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XM1000 Exhaust Gas Analyzer

1. sample vacuum at warning level The sample vacuum has exceeded the warning limit listed in section 3 2 1 Check the heated sample line and all filters for obstructions Clean or replace the filters as needed Make sure the check valve is fully open previous leak check failed The previous leak check of the sample line failed The XM will still operate however there is a risk that the sampled gases are being diluted with ambient air Perform another leak test see Chapter 7 section 1 2 as soon as possible and correct any leaks that exist in the sample line and connections 422 Faults and Warnings XM 1000 User Manual Chapter 5 Setup 1 0 XM 1000 Setup Parameters The XM contains many parameters that can be modified by an operator Most only need to be changed one time when the XM is initially installed and set up It is important for the operator to understand the organization of these parameters how to navigate through them to find the parameter of interest and how to change the selected parameter 1 1 Accessing the XM 1000 Setup Page The XM 1000 setup parameters are accessed as follows 1 Press SETUP The system displays the Setup Selection dialog box Setup Selection Cancel Chapter5 Setup 2 Touch the XM button The system displays the main setup page Analyzer Security A Programmable Analog Outputs 3 Monitored Limits 3 Calibration Gas Ports a Utilities
2. Si Inc Midwest amp Dynamatic Dynamometers XM1000 Portable 5 Gas Exhaust Analyzer USER MANUAL Dyne Systems Inc Contact Information Address W209 N17391 Industrial Drive Jackson WI 53037 U S A Toll Free Phone 800 657 0726 Fax 262 677 9308 Website www dynesystems com No part of this manual may be reproduced or transmitted in any form or by any means including photocopying recording or using information storage and retrieval systems for any purpose other than the purchaser s own use without the express written permission of Dyne Systems Co LLC 2002 2007 by Dyne Systems Co LLC All Rights Reserved Any other product names and services identified in this manual are trademarks or registered trademarks of their respective owners No such uses or the use of any trade name is intended to convey endorsement or other affiliation with Dyne Systems Co LLC Contact Information Shipping Address W209 N17391 Industrial Drive Jackson WI 53037 Mailing Address P O Box 18 Jackson WI 53037 Toll Free Phone 800 657 0726 Fax 262 677 9308 Web www dynesystem com Document Revision History Item Date Comment MAN XM1000 001 13 APR 2004 Initial Release MAN XM1000 002 05 JUN 2006 Minor updates due to component changes Added new fault MAN XM1000 003 27 FEB 2007 Spelling and grammar corrections Product Softw
3. 4 11 Chapter4 Analyzer Operation 5 1 Concentration Readings A typical concentration reading is shown below 5 1 2 4 12 Status Message if any Reading Units The name of the measured gas is located in the upper left corner of the reading e g O2 The concentration reading is the largest displayed item in the overall reading The units of the measured concentration value is located immediately to the right of the reading e g The reading may also contain a status message in the lower left corner During normal operation of the analyzer the status message area will be blank A list of possible status messages is presented in section 5 1 2 Background Colors The background color of the reading provides additional information White Default background color for all concentration readings when the XM is operating i e Purging or Sampling Light Gray When the XM is not operating i e in Standby mode the background color is light gray This color indicates that the XM is no longer acquiring concentration data from the Andros analyzer Also the text color of the reading value is changed from black to a dark gray to reinforce the fact that the readings are no longer being updated Yellow When the XM is operating the background color of a reading will change from white to yellow when the reading for the respective gas is no longer valid A status message will also be displayed Status messages are described
4. Monitors the pressure of all gases sample air or calibration flowing in the system When any gas is flowing in the system the pressure should read 5 0 psi Water Filter and Sensor This filter and sensor make the final check for moisture as the sample enters the Andros analyzer If any moisture is detected the XM will create a fault condition Flow Meter The adjustable flow meter is used to regulate the overall flow of gas in the system It should be set to 4 0 cubic ft hr Bypass Flow Switch The system flow rate is set at 4 0 cubic ft hr This flow rate provides adequate system response time and also guarantees the Andros analyzer gets a sufficient amount of gas to analyze Since the Andros only draws sample gas at a rate of approximately 1 6 cubic ft hr the excess sample is bypassed through a flow switch at a rate of 2 4 cubic ft hr i e 4 0 1 6 If the bypass flow falls below 1 2 cubic ft hr the XM will create a fault condition Clearly this switch provides immediate detection of a blocked sample output line XM 1000 User Manual 3 5 Chapter 3 Theory Of Operation 1 4 1 5 1 6 3 6 e Calibration Gas Regulator Adjusts the pressure of calibration gas during calibration Should be set at 5 0 psi e Calibration Gas Solenoids and Manifold The manifold contains two gas solenoids which are used to select and flow calibration gases from external gas canisters See Chapter 6 for a description on how to install and config
5. The factory default setting of this property is TRUE i e the Master Enable input is ignored Note Contact Dyne Systems if you wish to use the Master Enable input feature Application engineers will provide additional information on the wiring and setup of this feature XM 1000 User Manual Wiring 2 3 Chapter 2 Installation 4 0 Settings There are several user accessible settings within the XM system cabinet All have been properly set at the factory however each should be periodically monitored for long term drift and adjusted if necessary They are summarized below Refer to the diagram of the Sample Conditioning System shown in Chapter 3 section 1 3 to locate the devices to be adjusted Setting Value Instructions Flow Rate 4 0 SCFH Press the PURGE button to flow air through the XM Adjust the flow meter until the center of the floating ball is at the 4 0 SCFH standard cubic feet per hour graduation mark NOTE Earlier versions of the XM 1000 contained flow meters with metric scales i e LPM The flow rate for these units should be set to 2 0 LPM liters per minute Sample Line Pressure 5 0 psi Press the PURGE button to flow air through the XM Adjust the back pressure regulator until the pressure gage reads exactly 5 0 psi Calibration Line Pressure 5 0 psi Go to the calibration page and flow one of the calibration gases that is connected to one of the calibration ports calibration procedures are describ
6. eS 7 2 XM 1000 User Manual 1 1 1 Test Sequence Chapter 7 Utilities The indicator displays the current state of the test The various test states are described in the following table Test State Description Ready Initial test state when the HC Hangup test screen is initially displayed The test is waiting for the operator to touch the START button Purging The first phase of the test The sample pump is turned on to draw fresh air through the sample line The HC readings are not monitored during this test phase NOTE The Purging phase of this test is NOT the same as Purge mode for the XM When the XM is in Purge mode it draws fresh air from the AIR INPUT port and through sample conditioning system i e it only purges the sample conditioning system The purge state of this test assumes the sample probe is removed from the device under test and is connected to or near a source of fresh air such that the sample conditioning system AND the sample line are both purged Averaging After the configured Purge time has expired the test begins to average the HC readings for a fixed period of time specified by the Averaging time parameter Done The Averaging time has expired so the test is done The final average HC reading is displayed and can be saved if necessary Failed The test has been terminated due to an internal error 1 1 2 Test Parameters The following tes
7. Information The maintenance information page provides replacement instructions for both of the replaceable Andros sensors i e the NO and O sensors The installation date and the expected life of each sensor is displayed allowing an operator to anticipate approximately when a new sensor should be ordered Eventually the XM itself will generate a warning when either of the senors needs to be replaced The maintenance page is shown below Replacement instructions for the NO sensor are currently displayed Press the down arrow key to display the replacement instructions for the O sensor The replacement procedures for both sensors is also listed in Chapter 10 Maintenance Procedures The last step of each procedure requires the operator to return to this page select the appropriate sensor and then touch the Installation Complete button Maintenance Component Install Date Maintenance Information JAN 2004 Expected Life 18 months O2 Sensor 22 JAN 2004 Expected Life 18 months Replacement Instructions 1 Wait until a new NOx sensor required warning occurs and persists 2 Order a new NOx sensor immediately 3 Replace sensor by following procedure in the ANDROS Manual 4 Perform a ZERO calibration 5 Perform a SPAN calibration 6 Press the following button to reset the Install Date and complete the installation This step MUST be performed once but ONLY once after a new sensor is installed
8. Note In some situations it may be desirable to make temporary parameter changes and deliberately NOT save the changes to non volatile memory The XM power can then be cycled in order to remove the temporary changes and thus restore all parameters to their original state Note Touching the Save button saves ALL setup parameters to non volatile memory It is not possible to make several temporary parameter changes and then later try to make and save some permanent parameter changes Pressing the Save button at this time will save ALL previous changes to non volatile memory Backing Up and Restoring Setup Parameters The entire contents of non volatile memory i e all setup parameters can be saved to and restored from a disk file if necessary There are several reasons to do this Recover from catastrophic hardware failure If the non volatile memory device is damaged or destroyed all setup parameters can be restored after the hardware is repaired Recover from accidental parameter changes The XM has built in security features to prevent unauthorized personnel from changing setup parameters however if parameters are still accidentally changed for any reason they can be restored from the disk file The software application that provides the backup restore capability explained above is called Cell Assistant This application runs on a Windows NT computer It communicates via a serial cable connected to one of the optional
9. Perform a zero calibration procedure Chapter 6 section 1 1 6 Go to the Maintenance Information page Chapter 8 section 2 0 and select the O sensor 7 Touch the Installation Complete button to record the installation date 10 4 Maintenance Procedures XM 1000 User Manual Chapter 10 Maintenance Procedures 2 6 Replace NO Sensor The NO sensor in the Andros analyzer is an electro chemical sensor It has a limited life that begins when the sensor is removed from its storage container The Andros analyzer will inform the XM main computer when a new sensor should be installed The XM will then generate a warning see Chapter 4 section 8 2 When this warning occurs a new NO sensor should be ordered as soon as possible Note The replacement procedure for a NO sensor is also presented in the Maintenance Information page see Chapter 8 section 2 0 A new NO sensor is installed as follows Power down the XM and unplug the power cord Remove the existing NO sensor Follow the instructions in the Andros Product Manual Install the new NO sensor Follow the instructions in the Andros Product Manual Power up the XM Perform a zero calibration procedure Chapter 6 section 1 1 Perform a span calibration procedure for NO Chapter 6 section 1 2 NJ oO a FF W N Go to the Maintenance Information page Chapter 8 section 2 0 and select the NO sensor 8 Touch the Installation Complete button to record the
10. Switch Transducer Water Filter and Air Input Sensor E 2 gt lt a Sample Air f E Flow Meter Select Leak Check Single Head Solenoid Solenoid Sample Pump DM o Sample Cal Select Solenoid S S a Calibration Gas gt gt Water q lt gt K Regulator Condenser lt gt L Water Back pressure Set 5 PSI passive 4 gf Condenser Regulator active Set 5 PSIG Dual Head gt E Peristaltic gt lt 1 Liquid Pump Cal Gas Selection Solenoids 3 4 Liquid Drain Figure 3 3 Sample Conditioning System The various components of the sample conditioning system are described below e Sample Air Select Solenoid To Andros Cal Gas Port 1 Cal Gas Port 2 The sample conditioning system can only draw sample gas from two sources the heated sample line or ambient air This solenoid makes the selection Sample gas is selected during SAMPLE and STANDBY modes of operation it is also the default solenoid state when power is removed Ambient air is selected during PURGE mode and when ambient air is flowed during calibration XM 1000 User Manual Chapter 3 Theory Of Operation Water Condensers passive and active The two stage chiller consists of one passive and one active water condenser The chiller temperature is factory set at 5 C The chillers remove water from the sample gas with minimal loss of soluble gas The water collects at the bottom of
11. Vacuum settle time 5 sec 3 Vacuum hold time 45 sec 4 Max vacuum drop 0 5 psiv f Previous Result 1 O Test date 01 JAN 2004 1 Status FAILED 2 Information No test performed yet Service Maintenance Information Install date Install date 26 FEB 2004 26 FEB 2004 Andros System Information O Serial Number 15802 1 Model Number 6600 2 Hardware P N 451195 000 3 Hardware Rev 09 4 Software P N 878174 004 5 Software Rev 17 12 2 XM 1000 User Manual Chapter 12 Reference 2 0 Error Messages 2 1 The XM may return errors in response to operator actions these errors are referred to as synchronous errors because they are synchronized to a button press or other operator action The error message text directs the operator towards a solution The XM may also return asynchronous errors and notifications these errors may appear at any time Asynchronous errors are sent when the XM detects an error condition that is not due to an immediate operator action e g sample line over temperature fault The format of all error messages and notifications is displayed below nnn text nnn is a 3 digit error code This code should be used to look up the error in this manual if additional information is needed This code should also be referenced when contacting Dyne Systems for additional assistance The text field gives a brief single line explanation of the error Section 2 1 should be con
12. a corrosion resistant container and then properly disposed of 2 4 SAMPLE OUTPUT All sampled gases are discharged from this connector This connector should be connected to a pipe or tube that moves the sample gas to a place where is can be safely ventilated out of the testing area All gases that are flowed during calibration also exit via this port Again many of the calibration gases are extremely harmful if inhaled thus the sample output must be connected to a plumbing system that safely removes these gases 3 0 Wiring The XM requires 110 VAC from a standard outlet This is the only required electrical connection 3 1 Master Enable Even though the XM is designed to be a portable emissions analyzer it can also be permanently installed in a test cell and function has part of a much larger testing environment In some of these installations it may be desirable to allow an external device e g a Programmable Logic Controller to stop the XM during an emergency shutdown sequence The XM has a Master Enable input on one of its internal connectors 24 VDC must be present at this input in order of the XM to operate If 24 VDC is removed the XM will generate a Loss of Master Enable fault condition and enter standby mode After the Master Enable control signal is wired in to the XM the XM must be configured to use this input The Ignore Master Enable Input setup property must be set to FALSE as explained in Chapter 4 section 7 0
13. analyzer screen is described in section 5 0 The display also contains a resistive touch screen Touch screen buttons are large enough to be touched by a finger On some screens a touch screen stylus can be used for more precise manipulation of screen controls however the stylus is not absolutely necessary All screen controls can easily be manipulated using various membrane keys e g ENTER CANCEL and the arrow keys Note In order to avoid ambiguity in describing the operation of some screens the word touch is used to refer to the activation or pressing of touch screen buttons whereas the word press is used to refer to the pressing of membrane keypad buttons 4 2 Membrane Keypad The LCD display is surrounded by groups of membrane buttons These buttons are activated when they are firmly pressed The membrane keypad buttons are divided into three groups e Analyzer Operation buttons described in section 4 2 1 e Special Function buttons described in section 4 2 2 e Numeric Keypad buttons described in section 4 2 3 XM 1000 User Manual Operator Control Station Front Panel 4 7 Chapter4 Analyzer Operation 4 2 1 Analyzer Operation Buttons This group of five buttons are used during normal operation of the XM analyzer They are located to the left of the LCD display The function of each is described in the sections that follow When the RESET button is pressed a reset command is sent to the XM RESET The reset command w
14. analyzer utilities will be denied when the analyzer is in power up mode The XM is only in power up mode for a fraction of a second when the XM is powered up so it is unlikely that this error message will ever occur If this error does occur the XM is probably stuck in power up mode See Chapter 4 section 2 1 for more information regarding what conditions must satisfied for the XM to get out of power up mode 51 Analyzer is in warm up mode Requests to operate the analyzer perform calibration or run analyzer utilities will be denied when the analyzer is in warm up mode Wait for the XM to warm up and enter normal operating mode Warm up requirements are described in Chapter 4 section 3 1 XM 1000 User Manual Error Messages 12 5 Chapter 12 Reference Error Code Text Description 52 Master enable input not The XM is wired and configured to use the Master Enable input asserted however the input signal is not present The XM will not operate 1 e sample or purge until this signal is asserted Master Enable wiring and configuration is discussed in Chapter 2 section 3 1 53 Analyzer fault exists Requests to operate the analyzer perform calibration or run analyzer utilities will be denied if any analyzer faults exist All faults must be cleared before the request will be accepted 54 69 UNDEFINED 70 Invalid time date value An invalid date or time value was entered when setting the s
15. display objects in this case membrane keys are used to navigate the parameter list Each navigation method is described below 1 3 1 Stylus Navigation Setup tree folders can be expanded and collapsed by touching the boxes to the left of each folder Of course folders with no sub folders do not have a box next to them Parameter list items are selected by touching the parameter ID field of the appropriate parameter Double click the parameter ID field to modify the current value 1 3 2 Keypad Navigation Complete navigation of the setup tree and selection and editing of parameter values can be accomplished without a pointing device i e a stylus Keypad and touch screen keys provide the same functionality Selecting a Folder When the cursor is on the setup tree the following keypad keys are used to navigate through the entire setup tree Moves the cursor to the previous folder All parameters if any in this folder are displayed in the parameter list Moves the cursor to the next folder All parameters if any in this folder are displayed in the parameter list Expands the selected folder Collapses the selected folder NWee XM 1000 User Manual 5 3 Chapter5 Setup 5 4 cancer Collapses the entire setup tree and places the cursor on the top level folder Note Because of the limited viewing space available it is often easier to collapse the entire setup tree and navigate to another parameter than to use
16. e g purging sampling calibrating etc the XM has determined that all connected OCS s and or host computers are no longer communicating with the XM This is not allowed While operating at least one OCS or host computer must continuously communicate with the XM If not the XM will generate this fault and return to Standby mode XM 1000 User Manual Faults and Warnings 4 19 Chapter4 Analyzer Operation Fault Description heated filter is not enabled The heated filter has not been turned on or the temperature controller is disabled due to an error If no errors exit in the temperature controller hardware the heated filter must be enabled or bypassed as explained in section 1 1 in order for the XM to operate If the heated filter has disabled itself due to an error refer to Chapter 3 section 1 2 1 The theory of operation of the temperature controller is presented there along with some troubleshooting information The temperature controller hardware contains no user serviceable components contact Dyne Systems for additional help heated line is not enabled The heated sample line has not been turned on or the temperature controller is disabled due to an error If no errors exit in the temperature controller hardware the heated sample line must be enabled or bypassed as explained in section 1 1 in order for the XM to operate If the heated sample line has disabled itself due to an error refer
17. each case the function of the ENTER button should be obvious XM 1000 User Manual Operator Control Station Front Panel 4 9 Chapter4 Analyzer Operation The CANCEL button is typically used to clear the entire contents of a numeric entry edit box It is also used to duplicate the function of some touch screen buttons e g Cancel Quit etc is some contexts On some dialogs the CANCEL button will do both that is if a data entry box is empty pressing the CANCEL button will dismiss the currently displayed dialog by duplicating the function of a touch screen Done Cancel or Quit button On the other hand if a data entry box is not empty pressing the CANCEL button will first clear the contents of the edit box then pressing the CANCEL button again will dismiss the dialog box as previously described 4 10 Operator Control Station Front Panel XM 1000 User Manual Chapter4 Analyzer Operation 5 0 Main Analyzer Screen The main analyzer screen shown below is displayed during normal operation of the XM All displayed graphics objects e g concentration readings indicators duration counter etc are described in the sections that follow The System Monitor button is described in section 3 2 2 Touch to display System Monitor Concentration Readings System E L Monitor Touch to disoiay Fault List Indicators 00 00 12 Duration Counter Message Line Touch to display Message List XM 1000 User Manual Main Analyzer Screen
18. flowing currently flowing 151 Calibration port is not Cannot calibrate the Andros analyzer because the Gas Type for the connected selected calibration gas is set to NOT Connected 152 Port is not connected Cannot zero the Andros analyzer because the Gas Type of the to a zero gas currently selected calibration gas is NOT configured as a Zero Gas 153 Port is not connected Cannot span the Andros analyzer because the Gas Type of the to a span gas currently selected calibration gas is NOT configured as a Span Gas 154 Cannot span when Cannot span the Andros analyzer when flowing Air from the flowing Air purge input port 155 Andros is not ready to A command to zero the Andros analyzer will be rejected if the Zero Andros is not in Normal mode see Andros manual This error should really never occur since the calibration page will not allow a zero command to be issued until the Andros is ready XM 1000 User Manual Error Messages 12 7 Chapter 12 Reference Error Code Text Description 156 Andros is not ready to A command to span the Andros analyzer will be rejected if the span Andros is not in Normal mode see Andros manual This error should really never occur since the calibration page will not allow a span command to be issued until the Andros is ready 157 159 UNDEFINED OCS Communications Errors 160 169 These errors
19. in section 5 1 2 The background color of the reading will not return to white until the error condition is resolved Status Messages During normal operation of the XM the status message area of each concentration reading is blank however the following status messages may appear if error conditions exist These status messages are reported to the XM by the Andros analyzer Refer to the Andros Product Manual for additional information about the cause of each error condition Main Analyzer Screen XM 1000 User Manual 5 2 Chapter 4 Analyzer Operation e Data Invalid The Andros is reporting that the concentration readings for this gas are invalid Refer to the table in the Andros Product manual for possible causes e Span Fail This error is reported by the Andros after a failed span calibration operation Refer to the Andros Product manual for possible causes Zero Fail This error is reported by the Andros after a failed zero calibration operation Refer to the Andros Product manual for possible causes Indicators The left portion of the main screen contains three indicators FAULT Warning OK This indicator continuously shows the current error state of the XM All three possible appearances are shown below If no error or warning conditions exist OK will be displayed as shown in the left example The middle example shows the indicator state if one or more warning conditions exist Warnings may require operator attention b
20. is performed as follows 1 2 3 4 Close the valve at the end of the sample line Touch the START button Wait for the test to complete If you are NOT interested in recording the result touch the Done button to exit the test If you wish to save the result for comparison with other tests in the future touch the RECORD RESULT button The results of this test will then be added to the list of Previous Results Touch the Save button to guarantee the recorded results are saved into non volatile memory Touch the Done button to exit the test Note Touch the STOP button at any time to cancel the test 1 2 4 Previous Results 7 8 The results from the four previous tests are displayed here Recording and saving the results of previous tests is optional They can be used for comparison with future tests XM 1000 User Manual Chapter 8 Service 1 0 Overview Service tools provide access to system settings and system features that rarely need to be modified during normal operation of the XM 1 1 Accessing Service Tools Press the SERVICE button on the front panel of the Operator Control Station A dialog box containing all available service tools will be displayed Touch the appropriate button to launch the desired service tool Each tool is explained in the sections that follow Service Selection Maintenance Info Andros System Info System Time Date Cancel Chapter 8 Service 2 0 Maintenance
21. other hand can appear at any time and are not necessarily caused by any recent operator input Each message will list an error number and appropriate error text A comprehensive list of error messages is presented in Chapter 12 section 2 0 The message line is cleared when the RESET button is pressed The message line is also a button When touched a message list dialog pops up over the main screen The contents of the message list dialog are discussed in section 5 5 1 XM 1000 User Manual Main Analyzer Screen 4 15 Chapter4 Analyzer Operation 5 5 1 Message List The message line lists the most recent error or status message from the XM In situations where several messages occur is quick succession only the last message can be viewed A queue of the previous 16 messages is maintained in the OCS Touch the Message Line indicator to pop up a Message List dialog as shown below Connecting to XM Connected 037 Analyzer NOT in STANDBY mode The oldeset message is at the top of the list followed by successively newer messages Touch the Clear button to clear the message queue and or touch the Done button to dismiss the dialog Note The message list is useful when diagnosing problems It is rarely used during normal operation of the XM because most error and status messages persist long enough in the Message Line for the operator to view them 4 16 Main Analyzer Screen XM 1000 User Manual Chapter4 Analyzer Operation
22. out as Notes Notes are usually itemized at the end of various sections A sample note is displayed below Note This is an example of a note 1 6 Notices XM 1000 User Manual Chapter 2 Installation The XM 1000 is designed to be a portable emissions analyzer that can easily be moved from test cell to test cell however at each testing location several external connections must be made This chapter describes the plumbing and electrical accommodations that must exist at each testing location in order for the XM to function properly and safely 1 0 Overview A simplified external connection diagram is shown below AN AIR i SAMPLE A ni T P OUTPUT SAMPLE INPUT WATER OUTPUT i Figure 2 1 XM 1000 External Connections 110 VAC Chapter 2 Installation 2 0 Plumbing Several plumbing connections must be made at each test location where the XM operates The following table summarizes the thread size of each connection Connection Thread Size AIR INPUT 1 4 NPTF SAMPLE INPUT see section 2 2 SAMPLE OUTPUT 1 4 NPTF WATER OUTPUT 1 4 NPTF Note All plumbing connections must be made before operating the XM 2 1 AIR INPUT The XM requires a source of fresh air When operating in PURGE mode the XM draws in fresh air from this connector in order to purge the sample conditioning system and the And
23. the arrow keys to go from one folder to another Selecting a Parameter When you have selected the folder containing the parameter s you wish to modify press the ENTER key The cursor will move to the first parameter in the list The following keypad keys can now be used to navigate through the parameter list Moves the cursor to the previous parameter Moves the cursor to the next parameter Returns the cursor to the setup tree When you have selected the parameter you wish to modify press the ENTER key or touch the Modify button An appropriate dialog will pop up that allows the parameter to be modified The various types of parameters and the associated dialogs that modify each data type are discussed in the next section XM 1000 User Manual 1 4 1 4 1 Chapter5 Setup Data Types Every XM parameter is stored as one of four possible data types Each data type and the dialog presented to modify it are discussed below Binary This data type is a logic value that can only have one of two possible values e g YES or NO ON or OFF etc The following figure shows the pop up dialog for modifying binary data types The parameter name is displayed in the upper left corner of the dialog Invert Polarity 1 4 2 Yes No Cancel Press the Up and Down arrow keys to toggle between the two available values Touch the OK button to accept the parameter change touch the Cancel button to quit without making any ch
24. the chillers and is drawn away by the pumps Dual Head Peristaltic Pump The dual headed pump removes all water collected by the chiller The condensate may still contain traces of soluble sample gases therefore it should be collected in a suitable container and properly disposed of Pressure Transducer The pressure transducer continuously monitors the sample line vacuum while the XM is operating The readings should typically be just a few tenths of a psi vacuum Higher readings indicate partial obstructions in the sample line most likely due to dirty filters The vacuum readings are also used during the Leak Check utility see Chapter 7 section 1 2 Leak Check Solenoid This solenoid is only used during the Leak Check utility see Chapter 7 section 1 2 It closes immediately after the sample pump has created a high vacuum in the sample line It then stays closed while this utility checks for up stream leaks in the sample line by monitoring the vacuum readings Sample Pump and Back pressure Regulator The sample pump is responsible for pulling sample gas or ambient air through the sample conditioning system and on to the Andros analyzer The Back pressure regulator is adjusted to maintain 5 psig at the downstream side of the pump Sample Calibration Select Solenoid This solenoid is used during calibration to stop the flow of sample gas and to allow the flow of calibration gases to the Andros analyzer Pressure Gage
25. to Chapter 3 section 1 2 1 The theory of operation of the temperature controller is presented there along with some troubleshooting information The temperature controller hardware contains no user serviceable components contact Dyne Systems for additional help heated filter over temperature The temperature of the heated filter has risen above the allowable limit listed in section 3 2 1 This fault will persist until the temperature decreases and returns to the normal operating range or is bypassed as explained in section 1 1 NOTE Bypassing is not recommended for over temperature faults and should only be done if an urgent measurement must be made If the temperature continues to increase the temperature controller hardware will eventually shut down the heated filter as described in Chapter 3 section 1 2 1 heated filter under temperature The temperature of the heated filter has dropped below the allowable limit listed in section 3 2 1 The XM will return to warm up mode until the temperature increases or is bypassed as explained in section 1 1 heated line over temperature The temperature of the heated sample line has risen above the allowable limit listed in section 3 2 1 This fault will persist until the temperature decreases and returns to the normal operating range or is bypassed as explained in section 1 1 NOTE Bypassing is not recommended for over temperature faults and should only be do
26. 6 0 Analyzer Operation 6 1 Master and Computer Modes At any given time the XM will only accept analyzer commands e g purge sample or standby commands from one type of external source When in Master mode the XM will only accept commands from the OCS When in Computer mode the XM will only accept analyzer commands from a host computer connected to the optional computer port on the side of the XM This feature is intended to give a host computer a higher priority over the OCS when both types of devices are connected Whenever an analyzer command arrives from a host computer the XM is automatically switched to Computer mode Subsequent analyzer commands from the OCS will be rejected In order for the XM to accept analyzer commands from the OCS the OCS or the host computer must specifically command the XM to return to Master mode This usually requires a simple but deliberate button push on the OCS by an operator The Master Computer OCS button is shown in section 4 2 1 Note Itis rarely necessary to put the XM into Computer mode The XM will automatically switch to Computer mode whenever an analyzer command is received from a host computer This button is usually pressed to return the XM to Master mode prior to issuing an analyzer command from the OCS 6 2 Analyzer Modes The XM is always in one of three modes Sample Purge or Standby Sample and Purge are considered to be operating modes since the sample pump is running and con
27. AMDEN da aa ead aie le ts 6 1 Span Calibratioi s eccere crobo eani partes oido 6 2 PROCESSING CADA ed Waly dng ates aa 6 2 Managing Calibration Cases deed an eter eek Rea ed ag es 6 3 Callbrate ma Ys O A iid wo dak NS ates Ors wheels oda 6 5 Chapter 7 Utilities Accessing IES Aa 7 1 HC Hang p Testes d ada nat ti deh 7 2 Test SEQUENCE e 2 Wadia BER w a Ahad GS ee A iii 7 3 Test AAA oa tetra tea te ences te AE aa gel emcee as 7 3 Performing thes Pest ascii A aca 7 4 Previous Result awe aise Oe www ee ee 7 4 Leak CeCe sia pao a es 7 5 Test SEQUENCE 4c o e pared a RE a de 7 7 LES Parameters cok cle ea te hea ewe ene id aura waa was 7 7 P rfotming the Tests eave Giese A seen Seka ae Ss 7 8 Previous Results veia ties 7 8 Chapter 8 Service OVEVIEW A RO 8 1 Accessing Service Tools esseri aa A Wea Bee Main ae 8 1 Maintenance Information ia i065 bad Se heed earned 8 2 Andros System Information 0 0 00 0 cece eee nora 8 3 Set System ine Date coin a ah tamale See da Bed 8 4 A s eee eS wan Yo ota a A hated ees 8 5 System Dates its es a Eae gun ieiteh Gece cea ath quae ar gat aug at hate oe 8 6 Chapter 9 Security e enni a IN ee ee aoe amp Senet 9 1 Accessing a S c re Syste ys cei A ae ee es 9 2 Changing the Password id a di caw ad 9 3 Sec ring the AM a A a Dt rada 9 4 Chapter 10 Maintenance Procedures OVERVIOW 2 A a AAA Gates AA EAS 10 1 Maintenance Procedures las rn A pa paa 10 1 Replace Heated Filter Ple
28. E Yes No Selects if calibration functions are secured when Secure Mode is set to On 4 Secure UTILITIES Yes No Selects if utility functions are secured when Secure Mode is set to On 5 Secure SERVICE Yes No Selects if service tools are secured when Secure Mode is set to On 6 Powerup Secure Mode On Off Initial security state of the XM at power up Chapter9 Security 1 0 Accessing a Secure System 9 2 To access a secure system follow the procedure listed below 1 Press SETUP 2 Touch the XM selection button The Enter Password dialog box is displayed Enter Password a 3 Enter the password using the numeric keypad buttons and touch OK If the entered password is correct the XM 1000 main setup page will be displayed Note The factory default password is 1234 If the security feature is going to be used the default password should be changed to a more secure value as soon as possible Note Ifthe existing password is misplaced or forgotten contact Dyne Systems When the previous procedure has been successfully completed the XM is no longer in secure mode The operator has full access to all XM features including setup parameters calibration utilities and service tools When all changes have been made the XM can be re secured as described in section 1 2 Accessing a Secure System XM 1000 User Manual Chapter 9 Security 1 1 Changing the Password When a passwo
29. Installation Complete Messages 8 2 Maintenance Information XM 1000 User Manual Chapter 8 Service 3 0 Andros System Information The Andros system identification data is retrieved from the Andros analyzer when the XM is powered up This information may be useful in some service situations however it typically will NOT be needed during the normal operating life of the XM XM 1000 User Manual Andros System Information 8 3 Chapter 8 Service 4 0 Set System Time Date The system time and date are initially set at the factory Immediately after delivery of your XM the time and date may need to be adjusted due to changes in the time zone where the XM is located Adjustments for day light savings may also be necessary during the year Finally small adjustments to the system time may occasionally be needed due to clock drift The following page displays the current system time and date Touch the appropriate Edit button to modify the date or time 8 4 Set System Time Date XM 1000 User Manual Chapter 8 Service 4 1 System Time The following dialog is used to change the system time Touch the appropriate up and down arrow buttons to adjust the hours minutes and seconds Touch the AM button to toggle the AM PM setting Note The seconds value will continue to increment allowing the hours and minutes value to be changed without modifying the seconds value however once the seconds value is modified it will stop u
30. KEKE EERE Secure SETUP Yes Always Secure CALIBRATE Yes Secure UTILITIES Yes Secure SERVICE Yes Powerup Secur ode Off T DAO FPF WN EF OC Monitored Limits O Sample Line Temperature High Limit 200 0 C 1 Sample Line Temperature Low Limit 180 0 C 2 Filter Temperature High Limit 200 0 C 3 Filter Temperature Low Limit 180 0 C 4 Chiller Temperature High Limit 7 0 C 5 Chiller Temperature Low Limit 3 0 C 6 Sample Vacuum Warning Level 2 0 psiv 7 Sample Vacuum Failure Level 4 0 psiv Calibration Gas Ports FE Port 1 0 Connected Gas Type Not Connected 1 Description Chapter 12 Reference 0 NOx Sensor 1 02 Sensor 2 Installation Date 01 JAN 2004 3 Concentration HC 0 ppm 4 Concentration NO 0 ppm 5 Concentration CO 0 0 amp 6 Concentration CO2 0 0 Port 2 0 Connected Gas Type Not Connected 1 Description 2 Installation Date 01 JAN 2004 3 Concentration HC 0 ppm 4 Concentration NO 0 ppm 5 Concentration CO 0 0 6 Concentration CO2 0 0 amp Utilities HC Hangup Test 0 Purge time 20 sec 1 Averaging time 10 sec PA Previous Result 1 O Test date 01 JAN 2004 1 HC reading 0 ppm Leak Check 0 Target vacuum 5 0 psiv 1 Vacuum time limit 10 sec 2
31. Operator Control Station Front Panel XM 1000 User Manual Chapter4 Analyzer Operation Press this button to gain access to all available utilities e g HC Hangup UTILITIES Test or Sample Line Leak Check All system utilities are described in Chapter 7 os Reserved for future use Press this button to gain access to all available service tools Service tools SERVICE are described in Chapter 8 4 2 3 Numeric Keypad Buttons Lo 9 JC These keys are used to enter numeric data e g concentrations test parameters etc on many dialogs All data entry will be entered into the appropriate edit box The Left Arrow button can be pressed to erase the previously entered key the CANCEL button can be pressed to erase the entire contents of the selected edit box Miele The arrow keys provide many functions based on the context of the currently displayed dialog For example the Up and Down arrow keys are used to select items from lists All of the arrow keys are used to navigate through the parameter tree during setup When appropriate the Left arrow button performs a Backspace function by deleting the previously entered numeric key Each of these examples and many more is explained in other areas of this manual ENTER The ENTER button provides many functions in various contexts For example pressing ENTER finalizes numeric data entry The ENTER button also duplicates the function of touch screen buttons in various situations In
32. SD grounding device e g a wrist strap when handling internal components Failure to observe ESD grounding precautions may damage sensitive components Burns The heated sample line heated filter and heated in line pre filter are all heated and temperature controlled to 190 C 374 F The exposed metal parts on these heated components are EXTREMELY HOT and can cause severe burns Poisonous Gases The Bar 97 High calibration gas cylinder contains high concentrations of propane carbon dioxide carbon monoxide and nitrogen oxides Always make sure the cylinder valve is closed when not in XM 1000 User Manual Notices 1 5 Chapter 1 Introduction use i e calibrating When flowing gas from this cylinder during span calibration make sure the SAMPLE OUTPUT is properly ventilated Note Nitrogen oxides i e NO are extremely hazardous to your health and therefore must be properly ventilated Exposure to high levels of nitrogen oxides can lead to swelling and burning of tissue in the upper respiratory tract a build up of fluids in the lungs and in extreme cases death 3 6 User Servicing The XM 1000 contains a few user serviceable parts e g replacement filter hoses etc Access to internal components should only be performed under the supervision of Dyne Systems technical support specialists 3 7 Document Conventions Important information that would be overlooked if buried in larger paragraphs of the manual are broken
33. a Service Read Only Data D Description fWalve o Firmware Version Messages Save Modify 1 1 Setup Tree Basics All XM configuration parameters are organized using a standard Windows style configuration tree top portion of previous figure Each folder may contain configuration parameters and or other sub folders If a folder does contain configuration parameters these parameters will appear on the Parameter List bottom portion of previous figure when the folder is selected Some folders only contain other sub folders i e they contain no parameters 1 1 1 Folder Colors Yellow is the standard color for all property folders however some folders appear in red Red folders contain only non modifiable data items i e they are for display information purposes only Additional information about various non modifiable data types is provided in section 1 4 5 5 2 XM 1000 User Manual Chapter5 Setup 1 2 Parameter List Basics The parameters in a selected folder if any are listed on the lower portion of the Setup page The parameter list has three columns ID e Description e Value 1 3 Setup Tree and Parameter List Navigation If a stylus is available the setup tree and the parameter list can be manipulated just as a computer mouse is used to manipulate standard Windows controls In most cases a stylus is not available and or is not practical due to the small size of the
34. a a ins 3 2 Heated Sample Line and Heated FilterS oooooooooocooooo oo 3 2 Temperature Control A nia 3 2 Sample Conditioning System 20 0 eee eee eee 3 4 Andros LAMA ZE x otek Ls A A SI CARRS ot Ree Sead 3 6 Main Computer a asada o pra ae Lae wet o 3 6 Operator Control Station vin aes ete he Se eas Baoan e waked a 3 6 Chapter 4 Analyzer Operation T rni g On Th Analyzer 26 ite it een Sa cy keane is SIs oye 4 BYPASS S Wittin sosi ic path a ei e o SL ch one pare E 4 1 Power Up Mode satis Ei das 4 2 Power p Requirements dt ti A te ete E oes 4 2 Warm Up Mode s ig ac eat ae AS eee ee AS 4 3 Warm Up Requirements os Ayaan sos oc es 4 3 System Monitors nr a A A A A eee 4 4 Monitored Limits a es 4 4 Displaying the System Monitor 00 0c eee eee eee 4 5 Operator Control Station Front Panel 0 0 4 7 LCD Display with Touch Screen 4 32 4 eeda6 beeen ea died waa es 4 7 Membrane Keypaders astra a A Catwe nied 4 7 Analyzer Operation Buttons 0 cece eee eee eee 4 8 Special Function Buttons oooooooooooomrmsrrrrrr s 4 8 Numeric Keypad Buttons scsi gcd prints peda 4 9 Main Analyzer Screen A A it 2 4 11 Concentration Readings usan Ra 4 12 Background Colors uo ro ts a ei bs 4 12 Status Messages a A E e 4 12 o ges OO RR RO 4 13 DUO COM AAA ada 4 14 Paulita O co eee dee oe 4 14 Messages Line rc SSA E LAR CASAS 4 15 Message basis a eh oe aa ds ahs sl so d 4 16 Analyze
35. ace Figure 3 1 XM 1000 System Components Chapter 3 Theory Of Operation 1 1 1 2 Sample Probe The sample probe generally consists of a stainless steel pipe and a stainless steel ball valve The exact configuration of the sample probe and valve vary from customer to customer depending on their testing needs The length and diameter of the probe as well as any special probe mounting issues are addressed when the XM is purchased The valve is mainly used by the Leak Check utility Chapter 7 section 1 2 The valve must be closed such that this utility can create and hold a vacuum in the sample line in order to check the sample line for leaks Heated Sample Line and Heated Filters A block diagram of the heated sample line and filters if shown below The main functions of this subsystem are e Filter the Sample The heated pre filter contains a reusable 10 micron stainless steel filter element This filter should trap larger emissions debris It can easily be removed cleaned and replaced as needed The larger heated filter contains a disposable particulate filter Each new filter element is pre baked to remove hydrocarbons and is separately bagged e Prevent Condensation The entire subsystem is heated to 190 C to keep the temperature of the sampled gas above the dew point of the gas all the way from the sample probe to the sample conditioning subsystem Heated To Filter Sample Heated Pre Filter Condi
36. act on the operation of the XM When a fault occurs the fault indicator will turn bright red as shown in section 5 2 If currently operating e g purging sampling calibrating etc the XM will immediately return to Standby mode The fault list should then be displayed as described in section 5 4 Consult the tables in section 8 1 for a description of possible causes of each listed fault All fault conditions must be removed and the fault list must be cleared in order for the XM to resume operation Warnings do not have an immediate impact on the operation of the XM When a warning condition exists and no fault conditions exist the fault indicator will turn bright yellow as shown in section 5 2 The XM will continue to operate however the yellow warning indicator provides a continuous reminder that a potential problem exists which should be investigated as soon as possible Consult the tables in section 8 2 for a description of possible causes of each listed warning Note After all faults and warnings have been investigated press the RESET button to clear the list Any fault or warning conditions that persist will not be cleared Note The XM will not operate e g sample purge calibrate etc until all fault conditions have been removed and the fault list has been cleared 8 1 Faults A description of all XM faults is presented in the tables that follow Fault Description lost OCS and Host communication While operating
37. ailable due to maintenance issues The XM is not completely warmed up but an urgent reading must be made e Minimal or no moisture is present in the sample which is unlikely Enabling the bypass switch causes the XM to completely ignore all temperature readings and all control signals from the temperature controllers If the XM is in Warm Up mode when the bypass switch is enabled the XM will immediately exit Warm Up mode and enter Standby mode The XM can now be operated as usual No temperature related faults or errors will be detected Notes Always return the bypass switch to the off position i e not bypassed as soon as possible It is NOT a good practice to routinely leave the bypass switch enabled Notes Running the XM without a properly heated sample line may result in condensation in the sample line If the heated filter is enabled this condensation will prematurely clog the filter element 2 0 Power Up Mode Power Up mode is the initial mode of the XM when system power is first applied In this mode the XM checks various hardware components The mode indicator on the main screen section 5 2 will display the Power Up mode status These hardware checks occur in just a fraction of a second so the Power Up mode indication may not always be visible since the XM quickly transitions to Warm Up mode afterwards 2 1 Power Up Requirements The following hardware components are tested during Power Up mode If and when all hardware c
38. ain power button must always be pressed first Press the Red button to remove power from the XM power will also then be removed from the heated sample line and heated filter HEATED SAMPLE LINE This pair of buttons controls power to the heated sample line and the heated pre filter Since a properly heated sample line and pre filter are needed during normal operation of the analyzer the Green button should normally be pressed immediately after overall power is enabled Press the Red button to remove power from the heated sample line HEATED FILTER This pair of buttons controls power to the heated filter Since a properly heated filter is needed during normal operation of the analyzer the Green button should normally be pressed immediately after overall power is enabled Press the Red button to remove power from the heated filter 1 1 BYPASS Switch The bypass switch allows the XM to operate without a properly heated sample line and or heated filter This switch should typically always be off i e not bypassed since it is not a Chapter4 Analyzer Operation good practice to run the XM without a properly heated sample line and heated filter reasons for this are given in Chapter 3 section 1 2 Occasionally situations may occur where it becomes necessary to operate the analyzer without the heated sample line and or heated filter Several examples are listed below The heated sample line or heated filter is temporarily unav
39. ally performed throughout the normal operating life of the XM Each is described in this chapter 2 0 Maintenance Procedures The following table summarizes the maintenance procedures described in the sections that follow Procedure Section Replace Heated Filter Element 2 1 Clean or Replace Pre Filter Element 2 2 Replace Water Carry Over Filter WCOF 2 3 Replace Calibration Gas Cylinder 2 4 Replace O Sensor 2 9 Replace NO Sensor 2 6 Replace Peristaltic Pump Hose 2 7 Chapter 10 Maintenance Procedures 2 1 Replace Heated Filter Element The filter element in the heated filter can be replaced as described below 1 2 oN O oO A Power down the XM and unplug the power cord Wait for the heated filter to cool down Note The heated filter and the internal filter element can be EXTREMELY HOT Wait for the filter and the filter element to completely cool before attempting to replace the filter element Press downward on the filter handle and turn counter clockwise about an 1 8 of a turn and then lift the handle Unscrew the retaining disk at the bottom of the filter Replace the filter and re tighten the retaining disk Reverse the actions of step 3 to replace the filter assembly Power up the XM Perform a leak check Chapter 7 section 1 2 to make sure all connections are properly sealed 2 2 Clean or Replace Pre Filter Element The filter element in the heated pre filter element can
40. anges Note The ENTER and CANCEL keypad buttons duplicate the function of the OK and Cancel touch screen buttons Number This data type is a decimal number The allowable range and decimal precision depends on the specific parameter The following figure shows the pop up dialog for modifying number data types The parameter name is displayed in the upper left corner of the dialog Concentration HC 2200 Cancel XM 1000 User Manual 5 5 Chapter5 Setup Press the numeric keys to enter a new value Press the Left arrow key to erase the previously entered digit or press the CANCEL button to erase all previously entered digits Touch the OK button to accept the parameter change touch the Cancel button to quit without making any changes Note The ENTER and CANCEL keypad buttons duplicate the function of the OK and Cancel touch screen buttons The CANCEL button must be pressed twice the Ist press clears the entered data and the 2nd press dismisses the dialog box 1 4 3 List This data type can have one of several values that can be selected from a list of allowable values The following figure shows the pop up dialog for modifying list data types The parameter name is displayed in the upper left corner of the dialog HC Readings n Hexane Propane 5 6 XM 1000 User Manual Chapter5 Setup Use the Up and Down arrow keys to change the selection Touch the OK button to accept the parameter change touch the Cancel button
41. are Revisions This document is up to date with respect to the following versions of product software Product Version XM 1000 Main Computer 1 002 Operator Control Station 1 001 Chapter 1 Introduction CON CIVIC W A SINS lye Bata eyes SO a ins Pe ay SAAD See 1 1 Feat r s se des eot ghana de aa as laos es 1 1 A aus eum a Wiese ie Reuhe Rane erate haces as 1 2 jas Measurements secr saciado A it Se Sak 1 2 ts EIA AAA eee AN 1 2 Measurement Range id a a at Ela aa 1 2 Measurement Resolution ia a a ii ee es 1 2 Measurement ACUTE Pisce 1 3 Response Time Andros Analyzer Only oooooooooomo o o 1 3 A A ae 1 3 Operating Conditions o tata 1 4 NOCES A A Ada 1 5 ALCL Si ache A O II agian E atime Du 1 5 Elcctr ocution Hazard a a Dee id a aio 1 5 Electrostatic Dischatees a id da oo 1 5 US Le O a do 1 5 POISONOUS Cases bt eka 2 a a cia EE 1 5 User Servicing eS as bs RA a tdo leds 1 6 Document Conventions ii C295 ae na me ad 1 6 Chapter 2 Installation OVETVICW ta OS dd ea e as A EB ede 2 1 PND A Pere Soke eee a Ss a Re AE Read 2 2 AIRINPU Vic pia eS Pea aes OSS pa be Re aa Coe a ieee 2 2 SAMPEE TNPUT a eS da a ee oo 2 2 WATER OUTPUT ts eta imine 2 3 SAVPDE OUTPUT do eh ed oe Sa Sealer ead bated oe AR 2 3 WNE oF es re AAS a Y es ee dd Greet 2 3 Master BnaGle 5 lt option RR ERS 2 3 SETIN dato tias adi oia 2 4 Chapter 3 Theory Of Operation OVC WS a Asa 3 1 Sample Probe scalars is a
42. are typically due to bad cabling bad shielding and or severe electrical noise Error Code Text Description 160 Packet checksum Command packet is corrupt error 161 169 UNDEFINED Hardware Configuration Errors 170 179 These errors are boot errors and must be corrected before the XM accepts analyzer commands Error Code Text Description 170 Configuration This error is most likely to occur if someone attempts to upload a set of version newer than XM configuration parameters see Chapter 5 section 1 6 that was firmware created using the latest version of XM 1000 software into an XM that contains older software This is not allowed Contact Dyne Systems to get an upgrade for the XM software 171 EEPROM version The version number of the XM parameters stored in EEROM is newer newer than than the version number of the XM software itself This error is most firmware likely to occur if someone installs a new A D converter board which contains the serial EEPROM chip that was initialized using the latest version of XM 1000 software into an XM that contains older software This is not allowed Contact Dyne Systems to get an upgrade for the XM software 172 179 UNDEFINED 12 8 Error Messages XM 1000 User Manual Hardware Errors 180 199 Chapter 12 Reference These errors are caused by defective or failing hardware Erro
43. ation XM 1000 User Manual Chapter 12 Reference 6 0 Fuses Function Location Value Main FUI 20A Buss KTK 20 fast acting Heated Filter TB7 4 SA time delay Heated Sample Line Pre filter TB7 5 8A time delay Chiller TB2 1 6A time delay Safety Switches TB2 2 0 5 A Sample Pump TB1 1 2A time delay Peristaltic Pump TB1 2 2A time delay XM 1000 User Manual Fuses 12 13 Chapter 12 Reference 7 0 Figures Drawings and Schematics The following A size 8 x 11 in drawings are included at the end of this manual printed version only or in the file XM1000_Drawings_SizeA pdf included on CD Drawing No Description NONE NONE The following B size 11 x 17 in drawings are included at the end of this manual printed version only or in the file XM1000_Drawings SizeB pdf included on CD Drawing No Description DWG XM SCH 001 INPUT POWER DWG XM SCH 002 CPU 1 0 DWG XM SCH 003 SAMPLE SUB SYSTEM DWG XM SCH 004 HEATED FILTER CONTROL DWG XM SCH 005 HEATED SAMPLE LINE CONTROL 12 14 Figures Drawings and Schematics XM 1000 User Manual
44. be replaced or removed for cleaning as described below 1 2 Power down the XM and unplug the power cord Wait for the heated in line pre filter to cool down Note The heated pre filter and the internal filter element can be EXTREMELY HOT Wait for the filter and the filter element to completely cool before attempting to replace the filter element Firmly grasp the pre filter outer shell Grasp the valve and sample probe assembly and turn counter clockwise The top of the in line filter should screw out Do not lose the O ring The filter element will simply fall out Clean the stainless steel filter element or replace as needed Re attach the top of the in line pre filter Hand tighten only it should not be necessary to use excessive forces e g pipe wrenches Power up the XM Perform a leak check Chapter 7 section 1 2 to make sure all connections are properly sealed 10 2 Maintenance Procedures XM 1000 User Manual Chapter 10 Maintenance Procedures 2 3 Replace Water Carry Over Filter When the water filter element becomes clogged flow faults will occur This filter element is replaced as explained below 1 2 3 4 5 Power down the XM and unplug the power cord Unscrew the bowl assembly Unscrew the filter retainer screw Replace the filter Repeat steps 2 and 3 in reverse order to seal the new filter element 2 4 Replace Calibration Gas Cylinder Calibration gas cylinders eventually become
45. centrations are being measured Standby mode is the default mode when the XM is not operating 6 2 1 Standby Standby mode is the default mode of the XM All pumps are off and all solenoids are in their default i e not energized position Standby mode can be commanded at any time by pressing the STANDBY button on the front panel The XM will also transition from an operating mode i e sampling or purging to standby automatically if any fault conditions are detected 6 2 2 Sample and Purge Modes Sample and Purge modes are the operating modes of the XM The sample pump is running and drawing gas from one of two sources i e sample gas or ambient air The Andros analyzer is also running and measuring concentrations of the selected gas Referring to Figure 3 3 Sample Conditioning System the only difference between Sample and Purge mode is the state of the Sample Air Select Solenoid In sample mode this solenoid selects gas from the Sample Input which is connected to the heated sample line and filter In purge mode this solenoid selects gas from the Air Input XM 1000 User Manual Analyzer Operation 4 17 Chapter4 Analyzer Operation Enable Requirements To command sample or purge modes of operation press the SAMPLE or PURGE mode button respectively Before the XM will enter the selected mode the following requirements are checked and must be satisfied If not the sample or purge command will be rejected and an appropriate err
46. creating and holding a vacuum in the sample line and other components listed above The change in vacuum is continuously monitored for a fixed period of time If the final vacuum drop is less than a predefined limit the leak check has passed otherwise the leak check is considered a failure Note Ifthe previous leak check failed and the failed results are recorded the XM will continuously generate a previous leak check failed warning as explained in Chapter 4 section 8 2 This warning serves as a continuous reminder that all concentration readings are suspect since ambient air may be leaking into the sample line and diluting the measured gases Note If enabled the heated sample line and heated filters are VERY HOT Use extreme caution when attempting to tighten up fittings re seat filters etc in order to fix any leaks in the various components Note Improperly installed filters are a frequent source of leaks If a filter has recently been cleaned or replaced check that it has been properly seated Also the rubber O ring in the heated pre filter is a common source of leaks Make sure the O ring is clean and properly seated when closing the pre filter XM 1000 User Manual 7 5 Chapter 7 Utilities The main screen for the leak check utility is shown below The vacuum in the sample line is continuously displayed The change in vacuum i e A vacuum is shown in parentheses It is only displayed during the Holding Vacuum portion o
47. cted and configured as explained in section 2 0 Chapter 6 Calibration Note Because the Andros analyzer spans O during a zero calibration procedure each source of zero gas must contain 20 90 O3 1 2 Span Calibration Span calibration compensates for normal long term component drift during the normal operating life of the analyzer The Andros analyzer Product Manual recommends a span calibration be performed as follows As mandated by government programs regarding your test HC CO and CO channels once every 6 months NO channel after replacement of the NO sensor and once a month during normal operation e Immediately after any span calibration has failed As described in section 3 0 the span calibration procedure requires a span gas to be flowed through the Andros analyzer The XM provides two calibration ports to connect canisters containing various blends of span gases Configuring span gas data is explained in section 2 0 Note The Andros analyzer spans O during zero calibration 1 3 Accessing Calibration Press the CALIBRATE button on the front panel of the Operator Control Station A dialog box containing all available calibration selections will be displayed Touch the appropriate button to launch the desired selection Calibration Selection Calibrate Analyzer Manage Calibration Gases Cancel 6 2 XM 1000 User Manual Chapter6 Calibration 2 0 Managing Calibration Gases The XM has conne
48. ctions for two external calibration gas canisters Chapter 10 section 2 4 explains how to connect and or replace a calibration gas canister Once connected or replaced the operator must proceed to this page and define the contents of the calibration gas The following procedure describes how to define the contents of the gas canisters if any that are connected to each calibration gas port 1 Select the Gas Port to be configured by touching the Port 1 or Port 2 buttons Optionally the Left and Right arrow keys can be pressed to select the appropriate calibration gas port 2 Touch the UNLOCK button to enable access to all data for the selected port The lock feature is used to hopefully prevent accidental modification of calibration data XM 1000 User Manual Managing Calibration Gases 6 3 Chapter6 Calibration 3 Select the Gas Type for the selected port The following table explains each choice Gas Type Description Zero Gas The canister connected to this port contains a zero gas A zero gas typically contains pure nitrogen i e zero concentrations of HC CO CO and NO Note that the Andros always spans O when it zeros the analyzer therefore any connected zero gas must contain 20 90 oxygen Span Gas The canister connected to this port contains a blend of span gases The concentration of each gas must be entered NOT Connected Nothing is connected to this port Touch the Save button f
49. e XM will not function on until this problem is fixed 187 Serial Port 2 not detected i 188 Serial Port 3 not detected 189 Serial Port 4 not detected A 190 File open error The data file containing all configuration data could not be accessed in the non volatile memory device The memory device may be damaged The XM should be returned to Dyne Systems for repair 191 File write error An error occured while writing configuration data to the non volatile memory device The memory device may be damaged The XM should be returned to Dyne Systems for repair 192 File read error An error occured while reading configuration data from the non volatile memory device The memory device may be damaged The XM should be returned to Dyne Systems for repair 193 199 UNDEFINED XM 1000 User Manual Error Messages 12 9 Chapter 12 Reference Internal Software Errors 200 249 Internal software errors are generally due to programming errors in the XM They are also due to programming errors in one of the connected OCS s They are intended to catch programming errors that occur during product development they should never occur in the final release of this product None of these errors are documented in this manual instead Dyne Systems should be contacted if an error code in this range is detected 12 10 Error Messages XM 1000 User Manual Chapter 12 Reference 3 0 Replacement Parts The XM contains several components tha
50. ed in Chapter 6 While the calibration gas is flowing adjust the calibration gas regulator until the pressure gage reads exactly 5 0 psi Note Contact Dyne Systems if you are not comfortable adjusting any of the settings 2 4 Settings XM 1000 User Manual Chapter 3 Theory Of Operation This chapter describes the various components of the XM 1000 what function each component performs and how they work together to function as an emissions analyzer The information in this chapter provides a basic theory of operation and should be helpful in troubleshooting a variety of high level system issues if any that may be encountered during normal operation of the XM This chapter is NOT a service manual please contact Dyne Systems for help in troubleshooting problems with individual components 1 0 Overview A simplified block diagram of the entire XM 1000 is shown below The six main components of the XM include the sample probe the heated sample line and heated filters the sample conditioning system the Andros analyzer the main computer and the Operator Control Station OCS Each is described in the sections that follow Bypass Flow Sample 777 Conditioning System Sample Probe Heated Sample Line and Heated Filters Andros with valve Analyzer Operator Control Station Air Input Main Computer Host Computer Interf
51. ed in section 3 0 Duration Counter The duration counter displays the amount of time in hours minutes and seconds the XM operates in each mode except Standby mode The counter is reset to 00 00 00 whenever a new operating mode is selected It stops whenever the XM returns to Standby mode Note The duration counter also runs during Warm Up mode and stops when the XM finally warms up and enters Standby mode The duration counter can then be used to measure the XM warm up time Fault List A pop up dialog containing a list of all active faults and or warnings is displayed by touching the OK Warning FAULT indicator When this indicator turns bright red or yellow as shown in section 5 2 the operator typically displays the fault and warning list in order to determine the exact cause or causes of the error condition A sample fault list dialog is shown below Faults if any are listed first followed by all warnings if any Faults and Warnings and their causes are discussed in section 8 0 Note Press the RESET button to try to clear all existing faults and warnings Main Analyzer Screen XM 1000 User Manual Chapter4 Analyzer Operation MW FAULTS NONE O WARNINGS Zero calibration requested 5 5 Message Line The message line displays error messages and other notifications from the XM Most errors are caused by disallowed command attempts e g pressing the SAMPLE button while a fault exists Notifications on the
52. empty and must be replaced as follows 1 2 3 4 Power down the XM and unplug the power cord Close the valve on the gas cylinder to be replaced Using a 9 16 open end wrench disconnect the regulator assembly from the canister Connect the regulator assembly to the new canister Note These disposable Non Refillable Compressed Gas Cylinders MUST be properly disposed of per U S Regulations See the Scott Gas web site or call Scott Technical Service for information regarding the proper disposal of the canisters XM 1000 User Manual Maintenance Procedures 10 3 Chapter 10 Maintenance Procedures 2 5 Replace O Sensor The O sensor in the Andros analyzer is an electro chemical sensor It has a limited life that begins when the sensor is removed from its storage container The Andros analyzer will inform the XM main computer when a new sensor should be installed The XM will then generate a warning see Chapter 4 section 8 2 When this warning occurs a new O sensor should be ordered as soon as possible Note The replacement procedure for an O sensor is also presented in the Maintenance Information page see Chapter 8 section 2 0 A new O sensor is installed as follows Power down the XM and unplug the power cord Remove the existing O sensor Follow the instructions in the Andros Product Manual Install the new O sensor Follow the instructions in the Andros Product Manual 1 2 3 4 Power up the XM 5
53. ers in either of the two temperature controllers The temperature setpoint alarm settings tuning parameters etc have been correctly set at the factory and should only be modified by Dyne Systems personnel Note When enabled the heated sample line and filters are EXTREMELY HOT Be especially cautious when touching any of the exposed metal portions of the filters and or sample line Always let these components cool down before performing any service or maintenance procedures Note that the temperature of the heated pre filter is pseudo temperature controlled Its heating heating element is connected in parallel with the heating element in the heated sample line so it merely follows along with what temperature controller 1 is doing to the heated sample line The pre filter also has a built in over temperature switch which helps control its temperature The temperature of the pre filter can vary by 25 C XM 1000 User Manual 3 3 Chapter 3 Theory Of Operation 1 3 Sample Conditioning System A block diagram of the sample conditioning system is shown below The main function of this subsystem is to remove all moisture from the sample gas and deliver a dry sample to the Andros analyzer It is also responsible for delivering the sample gas to the Andros at a constant flow rate and pressure he Sample Input Pressure Gage Bypass Flow Pressure o
54. f the test otherwise it is blank Vacuum A 0 01 Holding Vacuum 04 FEB 2004 Passed Vacuum loss 0 05 psiv 01 JAN 2004 FAILED No test performed yet po 7 6 XM 1000 User Manual Chapter 7 Utilities 1 2 1 Test Sequence The indicator displays the current state of the test The various test states are described in the following table Test State Description Ready Initial test state when the leak check screen is initially displayed The test is waiting for the operator to touch the START button Creating Vacuum The sample pump is enabled in order to create the initial Target vacuum in the sample line As soon as the target vacuum is achieved the leak check solenoid is closed and the sample pump is turned off Vacuum Settling The test pauses for a few seconds immediately after achieving the target vacuum in order to let the vacuum reading settle After the settling time has expired the initial vacuum reading is made All changes to the vacuum reading that occur during the remainder of the test are referenced to this initial reading Holding Vacuum The test waits and monitors any drop in the initial vacuum reading Passed The Vacuum hold time has expired and the final computed vacuum loss is within acceptable limits FAILED The test was cancelled or the Vacuum hold time has expired and the final computed vacuum loss is NOT within acceptable limits 1 2 2 Tes
55. hecks succeed the XM transitions to Warm Up mode as described in section 3 0 e Andros Analyzer The XM attempts to establish communications with the Andros analyzer The XM cannot exit Power Up mode until the Andros analyzer responds to commands via the serial connection A notification message is displayed on the OCS every 2 seconds if the Andros fails to respond If this occurs check the power and serial connections to the Andros analyzer The XM is unusable until Andros communications is established Contact Dyne Systems if this notification message appears and persists e Heated Sample Line and Heated Filter Temperature Controllers 4 2 Power Up Mode XM 1000 User Manual Chapter4 Analyzer Operation The XM checks the status signal from the heated sample line temperature controller and from the heated filter temperature controller Each status signal will only be valid if the respective controller is enabled and functioning properly The operation of these temperature controllers is described in Chapter 3 section 1 2 1 Notes If one or both of the temperature controllers is not enabled or cannot be enabled due to a malfunction the bypass switch can be enabled The XM will then skip the temperature controller checks and proceed to Warm Up mode The bypass switch is described in section 1 1 3 0 Warm Up Mode 3 1 Immediately after the brief Power Up mode the XM enters Warm Up mode In this mode the XM waits until the heated sam
56. host computer ports on the back of the XM See Chapter 11 for information on Cell Assistant Note Another backup restore software utility is available to customers not requiring the Cell Assistant product Contact Dyne Systems for more information When saving all setup parameters to a disk file the default file name is XM_Config xm Change the filename to something more descriptive and informative prior to saving however do not change the xm file extension XM 1000 User Manual 5 9 Chapter5 Setup 1 7 Top Structure of the Setup Tree It is important for the person or persons responsible for setup and configuration of the XM to become familiar with the organization of all setup parameters Complete familiarity with the organization of the setup tree will make it easier to locate parameters of interest as needed The top of the setup tree is shown below Parameter searches typically begin from this level since this is the initial tree state when the setup page is first displayed Note Pressing the CANCEL button collapses the tree to the state shown below It is often easier to collapse the tree and start from the beginning when searching for and modifying several parameters Ea XM 1000 Analyzer Security Monitored Limits E Calibration Gas Ports Utilities Service 5 10 XM 1000 User Manual Chapter 6 Calibration 1 0 Overview In order to maintain the short term and long term accuracy of a
57. igits 0 to 9 87 Password length must be Password must be 4 to 10 digits in length 4 to 10 digits 88 99 UNDEFINED 12 6 Error Messages XM 1000 User Manual Chapter 12 Reference Utilities Errors 100 129 These errors are reported by various XM utilities Error Code Text Description 100 Minimum Purge time is The Purge time test parameter for the HC Hangup test must be 10 sec at least 10 seconds 101 Maximum Purge time is The Purge time test parameter for the HC Hangup test cannot 600 sec exceed the specified value 102 Minimum Averaging The Averaging time test parameter for the HC Hangup test time is 2 sec must be at least 2 seconds 103 Maximum Averaging The Averaging time test parameter for the HC Hangup test time is 300 sec cannot exceed the specified value 104 129 UNDEFINED Calibration Errors 130 159 These errors are reported during calibration and the management of calibration gases Error Code Text Description 130 No span gases defined The span button was pressed however no concentrations have been for this port defined for the currently flowing span gas i e they are all set to 0 Go to the Manage Calibration Gases page and enter one or more non zero gas concentration values for the selected span gas 131 149 UNDEFINED 150 No calibration gas is A zero or span command was issued however no calibration gas is
58. ill attempt to clear any faults that may exist The message lines of all connected OCS s will be cleared MASTER Press this button to toggle the XM between Master and Computer modes COMPUTER See section 6 1 for more information on Master and Computer modes Press this button to purge the sample conditioning system by flowing air through the system Purge mode is explained in section 6 2 2 Press this button to flow and analyze the sample gas Sample mode is SAMPLE explained in section 6 2 2 Press this button to cancel purge and sample modes Standby mode is STANDBY explained in section 6 2 1 4 2 2 Special Function Buttons This group of five buttons provide access to special function and utilities They are located to the right of the LCD display The function of each is described in the sections that follow Press this button to gain access to XM setup parameters Accessing and SETUP pa se at modifying setup parameters is explained in Chapter 5 Notes Some parameters affect the run time operation of the XM thus access to the XM setup page is denied if the XM is currently operating i e purging or sampling Notes XM setup parameters are secured thus a password may be required to access the XM setup page Security is discussed in Chapter 9 Press this button to gain access to all calibration features Analyzer calibration and the setup and management of calibration gases is explained in Chapter 6 CALIBRATE 4 8
59. information regarding possible causes and remedies of each fault Fault Description in flow fault There has been a substantial reduction in inlet side pressure out flow fault There may be an occlusion at output of the Andros analyzer infrared IR signal lost IR signal is lost or weak ambient temperature out of range The ambient temperate is outside the range 0 to 50 C system fault An Andros hardware failure has occurred IR source temperature exceeds 75 C IR source temperature is too high Power down the XM for approximately 1 2 hour to let the Andros cool and then re apply power If the problem persists contact Dyne Systems 8 2 Warnings A description of all XM warnings is presented in the following table Warning Description zero calibration requested This warning is periodically generated by the Andros analyzer A zero calibration procedure should be carried out as soon as possible as described in Chapter 6 section 1 1 The Andros issues this warning for many reasons which are also listed in Chapter 6 section 1 1 new NOx sensor required The full scale output of the NO sensor has dropped significantly since it was installed The NO sensor should be replaced as soon as possible new O2 sensor required The output of the O sensor has dropped significantly since it was installed The O sensor should be replaced as soon as possible
60. installation date This button also sends a New NO Sensor command to the Andros The Andros then measures the full scale output voltage of the new sensor and stores the value in non volatile memory It later uses this value to determine when the sensor output voltage has sufficiently diminished such that a new sensor should again be installed Note The Installation Complete button should ONLY be touched one time immediately after a new NO has been installed It should NEVER be touched again during the operating life of the existing sensor XM 1000 User Manual Maintenance Procedures 10 5 Chapter 10 Maintenance Procedures 2 7 10 6 Replace Peristaltic Pump Hose The peristaltic pump hose may eventually develop leaks due to fatigue from the constant compression by the peristaltic pump heads These leaks will typically cause the periodic leak checks of the sample line Chapter 7 section 1 2 to fail If leak checks are not being performed at regular intervals the XM cabinet should be opened periodically and inspected for signs of water leaking onto the bottom of the cabinet Note Leak checks Chapter 7 section 1 2 should be run at regular intervals Also the XM cabinet should be opened periodically to check for water leaks The goal is to discover leaks in the pump hose as soon as possible since this water will eventually damage the bottom of the XM cabinet if undetected for long periods of time The peristaltic pump h
61. lace the filters as needed Make sure the check valve is fully open insufficient bypass flow The bypass flow switch has tripped Check for obstructions at or near the SAMPLE OUTPUT port If there are no obstructions review Chapter 2 section 4 0 and check that the Flow Rate is set correctly water detected in water slip filter Moisture has been detected in the Water Carry Over Filter WCOF Verify that the sample chiller is operating properly since the chiller should remove all water from the incoming sample loss of master enable input The Master Enable input signal was de asserted while the XM was operating i e purging or sampling The Master Enable signal is described in Chapter 2 section 3 1 calibration timeout During calibration a ZERO or SPAN operation MUST be initiated within 90 seconds after the respective calibration gas has started to flow Excessive flowing and discharge of span gases is generally unnecessary and wasteful and perhaps dangerous if not properly vented This timeout prevents an operator from starting a calibration process 1 e flowing calibration gas and then walking away and forgetting to complete the process and stop the flow of calibration gas XM 1000 User Manual Faults and Warnings 4 21 Chapter4 Analyzer Operation The faults listed in the following table are detected and reported by the Andros analyzer Consult the Andros Product Manual for additional
62. ll appear in this list Notice that the configured concentrations for the current flow selection appear in blue just above each concentration reading 2 If gas from a calibration gas canister is selected check that the canister valve is open 3 Touch the FLOW button The indicator will display Wait XM 1000 User Manual Calibrate Analyzer 6 5 Chapter6 Calibration 4 Wait for the indicator to change to Ready to Zero or Ready to Span which depends on the type of selected calibration gas that is currently flowing This time period is controlled by the Andros analyzer When the Andros is ready the indicator will change to one of these messages 5 When ready manually check the readings and wait for them to stabilize A minimum of 30 seconds is typically required for span gas concentrations to stabilize Additional waiting may achieve greater stabilization however waiting more than 60 seconds is typically unnecessary and a waste of calibration gas 6 When the readings are stable touch the ZERO or SPAN button only one will be enabled depending on the type of calibration gas that is currently flowing The indicator will change to Zeroing or Spanning 7 Wait for the indicator to change to Done Touch the STOP button to stop the flow of calibration gas Close the valve on the calibration gas canister if needed Note Make sure the valves on all calibration gas canisters are closed when calibration is complete N
63. ll concentration readings the XM analyzer must be periodically calibrated This chapter describes how to manage calibration gases and how to use them to zero and span the analyzer 1 1 Zero Calibration Zero calibration compensates for short term conditions that affect gas concentration measurements e g changes in ambient temperature The Andros analyzer Product Manual recommends a zero calibration be performed as follows e Immediately prior to each automotive exhaust gas emissions test e Immediately prior to taking any important set of gas concentration data e Immediately prior to performing a span calibration In addition to the previously mentioned reasons the XM will generate a zero calibration requested warning see Chapter 4 section 8 2 whenever the Andros reports that a zero calibration should be performed The Andros will make this request under the following conditions e Immediately after power is applied e After being in Standby mode for more than 2 minutes e After a 5 C change in ambient temperature e After 30 minutes since the last zero calibration As described in section 3 0 the zero calibration procedure requires a zero gas to be flowed through the Andros analyzer The XM provides up to two choices for this gas First ambient air from the AIR INPUT port can be flowed and used as a zero gas This selection is always available during calibration Optionally a canister containing a zero gas can be conne
64. llowing button located in the upper left corner of the main display System me Monitor X The following System Monitor will then be displayed All displayed values are continuously updated Each has been previously discussed however the Analyzer Temperature value has not been previously described and is NOT monitored by the XM This temperature reading is made internally by the Andros analyzer The Andros will report analyzer temperature errors via the ambient temperature out of range fault as explained in section 8 1 XM 1000 User Manual Warm Up Mode 4 5 Chapter 4 Analyzer Operation Sample Line Temperature 200 188 c E 0 Heated Filter Temperature E 200 190 c jai Chiller Temperature Analyzer Temperature 14 70 0 22 psiv E pa Sample Vacuum 4 6 Warm Up Mode XM 1000 User Manual Chapter4 Analyzer Operation 4 0 Operator Control Station Front Panel The front panel of the OCS is shown below The two main components are the LCD display with touch screen and the membrane keypad buttons Each component is discussed in the sections that follow XM 1000 Gas Analyzer LCD Display with Touch Screen s E EE EE SS ea E Membrane Keypad Buttons 4 1 LCD Display with Touch Screen The most prominent front panel component is the 6 4 active matrix LCD display Concentration readings analyzer status and other information are displayed here The layout of the main
65. ment 5532 44 is 10 2 Clean or Replace Pre Ellter Element sra asa 10 2 Replace Water Carry Over Filter sii ia ja 10 3 Replace Calibration Gas Cylinder 0 0 0 cece eee o 10 3 Replace O2 SENSE dr riot pi eee end Sees 10 4 Replace NOW Senor ones zed This taa 10 5 Replace Peristaltic Pump HOS ii voy sal a a ea Ve ed WS 10 6 Chapter 11 Cell Assistant for Windows VCE O EN gang tl heater UNL eee eee hae a a vette Gad 11 1 Device Setup Pares ia a ae Si ene sas 11 1 A Bisa Sheg aa Wing oe wats nem Be RA 11 2 System Monitor Pave ats a ey clan ye Cae end Goce hen orev ea yee 11 3 Setup PARC ya a CA a eae erik OIG oa ee eee anaes 11 4 Calibrate Pages a a Sanat Eats vas DS 11 5 Utilities A alice hatin eee hap atts ons a aad Beatin 11 5 Service PAra a Gag EA athens ae ace 11 5 Device Channels qedar ER patas ES aS RR 11 5 Chapter 12 Reference Setup Parameter Hierarchy ii seaweed at 12 1 Error MICSSARES nis AI Rae ees tds 12 3 Error Codes a 2e eed II etwe mie hw a a 12 3 R placement Partsicko ati ds A AAA E DEU 12 11 Optional Pat as ts o EA ee Sota an 12 11 Manufacturer Contact Information 0 000 eee cece eee 12 12 Dyne Systems Co EC 2 34304 aya aoe te GR ee a Ae ee 12 12 PUSCS 20 foe tide eae ae ee eed Bere a een a cee ee ee 12 13 Chapter 1 Introduction 1 0 Overview The XM 1000 Exhaust Measurement System is designed to provide a low cost and portable tool for the analysis of exhaust gas comp
66. nd one OCS is currently accessing factory information No run time commands e g sample or purge will be accepted from any of the other attached OCS s until factory mode is exited NOTE Factory mode is only available to in house technicians at Dyne Systems This error should not occur at a customer site 35 XM is busy processing a previous command This error may occur if an operator tries to save setup data to non volatile memory while a previous save is still in progress It should rarely occur and is harmless Simply wait a few seconds and retry the command 36 Secure mode enabled function not allowed Setup calibration utilities and service functions may not be allowed when the XM is in secure mode Contact the person responsible for XM security A password is required to take the XM out of secure mode 37 Analyzer NOT in STANDBY mode Requests to enter setup calibration utilities or service modes are denied when the analyzer is currently operating i e purging or sampling Put the analyzer into standby mode and try again 38 Analyzer NOT in MASTER mode Many analyzer commands e g purge sample or standby are rejected if the analyzer is not in Master mode Press the Master Computer button to return the analyzer to Master mode then retry the original command 39 49 UNDEFINED 50 Analyzer is in power up mode Requests to operate the analyzer perform calibration or run
67. ne if an urgent measurement must be made If the temperature continues to increase the temperature controller hardware will eventually shut down the heated sample line as described in Chapter 3 section 1 2 1 4 20 Faults and Warnings XM 1000 User Manual Chapter4 Analyzer Operation Fault Description heated line under temperature The temperature of the heated sample line has dropped below the allowable limit listed in section 3 2 1 The XM will return to warm up mode until the temperature increases or is bypassed as explained in section 1 1 chiller temperature too high The temperature of the chiller has risen above the allowable limit listed in section 3 2 1 This fault will persist until the temperature decreases and returns to the normal operating range An improperly cooled chiller creates the risk of moisture entering the remainder of the sample conditioning system chiller temperature too low The temperature of the chiller has dropped below the allowable limit listed in section 3 2 1 The chiller and or chiller electronics may be malfunctioning Contact Dyne Systems for additional help no signal from vacuum transducer The vacuum transducer is disconnected is broken or has lost its 24 vdc excitation sample vacuum too high The sample vacuum has exceeded the allowable limit listed in section 3 2 1 Check the heated sample line and all filters for obstructions Clean or rep
68. nge HC 0 to 30 000 ppm n Hexane 0 to 60 000 ppm propane CO 0 to 15 00 CO 0to 20 00 NO 0 to 5 000 ppm 0 0 to 25 00 2 1 3 Measurement Resolution Gas Resolution HC 1 ppm CO 0 001 CO 0 01 NO 1 ppm O 0 01 1 2 Specifications XM 1000 User Manual 2 1 4 Measurement Accuracy Chapter 1 Introduction Gas Range Accuracy HC 0 to 2 000 ppm n Hexane 2 001 to 15 000 ppm 15 001 to 30 000 ppm 4 ppm or 3 of reading 5 of reading 8 of reading HC 0 to 4 000 ppm Propane 4 001 to 30 000 ppm 30 001 to 60 000 ppm 8 ppm or 3 of reading 5 of reading 8 of reading CO 0 00 to 10 00 10 01 to 15 00 0 02 or 3 of reading 5 of reading CO 0 00 to 16 00 16 01 to 20 00 0 3 or 3 of reading 5 of reading NO 0 to 4 000 ppm 4 001 to 5 000 ppm 25 ppm or 4 of reading 5 of reading 0 0 00 to 25 00 0 1 abs or 3 of reading 2 1 5 Response Time Andros Analyzer Only Gas Response Time HC lt 2 seconds CO lt 2 seconds CO lt 2 seconds NO lt 5 seconds O lt 10 seconds 0 10 to 20 9 lt 30 seconds 20 9 to 0 10 NOTE Add an additional 3 seconds to each of the Response Times listed above in order to account for the sampling delays due to the presence of the standard 10 ft heated
69. o File Saves a binary version of all setup parameters to a file This file can be loaded into the XM later on if necessary Load From File Restores all setup parameters from a binary file 11 4 Device Setup Pages XM 1000 User Manual 2 4 2 5 2 6 3 0 Chapter 11 Cell Assistant for Windows Calibrate Page This page is identical in appearance and function to the Calibration Selection page described in Chapter 6 section 1 3 Utilities Page This page is identical in appearance and function to the Utilities Selection page described in Chapter 7 section 1 0 Service Page This page is identical in appearance and function to the Calibration Selection page described in Chapter 8 section 1 1 Device Channels The XM 1000 device driver for Cell Assistant presents a large list of physical device channels to a running TestPlan Contact Dyne Systems for an up to date list of all device channels XM 1000 User Manual Device Channels 11 5 Chapter 11 Cell Assistant for Windows 11 6 Device Channels XM 1000 User Manual Chapter 12 Reference 1 0 Setup Parameter Hierarchy This section contains a comprehensive list of all configurable parameters in the XM 1000 The factory default value of each parameter is listed XM 1000 O Firmware Version 1 002 HA Analyzer 0 HC Readings n Hexane 1 Ignore Master Enable Yes Hope Security Secure Mode Off Password
70. ollowed by the LOCK button and configuration is complete for this port 4 Ifaspan gas canister is connected enter the concentrations of each of the four listed gases Enter 0 if the canister does not contain the specified gas Use the Up and Down arrow keys to select the various gases use the numeric keypad to enter the appropriate concentrations and then press the ENTER key set the concentration of the selected gas 5 Touch the Edit button to enter a description for the connected gas This description will be displayed as a calibration selection on the actual calibration page Touch the other Edit button to set the installation date of the canister Touch the LOCK button when all data has been entered Touch the Save button to save all configured calibration gas data in non volatile memory 6 4 Managing Calibration Gases XM 1000 User Manual Chapter6 Calibration 3 0 Calibrate Analyzer The main calibration page is shown below 00 00 00 FLOW Messages es The following procedure describes how to calibrate the analyzer 1 Make a Flow Selection using the Up and Down arrow keys The first item in the list i e Air is always present and can be used as a source for zero calibration One or two additional flow selections will exist depending on how the calibration ports have been configured Each calibration gas canister that has been connected and configured as described in section 2 0 wi
71. onents HC CO CO NO and O3 The exhaust gas components are analyzed using the Andros Model 6600 miniature automotive analyzer These analyzers are used in service garage equipment portable applications and inspection and maintenance programs throughout the world The Andros analyzer alone is not designed for continuous testing In order to perform continuous testing of engine exhaust the XM 1000 also has a well designed sample conditioning system and heated sample line and heated filtering system 1 1 Features The XM 1000 provides many of the features of high end gas analyzers but at a small fraction of their cost Heated Pre Filter to remove large particulates from the sample Heated sample line to keep the sample temperature above the dew point Heated filter to remove smaller particulates from the sample Two stage chiller to remove moisture from the sample Low Cost Leak Check HC Hangup Test Calibration Zero and Span Zero calibration with Zero calibration gas or with ambient air Purge Simplified Maintenance filters are easily replaced in the field Portability can easily be moved from one test cell to another Chapter 1 Introduction 2 0 Specifications 2 1 Gas Measurements 2 1 1 Measured Gases Gas Description HC Hydrocarbons as either n Hexane or Propane CO Carbon Monoxide CO Carbon Dioxide NO Nitrogen Oxides O Oxygen 2 1 2 Measurement Range Gas Ra
72. or message will be displayed XM must NOT be in a special function mode e g Calibrate Service Setup etc e XM must NOT still be in Power up or Warm up modes see section 2 0 and section 3 0 e No faults can exist e Master Enable is asserted if it is used as explained in section 3 1 If the previous requirements are satisfied the XM will enter the selected mode of operation The Andros analyzer will begin to measure concentrations All displayed readings are now valid and will be enabled i e white background as described in section 5 1 7 0 Setup Parameters The XM has very few setup parameters Most XM installations use the factory default settings and therefore do not require any modification of these parameters Path XM 1000 Analyzer ID Parameter Values Description 0 HC Readings n Hexane Selects if HC readings should be reported as HC n hexane Propane or as propane See Andros product manual for more information Default selection n Hexane 1 Ignore Master Yes No Selects if the XM requires the Master Enable input to be Enable asserted in order to operate The Master Enable input is described in Chapter 2 section 3 1 Default Yes 4 18 Setup Parameters XM 1000 User Manual Chapter4 Analyzer Operation 8 0 Faults and Warnings Various errors can occur during normal operation of the XM analyzer Each error is classified as a Fault or a Warning Faults have an immediate imp
73. ose can be replaced as follows 1 Power down the XM and unplug the power cord 2 Disconnect the bottom end of the pump hose s from the Y connector 3 Disconnect the upper end of the pump hose s from the respective chiller element Save the compression rings and note their position so they can be replaced on the new hose s Remove the four wing nuts from the pump heads Carefully remove the pump heads Remove the old hose s and install the new hose s A special tool provided by the pump head manufacturer is required in order to install the new hose This tool is included with the XM 1000 documentation packet 7 Re assemble the pump heads Make sure the keyed ends are properly aligned and fit together such that both pump heads rotate Re connect the bottom hose end s to the Y connector 9 Replace the compression rings on the upper end of the pump hose s and reconnect to the respective chiller element 10 Power up the XM 11 Perform a leak check Chapter 7 section 1 2 to make sure all connections are properly sealed 12 Press the PURGE button and observe that both pump heads are rotating Maintenance Procedures XM 1000 User Manual Chapter 11 Cell Assistant for Windows 1 0 Overview Cell Assistant for Windows is a data acquisition and control software package developed by Dyne Systems Many device drivers are available allowing Cell Assistant to acquire data from and to control many devices such as PLC s gas analy
74. ote The ZERO or SPAN button MUST be touched within 90 seconds after the respective calibration gas has started to flow If not a calibration timeout fault will occur Additional information for this fault is presented in Chapter 4 section 8 1 6 6 Calibrate Analyzer XM 1000 User Manual Chapter Y Utilities The XM utilities are a collection of tests that should be run periodically to check the integrity of various XM system components 1 0 Accessing Utilities Press the UTILITIES button on the front panel of the Operator Control Station A dialog box containing all available utilities will be displayed Touch the appropriate button to launch the desired utility Test Selection HC Hangup Test Leak Check Chapter 7 Utilities 1 1 HC Hangup Test The HC Hangup test is used to measure the magnitude of residual hydrocarbons that have accumulated i e are hung up in the sample line This build up of hydrocarbons cannot be zeroed out during calibration thus all HC concentration readings are continually affected The HC Hangup test should be run periodically to monitor the magnitude of hung up hydrocarbons When the HC reading becomes unacceptable the teflon tube in the sample line should be cleaned and or replaced The main test screen for the HC Hangup test is shown below one Stop RECORD RESULT 00 00 10 Test Parameters Previous Results Purge time 2 22 JAN 2004 Averaging time sec Messages
75. pass switch can be used to exit Warm Up mode and proceed to Standby mode The bypass switch is described in section 1 1 The bypass switch should be returned to the off position at the earliest opportunity after the heated sample line warms up XM 1000 User Manual Warm Up Mode 4 3 Chapter4 Analyzer Operation 3 2 3 2 1 4 4 System Monitor The XM continuously monitors several operating parameters The normal operating value of each parameter is listed below Monitored Value Nominal Value 0 Sample Line Temperature 190 C 1 Filter Temperature 190 C 2 Chiller Temperature 5 C 3 Sample Vacuum See text below All temperatures are electronically controlled and should be maintained within a few tenths of a degree celsius The sample vacuum is measured in psiv pounds per square inch vacuum When the sample pump is running the vacuum reading should be less than 0 5 psiv This reading will depend on the length and diameter of the sample line A typical reading may be only 0 2 psiv The vacuum readings will increase over time as the sample line becomes dirty and or the filters become clogged with exhaust debris Experience will be gained after some time in how to use the sample vacuum readings to determine the necessity to clean and or replace the filters and sample tubes Monitored Limits Once the XM has exited Warm Up mode and has entered a normal operating mode the following temperature and
76. pdating and the new value will take effect after the OK button is touched AE Sens XM 1000 User Manual Set System Time Date 8 5 Chapter 8 Service 4 2 System Date The following dialog is used to change the system date Touch the appropriate up and down arrow buttons to adjust the day month and year The keypad can also be used to manually enter the year value S 2 En ee Note The Today button shown in a disabled state in the previous figure is used when editing installation dates for calibration gas canisters An operator can manually enter an installation date or simply touch the Today button to use the current date 8 6 Set System Time Date XM 1000 User Manual Chapter 9 Security Setup Calibration Utilities and Service are secured features in the XM Each can be individually secured giving the XM administrator total control over which features and functions are available to an ordinary operator 1 0 Setup Parameters All security parameters and their location are listed below Path XM 1000 Security ID Description Values Description 0 Secure Mode On Off Displays the current security state of the system Must be set to On to secure selected features 1 Password Mee ee Existing password Consists of 4 to 10 digits Factory default 1234 2 Secure SETUP Yes always Access to SETUP parameters is always secure when Secure Mode is set to On 3 Secure CALIBRAT
77. ple line the heated filter and the chiller reach their proper operating temperatures A system monitor see section 3 2 is available to monitor the progress of various components as they warm up or cool down Warm Up Requirements The following tables lists the warm up requirements for various components The heated sample line and the heated filters must warm up to the indicated values Similarly the chiller must cool down to the indicated value These values are not the normal operating values they are merely the minimum required values that must be obtained in order for the XM to exit Warm Up mode and enter Standby mode The normal operating values are listed in section 3 2 Value to Exit Monitored Value Warm Up Time Sample Line Temperature 185 C 40 min Filter Temperature 185 C 15 min Chiller Temperature 6 C 15 min The preceding table also lists the approximate time required to reach the Warm Up mode exit values The heated filter and chiller reach their respective values fairly quickly whereas the heated sample line is significantly slower to warm up These times are approximate and will vary depending on the ambient temperature of the test cell where the XM is located This is especially true for the heated sample line The heated sample line can take a significantly longer time to warm up if located in cooler ambient surroundings Notes Ifthe heated sample line is not warming up fast enough the by
78. pressure limits are continuously monitored Monitored Limit Value 0 Sample Line Temperature High Limit 200 C 1 Sample Line Temperature Low Limit 180 C 2 Filter Temperature High Limit 200 C 3 Filter Temperature Low Limit 180 C 4 Chiller Temperature High Limit 7 C 5 Chiller Temperature Low Limit 3 C 6 Sample Vacuum Warning Level 2 0 psiv 7 Sample Vacuum Failure Level 4 0 psiv If any of the monitored temperatures fall out of range a fault condition will occur The XM will not operate until the fault condition is cleared In addition if the temperature of the heated sample line or the heated filter fall below their respective lower limits the XM will return to Warm Up mode as described in section 3 0 A warning condition will occur if the sample vacuum reaches the listed warning level value As explained in section 8 2 a warning condition will be indicated in order to remind the operator of a Warm Up Mode XM 1000 User Manual Chapter4 Analyzer Operation potential problem however the XM analyzer will continue to operate If the sample vacuum reaches the listed failure level a fault condition will occur and the XM will no longer operate High sample vacuum readings are typically caused by dirty and or clogged sample lines and filters 3 2 2 Displaying the System Monitor All monitored operating parameters can be displayed in a popup dialog by touching the fo
79. r Code Text Description 180 Invalid configuration The configuration FLASH chip contains an invalid data block blocks in Flash The FLASH part must be replaced and or erased The XM should be returned to Dyne Systems for repair 181 Flash erase failed A data block in the configuration FLASH chip failed to erase Press the save button again to see if the erase failure is intermittent If the problem persists the XM should be returned to Dyne Systems for repair 182 Flash write failure A write error occurred while saving configuration data to FLASH Press the save button again to see if the write failure is intermittent If the problem persists the XM should be returned to Dyne Systems for repair 183 EEPROM is damaged The contents of the EEPROM are invalid The XM will automatically try to erase and re initialize the EEPROM All data in the EEPROM will be reset to factory default values If the problem persists the XM should be returned to Dyne Systems for repair 184 EEPROM contents have This message is sent as a reminder that the contents of the been initialized EEPROM have been initialized i e reset to factory default values 185 EEPROM Write Timeout A write operation to the EEPROM failed to complete The serial EEPROM probably needs to be replaced Contact Dyne Systems 186 Serial Port 1 not detected This error is logged at power up if the XM fails to detect the hardware for the specified serial port This is a boot error thus th
80. r Manual Chapter 11 Cell Assistant for Windows 2 2 System Monitor Page This page duplicates the functionality of the system monitor dialog on the Operator Control Station See Chapter 4 section 3 2 for information regarding which data values are monitored and why Device Setup DyneSystems XM 1000 Chiller Temperature E 70 5 0 c 30 Analyzer Temperature 50 0 26 6 c DO Sample Vacuum E 14 70 0 05 psiv 10 00 oR __ cancel _ XM 1000 User Manual Device Setup Pages 11 3 Chapter 11 Cell Assistant for Windows 2 3 Setup Page This page provides one local setup parameter as well as access to the XM 1000 setup parameters The Setup page is shown below Device Setup DyneSystems XM 1000 The Sampling Frequency should be set as needed This parameter determines the rate at which Cell Assistant acquires concentration readings and other data from the XM The XM 1000 group of buttons provide access to the XM setup parameters The function of each button is explained below Button Function Modify Provides access to all XM setup parameters Pops up a dialog containing the standard parameter tree and parameter list as shown in Chapter 5 section 1 1 Text Dump Dumps a text version of all setup parameters to a file This file is for documentation purposes only A comprehensive list of parameters in presented in Chapter 12 section 1 0 was created using this feature Save T
81. r Operation ba A AA Re aoe hoe eA 4 17 Master and Computer Modest RAS 4 17 Analyzer Modesa os da a da dnd We ds 4 17 Standby 2 isis wide eare e sina ER La atts Blea amp aon 4 17 Sample and Purge Modes saved iin iver taeda aa 4 17 Seip Parameters aaa sound anc tan es eds tada balls teas ear see lt b 4 18 Fa ltsand Warnings eose SOs A ep haa ADA St en ey te SR OES 4 19 Faults ios gee dattan Eei loin Ds gas Side Gey See na pet aA ch gag aa hatha ree gh 4 19 WARNINGS A A aOR E AEE aAa Sahota kw Sater 4 22 Chapter 5 Setup XM 1000 Setup Para meters cine AS Soke Sao Rea 5 1 Accessing the XM 1000 Setup Page 0 0c cece eee cee eee 5 1 Setup les BASICS Aw ii a a AE a Bieter ane bat 5 2 Folder COIE a Seta hin a RS So 5 2 Parameter List Basist goa ton a4 de ao aah ape ne OM 5 3 Setup Tree and Parameter List Navigation 00000 eee eee 5 3 Stylus NVI e dvds eS cilia AA eke eae iaa 5 3 Keypad Navia il A E AS 5 3 DAS a Dita 5 5 E SS SS PECL REA Se BPRS He ESE RARE ne Sek 5 5 Number a AAA ese ened eres 5 5 ASE ARA A ADE RAE Wik Meee a le eS 5 6 SINE creche a eg O A mens Uae a och Me ea ih Gale Os 5 7 Non Modifiable Data Types 0 0 000 cece ene 5 8 Saving Setup Parameters ax ob hea ate aadod ot cowie Gees 5 9 Backing Up and Restoring Setup Parameters 0005 5 9 Top Structure of the Setup Tree 0 0 0 0 cece eee 5 10 Chapter 6 Calibration OVERVIOW A EI AA AAA RA ae Sentra BEY 6 1 Zero C
82. rd modification is attempted the XM displays the following dialog box Current Password New Password Confirm 0 e Enter the current password and press ENTER Enter the new password It must be a 4 to 10 digit number Press ENTER Enter the new password again in the Confirm field Touch OK kh O N Note When done touch the Save button on the main setup page to guarantee that the new password is saved in non volatile memory XM 1000 User Manual Accessing a Secure System 9 3 Chapter 9 Security 1 2 Securing the XM The XM security feature can be re enabled as follows 9 4 1 2 3 4 5 Set the Secure CALIBRATE parameter to the desired value Set the Secure UTILITIES parameter to the desired value Set the Secure SERVICE parameter to the desired value Set the Secure Mode parameter to On If this is the first time the security feature is bein enabled the Powerup Secure Mode parameter must be set to On Note When done touch the Save button on the main setup page to guarantee that all new security settings are saved in non volatile memory Note Be sure to set the Powerup Secure Mode parameter to On to totally secure the XM If not the XM can be put in a non secure mode by simply cycling the power Accessing a Secure System XM 1000 User Manual Chapter 10 Maintenance Procedures 1 0 Overview There are many maintenance procedures that must be periodic
83. ros analyzer of any previously sampled gases During calibration this connector can be used as a source of Zero air which allows the analyzer to be zeroed against ambient background concentrations in the test cell There are several connection options for this connector Connect a source of fresh air A source of fresh air can be piped in from an external source The fresh air contains no background concentrations of HC CO etc and can be used during calibration to zero the analyzer e Connect a source of background air Background air from the vicinity of the device under test can be piped in During calibration the analyzer can be zeroed against the background concentrations of HC CO etc Not connected Do not connect and simply use the background air in the vicinity of the XM 2 2 SAMPLE INPUT The sample input connection is unique to each device under test Dyne Systems will design a sample probe to satisfy your testing requirements 2 2 Plumbing XM 1000 User Manual Chapter 2 Installation 2 3 WATER OUTPUT All moisture in the sample gas is removed by the sample chiller as described in Chapter 3 section 1 3 The collected moisture is then removed from the chiller by a dual head peristaltic pump and discharged via this connector Note The water present at this connector contains small concentrations of soluble sample gases and is corrosive Do NOT let this liquid simply run onto the floor it should be collected in
84. run time commands e g sample or purge will be accepted from any of the other attached OCS s until setup is exited 31 XM in CALIBRATE mode All analyzer run time commands are rejected when the XM is in calibration mode This error occurs when multiple OCS s are connected to the XM and one OCS is currently calibrating the analyzer No run time commands e g sample or purge will be accepted from any of the other attached OCS s until calibration is exited 32 XM in UTILITIES mode All analyzer run time commands are rejected when the XM is in utilities mode This error occurs when multiple OCS s are connected to the XM and one OCS is currently running a utility No run time commands e g sample or purge will be accepted from any of the other attached OCS s until the utility is exited 12 4 Error Messages XM 1000 User Manual Chapter 12 Reference Error Code Text Description 33 XM in SERVICE mode All analyzer run time commands are rejected when the XM is in service mode This error occurs when multiple OCS s are connected to the XM and one OCS is currently accessing a service function No run time commands e g sample or purge will be accepted from any of the other attached OCS s until the service function is exited 34 XM in FACTORY mode All analyzer run time commands are rejected when the XM is in factory mode This error occurs when multiple OCS s are connected to the XM a
85. sampling line XM 1000 User Manual Specifications 1 3 Chapter 1 Introduction 2 1 6 Other Warm up Time 15 40 minutes Sample Flow Rate 4 0 cubic feet hour 2 1 7 Operating Conditions The XM 1000 must be installed in an environment conforming to the following specifications Temperature 0 C to 50 C 32 F to 122 F Humidity to 95 non condensing Altitude 300 m to 2 500 m 1 000 ft to 8 000 ft 1 4 Specifications XM 1000 User Manual Chapter 1 Introduction 3 0 Notices 3 1 3 2 3 3 3 4 3 5 Safety To prevent physical injury follow all standard safety precautions when installing operating and maintaining the XM 1000 and all peripheral equipment Refer to the American National Standards Institute ANSI or the Occupational Safety and Health Administration OSHA for additional safety information Follow all instructions in this manual e Always remove all power to any component before attempting to access any internal components e Obey all safety signs on the equipment and in this manual Electrocution Hazard This product and associated components are electrically energized Electric shock may cause serious injury or death Always disconnect line voltage before servicing the XM 1000 or any associated components Electrostatic Discharge Electrostatic discharge ESD can damage sensitive semiconductors on all circuit boards in the XM 1000 and associated components Always wear an E
86. save command XM 1000 User Manual Error Messages 12 3 Chapter 12 Reference Error Code Text Description 6 lt blank line gt This notification code is never displayed since it is a blank line It is sent to all connected OCS s when the Reset button is pressed in order to clear the message line 7 Password required Sent to an OCS that attempts to enter setup mode and secure mode is active The OCS will then display the Enter Password dialog requiring the operator to log in before any changes to the current setup can be made 8 Andros not responding still trying Sent every 2 seconds during power up mode while the XM main computer tries to establish communications with the Andros analyzer This message is typically never seen since Andros communications is typically established on the first attempt with no errors If this message is displayed check that the Andros power cable and serial port cable are properly connected 9 29 UNDEFINED Analyzer Run Time Errors 30 79 These errors are usually returned after a button press or operator action that is not permitted at this time due to existing errors or other conditions Error Code Text Description 30 XM in SETUP mode All analyzer run time commands are rejected when the XM is in setup mode This error occurs when multiple OCS s are connected to the XM and one OCS is currently accessing setup parameters No
87. sulted for additional information Error Codes Error codes are logically organized into the groups listed below Notification Codes 1 29 The XM returns these codes to the OCS when it needs to be notified of an event Error Code Text Description 1 Boot errors exist Sent to all connected OCS s when the XM is initially powered up and one or more fatal hardware errors have been detected Each OCS then polls the XM for a detailed list of the boot errors that were detected and displays them to the operator No XM commands will be accepted until all boot errors have been corrected The XM must be rebooted to clear out this error condition 2 XM settings have Sent to all connected OCS s when one of the OCS s has entered setup changed mode and changed a parameter Each OCS will refresh the currently displayed page in order for the configuration changes to take effect 3 EEPROM erase Sent only to the OCS that issued an erase EEPROM command to the completed XM This is a factory mode operation that can only be performed at Dyne Systems 4 Configuration erase Sent only to the OCS that issued an erase configuration command to completed the XM This is a factory mode operation that can only be performed at Dyne Systems 5 Configuration save Sent after the Save button has been pressed in setup mode and all completed configuration data has been successfully saved to non volatile memory Only sent to the OCS that issued the
88. t Parameters The following test parameters are set at the factory and cannot be modified Test Parameters Value Description Target vacuum 5 0 psiv The initially created vacuum that must be held during the test Vacuum time limit 10 sec The test is given this amount of time to create the target vacuum If the time limit expires before the target vacuum is achieved the test has failed The operator should look for one or more significant leaks in the system Vacuum settle time 5 sec After the target vacuum is achieved the sample pump is turned off and the leak check solenoid is closed Afterwards the XM pauses for the specified amount of time in order to give the vacuum reading time to settle When the settling time has expired the XM makes the initial vacuum reading All computed changes in vacuum are referenced to this initial reading Vacuum hold time 45 sec The leak check test waits for the specified time while continuously monitoring the drop in vacuum Max vacuum drop 0 5 psiv The maximum allowable vacuum loss during the test If the vacuum loss after 45 seconds is greater that this value the test is considered a failure Depending on the final magnitude of the vacuum loss check for small leaks at all connection points Tighten up all connections and repeat the test as often as needed XM 1000 User Manual 7 7 Chapter 7 Utilities 1 2 3 Performing the Test A leak check of the sample line
89. t need to be periodically replaced during the operating life of the XM They are summarized in the following table Contact Dyne Systems and provide the appropriate part number s The maintenance procedures to replace these components are given in Chapter 10 Part Dyne Systems P N Stainless Steel 10 micron pre filter element XM FILTERS 0000 Heated Filter Elements Box of 10 XM FILTERS 0001 Water Filter Cartridge 2 micron XM FILTERS 0100 Peristaltic Pump Tubing 25 ft piece XM TUBING 00000 O Sensor XM ANDROS 01000 NO Sensor XM ANDROS 01001 Bar 97 High Calibration Gas XM CALGAS 00000 Bar 97 Zero Air XM CALGAS 00002 4 0 Optional Parts The following optional components are available for the XM Contact Dyne Systems and provide the appropriate part number s Part Dyne Systems P N Additional connnection hardware for a 2nd calibration gas XM ASY GASCON 0 cylinder Includes pressure regulator swivel elbow and an appropriate length of tubing XM 1000 User Manual Replacement Parts 12 11 Chapter 12 Reference 5 0 Manufacturer Contact Information 5 1 Dyne Systems Co LLC For all service related questions contact Dyne Systems Co LLC at Address W209 N17391 Industrial Drive P O Box 18 Jackson WI 53037 Telephone 262 677 9300 Toll Free 800 657 0726 Fax 262 677 9308 World Wide Web http www dynesystems com 12 12 Manufacturer Contact Inform
90. t parameters can be modified as needed In general the duration of the purge and average states should be adjusted as needed to get the most stable readings For example longer sample lines may require the Purge time to be increased Each test parameter is changed by first selecting the parameter using the Up and Down arrow keys entering the new value and then pressing the ENTER button Finally touch the Save button to save the new parameter value in non volatile memory Test Parameters Range Description Purge time 10 to 600 sec The length of time the test purges the entire sample line and sample conditioning system before it begins to measure and average the HC concentration readings Default 30 sec Averaging time 2 to 300 sec The length of time the test measures and averages the HC concentration readings Default 10 sec XM 1000 User Manual 7 3 Chapter 7 Utilities 1 1 3 Performing the Test The HC hangup test is performed as follows 1 Remove the sample probe from the device under test and place it at or near a source of fresh air This ensures that all HC readings are due to hung up hydrocarbons in the sample line and are not coming from another source Touch the START button Wait for the test to complete If you are NOT interested in recording the result touch the Done button to exit the test If you wish to save the result for comparison with other tests in the fut
91. ters at all e g part numbers revision numbers test results etc These data items cannot be changed by the user and or cannot be changed from the Setup page Any attempt to modify them will result in one of the following error messages e Read only parameter Modification not allowed Parameter is for display and documentation purposes only e g the Firmware Version number cannot be changed Factory setting Modification not allowed Factory settings such as temperature and pressure limits cannot be changed Parameter is managed by another page Some data items can be changed but not from the Setup page For example calibration gas concentrations are listed in the Setup tree but can only be modified from the appropriate calibration page Note Some property folders contain only non modifiable data items These folders are colored red in the property tree The red colored folder serves as a reminder that none of the data items contained in the folder can be modified See section 1 1 for additional information 5 8 XM 1000 User Manual 1 5 1 6 Chapter5 Setup Saving Setup Parameters Touch the Save button in order to save ALL setup parameters to onboard non volatile memory Do this as often as necessary to avoid accidental loss of parameter changes Parameter changes take affect immediately after they are made however if the changes are not saved to non volatile memory they will be lost when power to the XM is removed
92. tioning 10 ft Heated Sample Line System po p Sample Input 1 2 1 3 2 Pseudo Temperature Controlled Temperature Temperature Controller 1 Controller 2 Figure 3 2 Heated Sample Line and Heated Filters Temperature Control Heating of the sample line can be enabled disabled and or bypassed as explained in Chapter 4 section 1 0 When enabled temperature controller 1 maintains the temperature of the sample line at 190 C The temperature is tightly controlled and should not vary by more than 2 C depending on ambient temperature conditions The XM main computer monitors the temperature XM 1000 User Manual Chapter 3 Theory Of Operation as explained in Chapter 4 section 3 2 and will create a fault condition if the temperature varies by more than 10 C As an additional safety feature the temperature controller will disable itself if the temperature reaches 205 C The controller also checks for broken thermocouples i e the temperature feedback source and for problems in the heater power electronics and will disable itself if necessary The temperature of the heated filter is controlled by temperature controller 2 The configuration of this controller is identical to the configuration of temperature controller 1 i e it can be enabled disabled or bypassed is controlled to 190 10 C has hard over temperature protection at 205 C etc Note Do NOT change any of the setup paramet
93. to quit without making any changes Note The ENTER and CANCEL keypad buttons duplicate the function of the OK and Cancel touch screen buttons 1 4 4 String This data type is simply a string of printable characters The maximum string length allowed depends on the parameter type the maximum length is typically 40 characters The following figure shows the pop up dialog for string data types The parameter name is displayed in the upper left corner of the dialog of tia ste sje 7 ele epofefefoffofefs s epofafofofofol fo fo apa EA ee E a XM 1000 User Manual 5 7 Chapter5 Setup This dialog presents a virtual keypad for entering alphanumeric data and other printable characters Touch the CAPS key to access upper case letters Touch the Other button to access punctuation marks and other unique printable characters A Space bar is also available When done touch the OK button to accept the parameter change or touch the Cancel button to quit without making any changes Note The ENTER and CANCEL keypad buttons duplicate the function of the OK and Cancel touch screen buttons The CANCEL button must be pressed twice the Ist press clears the entered data and the 2nd press dismisses the dialog box Note The numeric keypad buttons can also be pressed to enter numeric strings 1 4 5 Non Modifiable Data Types Many data items are present in the tree list of configuration parameters which are not really configuration parame
94. ure calibration gases and how to perform a calibration procedure Andros Analyzer The heart of the XM is the Andros Model 6600 Automotive Gas Analyzer The dry sample gas leaves the sample conditioning system and enters the Andros analyzer where the HC CO CO O and NO concentrations are measured Main Computer The main computer controls and supervises the overall operation of the XM All communications with the Andros analyzer the Operator Control Station and optionally a remote computer running Cell Assistant is handled by the main computer It also controls all pumps solenoids relays etc in the sample conditioning system Finally the main computer monitors many system variables e g sample line and filter temperatures sample line vacuum etc and generates faults if any problems exist Operator Control Station The Operator Control Station OCS is the main user interface device for the XM The OCS is fully described in Chapter 4 section 4 0 XM 1000 User Manual Chapter 4 Analyzer Operation This chapter describes the overall operation of the XM analyzer 1 0 Turning On The Analyzer The front of the XM contains the following pairs of push buttons POWER This pair of buttons controls power to the entire XM analyzer Press the Green button to apply power to the XM The Heated Sample Line and Heated Filter buttons will not function unless power to the entire XM is established thus the m
95. ure touch the RECORD RESULT button The HC reading will be added to the list of Previous Results Touch the Save button to guarantee the recorded results are saved into non volatile memory Touch the Done button to exit the test Note Touch the STOP button at any time to cancel the test 1 1 4 Previous Results 7 4 The results from up to ten previous tests are displayed here Recording and saving the results of previous tests is optional They are only used for comparison with future tests to estimate the amount and the accumulation rate of residual hydrocarbons XM 1000 User Manual Chapter 7 Utilities 1 2 Leak Check In order for the XM to accurately measure the concentrations of collected sample gases it is imperative there be no leaks in the system such that ambient air enters the system and dilutes the sample The sample conditioning system is leak tested at the factory however many of the external components in the sample path are routinely handled for many reasons e g filter replacement and can easily develop leaks at one or more connection point The leak check tests the following components and all associated connection points Refer to the Figures in Chapter 3 to identify the location of each component e Sample line valve e Heated pre filter e Sample line Heated filter Sample Air select solenoid Chillers Peristaltic pump hose Pressure transducer Leak check solenoid The leak check is performed by
96. ut they do not interrupt the operation of the XM Warnings are described in section 8 2 The right most example shows the indicator state if one or more fault conditions exist Faults require immediate operator attention XM operation will be halted if any faults occur Faults are described in section 8 1 Note This indictor is also a button When touched a fault list dialog pops up over the main screen The contents of the fault list dialog are discussed in section 5 4 Indicates the Master Computer mode of the XM as shown in the following examples The XM will typically always be in Master mode Computer mode is only used if the XM is remotely controlled by a host computer running Cell Assistant see Chapter 11 See section 6 1 for more information on Master and Computer modes a OK Master Computer XM 1000 User Manual Main Analyzer Screen 4 13 Chapter4 Analyzer Operation 5 3 5 4 4 14 Standby Purge Sample Indicates the current operating mode of the XM During normal XM operation This indicator will have one of the following three appearances Standby Sample and Purge are the three main modes the XM will be in at any given time They are described in section 6 2 1 and section 6 2 2 Immediately after power is applied the XM enters a power up state immediately followed by a warm up state The XM mode indicator annunciates these states as shown below Power Up mode is described in section 2 0 Warm Up mode is describ
97. ystem date and time of the XM 71 79 UNDEFINED Setup Errors 80 99 These errors are displayed when the XM is in setup mode and invalid parameter values are entered Error Code Text Description 80 Invalid character has been When entering a numeric value the only allowable characters entered are 0 through 9 and 81 No value entered The input value was blank 82 Read only parameter Some XM parameters e g the Firmware Version are read only Modification not allowed and cannot be changed 83 Factory setting Many factory settings e g system monitoring limits are listed Modification not allowed in the setup property tree for documentation purposes only and cannot be changed This error is returned if an operator attempts to modify a factory setting from the setup page 84 Parameter is managed by Some data items e g test parameters for some utility tests are another page listed in the setup property tree for documentation purposes only and cannot actually be modified from the setup page instead these parameters must be modified from the respective utility page This error is returned if an operator attempts to modify one of these parameters from the setup page 85 Incorrect password Password entered is not correct Try again If the password is lost or forgotten contact Dyne Systems 86 Password characters must Password must be numeric be d
98. zers fuel systems etc This section describes the Cell Assistant device driver for the XM 1000 Gas Analyzer Familiarity with Cell Assistant is assumed throughout this chapter 2 0 Device Setup Pages As with all Cell Assistant device drivers several Device Setup pages are available to configure the XM and to test all communications with the XM The tabs for these pages are summarized below Each is described in more detail in the sections that follow Device Setup DyneSystems XM 1000 3 3 x xM Monitor Setup Calibrate Utilities Service Port Chapter 11 Cell Assistant for Windows 2 1 XM Page This page duplicates the functionality of the main display on the Operator Control Station see Chapter 4 section 5 0 allowing the XM to be operated from this page In addition the Warning indicator shown below is also a button Click on this indicator with the mouse and a Fault List dialog box will pop up The fault list is described in Chapter 4 section 5 4 Device Setup DyneSystems XM 1000 x xM Monitor Setup Calibrate Utilities Service Port E O ppm ie 0 000 y nos O ppm c 0 01 y SAMPLE Pave 20 89 00 00 20 Sample Standby warning OK Cancel Note Issuing any XM command e g Purge Sample etc from this page will put the XM into Computer mode Master and Computer modes of operation are explained in Chapter 4 section 6 1 11 2 Device Setup Pages XM 1000 Use

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