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EC9832 Service Manual

1. 4 2 5 Instrument Status INSTRUMENT STATUS GAS FLOW 2 1 4 gt 1 26 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 03 0002 Figure 31 Instrument Status and Ranges 98320005 Rev B CHAPTER 4 TROUBLESHOOTING The INSTRUMENT STATUS screen provides information about several critical parameters in the EC9832 If any of the parameters displayed on the INSTRUMENT STATUS screen Vary significantly from the values shown in Figure 31 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 Several of the parameters displayed on the INSTRUMENT STATUS screen are affected by the potentiometer settings on the PREPROCESSOR POTS screen Ifa 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 SYSTEM TEMPERATURES CELL TEMP CONV TEMP CHASSIS TEMP FLOW TEMP COOLER TEMP MIRROR TEMP Figure 32 System Temperatures and Tolerances The SYSTEM TEMPERATURES screen provides the temperatures of the measurement cell the chassis temperature and the thermoelectric cooler temperature used to
2. ER FAI JURE REE ERENCE VOLT 12 V FAT RANGE URE AGE OU H OLT SU T OE PPLY ERATURE FAIL CONVE RTER ERATURE FAIL MIRR OR ERATURE FAIL URE 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 gauge pressure from the Pressure PCA is less than 20 torr bad pump or plugged orifice or greater than 200 torr plugged inlet Can also occur if the sample inlet is pressurized 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 Indica
3. a aaiaaiaavass svassavaana 17 Optics system Components aiaiiaiiaaiaaaiasssassaasaaai 16 Optodecoder circuit a iaaaavaaiaavassasaassasaasassaavaaaa 19 Orifice replacement a aaaaaaanvasvassassasaasanaaasaana 29 P Particulate filter maintenance a ava aaa vai aa 27 Periodic maintenance aaaisaas ssaasassassassaaaana 23 Pneumatic Diagram illustration 14 15 Power microprocessor module 2aaisisaisiaiani 10 Preamp test functiOon 2 aaiaiaiaaiaiasassssssasassnansaaani 55 Preamp Pressure board iaaiaaianiasisassanssssasaasani 19 Preamplifier board a aaiaaananiasassssssssassssassssnsanani 19 Preprocessor board aaaiaaaaiaasaniasaasaasansasnansannanannani 19 Preprocessor Pots and Ranges illustration 49 Preprocessor Pots Menu aaaiaaaaaaaiasi sasnassaseasannani 49 R Replaceable parts 11 svasa i i sva rn 48 Routine maintenance aaavaaaaavassasvssssssasasaaaaaa 26 S Sensor module ni 14 Service switches aaiaaaasaaiaaaaiansanaaaaannanaanaadaasanaaaaaa 6 EC9832 CO ANALYZER SERVICE MANUAL Sintered filter replacement 2 aaiaisaisiasassaia na 29 Sintered Filter Replacement illustration 30 Spare A i M aassum 48 System Faults display aaaaiaaiasaasass sassssssssassnsana 53 System Temperatures and Tolerances illustration 53
4. aaaaiaaaaixaaaiaaanaaanniunanniananaaanniaannaaai 33 D Detector signal adjustment a aavaiai sai sssani 31 Detector Signal Adjustment illustration 32 DFU replacement bsibsunaiiksskkgaaund altkeu 29 Diagnostic modes a2iaaaaaaaaaaaaaisasaasasaananaaananaaaaaa 55 E Electric test function aaaaisasasasasansnassnsnanaaas 55 Event Log acces had r 50 F Fan Hiltercle Mirmo 28 Filter maintenance aaaaaaaaaaaaaasaasssssnssasnasnsnsnanas 27 Filter narrow bandpass a a aaiasaaissssassssasassssssasani 18 Flow Pressure board calibration 37 38 G Gas filter correlation wheel a aaaaasasssssssssani 17 Gas Filter Correlation Wheel illustration 18 I Illustrations Cable Connections ocococcccncnccnnnonnnnnonos 7 Illustrations Correlation Wheel Motor IR Source GA O 33 Illustrations Detector Signal Adjustment 32 Illustrations Gas Filter Correlation Wheel 18 Illustrations Instrument Status and Ranges 52 Illustrations Instrument Status Ranges 37 40 41 43 44 Illustrations IR Detector Replacement 34 Illustrations Major Components 2 aiaiaaaai 13 Illustrations Opening the Front Panel 5 Illustrations Optical Path 22iaiaasvasssassssssasani 17 Illustrations Pneumatic Diagram 1
5. Record the front panel CO reading as the challenge value Compare the CO initial value and the challenge value They should agree within 0 2 ppm If the initial value is more positive than the challenge value the CO CO converter should be replaced Disconnect the challenge zero air and reconnect the sample line to the Sample inlet of the analyzer Verify that the analyzer is in the SAMPLE MEASURE mode 3 3 7 Detector Signal Adjustment 98320005 Rev B 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 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 16 31 EC9832 CO ANALYZER SERVICE MANUAL Figure 16 Det
6. Display switch assembly PCA Microprocessor SMD PCA 50 Pin YO Power supply 115 230 VAC to 12 VDC Orifice 14 mil B 98000180 13 _ Extraction tool filter and orifice B 98000190 Service kit pump B 98000242 Flow pressure assembly B 98107012 28P Flow control assembly PCA USB Board Assembly PCA Preprocessor Preamplifier detector assembly Motor correlation wheel Reflector optical interrupter Valve manifold assembly Source timing assembly Heater thermistor assembly Correlation wheel assembly A amp B 98300084 jm WHIWIWIWIWIWMIWINWINWINWINWIMNWINWI WI WIWI WIHWIJIWIWIWIlIHI WlJIWIWIlIWIWI NIN 98320005 Rev B CHAPTER 3 MAINTENANCE 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 EC9832 Analyzer Spare Parts Requirements Options and Accessories Description Part Number Pump external 115V 60 Hz 4 slpm at 20 inches Hg NES 884 017300 Pump external 110V 50 Hz 4 slpm at 20 inches Hg B 884 017301 Pump external 230V 50 Hz 4 slpm at 20 i
7. For the B series Analyzer you will need to disconnect the external pump 2 Completely unthread the filter cap by turning it counterclockwise 3 Pull the 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 98320005 Rev B CHAPTER 3 MAINTENANCE 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 3 3 4 DFU Replacement The zero air entering the CO CO converter is filtered by a disposable filtration unit DFU to prevent contamination of the pneumatics and measurement cell Failure of the DFU could result in poor zero readings or cell contamination This filter is located inside the analyzer connected to the rear of the CO CO converter To replace the filter 1 Turn off the pump 2 Remove and retain
8. Turn off the pump and allow to settle for 2 minutes Select the INSTRUMENT STATUS menu and record the GAS PRESSURE reading as the current ambient pressure 3 Plug the Sample inlet port 4 Turn on the pump and allow it to operate for 5 minutes to evacuate the pneumatics 5 Selectthe INSTRUMENT STATUS menu and monitor the GAS FLOW and GAS PRESSURE readings After 5 minutes the GAs rLow should indicate 0 00 slpm and the GAS PRESSURE should be equal to the ambient pressure vacuum capacity of the pump 15 torr 2 kPa see following conversion Note To convert vacuum capacity to equivalent atmospheric pressure perform the following calculation Current ambient pressure torr Vacuum Hg 25 32 Or Current ambient pressure kPa Vacuum kPa 6 Unplug the Sample port and reconnect the sample line If a leak is detected attempt to isolate the leak by using the VALVE TEST MENU and the pneumatic diagram to select and close off different sections of the analyzer 98320005 Rev B CHAPTER 3 MAINTENANCE Caution Do not use pressure to isolate leaks Pressure in excess of 5 psi will damage the pressure transducers The actual flow through the analyzer should be checked by turning on the exhaust pump and connecting a flowmeter to the Measure inlet ensure that the analyzer is in SAMPLE MEASURE Actual flow through the analyzer should be approximately 1 slpm If flow is too low perform
9. Verify that your instrument is in operating condition by performing 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 M MONITOR LABS INC ME xx xx ER W Figure 1 Opening the Front Panel 98320005 Rev B 5 EC9832 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 1s 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 SECONDAR
10. 99 85 0 99 62 20 60 1 500 SLPM 585 6 TORR VALVE TEST MENU VALVE 1 VALVE 2 VALVE 3 MEASURE ZERO GAS SPAN GAS VALVE 1 VALVE 2 Figure 30 Valve Test Menu OPEN CLOSED CLOSED CLOSED CLOSED CLOSED CLOSED CLOSED ON ENU see Figure 30 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 EVENT LOG indicate an error it will also provide information as to the Should the 1 portion or component of the instrument which is at fault 98320005 Rev B 98320005 Rev B RAM CHI FAILURI Y EAROM X DATA ERROR SERVICE ACTIVATED SWITCH LCD DISPLAY BUSY A D CONVERSION ERROR SYS FAILURE EM POWE SYSTEM POWE RESTORED ZERO TO 0 OR 99 INPUT TO 0 OR 99 ZERO FLOW SPAN RATIO SPAN RATIO ELECTRONIC ADJUST BACKGROUND POT LIMIT is J POT LIMITED lt 0 75 S1
11. CONVERTER l E AN H i nu 1 OPTIONAL N h HIGH PRESSURE N l SPAN VALVE i AIR t INTAKE a NARROW i BANDPASS i A FILTER i LA I R DETECTOR i OPTIONAL AND PREAMP 1 EZS VALVE i l MANIFOLD pr l l 4 WY N N ol FLOW PRESSURE Ly ut MODULE Wr CHASSIS FAN LEGEND ELECTRICAL PNEUMATIC IN i y x NK EX MICRO PROCESSOR BOARD ASSY FRONT PANEL Al CONTROLS pore AND A uy OUTPUTS Figure 5 System Block Diagram B Series 98320005 Rev B CHAPTER 2 THEORY OF OPERATION GAS FITTINGS 7 VALVE MANIFOLD Co Co CONVERTER gt MOTOR PART ICULATE OPTO DETECTOR FILTER OS B M PUMP MEASUREMENT CELL FAN ux a 2 DETECTOR lt L O FLOW CONTROL BOARD MODULE uy ac aa LE PRE PROCESSOR BOARD VOLTAGE REGULATOR BOARD POWER SUPPLY BATTERY MICROPROCESSOR BOARD A Figure 6 Major Components A Series GAS FITTINGS 7 VALVE CO CO2 CONVERTER MANIFOLD MOTOR OPTO DETECTOR SOURCE F Pl MEASUREMENT CELL FAN DETECTOR FLOW CONTROL BOARD MODULE PRE PROCESSOR BOARD i L VOLTAGE REGULATOR BOARD
12. 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 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 v
13. LOOP ENABLED PUMP SPEED COARSE 28 GAS PRESSURE 710 0 TORR GAS FLOW 1 000 SLPM Figure 20 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 Allow 30 seconds for the pressure reading to stabilise 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 J Note to convert from millibar to TORR multiply the pressure by 0 75 Set the CONTROL LOOP TO DISABLED and press Enter gt J This will disable the flow control loop Connect the calibrated pressure transducer to the sample inlet on the rear panel of the analyzer 98320005 Rev B 10 11 CHAPTER 3 MAINTENANCE Turn the pump ON from the secondary panel Set the PUMP SPEED COARSE to 99 and press Enter gt J 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 Set this reading in TORR as PRESSURE 1 LOW in the PRESSURE CALIBRATION MENU and press Enter gt J Disconnect the pressure transducer from the inlet and turn the pump OFF To verify that the pressure transducers on the standard flow control board are calibrated view
14. System Temperatures screen aaaiiaiaaississiasinir 53 T Theory Of operation iiaiaiaaiaissasassasassssasassssassnanaa 9 TroubleshootiN8 ccononconocnccnoncnonononononncnncnnonacnnos 48 55 V Valve Test MehW s sail ar lag alsk aaa 50 Valve Test Menu illustration a aa aaa iasi anni 50 Voltage Regulator board a aaiaaaassnssssasssssni aa 10 98320005 Rev B
15. analyser it must be set to 9832 in order to operate correctly The analyser 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 EC9832 A amp B series are STANDARD TRACE amp HIGH LVL 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 For A series analyzers the STANDARD type is selected For B series analyzers the ISO B type is selected The PRESSURE and FLOW CALIBRATION MENU s will change depending on which FLOW BLOCK TYPE is Selected 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 CRITICAL ORIFICE Designated flow rate of the critical orifice installed in the ISO B flow block For the EC9832B this should be set to 1 000 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
16. block ensuring that the O ring is in place around the base of the fitting 5 Reinstall the flow pressure assembly into the analyzer and reconnect the pneumatic and electrical connections 6 Turn on the pump 3 3 6 CO CO gt Converter Check The internal CO CO converter provides a source of continuous zero air for auto zero and background functions of the EC9832 Failure of the converter can result in drift poor sensitivity near zero and continuous electronic zero adjusts To check the CO CO gt conver Required equipment Test zero air supply 1 From the CALIBRATION MI ter ENU place the analyzer in CAL MODE Z ERO This will allow the analyzer to sample zero air from the zero air scrubber Allow sampling for approximately 5 minutes 2 Record the front panel CO reading as the initial value Note 98320005 Rev B CHAPTER 3 MAINTENANCE This value should be 0 00 0 1 ppm If it is not a background should be initiated by choosing CALIBRATION MENU BACKGROUND START and pressing enter to re establish the zero baseline The background will take approximately 5 minutes to complete Connect the challenge zero air to the Sample inlet of the analyzer Be sure the inlet pressure is maintained at ambient pressure 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 sampling for 5 minutes
17. detector 98320005 Rev B CHAPTER 4 TROUBLESHOOTING System Troubleshooting Table Symptom Possible Cause Fault Isolation Solution 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 3 C and stable 0 3 C 5 Low span Span setting Adjust the span using the calibration procedure in the EC9832 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 wheel Leaks A leak dilutes the sample stream and causes low span readings and noise See the leak test procedure in section 3 3 10 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 procedure in section 3 3 10 above 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 GLOBE on the 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 7 Zero drift CO CO converter Replace the converter failed Leak A leak dil
18. the PRESSURE CALIBRATION MENU and press Enter gt J Disconnect the pressure transducer from the flow control inlet and reconnect the inlet tubing The flow calibration must now be completed 3 5 2 3 Flow Calibration 1 From the HIDDEN MENU select the FLOW CALIBRATION MENU The menu of Figure 23 should be displayed FLOW CALIBRATION MENU CRITICAL ORIFICE 1 080 VALVE SEQUENCING ON AMBIENT PRESSURE 750 0 TORR GAS PRESSURE 710 0 TORR GAS FLOW 1 500 SLPM Figure 23 Flow Calibration Menu for ISO B flow block Set the CRITICAL ORIFICE to 1 500 and press Enter gt J Press Reset on the analyzer secondary panel The actual flow should now be checked by turning on the pump and connecting a flow meter to the sample inlet of the analyzer The flow should read approximately 1 0 slpm If the flow is too low perform the sintered filter orifice replacement procedure If flow is too high there is probably a leak Note The gas pressure and gas flow readings on the INSTRUMENT STATUS menu will not update until the startup routine is complete This completes the pressure amp flow transducer calibration procedure 98320005 Rev B CHAPTER 3 MAINTENANCE 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 dep
19. 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 98320005 Rev B CHAPTER 3 MAINTENANCE 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 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 PRESSUR
20. the sintered filter replacement procedure in section 3 3 5 If flow is too high there is probably a leak around the sintered filter or orifice 3 4 Hidden Menu 98320005 Rev B 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 J The following menu will be displayed HIDDEN MENU SERIES A ANALYZER TYPE 9832 SUB TYPE STANDARD FLOW BLOCK TYPE STANDARD PRESSURE CALIBRATION MENU FLOW CALIBRATION MENU Figure 19 Hidden Menu SERIES Allows the user to choose the correct series of analyser The options are A B amp s The selection must reflect the Hardware to which it is being installed i e for a EC9832 analyser it must be set to A and for a EC9832B analyser 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 analyser type The options are 9810 9811 9812 9820 9832 9841 9842 amp 9850 The selection must reflect the 37 EC9832 CO ANALYZER SERVICE MANUAL Hardware to which it is being installed 1 e for a EC9832
21. variables or signals on the preprocessor board Figure 28 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 The FLOW CONTROL POTS screen displays the potentiometer settings associated with several components variables or signals on the A series Flow Control board Figure 29 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 98320005 Rev B 49 EC9832 CO ANALYZER SERVICE MANUAL extreme limits of the potentiometer range and may be reason to suspect a problem FLOW CONTROL ZERO FAN SPEED CONTROL PUMP SPEED FINE PUMP SPEED COARSE FLOW CONTROL POTS GAS FLOW GAS PRESSURE Figure 29 Flow Control Pots Range 4 2 3 Valve Test The VALVE Menu INT INT INT EXT EXT EXT AUX AUX VALVE SEQUENCING TEST M 81 50 90 16 0
22. 25 CYCLI F Event Log Messages Description Checksum of memory at power down differs from checksum at restart EROM designated X detected error at location Y Unit taken out of service from front panel LCD constantly busy indicates hardware failure in display A D returned busy status Power removed from system Power applied to system Zero voltage controller reached limits before voltage reached set point Input controller reached limits before reference voltage reached set point Instrument flow has gone to zero 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 Action Battery failure or system software error If error persists call Ecotech Customer Service for instructions Check pressure board cable connections and pressure board Return analyzer to service using the front panel switch Check display cable connection display board and microprocessor board Normal at startup If failure persists replace microprocessor No action required No action required Reset analyzer check zero air source Check IR source The pump has failed or a flow obstruction has occurred Replace pump or clear obstruction
23. 4 15 Illustrations Preprocessor Pots and Ranges 49 Illustrations Routine Maintenance Components 27 Illustrations Sintered Filter Replacement 30 Illustrations System Block Diagram 12 Illustrations System Temperatures and Tolerances 53 Illustrations Valve Test Menu 22iaiaaciaicaiaa a 50 98320005 Rev B Installation 2 sko svara Ai is 5 Instrument Status and Ranges illustration 52 Instrument Status Ranges illustration 37 40 41 43 44 Instrument Status sCreen aa aaaiaaavaassassssssaasaaai 53 IR Gt Clr acosan aten ds ovens db tay a ar klu deste 18 IR detector replacement 2 aiaaiaaianiasi sassensanan 33 A A foss kall ll kl Bai 16 IR source replacement aaaiiiaaiasasssnssssassansanaa 32 L Leak checked 36 M Maintenance periodic aiaasaiiasassssssasassssasssanaa 23 Maintenance routine coooocnnnoncccnononcnononanononnanononanoss 26 Major Components illustration a 2 2 1 isv ai a 13 Meas rement cell innkosonlnastadan ast vk ri 18 Microprocessor board aiaiaiaaiaiasasansasassnsssasaasanas 10 Motor replacement aaniaianaiaaianiasssaansnsasnanannianaa 32 N Narrow bandpass filter a aaaiaiaaaasasasassssssassasanas 18 O Opening the Front Panel illustration 5 Optical detector iuris 17 Optical Path illustration
24. E Current gas pressure measured from the flow controller GAS FLOW Current gas flow measured from the flow controller 3 5 Pressure amp Flow Calibration 98320005 Rev B 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 150 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 4 fitting with hose to suit pressure transducer 39 EC9832 CO ANALYZER SERVICE MANUAL 3 5 1 Pressure Flow Calibration A Series 3 5 1 1 Setup Note The EC9832 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 J Press Reset on the analyzer secondary panel 3 5 1 2 Pressure Calibration 16 From the HIDDEN MENU select the PRESSURE CALIBRATION MENU The menu of Figure 20 should be displayed PRESSURE CALIBRATION MENU PRESSURE 1 HIGH 743 0 TORR PRESSURE 1 LOW 530 0 TORR VALVE SEQUENCING ON CONTROL
25. 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 CHAPTER 4 TROUBLESHOOTING 51 EC9832 CO ANALYZER SERVICE MANUAL Event Log Messages RESET DETECTION Reset button pressed or Unless the reset was not watchdog timer caused initiated by the user no reset action is required AZS CYCL AZS cycle started No action required HJ 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
26. POWER SUPPLY BATTERY MICROPROCESSOR BOARD L FRONT REAR Figure 7 Major Components B Series 98320005 Rev B 13 EC9832 CO ANALYZER SERVICE MANUAL 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 8 amp Figure 9 The pump causes sample air to be drawn into the sample inlet and through the 5 micron particulate filter The inherent differences between the A and B series analyzers is the method of flow control and the pump used These differences will be discussed in the following sections H i r a oe pm Gan 7 Le TAI bd Figure 8 Pneumatic Diagram A Series Particulate Filter The particulate filter 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 This filter is not supplied with the B series analyser and must be purchased as an option 98320005 Rev B CHAPTER 2 THEORY OF OPERATION CO CO Converter The CO CO catalytic converter uses platinum heated to 90 C as a conversion agent Heating the catalytic agen
27. RE UPDATE o a ER 45 4 TROUBLESHOOTING 2s1s000000iitis ssssssniossasi sntabus andaniakndad nnnda anniinau usikan andan anina ndan inadnn nna nnnkani assannninn ndan as nd a nis 48 T DCPOWER SUPPLY VOLTAGES b S fuses l n S TS Sa Sue Bose SO de aan OB l boat ans TS S T aa lla eee 48 4 2 TROUBLESHOOTING THE EC9832 ANALYZER c cccesssssecsessececssscecessnececeesaececseseeceesaeeecsessececseeeeeseseeecseaeeesseaeeeess 48 42 1 Preprocessor Pots Menu onda ai 49 4 2 2 Flow Control Pots Menu A Series Only secsi dish stundin duboanu asdatu ka saakasi ah ka 49 4253 Valve Test Men eke A A bes sete r eae visas hs Peas Races aes 50 ADA Event LOG ici is A A di 50 ADLIAOSTUMENESCCAUS A A ks a ak 52 4 2 0 System TEMperatuUres aslbs s s stkrl e lst ra sGokssoduta ta sdat askstki staaa sk ta 53 98320005 Rev B 1 EC9832 CO ANALYZER SERVICE MANUAL AEDT System FAUS van s ara kkk kkk kk 53 4 33 TEST BUNCTIONS EAEE S k a 55 4 IV OPM CA R Cain Rae Roe aod ce use E E a eE E 55 IL PLCAMD A A R R R k 39 ASIAN ld 55 4 3 4 Use Of Diagnostic Modes saias 5043 noes aka erena eso kers STEA u ak a ideada B Kuala aS 55 4 4 TROUBLESHOOTING GUIDE ccsecccsccecsessssscecececeesenseaecececeesesseaeceeececeeseaaeceeececeesaaeceeececeesaaeseeeeeceeseaaeaeeececeeneaeea 55 INDEX GSU ON 1 98320005 Rev B EC9832 CO ANALYZER SERVICE MANUAL Manual History This manual is the combination of two previous versions which have n
28. W ecotech environmen tal monitoring solutions EC9832 Carbon Monoxide Analyser Service Manual www ecotech com EC9832 CO ANALYZER SERVICE MANUAL Table of Contents MANUAL HISTORY stamsvsssa e as Ses i O 3 SAFETY REQUIREMENTS Ssi SU SO S a ad eee 4 SERVICE AND SPAREPART S a dias 4 10 INSTALLATION PEE E E sancecsesustussses E E EE O E E O EE dbece cseusuceesvosecslavessees 5 TEL INTA E CHECK E a a E E 5 LAL REMOVE the Top Cover mii asal 5 DDD SCL VICE DS WILCW AR a 6 LAS ANS pect the Components 6 I L Remsert Dislodged BOTAS boa 7 VV Ss Cable GCONNECHONS diaria 7 20 THEORY OB OPERATION vise csdisscsosscsscscascavsscscessescecechdesectssseccuecveesacdcssececsevevasseassscsitewsecs sesbescasdesssccdassscauuasoese 9 2 INSTRUMENT DESCRIPTION ssssccccd cevevacseeonncebeavevatececcaetagtenstuoes arka 10 211 Powert Microprocessor Module sss ra rk 10 DAL Sensor Module A id a rata 14 2 2 OPERATION MODES a 19 Zi ZAS Ar up Mode j ii 19 ZZ Meare MODE A A a a 21 223 AUD LORO A a E E Ea 21 3 O MAINTENANCE cossoic soconini necinccconusacodosvrncinncon nidan nnaaand aa nn Bland an a nN a Dilan ciao Inn On a a kaba b lann aknandan Da nspanDabalsaanda anndna nuna 23 3 1 MAINTENANCE SCHEDULE sv r askar Sv ils fatal Oa Sn ras V S ra a Fera aaa 23 32 REPLACEABLE PARTS cdt da di a rr ara 24 3 2 1 Expected Life Span of Consumables iii dani 25 3 3 MAINTENANCE PROCEDURES siii A a A adas 26 331 Check Particular a dee Os 27 3 3 2 Particul
29. Y Figure 2 The Secondary Panel A Series 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 98320005 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 98320005 Rev B EC9832 CO ANALYZER SERVICE MANUAL This page is intentionally left blank 98320005 Rev B CHAPTER 2 THEORY OF OPERATION 2 0 Theory of Operation 98320005 Rev B Carbon monoxide absorbs infrared radiation IR at wavelengths near 4 7 microns therefore the presence and the amount of CO can be determined by the amount of absorption of the IR The EC9832 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 conce
30. ate Filter Replacement Procedure aiaaiaaaiaiia a ssasaasansansanannnannnnnnnnnnnnnannnnnannnnnnnnnnnnnnnnnniannnnnai 27 3 33 61 1741 18 171 99 211 174 AAA NOOO N OO 28 3 3 4 DFU Replacement ia a AAA A A A ias 29 3 3 5 Sintered Filter Orifice Replacement B Series aaaaiadaaaaaiasaasansnnnannnnnannnnnannnnnnnannnnnannnnnanansnnnnnsnniannnanai 29 3 3 0 COCOS Converter Cle CK las A a ka kaa 30 3 3 7 Detector Signal AdjustMeNtiananin dd l se ja AEE E a ia 31 3 3 8 Correlation Wheel Motor IR Source Replacement aaaaaaiiaiaasansnasannnnnannnnnnnnnsnanannnnnannnnnnnnnsnnnansnniannnniai 32 3 3 9IR Detector Replacement anni A A A ia 33 LO Leak Test Procedure Treni ea eE E E E a E E E E E a a E E 34 JA HD EN MENU r a arar 37 3 4 1 Pressure amp Flow Calibration sub Mmenus aaaaaaxaxaiaiaaaaana nisannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnninnni 38 3 5 PRESSURE amp FLOW CALIBRATION eontre neirinne bl a Sak a v S a Bast aS aaa aa S ra a Ee aaa vaka raak 39 3 5 1 Pressure Flow Calibration A Serles aaaaaaiaaadaiiannssnnnnnannnnnnnnnnnnnnnnnnnnnnnnninnnnninsnnnnnnnnnnnnninnnnnnnnnnnnnnnnnnnn 40 3 5 2 Pressure Flow Calibration B Series ccccccccccccccssecececssecesseccecsssecesuesceceesaeeecsesseseeaeecsesaeeecuesaaesesseeeeesesaees 43 3 6 PREPROCESSOR DEVICE ID ENTRY cccccccesssssscecececeesessnaececcceesensnaececcesesesaaeeecececeensaaeaecececeesesaaeseeseseeessaaeeeeees 45 BU FIRMWA
31. ause of the sophisticated design of the EC9832 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 PREPROCESSOR POTS 98320005 Rev B CHAPTER 4 TROUBLESHOOTING VALVE TEST MENU EVENT LOG INSTRUMENT STATUS SYSTEM TEMPERATURES 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 45 REFERENCE GAIN O TEST MEASURE O REF VOLTAGE 3 70 4 30 VOLTS co 0 200 PPM CONC VOLTAGE 0 4 5 VOLTS Figure 28 Preprocessor Pots and Ranges The PREPROCESSOR POTS screen displays the potentiometer settings associated with several components
32. cool the detector Figure 32 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 4 2 7 System Faults 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 98320005 Rev B 53 EC9832 CO ANALYZER SERVICE MANUAL 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 the possible cause of the fault Message OUT ZERO OF SERVICE FLOW ZERO A series FLOW FAIL FAIL COOL CHOPPE B series LAMP SOURCE URE
33. d 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 l 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 l Set the DESIRED FLOW to 1 50 SLPM and press Enter gt J Press Reset on the analyzer and allow the flow to stabilize Verify the flowmeter reading is now 1 50 0 15 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 98320005 Rev B CHAPTER 3 MAINTENANCE 3 5 2 Pressure Flow Calibration B Series 3 5 2 1 Setup Note The EC9832B analyzer should be left running for at least one hour with the pump running before this procedure is attempted This will allow the flow bl
34. dicating when the center of each sector is the target of the IR source beam 17 EC9832 CO ANALYZER SERVICE MANUAL Figure 11 Gas Filter Correlation Wheel Measurement Cell The IR next enters the multiple pass optical measurement cell where it travels a mirror folded one meter path through the sample gas before exiting the cell See Figure 10 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 CO sensitive portion of the band centered at 4 7 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 7 microns shines on the detector it changes the current flowing through it This change produces the detected signal 98320005 Rev B CHAPTER 2 THEORY OF OPERATION 2 1 2 3 Electronics Preamplifier Board The preamplifier preamp board converts the current from the IR detector to voltage and amplifies it to a waveform containing a reference voltage peak measure voltage peak and the mask voltage valley Preprocessor The prepr
35. e Components A Series 98320005 Rev B CHAPTER 3 MAINTENANCE Figure 13 Routine Maintenance Components B Series 3 3 1 Check Particulate Filter The inlet filter prevents particulates from entering the pneumatic components of the EC9832 Contamination of the filter can result in degraded performance of the EC9832 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 Use Figure 14 as reference when performing the filter replacement procedure 98320005 Rev B 27 EC9832 CO ANALYZER SERVICE MANUAL ZD Z LLL yy Uy J ALLL PA gt D D zzz GY 2 Z Gy It NA WZ iffy 7 SWZ HG Figure 14 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
36. e 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 9 IR Detector Replacement Refer to Figure 18 98320005 Rev B 33 EC9832 CO ANALYZER SERVICE MANUAL Figure 18 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 3 Remove the four screws securing 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 10 Leak Test Procedure 3 3 10 1 A Series This is a test for the pneumatic system of the instrument The display readings will indicate whether the system is leakin 2 NOTE This procedure applies only to the instrument It does not include the EZS valve option T
37. ect to the Multidrop port on the back of the analyser 45 EC9832 CO ANALYZER SERVICE MANUAL 3 Select Serial Port and the COM Port on the computer from those listed on the Firmware Update screen l Firmware Update Connect to the analyser via which port type Serial Port Communication Port COM1 Sa Figure 24 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 ls Firmware Update What firmware to do you wish to load C ATEMPSV 1 03 0008 5 Browse Details Firmware 1 03 0008 S Date Friday 9 January 2004 3 31 07 PM Size KB 244 Figure 25 Firmware Update firmware selection screenshot 6 Click Next 7 Tick the boxes as shown in the figure below 98320005 Rev B CHAPTER 3 MAINTENANCE I Firmware Update Select the operations you wish to perform Enter bootloader Erase Flash ROM Erase EEPROM Erase RAM Upload Firmware a HDD SHA Run Firmware Previous Figure 26 Firmware Update operations screenshot 8 Ensure the analyser is switched off using the switch under the front panel 9 Click Start 10 Switch the analyser on 11 The Firmware Updater window will show each step as the firmware is uploaded DO NOT turn the analyser off until the Close button is enabled as shown below and the Analyser is
38. ector a gas filter correlation wheel measurement cell narrow band pass filter IR detector and preamp board as described in the following paragraphs Figure 10 illustrates the optical path IR Source The IR source is a heated resistor that generates broad band infrared radiation and irradiates the gas filter correlation wheel 98320005 Rev B 98320005 Rev B CHAPTER 2 THEORY OF OPERATION SO SS Aes CORRELATION WHEEL LR MIRROR BEAM OUT BANDPASS FILTER Figure 10 Illustrated Optical Path 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 7 microns and passing the CO insensitive wavelengths 2 the measure chamber which is filled with nitrogen and passes the CO 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 11 shows the gas filter correlation wheel The wheel is mounted on a shaft driven by a brushless DC motor Opto detector A reflective optical detector reacts to timing marks on the periphery of the wheel and generates a signal in
39. ector Signal Adjustment 3 Verify that the two signals on the detector signal differ in amplitude by approximately 15 refer to Figure 16 If they differ by less than 15 the correlation wheel may require replacement 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 8 Correlation Wheel Motor IR Source Replacement Refer to Figure 17 98320005 Rev B CHAPTER 3 MAINTENANCE Figure 17 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 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 7 Using a minifit extraction tool remove the two wires from the source to the electrical connection Remove the IR sourc
40. ending on which analyzer it is Then press Enter gt 2 Set the ANALYSER TYPE to 9832 and press Enter gt J 3 The display should now display 9832 CO ANALYZER 4 You may need to erase memory after this procedure to avoid any problems 5 Fromthe HIDDN MENU set the the ANALYSER SUBTYPE to HIGH LVL Then press Enter gt J 6 The display should now display 9832 CO ANALYZER This completes the analyzer device type programming 3 7 Firmware Update 98320005 Rev B 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 Analyser 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 analyser 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 computer You will need to select save as type All Files in the download window To update the firmware on the analyser 1 Run Firmware Updater from the Start Programs Ecotech Firmware Updater menu 2 Connect the 9800 analyser to the computer using a standard serial cable you must conn
41. erating 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 Weekly Monthly 6 Monthly 1 Year 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 2 4 Operation Manual 2 3 3 Service Manual 3 3 6 Operation Manual 3 2 Service Manual 3 3 4 Service Manual 3 3 5 Service Manual 3 3 7 Service Manual 3 3 10 Flow Calibration Check Calibrate Service Manual 3 5 Suggested interv als 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 98320005 Rev B 23 EC9832 CO ANALYZER SERVICE MANUAL 3 2 Replaceable Parts EC9832 Analyzer Spare Parts Requirements Description Level O ring orifice and filter B 25000447 007 1 Filter element 5 micron consumable 50 each 1 Filter sintered B 98000181 1 Infrared source CO to CO converter assembly Filter optical O ring optical filter O ring sapphire window Extraction tool minifit connectors Window sapphire PCA Voltage Regulator
42. he type of signal and noise present in ambient air analyzers and their application Ecotechs 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 Ecotech s analyzers have passed USEPA equivalency testing using this advanced signal filtering method EC9832 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 slight variations between the A and B series analyzers are illustrated using system block diagrams Figure 4 amp Figure 5 and major component layout diagrams Figure 6 amp Figure 7 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
43. he option if included in the instrument must be disabled to perform this test 1 Enter the TEST MENU and select OUTPUT TEST MENU then VALVE MENU from these items pick VALV T EST E SEQUENCING and set to OFF 98320005 Rev B 10 11 12 CHAPTER 3 MAINTENANCE Set all valves to CLOSED Press lt Pg Up gt to return to the OUTPUT TEST MENU and choose FLOW CONTROL POTS 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 Plug the inlet and auxiliary ports on the rear panel Also plug the top rear of the CO to CO converter located behind the valve assembly Verify GAS 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 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 reads 0 00 SLPM If the reading is not zero the leak is in the measure sample line 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 Return to the VALVE TEST MENU Close the INT VALVE 2 and open the INT VALVE 3 Re
44. is simulates a reference and measure 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 board reference and measure channels 4 3 4 Use of Diagnostic Modes 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 4 4 Troubleshooting Guide 98320005 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 55 EC9832 CO ANALYZER SERVICE 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 C
45. lled 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 1 2 B series Flow Control Flow Block The sample flow rate is controlled by a critical orifice in the flow block Displayed flow through the analyzer is calculated based upon flow through the orifice at a given upstream pressure This upstream pressure is monitored by a calibrated pressure transducer with the assumption made that the downstream side of the orifice is at less than half the pressure of the upstream side by the sample pump this is required for the orifice to remain critical Flow through the analyzer is verified by measuring the differential gauge pressure between the upstream side of the orifice and ambient pressure Sample Pump The sample pump is supplied as an option by Ecotech and is connected to the exhaust of the analyzer This vacuum pump must be capable of maintaining at least 1 2 atmosphere approximately 15 Hg or 50 kPa at sea level in order to keep the orifice flow critical Rear Fan The fan speed is connected directly to the flow block and is operated continuously to keep the chassis temperature low 2 1 2 2 Optics The optics of the EC9832 analyzer include an IR source an optical det
46. lyzer 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 EC9832 Operation Manual 2 2 3 Auto Zero Routines The EC9832 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 18 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 98320005 Rev B 21 EC9832 CO ANALYZER SERVICE MANUAL 2 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 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 98320005 Rev B CHAPTER 3 MAINTENANCE 3 0 Maintenance 3 1 Maintenance Schedule The following outlines a periodic maintenance schedule for the EC9832 analyzer This schedule is based on experience under normal op
47. nches Hg B 884 017302 Pump external 110V 50 Hz 4 slpm at 20 inches Hg B 884 017303 Rack mount kit with slides 98000036 2 PCA 50 Pin I O B 98000066 2 Battery power option 12 VDC 98000115 Filter particulate sample inlet 5 micron B 98000210 1 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 EC9832 Operation Manual 98307600 EC9832 Service Manual A amp B 98307601 3 2 1 Expected Life Span of Consumables Component Minimum Typical IR Source 98300049 2 years CO CO Converter 98300023 1 year 3 years 98320005 Rev B 25 EC9832 CO ANALYZER SERVICE MANUAL 3 3 Maintenance Procedures Following is a list of routine maintenance procedures which may be required over the life of the analyzer Recommended equipment to perform maintenance Toolbox Oscilloscope Digital multimeter DMM Computer or remote data terminal and connection cable for RS232 communication 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 CO free Test span gas source Leak tester Figure 12 Routine Maintenanc
48. ntains an absolute and a gauge pressure transducer to measure cell pressure and detect sample flow This board also powers the chassis fan B series only 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 98320005 Rev B 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 19 EC9832 CO ANALYZER SERVICE MANUAL 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 2 2 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 2 2 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 volts The reference voltage is proportional to the intensity of
49. ntrated sample of the measured gas 1 e CO is the filter for IR transmitted through the analyzer thus gas filter correlation The process further 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 CO 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 EC9832 analyzer uses the advanced digital Kalman filter This filter provides the best possible compromise between response time and noise reduction for t
50. ocessor contains circuitry for sampling the amplitude of the reference and measure pulses a regulator to keep the IR source at constant intensity two heater controls and miscellaneous logic to generate test signals One heater circuit controls the CO to CO converter to 90 C while the other controls the adjustable mirror plate in the measurement cell to 50 C 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 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 series only Preamp pressure board The pressure flow portion of the board co
51. ock temperature to stabilise to 50 C From the HIDDEN M J Press Reset on the analyzer secondary panel 3 5 2 2 Pressure Calibration 1 From the HIDD F N MENU select the of Figure 22 should be displayed PRES PRES ENU set the FLOW BLOCK TYPE TO ISO B and press Enter gt PRESSURE CALIBRATION MENU The menu PRESSURE CALIBRATION MENU SURE 1 HIGH SURE 1 LOW VALVE SEQUENCING AMBI GAS GAS ENT PRESSURE PRESSURE FLOW 743 0 TORR 70 0 TORR ON 750 0 TORR 710 0 TORR 1 500 SLPM Figure 22 Pressure Calibration Menu for ISO B Flow Block 2 Turn off the pump 3 Disconnect the inlet tubing from the flow block and connect a calibrated pressure transducer to this inlet 4 Allow 30 seconds for the pressure reading to stabilise 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 PR ESSURE CALIBRATION M ENU and press Enter gt l Note to convert from millibar to TORR multiply the pressure by 0 75 5 Connect the pump to the exhaust port and turn it on 98320005 Rev B 43 EC9832 CO ANALYZER SERVICE MANUAL Allow the pump to evacuate the cell and the pressure reading to stabilize This reading should be low typically 100 to 200 torr and is dependent upon the capacity of the pump Set this value as PRESSURE 1 LOW in
52. oltages 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 98320005 Rev B 98320005 Rev B CHAPTER 2 THEORY OF OPERATION 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 optional USB and TCIP connections 11 EC9832 CO ANALYZER SERVICE MANUAL POWER SUPPLY V REG BOARD ASSY OPTIONAL MEASURE 5 MICRON VALVE FILTER af MANIF gt SES INLET sameLe MANIFOLD FILTER seers 1 wir k SSEMBLY Far Tar nh PD 1 No SF Nr AUXILIARY Span Te gt PRE HEATER 1 Lnn 1 y F RE HEATEI 1 k SOURCE MOTOR lt if ZERO ha A L D lt GAS opto 1 a S 1 FILTER REFLECTOR y HIGH PRESSURE TT WHEEL l TANK EXHAUST 1i Ll OUTLET MEASUREMENT CELL 1 IL pul co TO coz CELL HEATER L A
53. ontrast 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 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 2 Replace the microprocessor board 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 A Series Pressurized Rx Cell Ensure Sample and Zero inlets are maintained at ambient pressure Plugged Orifice or Clean or replace the orifice and SS filter SS Filter B series 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 10 above IR source weak or Adjust the detector signal If you are unable to noisy detector obtain an acceptable reading replace the source or
54. 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 27 Firmware Update completion screenshot 98320005 Rev B 47 EC9832 CO ANALYZER SERVICE MANUAL 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 Microprocessor 12V GOOD TP1 PGND TP2 10 v TP3 20 v TP4 Voltage Reg TP7 AGND TP9 TP8 TP6 TP4 Preprocessor 12 v TP2 AGND 5 v 10 v 1 v COOLER 6 v SOURCE Flow Control TP1 AGND A Series Flow Pressure 10V TP2 AGND J1 4 B Series 10V J1 5 Response 20 0 5 v 10 0 5 v 20 0 5 v 12 0 5 v 10 0 5 v 10 0 5 v 5 40 25 v 12 0 5 v 5 40 25 v 10 0 5 v 1 0 3 v 6 40 3 v 5 0 25V 4 5 0 25V 12 0 5V 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 EC9832 Analyzer Bec
55. ow been merged into one document to cater for the continuing development of the EC9800 series analyzers The original manuals were EC9832 Service Manual PN 98320002 Rev F September 1998 The scope of this new manual covers the following analyzers EC9832 Carbon Monoxide Analyzer A Series PN 98321000 100 Both of the instruments are Manufactured by Ecotech P L in Australia and support the new SMD Microprocessor Board Part number 98000063 4 This manual is current for firmware version 1 03 and above This manual should only be used in conjunction with the EC9832 Carbon Monoxide Analyzer Operation Manual PN 98307600 Rev B May 2007 Ecotech Manual ID MAN 0011 Manual PN 98320005 Current Revision B Date Released May 2007 Description EC9832 Carbon Monoxide Analyzer Service Manual A amp B Series Revision History Rev Date Summary Affected Pages A April 2005 New Release for new Microprocessor Board AS B All series Combined Based on original manuals B May 2007 Updated language and links within pdf manual All 98320005 Rev B created EC9832 CO ANALYZER SERVICE MANUAL Safety Requirements 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 EC9832 is compliant with the requirements of EN61010 1 A2 1995 Safety Requirements for Equipment for Meas
56. s 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 98320005 Rev B CHAPTER 2 THEORY OF OPERATION 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 EC9832 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 measure allows the cell to be filled with zero air either from the internal zero air source with internal valves selected or 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 ana
57. t assures conversion of 0 to 200 ppm CO to less than 0 1 ppm CO even in the presence of 2 water During the startup and auto zero cycles sample is disconnected and air is pulled into the system through the CO CO converter and into the measurement cell This provides the analyzer with a stable reference of zero air to automatically correct for changes in the measurement path om z ue D ES ur A Figure 9 Pneumatic Diagram B Series 2 1 2 1 1 A series Flow Control 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 98320005 Rev B 15 EC9832 CO ANALYZER SERVICE MANUAL 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 contro
58. tes that the cell temperature is not within the acceptable limits A fault is indicated if the cell temperature is below 35 C or above 60 C Indicates that the converter temperature is not within the acceptable limits A fault is indicated if the converter temperature is below 80 C or above 100 C Indicates that the mirror temperature is not within the acceptable limits A fault is indicated if the mirror temperature is below 35 C or above 60 C 98320005 Rev B CHAPTER 4 TROUBLESHOOTING System Fault Messages Message FLOW BLOCK TEMP Description Failure Limits 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 EC9832 under the TEST MENU 4 3 1 Optic 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 Th
59. 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 98320005 Rev B 1 From the HIDDEN MENU select the FLOW CALIBRATION MENU The menu of Figure 21 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 21 Flow Calibration Menu for Standard flow block Verify the pump is turned OFF and the CONTROL LOOP is DISABLED in the FLOW CALIBRATION MENU 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 41 EC9832 CO ANALYZER SERVICE MANUAL 10 11 12 13 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 shoul
60. the IR signal 2 2 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 2 2 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 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 i
61. the Kynar nut from the end of the DFU 3 Remove and replace the DFU ensuring that the direction of flow is correct 4 Reinstall the Kynar nut ensuring that the ferrules are properly installed in the nut 5 Turn on the pump 3 3 5 Sintered Filter Orifice Replacement B Series 98320005 Rev B The sintered filter is used as a final filter to prevent contamination and blockage of the sample orifice If the filter becomes plugged the result is loss of sample flow through the analyzer Typically replacement of the sintered filter alone will be sufficient to maintain operation but occasionally the orifices should be checked and cleaned to ensure proper operation Required equipment Orifice filter removal tool P N 98000190 1 Turn off the pump 2 Disconnect the pneumatic and electrical connections from the flow pressure assembly and remove the block from the analyzer Refer to Figure 13 3 The sintered filter is located in the inlet fitting of the flow block refer to Figure 15 Remove this fitting and replace the filter be sure to use a new O ring Reinstall the fitting into the block ensuring that the O ring is in place around the base of the fitting 29 EC9832 CO ANALYZER SERVICE MANUAL Figure 15 Sintered Filter Replacement 4 The sample orifice is located in the outlet fitting of the flow block If desired remove this fitting and replace the orifice be sure to use a new O ring Reinstall the fitting into the
62. turn to the FLOW CONTROL POTS screen and observe the GAs FLow If the reading is not zero the leak is in the span gas line Return to the VALVE TEST MENU Close INT VALVE 3 and open INT VALVE 1 for normal operation Set VALVE SEQUENCING to on and then press lt Exit gt Remove the plugs from the inlet and auxiliary ports and from the CO to CO converter port 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 1 slpm If flow is too low perform the flow calibration in section 3 5 below 98320005 Rev B 35 EC9832 CO ANALYZER SERVICE MANUAL 3 3 10 2 B Series The leak check ensures the integrity of the pneumatic system and should be performed annually or after any maintenance on the pneumatic system To leak check the EC9832B perform steps 1 through 6 below Note This leak check procedure requires that the vacuum capacity of the pump be known and converted to an equivalent atmospheric pressure This can be obtained by connecting a vacuum gauge through a tee to the pump inlet 1 Disconnect the inlet line from the Sample inlet Leave the Exhaust port connected to the pump 2
63. urement 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 Equipment Rating 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 www ecotech com au 98320005 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
64. utes the sample stream and causes low span readings and noise See the leak test procedure in section 3 3 10 above 8 Unstable flow Failed pressure Recalibrate flow pressure board Replace board if or pressure board 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 98320005 Rev B 57 EC9832 CO ANALYZER SERVICE MANUAL System Troubleshooting Table displays BAD Wrong E Dia 4 Replace Preprocessor ANALYZER 3 Reprogram device ID Symptom Possible Cause Fault Isolation Solution 11 Analyzer Preprocessor ID set 1 Check JS connector on Microprocessor 2 Check J4 connector on Preprocessor 98320005 Rev B EC9832 CO ANALYZER SERVICE MANUAL INDEX C Cable Connections illustration 22 asivsiesai 7 CO CO2 converter iaaaaaaaaaaaaanannnnanananannnnnnnnnnnnnin 16 CO CO2 converter maintenance ss cai ai 30 Components maintenance aaaivaaasssassss sasasai 27 Correlation Wheel 0 cccccscessecccsesessssssesseessesseesees 17 Correlation wheel replacement s aaa vai 32 Correlation Wheel Motor IR Source Replacement illustration

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