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EC9850 Service Manual

1. en serene 65 Optical bandpass filter 17 Optics system components 17 Orifice Removal illustration 34 P Particulate filter maintenance 27 Periodic maintenance 22 Photomultiplier tube 18 PME k i iaa ala 18 PMT cooler replacement 42 PMT desiccant pack replacement 36 PMT high voltage supply and preamplifier 18 PMT housing removal 37 Pneumatic Diagram illustration 15 Power microprocessor module 9 Preamp test function 65 Preamp Pressure board 18 Preprocessor board 18 Preprocessor Pots and Ranges illustration 59 Preprocessor Pots Menu 59 1 EC9850 SO ANALYZER SERVICE MANUAL o Quick start vne beanies 20 R Reaction cell 01 31111 5 41 Reaction cell removal 37 Reference adjust s sivi span ny leh ljo ssoi 19 Reference detector UV 18 Replaceable parts 23 Routine maintenance 25 Routine Maintenance Components illustra
2. 60 Voltage Regulator board 10 Z Zero alr SCrUDbER caca 16 Zero MEASUTEG sise nee been ees 20 98507601 Rev D
3. 3 4 1 Pressure amp Flow Calibration sub menus The pressure and flow calibration menus allow the user to manually calibrate the pressure transducers and calibrate the flow of the flow controllers The contents 46 98507601 Rev D CHAPTER 3 MAINTENANCE of the pressure and flow calibration menus are described below Note that these parameters will vary depending on which flow block type is selected Refer to section 3 4 for further details CRITICAL ORIFICE Designated flow rate of the critical orifice installed in the ISO B flow block For the EC9850B this should be set to 0 650 unless otherwise specified DESIRED FLOW Desired flow rate that the standard flow block will maintain a constant flow at Note If the flow rate is changed within an A series analyzer the instrument must be reset in order for the change to take effect FLOW SPAN POINT During the flow calibration of the standard flow block this is where the externally measured flow rate is entered FLOW ZERO POINT During the zero flow calibration of the standard flow block this option must be set to set and enter pressed for the zero calibration to take effect Select cancel to abort this operation FLOW TRANSDUCER DF Selecting set loads the factory default calibration curve into the earom on the standard flow control board PRESSURE 1 HIGH Pressure entered during ambient calibration PRESSURE 1 LOW Pressure entered during low pressure calibration
4. ANALYZER SERVICE MANUAL 30 7 Disconnect the challenge zero air and reconnect the sample line to the Sample inlet of the analyzer Verify the analyzer is in the Sample Measure mode The life span of a zero air scrubber system is typically dependent upon the amount of SO the system is required to scrub The user should closely monitor the performance of the zero air system after initial installation and note when the zero air begins to degrade This interval can then be used as the baseline for establishing a zero air maintenance schedule If the instrument uses the Ecotech Zero Air Scrubber part number 98415105 1 the following replacement schedule can be used as a starting point for development of this schedule Average Ambient SO Concentration Charcoal Replacement Interval 0 to 30 ppb 12 Months 3 3 4 1 Charcoal Scrubber Replacement Procedure A Series Use Figure 13 as a reference when replacing the charcoal This procedure applies to both charcoal scrubbers The same type of scrubber can be used for the B series and mounted externally Hence the same procedure would apply 1 Open the Front Panel to access the service switches and the scrubber canisters Position the Pump Switch on the secondary panel to OFF 2 Remove the Kynar nuts and Teflon tubing from the canister Disengage the nylon restraining strap on the scrubber canister 3 Unscrew the canister cap and remove the plastic insert metal screen and felt pad Pour
5. Check Microprocessor test points listed in the Troubleshooting Voltages table table in section 4 Display Check the interface cable between the display and J6 on the microprocessor board Bad display or 1 Replace the front panel display Microprocessor PCA 2 Replace the microprocessor board 3 A bad cable is unlikely but if you suspect it perform a pin for pin continuity test using an ohmmeter 3 Zero flow Pump failed Replace the pump Filter Check the particulate filter Replace if dirty or plugged 98507601 Rev D 65 EC9850 SO ANALYZER SERVICE MANUAL System Troubleshooting Table Symptom Possible Cause Fault Isolation Solution Pressurized Rx cell Ensure Sample and Zero inlets are maintained at ambient pressure B series Plugged orifice Clean or replace the orifice Remove sintered filter B series if installed and discard Flow control Recalibrate the flow control assembly assembly A Series External Valves Select CALIBRATION EXTERNAL from the installed but not CALIBRATION MENU selected A Series 4 Noisy or Leaks A leak dilutes the sample stream and causes low unstable readings span readings and noise See section 3 3 13 Lamp not correctly Adjust the UV lamp If you are unable to obtain an positioned acceptable reading replace the lamp TE cooler or Rx cell A failed temperature control allows the instrument heater zero to drift with ambient temperature V
6. VALVE SEQUENCING Turn the valve sequencing on or off Same as in the Valve Test Menu When turned off the appropriate valve sequence will set ready for pressure calibration CONTROL LOOP When ENABLED the microprocessor controls the pump speed via the flow control pots to give the desired flow rate When DISSABLED the user can manually adjust the pump speed using the flow control pots For the standard flow block only 98507601 Rev D 47 EC9850 SO ANALYZER SERVICE MANUAL FLOW CONTROL ZERO This flow control pot is used to manually adjust the zero flow offset voltage during the zero calibration of the standard flow block PUMP SPEED COARSE FINE The two flow control pots PUMP SPEED COARSE s PUMP SPEED FINE are software controlled pots which control the pumps speed on the standard flow block AMBIENT PRESSURE Current ambient pressure measured from the ISO flow controller GAS PRESSURE Current gas pressure measured from the flow controller GAS FLOW Current gas flow measured from the flow controller 3 5 Pressure amp Flow Calibration The pressure and flow calibrations should be performed whenever a flow or pressure reading becomes suspect when a transducer is replaced or can be performed as an annual maintenance item The pressure and flow transducer calibration may be performed separately or together The following procedures cover both the STANDARD and rso B flow block types For bo
7. concentration voltage This voltage is taken as the zero signal level and this value is subtracted from any subseguent readings as an active zero compensation This is the analyzer s fine zero measurement The background is re run nightly at midnight unless background is disabled when manually selected through the CALIBRATION MENU or when another auto startup routine is performed 98507601 Rev D 19 EC9850 SO ANALYZER SERVICE MANUAL 2 2 1 4 Sample Fill Measure After the background the analyzer is switched into the Sample Fill mode where the reaction cell is filled with sample gas and finally to Sample Measure mode when actual gas measurement begins 2 2 1 5 Quick Start Routine If the analyzer power is removed for less than two minutes the full auto startup routine is replaced by a quick start routine The analyzer is returned to its last known operating parameters and normal operation is immediately restored This allows the analyzer to rapidly return to measurement mode and keeps data loss to a minimum If power is lost for greater than two minutes a full auto restart is performed 2 2 2 Measure Modes 2 2 2 1 Sample Measure Sample measure is the standard operating mode of the 9850 The cell is continuously filled with sample gas via the main valve manifold The PMT senses the fluorescent signal in the Rx cell and this signal is amplified conditioned by the preprocessor to become what is called concentration voltage This c
8. ranges in order to display Pass If FAIL is indicated this indicates a major failure in the affected area If the instrument is in startup mode sTART will be displayed Note The SYSTEM FAULTS screen only indicates PASS or FATL of the various analyzer parameters and is meant to indicate major failures Desired operating ranges are indicated in the INSTRUMENT STATUS and SYST EM TEMPERATUREs ranges section If analyzer readings are not within these ranges it could indicate deterioration of certain assemblies within the analyzer or minor failures The following table lists the possible system fault messages that are displayed on the primary screen if a major failure occurs If a fault message is displayed use the Troubleshooting Guide to find the possible cause of the fault Message OUT OF ZERO F SERVICE OW A series ZERO F B series LAMP FAILURE OW COOLER FATLURE REFERENCE VOLTAGE RANGE 12 VOLT FAILURE OUT OF SUPPLY System Fault Messages Description Failure Limits Indicates the Service switch is in the OUT position Unless the analyzer is being serviced this switch should be in the IN position Indicates that measured flow has gone below 0 05 SLPM Indicates that the gauge pressure from the Pressure PCA is less than 20 torr bad pump or plugged orifice or greater than 200 tor
9. Description Action Background cycle started No action required The value of the result of the previous background is stored here Unless the reset was not initiated by the user no action is required AZS cycle started No action required Occurs if unable to write to Battery failure or system datalogging memory software error If error persists call Ecotech Customer Service for instructions Reset button pressed or watchdog timer caused reset Occurs when Control Loop has been disabled and then automatically enabled after the main screen has been visible for the last 1 minute Occurs when valve sequencing has been disabled and then automatically enabled after the main screen has been visible for the last 1 minute No action required No action required 4 2 5 Instrument Status GAS FLOW GAS PRESSURE REF VOLTAGE CONC VOLTAGE ANALOG SUPPLY DIGITAL SUPPLY HIGH VOLTAGE LAMP CURRENT INSTRUMENT STATUS 0 375 0 625 690 760 2 3 2 7 0 0 4 2 11 6 12 4 8 5 2 700 720 34 36 VERSION 1 11 0002 Figure 34 Instrument Status Ranges If any of the parameters displayed on the INSTRUMENT STATUS screen vary significantly from the values shown in Figure 34 the fault or operational problem is probably related This is also true if one of the parameters is demonstrating a rapid change or is oscillating strongly around the desired setpoint For more 98507601
10. MODULE VALVES PRE PROCESSOR BOARD 1 1 f VOLTAGE REGULATOR BOARD POWER SUPPLY Val BATTERY MICROPROCESSOR BOARD f 1 FRONT REAR A 5 Figure 6 Major Components A Series INLET PORTS HIGH VOLTAGE POWER SUPPLY de Li FAN PMT HOUSING V LVES REFERENCE OPTIONAL KICKER DETECTOR INTERNAL amp LAMP FLUORESCENCE SPAN HOUSING CELL amp FAN CHAMBER PRESSURE Le MODULE PRE PROCESSOR BOARD E J VOLTAGE REGULATOR BOARD POWER SUPPLY BATTERY MICROPROCESSOR BOARD w Figure 7 Major Components B Series REAR 13 EC9850 SO ANALYZER SERVICE MANUAL 14 2 1 2 Sensor Module The sensor module can be divided into three areas of description pneumatics optics and electronics 2 1 2 1 Pneumatics The pneumatics system continuously supplies sample air to the measurement cell at a rate that allows the sample to be measured before exiting the analyzer The pneumatic system flow is illustrated in Figure 8 amp Figure 9 The pump causes sample air to be drawn into the sample inlet and through the 5 micron particulate filter The inherent difference between the A and B series analyzers is the method of flow control and the pump used These differences will be discussed in the following sections From the valve manifold the sample stream enters the hydrocarbon kicker described in more detail in the following paragraphs where possible hydrocarbon interferents are removed After being scrubbed of hydrocarbons
11. analyzer This vacuum pump must be capable of maintaining at least 1 2 atmosphere approximately 15 Hg or 50 kPa at sea level in order to keep the orifice flow critical Rear Fan The fan speed is connected directly to the flow block and is operated continuously to keep the chassis temperature low 2 1 2 2 Optics The optics in the 9850 analyzer consist of a discharge zinc UV lamp a Fabry Perot 214 nm UV bandpass filter UV grade fused silica lenses a colored glass 350 nm optical bandpass filter a UV sensitive photomultiplier tube and a solid state UV reference detector 98507601 Rev D UV Lamp The UV lamp generates broad band UV light which is used to irradiate the measurement cell UV Bandpass Filter The 214 nm UV bandpass filter limits the UV light within the cell to 214 nm which is the frequency of interest for SO fluorescent spectroscopy UV Grade Lenses Two UV grade fused silica lenses are present in the optical path The first is a plano convex lens which is used to focus the UV light inside the measurement cell The second is a bi convex lens which focuses the fluorescent light from the SO reaction onto the cathode of the PMT Optical Bandpass Filter The colored glass optical filter limits the light reaching the PMT to the freguency of interest for the photon emitted during the SO reaction 17 EC9850 SO ANALYZER SERVICE MANUAL 18 Photomultiplier Tube PMT The cooled PMT detects the amount of 350 nm
12. installed in the same way 41 EC9850 SO ANALYZER SERVICE MANUAL 42 10 11 12 13 From the underside of the heatsink remove the two screws that secure the PMT cold block to the heatsink and remove the cold block Refer to Figure 21 Remove the cooler from the heatsink and disconnect the cooler from the electrical connector Note If corrosion or moisture is detected inside the PMT housing assembly then the desiccant replacement interval should be reduced replace the desiccant more often Clean the cooler facings of the heatsink and PMT cold block and recoat with a thin layer of heatsink compound Dow Corning 340 or equivalent Install the new cooler in place on the PMT housing being careful to align it in the notch on the PMT cold block Ensure the orientation of the red black wires on the cooler are red on the right and black on the left when viewed from the wire side of the cooler Place the PMT cold block and cooler on the heatsink and secure with the screws from the underside of the heatsink Ensure the shoulder washers and neoprene washers are properly in place around the screws Caution Alternately tighten each of the screws securing the PMT cold block to the heatsink approximately 1 4 turn until the PMT housing and heatsink are secured flush with the cooler face and the screws are snug Do not overtighten Connect the cooler wires to the electrical connector red wire to pin 13 and black wire to
13. light proportional to the concentration of SO present in the measurement cell The PMT is connected to an integrated High Voltage Power Supply HVPS Preamp UV Reference Detector The UV detector is a solid state photo diode that monitors the intensity of the UV light entering the measurement cell This signal is used to compensate for variations in the UV lamp signal 2 1 2 3 Electronics O Reference Detector Preamplifier This circuit board is housed within the box labeled Reference Detector in Figure 6 The circuit board s function is to convert the current signal from the reference detector to a voltage signal and provide amplification A series only Preamp Pressure PCA This assembly is located at the end of the fluorescence cell as noted in Figure 7 The reference preamplifier detector portion of the board converts the current from the UV detector to voltage and amplifies it to a waveform proportional to the reference signal The pressure flow portion of the board contains an absolute and a gauge pressure transducer to measure cell pressure and detect sample flow This board also powers the chassis fan B series only Flow Control PCA The pressure flow portion of the board contains an absolute and a gauge pressure transducer to measure cell pressure and control sample flow This board also controls the pump speed powers the chassis fan and has a heater control circuit to heat the flow block A series only PMT High Volt
14. the sample enters the fluorescence cell where the SO measurement is accomplished During the startup and auto zero cycles sample is switched by the valve manifold to zero air from the zero air scrubber and into the measurement cell This provides the analyzer with a stable reference of zero air to automatically correct for zero baseline changes O Particulate Filter The particulate filter is designed to remove particles larger than 5 micrometers and to expose the sample to only nonreactive materials of Kynar Teflon and Viton The filtering agent is a 47 mm diameter 5 micron filter The filter body is made from Teflon The filter is held in the body by a Viton O ring and backed by a Teflon screen This filter is not supplied with the B series analyzer and must be purchased as an option 98507601 Rev D CHAPTER 2 THEORY OF OPERATION VALVE MO vs PORT OPEN TO COMMON 3 OPTION V3 OPTION NOAONANO 98507601 Rev D Figure 9 Pneumatic Diagram B series 15 EC9850 SO ANALYZER SERVICE MANUAL 16 Hydrocarbon Kicker A kicker is placed in the pneumatic system of the 9850 analyzer before the fluorescence cell to remove hydrocarbons that might interfere with the measurement of SO The kicker is composed of a Silastic membrane within a Teflon tubing jacket Sample is pulled through the internal membrane at 0 500 slpm while zero air is pulled through the outer jacket at 2 3 slpm in the opposite dir
15. the analyzer attempts to automatically change the pot position during adjustment then repeat step 9 Record the average measured flow from the flowmeter and enter it into the FLOW SPAN POINT and press Enter gt J Set the DESIRED FLOW to 0 50 SLPM and press Enter gt 4 Press Reset on the analyzer and allow the flow to stabilize Verify the flowmeter reading is now 0 50 0 05 SLPM Note After the instrument startup is complete verify the gas pressure is slightly below actual ambient pressure approximately 10 20 torr The gas pressure and gas flow readings may not bet updated during the startup routine This completes the flow transducer calibration procedure 3 5 2 Pressure Flow Calibration B Series 3 5 2 1 Setup 98507601 Rev D Note 51 EC9850 SO ANALYZER SERVICE MANUAL From the HIDD The EC9850B analyzer should be left running for at least one hour with the pump running before this procedure is attempted This will allow the flow block temperature to stabilize to 50 C EN M ENU set the FLOW BLOCK TYPE TO ISO B and press Enter gt 1 Press Reset on the analyzer secondary panel 3 5 2 2 Pressure Calibration 1 From the HIDDE NM of Figure 25 should be displayed ENU select the PRESSURE CALIBRATION MENU The menu PRESSURE CALIBRATION MENU PRESSURE 1 HIGH PRESSURE 1 LOW VALVE SEOUENCING AMBIENT PRESSURE GAS PRESSURE GAS FLOW 743 0 TORR 70 0
16. the charcoal out of the canister 4 Refill the canister with charcoal see the Replaceable Parts list for the part number 5 Replace the felt pad metal screen plastic insert and canister lid 6 Reconnect the Teflon tube to the canister and secure the canister with the strap 98507601 Rev D CHAPTER 3 MAINTENANCE Figure 13 Charcoal Replacement Procedure 98507601 Rev D 31 EC9850 SO ANALYZER SERVICE MANUAL 32 3 3 5 DFU Replacement B Series The zero air entering the analyzer is filtered by a disposable filtration unit DFU to prevent contamination of the pneumatics and Rx cell Failure of the DFU could result in poor zero readings or loss of purge supply air to the IZS module if installed This filter is located inside the analyzer just aft of the valve manifold It should be replaced annually or whenever it begins to discolor To replace the filter 1 Turn off the pump 2 Remove and retain the Kynar nuts from each end of the DFU 3 Remove and replace the DFU ensuring that direction of flow is correct from rear to front of analyzer 4 Reinstall the Kynar nuts ensuring that the ferrules are properly installed in the nuts 5 Turn on the pump 3 3 6 Orifice Removal for Replacement or Cleaning B Series Recommended equipment Orifice Filter Removal Tool part number 98000190 1 Remove the 1 4 Teflon lines from the tee in the exhaust arm of the Rx cell and unthread the tee fro
17. to choose the correct series of analyzer The options are A B s s The selection must reflect the Hardware to which it is being installed i e for a EC9850 analyzer it must be set to a and for a EC9850B analyzer set to B in order to operate correctly The s option is reserved for special system software ANALYZER TYPE Allows the user to choose the correct analyzer type The options are 9810 9811 9812 9820 9830 9841 9842 s 9850 The selection must reflect the Hardware to which it is being installed i e for a EC9850 analyzer it must be set to 9850 in order to operate correctly The analyzer type will default to gt if the device type has not been set or cannot be read from the preprocessor board SUB TYPE Allows the user to set the correct Hardware options for this analyzer The options for the EC9850 A amp B series are STANDARD TRACE s HIGH LVL GAS NAME Allows the user to set a 3 character name for the primary gas name The name entered here will be used to replace the primary gas name in all screens If the first character is a space then O3 will be used as a gas name FLOW BLOCK TYPE Displays the type of flow block installed If the flow block is not connected or calibrated then no type will be displayed For A series analyzers the STANDARD type is selected For B series analyzers the Iso B type is selected The PRESSURE and FLOW CALIBRATION MENU s will change depending on which FLOW BLOCK TyPE is selected
18. 1 1300 364 946 Fax 61 1300 668 763 Email Service ecotech ecotech com au Email Spare Parts parts ecotech com au Web www ecotech com au 98507601 Rev D CHAPTER 1 INSTALLATION 1 0 Installation 1 1 Initial Check Verify that the serial number label on the documentation and the serial number s on the analyzer match Check to make certain your instrument arrived undamaged If you find damage report it as described in the preface on the page titled Claims for Damaged Shipments and Shipping Discrepancies in the Operation manual Analyzers are shipped ready to power up Occasionally however rough handling during shipment causes dislodged PC boards disconnected cables or incorrectly positioned switches Verify that your instrument is in operating condition by performing the following procedure 1 1 1 Remove the Top Cover Grasp the front top corners of the front panel and pull forward The panel will pop loose and pivot forward See Figure 1 The top cover retaining hardware is then visible as shown in Figure 2 Use a screwdriver to unscrew the two captive screws When the two captive screws are loosened slide the cover backward about 4 inches and lift the top cover straight up GRIP GRIP HERE HERE GLB CLD 2 Ca TAS Figure 1 Opening the Front Panel 1 1 2 Service Switch 98507601 Rev D Opening the front panel allows a view of the secondary panel where four switches are visible The position of
19. 2004 New Release for new Microprocessor Board A amp B All series Combined Based on original manuals B Feb 2004 Changes to menu options and structure All C Jun 2005 Changed to updated EC manual All D April 2007 Updated specifications language and links within All 98507601 Rev D pdf manual created EC9850 SO ANALYZER SERVICE MANUAL Safety Reguirements O To reduce risk of personal injury caused by electrical shock follow all safety notices and warnings in this documentation This eguipment should always be used with a protective earth installed The EC9850 is compliant with the reguirements of EN61010 1 A2 1995 Safety Reguirements for Eguipment for Measurement Control and Laboratory Use If the equipment is used for purposes not specified by the manufacturer the protection provided by this equipment may be impaired Replacement of any part should only be carried out by qualified personnel only using parts specified by the manufacturer Always disconnect power source before removing or replacing any components Equipment Rating O O O O O 100 120 220 240V 10 50 60 Hz 250 VA max FUSE 5 3 15A T 250V All wiring must be in accordance with local norms and be carried out by experienced personnel Service and Spare Parts For world wide customer service amp spare parts contact ECOTECH Address Ecotech Pty Ltd 1492 Ferntree Gully Rd Knoxfield Australia VIC 3180 Phone 6
20. 5 Service Manual 3 3 7 Service Manual 3 3 13 Flow Calibration Check Calibrate Service Manual 3 5 Suggested intervals for normal operation and actual intervals will vary depending upon application The user can refer to this table as a guideline but should develop a maintenance schedule to suit their specific requirements 2 Replacement interval determined by ambient SO levels Humid conditions nay necessitate more frequent replacement 22 98507601 Rev D 3 2 Replaceable Parts 98507601 Rev D CHAPTER 3 MAINTENANCE EC9850 Analyzer Spare Parts Requirements Description O ring orific and filter Filter unit disposable Desiccant 5 gram pack 4 required Charcoal activated 2 pound bulk container Filter element 5 micron consumable 50 each Lamp assembly ultraviolet Filter glass U330 Filter ultraviolet O ring plano convex lens O ring reaction cell cover plate O ring U330 Heat sink compound O ring desiccant cap O ring adapter reaction cell collar O ring reaction cell to optical bench O ring ultraviolet filter Extraction tool minifit connectors Photomultiplier tube Pump PCA Voltage Regulator Display switch assembly PCA 50 Pin I O PCA Microprocessor SMD PCA USB Board Assembly Power supply 115 230 VAC to 12 VDC Orifice 10 mil Orifice 20 mil Extraction tool filter and orifice Service kit pump Lamp driver assembly PCA Prepr
21. ES B 1 2 Turn the analyzer off and disconnect power Remove the UV lamp access cover and remove the two captive screws that secure the kicker to the UV lamp housing Refer to Figure 11 Gently move the kicker forward away from the Rx cell Disconnect the 1 8 tubing from the Rx cell inlet and both 1 4 tubing lines from the tee on the Rx cell outlet Be sure to note which 1 4 line connects to which side of the tee Refer to Figure 16 Disconnect J1 J2 and J4 from the Preprocessor PCA and disconnect the PMT housing fan power cable the front connector from the Rx cell bulkhead Refer to Figure 16 Loosen the captive screws that secure the PMT housing to the chassis two screws secure to the side of the chassis and two screws secure to the bottom of the chassis Refer to Figure 16 Gently swing the kicker housing forward and out of the way of the UV lamp housing Grasp the Rx cell and PMT assembly by the top cross brace and gently lift it straight up out of the analyzer 98507601 Rev D 98507601 Rev D 10 11 CHAPTER 3 MAINTENANCE To separate the Rx cell from the PMT housing remove the three screws that secure the Rx cell to the PMT housing Refer to Figure 17 Gently pull the Rx cell straight away from the PMT housing assembly To reconnect the Rx cell to the PMT housing align the base of the Rx cell with the groove in the PMT housing mounting bracket and slide it gently into place against the PMT ho
22. LET and AUXILIARY ports on the rear panel Also plug the inlet of the zero air canister located behind the Front Panel 6 Verify cas FLOW in the FLOW CONTROL POTS screen reads 0 00 If the reading is not 0 00 the leak is somewhere between the valves and the flow block 7 Press lt Pg Up gt and select the VALVE TEST MENU Set INT VALVE 1 to OPEN return to the FLOW CONTROL POTS screen and verify GAS FLOW 0 00 SLPM If the reading is not zero the leak is in the measure sample line 98507601 Rev D 43 EC9850 SO ANALYZER SERVICE MANUAL 44 10 11 12 Return to the VALVE TEST MENU Close the INT VALVE 41 and open the INT VALVE 2 Return to the FLOW CONTROL POTS screen and observe the flow reading If the reading is not zero the leak is in the zero air line Return to the VALVE TEST MENU Close the INT VALVE 2 and open the INT VALVE 3 Return to the FLOW CONTROL POTS screen and observe the cas prow If the reading is not zero the leak is in the span gas line Return to the VALVE TEST MENU Close INT VALVE 3 and open INT VALVE 1 for normal operation Set VALVE SEQUENCING ON and then press EXIT Remove the plugs from the INLET and AUXILIARY ports and from the zero air scrubber port Verify that the flow returns to the original setting by observing the INSTRUMENT STATUS menu The actual f
23. Rev D 61 EC9850 SO ANALYZER SERVICE MANUAL information on the operational limits and fault messages refer to the table in section 4 2 7 System Faults Several of the parameters displayed on the INSTRUMENT STATUS screen are affected by the potentiometer settings on the PREPROCESSOR POTS screen If a parameter is out of the normal operating range make note of the parameter value proceed to the respective menu and examine the pertinent potentiometer settings 4 2 6 System Temperatures SYSTEM TEMPERATURES CELL TEMP 53 DEG C CHASSIS TEMP DEG C FLOW TEMP DEG C COOLER TEMP Figure 35 System Temperatures and Tolerances The syst EM T EMPERATURES screen provides the temperatures of the fluorescence cell the chassis and the thermoelectric cooler used to cool the PMT Figure 35 contains the nominal values that should be displayed on this screen If any of the parameters are outside the acceptable ranges a significant problem among these components is strongly indicated For more information on the operational limits and fault messages refer to the table in section 4 2 7 System Faults 62 Note Flow Temp does not appear in the B series 98507601 Rev D 4 2 7 System Faults The SYST CHAPTER 4 TROUBLESHOOTING EM FAULTS display is a pass fail indication of various parameters that are continually monitored These parameters must be within acceptable operating
24. S ecotech environmen tal monitoring solutions EC9850 A amp B Series Sulfur Dioxide Analyser Service Manual Revision D www ecotech com EC9850 SO ANALYZER SERVICE MANUAL 2 98507601 Rev D FRONT MATTER Table of Contents MANUAL HISTORY iii sea hud nata area tihi Reda date dark es ented edi ona ein nili 3 SAFETY REQUIREMENTS si A SNE RANA SAM Ne EAE EN EAE ERE T 4 SERVICE AND SPARE PARTS conri OE pa A A lei 4 1 0 INSTALLATION 8 isn SSNS Ee OSSE Eata 5 1 V INITIAL CHECK ion scat O sobs ue teo e EJ akal 5 T A Remove the TOP COVER nerina e 5 LEDS CF VICES WUGH ste uv tagu T E E dices 5 1 1 3 Inspect the Components 6 LRA Reinsert Dislodged Boards ss ccs 7 ETS Cable CONMECHONS ate ido atenas 7 2 0 THEORY OF OPERATION 9 2 11 INSTRUMENT DESCRIPTION vs ds aa o vous ba e dear e e events 10 2 1 1 Power Microprocessor Module iscrtan i s ie jele 70 Del OY NAAA NN 14 AI O Ein 19 2 24 212772 617 2 delia pi
25. T 1 000 SLPM PUMP SPEED COARSE 28 PUMP SPEED FINE 7 GAS PRESSURE 710 0 TORR GAS FLOW 1 000 SLPM Figure 24 Flow Calibration Menu for Standard flow block Verify the pump is turned OFF and the CONTROL LOOP is DISABLED in the FLOW CALIBRATION MENU Load the linearization table into the flow control board EAROM by setting FLOW TRANSDUCER DF to SET and pressing Enter gt A The linearization table contains the following parameters Flow points 0 0 5 1 75 2 5 3 25 3 75 Voltage points 0 0 13 0 91 1 783 2 5 3 478 Connect the calibrated flow meter to the sample inlet on the rear panel of the analyzer With the pump turned off verify that there is no flow Connect a Digital Volt Meter DVM to the FLOW test point on the Flow Control PCA TP1 is the OV connection and pin 5 of the J2 connector is the FLOW test point The Digital Volt Meter should be set to the 2V DC range 98507601 Rev D 10 11 12 13 CHAPTER 3 MAINTENANCE Adjust the FLOW CONTROL ZERO pot until the DVM reads slightly positive 0 to 0 5 VDC then press lt Enter gt Set the FLOW ZERO POINT to SET and press Enter gt 4 The GAS FLOW should now read 0 000 SLPM Disconnect the DVM Turn the analyzer pump ON and verify the CONTROL LOOP is still DISABLED From FLOW CALIBRATION MENU use the PUMP SPEED COARSE and PUMP SPEED FINE pots to adjust the measured flow external flowmeter to as close as possible to 0 50 SLPM Note If
26. TORR ON 750 0 TORR 710 0 TORR 0 500 SLPM Figure 25 Pressure Calibration Menu for ISO B Flow Block 2 Turn off the pump 3 Disconnect the inlet tubing from the flow block and connect a calibrated pressure transducer to this inlet 4 Allow 30 seconds for the pressure reading to stabilize to ambient pressure on both the calibrated pressure transducer and the analyzer This reading in TORR should be the ambient pressure Set this value as PRESSURE 1 HIGH in the PRESSURE CALIBRATION M ENU and press Enter gt 4 Note To convert from millibar to TORR multiply the pressure by 0 75 5 Connect the pump to the exhaust port and turn it on 52 98507601 Rev D CHAPTER 3 MAINTENANCE Allow the pump to evacuate the cell and the pressure reading to stabilize This reading should be low typically 100 to 200 torr and is dependent upon the capacity of the pump Set this value as PRESSURE 1 LOW in the PRESSURE CALIBRATION MENU and press Enter gt Disconnect the pressure transducer from the flow control inlet and reconnect the inlet tubing The flow calibration must now be completed 3 5 2 3 Flow Calibration 1 From the HIDDEN MENU select the FLOW CALIBRATION MENU The menu of Figure 26 should be displayed FLOW CALIBRATION MENU CRITICAL ORIFICE 0 650 VALVE SEOUENCING ON AMBIENT PRESSURE 750 0 TORR GAS PRESSURE 710 0 TORR GAS FLOW 0 650 SLPM Figure 26 Fl
27. age Supply and Preamplifier This is a single component within the PMT housing Its function is to supply high voltage to the PMT and to amplify the photocurrent signal from the PMT Preprocessor PCA This circuit board contains the analog electronics that condition the reference detector and PMT signals generate the lamp control and modulation signals and all the signals reguired for preamp optic and electronic test diagnostic functions It also contains a heater control circuit to heat the measurement cell to 50 C The board also contains an EAROM which contains device identification and stored setup parameters All circuitry adjustments are made via microprocessor controlled digital potentiometers Lamp Driver PCA The lamp driver contains a high voltage switching supply to start and maintain the UV lamp at a constant intensity This board is under the control of signals from the preprocessor PCA 98507601 Rev D CHAPTER 2 THEORY OF OPERATION 2 2 Operation Modes The analyzer operates in a number of different measurement modes These modes include startup measurement and auto zero modes Following is a description of each of the operating modes 2 2 1 Startup Mode When the instrument is initially powered up several components in the instrument are automatically configured by the microprocessor and an automatic zero is run This process reguires about 30 minutes Following is a description of the various adjustments made during t
28. ance 30 CO CO2 1 1 1 17 Cooler Replacement illustration 42 Cooler replacement PMT 42 D Data Logging nn 62 Desiccant pack replacement 36 DFU replacement nosies desig 33 Diagnostic modes serene 65 E Electric test function 65 Electronic zero adjust 19 21 Electronics oocnonnoccnonnoononnononononoononnonenonnonononnonenonoos 18 Event EOS oidor 60 F Fan filter cleaning 30 Filter maintenance 27 Filter optical bandpass 17 Filter UV bandpass ensnee 17 Elo Won 17 Flow Pressure board calibration 46 47 H Hydrocarbon 1 1 1 16 I Illustrations Cable Connections 7 Illustrations Cooler Replacement 42 Illustrations Instrument Status Ranges 46 50 51 53 54 62 Illustrations Major Components 13 Illustrations Opening the Front Panel 5 Illustrations Orifice Removal 34 Illust
29. aptive screws that secure the kicker to the UV lamp housing Refer to Figure 11 Gently move the kicker backward away from the UV lamp Disconnect the UV lamp from J1 of the Lamp Driver PCA 98507601 Rev D CHAPTER 3 MAINTENANCE 4 Loosen the two captive screws which secure the UV lamp in the holder Swing down the UV lamp holder and remove the UV lamp from the housing Refer to Figure 15 5 Position the new UV lamp into the housing ensuring the Max Output side is toward the Rx cell the leads from the UV lamp should be pointed toward the top of the housing Loosely secure the UV lamp holder with the captive screws Note UV lamp bodies may vary in diameter It may be necessary to add or remove a layer of heat shrink plastic from the UV lamp body to obtain a proper fit 6 Connect the UV lamp to JI of the Lamp Driver PCA 7 Turn the analyzer on and adjust the UV lamp refer to 3 3 7 1 8 Tighten the UV lamp cover screws and reinstall the kicker and cover plate 3 3 8 PMT Desiccant Pack Replacement 98507601 Rev D The PMT housing contains two desiccant packs to prevent condensation on the cooled PMT housing If the desiccant expires it will result in corrosion of the PMT housing and premature cooler failure It is recommended that the desiccant bags be changed at least annually If moisture is detected inside the housing or the desiccant packs are saturated the interval should be reduced To change the desiccant packs perf
30. at 20 inches Hg B 884 017302 Pump external 110V 50 Hz 4 slpm at 20 inches Hg OB 884 017303 Rack mount kit with slides 98000036 2 PCA 50 Pin I O MEA 98000066 2 Battery power option 12 VDC 98000115 Filter particulate sample inlet 5 micron MEM 98000210 1 Filter kit particulate sample inlet 5 micron 98000211 1 Calibration check kit internal zero span without AA 98000230 permeation tube 50 pin connector and shell kit 98000235 1 Charcoal scrubber for zero air generation O B 98415105 1 Charcoal scrubber for exhaust NES 98415105 1 EC9850 Operation Manual 98507600 EC9850 Service Manual 98507601 Reaction cell maintenance kit 98500061 KIT2 98507601 Rev D CHAPTER 3 MAINTENANCE Description Part Number Valve manifold kit external zero span EZS A B 98300087 EC9850 Analyzer Spare Parts Reguirements Options and Accessories 3 2 1 Expected Life Span of Consumables UV Lamp 1 to 2 years 3 3 Maintenance Procedures 98507601 Rev D Following is a list of routine maintenance procedures which may be reguired through the life of the analyzer Recommended eguipment to perform maintenance n U O Toolbox Oscilloscope Digital multimeter DMM Computer or remote data terminal and connection cable for RS232 communication Pressure transducer absolute and connection tubing calibrated in torr Flow
31. d GAS PRESSURE readings After 2 minutes the cas FLrow should indicate 0 00 sLPM and the GAS PRESSURE should be equal the vacuum capacity of the pump see following conversion 15 Torr 2 kPa Note To convert vacuum capacity to equivalent atmospheric pressure perform the following calculation Current ambient pressure Torr Vacuum Hg 25 32 Or Current ambient pressure kPa Vacuum kPa Unplug the Sample and Auxiliary inlets and reconnect the sample and zero air lines sections of the analyzer Caution Do not use pressure to isolate leaks Pressure in excess of 5 psi 35 kPa will damage the pressure transducers 3 4 Hidden Menu The new software features of the Ecotech Microprocessor board SMD version provides provisions for a hidden menu This enables the experienced user to access menus for maintenance purposes These menus eliminate the need for a portable computer to perform flow amp pressure calibrations 98507601 Rev D To access the hidden menu simultaneously press three keys on the front panel from the primary screen as follows Up arrow A lt Pg Up gt and Enter gt J The following menu will be displayed 45 EC9850 SO ANALYZER SERVICE MANUAL HIDDEN MENU SERIES A ANALYZER TYPE 9850 SUB TYPE STANDARD FLOW BLOCK TYPE STANDARD GAS NAME _ PRESSURE CALIBRATION MENU FLOW CALIBRATION MENU Figure 22 Hidden Menu SERIES Allows the user
32. digital Kalman filter This filter provides the best possible compromise between response time and noise reduction for the type of signal and noise present in ambient air analyzers and their application Ecotech s implementation of this filter enhances the analyzer s measurement method by making the filter time base variable depending on the change rate of the measured value If the signal rate is changing rapidly the instrument is allowed to respond quickly When the signal is steady a long integration time is used to reduce noise The system continuously analyzes the signal and uses the appropriate filtering time Ecotech s analyzers have passed USEPA equivalency testing using this advanced signal filtering method EC9850 SO ANALYZER SERVICE MANUAL 10 2 1 Instrument Description The instrument consists of a power microprocessor module and a sensor module The power microprocessor module contains the power supply voltage regulators and the system microprocessor The sensor module contains all components necessary to measure the pollutant gas The slight variations between the A and B series analyzers are illustrated using system block diagrams Figure 4 amp Figure 5 and major component layout diagrams Figure 6 amp Figure 7 2 1 1 Power Microprocessor Module The power microprocessor module can be described in three sections the power supply the voltage regulator and the microprocessor 2 1 1 1 Power Supply The p
33. drift The quality of the zero air system should be checked by challenging the analyzer with a known good zero air source such as commercially available Ultra Zero Air or a known good charcoal scrubber To check the zero air system perform the following Required equipment Test zero air supply 1 From the CALIBRATION MENU place the analyzer in CAL MODE ZERO This will allow the analyzer to sample zero air from the zero air scrubber Allow to sample for approximately 15 minutes 2 Record the front panel SO reading as the initial value Note This value should be 0 000 0 001 ppm If it is not a background should be initiated by choosing CALIBRATION MENU and BACKGROUND START then press lt Enter gt to re establish the zero baseline The background will require approximately 15 minutes to complete 3 Connect the challenge zero air to the Sample inlet of the analyzer Be sure the inlet pressure is maintained at ambient pressure 4 From the CALIBRATION MENU select CAL MODE MEASURE and press lt Enter gt This will allow the analyzer to sample the challenge zero air Allow to sample for 5 minutes 5 Record the front panel SO reading as the challenge value 6 Compare the initial SO value and the challenge value They should agree within 0 002 ppm If the initial value is more positive than the challenge value the zero air scrubber should be recharged or replaced 98507601 Rev D 29 EC9850 SO
34. e cable connector into the mating connector until a click is heard Then fold the retainers inward to secure the connection see Figure 3 Figure 3 Cable Connections 98507601 Rev D 7 EC9850 SO ANALYZER SERVICE MANUAL This page is intentionally left blank 8 98507601 Rev D CHAPTER 2 THEORY OF OPERATION 2 0 Theory of Operation 98507601 Rev D The EC9850 sulfur dioxide analyzer is based on classical fluorescence spectroscopy principles Sulfur dioxide exhibits a strong ultraviolet absorption spectrum between 200 and 240 nm Absorption of photons at these wavelengths results in the emission of fluorescence photons at wavelengths between approximately 300 and 400 nm The amount of fluorescence emitted is directly proportional to the SO concentration These characteristics are exploited by the 9850 SO analyzer UV radiation at 214 nm from a zinc discharge lamp is separated from the other wavelengths in the zinc spectrum by a UV bandpass filter The 214 nm radiation is focused into the fluorescence cell where it interacts with SO molecules in the beam path The resulting fluorescence is emitted uniformly in all directions A portion of the fluorescence i e that emitted perpendicularly to the excitation beam is collected and focused onto a photomultiplier tube A reference detector monitors the emission from the zinc lamp and is used to correct for fluctuations in lamp intensity The 9850 analyzer uses the advanced
35. e analyzer The nightly background routine is identical to the background described in the startup routine 2 2 3 2 Electronic Zero Adjust 98507601 Rev D Long term negative drift may occasionally cause the measurement voltage near zero to drift outside the range of the preprocessor measurement channel If this occurs the analyzer will initiate an electronic zero adjust to reset the preprocessor measurement zero adjustment This routine is identical to the electronic zero adjust described in the startup routine After an electronic zero adjust the analyzer will always perform a background to fine adjust for the new baseline value 21 EC9850 SO ANALYZER SERVICE MANUAL 3 0 Maintenance 3 1 Maintenance Schedule The following outlines a periodic maintenance schedule for the EC9850 analyzer This schedule is based on experience under normal operating conditions and may need to be modified to suit specific operating conditions and regulations It is recommended that this schedule be followed in order to maintain reliable long term operation of the analyzer Interval Item Procedure Section Weekly Inlet Particulate Filter Check Replace Service Manual 3 3 1 Event Log System Faults Service Manual 4 2 4 amp 4 2 7 Operation Manual 2 4 Monthly Service Manual 3 3 3 Operation Manual 2 4 Operation Manual 2 3 3 6 Monthly Service Manual 3 3 4 Service Manual 3 3 8 Operation Manual 3 2 1 Year Service Manual 3 3
36. e following table Circuit board illustrations indicating the test points and other component locations immediately follow the Troubleshooting Guide Troubleshooting Voltage Table Sv DVM DVM Microprocessor 12V GOOD 111 TP2 5V 0 5V 10V TP3 10V 0 5V 20V TP4 20V 0 5V Voltage TP7 AGND TP9 12V 0 5V Regulator TP8 10V 0 5V TP6 10V 0 5V TP4 5V 0 25V Preamp Pressure 10V TP2 AGND J1 4 10V 0 5V 10V J1 5 10V 0 5V Preprocessor TP1 AGND 12V 0 5V 5V 0 25V 10V 0 5V 10V 0 5V The 12V GOOD test point is a 5 volt status output from the power supply to indicate that the Mains supply is within the correct operating range 4 2 Troubleshooting the EC9850 Analyzer Because of the sophisticated design of the EC9850 analyzer a significant amount of information about the condition of the system is available on the front panel display You can therefore troubleshoot an operating instrument without opening the front cover The most useful menus in terms of troubleshooting are O PREPROCESSOR POTS O VALVE TEST MENU O EVENT LOG 98507601 Rev D 57 EC9850 SO ANALYZER SERVICE MANUAL 58 O INSTRUMENT STATUS O SYSTEM TEMPERATURES O SYSTEM FAULTS These menus provide information that may indicate a failure or an operational problem If instrument performance appears to have changed dramatically the component that is causing the
37. eached limits before reference voltage reached set point Instrument flow has gone to zero After AZS cycle ratio of reguested span to measured span is lt 0 75 After AZS cycle ratio of reguested span to measured span is gt 1 25 An analyzer electronic zero cycle was initiated Action Battery failure or system software error If error persists call Ecotech Customer Service for instructions Check Pressure PCA cable connections and Pressure PCA Return analyzer to service using the front panel switch Check display cable connection Display PCA and Microprocessor PCA No action reguired No action reguired Check Preprocessor PCA PMT or high voltage module Check UV lamp Lamp Driver PCA or Preprocessor PCA Reset analyzer check zero air source Check UV lamp The pump has failed or a flow obstruction has occurred Replace pump or clear obstruction Instrument span has drifted beyond acceptable limits Recalibrate Instrument span has drifted beyond acceptable limits Recalibrate Normal after reset or power failure If not associated with these check zero air supply 98507601 Rev D CHAPTER 4 TROUBLESHOOTING Message BACKGROUND CYCLE RESET DETECTION AZS CYCLE DATA LOGGING MEM FAIL CONTROL LOOP RESTARTED VALVE SEQUENCING RESTARTED Event Log Messages
38. ection Because of the counter propagating flows and differential partial pressures between the two flow channels hydrocarbon interferents diffuse through the membrane and are carried away in the exhaust flow Consequently the interference by hydrocarbons in the SO measurement process is minimized Zero Air Scrubber The charcoal scrubber is used to provide a clean SO gt free zero air supply for the automatic zero function of the instrument and for the kicker jacket flow This scrubber is not supplied with the B series analyzer and must be purchased as an option 2 1 2 1 1 A series Flow Control Flow Control Module The sample flow rate is monitored by measuring the pressure drop across a calibrated flow restrictor The upstream pressure of this restrictor is the sample cell pressure Mass flow through the restrictor is computed from the upstream and downstream pressures Since the pressure transducers used are temperature sensitive they are mounted in a temperature controlled block The sample air is then mixed with approximately 2 3 slpm of externally supplied zero air from the bypass jacket of the kicker This flow is then exhausted through the exhaust port of the instrument Sample Pump The rotary vane type pump is powered by a brushless DC motor Since the pump is working with a very light load it rotates very slowly resulting in very little bearing or vane wear The estimated pump life is in excess of 5 years The Pump speed is contr
39. ee a ae Ee dee a R aa eE aa Ee Eae R Ee R E pea 64 ABET RO ATE 64 AZ 222 7 EE TE E NOE VN AS 64 4 3 5 HA AUA AI AEE E E E A vij ni 64 4 3 4 Use of Diagnostic Modes vo iii 64 4 4 TROUBLESHOOTING GUIDE tai r e Na AA oi Rh A 65 INDEX E O I OOE OOOO E EO Mi 1 2 98507601 Rev D FRONT MATTER Manual History This manual is the combination of two previous versions which have now been merged into one document to cater for the continuing development of the EC9800 series analyzers The original manuals were a ML9850 Service Manual PN 98500022 Rev V December 1998 a ML9850B Service Manual PN 98507005 Rev P July 1999 The scope of this new manual covers the following analyzers a EC9850 Sulfur Dioxide Analyzer A Series PN 98501000 100 O EC9850B Sulfur Dioxide Analyzer B Series PN 98507000 1 Both of the instruments are manufactured by Ecotech P L in Australia and support the new SMD Microprocessor Board Part number 98000063 4 This manual is current for firmware version 1 11 and above This manual should only be used in conjunction with EC9850 Sulfur Dioxide Analyzer Operation Manual PN 98507600 Rev D April 2007 Ecotech Manual ID MAN 0023 Manual PN 98507601 Current Revision D Date Released April 2007 Description EC9850 Sulfur Dioxide Analyzer Service Manual A amp B Series Revision History Rev Date Summary Affected Pages A Jan
40. ee if the high voltage adjust reach 700 V potentiometer is at 99 If it is the high voltage 10 V power supply may be bad If the pot is not at 99 try restarting the instrument If the problem continues call the Service Response Center 10 Response time Low flow Check sample flow with flowmeter It should be not at specified 0 6 to 0 7 slpm STP Bypass kicker or replace value orifice if it is not Kicker damaged Perform leak test If there are no leaks bypass the kicker and re test the response time If the rise time corrects itself replace the kicker If not check the gas delivery system flow and particulate filter 11 PMT voltage High voltage Replace the HVPS Preamp module does not reach Bad Microprocessor Check that D5 HEART BEAT LED is flashing on 700 V 10 V or Preprocessor the Microprocessor Board Check Display PCA connection Replace the Microprocessor or Preprocessor PCA 12 Analyzer Preprocessor ID set 1 Check J5 connector on Microprocessor se lays BAD Wrong 2 Check J6 connector on Preprocessor ANALYZER 3 Reprogram device ID 4 Replace Preprocessor 67 INDEX A Auto zero routines 21 AZS cycle mode 20 B B ckground tesina oseke 19 Background auto 7 190 21 Block diagram iii ani slane 10 C Cable Connections illustration 7 Charcoal scrubber mainten
41. erify that the cell temperature is 50 3 C and that the TE cooler is 10 2 C 5 Low span Span setting Adjust the span using the calibration procedure in the EC9850 Operation Manual See the Zero flow symptom in this table Leaks A leak dilutes the sample stream and causes low span readings and noise See section 3 3 13 6 No response to Leaks A leak dilutes the sample stream and causes low span gas span readings and noise See section 3 3 13 No flow Check the INSTRUMENT STATUS MENU and verify flow Software lockup 1 Observe whether ECOTECH GLOBE on the display is turning 2 Verify that other menus can be selected 3 Press the Reset button on the secondary panel 4 Check that D5 HEART BEAT LED is flashing on the Microprocessor Board 7 Zero drift Leak A leak dilutes the sample stream and causes low span readings and noise See section 3 3 13 Charcoal saturated Replace the charcoal 8 Unstable flow Failed cell control The cell temperature SYSTEM TEMPERATURES or pressure heater screen should be 50 5 C readings 66 98507601 Rev D 98507601 Rev D CHAPTER 4 TROUBLESHOOTING System Troubleshooting Table Symptom Possible Cause Fault Isolation Solution 9 Instrument Reference voltage Perform UV lamp check and adjustment stuck inreference INSTRUMENT adjust STATUS screen not at 2 5 V High voltage won t Check to s
42. g the filter replacement procedure 1 Open the Front Panel to access the service switches and particulate filter Position the Pump Switch in the secondary front panel to OFF For the B series Analyzer you will need to disconnect the external pump 2 Remove the tubing from the front of the particulate filter 3 Unscrew and remove the 3 thumb screws Remove the filter cover and attached plate 4 Remove the O ring and the filter Discard the filter and save the O ring 5 Place a new filter over the Teflon screen and replace the O ring 6 Position the filter cover over the filter aligning the holes and install the three thumb screws Snug all three screws then tighten firmly with finger pressure 7 Reattach the tubing to the filter housing 8 Return the Pump to ON 9 Close the Front Panel Figure 12 Particulate Filter Replacement 98507601 Rev D CHAPTER 3 MAINTENANCE 3 3 3 Clean Fan Filter The fan filter is located on the rear of the analyzer If this filter becomes contaminated with dust and dirt it may affect the cooling capacity of the analyzer The fan screen should be cleaned by removing it from the analyzer and blowing it out with compressed air or by cleaning it with mild soapy water and air drying 3 3 4 Zero Air Scrubber The zero air supply is critical to the operation of the EC9850 Poor zero air can result in numerous problems such as inaccurate measurements near zero and span
43. he Rx cell to the PMT housing Refer to Figure 19 98507601 Rev D 98507601 Rev D 10 11 CHAPTER 3 MAINTENANCE Gently pull the Rx cell straight away from and PMT housing assembly To reconnect the Rx cell to the PMT housing align the base of the Rx cell with the groove in the PMT housing mounting bracket and slide it gently into place against the PMT housing Reinstall the three screws to secure the PMT housing to the Rx cell assembly and alternately tighten these screws to pull the Rx cell squarely into the PMT housing Reassemble the Rx cell PMT housing assembly and reinstall into the analyzer Figure 18 Rx Cell PMT Housing Removal A Series Figure 19 Rx Cell PMT Housing Separation 39 EC9850 SO ANALYZER SERVICE MANUAL 3 3 11 Rx Cell Cleaning The Rx cell cleaning procedure should be performed when zero values begin to drift when the analyzer can no longer accomplish an electronic zero adjust or can be performed as an annual periodic maintenance item 1 Remove the Rx cell PMT housing assembly from the analyzer refer to section 3 3 8 above 2 Remove the bulkhead end cap from the Rx cell Refer to Figure 20 Figure 20 Rx Cell Cleaning 3 Using a lint free cloth such as a Kimwipe thoroughly wipe and clean the inside of the Rx cell and bulkhead end cap using a high purity isopropyl alcohol and allow to air dry Caution Ensure hands and fingers do not
44. he startup routine All adjustments are automatically performed by the microprocessor no manual intervention is reguired During all the startup routines the cell is filled with zero air 2 2 1 1 Reference Adjust Reference adjust allows the gain of the preprocessor reference channel to be adjusted for the proper reference voltage level the reference voltage is proportional to the intensity of the UV lamp Prior to any adjustments being made the UV lamp is first allowed to stabilize for approximately 10 minutes After 10 minutes the preprocessor reference gain potentiometer is adjusted until a reference voltage of 2 5 0 2 volts is obtained After the reference voltage is set it is not adjusted again until another auto startup routine is performed or the reference voltage goes below 1 volt or above 4 volts 2 2 1 2 Electronic Zero Adjust Electronic zero adjust sets the preprocessor measurement channel to minimize any electronic or optical offset present at zero First the cell is allowed to fill completely with zero air The preprocessor measure coarse zero potentiometer is then adjusted until a concentration voltage of just above 0 00 volts is obtained This is the analyzers coarse zero adjustment Once this is set it is not readjusted until another auto startup routine is performed or the concentration voltage is sensed to be below 0 1 volts 2 2 1 3 Background Background allows the analyzer to sample zero air and measure the level of the
45. ler Replacement iii dis a egies 41 J 3 13 bedk Test Procedure ist sis iN id 43 3 4 HIDDEN MENU ui A daa iii 45 3 4 1 Pressure amp Flow Calibration sub menus nea rnnn nr rn nana nr rnnnnneo 46 3 9 PRESSURE amp FLOW CALIBRATION oser A Senja ena la vdaja jine 48 3 5 1 Pressure Flow Calibration A Series ossessione reperi essien rne 48 3 5 2 Pressure Flow Calibration B 39 27769 51 3 6 PREPROCESSOR DEVICE ID ENTRY vroren ioie EO buin ANE IN Gent 54 3 7 FIRMWARE UPDATE iin re a eb te leben ue EM aa ia a kata sb be Sl tt 54 4 0 TROUBLESHOOTING unit eke ARENI ARE A 4 60 80 2004 0000 210 804 osa 57 4 1 DE POWER SUPPLY VOLTAGES iin sidan ni dren ko E A ei lei odeta Vinji 57 4 2 TROUBLESHOOTING THE EC9850 ANALYZER ena nanasa nana nana nena 57 AZ 1 Preprocessor Pots MCN ss sesa pain odk DE tees 58 4 2 2 Flow Control Pots Menu A Series OnLy n i 58 4 2 3 Valve Tes EME obrani RRR ESSERE ER v Reiki 59 98507601 Rev D 1 EC9850 SO ANALYZER SERVICE MANUAL ADA Event LOB dpi dve dovodni GI Spi le idioti NN 59 4 2 5 Instrument Status iii tied ass ea A JE a RR EN Debitel iva 61 42 08 Ys tem TeMperdluT es a A A 62 4 2 7 System Falls ine dieti legi pi a iia 63 4 3 TEST FUNCTIONS sretni eae a R p
46. lis tds rise lo dde acid dei dobla da e 19 2 2 2 Medsure MES soda 20 2 2 3 Auto Zero AM e 27 3 0 MAINTENANCE STESS i eva 22 33 MAINTENANGE SCHEDULE users dr AE PR dotada a 22 3 2 REPLACEABLE PARTS iea vy ccs Dani rele a a 23 3 2 1 Expected Life Span of Consumables ccccccccccsccesscesscesscesecesecusecnseesseeseesseesseseseeeeesecsecaecaeesaecsaeeseeeasensees 25 3 3 MAINTENANCE PROCEDURES iii aa raaa TEE a a IE AN a AEA AAE AES ERE TEESI E aaRS 25 3 3 1 Check Particulate 47472 si ubite a ti AE A di 27 3 3 2 Particulate Filter Replacement Procedure cnn cnn oran ne conan anar nan nora cane rananconno 28 3 3 3 Clean Fan Filter A ejo av zadele deve podje ke vedala deje dajem geo ii ve a 29 3 3 4 Zero Air Scrubber seas ientra a aE 29 3 33 DEW Repl cement B Series Joena acia neke eli 32 3 3 6 Orifice Removal for Replacement or Cleaning B Series 32 3 3 7 UV Lampas erns UE A sees EA in E db AAA NS id 33 3 3 8 PMT Desiccant Pack Replacement pasini eniin a eaa e e a e i s 35 3 3 9 Rx Cell PMT Housing Removal SERIES B non nc canon non cnn nn nr anna renere renees 36 3 3 10 Rx Cell PMT Housing Removal 38 3 3 11 Rx Cell Cleaning 40 9 3 12 PMT Coo
47. low through the analyzer should be checked by turning on the pump and connecting a flow meter to the measure inlet ensure that the analyzer is in SAMPLE MEASURE Actual flow through the analyzer should be approximately 0 5 slpm If flow is too low perform the flow calibration in section 3 5 below 3 3 13 2 B Series The leak check ensures the integrity of the pneumatic system and should be performed annually or after any maintenance on the pneumatic system To leak check the EC9850B perform the following Note This leak check procedure requires that the vacuum capacity of the pump be known and converted to an equivalent atmospheric pressure This can be obtained by connecting a vacuum gauge through a tee to the pump inlet Disconnect the Sample inlet and zero air from the Auxiliary inlet Leave the Exhaust port connected to the pump Turn off the pump and allow to settle for 2 minutes Select the INSTRUMENT STATUS menu and record the GAS PR pressure E SSUR E reading as the current ambient Plug the Sample inlet and Auxiliary inlet ports Turn on the pump and allow it to operate for 5 minutes to evacuate the pneumatics 98507601 Rev D If a leak is detected the user can attempt to isolate the leak by using the VALVE EST MENU and the pneumatic diagram Figure 9 to select and close off different T CHAPTER 3 MAINTENANCE Select the INSTRUMENT STATUS menu and monitor the GAS FLOW an
48. m the fitting Refer to Figure 11 2 The sample orifice is located in the base of the tee Using the orifice filter removal tool remove the sample orifice The orifice may be replaced cleaned with alcohol or cleaned in an ultrasonic bath When reinstalling the new orifice be sure to use a new O ring and orient the orifice with the threaded port facing outward 3 The kicker orifice is located in one branch of the tee The orifice may be replaced cleaned with alcohol or cleaned in an ultrasonic bath When reinstalling the orifice be sure to use a new O ring and orient with the threaded port of the orifice facing outward 4 Reinstall the tee into the Rx cell Be sure to use Teflon tape around the NPT threads and connect the side of the tee with the kicker orifice to the 1 4 line from the kicker and the side of the tee without the orifice to the 1 4 line from the pump 98507601 Rev D CHAPTER 3 MAINTENANCE LL WC Figure 14 Orifice Removal 3 3 7 UV Lamp Proper operation of the UV lamp is essential to the EC9850 The UV lamp should be periodically checked to see if it is operating within acceptable parameters and may require periodic realignment to maintain sufficient UV light for analyzer operation Following are procedures to check align and replace the UV lamp assembly Warning The Lamp Driver PCA can generate in excess of 1000 volts Exercise extreme care when working in the vicinity of the Lam
49. make contact with the inside of the Rx cell or end cap during cleaning Finger oils will fluoresce and result in an artificially high zero signal After cleaning there should be no lint oils or residue present in the Rx cell 4 Reinstall the end cap using a new O ring part number 025 030810 5 Reinstall the Rx cell PMT assembly in the analyzer 40 98507601 Rev D 3 3 12 PMT Cooler Replacement 98507601 Rev D Caution CHAPTER 3 MAINTENANCE Because the PMT is extremely sensitive to light it is essential that before opening the PMT assembly to make sure that the analyzer is switched off In addition even when the analyzer is switched off is very important to cover the PMT at all times so that no direct light reaches its window Remove the Rx cell PMT housing assembly from the analyzer and separate the Rx cell from the PMT housing refer to section 3 3 11 above Remove the desiccant access cap and disconnect the electrical connector Remove the 12 screws that secure the PMT housing cover to the heatsink and lift the cover off the heatsink It may be necessary to loosen the crossbar or mounting bracket to remove the PMT housing cover Disconnect the HVPS Preamp from the PMT and remove the PMT from its housing Refer to Figure 21 Figure 21 Cooler Replacement Important Note the orientation of the red and black cooler wires as they relate to the PMT housing heatsink The new cooler must be
50. meter 2 slpm nominal Wire strippers Soldering iron Minifit extraction tool Orifice removal tool Assortment of 1 4 and 1 8 tubing and fittings Test zero air source Test span gas source Leak tester 25 EC9850 SO ANALYZER SERVICE MANUAL Figure 10 Routine Maintenance Components A Series Figure 11 Routine Maintenance Components B Series 26 98507601 Rev D CHAPTER 3 MAINTENANCE 3 3 1 Check Particulate Filter 98507601 Rev D The inlet filter prevents particulates from entering the pneumatic components of the EC9850 Contamination of the filter can result in degraded performance of the EC9850 including slow response time erroneous readings temperature drift and various other problems Several factors affect the filter replacement schedule In the springtime for example the filter might accumulate pollens and dust Man made environmental changes such as construction dust might indicate more freguent change or a climate where dry dusty conditions are normal might dictate more freguent filter replacement than climates with few natural pollutants Determining the schedule for changing the filter is best developed by monitoring the filter at weekly intervals for the first few months then adapting the schedule to fit the specific site 27 EC9850 SO ANALYZER SERVICE MANUAL 28 3 3 2 Particulate Filter Replacement Procedure Use Figure 12 as reference when performin
51. mperature is below 35 C or above 60 C START UP Indicates that the analyzer is in start up mode Usually after power SEQUENCE ACTIVE up orreset 4 3 Test Functions The following lists the available diagnostic modes in the EC9850 under the TEST MENU 4 3 1 Optic The optic test function turns on a small incandescent light bulb in the exhaust arm of the reaction cell The glow from this light simulates the glow of the normal fluorescent reaction of SO in the cell which is then detected by the PMT as if it were an actual signal This test is used to verify the operation of the PMT 4 3 2 Preamp The preamp test function generates an electronic test signal which is applied to the input of the PMT Preamp This simulates an input from the PMT and is then processed as if it were an actual signal This test is used to verify the operation of the PMT Preamp 4 3 3 Electric The electric test function generates an electronic test signal which is applied to the input of the preprocessor This simulates an input to the preprocessor and is then processed as if it were an actual signal This test is used to verify the operation of the Preprocessor PCA reference and measure channels 4 3 4 Use of Diagnostic Modes The diagnostic modes are actuated by selecting DIAGNOSTIC MODE OPTIC or PREAMP Or ELECTRIC and adjusting the TEST MEASURE potentiometer until a response simulated concentration i
52. n press Enter gt Note To convert from millibar to TORR multiply the pressure by 0 75 Set the CONTROL LOOP TO DISABLED and press Enter gt J This will disable the flow control loop Connect the calibrated pressure transducer to the sample inlet on the rear panel of the analyzer Turn the pump ON from the secondary panel Set the PUMP SPEED COARSE to 99 and press Enter gt 4 Allow approximately 1 minute for the pressure to drop to a stable reading This reading should be typically 100 to 200 torr lower than the ambient pressure depending upon the capacity of the pump 49 EC9850 SO ANALYZER SERVICE MANUAL 10 11 Set this reading in TORR as PRESSURE 1 LOW in the PRESSURE CALIBRATION MENU and press Enter gt Disconnect the pressure transducer from the inlet and turn the pump OFF To verify that the pressure transducers on the standard flow control board are calibrated view the GAS PRESSURE reading in the PRESSURE CALIBRATION MENU it should be at ambient pressure 2 TORR This completes the pressure transducer calibration procedure 3 5 1 3 Flow Calibration 1 50 From the HIDDEN MENU select the FLOW CALIBRATION MENU The menu of Figure 24 should be displayed FLOW CALIBRATION MENU DESIRED FLOW 1 00 SLPM FLOW CONTROL ZERO 81 FLOW TRANSDUCER DF CANCEL CONTROL LOOP ENABLED VALVE SEQUENCING ON FLOW ZERO POINT CANCEL FLOW SPAN POIN
53. ocessor PCA Reference Detector Valve manifold assembly Flow control assembly Cooler thermoelectric e ooro e e eoon e ooo e eoo a 98300046SP1 98412028 3 SP DIR IDR lu ju ju jun ju iu jubi uv iu rl w in ju ri un WwW WwW WwW WwW WwW uv jo vi on ju mm 23 EC9850 SO ANALYZER SERVICE MANUAL 24 EC9850 Analyzer Spare Parts Requirements Thermistor assembly Kicker assembly hydrocarbon scrubber 3 Heater and thermistor assembly 3 3 3 HVPS and preamplifier assembly photomultiplier 98500067 2 SP Pressure preamplifier assembly B Series Only B 98507008SP Level 1 General maintenance supplies and expendables such as filters O rings lamps etc Level 2 Critical items that are known from experience to have a higher failure rate such as pumps heaters converters valves and circuit boards Level 3 Other miscellaneous items not included in Level 1 or 2 This level includes other spare parts that are not expected to fail over a given time frame Components marked with shading are essential components which need to be kept on hand at all times EC9850 Analyzer Spare Parts Requirements Options and Accessories Description Part Number Pump external 115V 60 Hz 4 slpm at 20 inches Hg B 884 017300 Pump external 100V 50 Hz 4 slpm at 20 inches Hg B 884 017301 Pump external 230V 50 Hz 4 slpm
54. olled by a DC input voltage derived from two digital potentiometers under microprocessor control on the flow control board The pump speed is varied to achieve desired sample flow rate Rear Fan The fan speed is controlled by a variable input voltage derived from a digital potentiometer under microprocessor control on the flow control board The fan speed is controlled to begin operating at about 30 C chassis temperature and increase its speed in a linear fashion until it is at full operating speed about 50 C chassis temperature 98507601 Rev D CHAPTER 2 THEORY OF OPERATION 2 1 2 1 2 B series Flow Control O Flow Control The Sample flow is controlled by critical orifices in the pneumatic outlet of the measurement cell The Detector Pressure PCA monitors sample pressure and flow Sample flow rate is calculated based upon critical flow through an orifice at a given upstream pressure This upstream pressure is monitored by a calibrated pressure transducer with the assumption made that the downstream side of the orifice is sufficient to hold the orifice critical lt 1 2 the pressure of the upstream side Flow through the analyzer is verified by measuring the differential gauge pressure between the upstream side of the orifice and ambient pressure This differential pressure is due to the minor flow restriction through the kicker Sample Pump The sample pump is supplied as an option by Ecotech and is connected to the exhaust of the
55. oncentration voltage is then used to determine gas concentrations The UV lamp is also monitored so the measurement reading can be compensated for fluctuations in lamp output 2 2 2 2 Zero Measure Zero measure allows the cell to be filled with zero air either from the standard zero air source with internal valves selected or from an external zero air source with external valves selected Processing of the signal is identical to measurement processing the only difference is the source of the sample stream 2 2 2 3 Span Measure Span measure allows the cell to be filled with a span source either from an internal source such as the IZS oven or from an external source with the external valve manifold Processing of the signal is identical to measurement processing the only difference is the source of the sample stream 2 2 2 4 AZS Cycle The analyzer can be placed in an AZS cycle mode where the sample stream is automatically switched to zero then span then back to sample For further information on the AZS cycles refer to the EC9850 Operation Manual 20 98507601 Rev D CHAPTER 2 THEORY OF OPERATION 2 2 3 Auto Zero Routines The 9850 is an auto zero instrument The analyzer is allowed to periodically sample zero air and correct for the readings obtained 2 2 3 1 Background The auto zero function background is performed nightly at midnight unless background is disabled This compensates for drift in the measurement baseline of th
56. orm the following Caution Because the PMT is extremely sensitive to light it is essential that before opening the PMT assembly to make sure that the analyzer is switched off In addition even when the analyzer is switched off is very important to cover the PMT at all times so that no direct light reaches its window 1 Turn the analyzer off and disconnect power 2 Using an offset Phillips head screwdriver remove the desiccant pack access cap from the PMT housing Refer to Figure 11 35 EC9850 SO ANALYZER SERVICE MANUAL 36 6 Note Removal of the desiccant access cap may be easier if the Rx cell PMT housing is removed from the analyzer Refer to section 3 3 8 Remove the old desiccant packs and replace with new Do not attempt to dry and reuse the old packs Inspect the inside of the PMT housing by touch or with an inspection mirror to check for moisture inside the housing If moisture is detected inside the housing the desiccant pack replacement interval should be decreased Reinstall the desiccant cap by gently twisting and pressing the cap back into the PMT housing It may help to apply a small amount of lubricant to the O ring on the desiccant cap Secure with two screws Caution Do not attempt to insert the desiccant cap into the PMT housing by using the screws to pull the cap into place This will damage the PMT housing Reconnect power and restart the analyzer 3 3 9 Rx Cell PMT Housing Removal SERI
57. ow Calibration Menu for ISO B flow block Set the CRITICAL ORIFICE to 0 650 and press Enter gt 1 Press Reset on the analyzer secondary panel The actual flow should now be checked by turning on the pump and connecting a flow meter to the sample inlet of the analyzer The flow should read approximately 0 65 slpm If the flow is too low perform the sintered filter orifice replacement procedure If flow is too high there is probably a leak Note The gas pressure and gas flow readings on the INSTRUMENT STATUS menu will not update until the startup routine is complete This completes the pressure amp flow transducer calibration procedure 98507601 Rev D 53 EC9850 SO ANALYZER SERVICE MANUAL 54 3 6 Preprocessor Device ID Entry This procedure is only reguired if the microprocessor is not reading the device ID from the preprocessor board or if the preprocessor board has been replaced 1 From the HIDDN MENU set the SERIES to A or B depending on which analyzer it is Then press Enter gt 2 Set the ANALYZER TYPE to 9850 and press Enter gt J 3 Press Reset on the analyzer secondary panel The display should now display 9850 SO2 ANALYZER 4 You may need to erase memory after this procedure to avoid any problems This completes the analyzer device type programming 3 7 Firmware Update As improvements are made to the EC9800 series analyzers these can be easily passed on to the user by updating the firmwa
58. ower supply is a self contained unit housed in a steel case It is designed to meet UL VDE CSA and other regulatory requirements It converts 99 to 264 VAC 50 60 Hz to 12 VDC power for distribution within the analyzer The power supply also furnishes a 250 msec power extension in the event of power failure to allow the computer to store data before the power failure can affect it 2 1 1 2 Voltage Regulator The voltage regulator board regulates and distributes the different voltages needed throughout the system 12 VDC to 5 VDC for the digital circuitry and 12 VDC to 10 V for analog circuitry An additional 15 VDC supply is present to power the microprocessor display supplies and analog output circuits The voltage regulator also furnishes a 300 msec power extension in the event of power failure to allow the computer to store data before the power failure can affect it 2 1 1 3 Microprocessor The microprocessor board contains a battery backed clock calendar and an onboard 16 bit microprocessor MC68HC12 operating at 16MHz The microprocessor board is the control center for input and output apparatus such as the 2 inch by 4 inch liquid crystal display LCD keyboard switches the serial ports and the 50 pin I O connector on the rear panel The 50 pin I O connector input accepts control lines from the rear panel and sends status and failure signals to solid state relay drivers Support circuitry for the liquid crystal display includes a 20 V
59. p Driver Caution If the UV lamp is adjusted the analyzer will require recalibration 3 3 7 1 UV Lamp Alignment 98507601 Rev D Required equipment Oscilloscope 1 Turn the analyzer on and allow the UV lamp to warm up and stabilize about 15 minutes 2 Connect an oscilloscope to Preprocessor J5 3 REFX2 and 1171 AGND Adjust the scope for 0 5 V division and 20 msec division 3 Remove the UV lamp access cover and remove the two captive screws that secure the kicker to the UV lamp housing Refer to Figure 11 Gently move the kicker backward away from the UV lamp 33 EC9850 SO ANALYZER SERVICE MANUAL 4 Loosen do not remove the captive screws securing the UV lamp holder to the housing Refer to Figure 15 Figure 15 UV Lamp Replacement Physically adjust the UV lamp rotate and move left and right until the maximum peak voltage on the oscilloscope is obtained not to exceed 2 volts peak The minimum usable output from the lamp is about 0 25 volts peak If the UV lamp output is below 0 5 volts then replacement should be considered Tighten the UV lamp holder screws and verify the UV lamp has remained at its previously adjusted position Reinstall the kicker assembly and the UV lamp access cover Reset the analyzer and allow it to run a startup sequence 3 3 7 2 UV Lamp Removal and Replacement 1 Ze 34 Turn the analyzer off Remove the UV lamp access cover and remove the two c
60. pin 12 Reinstall the PMT housing cover ensuring that the O ring on the base of the cover remains in place Install two new desiccant packs in the PMT housing Reconnect the desiccant access cap electrical connector and reinstall the access cap 98507601 Rev D CHAPTER 3 MAINTENANCE Caution Do not attempt to install the desiccant cap into the PMT housing by using the screws to pull the cap into place This will damage the PMT housing A small amount of lubricant on the desiccant cap O ring will facilitate its installation 14 Reassemble the Rx cell PMT housing and reinstall in the analyzer 3 3 13 Leak Test Procedure 3 3 13 1 A Series This is a test for the pneumatic system of the instrument The display readings will indicate whether the system is leaking Note This procedure applies only to the instrument It does not include the EZS valve option The EZS valve option if included in the instrument must be disabled to perform this test 1 Enter the TEST MENU and select OUTPUT TEST MENU then VALVE TEST MENU from these items pick VALVE SEQUENCING and set to OFF 2 Set all valves to CLOSED ce Press lt Pg Up gt to return to the OUTPUT TEST MENU and choose FLOW CONTROL POTS 4 Turn the Pump Switch on the secondary panel to OFF and verify FLOW 0 00 sLPM If it does not read 0 00 the Flow Control PCA requires re calibration Return the Pump Switch to on 5 Plug the IN
61. power supply and digitally adjusted potentiometers for contrast level All analog voltages from the sensor assembly are digitized by the analog to digital A D converter for microprocessor use Digital to analog D A conversion of three channels is used to send O to 20 mA analog signals to the 50 pin I O connector 98507601 Rev D 98507601 Rev D CHAPTER 2 THEORY OF OPERATION The microprocessor has electrically erasable ROMs which store the operating program and internally logged data Program upgrades can be easily made through the serial port The Service and Reset switches are located on the front of the board and are accessible when the top is removed or when the front panel is opened The microprocessor also has provisions for USB and optional TCIP connections through the rare panel 11 EC9850 SO ANALYZER SERVICE MANUAL Figure 5 System Block Diagram B Series 12 98507601 Rev D FRONT 98507601 Rev D CHAPTER 2 THEORY OF OPERATION INLET PORTS fi PUMP PART RN HIGH VOLTAGE POWER SUPPLY de 11172 PMT HOUSING FILTER CHARCOAL KICKER CANISTER amp LAMP FLUORESCENCE REFERENCE HOUSING CELL DETECTOR FAN CHARCOAL 1 CHARCOAL FLOW CONTROL BOARD
62. problem can possibly be determined thereby speeding up the corrective process It may assist the operator to periodically check and record these parameters to establish an operational history of the analyzer In addition information from this section may be reguested by the Ecotech Service support personnel when assistance is reguired 4 2 1 Preprocessor Pots Menu PREPROCESSOR POTS MEASURE COARSE ZERO 25 70 REFERENCE ZERO 50 MEASURE GAIN 50 REFERENCE GAIN gt 5 95 TEST MEASURE 0 HIGH VOLTAGE ADJUST 60 70 LAMP ADJUST 80 90 REF VOLTAGE 1 0 4 0 VOLTS so2 0 20 PPM CONC VOLTAGE 0 0 4 2 VOLTS HIGH VOLTAGE 690 710 VOLTS Figure 31 Preprocessor Pots and Ranges The TEST MENU OUTPUT TEST MENU PREPROCESSOR POTS screen displays the potentiometer settings associated with several components variables or signals on the preprocessor board Figure 31 illustrates a typical screen for an instrument that is operating normally The value of the potentiometer settings is somewhat arbitrary and differences in the examples shown here and the values displayed on an operating instrument should not be construed as a definite indicator of a problem Potentiometer settings of 99 and 0 however represent the extreme limits of the potentiometer range and may be reason to suspect a problem except for TEST MEASURE which is zero unless changed by the operator 4 2 2 Flow Control Pots Menu A Series onl
63. r plugged inlet Can also occur if the Sample inlet is pressurized Indicates that the lamp current is not within the acceptable limits In the EC9850 a fault is indicated if the lamp current is below 20 mA or above 50 mA Indicates that the cooler temperature or voltage is not within the acceptable limits In the EC9850 a fault is indicated if the cooler temperature is above 15 C or below 0 C Indicates that the reference voltage is not within the acceptable limits In the EC9850 a fault is indicated if the reference voltage is below volts or above 4 volts Indicates that the 12 volt supply voltage is not within the acceptable limits A fault is indicated if the 12 volt supply voltage is below 11 1 volts or above 14 3 volts 98507601 Rev D 63 EC9850 SO ANALYZER SERVICE MANUAL 64 System Fault Messages Message Description Failure Limits HIGH VOLTAGE Indicates that the high voltage is not within the acceptable limits A FAILURE fault is indicated if the high voltage reading differs by greater than 25 of the expected value as determined from the high voltage pot setting CELL TEMPERATURE Indicates that the cell temperature is not within the acceptable limits FAILURE A fault is indicated if the cell temperature is below 35 C or above 60 C FLOW BLOCK TEMP Indicates the flow block temperature is not within acceptable limits A fault is indicated if the flow te
64. r a key to the valve names used in the menu 4 2 4 Event Log Upon noting a possible operational problem examine the EVENT LOG menu to determine whether the microprocessor is reporting a system failure or problem Should the EV ENT LOG indicate an error it will also provide information as to the portion or component of the instrument which is at fault 98507601 Rev D 59 EC9850 SO ANALYZER SERVICE MANUAL 60 Message RAM CHI FAILURI EAROM X DATA ERROR Y SERVICE SWITCH ACTIVATED LCD DISPLAY BUSY SYSTE FAILURE SYSTEM POWER HIGH VOLTAGE POT LIMITED TO 99 LAMP ADJUST ERROR ZERO POT LIMITED TO 0 OR 99 REF POT LIMITED TO O OR 99 ZERO FLOW SPAN RATIO lt 0 75 SPAN RATIO gt 1 25 ELECTRONIC ZERO ADJUST Event Log Messages Description Checksum of memory at power down differs from checksum at restart EROM designated X detected error at location Y Unit taken out of service from front panel LCD constantly busy indicates hardware failure in display Power removed from system Power applied to system High voltage adjustment exceeds range Lamp Adjust Pot reached limit before 35 mA lamp current was achieved Zero voltage controller reached limits before voltage reached set point Reference voltage controller r
65. rations Pneumatic Diagram 15 Illustrations Preprocessor Pots and Ranges 59 Illustrations Routine Maintenance Components 26 Illustrations Rx Cell Cleaning 41 98507601 Rev D EC9850 SO ANALYZER SERVICE MANUAL Illustrations Rx Cell PMT Housing Removal 38 Illustrations Rx Cell PMT Housing Separation 39 Illustrations System Block Diagram 12 Illustrations System Temperatures and Tolerances 63 Illustrations UV Lamp Replacement 35 Illustrations Valve Test Menu 60 Tristallation iii 5 Instrument Status Ranges illustration 46 50 51 53 54 62 Instrument Status screen 62 K Kicker hydrocarbon 16 L Lamp Driver board 18 Lamp maintenance 34 Lamp OV 17 Leak check isis veste aaa ec ieee ats 45 Lenses UV grade isc setos 17 M Maintenance periodic 22 Maintenance routine 25 Major Components illustration 13 Measure MOdES eeecessseceeeceeseecesneeeeeceeeeeesaeeeee 20 Microprocessor 00210 10 Modes of operation 19 O Opening the Front Panel illustration 5 Optic test function
66. re software operating within the Microprocessor board To update your EC9800 Analyzer download the Firmware Updater Software Install this software on a Windows based computer with a COM port To do this run the downloaded file setup exe by double clicking on it then follow the installation screens to install Next download the required software version for your 9800 analyzer from those listed at the bottom of this page eg V1 00 0002 by right clicking on the link and choosing Save Target As and saving the sx file on your computer You will need to select save as type All Files in the download window To update the firmware on the analyzer 1 Run Firmware Updater from the Start Programs Ecotech Firmware Updater menu 2 Connect the 9800 analyzer to the computer using a standard serial cable you can connect to either the Multidrop port on the back of the analyzer or the service port on the front of the analyzer 3 Select Serial Port and the COM Port on the computer from those listed on the Firmware Update screen 98507601 Rev D CHAPTER 3 MAINTENANCE pi Firmware Update Connect to the analyser via which port type Serial Port v Communication Port COM1 Figure 27 Firmware Update communication settings screenshot 4 Click Next 5 Enter the full path and file name of the firmware sx file you downloaded eg C TEMP V1 03 0001 SX assuming the file was saved to C TEMP Firm
67. s noted Response to tests will vary depending upon individual analyzer parameters These tests are typically 98507601 Rev D CHAPTER 4 TROUBLESHOOTING pass fail Functional problems can be isolated to a single component by logical use of the diagnostic modes 4 4 Troubleshooting Guide Use this troubleshooting guide to find the symptom then follow in order the possible causes and fault isolation solutions until the problem is discovered Then take the action described If you cannot identify the problem contact Ecotech at the locations given in the front of this manual System Troubleshooting Table Symptom Possible Cause Fault Isolation Solution 1 No display AC power 1 Verify that the line cord is connected instrument dead 2 Check that the power supply fuse is not open The fuse should be 5A 115 V or 3A 230 V 3 Verify that the voltage switch is in the proper position 2 No display Contrast Set or adjust the display contrast by misadjusted simultaneously pressing two keys on the front panel as follows Contrast Press Up arrow A and lt Select gt for darker contrast Down arrow Y and lt Select gt for lighter contrast DC power 1 Verify the cable connection from the power supply to the Vreg board 2 Check the Vreg board for correct voltages as listed in the Troubleshooting Voltages table in section 4 If incorrect voltages are found replace the power supply or Vreg 3
68. th procedures the following equipment 15 required Digital Volt Meter Pressure transducer absolute calibrated in torr Flowmeter slpm nominal 14 fitting with hose to suit pressure transducer Q n 3 5 1 Pressure Flow Calibration A Series 3 5 1 1 Setup Note The EC9850 analyzer should be left running for at least one hour with the pump switched on before this procedure is attempted This will allow the flow block temperature to stabilize to 50 C 48 98507601 Rev D CHAPTER 3 MAINTENANCE From the HIDDEN MENU set the FLOW BLOCK TYPE TO STANDARD and press Enter gt 1 Press Reset on the analyzer secondary panel 3 5 1 2 Pressure Calibration 1 98507601 Rev D From the HIDDEN MENU select the PRESSURE CALIBRATION MENU The menu of Figure 23 should be displayed PRESSURE CALIBRATION MENU PRESSURE 1 HIGH 743 0 TORR PRESSURE 1 LOW 530 0 TORR VALVE SEQUENCING ON CONTROL LOOP ENABLED PUMP SPEED COARSE 28 GAS PRESSURE 710 0 TORR GAS FLOW 0 500 SLPM Figure 23 Pressure Calibration Menu for Standard flow block Verify the pump is turned off by setting the pump switch to OFF on the secondary panel Allow 30 seconds for the pressure reading to stabilize to ambient pressure on both the calibrated pressure transducer and the analyzer This reading in TORR should be the ambient pressure Set this value as PRESSURE 1 HIGH in the PRESSURE CALIBRATION MENU and the
69. the toggle switches for operating mode is EC9850 SO ANALYZER SERVICE MANUAL DC PowerON Pump ON Service IN The Reset switch is not a toggle switch and is only activated when pressed It resets the microprocessor The pump switch is not applicable to the B line instrumentation because the flow is generated through the use of an external pump When in the OUT position the Service switch sets the ouT oF sERVICE bit in the 50 pin I O interface and in the status word from the serial port The OUT position has no other effect on the operation or validity of the data obtained from the analyzer When the Service switch is set from OUT to IN the instrument returns to the normal operating conditions Captive screws Figure 2 The Secondary Panel A SERIES 1 1 3 Inspect the Components Verify that the components were not damaged in shipping If any PC boards are dislodged or cables disconnected follow the instructions below 6 98507601 Rev D CHAPTER 1 INSTALLATION 1 1 4 Reinsert Dislodged Boards The bottom edge of the boards must be held in place by the guides The top of the boards must be attached to the metal bulkheads by the plastic or metal studs with spring tips 1 1 5 Cable Connections The cable connectors and the board connectors must be matched securely in place for correct connection The red indicator on each cable must be positioned at the arrowhead mark on the board connector Make the connection by pressing th
70. tion 26 Rx Cell Cleaning illustration 41 Rx Cell PMT Housing Removal illustration 38 Rx Cell PMT Housing Separation illustration 39 S Sample fill measure 20 Sample Measure violin 20 Scrubber maintenance 30 Scrubber zero ai 16 Sensor module 14 Serial Port 6 10 55 Service switches se revet er reserven ener 6 SPAN 111659111 sir so EEES 6 20 S Pale Parts sve soe eae 23 Startup Mode iii 19 2 System Faults display 64 System Temperatures and Tolerances illustration 63 System Temperatures screen 63 T MEP Sine 10 Theory of operation nerne 9 11 00101651100 1115 58 66 U SB ie cei este ie Beaten a Seed os ees 10 23 UV bandpass llenos ina 17 UN grade lenses a eeii eni 17 UV amp enes ad rte 17 UV lamp Maintenance 34 UV Lamp Replacement illustration 35 UV reference detector 18 17 Valve Test Menu ooo EEA 60 Valve Test Menu illustration
71. using Reinstall the three screws to secure the PMT housing to the Rx cell assembly and alternately tighten these screws to pull the Rx cell squarely into the PMT housing Reassemble the Rx cell PMT housing assembly and reinstall into the analyzer Figure 16 Rx Cell PMT Housing Removal SERIES B 37 EC9850 SO ANALYZER SERVICE MANUAL 38 Figure 17 Rx Cell PMT Housing Separation 3 3 10 Rx Cell PMT Housing Removal 1 2 Turn the analyzer off and disconnect power Remove the UV lamp access cover and remove the two captive screws that secure the kicker to the UV lamp housing Refer to Figure 10 Gently move the kicker forward away from the Rx cell Disconnect the 1 8 tubing from the Rx cell inlet and the 1 4 tubing line from the Flow Control inlet top fitting Refer to Figure 18 Disconnect J1 J2 and J4 from the Preprocessor PCA and disconnect the PMT housing fan power cable the front connector from the Rx cell bulkhead Loosen the captive screws that secure the PMT housing to the chassis two screws secure to the side of the chassis and two screws secure to the bottom of the chassis Refer to Figure 18 Gently swing the kicker housing forward and out of the way of the UV lamp housing Grasp the Rx cell and PMT assembly by the top cross brace and gently lift it straight up out of the analyzer To separate the Rx cell from the PMT housing remove the three screws that secure t
72. ware Update What firmware to do you wish to load CATEMP4Y1 03 0008 5X Browse Details Firmware V1 03 0008 5X Date Friday 3 January 2004 3 31 07 PM Size KB 244 Figure 28 Firmware Update firmware selection screenshot 6 Click Next 7 Tick the boxes as shown in the figure below 98507601 Rev D 55 EC9850 SO ANALYZER SERVICE MANUAL pi Firmware Update Select the operations you wish to perform Enter bootloader Erase Flash ROM Erase EEPROM Erase RAM Upload Firmware O O Run Firmware Previous i Figure 29 Firmware Update operations screenshot 8 Ensure the analyzer is switched off using the switch under the front panel 9 Click Start 10 Switch the analyzer on 11 The Firmware Updater window will show each step as the firmware is uploaded DO NOT turn the analyzer off until the Close button is enabled as shown below and the Analyzer is operating as usual again pi Firmware Update Connect to Analyser Enter Bootloader OK Erase EAPROM OK Erase EEPROM SKIPPED Erase RAM SKIPPED Upload Firmware OK Verify Upload OK Run Firmware OK Previous Close Figure 30 Firmware Update completion screenshot 56 98507601 Rev D CHAPTER 4 TROUBLESHOOTING 4 0 Troubleshooting 4 1 DC Power Supply Voltages Before consulting the troubleshooting section verify that the DC power supply voltages are present and within the specifications given for each printed circuit board listed in th
73. y The FLOW CONTROL POTS screen displays the potentiometer settings associated with several components variables or signals on the A series Flow Control board Figure 32 illustrates a typical test screen for an instrument that is operating normally Like PREPROCESSOR POTS the value of the potentiometer settings is somewhat arbitrary Potentiometer settings 99 and 0 however represent the 98507601 Rev D CHAPTER 4 TROUBLESHOOTING extreme limits of the potentiometer range and may be reason to suspect a problem FLOW CONTROL POTS FLOW CONTROL ZERO 81 50 90 FAN SPEED CONTROL 16 0 99 PUMP SPEED FINE 85 0 99 PUMP SPEED COARSE 36 20 60 GAS FLOW 0 505 SLPM GAS PRESSURE 585 6 TORR Figure 32 Flow Control Pots Range 4 2 3 Valve Test Menu VALVE TEST MENU INT VALVE 1 CLOSED INT VALVE 2 OPEN INT VALVE 3 CLOSED AUX VALVE 2 CLOSED EXT MEASURE CLOSED EXT ZERO GAS CLOSED EXT SPAN GAS CLOSED VALVE SEQUENCING ON The VALVE Figure 33 Valve Test Menu TEST MENU see Figure 33 displays the current status of each valve in the instrument This menu can be particularly useful in correcting flow problems in the machine The valves can be opened and closed from this menu thus allowing the operator to determine whether valves are operating correctly Valve sequencing must be on in order for correct gas measurement to be accomplished See the EC9850 Operation Manual fo

EC9850 Service Manual

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