operation and service manual - abb group...4210-osm, d1 i list of effective pages—4210 operation...

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4210-OSM D1: January 2002

OPERATION AND SERVICE MANUALModel 4210 Freezing Point Analyzer

NOTICE

Material contained within this manual is proprietary information ofABB Inc.

and is to be used only for the purpose of understandingand operating this product.

Specifications are subject to change without notice.

©2002, ABB Inc.

For further information or assistance contact:

ABB Inc.843 North Jefferson Street

P.O. Box 831Lewisburg, WV 24901

General Information: Telephone (304) 647-4358Fax (304) 645-4236

Field Service: Telephone (304) 340-0508

Aftermarket Spares: Telephone (304) 647-1736Fax (304) 647-1837

Please include Sales Order Number, Tag Number,Analyzer Part Number and Serial Number

4210-OSM, D1 i

LIST OF EFFECTIVE PAGES—4210 Operation and Service Manual

Date of issue for each version of this manual:

A1 February 1998B1 March 1999C1 December 1999C2 June 2000C3 October 2000C4 August 2001D1 January 2002

Revision status of each page in this manual:

Page No. Revision Status

All D1

The revision status is noted at the bottom of each page of this manual.

ii 4210-OSM, D1








4210-OSM, D1 iii

TABLE OF CONTENTS

Title Page

SECTION 1. INTRODUCTION

EQUIPMENT DESCRIPTION ................................................................................................... 1-1SPECIFICATIONS..................................................................................................................... 1-2

Range .................................................................................................................................. 1-2Performance ........................................................................................................................ 1-2Sample Conditions at Analyzer ........................................................................................... 1-2Connections ........................................................................................................................ 1-2Utilities ................................................................................................................................. 1-2Air ..................................................................................................................................... 1-3

AIR PURGE SYSTEMS ............................................................................................................ 1-3

SECTION 2. INSTALLATION

PREPARING FOR INSTALLATION ........................................................................................... 2-1Installation Tools and Equipment ......................................................................................... 2-1Purge Air Alarm ................................................................................................................... 2-1

PLUMBING CONNECTIONS .................................................................................................... 2-2ELECTRICAL CONNECTIONS ................................................................................................. 2-2STARTUP .................................................................................................................................. 2-3

SECTION 3. OPERATION

CONTROLS AND INDICATORS ............................................................................................... 3-1Sample Interface ................................................................................................................. 3-1Controller Assembly ............................................................................................................ 3-2Local Keyboard ................................................................................................................... 3-2

OPERATING MODES ............................................................................................................... 3-3Automatic Mode .................................................................................................................. 3-3Manual Mode....................................................................................................................... 3-3

ADJUSTING THE OPERATING PARAMETERS ...................................................................... 3-3OPERATING STATES ............................................................................................................... 3-4

Flush ................................................................................................................................... 3-4Rest ..................................................................................................................................... 3-4Cool ..................................................................................................................................... 3-4Warm ................................................................................................................................... 3-5Ready .................................................................................................................................. 3-5Washing .............................................................................................................................. 3-5Standby ............................................................................................................................... 3-5Error .................................................................................................................................... 3-5

ALARMS ................................................................................................................................... 3-6Fast Loop Low Flow Error ................................................................................................... 3-6Filter Differential Pressure Error .......................................................................................... 3-6Analyzer Low Flow Error ..................................................................................................... 3-6Low Standard Level Error.................................................................................................... 3-6External Error ...................................................................................................................... 3-6Low Difference Error ........................................................................................................... 3-6High Difference Error ........................................................................................................... 3-6Low Sample Error................................................................................................................ 3-7

iv 4210-OSM, D1

TABLE OF CONTENTS (continued)

Title Page

Low Calibration Sample Error ............................................................................................. 3-7High Sample Error ............................................................................................................... 3-7High Calibration Sample Error ............................................................................................. 3-7Cool Time-Out Error ............................................................................................................ 3-7Warm Time-Out Error .......................................................................................................... 3-7Low Sample Temperature Error .......................................................................................... 3-7

OUTPUTS ................................................................................................................................. 3-7Measuring Signals ............................................................................................................... 3-7Relay Outputs ...................................................................................................................... 3-8Sample Temperature Sensor ............................................................................................... 3-8Printer Output ...................................................................................................................... 3-8

INPUTS ..................................................................................................................................... 3-8External Commands Inputs ................................................................................................. 3-8External Alarms and Warnings Inputs ................................................................................. 3-9

CONFIGURATION PARAMETERS ........................................................................................... 3-9Sample Time ..................................................................................................................... 3-10Rest Time .......................................................................................................................... 3-10Wash Time ........................................................................................................................ 3-10Ready Time ........................................................................................................................ 3-11Cool Time-Out .................................................................................................................... 3-11Cooling Rate....................................................................................................................... 3-11Warming Time-Out ............................................................................................................. 3-11Warming Rate .................................................................................................................... 3-11Freezing Point Range Minimum ......................................................................................... 3-11Freezing Point Range Maximum ........................................................................................ 3-11Calibration Range Minimum ............................................................................................... 3-11Calibration Range Maximum .............................................................................................. 3-11Freezing Point Offset ..........................................................................................................3-11Calibration Offset ................................................................................................................ 3-11Range Offset ..................................................................................................................... 3-12Detector Threshold ............................................................................................................ 3-12Detector Offset .................................................................................................................. 3-12Hold-Off Time .................................................................................................................... 3-12Auto Wash Frequency ....................................................................................................... 3-12Display Width .................................................................................................................... 3-12Relay Outputs - Logical Inputs .......................................................................................... 3-12Cooling Control Parameters .............................................................................................. 3-12Additional Parameters ....................................................................................................... 3-13

SECTION 4. TECHNICAL DESCRIPTION

OPERATING PRINCIPLE ......................................................................................................... 4-1SYSTEM OVERVIEW ............................................................................................................... 4-1SAMPLE INTERFACE .............................................................................................................. 4-2ANALYSIS ASSEMBLY ............................................................................................................. 4-3CONTROLLER ASSEMBLY ...................................................................................................... 4-5

Power Supply ...................................................................................................................... 4-5Controller Electronics .......................................................................................................... 4-6

X PURGE .................................................................................................................................. 4-8X Purge Operation............................................................................................................... 4-8X Purge Override Option ..................................................................................................... 4-9

4210-OSM, D1 v

TABLE OF CONTENTS (continued)

Title Page

SECTION 5. MAINTENANCE

PREPARATION FOR MAINTENANCE ..................................................................................... 5-1USING THE LOCAL KEYBOARD ............................................................................................. 5-1TROUBLESHOOTING INSTRUCTIONS .................................................................................. 5-3CONTROLLER ASSEMBLY REPAIR ........................................................................................ 5-3

Opening the Controller Assembly ........................................................................................ 5-3Replacing Printed Circuit Boards ........................................................................................ 5-3Closing the Controller Assembly ......................................................................................... 5-5Replacing the Pressure Gauge ........................................................................................... 5-6Replacing the Pressure Regulator ...................................................................................... 5-6

ANALYSIS ASSEMBLY REPAIR ............................................................................................... 5-7Opening the Analysis Assembly .......................................................................................... 5-7Replacing the Cell Control Board ........................................................................................ 5-7Replacing the Light Source Lamp ....................................................................................... 5-7Replacing the Photodiode Detector ..................................................................................... 5-8Removing and Reinstalling the Detector Cell ...................................................................... 5-8

CONTROLLER ASSEMBLY ADJUSTMENTS........................................................................... 5-8Processor (CPU) Board ...................................................................................................... 5-9Signal-Analog Outputs Board ............................................................................................ 5-10Acquisition Board ............................................................................................................... 5-11LCD VGA Controller Board................................................................................................ 5-12Temperature Sensor Interface Board ................................................................................ 5-12Power Supply Board.......................................................................................................... 5-14

ANALYSIS ASSEMBLY ADJUSTMENTS ................................................................................ 5-15

SECTION 6. REPLACEMENT PARTS

ORDERING INFORMATION ..................................................................................................... 6-1ANALYSIS ASSEMBLY ............................................................................................................. 6-2CONTROLLER ASSEMBLY ...................................................................................................... 6-3X PURGE ASSEMBLY .............................................................................................................. 6-4

vi 4210-OSM, D1

ILLUSTRATIONS

Figure Description Page

1-1 Freezing Point Analyzer........................................................................................... 1-1

2-1 X Purge Assembly, Showing Alarm Connections..................................................... 2-12-2 Plumbing Connections ............................................................................................. 2-22-2 Electrical Connections ............................................................................................. 2-3

3-1 Freezing Point Analyzer .......................................................................................... 3-13-2 Sample Interface Controls and Indicators .............................................................. 3-13-3 Controller Assembly Controls and Indicators ......................................................... 3-23-4 Typical Configuration Parameters Table ............................................................... 3-10

4-1 System Block Diagram ........................................................................................... 4-14-2 Sample Interface Flow Diagram ............................................................................. 4-34-3 Analysis Assembly Block Diagram ......................................................................... 4-44-4 Power Supply Block Diagram ................................................................................. 4-54-5 Controller Electronics Block Diagram ..................................................................... 4-74-6 X Purge with Cover Removed ................................................................................ 4-8

5-1 Operating Screen .................................................................................................... 5-25-2 Printed Circuit Board Location ................................................................................. 5-45-3 CPU Board Connections ......................................................................................... 5-55-4 Controller Assemby and Gauge Panel .................................................................... 5-65-5 Processor Board Adjustments ................................................................................. 5-95-6 Signal-Analog Outputs Board Adjustments ........................................................... 5-105-7 Acquisition Board Adjustments ............................................................................... 5-115-8 LCD VGA Controller Board Adjustments ............................................................... 5-125-9 Temperature Sensor Interface Board Adjustments ................................................ 5-135-10 Power Supply Board Jumper Location .................................................................. 5-15

6-1 Analysis Assembly .................................................................................................. 6-26-2 Controller Assembly ................................................................................................ 6-36-3 X Purge Assembly .................................................................................................. 6-4

4210-OSM, D1 1-1

SECTION 1. INTRODUCTION

EQUIPMENT DESCRIPTION

The Freezing Point Analyzer (see Figure 1-1) consists of an X Purge Assembly, a ControllerAssembly, an Analysis Assembly, and a Sample Interface, mounted on a single chassisintended for attachment to the floor. Since all the equipment is accessible from the front ofthe chassis, the analyzer may be installed without rear access.

Figure 1-1. FREEZING POINT ANALYZER

The X Purge Assembly monitors Controller Assembly air purge pressure and removes powerto the analyzer after a drop in the Controller Assembly air purge pressure.

The Controller Assembly contains the power supplies, control electronics and the LCDscreen.

The Analysis Assembly contains the light source, measuring cell, photodiode detector, andthree temperature probes.

The Sample Interface, mounted on the sample plate, contains:

• the sample in valve

• the calibration in valve

X PURGEASSEMBLY

CONTROLLERASSEMBLY

ANALYSISASSEMBLY

SAMPLEINTERFACE

1-2 4210-OSM, D1

• the flowmeter for control of the sample flow, with associated needle valve

• the flowmeter for control of the cooling water flow, with associated needle valve

• shutoff valves at the WATER INLET, the CALIBRATION INLET, and the SAMPLE INLET

The air pressure regulator and associated pressure gauge, which provide air for valveswitching, are located between the Controller Assembly and the Analysis Assembly.

SPECIFICATIONS

CAUTION

Specifications are subject to change without notice.

Range

Up to two ranges programmable from -60° C to -10° C. The second range can be dedicatedeither to auto-calibration on a standard or to a second measurement stream.

Performance

Precision: within the standard laboratory test, ASTM D2386-88

Repeatability: ±0.5° C with 4-20 mA analog transmission

Cycle Time: programmable to balance correlation to laboratory testand optimized response time—typically three to eightminutes, depending on the application.

Sample Conditions at Analyzer

Pressure: 0.5 to 2 bars g

Temperature: -10° C to +50° C

Sample Flow Rate: about 20 liters/hour of continuous flow through the bypasscircuit

Ambient Temperature:the analyzer can be operated from 0° to 40° C, but thisdoes not correspond to the sample temperature limitation;therefore, it is recommended that the ambienttemperature be maintained between 20° and 35° C.

Connections

Sample Inlet/Outlet: 1/4-inch tube connection

Electrical: CENELEC and NEC

Utilities

Electrical: 115 V ±10%, 50 to 60 Hz; or 230 V ±10%, 50 to 60 Hz

4210-OSM, D1 1-3

Cooling Water: 30 liters/hour of clean water (maximum temperaturedepends on application)

Air

Instrument air is required for valve actuation.

Pressure: 4 to 7 bars g

Consumption approximately 300 liters per hour

AIR PURGE SYSTEMS

If the analyzer will be in a Class I hazardous location, an air purging system must be installedto reduce the risk of explosion. Class I locations are those in which flammable gases orvapors are or may be present in quantities sufficient to produce explosive or ignitablemixtures.

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4210-OSM, D1 2-1

SECTION 2. INSTALLATION

PREPARING FOR INSTALLATION

The analyzer should preferably be installed in a shelter with an ambient temperaturebetween 5 and 40° C. Since the construction and certification of the equipment authorizesits installation near analyzers which use or analyze hydrogen, it is possible to install thesedevices in the same room. The sampling, air, and water needs and the electricalconsumption are specified in Section 1.

Installation Tools and Equipment

The following tools and equipment are required to install and check out the analyzer.

Tools: #2 Phillips screwdriver#1 Phillips screwdriver3/16-inch flat blade screwdriver1/8-inch flat blade screwdriver1 set of metric open-end wrenches6-inch adjustable wrench12-inch adjustable wrench1 set of metric hex key wrenches

Equipment: Leak testing solution (e.g., Snoop®)Flow meterStop watch (if not using a digital flow meter)Chart recorderMultimeter

Purge Air Alarm

The analyzer contains circuits that detect the loss of purge air to the analyzer. These purgealarm circuits, which comprise the automatic safety device required by certification agencies,turn off analyzer power and generate alarm signals to the customer. The analyzer's purgealarm connections are located in the X Purge Assembly, as shown in Figure 2-1. Thecustomer has the responsibility to connect the purge alarm to a visual or audible annunciatorlocated in a constantly monitored area.

Figure 2-1. X PURGE ASSEMBLY, SHOWING ALARM CONNECTIONS

ALARMCONTACTS

2-2 4210-OSM, D1

PLUMBING CONNECTIONS

Connect the various inputs (WATER INLET, SAMPLE INLET, CALIBRATION INLET, and AIRINLET) to the Sample Interface as indicated in Figure 2-2 and verify each connection is tightand free from leakage.

Figure 2-2. PLUMBING CONNECTIONS

Connect the SAMPLE BYPASS VENT to the customer's sample return line. Connect theWATER OUTLET to a drain or a recirculation system as appropriate for the facility.

ELECTRICAL CONNECTIONS

CAUTION

All primary power and signal cables must be in conduit if the analyzeris located in a hazardous area.

Connect the various electrical lines as indicated in Figure 2-3 and verify each cableconnection before placing the analyzer in operation.

AIR INLET

SAMPLEBYPASS VENT

SAMPLE INLET

CALIBRATION INLET

WATER INLET

4210-OSM, D1 2-3

Figure 2-3. ELECTRICAL CONNECTIONS

STARTUP

WARNING

Ensure that the cooling water is flowing through the detector cell priorto applying power to the analyzer.

After verifying the various connections, apply power to the analyzer. Verify on the LCDscreen of the Controller Assembly that startup takes place without any error message (whichcould otherwise indicate a change of certain data files).

PowerFilter

TB61

InputPower

123456

CalibrationRequest

Standby(NO Contact)

Trend/Continuous 131415161718

13151719

Calibrationin Process

Calibration Signal4 - 20 mA isolated

Measuring Signal 4 - 20 mAisolated 750 ohm load

Output Valid

CONTROLLER ASSEMBLY

+

+-

-

NOTE: All relay contactsare voltage free.

RelayContacts

L1L2

GND

78

Error

Warning

RelayPCB

ConnectorRS-403-314 3

TB60

462

X PurgeUnit

1

1 These areexternally poweredrelay controls thatwill be connectedthrough anintrinsically safe(IS) barrier or othersuitable method ofprotection for thearea classification.

2-4 4210-OSM, D1

The LCD screen will indicate whether the analyzer is in “Manual” or in “Auto”. If necessarychange to “Manual” to open the sample valve, by pressing the "M" key on the keyboard.

Before you run an analysis you should purge the air and fluid lines, to eliminate any trappedmatter that could later be harmful to the operation of the analyzer.

Test all connections with a leak detection solution (e.g., Snoop®).

Adjust the WATER INLET and SAMPLE INLET flows on the Sample Interface, using theassociated needle valve of the appropriate flow meter.

Adjust the purge air pressure to 40 psig using the pressure gauge and associated pressureregulator.

Change to “Auto” to start the first measurement cycle by pressing the "A" key on thekeyboard.

4210-OSM, D1 3-1

SECTION 3. OPERATION

CONTROLS AND INDICATORS

The Freezing Point Analyzer's subassemblies are identified in Figure 3-1 and described inthe following paragraphs.

Figure 3-1. FREEZING POINT ANALYZER

Sample Interface

The controls and indicators for the Sample Interface are shown in Figure 3-2.

Figure 3-2. SAMPLE INTERFACE CONTROLS AND INDICATORS

X-PURGE

CONTROLLERASSEMBLY

ANALYSISASSEMBLY

SAMPLEINTERFACE

WATER FLOW ADJUST

SAMPLE FLOW ADJUST

SAMPLE FLOWMETER

PRESSURE GAUGE

SAMPLE VALVE

CALIBRATION VALVE

WATER FLOWMETER

WATER VALVE

3-2 4210-OSM, D1

Controller Assembly

The controls and indicators for the Controller Assembly are shown in Figure 3-3.

Figure 3-3. CONTROLLER ASSEMBLY CONTROLS AND INDICATORS

Local Keyboard

For adjustment and service usage, a control keyboard can be connected to the analyzer bymeans of a connector on the Processor PCB in the Controller Assembly.

WARNING

Before opening any analyzer doors or covers, ensure the area is safeand hazard-free and will remain so the entire time the analyzer is open.

Connect the local keyboard as follows:

1. Turn the Controller Assembly front panel latches full counterclockwise with a 5/16-inch(or 8 mm) hex key wrench.

2. Open the Controller Assembly front panel.

3. Locate the cable with the open connector on the left side of the enclosure and connectthe keyboard cable to it.

4. The operating screen should appear on the display.

The following commands are available by one-touch keying:

M (Manual): allows you to shift from automatic mode to manual mode.

N (Next step): in manual mode, this key allows you to follow, step by step, the differentphases of operation of the apparatus.

S (Standby): allows you to set the analyzer locally into “Standby.”

COOLERCONTROL PCB

POWERSUPPLY

PROCESSOR PCB SIGNAL-ANALOGOUTPUTS PCB

ACQUISITION PCB

LCD VGACONTROLLER PCB

TEMPERATURESENSOR INTERFACE

PCB

RELAYPCB

CABLE FORKEYBOARD

PRESSUREGAUGE REGULATOR

4210-OSM, D1 3-3

A (Auto): allows you to return to the automatic mode from the manual mode.

C (Calibration): when this key is activated, a calibration cycle will follow immediately afterthe end of the cycle in progress.

Q (Quit): allows you to stop the program and return to DOS control.

Esc (Escape): allows you to stop the program and display the configuration parameters.

OPERATING MODES

The analyzer has two operating modes: automatic and manual.

Automatic Mode

This is the normal (default) operating mode of the analyzer. Calibration, an operating optionin automatic mode, may be requested by the user by means of a local keyboard or byvoltage-free relays. During a calibration cycle, the calibration sample is admitted into theanalyzer by the calibration valve.

The control program of the analyzer operates a loop that refreshes data eight times eachsecond and stores a time count. All analog and digital inputs are monitored and analogoutputs are refreshed during each loop.

The operating cycle (or analysis cycle) is determined by the time required to perform ananalysis. The sequences within this cycle present different operating modes and states, asexplained in the following paragraphs.

Manual Mode

This may be selected using a local keyboard. Manual Mode is used when adjustingoperating parameters and when servicing the analyzer.

ADJUSTING THE OPERATING PARAMETERS

The operating parameters may be adjusted using a local keyboard. Normally theseparameters are set at the factory and are listed on the supplied Data Sheet. However, insome cases it may be necessary to adjust one or more parameters to compensate for sitevariations. If it is necessary to adjust any of the parameters, proceed as follows:

WARNING

Before opening any analyzer doors or covers, ensure the area is safeand hazard-free and will remain so the entire time the analyzer is open.

1. Connect the local keyboard as described in "Local Keyboard."

2. The operating screen should appear on the display.

3. Press the Esc key. A list of sample streams (0 through 3) appears on the display.

4. Select the appropriate stream using the "up" and "down" arrow keys.

5. Press the Enter key.

3-4 4210-OSM, D1

6. In the parameters table, you can change any parameter by using the "up" and "down"arrow keys to select that parameter.

7. To change a parameter enter the desired number when the cursor is in that parameter'sfield.

8. When you have finished with the parameters table, press the Esc key.

9. Select Y (yes) to save your changes or N (no) to retain the original values.

10. Press Esc to return to the main screen and continue the analysis.

OPERATING STATES

The analyzer has eight operating states or phases: flush, rest, cool, warm, ready, washing,standby, and error. During normal operation, the display will indicate the active state.

Flush

During the flush phase, the cell is purged by the fresh sample that then runs off to thesample return. The sample is usually that of the process to be controlled. In the case of acalibration cycle, it is the standard product. The duration of the flush phase is a userprogrammable parameter. The duration setting is usually between 30 and 60 seconds.

Rest

During the rest phase, the sample valve is closed so that the cell temperature and thedetector signal can stabilize. While the duration of this phase may be changed by means ofa user programmable parameter, it is usually set at about 30 seconds.

Cool

During the cool phase, the thermoelectric elements are supplied as follows.

If the cell temperature is higher than the maximum value of the measure range,the supply is at its maximum value.

If the cell temperature is within the measure range but 3° C higher or lower thanthe previously detected freezing point, the cooling rate is in high mode.

If the cell temperature is within an interval of ± 3° C of the previously detectedfreezing point, the cooling rate is in low mode.

In the first operating cycle, when there has been no previous detection, only thehigh cooling rate is used.

The cooling rate is not measured or adjusted directly. A temperature ramp is generated as asetpoint and the cooling power is modulated at the output in order to minimize the differencebetween the ramp temperature and the effective temperature of the cell at the same time.

During the cooling phase, the output signal of the detector is controlled. After a HOLD-OFFTIME that begins at the start of the cooling phase, if the optical detector signal varies bymore than a threshold value, it is considered that a freezing point has been reached. Whena freezing point is detected, the cooling phase terminates and the analyzer is switched to theWARM phase.

4210-OSM, D1 3-5

If COOLER TIME-OUT is reached before detection of a freezing point, the analyzer isswitched again to the flush phase and a warning is emitted (COOLER TIME-OUT).

The low and high cooling rates, the hold-off time, the cooler time-out, and the detectionthreshold may be changed by user-programmable parameters. Typically, the high coolingrate is 5° C per minute, the low cooling rate is 1° C per minute, the detection threshold is 0.3Volts, the hold-off time is 30 seconds, and the cooler time-out is 10 minutes.

If the difference between the ramp temperature and the effective cell temperature is higherthan 8° C, a cooling error is emitted and the following state will be ERROR.

Warm

When the first detection occurs (according to the detector threshold which has been set inthe parameter table), the thermoelectric coolers are supplied in such a way that the celltemperature can increase again slowly.

The warming rate is not measured or adjusted directly. A temperature ramp is generated asa setpoint and the warming power is modulated at the output in order to minimize thedifference between the ramp temperature and the effective temperature of the cell at thesame time.

During the warming phase the output signal of the detector is controlled. When the opticaldetector signal comes back to the previous detection level—plus the eventual detectionoffset—it is considered that the crystals have melted and the current cell temperature isconsidered the final freezing point value. At this point the warming phase terminates and theanalyzer switches to the READY phase.

Ready

During the ready phase, the state relay is active/inactive (customer selected), the 4 to 20 mAoutput signal is updated and any warning message on the display is deleted.

Washing

If a wash state has been requested by means of a local keyboard or by logic input from anexternal source, a wash may be triggered right after the ready phase.

During this wash phase, an optional valve would be actuated and the retained solvent wouldpurge the cell. The duration of this phase is user-programmable and typically set at 30seconds.

Standby

The standby state may be selected manually by means of a local keyboard or by logic inputfrom an external source. During standby, the sample valve is open and the sample flowsthrough the cell to the sample return or not, depending on the parameter settings. The two 4to 20 mA signals then follow the cell temperature, allowing the calibration of the temperaturesensor to be verified and adjusted. Any stored freezing point value is then cancelled, as wellas any possible alarms or warnings.

Error

This state corresponds to an operating error.

3-6 4210-OSM, D1

A lamp fault is detected by lamp current measurement. Accordingly, a low value maycorrespond to an open circuit and a high value to a short circuit. In the case of such an errordetection, this state will be cancelled if the original conditions are reestablished. A looselamp leads to an error condition that will automatically trigger, for example on tightening. Thetransmission of the error state will follow the same mode.

However, a cooling error state may only be acknowledged by toggling to “Standby” state andback again.

ALARMS

Alarms do not usually degrade the operating cycle. An alarm will toggle the respective relayand issue a message on the printer, if it is connected. The possible alarms are describedbelow.

Fast Loop Low Flow Error

This error is emitted by a sample system flow relay; it indicates that the fast loop flow is lowerthan the set threshold.

Filter Differential Pressure Error

This error is emitted by a differential pressure relay to the terminals of the filter; it indicatesan excessively high loss of load, probably due to clogging of the filter cartridge.

Analyzer Low Flow Error

This error is emitted by a flowmeter warning relay; it indicates that during the “Flush” phase,the sample flow to the analyzer is insufficient. A delay is added to this function in order toabsorb the read fluctuation that may arise when the sample intake valve opens.

Low Standard Level Error

This error is emitted by a low level contactor on standard product reserve; it indicates thatthere is an insufficient quantity of product to run a calibration cycle. Since the calibration istriggered manually, there is no cycle inhibit when this error condition occurs.

External Error

This error is emitted by a voltage-free relay; it will be shown on the display, issued by theprinter and actuate the alarm relay. This type of error may be used for any type ofinformation delivered by the system (temperature warning, for example).

Low Difference Error

This error is emitted when a freezing point is detected with a value of more than 3° C belowthe previous value.

High Difference Error

This error is emitted when a freezing point is detected with a value of more than 3° C abovethe previous value.

4210-OSM, D1 3-7

Low Sample Error

This error is emitted when a freezing point of the input sample is detected with a value lowerthan the range start.

Low Calibration Sample Error

This error is emitted when a freezing point of the standard (calibration) sample is detectedwith a value lower than the range start.

High Sample Error

This error is emitted when a freezing point of the input sample is detected with a value higherthan the range end.

High Calibration Sample Error

This error is emitted when a freezing point of the standard (calibration) sample is detectedwith a value higher than the range end.

Cool Time-Out Error

This error is emitted for a time-out higher than a predetermined value. When it is emitted,cooling halts and the analyzer switches to “Flush” phase instead of “Ready” phase.

Warm Time-Out Error

This error is emitted for a time-out higher than a predetermined value. When it is emitted,warming halts and the analyzer switches to “Flush” phase instead of “Ready” phase.

Low Sample Temperature Error

This error is emitted for an insufficient cell temperature increase after the intake of freshproduct.

The difference should be at least 14° C higher than the last freezing point value detected.Experience has shown that if this value is not reached, the repeatability and precision of themeasurements may be altered.

OUTPUTS

Measuring Signals

The two outputs of 4 to 20 mA are for the following:

• memorized values of freezing point measurements

• cell temperature follow-up

3-8 4210-OSM, D1

Relay Outputs

The NO or NC operating state may be modified by user programmable parameters.

Read Relay: This relay is activated when the freezing point measurement signal is validated.It is not activated when the signal is invalid, and its duration is programmable (usuallytwo seconds). At the same time the analog measurement signal is updated.

Calibration Relay: This relay is activated for the duration of each new calibration cycle.

Alarm Relay: This relay is activated if an alarm condition has been detected.Acknowledgement is automatic if the condition disappears.

Warning Relay: This relay is activated if a warning condition is detected. This error levelcan only be acknowledged by manual intervention.

Sample Temperature Sensor

A Pt 100 probe with two-wire connection is placed downstream from the measurement cellinput and may optionally allow delivery of a pneumatic signal at the analyzer output. It isalso possible to control a valve that routes the sample to a temperature exchanger.

Printer Output

The analyzer can also be connected to a serial printer through the RS232 COM 1 port. Thetransmission speed is 9,600 baud, 8 data bits, no parity, 2 stop bits. At the end of eachcycle, the freezing point value is reported, preceded by the date and the time. The report iscompleted by the identification of the cycle: “PRODUCT SAMPLE" or “CALIBRATION”.

If an error or warning condition arises, it will be reported on the printer.

INPUTS

External Commands Inputs

These inputs are for the terminal boards on which the normally closed relays will activate thefunction.

Calibration: After activation, this input will trigger a calibration cycle that will start at the endof the cycle in progress, if any. When a freezing point is detected during a calibrationcycle, the second 4 to 20 mA signal is updated instead of the first signal.

Measurement Memory/Follow-Up: After activation, this input will trigger each 4 to 20 mAanalog output in continuous follow-up mode. This mode permits verification of theproper settings of the electronics.

Standby: After activation, the analyzer is set into “Standby” and the sample runscontinuously through the cell, or does not run (customer selected).

After deactivation, the analyzer starts a new cycle in “Flush” phase.

4210-OSM, D1 3-9

This logical input may also be used to reinitialize the state of the analyzer. In this case,there is acknowledgement of the error messages and reinitialization of the calibrationvalues.

Selecting a Set of Parameters: There are four sets of user-programmable parameters.The set used by the analyzer is determined by the state of two relays: Selection Relay 1and Selection Relay 2.

SELECTION RELAY 1 STATE : 0 : 1 : 0 : 1 :SELECTION RELAY 2 STATE : 0 : 0 : 1 : 1 :SELECTED SET OF PARAMETERS : 0 : 1 : 2 : 3 :

External Alarms and Warnings Inputs

These six supplementary inputs each consist of one pair of terminals from which the state ofa relay (NO or NC according to the parameters set) permits the signalling of an externalalarm or warning state.

Fast Loop Low Flow: This alarm indicates that the flow value has dropped below apredetermined value on the detection sensor.

High Filter Differential Pressure: This alarm indicates that the pressurestat connected tothe terminals of the input filter has been triggered and that the filter is very probablyclogged.

Low Analyzer Flow: This alarm indicates that the flow in flush phase is lower than apredetermined value.

Low Standard Level: This alarm indicates that the level of standard remaining in reserve isinsufficient to run a calibration cycle.

External Alarm: This alarm indicates that an external relay has been activated. It is alsopossible to protect the analyzer and its proper operation with one or more peripheralwarnings and transmit them to the control room as a general alarm.

External Warning: This warning stops the operation of the analyzer and is transmitted to thecontrol room.

CONFIGURATION PARAMETERS

The analyzer may be configured using the local keyboard, as described in "Local Keyboard."

Moreover, the parameters accessible to the user may be changed. There are four sets ofparameters (0 to 3). The set of parameters used by the analyzer is determined by the stateof two voltage-free remote-linked relays.

To access the configuration parameters:

1. While an analysis is running, press the Esc key on the keyboard (this stops theanalysis).

2. When the parameters menu appears, cursor down to the desired set of parameters andthen press the Enter key.

3-10 4210-OSM, D1

3. When the selected set of parameters appears (see Figure 3-4), you can change anyparameter by using the up and down cursor keys to select that parameter.

Sample No 0SAMPLE TIME 60 S READY RELAY N/C 0REST TIME 3 S ERROR RELAY N/C 0WASH TIME 30 S WARNING RELAY N/C 0READY TIME 3 S CALIBRATE RELAY N/C 0COOL TIME OUT 15 M PRODUCT VALVE INVERT 1COOLING RATE 7.0 °C/M PRINTER O/P ENABLE 1WARM TIME OUT 15.0 M PROD VALVE IN STANDBY 1WARMING RATE 3.0 °C/M FAST LOOP FLOW N/C 0FREEZPOINT RANGE MIN -60 °C FILTER PRESSURE N/C 0FREEZPOINT RANGE MAX -30 °C ANALYZER FLOW N/C 0CALIBRATE RANGE MIN -60 °C CALIBRATE SAMPLE N/C 0CALIBRATE RANGE MAX -30 °C EXTERNAL WARNING N/C 0FREEZPOINT OFFSET +0.0 °C EXTERNAL ERROR N/C 0CALIBRATE OFFSET +0.0 °C SAVE PCX 0RANGE OFFSET 32 °C ERROR GAIN 17DETECTOR THRESHOLD 0.30 V INTEGRAL GAIN 7DETECTION OFFSET 0.0 V DERIVATIVE GAIN 3HOLD OFF TIME 3 S*10 MAX COOLANT TEMP +32AUTO WASH FREQUENCY 0DISPLAY WIDTH 900 S

Figure 3-4. TYPICAL CONFIGURATION PARAMETERS TABLE

4. To change a parameter, enter the desired number when the cursor is in that parameter'sfield.

5. When you have finished with the parameter table press the Esc key.

6. Select Y (yes) or N (no) to save your changes.

7. Press Esc to return to the main screen and continue the analysis.

Sample Time

The sample time may be selected in the range of 15 to 120 seconds. If the sample time istoo short, it may give rise to low temperature warnings and/or precision and repeatabilityproblems.

Rest Time

This time may be selected from between 15 and 120 seconds. If the rest time is too short, itmay give rise to false detection. This may be remedied by extending the hold-off time, whichis part of the cooling sequence.

Wash Time

The wash time may be selected from between 15 and 120 seconds. The optimal wash timedepends entirely on the sample function. The use of solvent to wash the interior of the cell isonly necessary in the case of particularly difficult samples.

4210-OSM, D1 3-11

Ready Time

This time may be set from 1 to 5 seconds.

Cool Time-Out

The cool time-out may be set from 1 to 10 minutes in one-minute increments. This timeshould be selected to avoid false warnings.

Cooling Rate

The cooling rate may vary from 0.1 to 9.9° C/minute. It should usually be set to 5° C/minute.

Warming Time-Out

The warming time-out may be set from 1 to 10 minutes in one-minute increments.

Warming Rate

The warming rate may vary from 0.1 to 9.9° C/minute. It should usually be set between 0.8and 1.0° C/minute.

Freezing Point Range Minimum

This value should be set between -60° C and -10° C by whole values of 1° C and be at least8° C lower than the selected maximum freezing point range value.

Freezing Point Range Maximum

This value should be set between -60° C and -10° C by whole values of 1° C and be at least8° C higher than the selected minimum freezing point range value.

Calibration Range Minimum

This is the same as Freezing Point Range Minimum, but for the calibration samples.

Calibration Range Maximum

This is the same as Freezing Point Range Maximum, but for the calibration samples.

Freezing Point Offset

This offset may be adjusted across the range from -16 to +16° C. It is added to the celltemperature when a freezing point is detected in order to obtain a value that will then beshown, transmitted and printed. This offset value is used to correlate the laboratory analysisvalue with the value indicated by the analyzer.

Calibration Offset

This is the same as Freezing Point Offset, but for the calibration samples.

3-12 4210-OSM, D1

Range Offset

The range offset may be between 0 and +40° C in increments of 1° C. This parameterallows the analyzer measurement range to be shifted to negative values.

Example:

If the typical range of the analyzer is -50° C to -20° C and a range offset of -4° Cis selected, the resulting range will be -54° C to -24° C.

Detector Threshold

The detector threshold may be selected between 0 and 2.5 Volts in increments of 0.01 Volt.This allows acceptance of detection differences that could be linked to the nature of thesample.

Detector Offset

The detection offset may be between 0 and 2.5 Volts in increments of 0.01 Volt.

Hold-Off Time

The hold-off time is set in seconds x 10 (i.e., a setting of 3 equals 30 seconds hold-off time).

Auto Wash Frequency

This function has not yet been implemented.

Display Width

This may be set in increments of 1 second. Display Width allows you to reduce or increasethe period of time displayed in the graphics window of the display (like the time base rate onan oscilloscope).

Relay Outputs - Logical Inputs

Each of the relay functions may correspond to an open or closed contact when the relay is tobe activated. Each of the logical input functions may be controlled by opening or closing arelay, depending on the requirements of the site.

The following is a list of the relay outputs and logical inputs:

4210-OSM, D1 3-13

OUTPUTS INPUTSReady relay Fast loop flowError relay Filter pressureOperation warning relay Analyzer flowCalibration relay Calibrate sample level

External warningExternal errorError gainIntegral gainDerivative gainMax coolant temp

Cooling Control Parameters

In order to align the cooling control operation, three parameters are accessible to the user:proportional, integral and derived. Each parameter may be adjusted between 0 and 99.

The following procedure should be used:

1. Adjust the proportional parameter to 10 while the integral and derived parameters areset to 0.

2. Run the analyzer and change the proportional parameter until the characteristicdamping of the cell temperature displays ripples.

3. Progressively increase the derived parameter in order to reduce the observed ripples toa minimum.

4. When the damping has reached its maximum (minimum ripple), an offset is usuallyobserved between the target temperature and the cell temperature, with this offset risingas the cell temperature drops. This offset may be reduced by increasing the value ofthe integral parameter.

Generally speaking, it is not advisable to try to eliminate completely all forms of ripple in thetemperature measurement, but rather to find the best possible compromise. The absence ofvariations of the same type on the 4 to 20 mA analog follow-up of the cell temperature willindicate a good compromise.

Additional Parameters

The user has access to two supplementary parameters that influence and force theoperation of the analyzer:

Product valve in standby: determines whether this valve will remain open (1) or closed (0)in “standby” mode.

Sample temperature error: determines whether a difference of less than 14° C between thesample temperature and the last detected freezing point value will be considered adeterminant (1) or operational (0) error.

3-14 4210-OSM, D1








4210-OSM, D1 4-1

SECTION 4. TECHNICAL DESCRIPTION

OPERATING PRINCIPLE

The Freezing Point Analyzer is used to measure the freezing point of a liquid hydrocarbonsample. First the sample is cooled, causing wax crystals to form. These crystals create adetector cell output, stopping the cooling cycle. When the cooling cycle stops the sampletemperature begins to rise, melting the wax crystals. The freezing point is defined as thattemperature where wax crystals disappear when the sample is allowed to warm up after thecooling phase.

One of the main components of the analyzer system is the detector cell, which operates asan optical latch or switch. When there are no wax crystals in the sample, no light is detectedand hence no output from the detector. When wax crystals are present, light is refracted tothe photodiode detector via the light guide, producing an output. The control circuitry of theanlayzer correlates the detector signal transition from signal to no-signal with thetemperature, to define the freezing point.

The remaining components of the analyzer system control and monitor temperature, cycletime, and operating states. In addition, the analyzer sends reports and operating status to thecontrol room via a printer, relay contacts, or a computer.

SYSTEM OVERVIEW

The Freezing Point Analyzer consists of a Sample Interface, an Analysis Assembly and aController Assembly. Refer to the system block diagram in Figure 4-1 for the followingdiscussion.

Figure 4-1. SYSTEM BLOCK DIAGRAM

SAMPLEINTERFACE

Contact Closures

Printer Input

Recorder Input

Detector Signal

Sample Temperature

Coolant Temperature

Cell TemperatureANALYSISASSEMBLY

CONTROLLERASSEMBLY

Cooler Control Voltage

Sam

ple

Valv

e C

ontro

l

Cal

ibra

te V

alve

Con

trol

Air I

n

Sample InSample Return

Water InWater Out

Sample In

Sample ReturnWater In

Water Out

Calibration In

Air Supply

Primary Power In

4-2 4210-OSM, D1

The Sample Interface provides the components to handle and control the sample input, thecalibration input, the cooling water input, and the instrument air input. The Sample Interfacecontrols the sample flow rate, and whether the sample or the calibration inputs are sent tothe detector cell. The Sample Interface also controls the flow rate of the cooling water,coupled to the heat exchangers within the Analysis Assembly. The instrument air pressure isset by a pressure regulator in the Sample Interface and is coupled to the ControllerAssembly solenoid valves, which provide valve control, and to the Analysis Assembly toprovide purge air.

The Analysis Assembly contains the detector cell and temperature probes to sense thesample, coolant, and cell temperatures, which are coupled to the Controller Assembly. Thecooler control voltage from the Controller Assembly is connected to the thermoelectriccoolers in the Analysis Assembly, which cool the detector cell. When the freezing point isdetected, a signal is generated and sent to the Controller Assembly.

The Controller Assembly has two main subassemblies: the Power Supply and the ControllerElectronics. The Power Supply contains the power supplies that provide operating voltagesfor the Controller Electronics, the Cooler Control Board that provides the control voltage tothe thermoelectric coolers in the Analysis Assembly, and the solenoid valves to provide theair control for the sample and calibration valves. In addition, the Power Supply contains theterminal board connections for peripheral equipment, such as a printer and/or a recorder.The Controller Electronics provides the operating control for the analyzer through the internalCPU and associated circuitry, by establishing cycle times, operating states, solenoid valvecontrol, data handling, and data outputs for peripheral equipment. The Controller Electronicsalso accepts the detector signal for processing and monitors the three temperatures(sample, coolant, and cell).

SAMPLE INTERFACE

The Sample Interface components typically consist of three shutoff valves, two air activatedswitching valves, two flow meters with associated needle valves, a pressure indicator, acheck valve, and a combined assembly. The combined assembly consists of a pressureregulator, a pressure indicator, and a filter. Refer to the Sample Interface flow diagram inFigure 4-2 for the following discussion.

The instrument air passes through the shutoff valve and is coupled to the combinationassembly, where the air pressure is regulated and indicated on the pressure indicator. Theoutput goes to the Controller Assembly to provide the control air via the solenoid valves tothe sample and calibration valves.

The calibration input passes through the shutoff valve and is coupled to the input of the airactuated calibrate valve. If the valve is open, the input is coupled to the junction at the outputof the sample valve, through the sample flowmeter to the detector cell in the AnalysisAssembly.

The sample input passes through the shutoff valve to the junction at the input of the samplevalve. When the sample valve is open, the sample passes through the flowmeter, where theflow rate is adjusted by the integral needle valve, and is coupled to the detector cell in theAnalysis Assembly. The sample pressure is measured on the pressure indicator at the inputto the flowmeter. When the sample valve is closed, the sample passes through the checkvalve to the sample return. This continuous sample flow insures that a fresh sample isavailable at all times.

The water input passes through the shutoff valve and the flowmeter, where the flow rate isadjusted by the integral needle valve, and is coupled to the heat exchangers in the Analysis

4210-OSM, D1 4-3

Assembly. The heat exchangers dissipate the heat from the thermoelectric coolers in theAnalysis Assembly.

Figure 4-2. SAMPLE INTERFACE FLOW DIAGRAM

ANALYSIS ASSEMBLY

The Analysis Assembly contains the detector cell, three temperature probes, a Cell ControlBoard, two Heat Exchangers, and thermoelectric coolers. The detector cell consists of a

WaterInput

WaterReturn

SampleReturn

SampleInput

SampleReturn

CalibrationInput

InstrumentAir

ToAnalysis

Assembly

ToControllerAssembly

SAMPLE INTERFACE

ControlAir

WaterInput

WaterReturn

SampleReturn

SampleInput

PI

PI

4-4 4210-OSM, D1

light source, a mirror, a window, two light guides, a photodiode detector, and a body. Referto the Analysis Assembly block diagram (Figure 4-3) for the following discussion.

Figure 4-3. ANALYSIS ASSEMBLY BLOCK DIAGRAM

The sample is injected into the detector cell and trapped there during the analysis cycle.During the analysis cycle, the cooler control voltage from the Controller Assembly is appliedto the thermoelectric cooler elements, driving the internal detector cell temperature down.Prior to the cell temperature reaching the freezing point, the light beam from the light source(LS) is concentrated by the vertically mounted light guide (LG), strikes the mirror (M) at a 45degree angle, causing the light beam to change from the vertical to the horizontal plane,passing through the window (W) to the wet portion of the detector cell where it strikes theinterior wall of the cell. No light is refracted to the photodetector (PD) light guide (LG) duringthis time because the light guide is mounted in the vertical plane. Therefore there is nooutput from the detector cell. As the cell temperature continues to drop, hydrocarbon waxcrystals begin to form, causing some portion of the light beam to strike the wax crystals andbe refracted into the vertical plane. The photodetector light guide senses the refracted light,coupling it to the photodiode detector (PD), which produces an output to the ControllerAssembly, via the amplifier on the Cell Control Board. This signal causes the cooler controlvoltage to be shut off, allowing the detector cell temperature to rise. The temperature rise inturn causes the wax crystals to melt. When there are no wax crystals remaining (i.e., nodetector output), this temperature is defined as the freezing point.

The detector cell is cooled by thermoelectric coolers (TEC), which have the property oftransferring heat from one side of the element to the other upon application of theappropriate voltage. The cool side of each element is attached to the body of the cell andthe warm side of the element is attached to the associated heat exchanger (HE). The waterflowing through the heat exchangers dissipates the heat, allowing the detector to cool.

SampleIn

SampleReturn

Cooler ControlVoltage from

ControllerAssembly

Cooler ControlVoltage from

ControllerAssembly To Controller

Assembly

Water Inlet fromSample System

Assy

WaterOutlet

To ControllerAssembly

LampVoltage

LampVoltage

Regulator

24V FromControllerAssembly

12V

Amp


CELL CONTROL BOARD DetectorOutput

PDLS

HETECHE TEC

LG

WM

HE = Heat ExchangerTEC = Thermoelectric Cooler

PD = Photodiode DetectorLG = Light GuideLS = Light SourceW = WindowM = Mirror

= Temperature Probe

LEGENDANALYSIS ASSEMBLY

Water

LG


4210-OSM, D1 4-5

The Cell Control Board contains an amplifier to boost the photodiode detector (PD) outputand a threshold circuit to ensure that the detector output exceeds a preset level. Thethreshold circuit eliminates noise spikes, etc., prior to coupling the detected signal to theController Assembly. This board also contains a controlled power supply for the light source(LS) and a monitor circuit to determine any lamp malfunction (e.g., open circuit orovercurrent condition). A lamp malfunction causes a logic signal to be generated andcoupled to the Controller Assembly.

Three temperature probes are installed in the Analysis Assembly to measure thetemperatures of the sample, the coolant and the detector cell. These signals are monitoredby the Controller Assembly.

CONTROLLER ASSEMBLY

The Controller Assembly consists of the Power Supply and Controller Electronics.

Power Supply

The Power Supply contains four solenoid valves, a Relay Board, a Cooler Control Board,and a Switched Mode Power Supply Unit. Refer to the Power Supply block diagram (Figure4-4) for the following discussion.

Figure 4-4. POWER SUPPLY BLOCK DIAGRAM

Control fromControllerAssembly

COOLERCONTROL

BOARD

RELAYBOARD

120 VACInput

-5 VDC

+5 VDC

-12 VDC

+12 VDC

-24 VDC

+24 VDC

SWITCHEDMODE

POWERSUPPLY

UNIT

Status Inputsfrom Controller

Assembly

ContactClosures to

Control Room

Control Signalsfrom Controller

Assembly

SolenoidValve

SolenoidValve

SolenoidValve

SolenoidValve

Air Input fromSample System

Assembly

Air Control toSample Valve

Air Control toOptional Valve

Air Control toCalibration Valve

Air Control toOptional Valve

To AnalysisAssembly

Cooler Control Voltage

to Thermoelectric Coolers

POWER SUPPLY (p/o CONTROLLER ASSEMBLY)

4-6 4210-OSM, D1

The solenoid valves switch the air on and off to the air actuated valves of the SampleInterface, thus controlling the flow paths in the analyzer. The solenoid valves are switchedby the presence or absence of 24 Volts on the solenoid valve coil. This actuating voltage issupplied from the Relay Board to the appropriate solenoid valve. The Relay Board alsoprovides contact closures to the remote Control Room to indicate analyzer status. The RelayBoard logic control and status inputs are derived from the Controller Electronics.

The Cooler Control Board amplifies a 0 to 5 Volt signal from the Controler Electronics to a 0to 24 Volt signal with a maximum current of 5 amperes. This signal is applied to thethermoelectric cooler elements located in the Analysis Assembly during the cooling cycle ofthe analyzer.

The Switched Mode Power Supply Unit provides the voltage sources for the electroniccomponents in the Analysis Assembly, the Power Supply and the Controller Electronics. Thefollowing voltages are provided by the Switched Mode Power Supply Unit:

–5 Volts+5 Volts–12 Volts+12 Volts–24 Volts+24 Volts

Controller Electronics

The Controller Electronics consists of an internal computer (CPU) and associated interfacecircuitry mounted on PC compatible electronic boards. The major components include: theLCD screen, the Processor Board (CPU), the Signal-Analog Outputs Board, the AcquisitionBoard, the Graphics Display Inverter Board, the Temperature Sensor Interface Board, andthe Interface Module. Refer to the Controller Electronics block diagram in Figure 4-5 for thefollowing discussion.The Processor Board (CPU), an industry-standard 80386-40 MHz, contains two flashmemories (unit D) and one static memory (unit E). This board has two serial input-outputports, configured as COM 1 and COM 2. The COM 1 port is normally connected to a serialprinter and the COM 2 port can be connected to a computer.

The Signal-Analog Outputs Board can process eight analog outputs of 0 to 5 Volts. Theseoutputs are equipped with sample and memory circuits, which are refreshed eight times asecond. Two of these outputs are converted into 4 to 20 mA signals by Analog Device 2B22modules. Five of the other outputs are used to control the Cooler Control Board, to providecompensation to the detector signal, and to provide temperature compensation for the cell,the coolant, and the sample temperatures.

The Acquisition Board has eight 12-bit analog input (A/D Converter) channels, one dual-buffered 12-bit output (D/A Converter) channel, a 16-bit digital input (TTL compatible), and a16-bit digital output (TTL compatible).

The LCD VGA Controller Board provides the control interface to the LCD screen.

The Graphics Display Inverter Board (Inverter Board) provides power to the LCD screen.

4210-OSM, D1 4-7

Figure 4-5. CONTROLLER ELECTRONICS BLOCK DIAGRAM

The Temperature Sensor Interface Board contains three amplifier circuits used in conjunctionwith the three temperature probes in the Analysis Assembly to measure the cell, the coolant,and the sample temperatures.

The cell temperature probe amplifier converts the resistance variation of the temperatureprobe into an output signal of -5 to +5 Volts. This output signal represents a temperaturevariation of 64° C. Consequently, the cell temperature compensation signal allows thiscompensation value to be varied from 0 to 5 Volts, that is, from -32° C to 0° C. The normalcompensation value is usually adjusted to -32° C, which means that a temperature of 0° Ccorresponds to an output of 0 Volts.

The coolant and sample temperature probe amplifiers convert the resistance variation of thetemperature probe into an output signal of -5 to +5 Volts. These output signals represent atemperature variation of 64° C, compensated to 32° C, which means that a temperature of 0°C corresponds to an output of 0 Volts.

PROCESSORBOARD(CPU)

LCD VGACONTROLLER

BOARD

LCDSCREEN

SIGNAL-ANALOGOUTPUTS

BOARDACQUISITION

BOARD

TEMPERATURESENSOR

INTERFACEBOARD

Temperature ProbeInputs from Analysis

Assembly

Detector Signal fromAnalysis Assembly

ControlVoltages to

Power Supply4 - 20 mAOutputs

CONTROLLER ELECTRONICS (p/o CONTROLLER ASSEMBLY)

INVERTERBOARD

4-8 4210-OSM, D1

X PURGE

X Purge Operation

X Purge (see Figure 4-6) reduces risk by two levels and turns off the analyzer when an alarmoccurs.

Figure 4-6. X PURGE WITH COVER REMOVED

When you turn the power ON, X Purge begins monitoring the Controller Assembly air purgepressure. When the air purge pressure reaches the specified level, the X Purge starts atimed cycle. If the air purge pressure remains at the specified level during the timed cycle, XPurge will supply power to the equipment when it completes the timed cycle. If the air purgepressure drops before the X Purge completes the timed cycle, X Purge resets the timer andstarts over. It continues to reset the timer until the analyzer achieves and maintains thecorrect pressure for a complete timed cycle. The X Purge will not supply power to theanalyzer until it sucessfully completes the timed cycle.

The X Purge cycle time depends totally on the application, but it may vary with analyzerconfiguration and condition. Refer to the analyzer label or Data Package for specific purgespecifications. Once X Purge applies power to the analyzer, power continues to the analyzeras long as the Controller Assembly maintains air purge pressure.

X Purge removes power from the analyzer when the Controller Assembly air purge pressuredrops below specifications. It locks out power to the analyzer and activates an alarm. Theanalyzer has connections available to the customer for connecting the purge alarm to avisual or audible annunciator located in a constantly monitored area.

In order to re-start the analyzer after an X Purge alarm, you must first correct the cause ofthe drop in pressure. Then turn the power OFF at the circuit breaker for at least ten secondsand turn the power back ON. This starts a new X Purge timed cycle, which it must completebefore it will supply power to the analyzer. If you do not correct the cause and cannotachieve and maintain pressure, the X Purge will not complete the cycle and will not supplypower to the analyzer.

When X Purge removes and locks out power to the analyzer after a drop in ControllerAssembly purge air pressure (or before pressure has initially attained the specified level),

OVERRIDEPUSHBUTTON

ALARMCONTACTS

REMOTEOVERRIDE

POWER IN

C4

4210-OSM, D1 4-9

you can use Override to provide power to the analyzer for troubleshooting or maintenancepurposes. Override does not cancel the X Purge power lockout but temporarily overrides it.

X Purge Override Option

WARNING

Before you enable X Purge Override to override its control of power tothe analyzer, ensure the area where the analyzer is located is safe andhazard free, and remains so for the entire time the X Purge housingcover is removed.

CAUTION

Override must not be left on during regular operation of the analyzer.

Use the X Purge Override Option only for start up, troubleshooting, and maintenance. Donot leave it on during regular operation of the analyzer. Override requires a well-lighted areato function. A light sensor inside the X Purge housing allows you to enable Override afteryou remove the X Purge housing cover. When you replace the cover, the light sensorcancels Override.

The following steps describe how to use the override function.

1. Ensure the area is safe and well-lit.

2. Remove the X Purge housing cover and press the Override button (see Figure 4-6) toapply power to the analyzer.

NOTE

CENELEC versions of the X Purge have a set screw in the lid that mustbe removed before the housing cover can be removed.

3. Perform the necessary maintenance and troubleshooting.

4. When you have completed the maintenance and troubleshooting, replace the X Purgehousing cover (and the CENELEC set screw).

5. To cancel Override safely and properly and to reset X Purge, turn the supply power OFFat the circuit breaker outside the analyzer (for at least ten seconds) and then turn powerON again.

6. With X Purge reset, the air purge timed cycle begins in the Controller Assembly.

When you use Override during start-up, it overrides the X Purge control of power to theanalyzer, but the air purge timed cycle continues. Once the Controller Assembly haspressurized and X Purge completes its timed purge cycle, the analyzer will have power fromthe X Purge. If you replace the housing cover without turning the power off at the circuitbreaker, the analyzer will still have power because of X Purge.

If the Controller Assembly pressure drops during Override use and if the timed cycle iscomplete, the X Purge will lock out its power to the analyzer. Since Override bypasses the XPurge, the analyzer will still have power. If you cancel Override by replacing the housingcover without turning off the power at the circuit breaker, the X Purge power lock out will

4-10 4210-OSM, D1

cause the analyzer to be without power. To restart X Purge, you must correct the cause ofthe drop in pressure, then turn power OFF (for at least ten seconds), and then ON again.The X Purge must complete its timed cycle before the analyzer will receive power.

NOTE

The remote control feature of the Override option is not available onCSA certified analyzers.

The X Purge housing has terminals for connecting a remote control override (see Figure 4-6), except in CSA certified analyzers. The customer is solely responsible for connecting andmaintaining the remote control switch. This remote control is only to be used during start-up,maintenance and troubleshooting. The customer must ensure the remotely controlledoverride is removed when start-up, maintenance and troubleshooting is completed.

4210-OSM, D1 5-1

SECTION 5. MAINTENANCE

PREPARATION FOR MAINTENANCE

This section of the manual provides a series of routine maintenance procedures whichshould be performed on a periodic basis to reduce failures and to enhance the equipmentoperational stability. Removal and replacement instructions are included for printed circuitboards and detector cell components. The latter portion of this section will includeadjustments, DIP switch positions, and jumper connectors, when printed circuit boards arereplaced.

The following tools and equipment are required to perform this maintenance.

Tools: #2 Phillips screwdriver#1 Phillips screwdriver3/16-inch flat blade srewdriver1/8-inch flat blade screwdriver1 set of metric open end wrenches6-inch adjustable wrench12-inch adjustable wrench1 set of metric hex key wrenches1 pair of tweezers

Equipment: Leak testing solution (e.g. Snoop®)Flow meterStop watch (if not using a digital flowmeter)Potentiometric recorder (two channels)Decade resistance boxSerial printerMultimeter (Fluke 80 series or equivalent)Pump to provide continuous circulation of the sampleSample container (approximately half full) with an output connection (tubing to the bottom of the container) and an input connection for a sample return

USING THE LOCAL KEYBOARD

Most of the maintenance procedures will require connecting the local keyboard to allow theanalyzer to be set to various operating states.

WARNING

Before opening any analyzer doors or covers, ensure the area is safe andhazard-free and will remain so the entire time the analyzer is open.

To connect the local keyboard proceed as follows:

1. Turn the Controller Assembly front panel latches fully counterclockwise with a 5/16-inch(or 8 mm) hex key wrench.


5-2 4210-OSM, D1

3. Locate the cable with the open connector (on the left side of the enclosure) andconnnect the keyboard cable to it.

4. The operating screen should appear on the display (see Figure 5-1).

Figure 5-1. OPERATING SCREEN

NOTE

In the following procedures, if there is no keyboard activity for 30seconds, the display will revert to the operating screen.

5. The following commands are available by one-touch keying:

M Manual: allows you to shift from automatic mode to manual mode.

N Next step: in manual mode, this key allows you to follow, step bystep, the different phases of operation of the analyzer.

S Standby: allows you to set the analyzer locally into “Standby”position.

A Auto: allows you to return to automatic mode from manual mode.

C Calibration: when this key is activated, a calibration cycle will followimmediately after the end of the cycle in progress.

Q Quit: allows you to halt the program and return to DOS.

01/26/99 08:35:36 COOL 162 AUTO 600

PARAMETER SET 0PROCESS SAMPLE FREEZE POINT -42.3 CCALIBRATE SAMPLE FREEZE POINT -45.0 CCELL TEMPERATURE -0.0 CWATER TEMPERATURE -10.0 CSAMPLE TEMPERATURE +25.0 C

PROCESS 4-20 O/P No 1 20.0 mACALIBRATE 4-20 O/P No 2 20.0 mADETECTOR SLOPE +0.00 VDETECTOR THRESHOLD +0.30 V

Trend/ConTStandbyCal RequestLamp FailFast LoopFilterFlowCal SampleExt WarningExt ErrorParams LSBParams MSBHoldDCDDSRCTS

ReadyErrorWarningCal StatusSample ValveCalib ValveFlush ValveReset ValveRange ErrorCooler TOCooler FailCoolerCal Ack.CommsPrinterSave PCX

4210-OSM, D1 5-3

TROUBLESHOOTING INSTRUCTIONS

Most troubleshooting should begin at the display. Periodic observation of the normal displayshould make abnormalities rather easy to spot. For example, if the temperature trace is notfollowing the desired line, it probably indicates a need to readjust the cooling rate parametersor a failure in the cooling circuit (Cooler Control Board, the signal into the Cooler ControlBoard, or the thermoelectric coolers).

When power to the analyzer is turned OFF (or an inadvertent shutdown occurs), a three-waysolenoid valve automatically shuts off sample and calibration flow to the analyzer.

CONTROLLER ASSEMBLY REPAIR

WARNING


Opening the Controller Assembly

To access the printed circuit boards and other components in the Controller Assemblyperform the following steps:

1. Turn the Controller Assembly front panel latches fully counterclockwise with a 5/16-inch(or 8 mm) hex key wrench.


Replacing Printed Circuit Boards

The five printed circuit boards of the Controller Assembly are located inan eight slot backplane in the following order from left to right:

Processor Board (CPU)Spare slotSignal-Analog Outputs BoardAcquisition BoardLCD VGA Controller BoardSpare slotTemperature Sensor Interface BoardSpare slot

CAUTION

Remove power from the analyzer before attempting printed circuit boardreplacement.

To protect printed circuit boards from damage, use a properly groundedanti-static wrist strap when handling all circuit boards.

5-4 4210-OSM, D1

Replace any of the printed circuit boards in the Controller Assembly in thefollowing manner (see Figures 5-2 and 5-3 for location and cabling):

Figure 5-2. PRINTED CIRCUIT BOARD LOCATION

1. Open the Controller Assembly front panel as described in “Opening the ControllerAssembly.”

2. Disconnect any cables to the selected board and remove the board.

3. Compare the removed board to the replacement board.

a. If any DIP switches are installed on the removed board, ensure that the positionsof the switches on the replacement board match those of the removed board.

b. If any jumpers are installed on the removed board, ensure that the jumpers onthe replacement board match those of the removed board.

FOR DETAILS ONCPU BOARD

CONNECTIONS,SEE FIGURE 5-1B

BACKPLANE BOARD

CPU

BO

ARD

SIG

NAL

-AN

ALO

G O

UTP

UTS

BO

ARD

ACQ

UIS

ITIO

N B

OAR

D

VGA

CO

NTR

OLL

ER B

OAR

D

TEM

P SE

NSO

R IN

TER

FAC

E B

OAR

D

Spare

Spare

Spare

CN1

CN5

CN4

CN3

CN3

CN4

CN1

CN1

CN3

1 2 12P2

4

3

2

1PCL-711 S

DISPLAY

P8P9

POWERSUPPLY

24V

GND

4210-OSM, D1 5-5

Figure 5-3. CPU BOARD CONNECTIONS

4. Install the replacement board.

5. Reconnect cables, using Figures 5-2 and 5-3 as guides.

6. If you have completed all work inside the Controller Assembly, close and secure theController Assembly as described in “Closing the Controller Assembly.”

Closing the Controller Assembly

To close the Controller Assembly perform the following steps:

1. Ensure all circuits boards are installed and the PCB holding bracket is in place.

2. Close the Controller Assembly front panel.

3. Tighten the panel latches.

KEYBOARDCONNECTOR

MOUSECONNECTOR

PRINTERCONNECTOR

5-6 4210-OSM, D1

Replacing the Pressure Gauge

The pressure gauge is located on the panel between the Controller Assembly and theAnalysis Assembly (see Figure 5-4). You can access the gauge from underneath the panel.

Figure 5-4. CONTROLLER ASSEMBLY AND GAUGE PANEL

1. Disconnect the line from the back of the gauge.

2. Loosen the screws on the plate that secures the gauge to the panel and then removethe plate.

3. Remove the gauge from the panel.

4. Insert the new gauge through the hole in the panel.

5. Install the plate that secures the gauge to the panel.

6. Tighten the screws holding the gauge and plate to the panel.

7. Reinstall the line on the back of the gauge.

Replacing the Pressure Regulator

The regulator is located on the panel between the Controller Assembly and the AnalysisAssembly (see Figure 5-4). You can access the regulator from underneath the panel.

1. Disconnect the lines from the back of the regulator.

2. Remove the regulator adjusting knob.

3. Remove the nut securing the regulator to the panel.

4. Remove the regulator from the panel.

5. Remove the adjusting knob from the new regulator.

6. Insert the new regulator through the hole in the panel.

Pressure Gauge Regulator

4210-OSM, D1 5-7

7. Fasten the nut securing the regulator to the panel.

8. Install the adjusting knob on the regulator.

9. Reinstall the lines on the back of the regulator.

ANALYSIS ASSEMBLY REPAIR

Opening the Analysis Assembly

WARNING


The following steps describe the removal and replacement of various components of theAnalysis Assembly.

1. Remove the power from the analyzer and close the WATER INLET, the SAMPLE INLET,and the AIR SUPPLY shutoff valves.

2. Loosen the hex socket head locking screw on the Analysis Assembly cover and removethe cover.

Replacing the Cell Control Board

1. Disconnect the detector coaxial cable from the Cell Control Board.

2. Remove the four nuts securing the cover on the Cell Control Board and remove thecover.

3. Disconnect the wires from the terminal board on the Cell Control Board.

4. Unscrew the four hex head standoffs and remove the Cell Control Board.

5. Install the replacement board in the reverse order of removing the board.

Replacing the Light Source Lamp

CAUTION

Do not touch the lamp with bare fingers.

1. Unscrew the lamp retaining cap from the lamp holder.

2. Remove the lamp with a pair of tweezers.

3. Install the new lamp with a pair of tweezers.

4. Reconnect the lamp retaining cap to the lamp holder.

5-8 4210-OSM, D1

Replacing the Photodiode Detector

CAUTION

Do not touch the photodiode detector with bare fingers.

1. Unscrew the optical detector cable assembly from the photodiode holder.

2. Disconnect the other end of the optical detector cable assembly from the Cell ControlBoard and remove the cable from the unit.

3. Connect the replacement optical detector cable assembly to the Cell Control Board.

4. Connect the other end of the replacement optical detector cable assembly to thephotodiode holder.

Removing and Reinstalling the Detector Cell

It will be necessary to remove the complete detector cell from the Analysis Assembly toreplace the thermoelectric coolers, the cell temperature probe, or any other internalcomponents. Remove the detector cell as follows:

1. Disconnect the stainless steel sample lines at the unions.

2. Disconnect and remove the coolant lines.

3. Disconnnect the electrical connector at the top of the detector cell.

4. Remove the four hex socket head screws securing the detector to the back plate andthen remove the detector cell.

5. Place the detector cell on a work bench.

6. Remove the four threaded rods holding the two acetal delrin blocks of the detector celltogether.

7. Carefully separate the acetal delrin blocks and replace the defective component.

8. Reinstall the detector cell in the reverse order of removal.

CONTROLLER ASSEMBLY ADJUSTMENTS

Some adjustments may be required periodically to compensate for component aging and toset different system parameters. Open the Controller Assembly front panel as described in“Opening the Controller Assembly.”

WARNING


4210-OSM, D1 5-9

Processor (CPU) Board

There are two different Processor (CPU) Boards used in the analyzer. When you replace aCPU Board you must use the same type of board—the boards are not interchangeable (seeFigure 5-5).

Figure 5-5. PROCESSOR BOARD ADJUSTMENTS

When you replace the old type CPU Board (832Z011-00), you set DIP switch S1 (see Figure5-5 for location) to meet the system requirements. If in doubt, set the switch to the samepositions as those on the removed board.

DIP switch S1 selections are as follows:

SwitchPosition Function Action

S1-1 On-Board Serial Port 1 Disable ON to disable(This switch overriden by Feature Setup selection) OFF to enable

S1-2 On-Board Serial Port 2 Disable ON to disable(This switch overriden by Feature Setup selection) OFF to enable

S1-3 On-Board Parallel Port Disable ON to disable(This switch overriden by Feature Setup selection) OFF to enable

S1-4 Console Mode Enable ON to enable(This switch enables console mode on Serial Port 1) OFF to disable

S1-5 Not Used

S1-6 Boot Disk ON to boot from solid state diskdevice SSDO

OFF to boot as specified in theFeature Setup Program(FSETUP.EXE)

SWITCH S1

NEW CPU BOARD (3617856-1)OLD CPU BOARD (832Z011-00)

5-10 4210-OSM, D1

The new CPU Board (3617856-1) has no switches or adjustments.

Signal-Analog Outputs Board

The Signal-Analog Outputs Board has four potentiometers that are used to set the 4 to 20mA current values (see Figure 5-6).

Figure 5-6. SIGNAL-ANALOG OUTPUTS BOARD ADJUSTMENTS

If necessary, the 4 mA and 20 mA current values can be adjusted using thesepotentiometers. In these procedures the analyzer is ON and in STANDBY and the cover isremoved from the Controller Assembly.

Adjusting the Measuring Analog Output

1. Connect a milliammeter in series with terminals 84 (+) and 85 (-).

2. Connect a keyboard to the CPU Board and exit from the application program bypressing the Q key (Quit). The prompt letter D will be displayed.

3. Type TESPROG and then press the ENTER key. A screen will appear which showsvarious options.

4. Using the left/right arrow key, select the Edit Menu and the DIGITAL-ANALOG mode.

5. First set the voltage level of MOD1 (Trend Channel) to 0.00 volts and adjust RV-2 for anoutput current of 4 mA.

6. Change the voltage level to 5.00 volts and adjust RV-1 for an output current of 20 mA.

7. Verify that the output current value is 12 mA when the voltage is set to 2.5 volts.

VR4 VR3 VR2 VR1

4210-OSM, D1 5-11

Adjusting the Calibration Analog Output

1. Connect a milliammeter in series with terminals 86 (+) and 87 (-).

2. Connect a keyboard to the CPU Board and exit from the application program bypressing the Q key (Quit). The prompt letter D will be displayed.

3. Type TESPROG and then press the ENTER key. A screen will appear which showsvarious options.

4. Using the left/right arrow key, select the Edit Menu and the DIGITAL-ANALOG mode.

5. First set the voltage level of MOD2 (Calibrate Channel) to 0.00 volts and adjust RV-4 foran output current of 4 mA.

6. Change the voltage level to 5.00 volts and adjust RV-3 for an output current of 20 mA.

7. Verify that the output current value is 12 mA when the voltage is set to 2.5 volts.

Acquisition Board

The Acquisition Board has a six-position DIP switch SW1 used to set the base address of theboard and a connector link to select the output (see Figure 5-7).

Figure 5-7. ACQUISITION BOARD ADJUSTMENTS

Perform the following adjustments with the power OFF.

JP1SW1(SW1-1 at left; ON at top)

5-12 4210-OSM, D1

Jumper orSwitch Position Action

JP-1 -5 VoltsSW1-1 OFFSW1-2 ONSW1-3 ONSW1-4 ONSW1-5 OFFSW1-6 ON

There are also five potentiometers on this board. They are set at the factory and should notrequire adjustment thereafter.

LCD VGA Controller Board

There are two controls (VO and VEE) located on the LCD VGA Controller Board in theController Assembly (see Figure 5-8). The VO control is used to adjust the intensity of thecursor. The VEE control is not used in this application.

A ribbon cable connects this board to the Graphics Display Inverter Board (located on theinside of the Controller Assembly door).

Figure 5-8. LCD VGA CONTROLLER BOARD ADJUSTMENTS

Temperature Sensor Interface Board

In these procedures, the analyzer is ON and in STANDBY and the Controller Assembly frontpanel is open. Figure 5-9 shows the location of the adjustments on the Temperature SensorInterface Board.

VEE VO

4210-OSM, D1 5-13

Figure 5-9. TEMPERATURE SENSOR INTERFACE BOARD ADJUSTMENTS

Adjusting the Sample Temperature Circuit

1. Connect a resistance box in place of the sample temperature sensor (terminals 5 and 6of terminal board TB4) and adjust the value to 100 ohms.

2. Measure the voltage at the terminals of the resistance box and adjust RV-9 to obtain avoltage of 300 mV. This corresponds to a current setting of 3 mA.

3. Adjust RV-3 to obtain a sample temperature reading on the Controller Assembly display(SAMPLE TEMP.) of 0° C.

4. Adjust the resistance box to a value of 87.83 ohms. Then adjust RV-6 so that thesample temperature reading on the Controller Assembly display (SAMPLE TEMP.) is -31° C.

5. Adjust the resistance box to a value of 112.06 ohms and verify that the sampletemperature reading on the Controller Assembly display (SAMPLE TEMP.) is +31° C.

Adjusting the Coolant Temperature Circuit

1. Connect a resistance box in place of the coolant temperature sensor (terminals 8 and 9of terminal board TB4) and adjust the value to 100 ohms.


3. Adjust RV-2 to obtain a water temperature reading on the Controller Assembly display(WATER TEMP.) of 0° C.

RV-9

RV-8

RV-7

RV-6

RV-5

RV-4

RV-1

RV-2

RV-3

5-14 4210-OSM, D1

4. Adjust the resistance box to a value of 87.83 ohms.

5. Adjust RV-5 so that the water temperature reading on the Controller Assembly display(WATER TEMP.) is -31° C.

6. Adjust the resistance box to a value of 112.06 ohms and verify that the watertemperature reading on the Controller Assembly display (WATER TEMP.) is +31° C.

Adjusting the Cell Temperature Circuit

1. First make sure that the parameter defining a freezing point offset is 0° C.

2. Connect a resistance box in place of the cell temperature sensor (terminals 11 and 12 ofterminal board TB4) and adjust the value to 100 ohms.


4. Adjust RV-1 to obtain a cell temperature reading on the Controller Assembly display(CELL TEMP.) of 0° C.

5. Adjust the resistance box to a value of 87.83 ohms.

6. Adjust RV-4 to obtain a cell temperature reading on the Controller Assembly display(CELL TEMP.) of -31° C.

7. Adjust the resistance box to a value of 112.06 ohms and verify that the temperaturereading on the Controller Assembly display (CELL TEMP.) is +31° C.

Power Supply Board

There is one jumper on this board (see Figure 5-10). Insert this jumper so that ayou canread the system's input voltage value (115V or 230V) on the jumper tab.

4210-OSM, D1 5-15

Figure 5-10. POWER SUPPLY BOARD JUMPER LOCATION

ANALYSIS ASSEMBLY ADJUSTMENTS

The only adjustment in the Analysis Assembly is VR-1 on the Cell Control Board. This is afactory adjustment and should not require adjustment on site.

POWER JUMPER

5-16 4210-OSM, D1








4210-OSM, D1 6-1

SECTION 6. REPLACEMENT PARTS

ORDERING INFORMATION

CAUTION

Since the particular application defines the component parts specific toany given system, refer to the “Recommended Spare Parts Lists” inthe analyzer's Data Package to obtain the full and correct part numberfor the desired part or assembly.

Include the following information, found in the Data Package and on the analyzer nameplate,in any communication concerning replacement parts or components:

• ABB Sales Order Number

• Analyzer Model Number

• Analyzer Part Number (P/N) and serial number

• Cell serial number

• For serial numbered subassemblies such as PC boards, include the serialnumber and the part number (including dash number and revision letter) for thesubassembly in the request

• Applicable references from the “Recommended Spare Parts List” of the DataPackage, included with each analyzer

• Description of part

Contact Aftermarket Spares for specific instructions and include a complete description of thecomponent, analyzer, symptoms and problems. Please address your requests as follows:

ABB Inc.Attention: Aftermarket Spares843 North Jefferson StreetP.O. Box 831Lewisburg, WV 24901

Telephone: (304) 647-1736Fax: (304) 647-1837

6-2 4210-OSM, D1

ANALYSIS ASSEMBLY

Description Part Number

Cell Control Board 832Z053-00Detector Cell Assembly 841A003-1Lamp, Filament 832Z064-00-1Fuse, 6A 250V (5mm x 20mm) 3617763-6A

Figure 6-1. ANALYSIS ASSEMBLY

DETECTORCELL

ASSEMBLY

CELL CONTROLPCB

4210-OSM, D1 6-3

CONTROLLER ASSEMBLY


Power Supply PCB, Modified 840D012-1Acquisition PCB 832Z016-00Graphics Display Inverter PCB 832Z017-00 (on back of door)Relay PCB 832Z037-00Cooler Control PCB 832Z042-10Fuse, 1A 250V (5mm x 20mm) 832Z055-1ALCD VGA Controller PCB 832Z013-00Fuse, 1.6A 250V (5mm x 20mm) 3615086-15Pressure Gauge, 0 to 100 psig 44726-4Regulator, 0 to 40 psig 3616975-2Processor PCB (application dependent—see Data Package)Signal-Analog Outputs PCB (application dependent—see Data Package)Temperature Sensor Interface PCB (application dependent—see Data Package)

Figure 6-2. CONTROLLER ASSEMBLY

COOLERCONTROL PCB

POWERSUPPLY

PROCESSOR PCB SIGNAL-ANALOGOUTPUTS PCB

ACQUISITION PCB

LCD VGACONTROLLER PCB

TEMPERATURESENSOR INTERFACE

PCB

RELAYPCB

CABLE FORKEYBOARD

PRESSUREGAUGE REGULATOR

6-4 4210-OSM, D1

X PURGE ASSEMBLY


X Purge PCB, NEC/CEN 115V 3528938-222X Purge PCB, NEC/CEN 230V 3528938-232X Purge PCB, CSA 115V 3528938-242X Purge PCB, CSA 230V 3528938-252

Figure 6-3. X PURGE ASSEMBLY

X PURGE PCB

ABB Inc.843 N. Jefferson StreetLewisburg, WV 24901 USA

Office: (304) 647-4358FAX: (304) 645-4236

Business Unit–Analyticalwww.abb.com/analytical

0107

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