dioxide exhibits a strong ultraviolet absorption spectrum between 200 and 240 nm Absorption of photons at these wavelengths results in the emission of fluorescence photons at wavelengths between approxi mately 300 and 400 nm The amount of fluorescence emitted is directly proportional to the SO concentration These characteristics are exploited by the EC9852 SO analyzer UV radiation at 214 nm from a zinc discharge lamp is separated from the other wavelengths in the zinc spectrum by a UV bandpass filter The 214 nm radiation is focused into the fluorescence cell where it interacts with SO molecules in the beam path The resulting fluorescence is emitted uniformly in all directions A portion of the fluorescence i e that emitted perpendicularly to the excitation beam is collected and focused onto a photomultiplier tube A reference detector monitors the emission from the zinc lamp and is used to correct for fluctuations in lamp intensity The 9852 analyzer uses the advanced digital Kalman filter This filter provides the best possible compromise between response time and noise reduct
39. ent was achieved PCA ZERO POT LIMITED TO Zero voltage controller Reset analyzer check zero 0 OR 99 reached limits before voltage air source reached set point REF POT LIMITED TO Reference voltage controller Check UV lamp 0 OR 99 reached limits before reference voltage reached set point ZERO FLOW Instrument flow has gone to The pump has failed or a Zero flow obstruction has occurred Replace pump or clear obstruction 52 98527601 Rev C 98527601 Rev C CHAPTER 4 TROUBLESHOOTING Message SPAN RATIO lt 0 75 SPAN RATIO gt 1 25 ELI ECTRONIC ZERO ADJUST BACKGROUND CYCL GJ RESET DETECTION AZS CYCL E DATA LOGGING MEM FAIL CONTROL LOOP RESTARTED VALVE SEQUENCING RESTARTED Event Log Messages Description After AZS cycle ratio of requested span to measured span is lt 0 75 After AZS cycle ratio of requested span to measured span is gt 1 25 An analyzer electronic zero cycle was initiated Background cycle started The value of the result of the previous background is stored here Reset button pressed or watchdog timer caused reset AZS cycle started Occurs if unable to write to datalogging memory Occurs when Control Loop has been disabled and then automatically enabled after the main screen has been visible
40. er component locations immediately follow the Troubleshooting Guide Troubleshooting Voltage Table set TO Microprocessor 12V GOOD TP1 TP2 5V 0 5V 10V TP3 10V 0 5V 20V TP4 20V 0 5V Voltage TP7 AGND TP9 12V 0 5V Regulator TP8 10V 0 5V TP6 10V 0 5V TP4 5V 0 25V Preamp Pressure 10V TP2 AGND J1 4 10V 0 5V 10V J1 5 10V 0 5V Preprocessor TP1 AGND 12V 0 5V 5V 0 25V 10V 0 5V 10V 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 correct operating range 4 2 Troubleshooting the EC9852 Analyzer Because of the sophisticated design of the EC9852 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 o PREPROCESSOR POTS o VALVE TEST MENU 98527601 Rev C 49 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL EVENT LOG INSTRUMENT STATUS SYSTEM TEMPERATURES Q 0 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 c
41. from the underside of the heatsink Ensure the shoulder washers and neoprene washers are properly in place around the screws Caution Alternately tighten each of the screws securing the PMT cold block to the heatsink approximately 1 4 turn until the PMT housing and heatsink are secured flush with the cooler face and the screws are snug Do not overtighten Connect the cooler wires to the electrical connector red wire to pin 13 and black wire to pin 12 Reinstall the PMT housing cover ensuring that the O ring on the base of the cover remains in place Install two new desiccant packs in the PMT housing Reconnect the desiccant access cap electrical connector and reinstall the access cap 98527601 Rev C CHAPTER 3 MAINTENANCE Caution Do not attempt to install the desiccant cap into the PMT housing by using the screws to pull the cap into place This will damage the PMT housing A small amount of lubricant on the desiccant cap O ring will facilitate its installation 14 Reassemble the Rx cell PMT housing and reinstall in the analyzer 3 3 10 Leak Test Procedure This is a test for the pneumatic system of the instrument The display readings will indicate whether the system is leaking Note This procedure applies only to the instrument It does not include the EZS valve option The EZS valve option if included in the instrument must be disabled to perform this test 1 E
42. gnal from the reference detector to a voltage signal and provide amplification Preamp Pressure PCA This assembly is located at the end of the fluorescence cell as noted in Error Reference source not found The reference preamplifier detector portion of the board converts the current from the UV detector to voltage and amplifies it to a waveform proportional to the reference signal The pressure flow portion of the board contains an absolute and a gauge pressure transducer to measure cell pressure and detect sample flow 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 PMT High Voltage Supply and Preamplifier This is a single component within the PMT housing Its function is to supply high voltage to the PMT and to amplify the photocurrent signal from the PMT Preprocessor PCA This circuit board contains the analog electronics that condition the reference detector and PMT signals generate the lamp control and modulation signals and all the signals required for preamp optic and electronic test diagnostic functions It also contains a heater control circuit to heat the measurement cell to 50 C The board also contains an EAROM which contains device identification and stored setup parameters All circuitry adjus
43. he sensor module can be divided into three areas of description pneumatics optics and electronics 2 1 Pneumatics The pneumatics 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 7 Error Reference source not found The pump causes sample air to be drawn into the sample inlet and through the 5 micron particulate filter From the valve manifold the sample stream enters the hydrocarbon kicker described in more detail in the following paragraphs where possible hydrocarbon interferents are removed After being scrubbed of hydrocarbons the sample enters the fluorescence cell where the SO measurement is accomplished During the startup and auto zero cycles sample is switched by the valve manifold to zero air from the zero air scrubber and into the measurement cell This provides the analyzer with a stable reference of zero air to automatically correct for zero baseline changes o Particulate Filter The particulate filter is designed to remove particles larger than 5 micrometers and to expose the sample to only non reactive materials of Kynar Teflon and Viton The filtering agent is a 47 mm diameter 5 micron filter The filter body is made from Teflon The filter is held in the body by a Viton O ring and backed by a Teflon screen 13 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL
44. heck Calibrate Service Manual 3 5 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 Replacement interval determined by ambient SO levels Humid conditions nay necessitate more frequent replacement 20 98527601 Rev C CHAPTER 3 MAINTENANCE 3 2 Replaceable Parts EC9852 Analyzer Spare Parts Requirements PCA Reference Detector 98100039 Valve manifold assembly 98300037 Flow control assembly 98300046SP1 Cooler thermoelectric 98412028 3 SP Thermistor assembly 98412028 4 SP Kicker assembly hydrocarbon scrubber 98520036 2 Description Level Desiccant 5 gram pack 4 required 1 Charcoal activated 2 pound bulk container 1 Filter element 5 micron consumable 50 each 1 Lamp assembly ultraviolet 2 Filter glass U330 3 Filter ultraviolet 3 O ring plano convex lens 3 O ring reaction cell cover plate 3 O ring U330 3 Heat sink compound 3 O ring desiccant cap 3 O ring adapter reaction cell collar 3 O ring reaction cell to optical bench 3 O ring ultraviolet filter 3 Extraction tool minifit connectors 3 Photomultiplier tube 3 PCA Voltage Regulator 3 Display switch assembly 3 PCA 50 Pin VO PCA Microprocessor SMD 3 PCA USB Board Assembly 3 Power supply 115 230 VAC to 12 VDC 3 Orifice 10 mil 3
45. ion for the type of signal and noise present in ambient air analyzers and their application Ecotech s implementation of this filter enhances the 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 This form of SO analysis allows an expansion of analysis into other Sulfur compounds The EC9852 coupled with a High Temperature Thermal Oxidizer HTO or H2S converter can convert other sulfur compounds into SO allowing them to all be analyzed by the same process The basis of this new analysis is that the EC9852 Hydrogen Sulfide H2S analyzer is fitted with a H2S converter or attached to the modified H2S 1100 converter externally that converts H2S into SO but does not convert other sulfur compounds such as Dimethyl disulfide CH3 2S2 Dimethyl sulfide CH3 2S and Methyl mercaptan CH4S This analysis coupled with a plain SO analysis can allow the levels of H2S present in the sample to be assessed by subtracting the total SO measured after the H2S conversion by the ambient SC from a plain Background sample EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL 10 The EC9852 Total Sulfur TS analyzer uses a HTO to convert
46. irmware 1 03 0008 S Date Friday 9 January 2004 3 31 07 PM Size KB 244 Figure 20 Firmware Update firmware selection screenshot 6 Click Next 7 Tick the boxes as shown in the figure below Firmware Update Select the operations you wish to perform Enter bootloader Erase Flash ROM Erase EEPROM Erase RAM Upload Firmware Run Firmware H RHUU RR Previous Figure 21 Firmware Update operations screenshot 8 Ensure the analyzer is switched off using the switch under the front panel 9 Click Start 10 Switch the analyzer on 98527601 Rev C 47 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL 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 RS 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 22 Firmware Update completion screenshot 48 98527601 Rev C CHAPTER 4 TROUBLESHOOTING 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 oth
47. l the leads from the UV lamp should be pointed toward the top of the housing Loosely secure the UV lamp holder with the captive screws Note UV lamp bodies may vary in diameter It may be necessary to add or remove a layer of heat shrink plastic from the UV lamp body to obtain a proper fit 6 Connect the UV lamp to J1 of the Lamp Driver PCA 7 Turn the analyzer on and adjust the UV lamp refer to 3 3 5 1 8 Tighten the UV lamp cover screws and reinstall the kicker and cover plate 3 3 6 PMT Desiccant Pack Replacement The PMT housing contains two desiccant packs to prevent condensation on the cooled PMT housing If the desiccant expires it will result in corrosion of the PMT housing and premature cooler failure It is recommended that the desiccant bags be changed at least annually If moisture is detected inside the housing or the desiccant packs are saturated the interval should be reduced To change the desiccant packs perform the following Caution Because the PMT is extremely sensitive to light it is essential that before opening the PMT assembly to make sure that the analyzer is switched off In addition even when the analyzer is switched off is very important to cover the PMT at all times so that no direct light reaches its window 1 Turn the analyzer off and disconnect power 2 Using an offset Phillips head screwdriver remove the desiccant pack access cap from the PMT housing Note Removal of the desiccant a
48. le 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 respective menu and examine the pertinent potentiometer settings 4 2 6 System Temperatures SYSTEM TEMPERATURES CELL TEMP E 53 DEG C CHASSIS TEMP DEG C FLOW TEMP DEG C COOLER TEMP S DEG C Figure 27 System Temperatures and Tolerances The SYSTEM TEMPERATURES screen provides the temperatures of the fluorescence cell the chassis and the thermoelectric cooler used to cool the PMT Figure 27 contains the nominal values that should be displayed on this screen If any of the parameters are outside the acceptable ranges a 54 98527601 Rev C CHAPTER 4 TROUBLESHOOTING 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 98527601 Rev C 55 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL 56 4 2 7 System Faults The sysTI EM FAULTS display is a pass fail indication of 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 the affected
49. llutants 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 24 98527601 Rev C CHAPTER 3 MAINTENANCE 3 3 2 Particulate Filter Replacement Procedure Use Figure 9 as reference when performing the 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 Remove the tubing from the front of the particulate filter 3 Unscrew and remove the 3 thumb screws Remove the filter cover and attached plate 4 Remove the O ring and the filter Discard the filter and save the O ring 5 Place a new filter over the Teflon screen and replace the O ring 6 Position the filter cover over the filter aligning the holes and install the three thumb screws Snug all three screws then tighten firmly with finger pressure 7 Reattach the tubing to the filter housing 8 Return the Pump to ON 9 Close the Front Panel Figure 9 Particulate Filter Replacement 98527601 Rev C 25 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL 26 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
50. meter settings associated with several components variables or signals on the Flow 50 98527601 Rev C CHAPTER 4 TROUBLESHOOTING Control board Figure 24 illustrates a typical test screen for an instrument that is operating normally Like PREPROCESSOR POTS the value of the potentiometer settings is somewhat arbitrary Potentiometer settings 99 and 0 however represent the extreme limits of the potentiometer range and may be reason to suspect a problem FLOW CONTROL POTS FLOW CONTROL ZERO 81 50 90 FAN SPEED CONTROL 16 0 99 PUMP SPEED FINE 85 0 99 PUMP SPEED COARSE 36 20 60 GAS FLOW 0 505 SLPM GAS PRESSURE 585 6 TORR Figure 24 Flow Control Pots Range 4 2 3 Valve Test Menu VALVE TEST MENU INT VALVE 1 CLOSED INT VALVE 2 OPEN INT VALVE 3 CLOSED AUX VALVE 2 CLOSED EXT MEASURE CLOSED EXT ZERO GAS CLOSED EXT SPAN GAS CLOSED VALVE SEQUENCING ON Figure 25 Valve Test Menu The VALVE TEST MENU see Figure 25 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 See the EC9852 Operation Manual for a key to the valve names used in the menu 9852760
51. nter the TEST MENU and select OUTPUT TEST MENU then VALVE TEST MENU from these items pick VALVE SEQUENCING and set to OFF Ze Set all valves to CLOSED ES 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 re calibration Return the Pump Switch to on 5 Plug the INLET and AUXILIARY ports on the rear panel Also plug the inlet of the zero air canister located behind the Front Panel 6 Verify cas FLOW in the FLOW CONTROL POTS screen reads 0 00 If the reading is not 0 00 the leak is somewhere between the valves and the flow block 98527601 Rev C 37 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL T7 Press lt Pg Up gt and select the VALVE TEST MENU Set INT VALVE 1 to OPEN return to the FLOW CONTROL POTS screen and verify GAS FLOW 0 00 SLPM If the reading is not zero the leak is in the measure sample line 8 Return to the VALVE TEST MENU Close the INT VALVE 1 and open the INT VALVE 2 Return to the FLOW CONTROL POTS screen and observe the flow reading If the reading is not zero the leak is in the zero air line 9 Return to the VALVE TEST MENU Close the INT VALVE 2 and open the INT VALVE 3 Return to the FLOW CONTROL POTS screen and observe the cas FLOw If the reading is not zero
52. obtained After the reference voltage is set it is not adjusted again until another auto startup routine is performed or the reference voltage goes below 1 volt or above 4 volts 2 2 1 2 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 potentiometer is then adjusted until a concentration voltage of just above 0 00 volts is obtained This is the analyzers coarse zero adjustment Once this is set it is not readjusted until another auto startup routine is performed or the concentration voltage is sensed to be below 0 1 volts 2 2 1 3 Background Background allows the analyzer to sample zero air and measure the level of the concentration voltage This voltage is taken as the zero signal level and this value is subtracted from any subsequent readings as an active zero compensation 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 or when another auto startup routine is performed 98527601 Rev C 17 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL 18 2 2 1 4 Sample Fill Measure After the background the analyzer is switched into the SO Sample Fill mode where the reaction cell is filled with sample gas and finally to
53. or controls the pump speed via the flow control pots to give the desired flow rate When DISSABLED the user can 40 98527601 Rev C CHAPTER 3 MAINTENANCE manually adjust the pump speed using the flow control pots For the standard flow block only 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 GAS PRESSURE Current gas pressure measured from the flow controller GAS FLOW Current gas flow measured from the flow controller 3 5 Pressure 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 The following procedures cover both the STANDARD and Iso B flow block types For both procedures the following equipment is required e Digital Volt Meter e Pressure transducer absolute calibrated in torr e Flowmeter 1 slpm nominal e 1 fitting with hose to suit pressure transducer 98527601 Rev
54. orrective 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 25 70 REFERENCE ZERO 50 MEASURE GAIN 50 REFERENCE GAIN gt 5 95 TEST MEASURE 0 HIGH VOLTAGE ADJUST 60 70 LAMP ADJUST 80 90 REF VOLTAGE 1 0 4 0 VOLTS S02 0 20 PPM CONC VOLTAGE 0 0 4 2 VOLTS HIGH VOLTAGE 690 710 VOLTS Figure 23 Preprocessor Pots and Ranges The TEST MENU OUTPUT TEST MENU PREPROCESSOR POTS screen displays the potentiometer settings associated with several components variables or signals on the preprocessor board Figure 23 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 The FLOW CONTROL POTS screen displays the potentio
55. play Check the interface cable between the display and J6 on the microprocessor board Bad display or 1 Replace the front panel display Microprocessor PCA 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 External Valves Select CALIBRATION EXTERNAL from the installed but not CALIBRATION MENU selected Leaks A leak dilutes the sample stream and causes low span readings and noise See section 3 3 10 Lamp not correctly Adjust the UV lamp If you are unable to obtain an positioned acceptable reading replace the lamp 98527601 Rev C 59 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL System Troubleshooting Table Symptom Possible Cause Fault Isolation Solution 4 Noisy or TE cooler or Rx cell A failed temperature control allows the instrument unstable readings heater zero to drift with ambient temperature Verify that the cell temperature is 50 3 C and that the TE cooler is 10 2 C Span setting Adjust the span using the calibration procedure in the EC9852 Operation Manual See the Zero flow symptom in this table 5 Low span Leaks A leak dilutes the sample stream and causes low span readings and nois
56. ptive screws that secure the kicker to the UV lamp housing Gently move the kicker backward away from the UV lamp 4 Loosen do not remove the captive screws securing the UV lamp holder to the housing Refer to Figure 11 29 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL Figure 11 UV Lamp Replacement Physically adjust the UV lamp rotate and move left and right until the maximum peak voltage on the oscilloscope is obtained not to exceed 2 volts peak The minimum usable output from the lamp is about 0 25 volts peak If the UV lamp output is below 0 5 volts then replacement should be considered Tighten the UV lamp holder screws and verify the UV lamp has remained at its previously adjusted position Reinstall the kicker assembly and the UV lamp access cover Reset the analyzer and allow it to run a startup sequence 3 3 5 2 UV Lamp Removal and Replacement 1 2 30 Turn the analyzer off Remove the UV lamp access cover and remove the two captive screws that secure the kicker to the UV lamp housing Gently move the kicker backward away from the UV lamp Disconnect the UV lamp from J1 of the Lamp Driver PCA Loosen the two captive screws which secure the UV lamp in the holder Swing down the UV lamp holder and remove the UV lamp from the housing Refer to Figure 11 98527601 Rev C CHAPTER 3 MAINTENANCE 5 Position the new UV lamp into the housing ensuring the Max Output side is toward the Rx cel
57. r Updated language company address and PDF links All 2006 created C August 09 Removed B series information and references to a various 98527601 Rev B series which is now standard EC9852 SO 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 EC9852 is compliant with the requirements of EN61010 1 A2 1995 Safety Re quirements for Equipment for Measurement Control and Laboratory Use If the equipment is used for purposes not specified by the manufacturer the protec tion 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 remov ing or replacing any components Equipment Rating O O O O O 100 120 220 240V 10 50 60 Hz 250 VA max 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 Ecotech Pty Ltd 1492 Ferntree Gully Rd Knoxfield Australia VIC 3180 Phone 61 1300 364 946 Fax 61 1300 668 763 Email Service ecotech ecotech com au Email Spare Parts parts ecotech com au Web
58. ration 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 4 for further details CRITICAL ORIFICE Designated flow rate of the critical orifice installed in the ISO B flow block For the EC9852B this should be set to 0 650 unless otherwise specified DESIRED FLOW Desired flow rate that the standard flow block will maintain a constant flow at FLOW SPAN POINT During the flow calibration of the standard flow block this is where 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 microprocess
59. round tesina insti 19 Background auto zero 21 Block diagramm c ccccsieccessecscceaeveeceessadeccdeaveesencasdeess 10 C Cable Connections Oollustraton 7 Charcoal scrubber maintenance ocooccccccnoninonnnnncnnss 30 CO CO2 converter 17 Cooler Replacement Ollustratton 42 Cooler replacement DMT eee ceeeeeeee eee 42 D Data Logging nnan ES 62 Desiccant pack replacement eseeseesteereeeeeees 36 DFU replacement ee ee eee cssecsecseecreeeeeeeeees 33 Diagnostic modes cococoocconoccnoncnncononncononononannncnnonacnnos 65 E Electric test functHon cc ccceceessessseseeeseesseseseees 65 Electronic Zero adjust c oooooococcnocnococonoconcconccnnonnos 19 21 Electronics kA ENNER ENEE 18 Event Loge oidor 60 F Fan filter cleaning seriinin 30 Filter maintenance occcncononnnonoconanananaccnononannnanononos 27 Filter optical bandpass ccesesseeseeceeeeeeseeeeeees 17 Filter UV bandpass c cescceseeseeeseceeeeneeeeeeneees 17 Elo Won 17 Flow Pressure board calibration 46 47 H Hydrocarbon Kicker 16 I Illustrations Cable Connectong H Illustrations Cooler Replacement ooooncnccnicncccnncnnon 42 Illustrations Instrument Status Ranges 46 50 51 53 54 62 Illustrations Major Components occooccconoccconinncnncnnos 13 Illustrations Opening the Front Panel 5 Illustrations Orifice Removal sosssoeoneeeses0e00s000e 34 Illustrations Pneumatic Diagram
60. s fail Functional problems can be isolated to a single component by logical use of the diagnostic modes 4 4 Troubleshooting Guide Use this troubleshooting guide to find the symptom then follow in order the possible causes and fault isolation solutions until the problem is discovered Then 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 58 98527601 Rev C CHAPTER 4 TROUBLESHOOTING 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 contrast by misadjusted 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 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 If incorrect voltages are found replace the power supply or Vreg 3 Check Microprocessor test points listed in the Troubleshooting Voltages table table in section 4 Dis
61. switch is not a toggle switch and is only activated when pressed It re sets 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 ana lyzer When the Service switch is set from OUT to IN the instrument returns to the normal operating conditions Captive screws 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 dislodged or cables disconnected follow the instructions below 6 98527601 Rev C 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 98527601 Rev C 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 ca ble connector into the mating connector until a click is heard Then fold the retainers inward to secure th
62. tments are made via microprocessor controlled digital potentiometers Lamp Driver PCA The lamp driver contains a high voltage switching supply to start and maintain the UV lamp at a constant intensity This board is under the control of signals from the preprocessor PCA 98527601 Rev C CHAPTER 2 THEORY OF OPERATION 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 requires about 40 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 Adjust Reference adjust allows the gain of the preprocessor reference channel to be adjusted for the proper reference voltage level the reference voltage is proportional to the intensity of the UV lamp Prior to any adjustments being made the UV lamp is first allowed to stabilize for approximately 10 minutes After 10 minutes the preprocessor reference gain potentiometer is adjusted until a reference voltage of 2 5 0 2 volts is
63. tor is computed from the upstream and downstream pressures Since the pressure transducers used are temperature sensitive they are mounted in a temperature controlled block The sample air is then mixed with approximately 1 5 2 3 slpm of externally supplied zero air from the bypass jacket of the kicker This flow is then exhausted through the exhaust port of the instrument 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 2 1 2 2 Optics The optics in the 9852 analyzer consist of a discharge zinc UV lamp a Fabry Perot 214 nm UV bandpass filter UV grade fused silica lenses a colored glass 350 nm optical bandpass filter a UV sensitive photomultiplier tube and a solid state UV reference detector
64. www ecotech com au 98527601 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 Ship ments 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 per forming the following procedure 1 1 1 Remove the Top Cover Grasp the front top corners of the front panel and pull 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 GLB GA Bled Clo Pla TAS Figure 1 Opening the Front Panel 1 1 2 Service Switch 98527601 Rev C 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 EC9852 SULFUR COMPOUNDS ANALYZER SERVICE MANUAL DC PowerON Pump ON Service IN The Reset

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