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1. a dl dl Ci3000 N KN _ o S O 0D 0 L 2 3 4 K1 4 C1 2 CB2 1 Al 2 CB2 2 Q 9 XENON XENON 4 IGNITION WATTAGE 10 CIRCUIT LAMP IGNITOR wa CIRCUIT TRANS a rm BREAKER RELAY L3 BREAKER DUCER IGNITION 9 O 5L3a DUCER BUL CE 5 CB1 K1 nn CB2 RELAY 4 3 XENON o KO 97 RELAY o 3 CAMP ef g D 1 XE i une o bAt 2 Fi O sav O PLC5 10 2 TP1 FUSE A1 4 32 31 o IGNITION BLEEDER INTERNAL 7 CAPACITOR RESISTOR p oa e C1 20K OHM 290 O42 PLC5 2 fat TE a 40 mfd 20W M 2 O ANALOG INPUT o r j W S MODULE See yas or WATTAGE IGNITOR O BOOSTER 232 9 IGNITION 9 AAEE ules L3b 2 TRANSFORMER Lag PULSE e o oo nT onga T1 E 2 ei RELAY APC1 O 1 gt lt K3 3 rc lt C gt E 6 7 1 L1 2 O O O Ne WATTAGE _ L1 2 TRANSDUCER RELAY PLC6 7 O 01 1 y MAIN 112 K9 PLC6 so WATTAGE h ANALOG OUTPUT lt 5 REGULATOR c REACTOR MODULE 5 0 3 a LL L1 L1 1 PLC6 19 Otto 2 i ARI o O XENON XENON 2 ao 4 IGNITION 3 CIRCUIT LAMP AUX MET LL CIRCUIT Y BREAKER RELAY REACTOR L BREAKER CB1 Ki L ye CB2 Ox O O O 3 x 4 3 4 5 6 TE i j RELAY COIL SWITCHING SOURCE AND PLC INDICATOR LIGHTS RELAY PLC TERMINAL LED K1 PLC3 2 Al K3 PLC3 3 A2 K5 PLC3 7 A5 K9 PLC3 17 B5 NOTE WHEN PLC LED IS2. Union Ring Mounting Ring a V v Pin Lamp Water Fitting Check that there is a sealing washer inside the lamp water fitting Connect the lamp and rotate it until the alignment pin falls into place Gently hand tighten the mounting ring 11409 SUOIDUNJE IN 01140 9uLIpe pue due UOUSYX z s 5 2 Xenon Lamp and Irradiance Control Malfunctions cont 5 2 2 Troubleshooting Guide MALFUNCTION Lamp fails to ignite PROBABLE CAUSE Chamber door open or switch failure Xenon lamp ignition breakers off Lamp assembled installed incorrectly CORRECTIVE ACTION Close door or check switch Turn on circuit breakers Check lamp Lamp output is high low Lamp will not operate above 1 Sun level Ci5000 only Lamp operating at excessive wattage Lamp ignitor lead off or loose Light rod dirty or damaged Light monitor malfunction Lamp burner socket damaged Low lamp starting voltage CS 6 cooling water flow low Ignitor malfunction Relay failure in lamp circuit PLC malfunction Burner is near end of life Lamp filters expired Burner tip socket damaged Incorrect irradiance calibration Interference filters expired Light rod is misaligned Wattage regulator malfunction 1 Sun or 2 Sun relay failure Burner is near end of life Lamp filters expired Burner tip socket damaged Incorrect irradiance calibration Interference filters expired Light rod
3. Voltage is present Continuity K3 5 amp K3 6 Ci3 amp Cid or K3 6 amp K3 7 Ci5 No Continuity 7 Check for 24Vac at relay K3 coil during pulse No voltage present 8 Check for continuity at terminals PLC3 1 and Voltage is present Z O continuity PLC3 3 during pulse Continuity 9 Check for 24Vac at TB3 7 amp TB3 9 Ci4 or No voltage TB3 5 amp TB3 8 Ci5 Lamp Water Temperature High Lamp Water Flow is Low Check CS 6 cooling system Section 5 5 Chamber Temperature is High Reset chamber safety thermo stat S4 in electronics drawer Install calibrated lamp Lamp and attempt ignition ignites Lamp does not ignite Previous lamp is malfunc tioning Inspect for dam age Check burner socket Measure line voltage and check transformer taps Set T1 lamp voltage boost to next higher selection see Section 5 1 5 On Ci3000 and Ci4000 replace ignitor On Ci5000 check 1 amp 2 Sun relays K15 and K4 Also check light rod clean liness integrity and light monitor filters and photo diodes Sec 7 2 9 Check voltage at breaker CB2 If no voltage replace breaker Coil has failed Replace relay K3 If LED A2 on PLC3 module is on during pulse replace PLC3 module If the LED is off download software program to PLC see Appendix A amp Sec 5 13 5 Ci3 denote Ci3000 Check breaker CB5 and T2 Replace failed breaker or
4. 6 8 and then the Irradiance Calibration Sec 6 9 to eliminate calibration as a contributive factor 2 Initiate standard test no 1 SAE J 1885 Set it up so the lamp will operate for 30 minutes 3 With the lamp operating confirm that the voltage signal from the light monitor is present at the PLC terminals PLC5 11 and PLC5 13 or at terminals PLC5 12 and PLC5 14 if the optional sensor is installed and is controlling irradiance A If no voltage is present there is a problem with the light sensor wiring interference filter or the photocell Check each of these before continuing See Section 7 2 9 B If the signal is present the light monitor is functioning properly 4 Shut off all power to the instrument at the wall mounted disconnect switch 5 Disconnect the AR1 1 lead from the wattage regulator and connect an ammeter in series with ee m Figure 5 2 10 Wattage Regulator Power LED the lead and terminal AR1 1 This will allow measurement of the 4 20mA drive signal from the PLC to the wattage regulator 6 Apply power to the instrument Initiate a custom test using wattage control rather than irradiance control Set the wattage level to minimum for the lamp type in use 1700 watts for Ci3000 2500 watts for Ci4000 4000 watts for Ci5000 Set the test duration to 30 minutes 7 Observe the LED indicator lights on the wattage regulator With power on and the xenon lamp operating the uppe
5. 1 Rack Bearings 201 Figure 8 11 2 Rack Driveshaft Components 201 Figure 8 11 3 Ci5000 Rack Hub 201 Figure 8 12 1 Chart Recorder Terminals 202 Figure 8 12 1 Chart Recorder Electrical Diagram 202 List of Tables Table 5 6 1 Lenze 8200 Blower Motor Controller Setup Codes 77 Table 5 13 1 PLC6 Indicator Light Legend 124 Table 8 5 1 Lenze 8200 Blower Motor Controller Setup Codes 192 This manual provides instructions for the trouble shooting calibration maintenance and repair or replacement of all applicable systems and com ponents of the Ci3000 Ci4000 and Ci5000 Weather Ometers These procedures should be performed only by a qualified service technician Specifications may be subject to change without notification Observe Precautions Before conducting any procedures read the warn ings and precautions in Section 2 0 Doing so will help ensure your safety and minimize the poten tial for damage to the instrument Beforehand always read the procedure that you will be con ducting to become familiar with the steps involved tools required and safety precautions Topics Covered This manual covers the following topics m Troubleshooting Power up Malfunctions Xenon Lamp amp Power Circuit Malfunctions Humidification Malfunctions Chamber Overtemperature Malfunctions CS 6 Lamp Cooling System Malfunctions Blower System Malfunctions Temperature Control Malfunctions Specimen Rack Drive Malfunctions Water Spray Malfunction
6. 340 420nm shown Channel 1 Capsule amp z gt Photodiode A10 Ci3000 Ci5000 amp Enhanced Ci4000 Light Sensor A13 Photodiode Filter Sensor Cell 2 Housing Housing Cover Interference Filter Note orientation of arrow Filter Housing and Beam Splitter Interference P Note orientation of arrow A10 Photodiode ER Sensor Cell 1 Older Ci4000 Dual Bandwidth Light Sensor Figure 8 2 8 Dual Bandwidth Light Sensors 8 2 Sensor Replacement cont 8 2 7 Light Monitor Photodiodes cont Sensor Pa Housing Interference Filter Note orientation of arrow A10 Photodiode Sensor Cell Filter Housing Cap Sensor BA Housing Cover NY DO NOT remove eee eis in this location Figure 8 2 9 Older Ci4000 Single Bandwidth Light Sensor Guidelines 1 The photodiode is fragile Handle it with care and avoid touching its front window If you do clean it with alcohol or optical cleaner and a soft cloth This applies to the interference filters as well 2 Always ensure that the direction arrow on the 340 or 420nm filter is pointing toward the photodiode direction of light travel when assembling the lig
7. ON PLC CONTACT IS CLOSED TO PROVIDE VOLTAGE TO RELAY n0110 due uouex 000F O9 Z 2 g eJ nbP Ci4000 a 3n 4 le 2 CB2 2 XENON XENON IGNITION WATTAGE CIRCUIT LAMP WATTAGE CIRCUIT TRANS 100 BREAKER RELAY tices ce BREAKER DUCER CB1 K1 CB2 gt IGNITOR ae RELAY r wj 9 K9 BOOSTER a L3a 2 NON 6 APC1 TRANSFORMER enon BLEEDER o Ar m o Oo Lo most j T1 CAPACITOR 56K OHM e 0 1 XENON o C1 1 O 062A cl C1 1 250V OL PLC5 ke LAMP 2 ANALOG INPUT RESISTOR XE o Atb Z NE MODULE R4 C2 2 C3 2 IGNITION 04 WATTAGE 1 8K OHM l PULSE en TRANSDUCER 2W j RELAY O ORI rere 34 39 K3 23 WATTAGE O 9 o O PLC5 8 a a TRANSDUCER 2 114 189 Ls RELAY A K9 L3b C2 1 C3 1 WATTAGE VOLTAGE TRANSDUCER 1 O 0 PLC6 7 BOOST BOOST WATTAGE 3g CAPACITORS A1a COIL o m PLC6 ee CAP RELAY REGULATOR 42 ANALOG OUTPUT L1 2 Te a 2 O O PLC6 19 2 2 XENON XENON MAIN AUX 1 8 L CIRCUIT LAMP REACTOR AMPLIFIER BREAKER RELAY REACTOR CTO RELAY BREAKER CBI Ki L1 L2 K5 0 Ox 2 5 6 L1 cs Ox O RELAY COIL SWITCHING SOURCE AND PLC INDICATOR LIGHTS RELAY PLC TERMINAL LED K1 PLC3 2 Al K3 PLC3 3
8. designed not only to help you pinpoint and verify malfunctions but to provide a basic explanation of operating principles of the various instrument subsystems Electrical block diagrams while simplified include accurate component wiring designations Additional Questions lf you have questions or encounter problems that are not addressed in this manual please contact Atlas Service at 773 327 4520 or send a fax to 773 327 5787 Chicago Illinois U S A 5 2 Xenon Lamp and Irradiance Control Malfunctions 5 2 1 Description Irradiance is provided by the xenon lamp system which is comprised of the xenon lamp and power Supply components that include the booster transformer T1 igniter L3 main reactor L1 auxiliary reactor L2 and wattage regulator AR1 The Ci3000 has a 4500 watt xenon lamp capable of operating from 1700 to 4500 watts The 6500 watt xenon lamp in the Ci4000 is capable of operating within the range of 2500 to 7400 watts The 12 000 watt lamp in the Ci5000 operates within the range of 4000 to 14000 watts The xenon lamp receives its high voltage ignition pulse from the igniter which drops out of the circuit after the lamp is operating steadily The instrument is designed to provide three ignition attempts before an ignition failure message is displayed on Data Panel MAIN page 1 At minimum wattage the lamp receives its power from the main reactor only At higher wattage levels the auxiliary reactor and watta
9. is off download the PLC software program to the PLC B3 Check for continuous 24Vac across Ci3 4000 TB3 7 and TB3 9 Ci5000 TB3 5 and TB3 8 This is the 24Vac supply to the 24Vac control circuit If 24Vac is not present check circuit breaker CB5 and the 24Vac output of the isolation transformer T2 at terminals T2 X3 and T2 X4 Replace the failed breaker or transformer 5 2 7 Troubleshooting Procedure Irradiance Low or High Wattage Regulator To maintain an accurate and stable irradiance level during a test the PLC receives a signal from the light monitor at PLC5 11 13 or PLC2 12 14 compares it to the irradiance setpoint reference and then alters its output at PLC6 7 19 to increase or decrease wattage regulator output 5 2 Xenon Lamp and Irradiance Control Malfunctions cont 5 2 7 Troubleshooting Procedure Irradiance Low or High Wattage Regulator cont This drive signal is applied to terminals AR1 1 and AR 1 2 of the wattage regulator AR1 Figure 5 2 9 Xenon Lamp Wattage Regulator Troubleshooting consists of first confirming light monitor operation and its output signal to the PLC Then the instrument is operated at constant wattage and the PLC output signal to the wattage regulator is checked If a stable drive signal is present but lamp operation is erratic or out of wattage tolerance it is likely that the wattage regulator is malfunctioning 1 Perform the Wattage Calibration Sec
10. module of the PLC see Sec 5 13 3 Run mid range wattage test again and check drive signal current No Check for 24Vac across continuity relay K9 coil terminals Voltage No voltage present present Replace relay K9 If B5 LED on PLC3 is on replace PLC3 If LED is off download software to PLC If operation not restored replace PLC3 See Section 5 13 5 Run standard test no 1 and confirm stable irradiance within test tolerance Reinstall old PLC 6 module amp confirm operation by running standard test no 1 5 2 Xenon Lamp and Irradiance Control Malfunctions cont 5 2 5 Troubleshooting Flow Chart 2 Sun Irradiance Considerations Ci5000 only 1 Create and initiate a custom 2 Sun test 2 Check for rack speed Rack at eal RAM AA JE of 10 RPM 1 RPM BUHARA VAN malfunctioning 3 Check for continuity between K14 relay termi Continuity Check for 0 volts between nals K14 3 and K14 4 ground and relay K15 terminal K15 3 If voltage present K15 or K14 is No stuck closed Replace bad continuity relay If A8 LED on PLC3 is on replace PLC3 If LED is off download software to PLC If operation not restored replace PLC3 See 4 Gheck for 24Vac at Ne VANA Section 5 13 5 K14 coil terminals K14 1 and K14 2 vaags Replace relay K14 present 5 With K14 operatin vonage Relay K4 is o k P 9 present ES properly check for volt age between ground and K4 relay terminal
11. A2 K5 PLC3 7 A5 K9 PLC3 17 B5 NOTE WHEN PLC LED IS ON PLC CONTACT IS CLOSED TO PROVIDE VOLTAGE TO RELAY u09 uo nd 9seq L z S SUOI JOUNJEW 011405 9uLIpe pue Gwe uou x 26 JINDID dweq uoueX 000GIO0 E Z S e nP j i al al Ci5000 E y an 5 e 3 4 K1 4 CB2 1 1 2 CB2 2 XENON XENON 7 de IGNITION 2 z CIRCUIT LAMP CIRCUIT BREAKER RELAY IGNITOR 1 TRANS 9 BREAKER O CY IGNITION r CB1 K1 s L3 Rie DUCER WATTAGE CB2 T PULSE Y Occ RELAY TRANS RELAY A 3 XENON lt C LLI Ko F o RELAY Y O A H DUCER 10 K3 O ol h LAMP 35 Mb S 9 e gt ru D BOOSTER XE 1 5 2 2 APC1 9 I O TRANSFORMER r a F r n la ma ajar foe T1 12 TO olas i D STEP DOWN 232 ama 5 Mu EW a O cO 63 mA PA o LLI Ez l IGNITION TRANSFORMER St08L0 78 MODULE 2 IGNITOR gt BLEEDER T3 O O E S CAPACITOR RESISTOR 2 4 M5 34133 35 L3 Ci 56K OHM O O l O O PLC5 8 gt t 80 MFD L oTP2 Y APC 5 Z LT po E IGNITION 14 CAP RELAY O K3 TB6 1 TB6 1 7 6 ini WATTAGE 1 4 0 PLC6 7 MAIN Tomo o lt e TRANSDUCER WATTAGE 3g PLC6 one ll 5 o
12. Ci3000 Ci4000 Ci5000 Weather Ometer Instrument Service Guide Doc No 07 7030 00 Revision 0 November 10 2006 b ATLAS 1 0 2 0 3 0 3 1 3 2 4 0 4 1 4 2 4 2 1 4 2 2 4 2 3 4 2 4 4 3 4 4 5 0 5 1 5 1 1 5 1 2 5 1 3 5 1 4 0 10 9 2 5 2 1 5 2 2 9 2 3 9 2 4 92L0 9 2 6 9 2 9 2 8 5 3 5 3 1 5 3 2 5 3 3 5 3 4 5 3 5 5 3 6 5 3 6 1 INTRODUCTION WARNINGS AND PRECAUTIONS REQUIRED TOOLS AND NIST TRACEABILITY Required Tools NIST Traceability DATA PANEL SERVICE AND SETUP PAGES Accessing the Service Pages Service Page Functions PID Loop Parameters Page 91 Manual Calibration Page 92 Manual Checkout Discretes Page 93 Manual Gheckout Analogs Page 94 Data Panel Control Pages Data Panel Error Messages TROUBLESHOOTING PROCEDURES QUICK GUIDE Power up Malfunctions Description Troubleshooting Guide Troubleshooting Flow Chart Troubleshooting Procedure Power Component Configuration Xenon Lamp and Irradiance Malfunctions Description Troubleshooting Guide Troubleshooting Flow Chart Lamp Ignition Failure Troubleshooting Flow Chart Irradiance High or Low Troubleshooting Flow Chart 2 Sun Irradiance Considerations Troubleshooting Procedure Lamp Ignition Failure Ignitor Troubleshooting Procedure Irradiance High or Low Watt Regulator Troubleshooting Procedure 2 Sun Irradiance Considerations Humidification Malfunctions Description Troubleshooting Guid
13. K4 3 No voltage Gheck for 24Vac at K4 present coil terminals K4 1 and K4 2 If no voltage is present replace K4 If voltage is present re place PLC3 Logic Output module see Sec 5 13 5 first 5 2 Xenon Lamp and Irradiance 2 Confirm that the Xenon Lamp and Ignition Control Malfunctions cont circuit breakers are turned on 3 Check for messages on the Data Panel MAIN 5 2 6 Troubleshooting Procedure page 1 Messages display Lamp Ignition Failure Ignitor EN A 2 y A Check the CS 6 lamp cooling system eem c Sec 5 5 if one of these messages appears Ignitor 1 aa Lamp Water Temperature High Monitor Lamp Water Flow is Low B If the message Chamber Temperature is High is displayed reset the chamber safety F thermostat 54 inside the electronics drawer ji gt 32 A j gt Press the red reset button on the thermostat Figure 5 2 5 Ci3000 Lamp Ignitor amp LS 8 y i j ute TE Figure 5 2 8 Chamber Overte a mperature Thermostat 4 Initiate standard test no 1 to attempt lamp ignition 5 If the ignition start pulse is audible up to 4 attempts but the lamp will not ignite the problem is either the lamp itself or low lamp circuit voltage A Install the calibrated reference lamp and initiate the test If the lamp lights then the previously installed xenon lamp is a alt malfunctioning Examine it for damage gure 5 2 7 Ci5000 Xenon Lamp Ignitor burner t
14. T UL REGULATOR 42 ANALOG OUTPUT 2 SUN SIO MODULE E AR1 e r L1 Lowcom60Hz a 3 2 O O PLC6 19 9 XENON XENON AUX 1 34 IGNITION Popi B LAY TRANSDUCER Lo RELAY NM t O x O O O 1 Ala COIL 2 2 w 3 4 T1 1 6 ee LI RELAY GOIL SWITGHING SOURCE AND PLC INDICATOR LIGHTS RELAY PLC TERMINAL LED K1 PLC3 2 Al K3 PLC3 3 A2 K5 PLC3 7 AS K9 PLC3 17 B5 NOTE WHEN PLC LED IS ON PLC CONTACT IS CLOSED TO PROVIDE VOLTAGE TO RELAY Washer lt lt Outer Filter Washer Install the two sealing washers onto the outer filter ends if none are in place Alignment Pin Ny Outer Filter Union Ring Upper Filter Housing Connect the upper filter housing to the outer filter Be sure to match the alignment pin and hole Gently hand tighten Inner Filter Union Ring Hold the lamp sideways and slowly slide the inner filter into the outer filter Do NOT drop the inner filter in place or damage may occur Figure 5 2 4 Xenon Lamp Assembly Guide Alignment Pin Lower Filter Housing Union Ring El e n i Spring V Union Ring Check that the spring inside the lower filter housing tube is in place Connect the lower f
15. ct a voltmeter with clip leads to terminals L3 1 and L3 2 Attempt lamp ignition while watching the meter The meter should indicate line voltage 230V or 480V during the ignition pulse A If line voltage is present during the ignition pulse the ignitor has failed Replace it see Section 8 6 B If no voltage is present continue below 7 Check relay K3 operation During an ignition attempt check for continuity between the terminals of Ignition Pulse Relay K3 There should be continuity for 1 second during each ignition pulse between terminals Ci3 4000 Terminals K3 5 and K3 6 Ci5000 Terminals K3 6 and K3 7 A If there is continuity across the K3 contacts during the ignition pulse then there is a problem with the line voltage supply to the relay Check wiring to the relay and voltage at the CB2 Ignition circuit breaker terminals CB2 2 and CB3 4 There should be line voltage between each terminal and ground If not replace the circuit breaker B If the relay does not activate its coil is bad or the PLC is not sending it an activation signal or the 24Vac supply to the PLC is bad B1 Check for 24Vac on the relay coil during the ignition pulse If 24Vac is present the coil is bad Replace the relay see Section 8 1 B2 During the ignition pulse check for continuity between terminals PLC3 1 and PLC3 3 If there is no continuity and the A2 LED on PLC3 is on replace the module see Section 5 13 5 first If A2
16. e Troubleshooting Flow Chart Humidification Failure Troubleshooting Flow Charts RH Control and Sensing Errors Troubleshooting Procedure Humidification Failure Troubleshooting Procedure RH Control and Sensing Errors RH Reading is 0 or 100 11 12 13 13 13 14 14 14 14 14 15 15 15 1 19 20 20 23 24 20 26 29 29 34 35 36 37 38 39 42 44 44 45 46 47 48 90 51 List of Figures Figure 5 1 1 Booster Transformer T1 21 Figure 5 1 2 Main Reactor L1 21 Figure 5 1 3 Auxiliary Reactor L2 21 Figure 5 1 4 Isolation Transformer T2 22 Figure 5 1 5 Chamber Safety Thermostat S4 25 Figure 5 1 6 Ci3000 Power Component Configuration Guide 26 Figure 5 1 7 Ci4000 Power Component Configuration Guide 27 Figure 5 1 8 Ci5000 Power Component Configuration Guide 28 Figure 5 2 1 Ci3000 Xenon Lamp Circuit 30 Figure 5 2 2 Ci4000 Xenon Lamp Circuit 31 Figure 5 2 3 Ci5000 Xenon Lamp Circuit 32 Figure 5 2 4 Xenon Lamp Assembly Guide 33 Figure 5 2 5 Ci3000 Xenon Lamp Ignitor 38 Figure 5 2 6 Ci4000 Xenon Lamp Ignitor 38 Figure 5 2 7 Ci5000 Xenon Lamp Ignitor 38 Figure 5 2 8 Chamber Overtemperature Thermostat 38 Figure 5 2 9 Xenon Lamp Wattage Regulator 40 Figure 5 2 10 Wattage Regulator Power LED 40 Figure 5 2 11 Wattage Regulator Output LED 41 Figure 5 2 12 One and Two Sun Circuit Block Diagram 42 Figure 5 3 1 Humidification System Plumbing Diagram 44 Figure 5 3 2 Air Pressure Regulator Bowl Drain Valv
17. e 48 Figure 5 3 3 Humidification Nozzle rear panel 48 Figure 5 3 4 Humidification Nozzle Detail 48 Figure 5 3 5 Humidifier Water Line Filter 48 Figure 5 3 6 Humidification Block Diagram 49 Figure 5 3 7 Humidification Solenoid Valve Locations 49 Figure 5 3 8 Humidification Water Control Relay Q1 50 Figure 5 3 9 Humidity PC Board Jumpers 50 Figure 5 3 10 APC1 Filter PC Board 51 Figure 5 4 1 Chamber Safety Thermostat S4 52 Figure 5 4 2 Chamber Overtemperature Alarm 52 Figure 5 4 3 Chamber Temperature Transmitter 59 Figure 5 4 4 Air Heater Control Relay Q2 56 Figure 5 5 1 Xenon Lamp Cooling System Electrical Block Diagram 59 Figure 5 5 2 CS 6 Lamp Cooling System Plumbing Diagram Ci3000 60 Figure 5 5 3 CS 6 Lamp Cooling System Plumbing Diagram Ci4000 Ci5000 61 Figure 5 5 4 CS 6 Lamp Cooling System 62 Figure 5 5 5 Testing the Flow Switch 67 Figure 5 5 6 CS 6 Pump Shaft Coupling 67 Figure 5 6 1 Lenze 8200 Blower Controller 69 Figure 5 6 2 Blower System Electrical Block Diagram 69 Figure 5 6 3 Blower Wheel Mounting 13 Figure 5 6 4 Lenze Display and Input Select Jumper 19 Figure 5 7 1 Black Sensor Transmitter amp Collector Ring Ci4000 Ci5000 78 Figure 5 7 2 Black Sensor Transmitter amp Collector Ring Ci3000 78 Figure 5 7 3 Temperature Control Systems Electrical Block Diagrams 79 Figure 5 7 4 Blower Controller and Chamber Temp Transmitter Ci4 Ci5 80 List of Figures cont Figure 8 3 6 CS 6 Circulator Pump and Mot
18. eck for continuity between terminals K14 3 and K14 4 A If there is continuity relay K14 is likely operating properly Check for voltage between ground and terminal K15 3 of relay K15 It should be 0 volts lf voltage is present K15 is stuck closed or contacts K14 9 and K14 11 of relay K14 are stuck closed Replace the malfunctioning relay Sec 8 1 B Ifthere is no continuity check for 24Vac at the K14 coil terminals K14 1 and K14 2 If voltage is present replace K14 If no voltage is present and the A8 indicator light on PLC3 is off download the software program to the PLC If indicator light A8 is on replace the PLC3 Logic Output module see Section 5 13 5 first 4 With relay K14 operating properly check for voltage between ground and terminal K4 3 of relay K4 A If voltage is present K4 is o k B If voltage is not present check for 24Vac at the K4 coil terminals K4 1 and K4 2 If voltage is present the PLC3 Logic Output module is malfunctioning Replace it see Section 5 13 5 first If voltage is not present relay K4 is stuck open Replace K4 Sec 8 1 8 2 Sensor Replacement cont 8 2 7 Light Monitor Photodiodes The LS 8 Light Monitor used on the Ci5000 Enhanced Ci4000and Ci3000 includes one or two capsules that contain an interference filter and a photodiode Light from the xenon lamp is transmitted to the photodiode via the quartz light rod The photodiode produces a microampere uA output
19. er Spray Systems 99 Electrical Diagrams 103 Malfunction Troubleshooting 99 Plumbing Ci3 100 Plumbing Ci4 Ci5 99 Water Solenoid Valves 100 Wattage Setting Minimum 40 Wattage Calibration 148 Wattage Powermeter Connections calibration 148 Wattage Regulators 40 X Xenon Lamp 1 amp 2 Sun Relays 42 Alignment Ci3 171 Alignment Ci4 Ci5 168 Assembly Guide 33 Burner Socket 158 Circuit Drawings 30 CS 6 Cooling System 59 Error Messages 17 Ignitors photos 38 Malfunction Troubleshooting 29 Min Wattage Setting 40 Operating Ranges 29 Outer Filter Cleaning 158 Water Flow Switch 67 Wattage Regulators photos 40
20. f Ci4 denotes Ci4000 output at T2 X3 amp T2 X4 transformer T2 Ci5 denotes Ci5000 5 2 Xenon Lamp and Irradiance Control Malfunctions cont 5 2 4 Troubleshooting Flow Chart Irradiance High or Low 1 Perform Wattage Cali bration and Irradiance Calibration procedures 2 Initiate standard test no 1 3 Confirm light monitor output at PLC5 11 amp 13 or at PLC5 12 14 for 2nd light sensor 4 Initiate custom watt age controlled test at minimum lamp wattage 5 Observe upper green Power LED on wattage regulator 6 Check drive current signal to wattage regu lator terminal AR1 1 Should be approx 4mA 7 Initiate custom mid range wattage test at Ci3 3000W Ci4 5000W Ci5 8000W 8 Observe lower green Output LED on wattage regulator Drive current is Replace PLC6 Analog still 4mA Output module see zero or Section 5 13 8 first unstable No output LED is off Current is zero or well above 4mA LED dim or off amp drive current well above 4mA Check light monitor filters amp photocells Sec 7 2 9 ae R4 is open circuited or Continuity wattage regulator failed Check for continuity at relay K9 K9 9 amp K9 10 Potential PLC6 module failure Confirm below Replace the wattage regulator Run mid range wattage test again Drive signal should be approximately 9 to 11mA Drive current still zero or out of range Replace the CPU
21. ge regulator in series with the main reactor contribute additional power and provide precision wattage control Irradiance control is provided by the light monitor which continuously monitors lamp output and provides a voltage signal to the PLC The PLC then increases or decreases lamp wattage to maintain a stable irradiance level Lamp wattage is continuously monitored by the wattage transducer A1 which provides a voltage signal to the PLC Lamp cooling is provided by the CS 6 lamp cooling system which pumps filtered D I water through the xenon lamp Heat is extracted from the cooling water by a tap water coil in the CS 6 reservoir tank In locations where tap water is expensive or its temperature is too high an optional LiquiAir unit or a refrigeration unit may be present to provide cooling of the lamp water Lamp malfunctions can result from numerous causes Ignition of the lamp can be prevented by a damaged or disconnected lamp a CS 6 malfunction such as low or lost water flow or by the malfunction of a lamp circuit component Low lamp irradiance output is often the result of burner or lamp filter aging or expired interference filters in the light monitor This section focuses on troubleshooting of the lamp assembly lamp circuit components and the light monitor For CS 6 troubleshooting refer to Section 5 5 65000W Xenon Lamp n0110 due uouex 00080 IL g G anliy
22. ht sensor The 300 400nm filter may be installed either way 3 DO NOT attempt to install a photodiode normally used with the 340 420nm filter in place of the one used with the 300 400nm filter or vice versa The spectral response of each is different and will result in erroneous readings 8 2 8 Chamber Overtemperature Thermostat This thermostat is accessed from inside the electronics drawer but may be easier to replace by removing the right side access panel N lt lt A M r Reset Chamber Wall BE ek las J et N Y are o Bl SET yina al Von he a RAV ay Say sy Ar Ul Ji Figure 8 2 10 Chamber Overtemp Thermostat S4 Guidelines 1 The face of the thermostat must be in contact with the exterior wall of the test chamber Apply a small amount of silicon thermal grease to the face of the thermostat when mounting a new one Thermal grease is commonly used in the electronics industry when mounting transistors to heat sinks to improve thermal transfer 2 Apply sealant to the mounting screws The screws extend into the test chamber and could allow leakage without sealant in place 8 2 9 Chamber Overtemperature Sensor Older Ci4000 only On some of the early Ci4000 instruments a Chamber Overtemperature alarm was included beside the Lamp Cooling Water Controller in the top section It has an RTD temperature sensor mounted in the test chamber Replace the three wire A sensor by d
23. ilter housing to the outer filter Gently hand tighten the union ring Burner Socket Union Ring Xenon Burner Sealing Washer l gt j Burner Base Turn the lamp upside down Check that the sealing washer is in place on the burner base Slide the burner up into the burner socket Look down through the lower filter housing to ensure that the burner tip is inside the burner socket Burner Tip Must Not Be Visible Beside Socket O29 Q g25 E COO Co Correct Incorrect End View of Lamp Burner Socket Union Ring Union Ring Union Ring Check that the burner tip is inside the socket as shown Gently hand tighten the union ring Clean the outer filter with an optical cleaner or a 1 1 mixture of alcohol and acetone Hold the lamp by the upper or lower filter housing only Lamp Electrode Union Ring Union Ring
24. ip and socket damage or corrosion Check the burner age as recorded on the Xenon Burner Warranty Log card The lamp may be at the end of its life 1200 hours or more Fi 1 Ensure that the xenon lamp is properly installed and that the ignitor lead is firmly secured to the lamp electrode Also ensure that the lamp lead connection to the ignitor terminal is secure and free of corrosion B If the calibration lamp will not ignite measure line voltage to the instrument and 5 2 Xenon Lamp and Irradiance Control Malfunctions cont 5 2 6 Troubleshooting Procedure Lamp Ignition Failure Ignitor cont check the transformer tap connections as described in Section 5 1 1 Setthe T1 booster transformer lead T1 3 to the next higher lamp boost voltage terminal Re attempt lamp ignition If the lamp still does not ignite continue below Also check the light rod for cleanliness and damage Confirm the LS 8 light sensor interference filters have not expired and that the photodiodes are functional Sec 7 2 9 CAUTION SHOCK HAZARD Conduct step 6 below with meter leads clipped onto the specified terminals DO NOT hold probes onto the terminals during lamp ignition or electric shock and injury may result Note In the steps below you must shut the instrument off with the front panel power switch after each attempt at igniting the lamp This will reset the lamp starting circuit 6 Check voltage to the ignitor Conne
25. is misaligned Wattage regulator malfunction Check lead connections Inspect clean light rod Check filters amp photodiodes Inspect replace Sec 7 2 4 Check adjust taps on T1 and L1 Check CS 6 see Section 5 5 Conduct procedure in 5 2 6 Conduct procedure in 5 2 6 Conduct procedure in 5 2 6 Replace xenon burner Replace lamp filters Inspect replace socket or burner Recalibrate Section 6 9 Check replace filters Sec 7 2 9 Align light rod Secs 7 2 14 amp 15 Conduct procedure in 5 2 7 Perform procedure 5 2 8 Replace xenon burner Replace lamp filters Inspect replace socket or burner Recalibrate Section 6 9 Check replace filters Sec 7 2 9 Align per Section 7 2 14 or 7 2 15 Conduct procedure in 5 2 7 Check fuse Check board output w lamp on Blown fuse F1 on A1 transducer A1 wattage transducer board failure No wattage display 5 2 Xenon Lamp and Irradiance Control Malfunctions cont 5 2 3 Troubleshooting Flow Chart Lamp Ignition Failure 1 Confirm Xenon and Ignition circuit breakers are on 2 Check lamp for age damage proper installa tion and ignitor lead con nections 3 Check for messages on Data Panel MAIN page 1 4 Initiate standard test no 1 Ignition pulse is not audible 5 Check for line voltage to ignitor during pulse No voltage present 6 Check for continuity between relay terminals Messages displayed Ignition pulse is audible
26. isconnecting it 0000 from the back of the alarm y aa Remove the old sensor from the test chamber Eurotherm 92 a es taking note of its insertion Figure 8 2 11 Chamber depth in its mounting Install Overtemperature Alarm the new sensor ALI Symbols 2 Sun Irradiance Levels 90 2 Sun Irradiance Test 42 6 Channel Chart Recorder 109 A Access Panel Removal 134 Air Filter Cleaning 165 Air Heater Element Resistance Values 89 Element Terminals 88 Power Ratings 81 Air Heater Control Relay Q2 56 Air Regulator Oil Trap Cleaning 165 Air Valve Damper Troubleshooting 88 Alignment Lamp Rack Light Rod 168 APC1 Filter PC Board 51 Atlas Fax Number 11 Auxiliary Reactor L2 21 B Bearings Specimen Rack 201 Black Panel Sensor Circuit Calibration 138 Sensor Check Procedure 137 Transmitters Collector Ring 78 Black Standard Panel Circuit Calibration 138 Error Messages 18 See also Sensor Temperature Error Message Sensor Check Procedure 137 Blower Error Message 17 Blower Controller 69 Blower Controller Code List 77 Blower System Blower Wheel Mounting 73 Chamber Overtemp 17 Controller Code Listing 77 Controller Error Messages 70 Controller Indicator Lights 70 Controller Keypad Functions 75 Controller Programming 76 Electrical Diagram 69 Malfunction Troubleshooting 69 Motor Controller Input Jumper 75 Blower Wheel Mounting 73 BP Transmit
27. or 184 Figure 8 3 7 Circulator Pump Motor Coupling 184 Figure 8 3 8 CS 6 Pump Motor Details 184 Figure 8 3 9 Ci3000 and Ci4000 Rack Motors 185 Figure 8 3 10 Ci5000 Rack Motor amp Controller 185 Figure 8 3 11 Rack Drive Gear Alignment 185 Figure 8 3 12 Ci4000 Rack Motor Wiring Diagram 186 Figure 8 4 1 Rack Specimen Spray Solenoid Valves 186 Figure 8 4 2 CS 6 and Humidification Solenoid Valves 186 Figure 8 5 1 Rack Speed Controller Ci5000 187 Figure 8 5 2 Water Resistivity Monitor 187 Figure 8 5 3 Transmitter Locations 187 Figure 8 5 4 Chamber Overtemperature Alarm 188 Figure 8 5 5 Lamp Water Temperature Controller 189 Figure 8 5 6 Blower Motor Controller 190 Figure 8 5 7 Lenze Display and Input Select Jumper 190 Figure 8 5 8 AFE Data Panel Mark I early Ci4000 193 Figure 8 5 9 AFE Data Panel Mark II 193 Figure 8 5 10 Typical PLC Module side view 194 Figure 8 5 11 PLCO Fuse 195 Figure 8 6 1 Ci4000 Xenon Lamp Ignitor 196 Figure 8 6 2 Ci5000 Xenon Lamp Ignitor 196 Figure 8 6 3 Ci4000 Ignitor Terminal 196 Figure 8 6 4 Ci4000 Ignitor Sealing Washers 196 Figure 8 7 1 Xenon Lamp Wattage Regulator 197 Figure 8 7 2 Wattage Regulator Trimpots 197 Figure 8 8 1 CS 6 Reservoir Tank 198 Figure 8 8 2 Level Switch Float Orientation Dry 198 Figure 8 9 1 Ci4000 Air Heater 198 Figure 8 9 2 Ci4000 Rack Hub 198 Figure 8 9 3 Ci5000 Rack Hub 198 Figure 8 9 4 Air Heater Terminals 200 Figure 8 10 1 Collector Ring 200 Figure 8 11
28. proportional to the light intensity it receives passing through the interference filter Older Ci4000 instruments have either a single light sensor in a sheetmetal enclosure or an optional dual band sensor in a machined aluminum housing In all three light monitors the types of photodiodes used are the same but their mountings differ Note The photodiode used with a 340 or 420nm narrow band interference filter is different than the one used with a 300 400nm wide band filter Do not mix them Photodiode Part Numbers 340nm 420 nm 300 400 nm Older Ci4000 09 3515 00 09 3515 00 09 3493 00 Ci3 Ci5 amp Ci4000 09 3529 00 09 3530 00 09 3531 00 Enhanced LS 8 capsule assembly including photodiode Leads for code jumpering yj Interference Filter Photodiode Figure 8 2 7 LS 8 Light Sensor Capsule Assembly ma ba Optional Channel 2 onnecior Interference Filter _ 300 400nm shown Capsule Channel 2 Dover O Ring Capsule amp Photodiode a Z A13 Beam Splitter not present N on single bandwidth units Z Channel 1 Interference Filter
29. r green lamp should be on indicating that the regulator is receiving power 5 2 Xenon Lamp and Irradiance Control Malfunctions cont 5 2 7 Troubleshooting Procedure Irradiance Low or High Wattage Regulator cont A If the LED is off check for continuity across terminals K9 9 and K9 10 of relay K9 If there is continuity then resistor R4 Ci4 only is open circuited or the wattage regulator has failed Replace the regulator per Section 8 7 Soft Start LED Output LED ha cml Figure 5 2 11 Wattage Regulator Output LED B Check for 24Vac volts across the K9 relay coil terminals K9 1 and K9 2 B1 If voltage is present and there is no continuity between terminals K9 9 and K9 10 replace relay K9 per Section 8 1 B2 If voltage is not present and the B5 LED on PLC3 is on replace the PLC3 module see Section 5 13 5 If B5 is off download the software program to the PLC If this fails to restore operation replace PLCS 8 Observe the ammeter on the AR1 1 terminal It should display a reading of approximately 4mA A If the ammeter reading is zero or well above 4mA there is potentially a problem with the PLC Analog Output PLC6 module This will be checked in a later step 9 Stop the wattage test and alter it to the mid range operating wattage level shown below Ci3000 3000 watts Ci4000 5000 watts Ci5000 8000 watts 10 Initiate the new test to ignite the lamp 11 Observe
30. r the components driving them Fig 5 2 9 Additionally if the error message Test Irrad Not Match with Filters appears on the screen at the start of a test it indicates that the irradiance level chosen is in the 2 Sun range and you must recalibrate the lamp for this irradiance level 2 Sun irradiance levels are defined as follows 0 70 W m or higher 340 nm filter 1 40 W m or higher 420 nm filter 75 0 W m or higher 300 400 nm filter At 1 Sun irradiance levels the rack rotates at 1 RPM At 2 Sun levels it rotates at 10 RPM Relay K14 switches the input to the rack speed controller Conduct the procedure below to determine the cause of 2 Sun operation failure L3 PLC3 LOGIC IGNITOR OUTPUT L3 12 MODULE X AB 33 TBs EB PLC3 10 M4 24Vac RACK TB3 5 TB6 1 TB3 9 MOTOR TB3 6 K14 1 K14 2 SPEED TB3 7 COIL CONTROL K14 9 wc Kia nef K14 11 __K15 1 C K15 RACK ONE SPEED ka SUN 14 58 Ai E ME L RELAY TB3 11 A14 S1 A14 S2 j R2 j 10K L1 LOW MAIN K4 C K4 1 PLC3 5 REACTOR TWO O PLC3 LOW COM HI SUN J l ka LOGIC PERR A OUTPUT MODULE TB3 8 24Vac TB2 2 Figure 5 2 12 One and Two Sun Circuit Block Diagram 1 Program a custom 2 sun irradiance test with the parameters shown below Test List Data Panel page 6 Select an unused Custom test Press F6 the test number and Enter three times Press F2 Test Criteria Data Panel page 7 Total Segment
31. s Water Resistivity Monitor Malfunctions Optional Chart Recorder Malfunctions Data Panel Malfunctions PLC Programmable Logic Controller Malfunctions Optional Data Acquisition System Malfunctions Reference Material Test Malfunctions SRM m Calibration Black Sensor BPT and BST Chamber dry bulb Sensor Relative Humidity Lamp Wattage Lamp Irradiance Air valve Damper Rack Speed Control Resistivity Monitor Lamp amp Rack Alignment m Maintenance Lamp Water Fitting Gasket Lamp Outer Filter Cleaning Light Rod End Cleaning Lamp Burner Socket Inspection Test Chamber Cleaning Demineralizer Cartridge Replacement Flow Switch Filter Screen Cleaning Lamp Water Reservoir Cleaning Light Monitor Filter Replacement Inlet Air Filter Cleaning Humidifier Water Filter Cleaning Humidifier Inspection Cleaning amp Adjustment Air Regulator Oil Trap Cleaning Lamp Rack amp Light Rod Alignment Component Replacement Relay Replacement Sensor Replacement Electric Motor Replacement Solenoid Valve Replacement Controller and Transmitter Replacement Ignitor Replacement Wattage Regulator Replacement CS 6 Cooling Coil amp Level Switches Air Heater Replacement Collector Ring Replacement Rack Bearing Replacement Chart Recorder Replacement Data Panel and Software Downloading m Appendix A PLC and Data Panel Software Configuration B Optional Yokogawa Chart Recorder Manual C Component Parts Lists The Troubleshooting section is
32. s 1 Duration Units Time Black Sensor BPT Black Temp Active Yes Radiation filter 340 nm Chamber Temp Active No Segment Data Panel page 8 Segment Number 1 Light or Dark Light Time or Irradiance 30 min Irradiance 1 50 W m Black Temp 80 Chamber DB Temp 60 C Relative Humidity 0 Segment cont Data Panel page 9 Set sprays to off Test List Data Panel page 6 Press F8 Press F5 the custom test number and Enter three times to load the new custom test Run Stop Segment Data Panel page 3 Test Duration O hours 30 min 2 Press F4 on RUN STOP page 3 to start the test CAUTION SHOCK HAZARD In the procedures below you must check for voltages at live electrical terminals Avoid contact with component terminals and wear insulated gloves to prevent electrical shock 3 When the Ci5000 is running a test at 2 Sun irradiance level the rack should be rotating at 10 RPM Check rack speed If it is rotating at 1 RPM relay K14 or the rack speed control A14 is malfunctioning see Section 5 8 5 2 Xenon Lamp and Irradiance Control Malfunctions cont 5 2 8 Troubleshooting Procedure 2 Sun Irradiance Considerations cont In 2 Sun mode PLC3 de energizes closes the 2 Sun relay K4 It also energizes relay K14 causing the 1 Sun relay relay K15to open K14 also causes closure of contacts A14 S2 and A14 S3 of the A14 rack speed control board to provide 10 RPM rack rotation see Fig 5 2 9 3 Ch
33. ters 4 Collector Rings 78 Burner Socket Maintenance 158 C Calibration 134 Black Sensor Check 137 Black Sensor Circuit 138 Calibration Schedule 136 Chamber Sensor Check 141 Chamber Sensor Circuit 143 Ci5000 Rack Speed 154 Component Locations 134 Damper Calibration 153 Irradiance Calibration 151 Procedures 134 Relative Humidity 146 147 Water Resistivity Monitor 156 Wattage Calibration 148 Chamber Dry Bulb DB Error Message 18 See also Sensors Temperature Error Message Sensor Check 141 Temp Sensor Locations 142 Transmitter Location 141 Transmitter Terminals 141 Chart Recorder 109 Channel Assignments 109 Electrical Diagram 112 Error Messages Fatal 112 LIST Printout 109 Malfunction Troubleshooting 109 mR1000 Manual 205 Recorder Replacement 202 Chart Recorder Block Diagram 112 Control Panel See Data Panel Error Messages CS 6 Lamp Cooling System Demineralizer Cartridge Replacement 160 Electrical Diagram 59 Flow Switch Filter Cleaning 160 Flow Switch Testing 67 Malfunction Troubleshooting 59 Plumbing Diagram 60 Pump Motor Coupling 67 Reservoir Cleaning 162 Reservoir Diagram 62 CS 6 Pump Shaft Coupling 67 D Damper Calibration 153 Chamber overtemp 17 Safety Thermostat 23 Photo of 25 Tools Required 13 Transformer Reactor Gonfig 20 Configuration Guides 26 Transformer T1 21 W Water Control Relay Q1 50 Water Resistivity Monitor 104 Calibration 156 Malfunction Troubleshooting 104 Sensor Cleaning 108 Wat
34. the green LED indicator light on the lower circuit board of the wattage regulator This is the output indicator and becomes brighter as output increases It should be on brightly A If the LED is very dim or off and the ammeter reading is well above 4mA there is a problem with the wattage regulator output Replace the regulator Section 8 7 B If the ammeter reading is zero still at 4mA or is unstable there is a problem with the PLC Analog Output PLC6 module or the PLC CPU PID settings corrupt PLC software or CPU failure B1 Replace the PLC6 module see Sec 5 13 8 first Run the mid range wattage test again Check the level and stability of the ammeter reading It should be very stable and approximately 5 to 10 mA B2 If replacement of the PLC6 module does not correct the problem download the custom programs from the PLC to a laptop computer and replace the CPU module of the PLC see Sections 5 13 and Appendix A Upload the custom pro grams and the correct PLC operating software Run the mid range wattage test again and observe the ammeter reading for stability If this corrects the problem reinstall the old PLC6 module and confirm operation 5 2 Xenon Lamp and Irradiance Control Malfunctions cont 5 2 8 Troubleshooting Procedure 2 Sun Irradiance Considerations If the xenon lamp in the Ci5000 fails to operate at higher 2 Sun irradiance levels there may be a malfunction of the 1 Sun or 2 Sun relays o
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