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1. 02 NA uN 02 2 v2 2 t9 F2 LA 18 98117601 Rev B CHAPTER 3 MAINTENANCE EC9811 Analyzer Spare Parts Requirements Description Part Number Level PCA USB Board Assembly 98007502 3 Heater thermistor assembly A amp B 98300061 3 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 EC9810 Analyzer Spare Parts Requirements Options and Accessories Description Series Part Number Rack mount kit with slides A amp B 98000036 2 Battery power option 12 VDC A amp B 98000115 Filter kit particulate sample inlet 5 micron A 98000211 1 50 pin connector and shell kit A amp B 98000235 1 EC9811 Operation Manual A amp B 98117600 EC9811 Service Manual A amp B 98117601 Valve manifold kit external zero span EZS A amp B 98300087 Reaction cell maintenance kit A amp B 98110019 KIT1 3 2 1 Expected Life Span of Consumables 98117601 Rev B Com
2. 2 Set all valves to CLOSED 26 98117601 Rev B CHAPTER 3 MAINTENANCE 3 Press lt Pg Up gt to return to the OUTPUT TEST MENU and choose FLOW CONTROL POTS 4 Turn the Pump switch on the secondary panel to OFF and verify FLOW 0 00 sLPM If 1t does not read 0 00 the Flow Control PCA requires recalibration Return the Pump switch to ON 5 Plug the inlet and auxiliary ports on the rear panel 6 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 7 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 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 GAS FLOW If the reading is not zero 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 to O
3. 27 Power microprocessor module 9 Preamp test function 51 Preamp Pressure board A 16 Preamplifier board A 15 Preprocessor board resres iseer 16 Preprocessor Pots and Ranges illustration 46 Preprocessor Pots Menu 46 Q QUICK Start ees steer d reco tote tee esten 17 R Reference adjust sss 16 Replaceable parts 20 Routine maintenance seseeeeeenenrn 23 S Sample measurement sese 17 Sensor mod le 5 2 hee etr rte doc 13 Serlal Port sauer 6 10 42 SEFVIGE Witches a ss 6 Sintered filter replacement sess 27 Sintered Filter Replacement illustration 27 EE 20 Startup Mode ni a 16 System Faults display eee 50 System Temperatures and Tolerances illustration 49 System Temperatures screen 50 T POUR E 10 Theory of operation sese 8 Troubleshooting esee 45 52 1 EC9811 ANALYZER SERVICE MANUAL U USB be meatus 10 21 UV detector iode ront eR 15 UV lamp maintenance cocococccnconocononcnnncnnonannninnonacnnos 28 UN Ee 15 V Valve Test Menu oooooonoconcnooonnnononcnonoonnncnnnnnnnocnnnnnnno 47 Valve Test Menu 47 Voltage Regulator board sess 10 Z Zero iiec tr ERR EE 17 98117601 Rev B
4. Flow Pressure 10V TP2 AGND J1 4 10V 0 5V B Series 10V J1 5 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 EC9811 Analyzer 98117601 Rev B Because of the sophisticated design of the EC9811 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 g VALVE TEST MENU m EVENT LOG 37 EC9811 ANALYZER SERVICE MANUAL 38 o INSTRUMENT STATUS o SYSTEM TEMPERATURES o 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 Ecotech Service support personnel when assistance is required 4 2 1 Preprocessor Pots Menu PREPROCESSOR POTS MEASURE COARSE ZERO 62 10 90
5. 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 3 1 Startup Mode When the instrument is initially powered up several components in the instrument are automatically configured by the microprocessor This process can require up to 30 minutes to complete Following is a description of the various adjustments made during the startup routine All adjustments are automatically performed by the microprocessor and no manual intervention is required 2 3 1 1 Reference Adjust Reference adjust allows the input gain of the preprocessor measurement channel to be adjusted for the proper reference voltage level the reference voltage is proportional to the intensity of the UV lamp The microprocessor initially adjusts the lamp adjust potentiometer for a lamp current of 10 mA then the input potentiometer for a reference voltage of 3 0 0 2 volts 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 After the UV lamp is adjusted the reference voltage is continuously monitored to ensure it is stable during operation If the reference voltage becomes momentarily unstable the analyzer will display REFERENCE STABILIZATION until the lamp achieves stability 2 3 1 2 Zero Adjust After the
6. 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 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 by simultaneously misadjusted pressing two keys on the front panel as follows Contrast Press Up arrow A and Select for darker contrast Down arrow Y and Select for lighter contrast 98117601 Rev B CHAPTER 4 TROUBLESHOOTING Symptom 3 Zero flow 4 Noisy or unstable readings 5 Low span 6 No response to System Troubleshooting Table Possible Cause DC power Display Bad display or Microprocessor PCA Pump failed Filter Flow control assembly A Series Pressurized Rx cell Plugged orifice or SS filter B series Leaks Particulate filter Rx cell temperature Scrubber Rx cell dirty UV lamp UV detector Span setting Scrubber Rx cell dirty UV lamp No flow Leaks Instrumen
7. 3 3 5 Service Manual 3 3 7 Flow Calibration Check 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 98117601 Rev B 17 EC9811 ANALYZER SERVICE MANUAL 3 2 Replaceable Parts EC9811 Analyzer Spare Parts Requirements Description Level O ring reaction cell tube 2 required Filter element 5 micron consumable 50 each Scrubber assembly ozone Lamp assembly ultraviolet ozone measuring Lamp ultraviolet ozone generating osmon Fitting reducing ferrule amp B Scrubber material carulite O ring carulite scrubber 025 030850 O ring quartz window O ring ozone chamber 25000442012 O ring ozone chamber 25000442032 Mass flowmeter 290001341 Window quartz Tube reaction cell PCA Voltage Regulator Display switch assembly PCA Microprocessor SMD PCA 50 Pin I O Power supply 115 230 VAC to 12 VDC PCA Preprocessor PCA Lamp Driver Filter particulate sample inlet 5 micron 980003104 PCA Internal Zero Span Control os0036 PCA Preamplifier Detector Flow control Module Thermistor assembly Heater and thermistor assembly internal 98110013 zero span Valve manifold main A 98300037 Filter felt carulite scrubber
8. Ecotech Customer Service for instructions 98117601 Rev B 39 EC9811 ANALYZER SERVICE MANUAL Message SERVICE SWITCH ACTIVATED T LCD DISPLAY BUSY A D CONVERSION ROR 1 2 SYSTEM POWER FAILURE SYSTEM POWER RESTORED INPUT POT TO 0 OR 99 LAMP ADJUST POT LIMITED TO 0 OR 99 FLOW SPAN RATIO lt 0 75 SPAN RATIO gt 1 25 RESET DETECTION AZS CYCL ELECTRONIC ZERO ADJUST DATA LOGGING MEM FAIL Event Log Messages Description 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 Input pot adjustment exceeds range Lamp adjust pot reached limit before 10 mA lamp current was achieved Zero voltage controller reached limits before voltage reached set point Instrument flow has gone to Zero After AZS cycle ratio of requested span to measured span is 0 75 After AZS cycle ratio of requested span to measured span is 21 25 Reset button pressed or watchdog timer caused reset AZS cycle started An analyzer electronic zero cycle was initiated Occurs if unable to write to datalogging memory Action Return analyzer to service using the front panel switch Che
9. MEASURE FINE ZERO 42 0 99 INPUT 68 10 90 TEST MEASURE 0 LAMP ADJUST 58 40 80 REF VOLTAGE 4 VOLTS 03 20 CONC VOLTAGE 0 4 5 VOLTS LAMP CURRENT 5 10 5 MA Figure 17 Preprocessor Pots and Ranges The PREPROCESSOR POTS screen displays the potentiometer settings associated with several components and variables on the preprocessor board Figure 17 illustrates a typical test screen for an instrument that is operating normally The values of the potentiometer settings are somewhat arbitrary so 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 The exception is TEST MEASURE Which is zero unless changed by an operator 4 2 2 Flow Control Pots Menu The FLOW CONTROL POTS screen displays the potentiometer settings associated with several components variables or signals on the A series Flow Control board Figure 18 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 98117601 Rev B CHAPTER 4 TROUBLE
10. 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 Fax Email Service Email Spare Parts Web 61 1300 364 946 61 1300 668 763 ecotech ecotech com au parts ecotech com au www ecotech com au 98117601 Rev B CHAPTER 1 INSTALLATION 1 0 Installation 1 1 Initial Check Verify that the serial number label on the documentation and the serial number s on the analyzer match Check to make certain your instrument arrived undamaged If you find damage report it as described in the preface on the page titled Claims for Damaged Shipments and Shipping Discrepancies in the Operation manual Analyzers are shipped ready to power up Occasionally however rough handling during shipment causes dislodged PC boards disconnected cables or incorrectly positioned switches Verify that your instrument is in operating condition by performing the following procedure 1 1 1 Remove the Top Cover 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 s
11. SERVICE MANUAL 14 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 2 2 2 Optics D UV Source The UV source is a mercury vapor lamp operated at 10 mA by a regulated power supply The lamp temperature is controlled to approximately 50 C to ensure stable operation Measurement Cell The measurement cell is a glass tube with the UV source at one end and the UV detector at the other UV Detector The detector is a solar blind vacuum diode sensitive only in the spectral region where absorbs 2 2 2 3 Electronics D Preamplifier Board The preamplifier preamp board converts the current from the UV detector to voltage and amplifies it The microprocessor measures the light inten
12. conversion of three channels is used to send 0 to 20 mA analog signals to the 50 pin I O connector 98117601 Rev B 98117601 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 USB and optional TCIP connections through the rare panel Figure 4 System Block Diagram 11 EC9811 O ANALYZER SERVICE MANUAL 12 Figure 5 Major Components 2 2 2 Sensor Module The sensor module can be divided into three areas of description pneumatics optics and electronics 2 2 2 1 Pneumatics The pneumatic system continuously supplies particulate free sample air to the measurement cell at a rate that allows the sample to be measured before exiting the analyzer The pneumatic system flow is illustrated in Figure 6 The pump causes sample air to be drawn into the sample inlet and through the 3 micron particulate filter 98117601 Rev B D CHAPTER 2 THEORY OF OPERATION Gg MICRO SE DN ieu e 24 Jee d a Figure 6 Pneumatic Diagram Particulate Filter The part
13. fan filter is located on the rear of the analyzer If this filter becomes contaminated with dust and dirt it may affect the cooling capacity of the analyzer The fan screen should be cleaned by removing it from the analyzer and blowing it out with compressed air or by cleaning it with mild soapy water and air drying 3 3 4 Pneumatic Cleaning 3 3 4 1 Cleaning the Cell Tube Cleaning the cell tube requires removal of the glass tube from the two end blocks 1 Warning Apply minimal pressure while installing or removing the tube as it may fracture and cause serious injury to the operator Loosen the retaining nut at the end of the tube Slide the glass tube toward the front of the instrument until it is free of the rear mounting block Rotating the tube and using both hands will help Gently raise the rear of the glass tube and slide the tube rearward until it is free of the forward mounting block Inspect the tube for any particulate matter deposited on the inner walls of the tube If any residue is detected the entire pneumatic system should be cleaned Do not clean the ozone scrubber Clean the glass tube by swabbing with clean soapy water in both directions Rinse in deionized water then in isopropyl alcohol Dry in air Examine by looking down bore to light No lint grease or particulate matter should be present Replace the clean dry tube in the blocks by first placing the tube in the front block and sliding it into the rea
14. of this page e g V1 00 0002 by right clicking on the link and choosing Save Target As and saving the sx file on your computer You will need to select save as type All Files in the download window To update the firmware on the analyzer 1 Run Firmware Updater from the Start Programs 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 98117601 Rev B CHAPTER 3 MAINTENANCE W Firmware Update Connect to the analyser via which port type Serial Port Communication Port COMI ha Figure 13 Firmware Update communication settings screenshot 4 Click Next 5 Enter the full path and file name of the firmware sx file you downloaded e g C TEMP V1 03 0001 SX assuming the file was saved to C TEMP W Firmware Update What firmware to do you wish to load CATEMP V1 03 0008 5X Browse Details Firmware V1 03 0008 5X Date Friday 9 January 2004 3 31 07 PM Size 244 Figure 14 Firmware Update firmware selection screenshot 6 Click Next 7 Tick the boxes as shown in the figure below 98117601 Rev B 35 EC9811 ANALYZER SERVICE MANUAL 36 10 11 W Firmware Update Select the o
15. reference voltage is set the analyzer must adjust the preprocessor to offset the electronic signal present during the zero background cycle The cell is filled with zero air then the preprocessor measure coarse zero and measure fine zero potentiometers are adjusted until the concentration voltage is just above 0 00 volts the concentration voltage is a signal proportional to the measurement 98117601 Rev B 15 EC9811 ANALYZER SERVICE MANUAL 16 of gas After startup this signal level is continuously monitored and adjusted as necessary 2 3 1 3 Sample Measurement The EC9811 is a stream switched analyzer This means that the analyzer is constantly switched between a background zero cycle and a measure cycle These streams are switched approximately every 10 seconds The difference in detected signal between the two cycles is proportional to the measurement concentration The current operational mode is displayed on the analyzer main screen SAMPLE FILL MEASURE Or BACKGROUND FILL MEASURE 2 3 1 4 Quick Start Routine If the analyzer power is removed for less than two minutes the full startup routine is replaced by a quick up routine The analyzer is returned to its last known Operating parameters and normal operation is restored This allows the analyzer to rapidly return to measurement mode and keeps data loss to a minimum If power 1s lost for more than two minutes a full auto restart is performed 2 3 2 Meas
16. 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 DESIRED FLOW Desired flow rate that the standard flow block will maintain a constant flow at Note If the flow rate is changed within an A series analyzer the instrument must be reset in order for the change to take effect FLOW SPAN POINT During the flow calibration of the standard flow block this is 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 EEPROM on the standard flow control board PRESSURE 1 HIGH Pressure entered during ambient calibration PRESSURE 1 LOW Pressure entered during low pressure calibration VALVE SEQUENCING Turn the valve sequencing on or off Same as in the Valve Test Menu When turned off the appropriate valve sequence will set ready for pressure calibration CONTROL LOOP When ENABLED the microprocessor controls the pump speed via the flow control pots to give the desired flow rate When DISSABLED the user can manually adjust the pump speed using the flow control pots For the standard flow
17. C9800 analyzer family uses the advanced digital Kalman filter This filter provides the best possible compromise between response time and noise reduction for the type of signal and noise present in ambient air analyzers and their applications The Ecotech s implementation of this filter enhances the analyzer s measurement method by making the time constant 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 2 1 Ozone generator theory 98117601 Rev B Oxygen absorbs ultraviolet light whose wavelength is approximately 185 nanometers nm The energy at this wavelength is sufficient to dissociate the oxygen molecule into two atoms The oxygen atoms then react with oxygen molecules to form ozone A mercury vapor lamp is used as the source of 185 nm light This lamp differs from lamps used for ozone measurement in the type of glass used in the lamp envelope The envelope of an ozone producing lamp is transparent to 185 nm light The envelope of an ozone free lamp is opaque to 185 nm light Ambient air is pushed through a scrubber and a particulate filter so that interferant free air is intro
18. N and press lt Exit gt Remove the plugs from the inlet and auxiliary ports 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 98117601 Rev B 27 EC9811 ANALYZER SERVICE MANUAL 28 To access the hidden menu simultaneously press three keys on the front panel from the primary screen as follows Up arrow A Pg Up and Enter 1 The following menu will be displayed HIDDEN MENU SERIES A ANALYZER TYPE 9811 SUB TYPE STANDARD FLOW BLOCK TYPE STANDARD GAS NAME PRESSURE CALIBRATION MENU FLOW CALIBRATION MENU Figure 10 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 an EC9811 analyzer it must b
19. RE CELL TEMPERATURE FAILURE FLOW BLOCK TEMP Wei TABILIZATION START U SEQUENCE ACTIVE LAMP TEMPERATURE FAILURE System Fault Messages Description Failure Limits Indicates the Service switch is in the OUT position Unless the analyzer is being serviced this switch should be in the IN position Indicates that measured flow has gone below 0 05 SLPM Indicates that the lamp current is not within the acceptable limits In the EC9811 a fault is indicated if the lamp current is below 5 mA or above 15 mA Indicates that the reference voltage is not within the acceptable limits In the EC9811 a fault is indicated if the reference voltage is below 1 volt or above 4 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 Indicates that the cell temperature is not within the acceptable limits A fault is indicated if the cell temperature is below 5 C or above 60 C 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 Displayed If the reference voltage becomes momentarily unstable It is displayed until the lamp achieves stability Indicates that the analyzer is in start up mode Usually after power up or reset Indicates th
20. SHOOTING 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 18 Flow Control Pots Range 4 2 3 Valve Test Menu VALVE TEST MENU INT VALVE 1 OPEN INT VALVE 2 CLOSED INT VALVE 3 CLOSED EXT MEASURE OPEN EXT ZERO GAS CLOSED EXT SPAN GAS CLOSED AUX VALVE 1 CLOSED VALVE SEQUENCING ON Figure 19 Valve Test Menu The VALVE TEST MENU 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 S EQUENCING must be ON in order for correct gas measurements 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 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
21. ample 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 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 21 EC9811 ANALYZER SERVICE MANUAL 22 3 3 2 Particulate Filter Replacement Procedure Use Figure 8 as reference when performing the filter replacement procedure Figure Particulate Filter Replacement Open the front panel to access the service switches and particulate filter Position the Pump switch in the secondary front panel to OFF Completely unthread the filter cap by turning 1t counterclockwise 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 Remove inspect and wipe down the O ring Replace the O ring only if damaged Remove discard and replace the old filter membrane 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 Return the Pump to ON Close the front panel 98117601 Rev B CHAPTER 3 MAINTENANCE 3 3 3 Clean Fan Filter The
22. block only 98117601 Rev B 29 EC9811 ANALYZER SERVICE MANUAL 30 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 amp Flow Calibration The pressure and flow calibrations should be performed whenever a flow or pressure reading becomes suspect when a transducer is replaced or can be performed as an annual maintenance item The pressure and flow transducer calibration may be performed separately or together The following procedures cover both the STANDARD and 1So B flow block types For both procedures the following equipment is required o Digital Volt Meter a Pressure transducer absolute calibrated in torr o Flowmeter slpm nominal o La fitting with hose to suit pressure transducer 3 5 1 Pressure Flow Calibration A Series 3 5 1 1 Setup Note The EC9811 analyzer should be left running for at least one hour with the pump switched on before this procedure is attempt
23. ck display cable connection Display PCA and Microprocessor PCA Normal at startup If failure persists replace microprocessor No action required No action required Check UV lamp or clean Rx cell Check UV lamp Lamp Driver PCA or Preprocessor PCA Reset analyzer check zero air source The pump has failed or a flow obstruction has occurred Replace pump or clear obstruction Instrument span has drifted beyond acceptable limits Recalibrate Instrument span has drifted beyond acceptable limits Recalibrate Unless the reset was not initiated by the user no action is required No action required Normal after reset or power failure If not associated with these check zero air supply Battery failure or system software error If error persists call Ecotech Customer Service for instructions 40 98117601 Rev B CHAPTER 4 TROUBLESHOOTING Message CONTROL LOOP RESTARTED VALVE SEQUENCING RESTARTED Event Log Messages Description Occurs when Control Loop has been disabled and then automatically enabled after the main screen has been visible 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 No action required No action required 4 2 5 Instrument Status 98117601 R
24. crews When the two captive screws are loosened slide the cover backward about 4 inches and lift the top cover straight up GRIP GRIP HERE HERE PD GEN 9 ra TA Figure 1 Opening the Front Panel 1 1 2 Service Switch 98117601 Rev B 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 EC9811 ANALYZER SERVICE MANUAL DC PowerON Pump ON Service IN 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 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 d L sur nm AGSORPRON MERGIFEMONT ou 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 1 1 4 Reinsert Dislodged Boards The bottom edge of the boards must be held in place by the guides The top of
25. duced to the ozone generating cell The air is passed through a mass flowmeter before entering the cell so the quantity of air diluting the ozone is known In the cell oxygen in the air is irradiated by the mercury vapor lamp and a constant number of ozone molecules per unit time are produced The power applied to the mercury vapor lamp determines the rate of ozone molecule generation The concentration of ozone exiting the cell is directly proportional to the lamp current and inversely proportional to air flow rate EC9811 ANALYZER SERVICE MANUAL 10 2 2 Instrument Description The instrument is designed in a modular format consisting of a power microprocessor module and a sensor module The power microprocessor module contains the power supply voltage regulators and the system microprocessor The sensor module contains all components necessary to measure the pollutant gas The layout of the EC9811 is illustrated in the system block diagrams Figure 4 and major component layout diagram Figure 5 2 2 1 Power Microprocessor Module The power microprocessor module can be described in three sections the power supply the voltage regulator and the microprocessor 2 2 1 1 Power Supply The power supply is a self contained unit housed in a steel case designed to meet CE requirements It has an input voltage of 115 230VAC 50 60 Hz manual switch selectable and an output voltage of 12 VDC power for distribution within the analyzer T
26. e e dp eee ed s 17 3 2 REPLACEABLE PARTS eeu ee pee ER CE E eee pe See 18 3 2 1 Expected Life Span of Consumables a i 19 3 3 MAINTENANCE PROCEDURES eee ettet edet e eet ii ENEE 20 3d Check Parfic late Fit eei ar ob sata E cob boa sa Maru e EES 21 3 3 2 Particulate Filter Replacement Procedure eee eee nennen 22 3 3 J9 Clean Fan lee PS cere ta bec esce eru depend ene ee ec eC Uus te 23 e 23 3 3 3 UV Lamp Checklist 24 SEENEN ENEE 24 3 3 Leak Test Procedures un ti tad WR PO cui E NHIEU Qe eeu 26 3Z HIDDEN MENU dine eter ep e tpe teen ote e cepta etie ice e ety rd eere 27 3 4 1 Pressure amp Flow Calibration eese eene eet 29 3 5 PRESSURE amp FLOW CALIBRATION ener eneenr ener enne sien teni sehr RR seen teres ente sete 30 3 5 1 Pressure Flow Calibration A Series 30 3 6 PREPROCESSOR DEVICE ENTRY GEM 33 S T FIRMWARE UPDATE tic 34 4 0 TROUBLESHOOTING ep 37 4 1 DC POWER SUPPLY VOLTAGES cssccccssssscecssscecesssnsecssssececssnseceesansecsesaececessecsesaesecseaaeseceessecsesaesecsesaeeeseeeeesess 37 4 2 TROUBLESHOOTING THE EC981 1 ANALYZER ccccssscccesssececsescecesssececsesaececeesaeceesaeeecsesaececseseeeesuseeceeaeeeeneeeeeees 37 4 21 Preprocessor Pots Menw a eter EENS ENEE SEN 38 4 2 2 Flow Control Pots Men
27. e lamp temperature is not within acceptable limits A fault is indicated if the lamp temperature is below 35 C or above 60 C 4 3 Test Functions The following diagnostic modes are available in the EC9811 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 UV detector preamp This simulates an input from the detector 98117601 Rev B 43 EC9811 ANALYZER SERVICE MANUAL 44 and is then processed as if it were an actual signal This test is used to verify the operation of the detector 4 3 3 Electric The electric test function generates an electronic test signal which is applied to the input of the preprocessor This simulates 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 4 3 4 Use of Diagnostic Modes The diagnostic modes are actuated by selecting DIAGNOSTIC MODE 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 pass fail Functional problems can sometimes be isolated to a single component by logical use of the diagnostic modes 4 4 Troubleshooting Guide
28. e set to A 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 amp 9850 The selection must reflect the Hardware to which it is being installed i e for an EC9810 analyzer it must be set to 9810 in order to operate correctly The analyzer type will default to gt 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 9811 are STANDARD amp WITH 12S If the Internal Zero amp Span IZS option is installed then wITH 175 should be selected 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 For A series analyzers the STANDARD type is selected 98117601 Rev B CHAPTER 3 MAINTENANCE 3 4 1 Pressure 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
29. easurements and the ozone concentration as follows 1 760 10 O3 our es ini E Cp Cr Equation 1 where O3 our O concentration ppm absorption coefficient of O at 254 nm 308 atm em at 0 C and 7160 torr 760 torr 2 101 kPa 1 optical path length cm T sample temperature K P sample pressure torr L correction factor for O losses A number of compounds absorb at 254 nm the predominant wavelength emitted by the UV lamp Such compounds include aromatics SO and others The scrubber selectively removes but passes the interfering compounds Thus the intensity ratio described in the previous paragraph is a function of only ozone absorption The microprocessor and electronics of the EC9811 control measure and correct for all the major external variables to ensure stable and reliable operation For example the absorption coefficient is temperature and pressure sensitive The 8 98117601 Rev B CHAPTER 2 THEORY OF OPERATION EC9811 contains temperature and pressure sensors which are used to correct the coefficient for prevailing conditions This ensures that an EC9811 analyzer calibrated under one set of conditions will still be accurate when operated in another The EC9811 analyzer has no internal mechanical adjustments The microprocessor monitors all critical variables and makes the necessary adjustments The algorithms have been designed so that no adjustments affect calibration The E
30. ed This will allow the flow block temperature to stabilize to 50 C From the HIDDEN MENU set the FLOW BLOCK TYPE TO STANDARD and press Enter gt 1 Press Reset on the analyzer secondary panel 98117601 Rev B CHAPTER 3 MAINTENANCE 3 5 1 2 Pressure Calibration 98117601 Rev B 1 From the HIDDEN MENU select the PRESSURE CALIBRATION MENU The menu of Figure 11 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 11 Pressure Calibration Menu for Standard flow block Verify the pump is turned off by setting the pump switch to OFF on the secondary panel Allow 30 seconds for the pressure reading to stabilize to ambient pressure on both the calibrated pressure transducer and the analyzer This reading in TORR should be the ambient pressure Set this value as PRESSURE 1 HIGH in the PRESSURE CALIBRATION MENU and then press Enter 1 Note To convert from millibar to TORR multiply the pressure by 0 75 Set the CONTROL LOOP TO DISABLED and press Enter J This will disable the flow control loop Connect the calibrated pressure transducer to the sample inlet on the rear panel of the analyzer Turn the pump ON from the secondary panel Set the PUMP SPEED COARSE to 99 and press Enter 1 Allow approximately 1 minute
31. ev B GAS FLOW GAS PRESSURE REF VOLTAGE CONC VOLTAGE ANALOG SUPPLY DIGITAL SUPPLY INSTRUMENT STATUS 0 375 690 2 0 0 00 11 6 O3 GEN FLOW LAMP CURRENT VERSION 1 11 0002 10 0 625 760 3 20 4 50 12 2 5 2 2 Figure 20 Instrument Status Ranges If any of the parameters displayed on the INSTRUMENT STATUS Screen vary significantly from the values shown in Figure 20 the fault or operational problem is probably related This is also true if one of the parameters is demonstrating a rapid change or is oscillating strongly around the desired setpoint For more information on the operational limits and fault messages refer to the table in section 4 2 7 System Faults Several of the parameters displayed on the INSTRUMENT affected by the potentiometer settings on the PR STATUS Screen are EPROCESSOR 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 41 EC9811 O ANALYZER SERVICE MANUAL 4 2 6 System Temperatures SYSTEM TEMPERATURES CELL TEMP LAMP TEMP CHASSIS TEMP FLOW TEMP Figure 21 System Temperatures and Tolerances The SYSTEM TEMPERATURES screen provides the temperatures of the lamp the chassis and the flow control block Figure 21 contains the nominal values which should be displayed on this screen If any of
32. fficiency The operator should maintain a log of the instrument gain at each calibration Any time this number increases by more than 15 from a known good calibration point scrubber efficiency should be checked 3 3 6 1 Ozone Scrubber Test This test may be performed on ambient sample gas if the reading is at least 100 ppb ozone Use of ozone span gas made up in zero air is recommended for full confidence in the result of this test 1 Generate 400 ppb ozone 2 Verify that the analyzer reads 400 PPB 10 and record the reading 3 Select the TEST MENU screen from the MAIN MENU Select ZERO SOURCE CHECK and press lt Enter gt 4 Move to the CALIBRATION MENU and select CALIBRATION MANUAL then select CAL MODE ZERO and press lt Enter gt Press the lt Exit gt key to return to the initial screen 5 The reading should remain at a value between 1 of the initial reading e g 4 ppb for a 400 ppb Oy level A negative reading indicates that the primary scrubber is less efficient than the secondary scrubber A positive reading indicates that the secondary scrubber is less efficient If the reading is outside of this range replace the appropriate scrubber 6 Upon completion of the test return the instrument to normal operation by 1 setting the CALIBRATION MENU CAL MODE to MEASURE and 2 setting the TEST MENU ZERO SOURCE to STANDARD Confirm the selections by pressing lt Enter gt Press lt Exit gt to retur
33. 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 1 31 EC9811 ANALYZER SERVICE MANUAL 10 11 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 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 l 32 From the HIDDEN MENU select the FLOW CALIBRATION MENU The menu of Figure 12 should be displayed FLOW CALIBRATION MENU DESIRED FLOW 0 50 SLPM FLOW CONTROL ZERO 81 FLOW TRANSDUCER DF CANCEL CONTROL LOOP ENABLED VALVE SEQUENCING ON FLOW ZERO POINT CANCEL FLOW SPAN POINT 0 500 SLPM PUMP SPEED COARSE 28 PUMP SPEED FINE 7 GAS PRESSURE 710 0 TORR GAS FLOW 0 500 SLPM Figure 12 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 EEPROM by setting FLOW TRANSDUCER DF 0 SET and pressing Enter 1 The linearization table contains the following pa
34. he 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 2 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 2 2 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 the analog to digital A D converter for microprocessor use Digital to analog D A
35. iculate filter is designed to remove particles larger than 5 microns and to expose the sample to only inert 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 analyzer and must be purchased as an option Ozone Scrubber The ozone scrubber uses manganese dioxide coated screens to remove only ozone from the air stream As such interferences are sampled on both cycles and their effect is canceled making the instrument selective for The copper screens in the scrubber have been carefully coated with manganese dioxide MnO The performance of the selective scrubber is process sensitive and the scrubber must be manufactured under strict quality conditions to perform correctly Incorrectly coated screens will result in unpredictable instrument performance Use of any scrubber other than those provided by Ecotech is not permitted for monitoring under USEPA regulations without prior approval 2 2 2 1 1 Flow Control 98117601 Rev B 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 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 13 EC9811 ANALYZER
36. n 38 4233 TAY KAIAN TREO 39 4 2 4 Event L g nre pao 39 ADLIANSTUMERES AUS a aid asia 4 4 2 6 System Temperatures cia A tee ete ees cape deg eda Bice A i T ER 42 212 7 System in d eive e RW Ra pet EE eee dede e eee ike EE 42 4 3 TEST F NCTIONS i ng pee be i a pec etre ite Misia eade e tel e e cte e 43 LIRE IG EE 43 98117601 Rev B 1 EC9811 ANALYZER SERVICE MANUAL 7 3 2 Preamp s o Rd vA et RA REG eue RA eder qe e yat enr RAE E Ot Peer ee ee eC Te 43 E EleCIt1G sni etes ima es i nee ensis 44 2 3 4 Use Of Diagnostic Modes iii ai e eet e eor ge e Re e ET Rte ed 44 4 4 TROUBLESHOOTING GUIDE scsesscsccecsesessscecececeesesseaececececsesaaeceeececsesuaaececececeeaaesecececsessaaeseeececseseasaeeececeeneaaeea 44 IA AA PERRA 1 98117601 Rev B FRONT MATTER Manual History This manual is a newly designed manual to cater for the continuing development of the EC9800 series analyzers The original manual was o ML9811 Operation Manual PN 98117601 Rev September 1998 The scope of this new manual covers the following analyzer o EC9811 Ozone Analyzer with internal and External Zero and Span PN 98111000 100 o 9811 Ozone Analyzer with internal and External Zero and Span Systems PN 98115000 100 This instrument is Manufactured by Ecotech P L in Australia and supports the new SMD Microprocesso
37. n to the initial screen 7 The initial screen ozone reading should return to the original value of 400 PPB 10 If you are running the test on ambient air the air sample may vary during the time it takes to run the test 3 3 6 2 Scrubber Replacement 1 Press the Power switch to the OFF position 2 Unscrew the retaining nut located on the elbow of the scrubber to be changed Disconnect the tubing from the joint 98117601 Rev B 25 EC9811 ANALYZER SERVICE MANUAL 3 Remove the scrubber from the retaining clip See Figure 9 4 Unscrew the retaining nut on the elbow joint at the bottom of the scrubber Disconnect the tubing from the joint 5 Connect the tubing to the new scrubber and tighten the retaining nut at the bottom of the new scrubber 6 Press the scrubber into the retaining clip and connect the tubing to the top elbow joint Tighten the retaining nut 7 Replace the top cover and close the front panel Figure 9 Scrubber Replacement 3 3 7 Leak Test Procedure This is a test for the pneumatic system of the instrument The display readings will indicate whether the system is leaking or not Note This procedure applies only to the instrument It does not include the EZS valve option The option must be disabled to perform this test 1 Enter the TEST MENU and select OUTPUT TEST MENU then VALVE TEST MENU from these items pick VALVE SEQUENCING and set to OFF
38. nt gain is not set to 0 000 98117601 Rev B 45 EC9811 ANALYZER SERVICE MANUAL System Troubleshooting Table Symptom Possible Cause Fault Isolation Solution span gas Leaks A leak dilutes the sample stream and causes low span readings and noise See section 3 3 7 above No flow Check the INSTRUMENT STATUS menu and verify flow 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 Leak A leak dilutes the sample stream and causes low span readings and noise See section 3 3 7 above Zero air source Replace zero air source 8 Unstable flow Failed flow control The flow temperature SYSTEM or pressure heater TEMPERATURES screen should be 50 5 C readings 9 Instrument Reference voltage Perform UV lamp check and adjustment stuck in reference INSTRUMENT adjust STATUS screen not at 3 volts Lamp current not at Replace UV lamp Lamp Driver PCA or 10 mA Preprocessor PCA 10 Response time Low flow Check sample flow with flowmeter It should be not at specified 0 4 to 0 6 slpm STP Replace SS filter or orifice value if it is not 11 Analyzer Preprocessor ID set 1 Check J5 connector on Microprocessor lays BAD Wrong 2 Check J4 connector on Preprocesso
39. perations you wish to perform Enter bootloader Erase Flash ROM Erase EEPROM Erase RAM Upload Firmware O O Run Firmware Previous Figure 15 Firmware Update operations screenshot Ensure the analyzer is switched off using the switch under the front panel Click Start Switch the analyzer on 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 ip Firmware Update Connect to Analyser Enter Bootloader DK Erase EAPROM OK Erase EEPROM SKIPPED Erase RAM SKIPPED Upload Firmware OK Verify Upload OK Run Firmware OK Previous Close Figure 16 Firmware Update completion screenshot 98117601 Rev B 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 Troubleshooting Voltage Table PCB Supply DVM DVM Response Microprocessor 12V GOOD TP1 PGND TP2 5V 0 5V 10V de 10V 0 5V 20V 20V 0 5V Voltage TP7 AGND TP9 12V 0 5V Regulator 10V 0 5 10V 0 5 5 0 25 Preprocessor 12V 0 5V 5V 0 25V 10V 0 5V 10V 0 5V Lamp Driver 12v 0 5V Flow Control 5 0 25V A Series 4 5 0 25V 12 0 5
40. ponent Minimum Typical UV lamp O3 measurement 6 months 1 to 2 years 98100011 O scrubber filter 881 025001 1 to 2 years UV lamp 03 Generating 98110012 6 months 1 2 years 19 EC9811 ANALYZER SERVICE MANUAL 20 3 3 Maintenance Procedures Following is a list of routine maintenance procedures which may be required through the life of the analyzer Recommended equipment to perform maintenance Toolbox o Oscilloscope o Digital multimeter DMM o Computer or remote data terminal and connection cable for RS232 communication a Pressure transducer absolute and connection tubing calibrated in torr o Flow meter 1 slpm nominal Wire strippers o Soldering iron o Minifit extraction tool o Orifice removal tool o Assortment of 1 4 and 1 8 tubing and fittings o Test zero air source D Test span gas source o Leak tester 98117601 Rev B CHAPTER 3 MAINTENANCE Figure 7 Routine Maintenance Components 3 3 1 Check Particulate Filter 98117601 Rev B The inlet filter prevents particulates from entering the pneumatic components of the EC9811 Contamination of the filter can result in degraded performance of the EC9811 including slow response time erroneous readings temperature drift and various other problems Several factors affect the filter replacement schedule In the springtime for ex
41. r ANALYZER 3 Reprogram device ID 4 Replace Preprocessor 12 No Ozone Tubing missing Verify ozone generator output connected to inlet output Ozone lamp not Plug in lamp plugged in Generator turned off Instrument must be in MANUAL CAL SPAN or generator must be turned on using O3 GEN MENU Burned out ozone Replace ozone producing lamp producing lamp 98117601 Rev B INDEX B Block diagram eee 9 11 Cable Connections 7 Cell tube cleat T a annenin 26 Components 24 D DATA LOGGING efi ta 48 Diagnostic modes eee 52 E Electric test function ooooonncnoncnocnconnnnnconnonononononnnnos 51 Electronic system components 15 Bv nt LOS iiine ere eet 47 F Fan filter cleanmng eee 26 Filter maintenance cccncocononcncnnnonnnanananininannannns 24 27 Flow Pressure board calibration 34 35 I Illustrations Cable 7 Illustrations Instrument Status Ranges 34 37 38 40 41 49 Illustrations Major Components 12 Illustrations Opening the Front Panel 5 Illustrations Ozone Scrubber Test 30 Illustrations Pneumatic Diagram 14 Illust
42. r 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 EC9811 Ozone Analyzer Operation Manual PN 98117601 Rev B April 2007 Ecotech Manual ID MAN 0004 Manual PN 98117601 Current Revision B Date Released April 2007 Description EC9811 Ozone Analyzer with Internal and External Zero and Span Service Manual Revision History Rev Date Summary Affected Pages A October 2005 New Release for new Microprocessor Board All Based on original manuals B April 2007 Updated specifications language and links All within pdf manual created 98117601 Rev B 3 EC9811 O 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 EC9811 is compliant with the requirements of EN61010 1 A2 1995 Safety Requirements for Equipment for Measurement Control and Laboratory Use If the equipment is used for purposes not specified by the manufacturer the protection provided by this equipment may be impaired Replacement of any part should only be carried out by qualified personnel only using parts specified by the manufacturer Always disconnect power source before removing or replacing any components Equipment Rating O O O O
43. r block The O rings on either end of the Rx cell mounting may also be replaced Tighten the retaining nut Perform the leak test 3 3 4 2 Cleaning the Lines The pneumatic lines sample and exhaust may be cleaned by removing and washing with a methanol cotton swab pushed through and dried by blowing with zero air or dry nitrogen Do not clean the scrubber 98117601 Rev B 23 EC9811 ANALYZER SERVICE MANUAL 24 Note After tube or cell cleaning the analyzer should be allowed to sample at approximately 0 400 ppm overnight to recondition the pneumatics prior to calibration 3 3 5 UV Lamp Check The UV lamp must be of sufficient intensity to ensure proper operation of the analyzer A weak UV lamp will cause the analyzer output to become noisy If the signal becomes extremely weak measurement will stop completely The intensity of the UV lamp is reflected by the gain required to maintain a sufficient signal This gain can be viewed as the input potentiometer setting in the PREPROCESSOR POTS MENU As the intensity of the UV lamp decreases the setting of the input potentiometer will increase The decrease in lamp intensity is typically very slow but since the reference voltage is usually only adjusted during a startup cycle there will sometimes be a dramatic increase in the Input potentiometer setting As a routine maintenance procedure the operator should maintain a log and record the input pot setting in
44. rameters 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 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 Enter 98117601 Rev B CHAPTER 3 MAINTENANCE 7 Set the FLOW ZERO POINT to SET and press Enter J The GAS FLOW should now read 0 000 SLPM 8 Disconnect the DVM 9 Turn the analyzer pump ON and verify the CONTROL LOOP is still DISABLED 10 From FLOW CALIBRATION MENU use the PUMP SPEED COARSE and PUMP SPEED FINE pots to adjust the measured flow external flow meter 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 11 Record the average measured flow from the flow meter and enter it into the FLOW SPAN POINT and press Enter J 12 Set the DESIRED FLOW to 0 50 SLPM and press Enter 1 13 Press Reset on the analyzer and allow the flow to stabilize Verify the flow meter reading is now 0 50 0 05 SLPM Note After the instrument startup is complete
45. rations Preprocessor Pots and Ranges 46 Illustrations Routine Maintenance Components 24 Illustrations Sintered Filter Replacement 27 Illustrations System Block Diagram 11 Illustrations System Temperatures and Tolerances 49 Illustrations Valve Test Menu 47 Installation eiie tt poene cette 5 Instrument Status Ranges illustration 34 37 38 40 41 49 Instrument Status screen 49 L Lamp Driver board sse 16 Lamp mammtenance 28 Leak check temet mette 32 LOGGING ient EORR 48 M Maintenance periodic oocoooncccononoconononononncnnnonononnnnns 19 Maintenance routine sese 23 98117601 Rev B CHAPTER 4 TROUBLESHOOTING Major Components illustration 12 Measurement 15 Microprocessor 10 Modes of operaton 16 O Opening the Front Panel illustration 5 Optics system components 15 Ozone scrubber description 13 Ozone scrubber 29 Ozone Scrubber Test illustration 30 P Particulate filter maintenance 24 Periodic mauntenance 19 Pneumatic diagram seen 13 14 Pneumatic lines cleaning
46. sity during the scrubbed air cycle and during the sampling cycle The ratio of the intensities is proportional to concentration Preprocessor PCA This circuit board contains the analog electronics that condition the detector signal generate the lamp control signals and generate all the signals required for preamp optic and electronic test diagnostic functions It also contains a heater control circuit to heat the UV lamp block to 50 C The board also contains an EEPROM which contains device identification and stored setup parameters All circuitry adjustments 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 98117601 Rev B CHAPTER 2 THEORY OF OPERATION o Flow Control PCA The pressure flow portion of the board contains an absolute and a gauge pressure transducer to measure cell pressure and control sample flow This board also controls the pump speed powers the chassis fan and has a heater control circuit to heat the flow block A series only o Pressure PCA The pressure flow portion of the board contains an absolute and a gauge pressure transducer to measure cell pressure and detect sample flow This board also powers the chassis fan and has a heater control circuit to heat the flow block 2 3 Operation Modes
47. t gain Fault Isolation Solution 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 If incorrect voltages are found replace the power supply or Vreg 3 Check Microprocessor test points listed in the Troubleshooting Voltages table in section 4 1 Check the interface cable between the display and J6 on the Microprocessor board 1 Replace the front panel display 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 Replace the pump Check the particulate filter Replace if dirty or plugged Recalibrate the Flow Control Assembly Ensure sample and zero inlets are maintained at ambient pressure Clean or replace the orifice and SS filter A leak dilutes the sample stream and causes low span readings and noise See section 3 3 7 above Replace the particulate filter Ensure the reaction cell and analyzer covers are installed Check ozone scrubber Clean Rx cell Check UV lamp Replace UV detector Adjust the span using the Calibration Procedure in Chapter 3 Calibration Check ozone scrubber Clean Rx cell Check UV lamp See the Zero flow symptom in this table A leak dilutes the sample stream and causes low span readings and noise See section 3 3 7 above Verify the instrume
48. tHY acotech environmental monitoring solutions EC9811 Ozone Analyser with internal zero amp span Service Manual www ecotech com FRONT MATTER Table of Contents MANUAL HISTORY ata a tet et a E I bem mant mU 3 SAFETY REQUIREMENTS tia 4 SERVICE AND SPARE PARTS E HR eere e e tete ee nte ree LL o QE P Die Ee 4 1 0 INSTALLATION eec sooo erar io eere erp seen uen Foren so Tae NE E E cn a ane RUE 5 TeV INITIAL CHEGK ii eet a iei de te ecd tee P echec 5 I II Remove th TOP COVeF i ri E is 5 1 1 2 Service SWUCN sin 5 LAGS Inspect AE INT E AEN 6 1 1 4 Reinsert Dislodged enne entrent nenne trennen trennen 6 T 1 3 CADE EE 7 2 0 THEORY OF OPERATION WE 8 2 1 OZONE GENERATOR THEORY reat o reee e eaer en Er EEr Ee E EEn EN EEN Seer REEE Epee aE opa E eNe 9 2 2 INSTRUMENT DESCRIPTI N 5 etit einn ee i npn re esed cede a re Rede pute e eee aee svo E ENEE Seed ee eege 10 2 2 1 Power Microprocessor Module EEN 10 2 2 2 Sensor Module sisinio ee eed edes ee eee ee deae eee ree pee pe eee ve Eee dead ese eese drea veo NEEN 12 2 30 PERATION mette natione atn OI etis 15 2 3 1 St rt p saos a ae Do D E e NO PO Re rettet rto 15 2 3 2 Me sure EE 16 3 0 MAINTENANCE DP 17 3 1 MAINTENANCE SCHEDULE 4 ete endete cet dd ee tet tec ipee ecd ev ee
49. the boards must be attached to the metal bulkheads by the plastic or metal studs with spring tips 6 98117601 Rev B CHAPTER 1 INSTALLATION 1 1 5 Cable Connections 98117601 Rev B 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 EC9811 ANALYZER SERVICE MANUAL 2 0 Theory of Operation Ozone exhibits strong absorption in the ultraviolet spectrum around 250 nanometers nm The EC9811 ozone analyzer exploits this absorption feature to accurately measure ozone concentrations to less than 0 5 ppb A stream switched single beam photometer serves as the basis for the EC9811 A mercury vapor lamp is used as the source and a solar blind vacuum photodiode is used as the detector A glass tube serves as the absorption cell During the reference cycle of the stream switching process air is drawn into the photometer through a scrubber which removes all ozone and the light intensity Io is determined The valve is then switched to allow ambient air to fill the cell During this measurement cycle the light intensity I is determined The Beer Lambert Law gives the relationship between these m
50. the PREPROCESSOR POTS MENU On a routine basis As the potentiometer setting approaches 100 the maximum available gain setting replacement of the lamp should be considered 3 3 5 1 UV Lamp Replacement 1 Turn the analyzer off 2 Remove the analyzer cover and the internal reaction cell cover 3 Remove the screw securing the green ground wire to the UV lamp block 4 Loosen the thumb screw securing the UV lamp and slide the lamp out of the block 5 Install the new UV lamp in reverse order of the above steps Be sure to insert the lamp completely in the block to achieve maximum signal strength 3 3 6 Ozone Scrubber The performance of the ozone scrubber is critical to the EC9811 Although the ozone scrubber will theoretically last forever if exposed to only O3 and air exposure to other elements in the atmosphere will adversely affect the life span of the scrubber A weak or failed scrubber can result in noisy measurement frequently caused by excessively high gain 98117601 Rev B CHAPTER 3 MAINTENANCE The quickest indicator of ozone scrubber efficiency is the instrument gain of the analyzer This is calculated automatically by the analyzer every time it is manually calibrated As scrubber efficiency decreases instrument gain must increase to compensate for it Since this number is however affected by factors such as atmospheric pressure and cell cleanliness it is only an indicator not a true test of scrubber e
51. the parameters are outside the acceptable ranges a significant problem among these components is strongly indicated For more information on the operational limits and fault messages refer to the table in section 4 2 7 System Faults 4 2 7 System Faults The SYSTEM FAULTS display provides start pass or fail indications for various parameters which are continually monitored These parameters must be within acceptable operating ranges in order to display Pass If FAIL is indicated this indicates a major failure in that area If the instrument is in startup mode START will be displayed Note The SYSTEM FAULTS screen only indicates PASS or FAIL for the various analyzer parameters and indicates a major failure 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 FAULTS messages which 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 42 98117601 Rev B CHAPTER 4 TROUBLESHOOTING Message OUT OF SERVICE N ERO FLOW LAMP FAILURE REFERENCE VOLTAGE OUT OF RANGE 12 VOLT SUPPLY FAILU
52. ure Modes 2 3 2 1 Sample Measure Sample measure is the standard operating mode of the EC9811 2 3 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 3 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 98117601 Rev B CHAPTER 3 MAINTENANCE 3 0 Maintenance 3 1 Maintenance Schedule The following outlines a periodic maintenance schedule for the EC9811 analyzer This schedule is based on experience under normal operating conditions and may need to be modified to suit specific operating conditions It is recommended that this schedule be followed in order to maintain reliable long term operation of the analyzer Interval Item Procedure Section Weekly Inlet Particulate Filter Check Replace Service Manual 3 3 1 Event Log System Faults Service Manual 4 2 4 amp 4 2 7 Operation Manual 2 4 Monthly Service Manual 3 3 3 Operation Manual 2 4 Operation Manual 2 3 3 6 Monthly Service Manual 3 3 6 Operation Manual 3 2 1 Year Service Manual 3 3 4 Service Manual
53. 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 1 2 Set the ANALYZER TYPE to 9811 and press Enter J 98117601 Rev B 33 EC9811 O ANALYZER SERVICE MANUAL 34 3 Press Reset on the analyzer secondary panel The display should now display 9811 03 ANALYZER 4 You may need to erase memory after this procedure to avoid any problems This completes the analyzer device type programming 3 7 Firmware Update As improvements are made to the EC9800 series analyzers these can be easily passed on to the user by updating the firmware software operating within the Microprocessor board To update your EC9800 Analyzer download the Firmware Updater Software Install this software on a Windows based computer with a COM port To do this run the downloaded file setup exe by double clicking on it then follow the installation screens to install Next download the required software version for your 9800 analyzer from those listed at the bottom

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