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PINSSAR DPMRA01.A Service Manual Download Page 13

PIN-M-02 DPMRA01.A Service Manual 

Copyright © Pinssar (Aust) Pty Ltd 2019. The PINSSAR logo is a registered trademark of Pinssar Pty Ltd 

 

Page 13 of 

96

 

Included in the Service Manual is a recommended diagnostic process, troubleshooting 
guide, module replacement, test and recommissioning procedure. 

5 

Service Safety 

Read  this  Service  Safety  section  carefully  before  accessing  the  DPM  Reader 
DPMRA01.A via the front access door or before proceeding with either a planned 
service  or  conducting  inspections,  maintenance,  repairs  or  diagnostic 
evaluations. 

Important Warning 

Before  accessing,  inspecting  and  conducting  the  service  on  the  DPM 
Reader  DPMRA01.A,  ensure  that  both  the  Mains  and  Battery  Isolation 
switches  are  turned 

“OFF”,  and  the  power  button  is  also  in  off  position, 

flush with the enclosure, and the mains power lead is unplugged. 

Disconnecting the AC mains power lead is an additional safety precaution 
which  is  recommended  prior  to  reading  and  fully  understanding  the 
dangers as described and illustrated in this DPM Reader Service Manual. 

The  picture  in  Figure  3  shows  the  locations  of  the  power  control  devices  used  for 
isolating power, as described the following sections of this manual. 

Summary of Contents for DPMRA01.A

Page 1: ...DPM Reader Service Manual for Model DPMRA01 A ...

Page 2: ...ed company makes no representation or warranties about its accuracy reliability completeness or suitability for any particular purpose and disclaims all responsibility and all liability including without limitation liability in negligence for all expenses losses damages including indirect or consequential damage and costs which you might incur as a result of the information and statements made in ...

Page 3: ...5 1 3 In Line Air Heater 16 5 1 4 Pinch Value 17 5 1 5 Blower 17 5 1 6 Silicon vacuum air tubes 17 5 2 Locations and safety warnings on each component 17 5 2 1 DPM Reader Layout and Locations of Warnings 17 5 2 2 240VAC Mains Caution Areas 17 5 2 3 Battery and DC Caution Areas 17 5 2 4 Laser light Caution 17 5 2 5 Heat generating components 18 6 DPM Reader Servicing 19 6 1 Tools required 19 6 2 Bo...

Page 4: ...39 9 1 1 2 Checking SIM card extension adapter insertion onto the Wireless Modem Router41 9 1 1 3 Accessing the SIM card reader extension adaptor 41 9 1 1 4 SIM Card slot located on the Wireless Modem Router 41 9 1 1 5 Replacing Wireless Modem Router SmartFlex module 42 9 1 2 FAN fault servicing 44 9 1 2 1 Fan operation diagnostics 44 9 1 2 2 Checking fan s cable connection 44 9 1 3 05 0790 Fan As...

Page 5: ...ion 60 9 2 3 2 Replacing Pinch Valve 61 9 2 4 100977 Tee Piece and Holder Replacement 61 9 2 5 05 0785 Air Heater Assembly Replacement 63 9 2 6 05 0791 Air Flow Sensor Assembly Replacement 64 9 2 7 Blower Speed Controller Replacement 64 9 3 Enclosure mounted components 65 9 3 1 Power Button Fault Servicing 65 9 3 1 1 Check connections 65 9 3 1 2 Electrical test 66 9 3 1 3 Power Button replacement ...

Page 6: ...de 78 12 Fault Finding Using the HMI 79 12 1 Valve 79 12 2 Heater 81 12 3 Amplifier 82 12 4 Sensor 83 12 5 Laser 85 12 6 Blower 86 12 7 Ambient Temperature 87 12 8 Pressure 88 12 9 PSU 89 12 10 Battery 90 12 11 LED 91 13 Operating Log Guide 93 13 1 Log Table 93 13 2 Blower RPM 93 13 3 Dark Light Reading 93 13 4 Sample Status 94 14 FAQ s 95 ...

Page 7: ...Ltd Page 7 of 96 1 General The DPM Reader model number DPMRA01 A is designed for vertical mounting onto a flat surface The Reader is a stand alone device with USB Ethernet and Wireless connectivity Limited AC Mains fail battery back up is provided using an internal Lithium Ion Phosphate battery FIGURE 1 PICTURE OF THE DPM READER ...

Page 8: ...n Please read the installation manual thoroughly before installation Incorrect operation could result in death or serious injury The DPM Reader DPMRA01 A weighs approximately 32Kg and is considered a two person lift packed or unpacked Care must be taken carrying the unit The reader contains sensitive electronic measuring equipment which will be damaged if the unit is dropped from any height or exc...

Page 9: ...rmination into the enclosure is one 1 meter in length and therefore we recommend that the power socket dedicated to the DPM Reader should be installed within 500mm of the left hand side of the enclosure The socket should be wired through a suitable circuit breaker via an RCD device Two labelled isolation switches are provided on the left hand side of the DPM Reader One is to isolate the AC mains t...

Page 10: ...s no requirement to open the enclosure to gain access to the laser scattering measurement chamber during the installation process however should the laser scattering measurement chamber be dissembled in the field for any reason you may be exposed to the laser beam causing possible injury to the unprotected eye Avoid visual contact with the laser beam 2 4 Earthing The mains earth is connected via t...

Page 11: ...me This also facilitates ease of serviceability The reader emission concentration measurements can be sent real time to a server via an IP Network for evaluation and storing An Ethernet socket located on the left hand side of the Reader facilitates connectivity to a wired LAN alternatively wireless connectivity can be provided wireless router and antenna which is configurable for Wi Fi or cellular...

Page 12: ...Service Manual Very real dangers such as AC high voltage unprotected fan blades and an operational laser may be present when accessing the DPM Reader via the front access door Specific areas within the DPM Reader where these dangers may exist are pointed out and illustrated along with the power states associated with the dangers The Service Manual provides the information required to undertake eit...

Page 13: ...ions maintenance repairs or diagnostic evaluations Important Warning Before accessing inspecting and conducting the service on the DPM Reader DPMRA01 A ensure that both the Mains and Battery Isolation switches are turned OFF and the power button is also in off position flush with the enclosure and the mains power lead is unplugged Disconnecting the AC mains power lead is an additional safety preca...

Page 14: ...y Pinssar as having completed this training 2 Tamper proof seal To gain access to the unit the tamper proof seal on the access door will need to be broken If you have had the instructional training you will have been issued replacement serial numbered tamper proof labels and a service register Reader warranty may be void if the tamper proof seal is found to be broken or the unit has been accessed ...

Page 15: ...ety Control Levels SCL defines the five safety conditions on the DPM Reader depending on the states of Mains Isolation Switch Battery Isolation Switch and Power Button These are located as shown in Figure 3 Familiarise yourself with the respective Safety Control Levels as detailed in the table below Please Note SCL1 2 and 3 requires the highest attention to safety SCL4 is the required safety level...

Page 16: ...r Electrical Safety Testing per section 7 TABLE 1 SAFETY CONTROL LEVELS FOR DPM READERS A Safety Control Level SCL will be indicated for each modules service instruction 5 1 1 SCL Levels 1 Electric Shock Caution Switch states in SCL 1 may expose the service electrician to come into direct contact with the AC mains which may cause serious injury and or fatal shock Keep a good distance from the iden...

Page 17: ...PM Reader Layout and Locations of Warnings Figure 4 identifies the applicable hazards and locations of the various components within the DPM Reader 5 2 2 240VAC Mains Caution Areas When the AC Mains power cable is connected and the Isolation Switch is in the ON position 240 110AC power will be present at the terminals of the Mains Isolation Switch and on the Main PSU Input terminals 5 2 3 Battery ...

Page 18: ...of Pinssar Pty Ltd Page 18 of 96 FIGURE 4 LOCATIONS WITHIN THE DPM READER OF HAZARDOUS AREAS 5 2 5 Heat generating components Location of the DC fan and heat generating components such as the blower pinch valve and heater have been identified in Figure 4 Warning Mains Voltage Warning 3B Laser Warning Heat hazards ...

Page 19: ...pen ended metric spanners sizes 5mm 5 5mm to 19mm 7 Long shanked nut driver 13mm mounting plate nuts 8 M3 Socket driver 9 M5 Socket driver 10 M5 5 Socket driver 11 Adjustable spanner for imperial size slot on external filter 12 Heat gun 13 Pinssar Cyclone Spanner 48 1249 14 Ethernet cable 15 Windows computer with Ethernet Cable 16 Red Lion Crimson 3 0 software 17 USB Milspec cable 18 Torch light 1...

Page 20: ...tenance requirements Items Action Harsh environment Minimum Period months Normal environment Minimum Period months 1 External high dust humidity filter Draining filter housing 3 6 Cleaning metal fine mesh filter 12 2 Internal clean air filter cartridge Replacement 6 12 3 Cyclone Filter Cleaning 0 5 1 4 On Off Button Cleaning 3 6 5 Measurement chamber Replacement 12 6 Visual inspection Per section ...

Page 21: ...pe before the re assembling unit 6 5 2 Draining filter housing The external high humidity and dust filter housing can be drained by unscrewing the drain plug at the bottom of 95S6 filter bowl as shown in Figure 6 Let it drain until there is no evidence of water droplets still forming in the drain hole Replace the threaded drain plug screwing until hand tight FIGURE 6 05 0795 COMPLETE FILTER ASSEMB...

Page 22: ... be taken not to distort or damage the fine mesh If the fine mesh is damaged during this process it is to be replaced FIGURE 7 FINE MESH FILTER After flushing cleaning visually inspect the filter cartridge to confirm its integrity for continued service Ensure the fine mesh filter is dry before reinstalling Reinstall in the reverse order 6 6 Internal clean air filter cartridge replacement Warning S...

Page 23: ...g the used with a new filter cartridge make sure the gasket is re fitted as illustrated in Figure 8 The arrow showing air flow direction on the replacement clean air filter cartridge should point inward towards canister Prior to re fitting the rotating disc use 4 6 wraps of PTFE tape on the thread Once the gasket and replacement clean air filter is aligned by hand and inserted into the canister po...

Page 24: ...chamber block laser light detector sensor light trap airflow pipe fittings and mounting bracket assembly DO NOT disassemble these from the chamber block Removal Refer to Figure 10 1 Detach the green grounding cable attached to the common Earth stud on the enclosure as illustrated in 2 Remove the two cables from the amplifier board Do not pull on the wires instead grip the connector as there will b...

Page 25: ...s provided for the replacement measurement chamber and return to the manufacturer Install 1 Reconnect the lower air hose 2 Connect two cables running from DPM Carrier board to Laser Amplifier board 3 Place Laser chamber assembly in position 4 Secure with three screws 5 Reconnect the upper air hose 6 RTV the connectors on the Amplifier board 7 Resecure wiring with cable tie 8 Enter the calibration ...

Page 26: ...ng Tasks Warning Set DPM Reader to Safety Control Level 5 and unplug the mains lead from the supply leaving the mains lead plugged into the DPM Reader Task No Items Test Measure Result 1 Mains Supply Cable Test and Tag Earth Continuity and Insulation Resistance as per local electrical laws and regulations If test fails electrical safety checks are to undertaken within the DPM Reader by a qualified...

Page 27: ...e located on the inside of the enclosure access door For your reference please use Figure 12 to locate any of the components modules as listed in the visual inspection tables The visual inspection should be carried out in two stages The first stage is a visual and auditory inspection which requires the DPM Reader to be switched ON to SCL Level 1A All hazard precautions will apply The second stage ...

Page 28: ...PIN M 02 DPMRA01 A Service Manual Copyright Pinssar Aust Pty Ltd 2019 The PINSSAR logo is a registered trademark of Pinssar Pty Ltd Page 28 of 96 FIGURE 12 DPM READER COMPONENT LOCATION DIAGRAM ...

Page 29: ...nts Replace ethernet cable and gland 3 Mains Power Cable Inspect cabling for nicks cuts abrasion or dents Replace mains cable 4 External Multi Band Antenna Wi Fi Cellular bands Check for physical damage to any part of the low profile antenna Replace as per section 9 3 5 5 External Multi Band Antenna Wi Fi Cellular bands Loose and not securely fitted to top of enclosure Firmly fasten the internally...

Page 30: ...to underside of bowl Fasten with spanner 15 Exhaust Exhaust mesh clean and unrestricted external Remove blockage and clean the mesh 16 Exhaust Not lose and tightened from the inside of enclosure Align vertical and fasten 17 Cyclone Inlet Secure External gasket in good condition Refit replace gasket if necessary 18 Power ON button external Visual whilst at least the Mains Isolation Switch is in the...

Page 31: ...er to Safety Control Level 4 Task No Components Inspection Corrective Action 1 DPM Carrier Board All four PCA mounting fasteners secured to the Right Hand Gear Plate Re tighten fasteners Inspect for component or PCB physical damage such as burn marks PCA board replacement as per section 9 2 1 Ensure all jumper cable plugs and sockets are firmly secured to the corresponding plugs and sockets on the...

Page 32: ...ight Hand Gear Plate Fasten securely refer to replacement instruction 8 Blower Cable connection to blower drive controller Check wires not crimped or broken no connectors hard wired 9 Blower Tubing condition from blower and exhaust port Check tightness of Heat Shrink seal around 19mm OD Polytube 10 Blower Blower running but no air flow Check the tubing in the pinch valve is not crimped when remove...

Page 33: ...lign and re tighten fasteners 18 Measurement Chamber Check to ensure measurement chamber L bracket fastened correctly to Right Hand Gear Plate Re fasten three mounting bracket fasteners 19 Blower Drive Controller Ensure the driver is fastened securely to the Right Hand Gear Plate Hand tighten the two M3 nyloc nuts securing the controller to the RH Gear Plate 20 Clean air filter Canister Check airf...

Page 34: ... the AC DC Power Distribution Board Firmly re insert 29 Battery Sensor battery to be firmly secured to enclosure mounting tray with bracket fastened correctly with 2 fasteners Re fit seated correctly and or remove double sided adhesive clean and re apply with new adhesive Power connectors pressed in firmly onto battery terminals Firmly re insert 30 Cellular and Wi Fi wireless modem router Unit to ...

Page 35: ...DIN rail Unlock unit from DIN rail and firmly re insert to DIN rail ensure pins to bus bar not bended and damaged 37 Axioline F Analog output module Signal connectors to Carrier Board pressed in firmly into unit Firmly re insert 38 Axioline F DI16pt DO16pt module Unit to be firmly secured to DIN rail Unlock unit from DIN rail and firmly re insert to DIN rail ensure pins to bus bar not bended and d...

Page 36: ...nnector into DPM DC DC Converter at the end of DC axial fan cable Firmly re insert 49 DC axial fan Fitted securely onto DIN Rail Re fit using sprung loaded snap in DIN Rail mounting bracket 50 SIM card reader socket Internal SIM ribbon cable damaged or crimped Replace SIM card reader socket and ribbon cable 51 DC isolation switch internal battery Input and output DC power cable pairs connected sec...

Page 37: ... damage or burn smell Replace PCA as per section 9 1 7 3 60 Cyclone Inlet Installation condition of the internal plastic cap body to the cyclone metal body and fitting of the silicon vacuum tubing onto the plastic tube adaptor Check for cracks in plastic cap body if cracked replace Refit silicon vacuum tubing 61 Cyclone Inlet Fitting and alignment of plastic tube adapter Straighten and if required...

Page 38: ...ection of the DPM Service Manual details the correct method for diagnosis and replacement of a faulty module in the field The following activities should only be carried out by a suitably qualified and competent technician The Reader is divided in to three main functional areas these being The Left Gear Plate These components are primarily related to the power distribution communication and PLC Th...

Page 39: ... in conjunction with the information in this section when determining the root cause of an issue and the appropriate solution 9 1 05 0788 Left Gear Plate Assembly Components FIGURE 14 LEFT HAND GEAR PLATE 9 1 1 Wireless Modem Router Fault Diagnostics and Replacement 9 1 1 1 WIRELESS MODEM ROUTER STATUS Visually check the status indicator LEDs on Wireless Modem Router Warning Set DPM Reader to Safe...

Page 40: ... made it will blink PORT1 Green On Off On Yellow On Blinking Off Blinking TABLE 7 ROUTER STATUS LEDS EXPLANATION Should any of the expected LED status reporting not be in accordance with the above table check the following 1 Connectivity of the wireless router power cable connection 2 That the SIM card adapter extension flexible ribbon cable is correctly inserted into the SIM card slot of the wire...

Page 41: ...acing a SIM card make sure the SIM card is inserted in the direction to SIM card reader socket refer to a diagram on the socket Push SIM card in until it stops at the end of the socket this should lock the Sim card into position Screw the dust cap back onto the SIM card reader extension adaptor and hand tighten 9 1 1 4 SIM CARD SLOT LOCATED ON THE WIRELESS MODEM ROUTER Warning Set DPM Reader to Sa...

Page 42: ...MARTFLEX MODULE Removal Warning Set DPM Reader to Safety Control Level 4 1 Remove the sim card adapter from the Router 2 Remove the three antenna cables and power cable FIGURE 17 ROUTER ANTENNA AND POWER CONNECTIONS 3 To remove from din rail loosen end stop with a flat screwdriver 4 Push router towards the bottom of the DPM Reader and tilt up 5 Remove the two mounting screws that mount the router ...

Page 43: ...with female socket goes to Wi Fi Connect power connector 3 Place router over top of din rail push towards the bottom of the DPM Reader then push down onto the din rail 4 Tighten end stop against the side of the router with a flat screwdriver 5 Insert Sim card adapter It should be inserted into SIM1 socket with the red header in the opposite direction to the SIM2 socket as shown below Press Sim ada...

Page 44: ...evel 2 The fan is switched on as soon as the DPM Reader is powered on If this is not the case you will need to 1 Take a closer look at whether an object is preventing the fan blades from turning 2 Inspect that the fan power connector is fastened correctly to the DC power board 3 Determine whether the fan is in fact faulty Warning Do not put any object or your fingers into a rotating fan this may c...

Page 45: ...ning Set DPM Reader to Safety Control Level 4 1 Using an M5 5 socket remove the 2 nyloc nuts and washers 2 Unplug the connector from the DPM Power Supply FIGURE 20 FAN ASSEMBLY REMOVAL Installation Warning Set DPM Reader to Safety Control Level 4 1 Place the fan in position and add a flat washer and new nyloc nuts both sides of the fan and tighten using an M5 5 socket Do not reuse nyloc nuts 2 Plu...

Page 46: ...ader to Safety Control Level 4 1 Place clamp over the battery and fix with 2 screws using a No 2 Phillips head screwdriver Reminder Ensure the red wire is connected to the positive terminal and the black wire to the negative terminal which are clearly marked on the battery Ensure a tight fitting of the cable terminals onto the corresponding fixed battery terminals 2 Allow the battery to charge for...

Page 47: ...le for physical damage and assess whether they should be replaced Check that the wire connections onto the respective input and output terminals ensuring the cables are not broken or damaged 9 1 5 3 REPLACING ISOLATION SWITCH Warning Set DPM Reader to Safety Control Level 4 Refer to Figure 22 Isolation switch assembly diagram Before removing any of the cables from terminals on the switch be sure t...

Page 48: ...358 Power Supply Unit PSU Fault Finding 9 1 6 1 CHECK CONNECTIONS Warning Set DPM Reader to Safety Control Level 4 Check all the connectors to every terminal on the PSU and make sure none of the connectors or cables are damaged or faulty 9 1 6 2 ELECTRICAL TEST Warning Set DPM Reader to Safety Control Level 1D Warning Be sure to follow correct live Electrical Testing procedures Refer to Figure 23 ...

Page 49: ...0 240VAC 3 Test DC output voltage from PSU Orange Cable is marked with a on the PSU board and ground black is the alternative pin The voltage should be above 14 5VDC FIGURE 23 AC AND DC VOLTAGE TEST POINTS IN THE PSU 9 1 6 3 80358 POWER SUPPLY UNIT REPLACEMENT Removal Warning Set DPM Reader to Safety Control Level 4 Refer to Figure 24 1 Unplug 3 connectors 2 Using an M5 5 socket remove the 4 nyloc...

Page 50: ... wires into correct positions 4 Add RTV to connectors on PSU Check connections thoroughly and undertake Section 7 Electrical Safety Testing 9 1 7 97 0017 Power Distribution Board PDB 9 1 7 1 CHECK CONNECTIONS Warning Set DPM Reader to Safety Control Level 4 Check all the connectors to every terminal on the PDB and make sure all connectors are press fitted firmly into the corresponding PCU Socket a...

Page 51: ... trademark of Pinssar Pty Ltd Page 51 of 96 FIGURE 25 DC VOLTAGE TEST POINTS FOR PDU 9 1 7 3 POWER DISTRIBUTION BOARD PDB REPLACEMENT Removal Warning Set DPM Reader to Safety Control Level 4 Refer to Figure 26 FIGURE 26 REMOVING THE PDB 1 Unplug connectors 24VDC 14 5VDC 5VDC 14 5VDC 15VDC Step 2 Step 1 ...

Page 52: ...ew nyloc nuts in 4 positions 3 Tighten nyloc nuts using a M5 5 socket 4 Re connect all connectors in the correct position as shown 5 Apply RTV to connectors on Power Distribution Board 9 1 8 80359 Pico UPS 9 1 8 1 CHECK CONNECTIONS Warning Set DPM Reader to Safety Control Level 4 Refer to Figure 27 Check all connections to the Pico UPS 1 Output to PDU 2 Supply from PDB 3 Charge to Battery FIGURE 2...

Page 53: ...flat washers and nyloc nuts to 3 points shown keeping the top right point free for a standoff 2 Tighten using an M5 5 socket 3 To the top right corner fix a flat washer spring washer 20mm M F standoff flat washer P clip flat washer and nyloc nut 4 Use M5 socket to tighten standoff 5 Fix the Spade terminals as per the wiring diagram and markings near the Pico UPS terminals 6 Apply RTV to spade term...

Page 54: ...ate 1 and push unit down in position 2 Reconnect Ethernet USB and power connectors and temperature sensor to RS232 port 3 Replace cut cable tie at back of the unit 4 With cutters trim off excess cable tie 5 Push end stops up against Red Lion unit and tighten with a flat screwdriver 6 Apply RTV the connectors in place 9 1 10 Compact Flash Card Removal Warning Set DPM Reader to Safety Control Level ...

Page 55: ...r to Safety Control Level 4 WARNING The card should be preformatted prior to installation Failure to do so may result in lost data To install a compact flash card push it in taking note of the orientation of the card as per the Figure 30 9 1 11 112212 Phoenix Contact Relays Removal Warning Set DPM Reader to Safety Control Level 4 Refer to Figure 31 1 Release locking clip 2 Pull relay up FIGURE 31 ...

Page 56: ...registered trademark of Pinssar Pty Ltd Page 56 of 96 Installation Warning Set DPM Reader to Safety Control Level 4 Refer to Figure 31 1 Insert in to relay holder taking care to align the pins on the relay with the sockets in the holder 2 Engage locking clip FIGURE 32 INSTALLING PHOENIX RELAYS ...

Page 57: ...td Page 57 of 96 9 2 05 0788 Right Gear Plate Assembly Components FIGURE 33 RIGHT HAND GEAR PLATE 9 2 1 05 0793 DPM Carrier Board Removal Warning Set DPM Reader to Safety Control Level 4 Refer to Figure 34 1 Unplug all connectors show by red arrows 2 Using an M5 5 socket remove the 5 nyloc nuts and washers shown by purple arrows ...

Page 58: ...re 2 Secure with 5 new nyloc nuts and flat washers 3 Reinstall cables as per diagram below 4 RTV connectors FIGURE 35 CARRIER BOARD Key Description 1 DPM Carrier Board 6 DPM Power supply 42 Tee Piece Q PDB Connector R Relay Output Connector S Analog Output Connector T Analog Input Connector U Air Flow Sensor Connector V Pinch Valve Connecter W Blower Connector X Heater Connector Y DPM Amplifier Co...

Page 59: ...t disconnect Blower power cable and carry out a continuity test of the blower motor Replace if the blower fails the test 9 2 2 2 REPLACING BLOWER Removal Warning Set DPM Reader to Safety Control Level 4 Refer to Figure 36 FIGURE 36 REMOVING BLOWER 1 Using an M5 5 socket remove the 4 nyloc nuts and washers 2 Using an M5 socket remove the standoff and washer in bottom left corner 3 Unplug connector ...

Page 60: ...h valve power cable blue pair to the header labelled Pinch valve on DPM main board and make sure the cable has not been damaged Check silicon tubing paths and tube condition Check that the clear silicon tubes have not been removed from the pinch valve and are seated into the back of the provided slots on the pinch value header Ensure that the clear silicon vacuum tube from the air flow sensor is i...

Page 61: ...ivity 9 2 3 2 REPLACING PINCH VALVE Removal Warning Set DPM Reader to Safety Control Level 4 1 Unplug the connector from DPM Power Board Refer to Figure 35 label V 2 Referring to Figure 38 use an M5 5 socket remove the 2 nyloc nuts and washers 3 Remove hoses for pinch valve FIGURE 38 REMOVING THE PINCH VALVE Installation Warning Set DPM Reader to Safety Control Level 4 1 Place pinch valve onto the...

Page 62: ...l 4 Refer to Figure 39 1 Remove the hoses to the Tee Piece 2 Cut the cable ties to remove the holder from the DPM Reader FIGURE 39 AIR CIRCUIT TEE PIECE Installation Warning Set DPM Reader to Safety Control Level 4 Refer to Figure 41 1 Place the Tee Piece and holder in position and connect the hoses as shown in Figure 40 2 Place two cable ties across the holder and through the sticky mount ...

Page 63: ...Page 63 of 96 FIGURE 40 AIR CIRCUIT HOSE ROUTING AND LAYOUT 9 2 5 05 0785 Air Heater Assembly Replacement Removal Warning Set DPM Reader to Safety Control Level 4 Refer to Figure 41 FIGURE 41 REMOVING AIR HEATER ASSEMBLY 1 Disconnect 2 hoses 2 Using an M5 5 socket remove the 2 nyloc nuts and washers 3 Disconnect cable Step 1 Step 2 ...

Page 64: ...r Assembly Replacement Removal Warning Set DPM Reader to Safety Control Level 4 Refer to Figure 42 FIGURE 42 REMOVAL OF AIR FLOW SENSOR 1 Cut cable tie 2 Unplug connector 3 Using No 1 Phillips head screwdriver undo the 4 screws and washers Installation Warning Set DPM Reader to Safety Control Level 4 1 Secure air flow sensor with 4 screws 2 Connect cable to Air flow sensor 3 Secure cable tie onto ...

Page 65: ...g an M5 5 socket remove the 2 nyloc nuts and washers Installation Warning Set DPM Reader to Safety Control Level 4 1 Place the speed controller assembly in position on standoffs 2 Secure two new nyloc nuts and flat washers 3 Re connect the cables from speed controller 4 RTV the connectors on the cables 9 3 Enclosure mounted components 9 3 1 Power Button Fault Servicing 9 3 1 1 CHECK CONNECTIONS Wa...

Page 66: ...d is to be replaced If power button is functional and controls DPM Reader power fine but the power button s LED does not illuminate at all during operation the power button s LED is faulty and the power button must be replaced Warning Set DPM Reader to Safety Control Level 4 Unplug the power button s four way phoenix connector from the power board Use a multi meter to test the continuity of the co...

Page 67: ...cable 4 Plug the connector into the header After the replacement check connections thoroughly close the cabinet door and implement Safety Control Level 2 to check the function of the new button Warning Set DPM Reader to Safety Control Level 2 FIGURE 45 POWER BUTTON INSTALLATION DETAILS 9 3 2 100900 Pressure Relief Valve Replacement Removal Warning Set DPM Reader to Safety Control Level 4 Refer to ...

Page 68: ...pound to the lock nut 9 3 3 05 0816 Cyclone Assembly Replacement Removal Warning Set DPM Reader to Safety Control Level 4 Refer to Figure 47 1 Remove retainer from outside of enclosure using a Pinssar cyclone spanner whilst holding the cyclone assembly from the inside with your hand 2 Disconnect the black silicone hose from the cyclone fitting External View Internal View FIGURE 47 REMOVAL OF CYCLO...

Page 69: ...ader to Safety Control Level 4 Refer to Figure 48 External View Internal View FIGURE 48 REMOVAL OF EXIT VALVE ASSEMBLY 1 Remove heat shrink from exhaust tailpiece 2 Remove nut from inside the enclosure while pulling the Exit Valve out from the outside of the DPM reader Installation Warning Set DPM Reader to Safety Control Level 4 1 Slide 110mm length of 24mm heat shrink over the clear tube attache...

Page 70: ...dhesive tape left on the enclosure External View Internal View FIGURE 49 REMOVAL OF ANTENNA Installation Warning Set DPM Reader to Safety Control Level 4 1 Remove the protective paper from the adhesive on the antenna 2 Insert into DPM Reader enclosure 3 Secure nut to underside of antenna 4 Apply Thread Locking compound to back of lock nut 5 Secure cables as indicate in Section Error Reference sour...

Page 71: ...l 4 1 Bend the legs of the Sensor at 45 degrees away from the flat side of the sensor Insert the sensor into the slot on the Sensor Spacer Ensure the flat surface of the sensor is placed flat to the enclosure 2 Replace the Spacer and stainless steel clamp assembly Reattach screws and new Nyloc nuts 3 Reconnect the sensor cable to the Carrier Board and secure the wire to the enclosure 4 Reattach th...

Page 72: ...trademark of Pinssar Pty Ltd Page 72 of 96 9 4 Wiring Looms 98 1112 Rev A 98 1097 98 1098 98 1116 98 1117 98 1118 98 1119 98 1169 98 1123 98 1126 98 1120 98 1121 98 1115 98 1114 98 1113 98 1122 98 1124 98 1129 98 1128 98 1125 98 1127 98 1130 98 1132 97 0019 98 1131 05 0814 110633 98 1170 98 1172 98 1173 ...

Page 73: ... Outputs 98 1126 Wiring PLC to Relays Digital Outputs 98 1127 Wiring Relays to Carrier Digital Outputs 98 1128 Wiring Carrier to Amplifier 98 1129 Wiring PLC to Amplifier Analog Inputs 98 1130 Wiring Sensor Airflow 98 1149 Mating Cable USB 98 1150 Mating Cable Power Unterminated 98 1169 Power switch loom 98 1170 Wiring USB Internal 98 1172 Wiring Temperature Sensor Module to Red Lion 98 1173 Wirin...

Page 74: ...lation Switch and test again 3 Battery Isolation Switch Battery voltage across switch input terminals whilst connected to the internal battery DC voltage 11 5 15VDC Voltage at the output terminals when switch is turned OFF 0 VDC Output voltage when switch is ON DC voltage 11 5 15VDC If the battery voltage is 0VAC on the Isolation switch output terminals in the ON position check terminals are secur...

Page 75: ...1 5 15VDC 11 Temp Sensor Check output voltage at sensor connection on Temperature Sensor Module DC Voltage 5 7VDC 12 Cellular and Wi Fi wireless modem router Power connector Ethernet connectors antenna connectors and SIM ribbon pressed in firmly into unit Firmly re insert 13 Blower Burn smell or not functional during measurement cycle SCL1 Confirm voltages in HMI Replace blower as per section 9 2 ...

Page 76: ... OVERVIEW HMI LANDING PAGE Note The bottom left button on the HMI window is the back button used to return to the SYSTEM OVERVIEW page as shown by the red arrow on the left Technicians can use the SYSTEM OVERVIEW page Figure 51 to start their diagnostics of issues with the DPM Reader There are 13 component pages used to assist technicians in identifying and rectifying problems with the Reader The ...

Page 77: ...k on Remote View 11 2 HMI Navigation The SYSTEM OVERVIEW page Figure 51 will allow navigation to many different screens to allow monitoring of the various components of the DPM Reader The following diagram Figure 52 shows the various screens that can be accessed from the buttons on the left hand side of the SYSTEM OVERVIEW screen Clicking on the various component boxes on the other parts of the SY...

Page 78: ...ful to place the DPM Reader in standby mode where it will stop taking samples To do this navigate to the SYSTEM EVENT SETTINGS page and change the bSystemSample value in the COUNT column to 0 seconds This will stop the DPM Reader from sampling until the DPM Reader is powered off then on again or the 0 is changed to 240 seconds to start the countdown for the next sample Remember to reactivate this ...

Page 79: ... 54 will take the user to the VALVE STATUS page see Figure 55 The red VALVE box in Figure 54 indicates that there is an error in pinch valve operation The VALVE STATUS page allows users to monitor and manually control the pinch valve Activating the pinch valve will allow the blower in the DPM Reader to draw sample air into the DPM Reader through the inlet at the bottom When the valve is off it wil...

Page 80: ...rademark of Pinssar Pty Ltd Page 80 of 96 FIGURE 54 SYSTEM OVERVIEW PAGE SHOWING PINCH VALVE ERROR RED FIGURE 55 VALVE STATUS PAGE fCurrent is the current consumption for the pinch valve during the last sample This should fall within the range of fCurrentLow to fCurrentHigh If it is outside of this range ...

Page 81: ...M Reader When OFF the pinch valve will sample air through the Humidity filter If it is not working check the status of Phoenix Contact Relay No 3 when the pinch valve is manually set to ON Check that the digital output voltage for the relay is 5VDC using a multimeter Check the 12VDC is present on the pinch valve output header on the DPM Carrier Board when the pinch valve is manually turned on Ther...

Page 82: ...the thermometer in HMI window on SYSTEM OVERVIEW page If the temperature is not rising then there is a physical problem with the heater To isolate the problem check the status of relay No 7 on Phoenix Contact Relays by measuring the output voltage using a multimeter The digital output voltage should be 5VDC Also check the heater connection on DPM carrier board is 12VDC If there is voltage out of t...

Page 83: ...YSTEM OVERVIEW page one level up by clicking the button on the bottom left corner Also check the voltage on the digital outputs out of Relay No 8 on Phoenix Contact Relays using multimeter is 5VDC Check the amplifier connection on DPM carrier board After a cycle has run check the fZeroAverageValue is between 5000 to 7500 If outside of these limits the value indicates a problem in DPM Amplifier boa...

Page 84: ...of fCurrentLow 100 and fCurrentHigh 250 If fCurrent is outside the range of setpoints wait for two more cycles to complete to see if the problem is persistent as the error may resolve itself automatically After a cycle is complete check the iDarkLightReading is 205 If it is higher than 205 it will show an unhealthy reading of sensor shown as bStatus ON To resolve this issue first check the connect...

Page 85: ...as an issue Check the digital output of relay No 5 is 5VDC while manually turning on and off the Amplifier Check the DPM carrier board output for the sensor The Amplifier Sensor and Laser are part of the calibrated sub assembly so the whole 05 0773 Laser Chamber sub assembly will need to be replaced if one of these components is faulty to maintain the calibration of the unit 12 5 Laser From the SY...

Page 86: ...s of relay No 6 in the Phoenix Contact Relays by confirming the digital output voltage is 5VDC Check the connection on DPM carrier board and check the output on DPM carrier board for the laser 12 6 Blower From the SYSTEM OVERVIEW page clicking on the BLOWER box will take the user to the BLOWER STATUS page Figure 60 This will allow operators to monitor and manually control the state of the Blower m...

Page 87: ...lower Speed Controller output FIGURE 60 BLOWER STATUS PAGE 12 7 Ambient Temperature From the SYSTEM OVERVIEW page clicking on the A TEMP box will take the user to the AMBIENT TEMP STATUS page Figure 61 This will allow operators to monitor the current temperature of the DPM reader in F and C The temperature is measured from the inside of the enclosure wall located close to the Humidity Filter The t...

Page 88: ...o cycles to complete to see if the issue is persistent If the issue is persistent check the wiring of temperature sensor module with Red Lion and with the sensor If the fault cannot be diagnosed replace the 05 0793 DPM Power Supply PCB with Temperature Sensor and two cables 12 8 Pressure From the SYSTEM OVERVIEW page clicking on the PRESS box will take the user to the PRESSURE STATUS page Figure 6...

Page 89: ...sure check the wiring for the pressure sensor out of the DPM carrier board to the Pin 17 on Analog Input module of the Phoenix Contact PLC If there is still an error the DPM Carrier board will need to be replaced as the pressure sensor is on this board 12 9 PSU From the SYSTEM OVERVIEW page clicking on the PSU box will take the user to the MAINS POWER SUPPLY STATUS Page Figure 63 This will allow o...

Page 90: ...page Figure 64 This will allow operators to monitor the state of the battery bStatus is ON if the battery is experiencing a fault This will occur if fScaledVoltage is outside of the range of fVoltageLow and fVoltageHigh Wait for two cycles to complete to see if the issue is persistent If the issue persists check the battery connections and measure the voltage across battery terminal with a multime...

Page 91: ... is a registered trademark of Pinssar Pty Ltd Page 91 of 96 FIGURE 64 BATTERY STATUS PAGE 12 11 LED From the SYSTEM OVERVIEW page clicking on the LED box will take the user to the BLOWER STATUS page Figure 65 This will allow operators to monitor and manually control the state of the LEDs ...

Page 92: ...D will be green If the DPM Reader is running on battery the LED will be red The LED will blink either red or green when the DPM Reader is sampling during the period of sampling If LED is not blinking during a sample then go to the LED status page on the HMI window to manually turn on and off the LED Check if the real time status of the LED turns on and off accordingly Check the connection of the w...

Page 93: ...rage flow value from airflow sensor CF fSensorCurrent Light sensor current Sys sSerialNumber Reader serial number CF fPSUCurrent Power supply current CF fPressure Air pressure value CF fPSUVoltage Power Supply Output Voltage CF fAmbientTemp Air temperature value TABLE 10 LOG TABLE DATA FIELDS EXPLANATION For all amperage and voltage fields i e pinch valve temp sensor etc technicians can refer to t...

Page 94: ...atus 2 Ethernet Status 3 Laser Status 4 Sensor Status 5 Heater Status 6 Blower Pump Status 7 Valve Status 8 Unused 9 Sampling Status 1 stopped 0 running 10 Unused 11 Pressure Sensor Status 12 Ambient Temp Sensor Status Most Significant Bit Example 0001000000 binary 64 decimal Error with blower Technicians can easily convert this code using a scientific calculator as illustrated below The error cod...

Page 95: ...entative to determine any impact that may occur by altering the sample interval 3 Does the DPM Reader require regular interval or periodic servicing even though it appears to be working fine Answer Yes Periodic service is very important for maintaining measurement performance and to maximise the operational lifetime of DPM Reader 4 Can any competent person complete the regular interval service Ans...

Page 96: ...formance and secondly cause other issues effectively invalidating the warranty It can also invalidate any certifications such as RCM Australia CE Europe 8 What is the Safety Control Level SCL Answer The DPM Reader depending on Mains and Battery Isolation switch positions and the power on switch position can be in different power on states There are dangers associated with each state and this is cl...

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