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ELTRA CS-800, Manual

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ELTRA CS-800 Manual Download Page 34

 

34

 

 

Fig. 9: oxygen gauge 

If the pressure is remarkably lower than 1.5 bar (22 psi) then 

– 

Check the pressure of the oxygen bottle. 

– 

Check the pressure regulator of the oxygen bottle  

– 

Do leakage check. 

See chapter Leak Checking

  

3.4.2 

85B

No flow   

If this message permanently remains in the “status window”, check the flow on the 
lower flow meter (Rotameter). The ball has to be in the range of 180 L/h. If it is in 
this range, then click on the “device state” window icon.  

 

Fig. 10: device state window icon  

Check the graph for L/h. (See software helps). If the vertical bar is not in the middle 
of the base line then calibrate the flow in the software as follows.  

3.4.3 

86B

Pre-purging  

If this message permanently remains in the “status window”, click the icon of the 
“configuration window”. 

 

Fig. 11: icon configuration window  

The duration of pre-purging is possibly entered much too long. Reasonable values 
are between 1 and 5 seconds, maximum 10 sec for very low carbon analysis. 

3.4.4 

87B

Waiting for stability   

If this message permanently remains in the “status window”, the infrared cell base 
lines are not stable or out of range.Click the Base line Icon and check. 

Summary of Contents for CS-800

Page 1: ... Eltra GmbH 42781 Haan Retsch Allee 1 5 Germany 13 12 2013 0000 Manual CS 800 Carbon Sulfur Determinator Original ...

Page 2: ...2 Copyright Copyright by Eltra GmbH Haan Retsch Allee 1 5 D 42781 Haan Federal Republic of Germany ...

Page 3: ...3 ...

Page 4: ...stic tube of the oxygen supply 31 3 2 12 Twisted plastic tube inside the analyzer 31 3 2 13 Oxygen supply is interchanged with the compressed air supply 31 3 2 14 Blocked dust filter cartridge 31 3 2 15 Blocked fittings 31 3 2 16 Blocked flow sensor assembly 31 3 2 17 Electronic problem 31 3 3 High carbon results are erratic 32 3 4 No combustion 33 3 4 1 No oxygen pressure 33 3 4 2 No flow 34 3 4 ...

Page 5: ...ts 61 3 18 No oxygen flow 61 3 19 Status window message Waiting for stability 61 3 19 1 Reasons for instability 62 3 19 1 1 Too low deviation value 62 3 19 1 2 Too high noise 62 3 19 1 3 Too high drift 62 3 20 Furnace opens with delay after the end of analysis 62 3 21 Oxygen pressure falls when the furnace opens 64 3 22 Combustion without starting analysis 65 3 23 Crucible cracks or melts 68 3 24 ...

Page 6: ...ovement 92 4 4 Pressure regulation 93 4 5 Purge pressure 94 4 6 Closing cone adjustment 96 4 7 Linearisation 97 4 8 Balance programming 97 4 9 Induction generator control 97 5 Service 100 5 1 IR paths cleaning and replacing 100 5 1 1 Available infrared paths 101 5 2 Infrared electronics 102 5 3 General test points 103 5 3 1 Supply voltages and thermostatic control circuit 103 5 3 2 Supply voltages...

Page 7: ...ng circuit 126 6 1 6 Furnace 128 6 1 7 Furnace cleaning 130 6 2 Wiring I 133 6 2 1 UNI 1 143 6 2 2 Gas flow system 144 6 2 3 Valve controlling 146 6 2 3 1 Opening the furnace 147 6 2 3 2 Closing the furnace 147 6 3 Spare parts kits 147 6 3 1 Common spare parts kit for all analysers 147 6 3 2 Spare parts kit for CS 800 149 7 Maintenance 151 8 Index 152 Appendix following page ...

Page 8: ... the analyzer s cabinet Pos 1 3 0010 ELTR A 0099 Standard Kapitel Standar d M odul e El tra 9905 M odul N OTIC E ser vice manual general 7 mod_1379490471353_9 docx 48808 1 NOTICE In this service manual no information is repeated from the operation manual as it may be appreciated Service should only be done by persons who have mastered the servicing and maintenance of this device as well as having ...

Page 9: ...overview Pos 3 2 0010 ELTR A 0015 ser vice_i nstr uctions CS 800_Ser vice 0010 Änderungen Ü bersicht 1005 Modul Änderungen C S 800 7 mod_1379493542394_9 docx 48878 22222222 1 2 1 8BUp to S N 0766xxxxxx The CS 800 analyzers are equipped with a flow sensor with optical elements and with the corresponding board HF 3 and HF 4 Fig 1 Draft flow sensor and HF 3 ...

Page 10: ...10 Fig 2 Draft 12057 ...

Page 11: ...11 Fig 3 Draft 11660 ...

Page 12: ...12 Fig 4 Draft 12200 ...

Page 13: ...mit for the induction furnace on board HF 41 42 adjustment Oxygen flow only during combustion on board jumper Gas saving mode by controlling the oxygen flow start stop by the software This function has been included later in the software from SN 1080xxxx Analyzers from SN 0767 to SN 1079 can be upgraded with this function For description see corresponding service manual Fig 5 Draft 2 01 1 1 pressu...

Page 14: ...14 Fig 6 Draft 12058 Signal and control ...

Page 15: ...15 Fig 7 Draft 11665 Gas flow diagram 2 3 10BFrom S N 0951xxxxxx to 1079xxxxxx The CS 800 has an additional purging inlet on top of the combustion chamber ...

Page 16: ... good care has to be taken when changing the EPROMS The wiring has also changed It has been modified to be used with the IR 4 and the four IR cell rack As the 4 cell software was not available the CS 800 was equipped with the still available with the 3 range IR cell using an adapter and the 3 cell software up to SN 1079xxxx ...

Page 17: ...17 Fig 8 Draft 6 2 4 Gas flow diagram furnace closed ...

Page 18: ...18 Fig 9 Oxygen flow schematically ...

Page 19: ...19 Fig 10 Draft 12059 signal and control board ...

Page 20: ...aving mode is available and selectable in the PC software PLOTCS When an analysis has not been carried out for a period of time the analyzer will automatically switch to Gas Conservation Mode This effectively means the carrier gas flow rate is reduced to a minimum only allowing a small amount of oxygen to circulate through the IR cell etc The period of time before the Gas Conservation is activated...

Page 21: ...21 Fig 12 Draft VG 96 connector ...

Page 22: ...22 Fig 13 Draft 1 14 4 1 ...

Page 23: ...23 Fig 14 Draft IR 45 power supply ...

Page 24: ...24 Fig 15 Draft IR sources Fig 16 Draft 7 pin plug ...

Page 25: ...dert am D 41469 Neuss Mainstr 85 Block 20 Zeichnungs Nr Bez Datum Name 19 07 2004 19 07 2004 gez gepr Sanda Polemitis Benennung 6 1 2 3 4 7 9 8 5 2 2 1 1 3 4 rs rt 16 15 12061 72 cm 72 cm 14 16 13 9 GND 14 Shield sw sw 34 2 3 13 4 11 26 27 1 gn ge gn br ws ge gn br ws ge gn br ws ge Flow rate Power Power 11 4x0 14mm x 30cm Regulating valve V6 pump 50 8 40 41 NC NC 16 x 0 14mm x 75cm vi vi Generato...

Page 26: ...26 2 6 13Bnew pneumatics from end 2007 Fig 18 Draft new pneumatics from end 2007 Pos 4 0010 ELTR A Seitenumbruch 6 mod_1368796429449_0 docx 41468 1 ...

Page 27: ...se lines is either over 9 5Volts or below 9 5 Volts In order to read the base line voltages of all IR cells available click on base lines Fig 1 Base lines A window appears at the right upper end of the screen showing the base lines moving from the left to the right time coordinate In the middle of the right end of this base lines window there is a small button After clicking on it a new window app...

Page 28: ... out further analyses As long as the base line remains below 10V the results are correct If a base line is below 9 5V an adjustment should be done as advised above If this is not possible then most probably there is a fault or a very strong contamination In case of contamination all cells available should have very low voltages even negative ones If all available cells are below 9 5V there is most...

Page 29: ...enoid valve Bent plastic tube of oxygen supply A heavy item is placed on the plastic tube of the oxygen supply Twisted plastic tube inside the analyzer The oxygen supply is interchanged with the compressed air supply Blocked dust filter cartridge Blocked fittings Blocked flow sensor assembly Electronic problem 3 2 1 67BBlocked metal dust filter Clean the metal dust filter according to the operatio...

Page 30: ...erly open It is not necessarily enough to have sufficient oxygen flow if only the right pressure is adjusted on the oxygen regulator of the bottle cylinder It is equally important to properly open the small tap at the outlet of the pressure regulator If this outlet tap of the regulator is not properly open you may have enough pressure at the analyzer when there is no or little oxygen demand But wh...

Page 31: ...the gas flow circuit this dust cartridge is connected after the metal filter and its following glass tube with magnesium perchlorate so that the carrier gas passing thru the cartridge is already filtered The cartridge is used as an additional safety to ensure that the carrier gas passing thru the IR cell and the flow sensor are as clean as possible Therefore it takes long until the cartridge is co...

Page 32: ...1368522482685_9 docx 40088 33 1 3 3 16BHigh carbon results are erratic Pos 5 8 0010 ELTR A 0015 ser vice_i nstr uctions CS 800_Ser vice 0015 Fehler 0120 M odul U nreg elmäßige Kohl enstoff Ergebnisse ELTRA 6 mod_1377688598908_9 docx 46519 32333333444444 1 Even if the filter may be brushed and cleaned in ultrasonic cleaner someday will not be able to be cleaned any more Filters don t last forever C...

Page 33: ...contacts High Voltage An electric shock can cause injuries in the form of burns and cardiac arrhythmia respiratory arrest or cardiac arrest Disconnect the mains power plug before opening the analyzer s cabinet Pos 5 12 0010 ELTR A 0015 service_instructions C S 800_Ser vice 0015 Fehl er 0130 Modul Kei ne Verbr ennung Fehl er ELTR A 6 mod_1377688599501_9 docx 46543 222333333444444 1 After clicking S...

Page 34: ...ce state window icon Check the graph for L h See software helps If the vertical bar is not in the middle of the base line then calibrate the flow in the software as follows 3 4 3 86BPre purging If this message permanently remains in the status window click the icon of the configuration window Fig 11 icon configuration window The duration of pre purging is possibly entered much too long Reasonable ...

Page 35: ... window it means that definitely the command for starting combustion is given by the software so that if still there is no combustion there must be probably a hardware reason for this fault NOTICE As a matter of fact it happened several times that we received requests for help in cases of no combustion from people who tried to test the functionality of the generator by using empty crucibles After ...

Page 36: ... on TP13 despite having 0 5 V on TP9 the HF 42 circuit board is defective NOTICE After replacing the HF 42 board make sure that the 50 pin plug is properly inserted It takes a lot of force to push in 50 pins at once 50 pin plugs that haven t been properly inserted are a frequent problem Tighten the screws of the plug properly to ensure a proper connection to the board 3 4 7 2 Checking the generato...

Page 37: ...f the generator tube doesn t glow Check the voltage of the filament on the transformer there should be 10 V AC on the secondary If not then measure 220 V AC on the primary leads 2 3 NOTICE Set the power switch to pos 1 before removing the tube although it would be best to completely turn off the device and unplug the power cord DANGER Mortal danger from electric shock Exposed power contacts High V...

Page 38: ... needs to be replaced 3 4 7 4 Checking the primary voltage on the high voltage transformer DANGER Mortal danger from electric shock Exposed power contacts High Voltage When checking for induction power always keep the furnace closed On the primary side of the high voltage transformer you should be able to measure about 210 V AC if not the triac is possibly defective 220 VAC between contact 2 and 3...

Page 39: ...evel of about 10A then a faulty component prevents oscillations so that the tube takes all this power causing overheating of the tube within several seconds If the current does not increase it means that the generator does not take power for example due to a broken grid resistor In case the transformer has 210 V AC on the primary coil and there is still no combustion check the windings of the tran...

Page 40: ...re should be no measurement on the rectifier under power If no spare rectifier available to exchange then test by using a scope according to the following drawing Fig 19 Rectifier 220 VAC Insulating transformer 220 VAC Adjustable transformer Rectifier about 4000 Ω ...

Page 41: ... contacts High Voltage Before touching any components or wiring make sure the capacitors are discharged You should check the connections in the oscillator circuit to ensure all screws are turned tightly especially all the cap screws on the combustion coil The electrical connections and resistors should be checked with an ohmmeter If the resistor 2 7K 100W 3 is open circuit then there is no oscilla...

Page 42: ... the analysis cycle in order to check whether there was combustion it could be already too late for the tube due to overheating When there are no oscillations the tube takes a high DC current so that after several seconds the anode of the tube starts glowing from the lower end This can be visible when the environment is not bright or it is dark It is practically not possible to do any measurements...

Page 43: ...al Other false controls from the electronics Clean the valves Replace inadequate contact points in the oscillating circuit Pos 5 15 0020 Überschriften ELTRA 1 1 Überschriften 11 Electronic dri vers malfunctioning ELTR A 6 mod_1368609174185_9 docx 40270 222 1 3 6 19BElectronic drivers malfunctioning Pos 5 16 0010 ELTR A 0015 service_instructions C S 800_Ser vice 0015 Fehl er 0140 Modul El ektr oni ...

Page 44: ...il with 200mA load We only have reports of failure when somebody tries to measure the valve voltages accidentally causing a short circuit In case of short circuit the drivers are immediately destroyed Therefore it is practically not possible to realize the short circuit It is however not a coincident when drivers working for lots of years in an analyzer fail just in the moment when somebody tries ...

Page 45: ...6 mod_1368610904372_9 docx 40292 22 1 3 7 20BFurnace does not close Pos 5 18 0010 ELTR A 0015 service_instructions C S 800_Ser vice 0015 Fehl er 0145 Modul Ofen schli eßt nicht ELTRA 6 mod_1377688602089_9 docx 46579 2 1 Fig 23 Pneumatics schematically 1 2 3 4 6 7 8 9 V10 10 11 13 12 14 15 11190 ...

Page 46: ...he operator The pressure regulator 8 is found on the inside on the right side section of the analyzer installed on the rear panel One of the pneumatic valves V7 or V10 or both is malfunctioning The magnetic coil of the pneumatic valve V7 or V10 is not powered The furnace floor goes up when valve V10 receives 24 VDC The 24 V DC comes from the microcontroller board if not replace the electronic driv...

Page 47: ...sis During combustion the software takes the peak maximum to add to the entered comparator value an additional amount depending on the actual peak maximum 3 8 1 91B Additional reasons for excessive analysis duration could be Dirty dust trap Saturated chemicals Cotton glass or quartz wool is pressed too tightly The oxygen is not pure or the catalyst furnace is faulty or is cold or the copper oxide ...

Page 48: ...er START If the drift is larger then check the IR source voltage RF interference on the IR cell or on the electronic units If the generator s high frequency disrupts the electronic units or the infrared cell then the base line on the PC monitor appears jerky ...

Page 49: ...e cover 3 does not seal tightly with the plates 4 and 5 or with the contract straps behind it on the front panel 6 One or both filters 7 are not OK The filter 11 can also be damaged in this way When the ground strip 12 is not connected after removal or replacement of the oscillator the filters 7 will defect The capacitor 9 is out of order The capacitor 10 is out of order This is however less likel...

Page 50: ...ication Overview Pos 5 23 0020 Überschriften ELTRA 1 1 Überschriften 11 U nregel mäßige Ergebnisse Irregul ar results ELTR A 6 mod_1368621241035_9 docx 40358 22 1 3 10 23BIrregular results Pos 5 24 0010 ELTR A 0015 service_instructions C S 800_Ser vice 0015 Fehl er 0160 Modul U nregel mäßige Ergebnisse ELTR A 6 mod_1377688605378_9 docx 46615 2 1 There are a lot of different reasons for this Satura...

Page 51: ... 0 oder 00 0ppm ELTRA 6 mod_1377688605901_9 docx 46627 2 1 Pos 5 27 0020 Überschriften ELTRA 1 1 Überschriften 11 C ombusti on tube life ti me is too short ELTR A 6 mod_1368628553320_9 docx 40424 222 1 3 12 25BCombustion tube life time is too short Pos 5 28 0010 ELTR A 0015 service_instructions C S 800_Ser vice 0015 Fehl er 0170 Modul H altbar keit Ofen zu kurz ELTRA 6 mod_1377688607086_9 docx 466...

Page 52: ...n it may break Check the length of the combustion tubes to be not longer than 145 mm The upper furnace closing part 17 does not provide enough space for the combustion tube To check this install a combustion tube as usually but without the O rings 11 and 12 After fixing the wing nuts 3 and 9 move the tube up and down If the tube does not move at least 0 5 to 1 mm replace the part 17 or make room f...

Page 53: ...ust the temperature See chapter IR cell temperature control Device state IR Temperature IR C IR Power Pos 5 31 0020 Überschriften ELTRA 1 1 Überschriften 11 Breaker turns off at the begi nni ng of combusti on ELTR A 6 mod_1368688648887_9 docx 40470 3222334443 1 3 14 27BBreaker turns off at the beginning of combustion Pos 5 32 0010 ELTR A 0015 service_instructions C S 800_Ser vice 0015 Fehl er 0180...

Page 54: ... window If not but Waiting for stability appears instead the reason is that after restarting the device and the oxygen flow the infrared base line could drift In order to save time there is a possibility to start without waiting for stability Quit by pressing STOP Go to the power user level and click on the button Stable The analysis cycle starts then without waiting for base line stability of the...

Page 55: ...e transformer is functioning properly Otherwise replace the transformer The cables 4 and 5 are then reconnected If the problem still remains Unplug the analyzer from the mains power The cable 7 is unscrewed and removed from the capacitor 8 After the generator starts Analyzing the cable 7 carries a voltage of about 7000 Volts The cable 7 therefore should be laid so that its end is at least 10 cm aw...

Page 56: ...rom any nearby objects The wire 1 and the copper band 2 for example should be placed far away from the plate 3 The power cable 4 should have a maximum distance from any surrounding object The copper band 5 should be placed as far as possible away from the capacitor 6 This is why the copper band 5 should always be bent around the insulator 7 If the tube 8 needs to be replaced loosen the screw 9 pul...

Page 57: ...s Pos 5 34 0010 ELTR A 0015 service_instructions C S 800_Ser vice 0015 Fehl er 0185 Modul Br aker turns off at the End ELTRA 6 mod_1377688608489_9 docx 46687 222 1 Causes The triac is malfunctioning The so called Latch up effect causes the triac to remain conductive in one direction after triggering The transformer is then acting as a short circuit because it is fed with a DC voltage Replace the T...

Page 58: ...rough the moisture trap 4 and through the filter cartridge 1 into the open air in the direction of the arrow Following this the pneumatic valve shuts and the furnace opens lift downwards When dust comes out of the furnace after this process this will cause that the pressure in the furnace is not sufficiently reduced The causes Too much dust in the dust trap 3 a few hundred analyses without cleanin...

Page 59: ...4443 1 After pressing the START button the following message appears no oxygen pressure 3 17 1 93BPossible faults on the front panel of the analyzer Fig 34 Front side panel Is the power switch 1 set on position 2 The pressure on the oxygen gauge 2 may be too low 1 5bar is normal 22psi The pressure remains constant when the furnace is closed and it sinks during the upward movement of the furnace fl...

Page 60: ... analyzer The contents of the gas cleaning furnace could be worn out and clogged 3 17 3 95BInside the analyzer 3 17 3 1 Oxygen solenoid valve V5 may be defective Open the left side panel of the analyzer Unscrew the upper tube 1 The oxygen should rush out when the power switch is set to pos 2 If not There may be no oxygen supplied Fig 35 terminal of the solenoid coil 220V AC is not measured on the ...

Page 61: ...xygen flow Pos 5 40 0010 ELTR A 0015 service_instructions C S 800_Ser vice 0015 Fehl er 0196 Modul N o oxyg en fl ow 7 mod_1380622985194_9 docx 49418 22334443 1 Possible reasons No oxygen pressure See corresponding chapter The software is in the gas saving mode If this is the case the flow will be restored when the mouse is moved or when a key is pressed like F4 for entering the sample weight or F...

Page 62: ...forget to connect the interchanged connectors to the original position again If the noise is created by the IRC board change it Remark In such case theoretically the noise could be created by the corresponding analog input of the microcontroller board however this possibility is very unlike 3 19 1 3 Too high drift Another reason for report of instability is a too high drift of at least one cell so...

Page 63: ... by pressing F2 there are the following possible reasons for the fault The valve V1 cannot open to release the oxygen pressure In order to verify that turn the twist grip on top of the dust filter to enable the oxygen pressure to escape If then the furnace opens it is obvious that the pressure could not be released after the end of analysis resp after pressing F4 The valve V1 is energized for rele...

Page 64: ... falls when the fur nace opens ELTRA 6 mod_1377688611553_9 docx 46759 2 1 Fig 37 Front panel Regardless of whether the furnace is opened or closed the oxygen pressure shown on the pressure gauge 2 must remain 1 5 bar 22 5psi constant If however the oxygen pressure falls when the furnace is open then either the valve V2 is defective or its control is incorrect When the furnace is open the valve V2 ...

Page 65: ...chriften ELTRA 1 1 Überschriften 11 C ombusti on without starting anal ysis ELTR A 6 mod_1368706920531_9 docx 41209 222 1 3 22 35BCombustion without starting analysis Pos 5 50 0010 ELTR A 0015 service_instructions C S 800_Ser vice 0015 Fehl er 019525 M odul C ombustion without starting anal ysis ELTR A 6 mod_1377688612362_9 docx 46771 2 1 In this case the combustion of the sample begins immediatel...

Page 66: ... furnace closed while testing availability of induction power Fig 39 microcontroller board The drivers of the microcontroller board are out of order when the combustion starts without pressing F5 or clicking START and without Analyzing on the screen there is only 0 5V DC on TP9 instead of 1 2V DC Replace the electronic drivers ...

Page 67: ...is out of order If no scope is available the pulses can be detected by using a voltmeter Normal values are about 0 V AC without pulses and about 1 V AC with pulses This indicated value can be different depending on the type of the voltmeter used Possible reason The triac is faulty short circuit and has to be replaced Fig 41 circuit board HF 42 ...

Page 68: ...A 6 mod_1377688613320_9 docx 46795 1 1 When the analysis cycle is carried out normally and the sample is burned but no peak on the screen possible reasons are the following The IR cell could be faulty Check the base lines See chapters Check base lines and Infrared cell adjustments If the base lines are as described the IR cell can be regarded as ruled out If the base lines are practically at zero ...

Page 69: ...ter the start of combustion If the minimum analysis time is set for example to 4 seconds the analysis may be terminated before the peak starts If the minimum analysis time is set far over 8 seconds the peak starts before the minimum time expires Due to the IR signal being then higher than the comparator level the analysis continues until the IR signal comes down to the comparator level unless the ...

Page 70: ... Infrared base line adjustments For replacing the chopper see chapter Chopper Pos 5 61 0020 Überschriften ELTRA 1 1 Überschriften 11 Sample burns but no peak on the screen 7 mod_1381400077047_9 docx 49828 222 1 3 28 41BSample burns but no peak on the screen Pos 5 62 0010 ELTR A 0015 service_instructions C S 800_Ser vice 0015 Fehl er 019555 M odul Sample burns but no peak on screen 7 mod_1381400241...

Page 71: ...ly and the distance to the base line is in the range of 10 to 50mV Depending on the blanks of the crucibles and on the oxygen purity the level of the tailing can be as high as 100mV When the burning is extremely long the level of the low carbon tailing even starts to grow Possible solutions Reduce the analysis time Increase the comparator level of the low carbon range Reduce the generator time ...

Page 72: ...ells have a tailing due to combustion gases entering the chopper housing causing permanent IR absorption for all cells available If the faulty window is on the IR sensor side there is tailing of the damaged cell only Solution Replace the part having the faulty window Replacing the window only is rather tricky because the window should be available the faulty window must be removed the surface for ...

Page 73: ...ion window After expiring of T2 and T3 V3 closes the oxygen to normally continue being supplied by the lance valve V2 until the end of analysis But if V2 blocks there is no flow any more so that the combustion gases remain in the IR paths constantly absorbing IR Radiation In this case the shape of the IR signals is repeatable as long as T2 and T3 remain unchanged unless V2 sometimes jams occasiona...

Page 74: ...settings 6 mod_1377688625026_9 docx 46855 31 1 Abb 43 Gas flow controller Set the flow rate with P1 of the HF 42 to about 180 l h Observe the flow rate on the lower flow meter of the analyzer Wait until the value is stable The output of the flow sensor is found on TP10 of the HF 42 board TP15 is GND With a flow of 180 l h the voltage is about 2 5 3V Please note without flow the output voltage of t...

Page 75: ...tions for the oxygen flow The factory setting of the jumper is for External flow enable by connecting the pins A1 A2 In this case the microcontroller board can start and stop the flow enabling gas saving mode When moving the jumper to B1 B2 for On board flow enable the flow will start and stop with the analysis begin and the analysis end in other words there is flow only during analysis This can b...

Page 76: ... mod_1368781633747_9 docx 41415 322332 1 4 1 2 103BGas flow regulation Pos 7 7 0010 ELTR A 0015 ser vice_i nstr uctions CS 800_Ser vice 0020 Einstellungen Tests und Funkti onsbeschrei bung 0215 Modul Gas Fl ow D etails 6 mod_1377688625763_9 docx 46879 343 1 Fig 27 gas flow regulation UNI Board ...

Page 77: ...e HF 42 board compares this flow value with the flow set point value The signal resulting from the comparator controls a pulse width modulator Its output can be seen on TP 8 TP 15 is GND The pulse width modulated signal runs a power transistor which in turn supplies the output signal to the flow regulating valve The duty cycle of the output signal determines its DC voltage which with a flow of abo...

Page 78: ...e of failure of a previous version sensor it is advisable to replace it by the new version In this case the part numbers of the complete assemblies should be used for ordering In case the analyzer has already the new version sensor the order should include the spare part number See attached drawings The new flow sensor cannot be used as a replacement for the older flow sensor consisting of a rotam...

Page 79: ...n The negative output peaks of the cell will also change to smaller amplitude The base line is not regulated any more Due to a recalculation formula the base lines on the screen are always zero volts the peaks are positive and they are always of equal amplitude and surface for same sample and same weight regardless the path contamination regardless the cell base line level and regardless the cell ...

Page 80: ...80 Abb 46 IRC 1 3 ...

Page 81: ...tatic control circuit TP 1 GND TP 7 IR source voltage TP 12 5V supply TP 13 Heating transistors control voltage TP 26 IR temperature actual value TP 27 24V supply TP 28 IR temperature set point 4 2 2 2 Supply voltages for IR signal processing circuit TP 6 12V TP 21 12V ...

Page 82: ...82 Fig 29 Mainboard Cut out IR Cell general test points ...

Page 83: ...t points IR ranges 4 2 3 1 Supply voltages for IR signal processing circuit TP 15 5V reference TP 20 Analog GND 4 2 3 2 Outputs base lines about 8VDC For golden paths adjust 6VDC TP 22 Output section 1 TP 25 Output section 2 TP 24 Output section 3 ...

Page 84: ...nstructions C S 800_Ser vice 0020 Einstell ungen Tests und Funktionsbeschr eibung 0235 M odul IR cell temp regul ati on gener al descri ption 6 mod_1377688627445_9 docx 46927 4244444434344343444 1 board sections 4 3 2 1 4 cells IR module Hi S Lo S Hi C Lo C 3 cells IR module S Hi C Lo C 3 cells IR module Hi S Lo S C 2 cells IR module S C 2 cells IR module C C 2 cells IR module S S 1 cell IR module...

Page 85: ...Test C of JP1 in order to switch off the temperature control so that a power supply of 1A is adequate If a jumper is available on position 3 or 4 Analysis this jumper can be moved to position 2 The positions 3 and 4 are simply parking positions for jumpers to simply be available when needed There are no tracks connected on the pins of the Analysis positions 3 and 4 of JP1 4 Make sure that the gain...

Page 86: ...y at 8V baselines or 5V to 6V in case of clean golden paths Install the IR module into the analyzer Allow sufficient time for the base lines to stabilize Start gas flow and check the base lines again If any of them is significantly over 8V then readjust 4 2 6 2 Drift too large Check the temperature regulation Unstable power supply Defective IR source NOTICE If it is shown on the display that the i...

Page 87: ...ies Normally the voltage of each source is 1 75 VDC The total voltage of all available cells can be measured on test point TP7 against TP1 GND Caution In case of adjusting resp changing the IR source voltage the base lines take a few minutes to stabilize at a new level In case of problems with adjusting the base line see chapters Infrared cell adjustments and Infrared power supply ...

Page 88: ...ture of JP1 and mainly there is no jumper on position 5 Hi Temp of JP1 In other words when no jumper is set this temperature range is already by default A jumper in position 6 Lo Temp will keep this range so there is no difference but the jumper will be available when a jumper is elsewhere really needed 3 73V 100 C 3 98V 125 C This temperature range is available for heated paths only They are the ...

Page 89: ... gain Recalculation factor 39 5 For standard gain Recalculation factor 20 59 4 2 8 3 IRC board and cross talk For non soldered sections at place of the capacitors C90 to C93 jumpers must be soldered short pieces of wire to connect not used IR outputs to GND There is a peak to see on the screen if not available IR cells are selected in the PC software For example if an analyzer has one carbon cell ...

Page 90: ... 16 0010 ELTR A 0015 service_instructions C S 800_Ser vice 0020 Einstell ungen Tests und Funktionsbeschr eibung 0240 M odul Pneumati v parts 6 mod_1377688628541_9 docx 46939 24434433444 1 Fig 33 Pneumatics parts Pneumatics parts showing the location of the pneumatic valves V7 V8 and V10 as well as the position of the pressure regulator 8 8 ...

Page 91: ...91 Abb 47 Pneumatics parts 2 1 3 4 5 6 7 8 9 10 11 12 13 14 15 ...

Page 92: ...sure on gauge 13 to be between 4 6 bar 60 85psi Press F2 to open the furnace Pull to unlock and then rotate the knob of the pressure regulator 8 counter clockwise for minimum pressure zero pressure Turn the screw 5 counter clockwise until the magnetic switch support 4 is free to move up and down on the cylinder 6 Shift the magnetic switch upwards up to the end of its adjusting range Press F2 for c...

Page 93: ...the restrictor 12 should be adjusted for lower flow by turning it clockwise It can even be completely closed by turning it clockwise up to the end of its range The flow adjusted with this restrictor is for cooling the combustion coil to ensure very long service life According to our experience the combustion coils of our analyzers don t need replacement even after years of operation Pos 7 19 0020 ...

Page 94: ...94 bar 0 5 1 1 5 2 2 5 0 PR2 1 Fig 49 Front side 4 5 47BPurge pressure Fig 50 PR2 5 6 ...

Page 95: ...el It is positioned horizontally The oxygen pressure at the outlet of the PR2 should be 0 35 bar 5psi The pressure can be checked by applying a T piece on the outlet of the pressure regulator and connecting a pressure gauge 1 as indicated above Pull and rotate the knob of the pressure regulator PR2 until the correct pressure is shown on the gauge ...

Page 96: ...ent ELTR A 6 mod_1369381713916_9 docx 42030 232322 1 4 6 48BClosing cone adjustment Pos 7 22 0010 ELTR A 0015 service_instructions C S 800_Ser vice 0020 Einstell ungen Tests und Funktionsbeschr eibung 0265 M odul Cl osing cone adj ustment 6 mod_1377688631483_9 docx 46999 242424 1 ...

Page 97: ...inearisati on 6 mod_1377688631703_9 docx 47011 42244 1 See software helps Pos 7 25 0020 Überschriften ELTRA 1 1 Überschriften 11 Bal ance pr ogramming ELTR A 6 mod_1369384797393_9 docx 42074 2422242 1 4 8 50BBalance programming Pos 7 26 0010 ELTR A 0015 service_instructions C S 800_Ser vice 0020 Einstell ungen Tests und Funktionsbeschr eibung 0275 M odul Balance pr ogramming 6 mod_1377688631889_9 ...

Page 98: ...umper J2 to B1 B2 Connect a digital multi meter on TP1 TP15 is GND Adjust only while the furnace is active Start the analysis adjusting P2 until 6 3V DC is reached on TP1 for copper analysis adjust 1 2V DC The following diagrams show the relationship between the set value adjustment with P2 on the HF 42 board and the generator parameters Fig 54 Diagramm generator current vs setpoint ...

Page 99: ...3BAdjustments tests and working instructions 99 Fig 55 Diagramm generator power vs setpoint Pos 8 0010 ELTR A Seitenumbruch 6 mod_1368796429449_0 docx 41468 24222222 1 ...

Page 100: ...e plate 4 by unscrewing the four screws 5 Take out the pre amplifiers 6 together with the spacers 7 Clean the paths with a cleaning solvent e g ethanol With a three part path such as B and C the windows can be cleaned on the inside using a cotton swab In case of a single part path such as A the path is filled with ethanol and after a few minutes oxygen is blown in to clean and dry out the path Soi...

Page 101: ...ight S Material Sample weight 1 mm 3 mm 6 Metals 500 mg 6 mm 5 Metals 500 mg 10 mm 40 Non Metals 200 mg 20 mm 20 Non Metals 200 mg 30 mm 40 mm 50 mm 100 mm 4 Non Metals 200 mg 120 mm 0 2 Metals 500 mg 140 mm 170 mm 200 mm 0 1 Metals 500 mg 275 mm 300 mm 0 3 Metals 500 mg Comments 1 5 g Tungsten accelerator are needed when analyzing Metals Above sample weights for metals and alloys are just guideli...

Page 102: ...0821864_9 docx 42223 2432 1 5 2 53BInfrared electronics Pos 9 5 0010 ELTR A 0015 ser vice_i nstr uctions CS 800_Ser vice 0025 Ser vice 0315 M odul Infrar ed el ectronics 6 mod_1377688640668_9 docx 47107 12222 1 See chapter Infrared power supply and chapter Infrared baseline adjustments Fig 57 Circuit board IRC1 3 ...

Page 103: ...er vice 039515 Modul General Test Poi nts 7 mod_1381924872474_9 docx 49938 33221223 1 Fig 35 Mainboard Cut out IR cell general test points 5 3 1 114BSupply voltages and thermostatic control circuit TP 1 GND TP 7 IR source voltage TP 12 5V supply TP 13 Heating transistors control voltage TP 26 IR temperature actual value TP 27 24V supply TP 28 IR temperature set point 5 3 2 115BSupply voltages for ...

Page 104: ...ELTR A 0015 ser vice_i nstr uctions CS 800_Ser vice 0025 Ser vice 039520 Modul IR cannel test poi nts 7 mod_1381925324500_9 docx 49949 221333 1 Fig 36 Mainboard Detail IR cell test points IR channels 5 4 1 116BSupply voltages for IR signal processing circuit TP 15 5V reference TP 20 Analog GND 5 4 2 117BOutputs base lines about 8VDC Less no problem TP 22 Output section 1 TP 25 Output section 2 ...

Page 105: ...ated the module can be operated with a power supply of 24V 1A In case of servicing an IR cell the IR cell module has to be taken out of the analyzer s cabinet and be operated on a desk using an external power supply The 24V power can then be connected on the connector J1 of the IRC board See graphic below Fig 58 IR power supply If there is no power supply 24VDC 5A the IR module can be operated by ...

Page 106: ...s 3 To install or removing the IR source 2 the complete chopper motor assembly 1 together with the mounted paths and pre amplifier should be removed from the infrared unit See chapter IR paths cleaning and replacing The chopper motor housing 1 does not need to be unscrewed Either by removing or installing the IR source In order to remove the IR source unscrew the nuts 4 with a 5 5 mm wrench and co...

Page 107: ...n case of previous IR cell models having a base line around zero volts For correcting the position of bent IR sources use a thin forceps or carefully push them to the right central position by using a thin screw driver Take care not to bend the wires too far They are quite hard so that when bending back and forth they may break In case of changing a source the wires must be very properly soldered ...

Page 108: ...Set the power switch 1 to pos 2 Close the furnace Press and hold the button 43 The entire system will be checked for leaks The leakage test is completed when the initial pressure drops about 5 seconds on gauge 12 and then remains constant the gas system is ok Should there be a continuous pressure drop then release the button 43 open the furnace press and hold the button 43 again If the pressure is...

Page 109: ...Service 109 10 10 11 9 b7 10 1 12 8 5 6 Fig 60 b7 10 1 ...

Page 110: ...Service 110 ...

Page 111: ...essure remains constant then the furnace outlet system is leaking 5 7 1 2 Leaks in the furnace outlet system After following the instructions in the section Leaks in the furnace check if the handle 8 is properly shut or else there will be a major gas leak from the dust filter Check the following components for leakage by squeezing the following tubes while pressing and holding the button 43 Tube t...

Page 112: ...5 M odul Sol enoid val ves cleaning 6 mod_1377688643571_9 docx 47227 2332333444 1 Fig 61 Solenoid valves 3 13 1 Turn the power switch to pos 0 Unplug the main power plug as well Remove the connector 7 Unscrew the nut 1 Remove the coil 2 only with the 2 2 valve Unscrew counter clockwise the hexagon screw on the armature housing Remove the armature 5 only with the 2 2 valve NOTICE Do not lose the sp...

Page 113: ...leaning Pos 9 19 0010 ELTR A 0015 service_instructions C S 800_Ser vice 0025 Ser vice 0370 M odul Fl ow sensor r epl aci ng cl eani ng 6 mod_1377688643774_9 docx 47239 3232232334434 1 Fig 39 Flow sensor 3 14 5 9 1 119BFlow sensor replacing Set the power switch to pos 0 Remove the left side panel of the analyzer Unplug the two cables at the rear side of the infrared rack 1 9 5 6 7 11 10 ...

Page 114: ...Pos 9 20 0020 Überschriften ELTRA 1 1 Überschriften 11 Furnace pneumatics additi onal safety featur es opti onal ELTR A 6 mod_1369643455549_9 docx 42531 222222232 1 5 10 61BFurnace pneumatics additional safety features optional Pos 9 21 0010 ELTR A 0015 service_instructions C S 800_Ser vice 0025 Ser vice 0380 M odul Furnace pneumatics additi onal safety features opti onal 6 mod_1377688644179_9 doc...

Page 115: ...os 9 24 0020 Überschriften ELTRA 1 1 Überschriften 11 Gas saving mode ELTRA 6 mod_1369643654807_9 docx 42575 2222322223233 1 5 12 63BGas saving mode Pos 9 25 0010 ELTR A 0015 service_instructions C S 800_Ser vice 0025 Ser vice 0390 M odul Gas savi ng mode 6 mod_1377688644613_9 docx 47287 3333234334 1 NOTICE This option is functional with EPROMS and PC software versions later than June 2001 If the ...

Page 116: ...umbruch 6 mod_1368796429449_0 docx 41468 2222322232444 1 TP15 TP16 TP17 TP18 TP19 TP20 HF41 12008 TP9 TP12 TP13 TP14 TP10 TP11 TP8 TP7 TP5 TP6 TP3 TP4 TP2 TP1 I C 1 J2 B3 B2 B1 B4 A1 A2 A3 A4 A B J2 flow enable power adjust On board flow enable Continuous flow External On board HF41 P3 TP20 TP16 TP18 TP19 TP17 TP1 TP2 TP3 TP4 TP9 TP5 TP10 TP11 TP13 TP14 TP8 TP7 TP12 P2 P1 HF42 J2 TP6 J3 B3 B2 B1 B...

Page 117: ...73449838307_9 docx 43582 22322 1 6 1 64BOrdering numbers Pos 11 3 0010 ELTR A 0015 service_instructions C S 800_Ser vice 0030 Sonstig es 3005 Modul Miscellaneous 7 mod_1382356011780_9 docx 49979 222222223333333 1 Fig 40 4 1 1 05020 Chopper blade 05030 Chopper blade holder 05064 Chopper motor 05048 Infrared source emitter 70280 O ring 70330 O ring 75120 Spring 75130 Retaining washer 75120 75190 751...

Page 118: ...dow source side 05160 IR path connector with window detector side 05170 Gas conditioner 05244 IR 4 chopper 05260 IR path tube advice the length 05270 Threaded rod advice the length 05275 Infrared preamplifier 06210 IR cable 06670 IR zero adjustment board 06733 Infrared electronics board 15207 Gas flow sensor 70180 O ring 70330 O ring ...

Page 119: ...Miscellaneous 119 77510 Heaters for IR cell ...

Page 120: ...Miscellaneous 120 6 1 2 121BFront side Fig 41 Front side ...

Page 121: ...id valve 11415 Oxygen stop solenoid valve 11430 Purge solenoid valve 11440 Bypass solenoid valve 11492 Pressure regulator 11492 Inlet pressure regulator 11495 Purge pressure regulator 12016 Gas flow and furnace control board HF 42 12044 Transformer 16100 Power supply board NK 31 18467 Microcontroller board UNI ...

Page 122: ...Miscellaneous 122 6 1 3 122BRight side Fig 42 Right side ...

Page 123: ...s 123 11190 Exhaust muffler 13850 Centrifugal blower 11376 Fixing plate for 11822 77050 TRIAC 11492 Pressure regulator 77135 Capacitor 11822 Pnematic valve block 12045 Transformer 12080 Rectifier 12100 Transformer ...

Page 124: ...1 4 123BPneumatics Fig 43 Pneumatics 60234 26319 60635 60631 60635 60631 60635 60631 60635 V7 V8 V10 60552 26618 Piston 60558 26618 26319 26618 60522 60522 Cushioning 60234 Coil cooling 60234 26319 60635 60240 60240 60513 ...

Page 125: ...Miscellaneous 125 26319 Hollow screw 26618 Valve block 60234 Pneumatic valve 60240 Silencer 60513 Fiting 60522 Fiting 60631 Closure 60635 Seal ...

Page 126: ...Miscellaneous 126 6 1 5 124BOscillating circuit Fig 44 Oscillating circuit ...

Page 127: ...nd connector 13150 Anode heat sink 13160 Coil heat sink 13170 Radiation shield 13175 Insulator 13210 Grid choke 13220 Anode choke 13250 Chassis support 13260 High voltage filter 13270 Resistor 77140 HF filter 77210 Oscillator tube 77322 Capacitorr 77330 Capacitor 77335 Capacitor 77333 Filter 77345 13261 13262 77340 77341 77342 Capacitor 77350 Capacitor 100 nF 77489 Bracket 77600 Resistor 77610 Res...

Page 128: ... 1 6 125BFurnace 14009 14014 14090 14100 14030 14021 14200 14210 14026 14165 76003 76003 14120 B9 1 3 70390 90150 14168 14180 14170 14185 76005 14035 70380 13067 14110 14130 70380 76002 14160 14150 14220 14161 71031 71010 ...

Page 129: ... 14110 Threaded rod 14120 Furnace cover 14130 Combustion tube 14150 Lower log 14160 Upper log 14161 Lower knurled nut 14165 Upper knurled nut 14168 Pedestal 14170 Pedestal mount 14180 Furnace closure 14185 Tray 14200 Metal tube 14210 Threaded rod 14220 Cylinder support 70380 O ring 70390 O ring 71010 Cleaning brush for pedestal 71031 Cleaning brush for radiation shield 76002 Washer 76003 Wing nut ...

Page 130: ...Miscellaneous 130 6 1 7 126BFurnace cleaning 75130 14080 75122 70120 14072 14051 14045 75150 14021 14160 ...

Page 131: ...ning assembly unit 14021 Upper furnace lock 14045 Cleaning brush for combustion tube 14051 Brush holder 14072 Ceramic heat shield for brush 14080 Cleaning mechanism Rod 14160 Upper log 70120 O ring 75122 Spring 75130 Safety spring 75150 Metal tube ...

Page 132: ...Miscellaneous 132 21010 Heather section 21120 Quartz tube 70380 O Ring 70380 21120 21010 ...

Page 133: ... 1 Überschriften 11 Wiring ELTR A 6 mod_1374744322423_9 docx 44380 233322 1 6 2 65BWiring I Pos 11 5 0010 ELTR A 0015 service_instructions C S 800_Ser vice 0030 Sonstig es 3010 Modul Wiring 7 mod_1382358726481_9 docx 49990 222232213344 1 Fig 46 12056 6001 ...

Page 134: ...Miscellaneous 134 Fig 47 12055 I ...

Page 135: ...Miscellaneous 135 Fig 48 12055 II ...

Page 136: ...Miscellaneous 136 Fig 49 12072 ...

Page 137: ...Miscellaneous 137 Fig 50 12064 ...

Page 138: ...Miscellaneous 138 Fig 51 12550 Vacuum cleaner ...

Page 139: ...Miscellaneous 139 Fig 52 12015 I ...

Page 140: ...Miscellaneous 140 Fig 53 12015 II ...

Page 141: ...Miscellaneous 141 Fig 54 12016 ...

Page 142: ...Miscellaneous 142 100k 50W 1µF 1µF 100nF 100nF 600pF 22 10W F11 126 36 500pF 100pF 500pF 500pF 7kV 2k7 100W 600pF A m p l i t u d e c i r c l e 1 2 0 8 5 ...

Page 143: ...Miscellaneous 143 6 2 1 127BUNI 1 ...

Page 144: ...Miscellaneous 144 6 2 2 128BGas flow system ...

Page 145: ...Miscellaneous 145 ...

Page 146: ...Miscellaneous 146 6 2 3 129BValve controlling Fig 55 Valve controlling I 11001 6001 ...

Page 147: ...furnace area from the top and from the bottom through the dust filter Before the furnace closing cone reaches the O ring to seal the oxygen which enters the furnace area escapes purging the air out of the furnace After the cone seals the furnace the incoming oxygen leads to a growing pressure in the furnace When this pressure reaches approx one bar 15 psi the pressure switch will close zero volts ...

Page 148: ...n board NR32 1 15063 Gasflow sensor 300 l h 1 15083 Gas flow meter 15 l h 1 15087 Gasflow meter 300 l h 1 15095 Gasflow meter 600 l h 1 15098 Gas flow control board FC 21 1 16110 Power supply board NK 32 1 16114 Power supply 24V 5A 18173 PC cable 1 18454 Balance cable 1 21120 Quartz tube for purification furnace 1 35310 Pressure switch 1 70120 O ring 3 4 x 1 9 VT furnace cleaning rods CS 800 and f...

Page 149: ...i 1 72020 Gauge 10 bar 140 psi 1 73020 Tube transparent 5m 73030 Tube black id 4 od 5 5m 73040 Tube black id 6 od 9 1m 75120 Spring 1 75130 Retaining washer 1 75190 Washer 1 77140 HF filter 250 V 1 78010 Mains power switch 1 90290 Copper oxide 100g 92610 Tube of grease 1 6 3 2 131BSpare parts kit for CS 800 Part Number description quantity 11105 Metal dust filter 1 11115 Plastic tube 75mm 11120 Pa...

Page 150: ...ombustion tube l 145 id 32 od 36 mm 2 14168 Pedestal 1 15207 Gas flow sensor 1 20000 Catalyst furnace 1 20040 Catalyst tube 200 x 16mm 1 75122 Spring 1 75130 Safety ring 1 77050 Triac 1 77135 Capacitor 2µF for blower at the generator unit 1 77210 Oscillator tube 1 77322 Capacitor 100 pF 30KVA 1 77333 10V 10A filter 2 77350 Capacitor 1µF 50V 2 77600 Grid resistor 1 77610 Resistor 1 80925 Sets of fu...

Page 151: ...d base line adjustments Check the metal dust filter Clean it or if necessary replace it See chapter Fluctuating gas flow See chapter High carbon results are erratic and See chapter Furrnace large collection of dust when opening Check the flow See chapter Gas flow controller Carry out leakage test Check the chopper purging The flow rate should be around 10 L h Test the power of the induction furnac...

Page 152: ...nts 84 base lines 27 Base lines window 27 Breaker turns off 53 Breaker turns off at the end of the analysis 57 C Changes serial number from 0767xxxxxx to 0950 xxxxxx 13 from 0951xxxxxx to 1079 xxxxxx 15 from 1080xxxxxx to 1556 xxxxxx 20 from 1557xxxxxx 25 up to 0766xxxxxx 9 Check base lines 27 chemicals blocked 29 Chopper motor doesn t rotate 70 circuit breaker 53 Closing cone adjustment 96 Combus...

Page 153: ... setting gas saving mode 116 Hi S 84 Hi C 84 High carbon results are erratic 32 high frequency generator 1 4 4 1 4 5S 41 49 higher sensitivity gain 89 I IC 15 43 IC 16 43 Icon Base line 35 configuration window 34 Induction generator control 97 Infrared base line adjustments 78 Infrared cell modification general information 78 Infrared electronics 102 infrared paths 101 Infrared power supply 105 In...

Page 154: ...sducer 13 R Reasons for instability 62 Rectifier 40 restricted oxygen supply 29 S Sample burns but no peak on the screen 70 Service 100 service manual notes 8 Signal and control 14 signal and control board 19 12061 25 single carbon range 84 Solenoid valves cleaning 112 Source voltage reducing 85 Spare parts kits 147 Status window message sulfur range 84 T TD 62083 43 test points general IR Cell 82...

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Page 158: ...Copyright Copyright by Eltra GmbH Haan Retsch Allee 1 5 D 42781 Haan Federal Republic of Germany ...

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