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©Copyright MAC Instruments 2005. All Rights Reserved.

MAC155 Rev. 12

Pg 33

MAINTENANCE

Before performing any maintenance procedure, study the manual until
the procedure is understood. If there is any confusion or doubt,
contact the factory for further assistance.

Only trained personnel familiar with this type of equipment and the
hazards involved should attempt maintenance. There is a danger of
severe burns from hot surfaces and electrical shock or electrocution
from dangerous electrical voltages.

There are several components within the MAC155 Probe that may require

maintenance or even replacement from time to time.

FILTER / EXTENSION TUBE

INSTALLING THE FILTER

1. Remove the filter cover

2. Remove the compression spring

3. Slide the filter retainer bushing off

4. Slide the old filter off

5. Clean the filter element or replace it with a new or previously cleaned filter

element.

6. Slide the replacement filter over the end of the barrel

7. Cover the inside diameter of the filter retaining bushing with anti-seize

compound being careful to not get any of the compound on the filter

element.

8. Slide the retaining bushing up against the filter element.

9. Slide the compression spring over the barrel.

10. Screw the filter cover onto the barrel, tightening by hand.

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Summary of Contents for MAC155H

Page 1: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Rev 12 Instruction Manual for the MAC155L MAC155H Moisture Analyzer ...

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Page 3: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Rev 12 Instruction Manual for the MAC155L MAC155H Moisture Analyzer ...

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Page 5: ...R 5 CASE COOL 6 FILTER BLOW BACK 6 INSTALLATION 9 MOUNTING ADAPTER 11 WALL MOUNT REMOTE SAMPLING PROBE OPTION 12 PROBE WIRING 12 PROBE JUNCTION BOX 15 MAC155 PROBE JUNCTION BOX OPTION 15 MAC155 CONTROLLER FIBER OPTIC CONVERTER JUNCTION BOX OPTION 16 PROBE INSERTION 16 FILTER BLOW BACK AIR SUPPLY OPTION 17 CONTROLLER WIRING 18 PROBE TO CONTROLLER WIRING 18 CURRENT LOOP WIRING 19 MAINTENANCE MODE CO...

Page 6: ...TS 45 M1 Test of sample gas flow path 45 M2 Test of reference gas flow path 46 M3 Sampling pump test 47 M4 Calibration pump test 48 Electrical Tests Controller 48 Power Supplies 50 LED Status Indicators 50 Electrical Tests Probe 51 15V Power 51 5V Digital Power 52 5V Analog Power 52 Status Indicators 52 CONTROLLER MENU NAVIGATION 55 GENERAL MENU OPERATION 55 SETUP MENU 56 TIME SET 56 SET AUTO CALC...

Page 7: ...69 PLC INTERFACE OUTPUTS 69 PLC INTERFACE INPUTS 71 ETHERNET CONTROLLER OPTION 72 INITIAL SETUP 72 Hardware Requirements 72 Communication with Controller 72 CONTROLLER LOGIN 72 NORMAL OPERATION SCREEN 74 TIME SET UP 75 CALIBRATE OPERATION SCREEN 76 CALCHECK OPERATION SCREEN 77 IN MAINTENANCE OPERATION SCREEN 78 GENERAL CONFIGURATION MENU 79 ALARM EMAIL SETUP 79 Email To 80 Email From 80 Email Subj...

Page 8: ...ampling Probe Mounting Hole Layout 97 Probe Assembly 99 Controller Outline 101 Controller Assembly 120V 103 Probe Main Board Layout 105 Controller Main Board Layout 107 PLC Interface Wiring Diagram 109 PLC Interface Wiring Diagram continued 111 Probe to Controller Wiring 113 Probe to Controller Wiring 230V 115 Probe to Controller Wiring Remote Probe Power 117 Probe to Controller Wiring With Fiber ...

Page 9: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Rev 12 Pg v 127 ...

Page 10: ...o Probe Connectors 18 Figure 12 Controller PE GND stud 19 Figure 13 MAC155 0 5V Operation 20 Figure 14 Water Level Sensor Location 24 Figure 15 Water Filling Flushing Kit 25 Figure 16 Filling Water Tank 26 Figure 17 Draining Water Tank 27 Figure 18 Normal Display 29 Figure 19 Main Board Status Indicators 29 Figure 20 15V Power Supply Status Indicators 31 Figure 21 5V Power Supply Status Indicator ...

Page 11: ...elect 61 Figure 43 Forced Analog Output Menu 62 Figure 44 Force Calibration Pump ON Menu 63 Figure 45 Force Blow Back Sol ON Menu 63 Figure 46 Forced Case Heater Menu 64 Figure 47 Force Cond Temp to 100 Menu 64 Figure 48 Force Cond Temp to 130 Menu 65 Figure 49 Force Probe into Calibration Menu 66 Figure 50 Force Probe to Verify Calibration 67 Figure 51 Force Probe Maintenance Mode 67 Figure 52 PL...

Page 12: ...Time Setup Menu 83 Figure 64 MAC155 Time Setup Menu 83 Figure 65 MAC155 Time Setup Menu 84 Figure 66 MAC155 Time Setup Menu 85 Figure 67 Modbus 8bit Input Word 87 Figure 68 Modbus 8bit Output Word 87 Tables Table 1 DC Power Conductor Size vs Length 14 Table 2 Main Board Status Indicators 30 ...

Page 13: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Rev 12 Pg ix ...

Page 14: ...ct with surface could cause burns Risk of electric shock High voltage is present which could cause electric shock Consult Service Manual Read manual before performing any operation Protective Conductor Terminal Provides termination point for unit protective earth ground connection Only one wire is allowed on screw or stud L Important Note Information following this symbol requires special attentio...

Page 15: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Rev 12 Pg xi ...

Page 16: ......

Page 17: ...monitored and a controller which is typically located in a control room The MAC155 has multiple ranges which are user selectable using the display and pushbuttons on the controller It is necessary to do a calibration sequence if the range is changed The unit is shipped preset and calibrated to the range indicated on the order Refer to the blue factory configuration sheet that was shipped with the ...

Page 18: ...ds approximately 17 ounces 500mL of distilled water Under normal operating conditions the water will last for over a year It is recommended however that the reservoir be drained and re filled at least once per year THEORY OF OPERATION The MAC155 Probe contains a proprietary high temperature capacitive sensor that responds to the partial pressure of the water vapor that is dissolved in the atmosphe...

Page 19: ...wo points The calibrator consists of the following pieces of hardware Water Tank Condenser Calibration Valve Calibration Pump WATER TANK The water tank holds a supply of distilled water that is used to generate the water vapor that is in the reference gas stream The tank holds enough water for more than a year of normal operation The water tank has a built in water level detector that provides a L...

Page 20: ... by volume level CALIBRATION VALVE The calibration valve is normally closed when the instrument is in the RUN mode The calibration valve opens in the CALIBRATION OR CALIBRATION CHECK modes to allow the reference gas to flow to the sensor CALIBRATION PUMP The calibration pump starts to run when the instrument is in the CALIBRATION OR CALIBRATION CHECK modes This pump runs at twice the speed of the ...

Page 21: ...ension tube is to draw the sample atmosphere at a point well away from the wall of the stack or duct The 3 foot 0 9 meter extension tube can be cut to any desired length Figure 2 Extension Tube cut to 12 inch 30cm CASE HEATER The MAC155 Probe contains water that must be protected from freezing when the instrument is mounted outside in geographic locations where the ambient temperature may fall bel...

Page 22: ... should be implemented This option requires the user to supply a source of 10 psi 69kPa clean dry and oil free air into the 0 170 barbed hose fitting on the MAC155 case see figure 3 FILTER BLOW BACK The MAC155 Probe is protected from particle build up by a 10 micron filter element This option allows air to be injected into the barrel to clean the filter The blow back option can eliminate the need ...

Page 23: ...sed Air Input It is required to provide clean dry instrument air for the compressed air input Failure to do so may result in damage to the moisture sensor which is not covered under the warranty LWhen first installing the unit the air lines should be purged before connecting to unit Air Input Fitting ...

Page 24: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 8 ...

Page 25: ...l connections are made through two waterproof NEMA 4 IP 65 connectors Although the MAC155 Probe is suitable for outdoor installation it should not be mounted where it would be exposed to direct sun light or high ambient temperature unless the case cool option is used LDO NOT install the MAC155 Probe in a location where it will be exposed to direct sun light or high ambient temperature unless the c...

Page 26: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 10 Figure 5 Typical MAC155 Probe Installation ...

Page 27: ...ing cap is to cover the hole in the mounting adapter if the MAC155 Probe is removed The clamp is used to hold either the sealing cap or the MAC155 Probe in place A Teflon gasket is also provided with the mounting adapter This gasket goes between the MAC155 Probe and the ferrule on the mounting adapter The gasket is also used with the sealing cap if the MAC155 Probe is removed The mounting adapter ...

Page 28: ... hole layout for mounting the probe The probe should be mounted to the wall or panel using 4 fillister head screws PROBE WIRING The MAC155 is powered by a nominal 120 VAC 50 60 HZ 3A max power source The 240V option allows operation from a 240V 50 60Hz 1 5A supply LRefer to the wiring diagram for probe wiring at the end of this manual for detailed information Two connectors are provided on the out...

Page 29: ...unded termination point The PE stud should be terminated before any other connections to the unit are made with a 14 gauge 2 5mm2 or larger wire It is not permitted to terminate more than one wire on this stud Failure to properly terminate the Protective Earth Ground Terminal connections as specified could result in personal injury or death The DC Power wires between the MAC155 Probe and the MAC15...

Page 30: ...struments 2005 All Rights Reserved Pg 14 Maximum length of Wires One Way Wire Size AWG Nom Size mm2 150 Feet 12 4 mm2 240 Feet 10 6 mm2 400 Feet 8 10 mm2 600 Feet 6 16 mm2 1000 Feet 4 25 mm2 Table 1 DC Power Conductor Size vs Length ...

Page 31: ...fective to mount DC power supplies near the MAC155 probe In some cases it is also desirable to obtain AC power from a source close to the MAC155 probe rather than running it from the MAC155 Controller In some installations it is desirable to replace the shielded twisted pair RS485 signal cable that usually runs between the probe and controller with a fiber optic cable This provides a high level of...

Page 32: ...e measuring approximately 7 5 X 7 5 X 2 5 The 6 conductor I O cable connects between the controller and the terminal strip in the fiber optic converter junction box The I O cable supplies 15V DC power to the fiber optic converter module as well as the RS485 digital communication signal Refer to the controller fiber optic converter outline drawing and wiring diagram at the end of this manual for de...

Page 33: ...inserted into the adapter by placing the gasket over the probe barrel and then inserting the probe barrel into the mounting flange adapter Insertion into the mounting flange adapter requires an assistant to hold the MAC155 Probe until the clamp can be installed and secured The gasket must be seated in the grooves of the mating parts to assure a seal After the clamp is installed check the gasket fo...

Page 34: ...ntroller I O Pin Designations PROBE TO CONTROLLER WIRING Using the supplied cables connect the controller to the probe The rear of the controller provides the appropriate connections The wiring to the 3 pin AC Power to Probe connector and the 6 pin CONTROL I O TO PROBE is covered in the PROBE WIRING section Figure 11 Controller to Probe Connectors ...

Page 35: ...anel of the controller via a menu and pushbuttons Refer to the Setup section for the controller 0 TO 10V OR 0 TO 5V OPERATION The current loop configuration provides a high degree of immunity from interference To obtain a 0 to 5V or 0 to 10V signal configure the current loop for a 0 to 20mA output Selection of the 0 to 20mA option is explained in detail in the Controller Setup section A voltage pr...

Page 36: ...AINTENANCE MODE CONTACT The maintenance mode relay contact Normally Closed is wired to terminals on the rear of the controller When power is applied to the MAC155 this contact opens The contact can also be closed by placing the unit into the maintenance mode manually thru the Maintenance menu accessible by the push buttons on the front panel The Maintenance Mode terminals are provided to interface...

Page 37: ...d circuit must match the output of the solid state relay contacts RS485 COMMUNICATIONS The RS 485 port is provided on the rear of the controller to implement communications to external devices The external devices must be capable of Modbus RTU communication and the Modbus Communication option must be purchased The RS485 port can also communicate with the optional MAC155 PLC Interface Implementatio...

Page 38: ......

Page 39: ...f the MAC155 is not in operation when the monitored equipment is in operation remove the MAC155 from the mounting tube and seal the mounting tube with the sealing cap provided WATER TANK PREPARATION Before the MAC155 Probe can be placed in operation the water tank must be filled with distilled water Do Not use deionized water The tank holds approximately 17 fluid ounces 500mL which is enough to la...

Page 40: ...sensor If the water level falls below a minimum level the Low Water alarm will be activated L The Low Water alarm signal indicates that service to the water tank is required WATER FILLING FLUSHING KIT A funnel and drip prevention tube are supplied with the MAC155 to be used when filling the tank This funnel should not be used for any other purpose and it ...

Page 41: ...e on a level surface and open the cover Remove the plug by releasing the retention lever and pulling the plug straight out Place the drip prevention tube over the fill port Use the funnel and fill the tank until the tank overflows Hold the drip prevention tube at a slightly up angle Remove the drip prevention tube Reinsert the fill plug and close the retention lever Make sure the plug is tight as ...

Page 42: ...ater from the tank Draining is performed by first removing the fill plug then disconnecting the tubing that comes from the tank to the calibration pump at the calibration pump end and connecting the siphon pump to the to this tube that goes to the tank Pump water out of the Tank by squeezing and releasing the large size tubing Once flow is started siphoning action should draw the remaining water f...

Page 43: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Rev 12 Pg 27 Figure 17 Draining Water Tank Siphoning Pump ...

Page 44: ...ed from the ground pin of the power connector to a proper earth ground Also check that the AC voltage is correct 120 VAC 50 60 HZ or 240 VAC 50 60 Hz and is connected to the correct pins of the power connector Refer to the connection diagram When power is first applied to the MAC155 Probe the LED s on the power supply board labeled 15 V and 15 V should light up If they do not turn off power and ch...

Page 45: ... pump will stop running and there will be no status messages displayed on the screen Figure 18 Normal Display STATUS INDICATORS There are nine LED s on the main board that indicate the status of various functions They can be observed to confirm that theMAC155 Probe is operating correctly or they can be used for troubleshooting when problems occur Figure 19 Main Board Status Indicators Tank Heater ...

Page 46: ...F indicates power off Note case heater is an option ON OR OFF Case Cool Power to case cool solenoid status ON indicates power on OFF indicates power off Note case cool is an option ON OR OFF Water Level OK During normal operation this LED should be ON OFF indicates water tank needs service ON BLOW BACK Power to blow back solenoid status ON indicates solenoid power on OFF indicates solenoid power o...

Page 47: ...C155 can be placed into a calibration check once every 24 hours The time this function will activate is determined by the setting in the controller A time setting of 0 00 will disable the automatic calibration check The default time is 0 00 Navigation through the MAC155 Controller s Setup menu will provide a menu selection allowing the user to change the time of the daily calibration check While i...

Page 48: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 32 Notes ...

Page 49: ...ithin the MAC155 Probe that may require maintenance or even replacement from time to time FILTER EXTENSION TUBE INSTALLING THE FILTER 1 Remove the filter cover 2 Remove the compression spring 3 Slide the filter retainer bushing off 4 Slide the old filter off 5 Clean the filter element or replace it with a new or previously cleaned filter element 6 Slide the replacement filter over the end of the b...

Page 50: ...on should be used This option automatically cleans the filter by blowing user supplied compressed air in the reverse direction through the filter once per day during the calibration check In order to minimize the time that the MAC155 Probe is out of service it is recommended that if the filter ever becomes clogged it be replaced with a new or previously cleaned filter element The dirty filter can ...

Page 51: ...sed they should not be blown from the filter with compressed air but should instead be allowed to evaporate in a well ventilated area far removed from sources of ignition If compressed air were used a highly explosive cloud of mist and vapor would be generated This could also cause a hazard if inhaled or if it were to get into the eyes Figure 22 MAC155 Probe Filter Parts Figure 23 Probe Filter Par...

Page 52: ...k should be drained flushed and refilled at least once per year Read the OPERATION section in this manual for information about filling the tank When it is time to re fill the water tank proceed as follows 1 Remove all electrical power from the instrument and then open the cover 2 Loosen the mounting clamp on the barrel of the MAC155 Probe just enough to rotate the instrument clockwise approximate...

Page 53: ... revolution every 4 seconds This low speed combined with the sturdy construction of the pump assures a long life A new pump can produce a vacuum of approximately 8 psi 55 kP The pump will perform properly as long as it can produce a vacuum of at least 0 5 psi 3 4 kP The pump can be tested in the following way 1 Disconnect all electrical power to the MAC155 Probe 2 Open the cover Disconnect the sil...

Page 54: ...he sampling pump to assure that the sensor is flooded with the calibration gas The calibration pump can be tested in the same way as the sampling pump The pump will work properly as long as it can maintain a vacuum of at least 0 5 psi 3 4 kP at its suction port The calibration pump can be tested as follows 1 Disconnect all electrical power to the MAC155 Probe 2 Open the cover and connect a hose fr...

Page 55: ...ev 12 Pg 39 PERISTALTIC PUMP TUBING REPLACEMENT Figure 24 Peristaltic Pump stand in Tubing 6 Remove the two screws holding the plastic head assembly and remove the assembly from the motor Figure 25 Peristaltic Pump Assembly Remove Screws Pump Housing Pump Motor ...

Page 56: ...equired and remove the old tubing by pulling the white cam wheel and tubing out of the plastic housing Figure 26 Peristaltic Pump Housing Figure 27 Disassembled Peristaltic Pump Housing 8 Wrap the new hose around the cam wheel and insert the wheel and hose into the housing Housing Front Rubber Washers Cam Wheel Housing Back ...

Page 57: ...sing Insert the two screws through the holes in the housing and place the two black rubber washers over the ends of the screws to hold them in place 10 Mount the housing onto the motor Note that the flat on the motor shaft must line up with the internal flat in the cam wheel Tighten the screws ...

Page 58: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 42 ...

Page 59: ...an be thought of as the Moisture Analyzer Additional equipment in the MAC155 Probe is there only for checking the calibration of the Moisture Analyzer The equipment that is used to check the calibration can be thought of as the Calibrator The Moisture Analyzer and the Calibrator share certain hardware in the MAC155 Probe The same power supply is used and a single processor operates each part of th...

Page 60: ...it containing tubing fittings and tubing is included with the MAC155 Probe to facilitate connections of the test gauge to the MAC155 Probe Do NOT use a liquid filled manometer when testing differential pressures in the MAC155 Probe There is danger of sucking the liquid into the MAC155 Probe and causing damage Troubleshooting the electrical components of the MAC155 Probe requires the use of a multi...

Page 61: ...moved and blown out as described in the maintenance section of this manual The silicone rubber tubing running from the sensor module to the sampling pump should be removed and tested for blockage Replace the tubing if it appears to be brittle or degraded in any way Do the same for the tubing between the exhaust port of the sampling pump and the sample exhaust port The sampling pump and the barrel ...

Page 62: ...th The components in the reference gas flow path are the calibration pump the water tank the condenser the calibration valve and the barrel It is highly unlikely that the flow path for the reference gas would become blocked The most likely source of problems is a defective sampling pump or a loose plug in the water tank When the sampling pump runs it forces ambient air from inside the MAC155 Probe...

Page 63: ... M3 If the calibration pump is working properly and the water tank tubes and fill plug are not leaking the reference gas must flow into the barrel when the pump runs M3 Sampling pump test A new pump can produce a vacuum of approximately 8 psi 55 kP The pump will perform properly as long as it can produce a vacuum of at least 0 5 psi 3 4 kP The pump can be tested as follows 1 Disconnect all electri...

Page 64: ...ment and place it in the calibration check mode Note the reading on the vacuum gauge If it is at least 2 psi vacuum the calibration pump is operating properly 4 Disconnect electrical power disconnect the vacuum gauge and close the cover 5 The instrument may be returned to service Electrical Tests Controller When power is applied to the MAC155 controller the display on the front panel should light ...

Page 65: ...ev 12 Pg 49 Figure 28 AC Input Fuse Location Other fuses located on the back of the controller are for the 120V AC power and the 15V DC power feeding the probe Figure 29 Probe Fuse Location on Controller If the fuses test OK open the top cover of the controller ...

Page 66: ...so supplies DC power to the MAC155 probe in addition to the remaining 15V supply Each power supply has a green LED which indicates if voltage is present on the output The power supplies have a current limit function so it is possible for a short circuit to exist on the output of the supply without blowing any of the fuses The power supply voltages can be measured at the 4 pin connector located nea...

Page 67: ...ine 9 LED s to aid in diagnosing potential problems with the MAC155 probe The probe receives 120V AC power and 15V DC power from the MAC155 controller Fuses for these lines are located on the back of the controller 15V Power Two LED s labeled 15V and 15V are located in the upper left of the main board Test points are located to the right of these LED s where the DC voltage can be measured Refer to...

Page 68: ...There is no LED indicator to represent this supply due to the nature of the low current output available Test points are available for the 5V analog supply at the tope edge of the main board just below the sensor module LThe 5V analog supply should measure between 4 97V and 5 03V Status Indicators A group of 6 six LED s are located at the bottom of the main board near the center Refer to Figure 19...

Page 69: ...rature is below 45 F 7 C If the probe is equipped with the case heater option 120V AC power is applied to the case heater when ever the LED is ON Filter Blow Back The Blow Back LED comes on for 2 sec when a calibration check cycle is initiated If the probe is equipped with the Filter Blow Back Option 120V AC power is applied to the blow back solenoid valve whenever the LED is ON Water Level OK The...

Page 70: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 54 ...

Page 71: ...ontroller s display To enter the menu system press the lower pushbutton indicated by a black cap Upon pressing this button the controller will enter the general menu display Three different menu selections are available Maintenance Diagnostic and Setup Figure 30 General Menu Display If none of the available menu selections are desired pressing the button previously pressed to enter the menu displa...

Page 72: ... the clock one minute If the minute pushbutton is continuously pressed the clock will auto increment 1 minute approximately of a second Setting the Hours Pressing the Red pushbutton will increment the hour of the clock Each press of the button will increment the clock one hour If the Hour pushbutton is continuously pressed the clock will auto increment 1 Hour approximately of a second Exiting Time...

Page 73: ... per 24hr time period Set the Auto CalCheck Time using the same method as described in the Time Set Menu Setting a time of 0 00 will disable the Auto CalCheck Figure 32 Auto CalCheck Time Set Menu DISPLAY BRIGHTNESS SELECTION The menu will allow the user to select four different VFD brightness settings Level 1 100 Level 2 75 Level 3 50 Level 4 25 The default level is 100 Figure 33 Display Brightne...

Page 74: ...es two different current loop scales Scale 1 4 20mA Scale 2 0 20mA The default level is 4 20mA PROBE MBV RANGE SELECTION Figure 35 Probe MBV Range Selection Menu The MAC155 L menu provides two different MBV range scales Scale 1 3 15 Scale 2 6 30 While the MAC155 H menu provides four different MBV range scales Scale 1 3 15 Scale 2 6 30 Scale 3 9 45 Scale 4 12 60 ...

Page 75: ...ower must be removed from the MAC155 and then reapplied MAINTENANCE RELAY SET UP Figure 36 Maintenance Relay Setup Menu This menu is to enable the maintenance contacts to close during calibration and calibration check modes Press ENABLE to have the Maintenance contacts close during the CAL and CAL CHECK modes PLC INTERFACE SET UP Option Figure 37 PLC Interface Setup Menu This menu is for enabling ...

Page 76: ...tting the MODBUS RTU slave address for the MAC155 After pressing enter the following screen will appear Figure 39 MODBUS address setup 1 Press the INCREMENT or DECREMENT buttons to select the 1st digit of the desired MODBUS slave address Pressing enter will enter the first digit and move the cursor to the 2nd digit as shown below Figure 40 MODBUS address setup 2 ...

Page 77: ...P Option Figure 41 MODBUS RTU Baud rate setup This menu item is used to set the desired baud rate for MODBUS RTU communications Pressing ENTER will bring up the following display Figure 42 MODBUS Baud rate select Use the INCREMENT and DECREMENT buttons to select the desired baud rate and press enter ...

Page 78: ... Range 4 0 mA 0 20 8 0 mA 25 40 12 0 mA 50 60 16 0 mA 75 80 20 0 mA 100 100 Example using above table a 15 full scale instrument 50 of full scale is 7 5 MBV This output signal will be present on the analog output until exiting the menu and the probe updates the cache with the latest MBV value Figure 43 Forced Analog Output Menu This provides a simple way to test the MAC155 Probe output circuit and...

Page 79: ...n at the previously set value until the enable button is pressed or until the diagnostic menu is exited MANUAL CAL PUMP OPERATION Figure 44 Force Calibration Pump ON Menu Pressing the Enable pushbutton the calibration pump should run This provides a convenient way to test the pump driver circuit the pump motor and to allow pneumatic testing of pump as described in other sections of this manual The...

Page 80: ...e EXIT pushbutton is disabled until the DISABLE button is pressed MANUAL CASE HTR OPERATION Figure 46 Forced Case Heater Menu If the MAC155 Probe is equipped with the case heater option the case heater will be turn on for 1 second and then turn off for 10 seconds if the Enable pushbutton is pressed The case heater will repeat this cycle until the Disable button is pressed The EXIT pushbutton is di...

Page 81: ... the EXIT button before the DISABLE button will result in no change in the display since the EXIT button is disabled during this forced condition FORCE COND TEMP 130 Figure 48 Force Cond Temp to 130 Menu This menu option forces the condenser to 130 F A number will appear below the first line when enabled This additional number represents the actual temperature of the condenser and can be used to v...

Page 82: ...period of 12 minutes When the calibrator has finished generating the low and high calibration points the new calibration values are stored in the MAC155 Probe and then returns to normal operation Verification that the probe has accepted the command to perform a calibration procedure is indicated with a message on the display If the mode is inadvertently entered the procedure can be canceled by pre...

Page 83: ... generate a calibration gas stream of 80 of full scale for a period of 11 minutes At the end of that period the MAC155 Probe returns to the normal mode The calibration of the probe is left unchanged MANUAL PROBE MAINTENANCE MODE Figure 51 Force Probe Maintenance Mode When this mode is manually activated the Filter Blow Back Solenoid will be energized providing compressed air to clear the flow prov...

Page 84: ...and six outputs are available to interface to a PLC LEDs indicate if signals are present on the inputs and outputs There is also a bi color STATUS LED that provides information with respect to the communications via RS485 with the controller Normal communications is indicated when the STATUS LED is green and flashes on and off approximately every 2 seconds The STATUS LED can indicate a communicati...

Page 85: ... relay LOW WATER OUTPUT If the probe generates a LOW WATER Alarm a dry relay contact will close and the RED LOW WATER LED will illuminate confirming the activation of the relay The PLC Interface will also provide a General Alarm condition If this alarm is active service to the water tank is required PRESSURE ERROR OUTPUT If the probe detects a pressure sensor error it will initiate an alarm The PL...

Page 86: ...D will illuminate confirming the activation of the relay This relay output will be active any time the Local Alarm Relay is active The exception to this is if there is a loss of communications between the PLC interface and the MAC155 Controller RUN OUTPUT This output is active when the probe is operating normally Any alarm conditions or maintenance activities will deactivate this output ...

Page 87: ...ut signal should be applied for a minimum of 10 seconds to ensure the PLC interface has communicated the request to the controller MAINTENANCE Applying 24VDC to this input will place the MAC155 into a maintenance mode The MAC155 will maintain this mode until the input is removed When this input is active the MAC155 controller will indicate the maintenance mode on the display The PLC interface outp...

Page 88: ... a personal computer with a network interface card web browser and active network connection Connection directly to the controller requires the same hardware with the addition requirement of a 10Base T network crossover cable Communication with Controller Communication with the controller is all completed with a web page interface This web page will allow complete configuration of the MAC155 as we...

Page 89: ... After pressing enter you should be greeted with a pop up login box The default username MAC155 and password MAC155 need to be entered to proceed to the normal operation web page The user name and password can be changed to one of your choosing This is explained in another section Figure 54 Login Screen ...

Page 90: ... first area that may need attention is the MAC155 Time If the time was not set using the controller s menu system it can be set at this time This is accomplished by clicking on the Set MAC155 Time button Please note the Refresh button The web page will not automatically update To see any changes in the condition of the MAC155 the Refresh button must be clicked This includes any alarm or mode chang...

Page 91: ... MAC155 Time Set button will present the Change MAC155 Time web page The current time and date will be visible Note any discrepancies between the actual time and the MAC155 time Click on any boxes that need to be changed and then click Set Clock to make the changes permanent and hereby updating the controller s internal clock ...

Page 92: ...ication the controller received the command without error The Calibration mode causes the calibrator section of the MAC155 Probe to generate a calibration gas stream of 40 of full scale moisture by volume MBV for a period of 10 minutes After the generation of 40 of full scale moisture by volume the calibrator will then generate a calibration gas stream of 80 of full scale MBV When the calibrator h...

Page 93: ...med when refreshing the page and viewing the Mode text box Upon completion of the calibration mode Normal will be displayed in the text box CALCHECK OPERATION SCREEN Figure 58 MAC155 CalCheck Mode Pressing the CalCheck button places the MAC155 into a CalCheck mode The page will refresh and the text under mode will change to CalCheck This will remain until the probe has completed the CalCheck cycle...

Page 94: ...TENANCE OPERATION SCREEN Figure 59 MAC155 Time Setup Menu The In Maintenance mode can be executed by clicking on the Maintenance button The probe will stay in the in maintenance mode until cancelled by pressing the Exit Mode button or by the menu on the MAC155 controller If the mode is inadvertently entered the procedure can be canceled by pressing the EXIT Mode button It is recommended doing this...

Page 95: ...ffects the alarm reporting and operation of the MAC155 Each menu is explained in further detail following this description Figure 60 General Configuration Menu ALARM EMAIL SETUP A MAC155 controller equipped with the Ethernet option is capable of sending an email to any email account This account could be for a cell phone personal data assistant PDA pager personal computer etc What ever is most con...

Page 96: ...field is the desired email address that will be placed in the Email From field This does not have to be a valid email address Email Subject This field contains the subject of the email The default is MAC155 Alarm Placing a different subject line in this filed can provide more detail as to where the alarm is actually from An example would be for a location with more than one MAC155 the subject coul...

Page 97: ...ires a login to send email this check box will need to be checked so the username and password are sent when connecting to an email server Email Server User Name This field contains the user name required by the outgoing mail server If your email server does not require authorization you can leave the default user name Email Server Password This field contains the user password required by the out...

Page 98: ...5 L determines which scales will be available in the drop down menu Figure 62 MAC155 Time Setup Menu NETWORK CONFIGURATION MENU Clicking the Network Configuration Menu button from the main menu will load the menu shown below This menu provides three areas that need to be configured for maximum performance of the MAC155 in your network environment Each menu is explained in further detail following ...

Page 99: ...DDRESS CONFIGURATION This menu changes the default IP address of the MAC155 to an IP address that is compatible with your network Initial connection to the MAC155 using the default IP address of 192 168 0 1 This default address can be changed using the network address configuration Figure 64 MAC155 Time Setup Menu ...

Page 100: ...to a calibration check once every 24 hours The time this function will activate is determined by the setting in the controller The default time is 0 00 The MAC155 can be placed into a calibration check once every 24 hours The time this function will activate is determined by the setting in the controller The default time is 0 00 The menu allows the user to change the time of the daily calibration ...

Page 101: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Rev 12 Pg 85 Figure 66 MAC155 Time Setup Menu ...

Page 102: ... during communications The baud rate of the RS 485 serial communications must be set to the common baud rate of the master Modbus Setup The baud rate and slave number must be configured for correct Modbus communications The Baud rate and slave number are set using the setup menu Navigation instructions to the MAC155 setup menu and corresponding Modbus setup menu can be found in the CONTROLLER MENU...

Page 103: ... and Calibration check modes will return to Run mode after the 22 minute calibration or calibration check process Controller Outputs The MAC155 recognizes Function 01 Read Coil Status This function should be used to read the state of each address location Compare the bit pattern to the table following The table represents address locations 17 24 Modbus 8Bit Output Word 7 6 5 4 3 2 1 0 Address Loca...

Page 104: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 88 Drawings Mounting Outline ...

Page 105: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Rev 12 Pg 89 ...

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Page 107: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Rev 12 Pg 91 Typical Installation ...

Page 108: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 92 ...

Page 109: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Rev 12 Pg 93 Mounting Adapters ...

Page 110: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 94 ...

Page 111: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Rev 12 Pg 95 Wall Mount Remote Sampling Probe Outline ...

Page 112: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 96 ...

Page 113: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Rev 12 Pg 97 Wall Mount Remote Sampling Probe Mounting Hole Layout ...

Page 114: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 98 ...

Page 115: ...nstruments 2005 All Rights Reserved MAC155 Rev 12 Pg 99 Probe Assembly CAL SOL Valve Condenser Main Board Water Level Switch Fill Port Case Heater CAL Pump Sample Pump Water Tank Sensor Head Fitting Blow Back Sol Valve ...

Page 116: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 100 ...

Page 117: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Rev 12 Pg 101 Controller Outline ...

Page 118: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 102 ...

Page 119: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Rev 12 Pg 103 Controller Assembly 120V Main Board 5V Power Supply 15V Power Supply 15V Power Supply ...

Page 120: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 104 ...

Page 121: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Rev 12 Pg 105 Probe Main Board Layout ...

Page 122: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 106 ...

Page 123: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Rev 12 Pg 107 Controller Main Board Layout ...

Page 124: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 108 ...

Page 125: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Rev 12 Pg 109 PLC Interface Wiring Diagram ...

Page 126: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 110 ...

Page 127: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Probe MAC155 Rev 8 Pg 111 PLC Interface Wiring Diagram continued ...

Page 128: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 112 ...

Page 129: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Probe MAC155 Rev 8 Pg 113 Probe to Controller Wiring ...

Page 130: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 114 ...

Page 131: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Probe MAC155 Rev 8 Pg 115 Probe to Controller Wiring 230V ...

Page 132: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 116 ...

Page 133: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Probe MAC155 Rev 8 Pg 117 Probe to Controller Wiring Remote Probe Power ...

Page 134: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 118 ...

Page 135: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Probe MAC155 Rev 8 Pg 119 Probe to Controller Wiring With Fiber Optic Communications ...

Page 136: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 120 ...

Page 137: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Probe MAC155 Rev 8 Pg 121 Probe to Controller Wiring 230V With Fiber Optic Communications ...

Page 138: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 122 ...

Page 139: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Probe MAC155 Rev 8 Pg 123 Probe to Controller Wiring 230V With Remote CD Power ...

Page 140: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 124 ...

Page 141: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Probe MAC155 Rev 8 Pg 125 Probe Junction Box Outline Drawing ...

Page 142: ...MAC155 Rev 12 Copyright MAC Instruments 2005 All Rights Reserved Pg 126 ...

Page 143: ... Copyright MAC Instruments 2005 All Rights Reserved MAC155 Probe MAC155 Rev 8 Pg 127 Controller Fiber Optic Converter Outline ...

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