680 Emission Analyser Service Manual
Contents
1. date and time confirm with Continue then Exit Oxygen Cell Select Oxygen cell Ensure that the oxygen cell is correctly connected and then select Install new cell to perform an installation If unsuccessful rectify the fault and then repeat the installation Exit Oxygen cell Flow Setup Connect the flow gauge to the sample probe inlet Select Live Readings check that the pump turns on and that a flow of greater than 6 0 L min is present Exit Live Readings select Oxygen cell and click Retest This will force the analyser to perform an autozero During the autozero ensure that the flow at the sample inlet is less than 5 0 L min and a flow is present at the inlet of the charcoal filter Ensure that NO flow is present at the cal gas port Disconnect the pipe to the pressure sensor and connect the digital manometer ensure that the connection is gas tight Block off the sample inlet and select live readings Check that the reading on the manometer falls to less than 400mbar Allow the reading to stabilise and note the final value displayed on the manometer Exit Live Readings and ensure that the pump turns off wait 30 seconds and check that the reading has not changed by more than 20mbar of the final value displayed If the reading changes by more than 20mbar check the system for leaks resolve amp recheck Disconnect the manometer and reconnect the pres2. 0 001 Unleaded Petrol L P G or C N G 31 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C Environmental Operating temp 45 to 40 C Storage temp 20 to 55 C Warm up Time lt 60 seconds Response Time 11 seconds to 95 of final reading with 8 metre sample hose Flow Rate 8 litres min nominal 5 litres min minimum Operating Pressure 750 1100 mbar 1013 mbar nominal Power Reguirements 100 240 volts AC 50 60 Hz Power Consumption 60 watts maximum Size 343mm 13 5 W x 220mm 8 7 D x 170mm 7 H Weight 5 2kg 32 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C A V O PBS B X lt lt a v APPENDIX 1 LIST OF ICONS Exit from program or current test page Display context sensitive help Starts the MOT procedure Calls up a live display of gases engine speed oil temperature and calculated Lambda for test and repair operations Information page Contains data regarding software versions serial numbers pefs calibration dates Selects the next menu Returns to previous menu Next continue Back return Accept Cancel 33 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C O Repeat Print Edit personal garage header gt Add delete testers L Set adjust time and date Auotzero uotzer Check replace Oxygen Cell I O HC Residue test E Leaktest L Service Mode x Audit
3. Water Trap fitted to Fig 4 Flow Diagram host trolley E i FL5004A x The Processor board requires programming according to the specific customer 680 Emission Analyser Service Manual June 2008 TES1567 Issue C For part number see TES1601 CABL7022 Pd NOx 02 Cell Cell SWIT5029 AS09190 CONNO125 RS232 TRDUO134 B 120 BN 120 PWRSOO26 G Y 100 EARIH o O He C STUD Pe o 9 5 i AS09138 QS o i MA i o i o pi za AS09137 TO SOLENOID BLUE RI ORANGE AS09189 ific customer FROM PUMP 10 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C Auto Zero The analyser performs regular zero operations to ensure continued accuracy The time intervals between zeroes from switch on are 5 minutes 15 minutes then every 30 minutes thereafter A manual zero can also be performed from the Tools amp Setup menu The analyser will also perform a zero if any of the gas channels drift negative by more than the Maximum Permissible Error MPE These are as follows HC 12ppm CO 0 06 CO 0 5 O 0 1 When a zero is initiated the changeover solenoid see fig 4 is energized Gas flow to the bench is changed from the filters and sample inlet to the autozero port via the Zero filter and 1 5 psi check valve The vacuum of the pump is great enough to open the 1 5 psi valve but not the 3 0 psi one both devices are one way valves This ensures that cle
4. Zero Filter Sample Pump W Sample Filter ater FILT0029 Inlet FILT0048 Outlet Outlet Flow Processor Power Supply Transducer Board IR Bench underneath cover 3psi Changeover pd Pump Pump 1 5psi Check Valve Check Valve Solenoid Gas head Liquid head FILT0048 Fig 3 Components 8 of 36 Processor Board Power Supply Unit PWRS0026 1 5 psi Check Valve VALV0019 En Zero Filter FILT0029 Autozero Port ep mi 680 Emission Analyser Service Manual June 2008 TES1567 Issue C IR bench TRDUO134 TT d For part number see TES1601 0000 00000 0000 guaano Liquid Flow Transducer amp IT T PID gt e ojm OL 3 0 psi Check valve VALV0020 JAL 1 2 Cal Gas Port i te Changeover Solenoid cal CLE H LD pS VALV0033 nee 1 T Approx Bench Filter 7 L7 7 S Umi FILTOO48 j A eee Gas Filter Approx rh pesi n 5 L min Sample Inlet jeli Ci IT 5 Oxygen Cell T Water Trap L Tea P TRDU0067 in amp Primary Filter Pump Filter Manifold mo FILTO048 PFITO049 I Water Outlet L Flow approx 8L min From Sample Sample Outlet requirements See appendix 2 for further details 9 of 36 i Hose Prob aid PFITO010
5. 1 Bench Extended Error Status Byte 1 00 Byte 2 00 Byte 3 00 Byte 4 00 Bench Gas Channel Raw Counts 36319 35100 HC Channel CO Channel CO2 Channel 27735 O2 Channel 41411 NOx Channel 0 Reference Channel 33207 Fig 17 Bench Diagnostics The raw channel counts are useful to determine if the bench is becoming contaminated Should any or all of the counts fall to 20000 or less the bench will flag a low light warning and this will be displayed as a fault code see section on fault codes The counts should be checked before calibration to avoid a potential failure shortly after If the counts for any of the channels are less than 25000 it would indicate that the bench is becoming contaminated and preventative action should be taken i e service replacement If all of the channels are low it may indicate possible flooding or a light source failure 27 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C Replacing the Bench The bench is mounted above the power supply and is held by two rubber anti vibration mounts and M4 nuts Gas is supplied to the bench directly from the output of the pump however as the flow from the pump is too high gas for the bench is sampled off using a bypass with a 1mm orifice restrictor WARNING Always ensure that the correct antistatic precautions are taken when handling the IR Bench To replace the bench first discon
6. Analyser Service Manual June 2008 TES1567 Issue C Code FO on ByteO indicates low light level on all IR channels This is the type of code that would be expected if the bench had been flooded List of Fault Codes BYTE CODE HEX DESCRIPTION 0 10 Reference channel light level below operational specifications 20 Low HC light level during AUTOZERO 40 Low CO2 light level during AUTOZERO 80 Low CO light level during AUTOZERO FO Low Light All Channels during AUTOZERO 1 All Codes Not used 2 All Codes Not used 3 01 O2 signal 7mV during bench zero 02 O2 signal 3mV during bench zero 08 Hexane span fail during calibration 10 Propane span fail during calibration 20 CO2 span fail during calibration 40 CO span fail during calibration 80 NO span fail 5 gas units only 30 of 36 680 Emission Analyser Service Manual June 2008 TECHNICAL SPECIFICATIONS Measured Gas HC Hydrocarbons CO Carbon Monoxide CO Carbon Dioxide O Oxygen Ranges CO O to 10 96 CO O to 20 96 HC 0 to 10000 ppm O5 O to 25 Accuracy Performance OIML R99 Class 0 HC 8 ppm HC absolute or CO 0 0295 CO 5 of reading CO 0 30 CO whichever O 0 10 O is wider Resolution HC 1 ppm vol CO 0 01 vol CO 01 vol O 0 01 vol RPM TES1567 Issue C O 10 000 rpm with DIS Wankel and 4 stroke selection Oil Temperature 0 120 C Lambda Calculated using Brett Schneider formula Resolution Fuel type selection
7. Fig 11 Service Mode Authorisation enable When the code is entered the service menu will automatically be displayed Fig 12 The analyser will then stay in service mode until the exit icon is selected Petrol Emissions Analysis WGTS3UK Software version 1 0 0 Database version August 2007 Fig 12 Service Mode 20 of 36 June 2008 TES1567 Issue C 680 Emission Analyser Service Manual For Basic MID compliant analysers i e those sold outside the UK service activation is achieved by shorting the pins of LK2 on the processor board together refer to Figs 13 amp 14 When the pins are shorted the analyser will automatically enter service mode and stay there until exit is selected Only authorised service personnel may activate service mode Refer to test procedure Waiting for service mode activation ig 13 Service Mode Jumper Enable F J tl Short pins of LK2 Fig 14 Service Jumper 21 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C SET UP Function Test equipment required Flow Gauge 0 12 litres min Manometer digital 0 2000mbar Mixture gas comprising 3 5 Vol CO Nom 14 0 Vol CO Nom 2000ppm Vol C3Hg Nom Balance No Connect unit to mains supply and switch on Time amp Date Enter the Service Mode An Authorisation Code will be required and select Date amp Time Check that both the date and time are correct If they are not correct then set the
8. Log Diagnostics 34 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C zl MU C 4 Y 9 Calibration Flow Setup IR Bench Diagnostics Serial Number 35 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C AFTER SALES SERVICE Apart from the routine maintenance and adjustments stipulated in this manual the eguipment must not be tampered with in any way All further servicing must be carried out only by an engineer from an Authorised Agent Failure to observe these conditions will invalidate the Guarantee Helplines On Site Service Overhaul Spare Parts If you reguire a Service Engineer to attend ON SITE either due to an eguipment fault or for machine calibration or if the equipment covered by this manual requires to be sent back for factory overhaul or if you need spare parts please contact our Product Support Helpline at the following number during normal office hours Tel 0845 634 9904 Fax 0845 050 99363 Email support CryptonTechnolo A fully comprehensive Product Support Contract is also available which provides additional assistance with eguipment technical support Please contact Product Support on the above Helpline no for further details Call Crypton Helpline for details of local service agents Overseas Service abroad is provided by the agent from whom your eguipment was purchased Crypton provide information and contracts covering Car Data Fault Co
9. filter in this trap its purpose is to help to cool the sample and remove a large proportion of the water vapour before it reaches the analyser From there the sample is passed through a dual bowl filtration system The first bowl consists of a primary filter and water trap Residual moisture is separated from the gas in this bowl and the condensed liquids are removed from the bottom of the bowl by the liquid head of the pump There is a 75 micron nylon filter to remove the larger particulates and a pump filter to prevent contamination of the liquid head The dry gas is then passed through the gas filter bowl which houses a 0 6 micron filter to remove the residual contaminants This is followed by a bench filter which is fitted purely to prevent contamination of the bench and internals in the event of failure of any of the external filtration components From there the sample passes through the changeover solenoid and gas head of the pump and then on to the IR bench The cell for measuring oxygen is positioned in the exhaust tract of the sample Preconditioning Water Trap Fitted to Host Trolley 7 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C Water Trap 8 uM Primary Filter Gas Filter Calibration Gas FILTOO41 FIL T0040 Port Cell ZERO WATER TRAP O GAS NILTER CAL GAJ NOX CELL EL NL RYMARY FILTER B Mali t SERVICE REPLACEME ONLY n 1 FILTER WATER INLET L e REPLACEMENT ONLY OUTIZ
10. gas configuration measuring CO CO2 HC and O2 is the most common found in Europe as there is no legislation concerning levels of NOx produced by a vehicle The particular advantages of the bench in the 680 are its low power consumption typically less than 0 75W wide power supply range 8 42V DC and fast warm up time less than 60 seconds The bench derives power and communications via the 20 way ribbon connector Communications are via an RS232 link see Fig 16 for connector pin out 19 20 VPWR OO VPWR TACH OO TXDZ USER7 O O RXDZ USER3 OO Vec USER6 OO USERS USER4 O O USER2 USERI O O USERO EXTA3 O O EXTINT EXTA2 O O EXTAI GND o ol GND 1 2 Fig 16 Bench Connector Pins 1 5 and 17 are additional user inputs and are not used These pins are connected directly to ground at the processor board Pins 6 13 and 15 are user outputs and are not used These pins are connected to ground via 4K7 resistors at the processor board 26 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C Bench Diagnostics A diagnostics screen is available from the service menu This screen displays live raw counts from the bench along with extended error codes sample cell temperature and pressure etc Fig 17 Bench Information and Environmental Data Status 00 Manufacture Date Nov 09 2007 Revision 02 Sample Cell Pressure mBar 1017 Sample Cell Temperature 9C 30
11. CRYPTOr In TUNE WITH THE FUTURE o ZERO WATER TRAP rires PRIMARY FILTER IZ d z z P s SERVICE REPLACEME ONLY WATER ILTER RVICE REPLACEMENT ONLY OUTIZ 680 Emission Analyser Service Manual TES1567 Issue C June 2008 680 Emission Analyser Service Manual June 2008 TES1567 Issue C This page intentionally blank 2 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C CONTENTS THEORY OF OPERATION e enne seen ANNR nahm u nana aa aiiai u nun aiana 5 POWER SUPPLY 0 2 02255522202252402434822028028022 323 8 5 4 EFE ERR EERERBRERBREREENRIDRSRRER RSEN 6 SAMPLING AND FILTRATION SYSTEM eee een enne enne nnne 7 Sampling Gas LLe eee ee eens eens eases ANN NA eases eee eee eases sees 7 Auto ZETO LLL a A RNNNNNNNNNNNNNNNNN RRNA ANN NN eee eee 10 CalibratiOn 5 42 12 015 9v 055222 055922522022 025 024050228 025022 SAY EEFTRRERSUEDRESOSSSIRRARSSAA 11 POTENTIAL PROBLEMS AND CAUSES e eere enean anna 12 Gas Flow Restricted e oeese eee eee a nennen nean ununi 12 Leak Test Failure 1 0 1 1 112 220 20 nn ananasnuEa sRaRARERREERRERRRRRRRRRRARRSRR ERROR 12 PROCESSING CIRCUITRY e eseeseesne hne hn enne h nean annuntiat unus ununun 14 Processor PCB NARA EARRA ERARA ERAEN KARRERA ARENAER RERNA 14 Replacing the Processor PCB ccsceeeseeeeeeeeeeeeeueeeeuaeeeuaeeeuaeeeuaeeeuaeeauaee
12. This is achieved by comparing data from the analyser including serial number firmware version etc with that stored in the audit log A code corresponding to the current state of the audit log is then stored in the analyser In each analyser supplied by Crypton this code is reset so that the program will recognize it as a replacement new analyser and update the audit log with the new serial number However should an analyser be used that has not been reset it will invalidate the audit log see Fig 15 as the analyser serial number will not match that already stored in the log It will then need entry to the Service Mode for rectification Petrol Emissions Analysis WGTS3UK Software version 1 0 0 Database version August 2007 The audit log is invalid Contact Product Support Fig 15 Audit Log Invalid From service mode select Audit Log Diagnostics If an analyser has been used that has not been reset the program will then prompt the operator to reset the serial number The audit log will then be updated and normal operation restored 25 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C IR BENCH The bench fitted to the 680 module is a Non Dispersive Infra Red NDIR type found in most automotive emission analysers The bench uses the NDIR technigue to measure CO CO2 and HC Oxygen and Oxides of Nitrogen NOx may also be measured by using electrochemical cells fitted externally to the bench The 4
13. an air for the zero is pulled only through the charcoal filter The purpose of this charcoal filter is to remove any residual ambient Hydrocarbons thus ensuring a more accurate zero The zero routine consists of a 30 second purge to ensure that there is no sample gas left in the system followed by the zero command to the IR bench This will typically take a further 10 seconds for the bench to respond After the zero the analyser will check the oxygen cell Cell millivolts at this point must be within 5 13mV for the cell to pass This is followed by temperature compensation of the pressure transducer No operator intervention is necessary Calibration When calibrating the correct tag values must be entered These are the gas bottle concentrations as shown on the bottle certificate The sample cell pressure is also displayed at this point and should be checked to ensure that it is within 20mbar of ambient The analyser will then perform an Autozero as described above After the zero the calibration gas bottle should be connected to the Gas Cal port and the bottle pressure set using a digital manometer to between 1350 and 1450mbar It may be noted that the Calibration Gas Port uses the same changeover solenoid as the Autozero The bottle pressure when set correctly is high enough to open the 3 0 psi valve but at the same time reverse bias the 1 5 psi one and ensure that it stays shut This forces calibration gas through the solenoid and
14. auags 15 OPERATION AND CONTROL AA nemnda panine aipuan nena a nana 17 SERVICE MODE 2 55 5 2 6 o oaa ipak ORRoRRUERORUURRRRARSERSARAREERER RERRRERPRREERSRRRRRRaER 20 Set Up Function aaa ERA ANA ANA NA nma umana nana seus u sus earran 22 Replacing the Analyser eee eee eee eee eene nn enean une u nana nana nan 25 TR BENCH 5 5 25 25353 5 8509055025008 822 0308280280008 RVORURI SES EEPUROPRRUERREEOSSUERORASENE 26 Bench DiagnostiCS ina N RRNA NANA RNA NN NANA u uuu u uua uuu ua uuu uuu 27 Replacing the Bench nan A nune uuu aaoi ieaiai Eiaa iniaa uan 28 Faultcodes 5 502 edecuscsuUsuen EN HA iin 29 List of Fault Codes e eeeeeeeeeeen a nenne hne h neun annua nana 30 TECHNICAL SPECIFICATIONS ee esreee eene a nean annua ana unnann 31 APPENDIX 1 LIST OF ICONS ee eee eee eene n nenne annum anat 33 AFTER SALES SERVICE ee eeeeeneenenne hne RN enne h nenne h nanus u nana 36 3 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C This page intentionally blank 4 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C INTRODUCTION The 680 is a microprocessor controlled exhaust gas analyser employing non dispersive Infra Red NDIR measuring technigues and designed primarily for the legislative MOT test on petrol CNG LPG vehicles The unit measures Carbon Monox
15. bench raw data see section on IR Bench A Tools amp Setup menu Fig 9 is available from the Main Menu This allows the user to perform other basic functions such as setting the time performing a manual zero performing a leak test etc Service mode is also accessed from this menu Petrol Emissions Analysis WGTS3UK Software version 1 0 0 Database version August 2007 Fig 9 Tools amp Setup 18 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C It is also possible to view the Audit Log Fig 10 from this screen All analysers approved for sale in Europe from October 2006 must have an Audit Log which records updates changes to the software plus the analyser serial number etc Validation Header Analyser Serial Nu Recorded Events 24 09 2007 11 27 Software Version 0 0 0 9883 imber Di Fig 10 Audit Log 19 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C SERVICE MODE Set up of the analyser is performed from the Service Mode There are two methods of entering Service mode dependent on the legislative market On UK analysers an Authorisation code is required Fig 11 An authorisation code only available to approved service personnel is required to perform service operations Contact Calibration Authorisations quote the Request Code and enter the Authorisation Code your are given Request Code a8b6 0408 3ed3 a178 Authorisation Code
16. de Information Diagnostic Information Software Support Contracts Software Updates 8 Accessories 36 of 36
17. e is 100 240V AC 50 60Hz and no adjustments are necessary within this range The DC outputs are 5V 0 25V 12V 1 0V 12V 1 0V The outputs can be measured at the power connector of the processor bd SK4 as shown in fig 2 For part number see TES1601 ocooo ooooo O 12V Fig 2 Power Supply Connections Power for the processor is derived from the 5V rail The IR bench pump and solenoid are driven from the 12V rail The 12V rail is used solely for the amplifier of the pressure transducer and for RS232 communications when fitted x The Processor board requires programming according to the specific customer requirements See appendix 2 for further details 6 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C SAMPLING AND FILTRATION SYSTEM The sampling system comprises a sample probe with 8 5m hose 12V DC dual headed pump 3 stage filtration system and changeover solenoid for use when the analyser is performing a routine zero function Please refer to Fig 4 and drawings AS09121 and AS08754 for details and part numbers of the pneumatics components Sampling Gas Please refer to Figs 3 amp 4 Gas is drawn from the vehicle exhaust by means of the pump via the sample probe hose and filtration system The gas flow at the sample inlet of the analyser given clean filters is around 8L min On UK analysers there is a preconditioning water trap shown below fitted to the host trolley There is no
18. everse of the removal procedure Bench Connector Fixing screw Coloured tracer SK6 Power Connector Denoting Pin 1 SK4 Solenoid Connector SK2 Pump Connector SK1 Vacuum Pipe Fixing screws Fig 6 PCB Fixings 15 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C After replacing the PCB it will be necessary to perform some basic set up functions These include setting the flow limits serial number and performing a calibration to ensure that the recalibration date is set Refer to the SET UP Function procedure in the Service Mode section for further details Note If the PCB has previously been used in another analyser a problem may be encountered with the audit log stored on the PC 16 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C OPERATION AND CONTROL As previously stated from start up the application will first perform an autozero After the zero the Main Menu is displayed Legislative and market variations affect only the language and in some cases the inclusion of a legislative procedure icon Fig 7 below shows the difference between the basic MID Measurement Instruments Directive compliant analyser and the UK Analyser which must include the MOT procedure All operations are performed using the icons in the toolbar on the right hand side of the screen Petrol Emissions Analysis WGTS3 Software version 1 0 0 Petrol Emissions Analysis WGTS3UK Softwa
19. ide CO Hydrocarbons HC and Carbon Dioxide CO2 A further channel Oxygen O2 is measured using a chemical cell A fifth compound Oxides of Nitrogen NO is available as an option The unit automatically compensates for zero drift by performing a zero check 5 minutes 15 minutes and every 30 minutes thereafter from switch on THEORY OF OPERATION Non dispersive infrared spectrometry relies on the way different gases absorb infrared radiation at specific frequencies see fig 1 The amount of radiation absorbed can be used to calculate the concentration of a sample gas The sample gas is passed through the sample cell where an infrared source is positioned at one end and an array of detectors at the other Placed just in front of the detector array is a series of filters designed to be transparent only to the selected frequencies of radiation This arrangement allows the concentrations of several gases to be determined Absorption Spectra 100ppm metres 0 14 4 06 co2 0 12 1 05 Propane 010 N o TU o o poi o o V s n Hexane o o E 5 S 2 E 2 o a2 2 lt lt 0 02 F T T T T T T T T T 0 1 3 0 3 2 34 3 6 3 8 40 42 44 46 48 50 Wavelength um Fig 1 Absorption Spectra 5 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C POWER SUPPLY PWRSO026 There is a 65W multi rail switched mode power supply providing power for the analyser Input rang
20. just been changed Occasional contamination in liquid head of pump preventing the valves from closing correctly Check s The test is performed in two parts I Threshold test II Leak test The threshold test is performed to ensure that the pump is in reasonable condition and is actually running When a leak test is performed the PC will run the pump for 20 seconds to allow the vacuum to stabilise At the end of this 12 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C period the output of the pressure transducer is checked to see if it is above the 3V limit shown on screen This is a generic limit common to all 680 analysers After the threshold test the pump will be turned off and the vacuum voltage monitored for a further 10 seconds The leak test limit is dynamic and will change depending on the performance of the pump The limit is 95 of the final value and is shown on the screen Check s e Pump operation Is the pump actually running Ensure that there is a flow of at least 6L min at the sample inlet e Disconnect and retest If problem cured inspect joints for leaks damage Also ensure flexible probe is not damaged In cases of extreme exhaust gas temperature the p t f e liner may melt and cause leak test failure Sample probe hose assembly SP8 Check flexible p t f e liner inside braiding Replace the flexible probe end if necessary SP8X B Check joints e Ifthe tes
21. nect the pipes from the inlet and outlet see Fig 18 Then disconnect the 20 way ribbon from the left hand side Disconnect ribbon Disconnect gas pipes Fig 18 Bench Connections Finally unplug the Oxygen cell connector from underneath the bench processor board on the right hand side Fig 19 Note this connector may be glued into place with silicone adhesive to prevent disconnection during transit The securing nuts may then be undone and the bench lifted clear Replacement is the reversal of this process Oxygen cell connector NOx connector 5 gas units only Fig 19 Oxygen Connector 28 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C Fault codes Failure of the bench is indicated by a set of fault codes For instance should the bench fail and or stop communicating with the processor PCB a Not Responding NR screen will be displayed Fig 20 680 Gas Analyser IR Bench error Restarting may cure If fault persists please contact Product Support guoting error code NR Fig 20 Bench Not Responding There are also a set of Extended Errors which may be displayed These are in the form of four Bytes of error codes ByteO to Byte3 left to right and will be displayed as shown if Fig 21 below 680 Gas Analyser IR Bench error Restarting may cure If fault persists please contact Product Support quoting error code fO 00 00 00 Fig 21 Bench Fault Code 29 of 36 680 Emission
22. ng Ensure that the nitric oxide cell is correctly connected and then select Install new NOx sensor to perform a NOx cell installation If unsuccessful rectify the fault and then repeat the installation Connect nitric oxide sample gas to the CAL gas calibration port DO NOT TURN ON THE GAS Select NOx calibration and if necessary edit the gas tag values for the gas sample to be used When completed select Calibrate with tag values shown The analyser will display open gas bottle Set the bottle pressure to 1400mbar 50mbar and select Press when done The analyser will perform a calibration with no operator intervention required Disconnect the calibration gas Should the calibration fail the installation and calibration must be repeated after rectifying the fault Setting the serial number Enter the Service Mode on WGTS3 and select 680Serial Number Update Enter the analyser serial number as shown on the serial label on the front of the analyser and click Continue This completes the Set up 24 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C REPLACING THE ANALYSER Legislation for the MID dictates that there will be an audit log containing details of program versions updates calibrations replacement analysers etc held on the computer and viewable by the recognized authorities Each time the program and the 680 are run together WGTS3 performs an action to verify the audit log
23. nue The analyser will then perform a calibration with no operator intervention reguired Should the calibration fail due to a mismatch of the gas tag values and the actual concentration the calibration must be repeated after rectifying the fault Return to main menu Select Live Readings the analyser will display readings and the pump will be running Check that the readings are within the following limits co lt 0 02 CO lt 0 10 HC 6 ppm O 20 9 0 5 absolute Connect flow gauge to sample probe inlet and ensure that a flow rate of greater than 6 0 L min is present Restrict the inlet flow to 3 0 L min 0 25L min and ensure that the Gas Flow Restricted screen is displayed Remove restriction and ensure that readings are displayed Exit Live Readings and disconnect the flow gauge 23 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C NOTE The IR bench uses a variable P E F for improved accuracy These are displayed on the Information page of the Analyser Example Gas used 1945ppm Propane PPM P E F 800 0 523 2000 0 508 4000 0 493 P E F applied lt 0 509 If the unit is a 4 gas analyser proceed to Setting the serial number If a 5 gas unit is required perform the following section to install the NOx cell NOx Installation Calibration 5 gas units ONLY Cut Link 1 on the processor bd Perform Leak Test ensure that test passes before continui
24. pump head and thus on to the bench avoiding the filters and sampling system The analyser will then perform a gas purge This uses the oxygen cell to ensure that a calibration gas is actually present Attempting to perform a calibration on ambient air may cause the bench to corrupt its internal memory settings thus rendering it inoperable To prevent this the oxygen reading must fall to 0 2 or less for the calibration to continue There is a 120 second countdown at this point If the limit is not reached within the countdown the calibration will fail After the purge the calibration command will be sent to the IR bench No operator intervention is necessary Following the calibration the gas must be connected to the sample inlet and the pressure set to the ambient reading The analyser will then check that the readings are within 3 of the entered tag values as set by the legislation Again the oxygen cell is used to check for the presence of the calibration gas The limit is 0 1 to allow for the beating effect of the pump This check also has a 120 second countdown Failure to reach the limit will result in failure of the calibration 11 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C POTENTIAL PROBLEMS AND CAUSES Gas Flow Restricted Restriction of the gas to the point where the flow at the inlet is 4L min or less The flow transducer see fig 4 continuously monitors the vacuum after the filters to ensu
25. re that the flow is at a reasonable level and response time of the analyser is not too badly affected by contamination blocked sample pipe etc The output of the transducer is in volts and when the vacuum reaches a predefined point set up on production and usually between 1 5 and 2 5V refer to test specification TS1292 for set up procedure the analyser will trigger a Gas Flow Restricted message Common causes Heavily contaminated filters or blocked sample hose probe Another possible but much less likely cause is the incorrect setting failure of the flow transducer and associated circuitry Check s e Disconnect sample hose from analyser If problem cured blow out hose probe assembly with airline Inspect flexible probe end for damage kinks e Unscrew filter bowls If problem cured replace filters The nylon filter may be washed with warm soapy water DO NOT USE SOLVENTS e Ensure no kinking or pinching of pipe work e Select Information page Check pneumatics settings and ensure that that Flow Vacuum Limit between 1 5 amp 2 5 Zero amp Calibration Vacuums between 0 3 and 0 5 Leak Test Failure During normal operation the 680 forces a leak test every day from switch on One of the most common faults in a gas analyser is failure of this test Common causes Faulty joints particularly in sample probe hose assembly and between the two filter bowls Damaged O ring seals of filter bowls particularly if filters have
26. re version 1 0 0 Database version August 2007 UK Legislative Procedure Fig 7 Main Menu A description of each icon is displayed by holding the mouse cursor over that icon For a list of all icons refer to Appendix 1 17 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C Selecting the Information icon displays an Information page Fig 8 which includes details useful for basic diagnostic purposes Software versions Dates amp Times Database 1 0 0 10684 Date 24 01 2008 Program 1 0 0 Time GMT 16 31 31 Program revision 10684 Last calibration 22 01 2008 Analyser 01 00 Calibration due 22 07 2008 Analyser data server 1 0 0 7 Last leak test 24 01 2008 Bench revision 02 Last HC residue test 16 35 21 Analyser 2 GMT 22 01 2008 configuration code Analyser on time s 3274 Serial numbers Pneumatics Analyser serial number D680 005 Flow vacuum limit Bench serial number 0000116 Zero vacuum Calibration vacuum Calibration tag values Propane ppm 1955 Gas Bench Data Hexane ppm 970 HC Channel CO vol 3 480 CO Channel CO2 vol 14 00 CO2 Channel O2 Channel Reference Channel Sample Cell Pressure mBar PEF values 4000 ppm 0 494 accum 3 Fig 8 Information Page Included are details of program versions pneumatics settings calibration dates and a snapshot of the IR
27. sure sensor Select Flow Setup Follow the on screen instructions and adjust the Offset using R7 and Gain using R9 see Fig 5 Processor Board Note This is an iterative process and the program may repeat the settings When offset and gain are acceptable the program will then display the instruction to attach the flow gauge Set the flow to 4 0 L min 0 25L min With the correct flow set select continue this will set the low flow limit Exit Service Mode Return to Main Menu and select Information 22 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C Check the Pneumatics settings and ensure that the Flow Vacuum Limit is between 1 50 2 50 and both Zero Vacuum and Calibration Vacuum readings are between 0 30 0 50 Exit Information and select Leak Test Ensure Leak Test passes Gas Calibration Select gas Calibration Using a digital manometer check the displayed Sample Cell Pressure mbar is correct to within 20mbar of ambient Enter the gas tag concentration values recorded on the calibration gas bottle certificate being used When completed select continue Connect the calibration gas mixture to the Cal gas port DO NOT TURN ON THE GAS The analyser will perform an auto zero and then display open gas bottle Turn on the gas with the bottle pressure set to 1400mbar 50mbar and select conti
28. t still fails pinch off the pipe immediately after the gas filter bowl see below and retest If problem cured check all joints on sample inlet and filter bowl assembly particularly the bowl to bowl adapter Unscrew filter bowls and ensure the O rings are in good condition and have not been pinched during assembly Check joints Pinch off here aso z O WV pri Check joints Se 13 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C PROCESSING CIRCUITRY Processor PCB Refer to drawing AS09094 for schematic and layout of PCB The 680 is controlled entirely by the PC No autonomous functions are performed within the module The PC communicates with the module via a USB link Commands are sent over the link to a small processor bd which interprets them and communicates with the IR bench via an RS232 link The processor board consists of an 18F series PIC There is a real time clock RTC on board which is used for calibration dates leak test etc When the module is powered LED D4 See fig 5 will flash once per second This is driven by the RTC and a processor interrupt and indicates that the processor core is healthy and functioning When there is communication between the computer and the module LEDs D5 and D6 will flash rapidly These are the communications LEDs When the computer application is started it will force the module to perform an autozero and
29. then display Main Menu control and operation will be discussed later in this manual While in Main Menu the application will poll the module every 2 seconds to check its status This can be seen by D5 and D6 flashing briefly If an autozero is required the computer will automatically initiate it LED D7 is not currently used D5 amp 6 D4 R7 H9 Pump amp Solenoid Communications Processor Offset Gain drivers Healthy Fig 5 Processor PCB 14 of 36 680 Emission Analyser Service Manual June 2008 TES1567 Issue C Pump and Solenoid drive is achieved via two MOSFET transistors TR1 and TR2 All Data and Program memory on the board is held within the Processor This device is electrically erasable so reprogramming the analyser can be performed by the host PC via the serial link Communications to the bench are through the RS232 device IC6 and the 20 way connector SK6 The bench also obtains power from the 12V rail through this connector Replacing the Processor PCB WARNING Always ensure that the correct antistatic precautions are taken when handling the Processor PCB The board is secured to the chassis by 3 M3 screws see fig 6 below Carefully note positions and orientation of the bench power supply solenoid and pump connectors and disconnect them Disconnect the 4mm silicone vacuum pipe from P2 of the vacuum transducer Undo and remove the three fixing screws The PCB may then be removed from the analyser Refitting is the r
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