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CHAPTER 5 PREVENTIVE MAINTENANCE...................................................5-1

Safety Precautions............................................................................................................ 5-1
Replacement Parts List..................................................................................................... 5-1
Relay Board Replacement................................................................................................ 5-2
Switch Board Replacement.............................................................................................. 5-2
Precision Orifice Check ................................................................................................... 5-3
Span Solenoid Valve Check............................................................................................. 5-3
Flow Leak Check ............................................................................................................. 5-4
Spare Parts ....................................................................................................................... 5-4
Service Locations............................................................................................................. 5-5

CHAPTER 6 TROUBLESHOOTING ................................................................6-1

Troubleshooting Guide .................................................................................................... 6-1

APPENDIX A WARRANTY.............................................................................. A-1

APPENDIX B SCHEMATICS ..................................................................... B-1

LV200 AC Wiring Schematic..........................................................................................B-1
Main Control & Relay Board...........................................................................................B-2
200L Switch Board (Dual and Single).............................................................................B-3
Terminal Board ................................................................................................................B-4

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Summary of Contents for 10519

Page 1: ...The 220V option complies with 89 336 EEC directive for electromagnetic compatibility Model 200L Instruction Manual Single Dilution Probe Controller Part Number 10519 20Dec2007 ...

Page 2: ...ons terms and pricing are subject to change Not all products are available in all countries Please consult your local sales representative for details Thermo Fisher Scientific Air Quality Instruments 27 Forge Parkway Franklin MA 02038 1 508 520 0430 www thermo com aqi ...

Page 3: ...ientific has contracted with one or more recycling disposal companies in each EU Member State and this product should be disposed of or recycled through them Further information on Thermo Fisher Scientific s compliance with these Directives the recyclers in your country and information on Thermo Fisher Scientific products which may assist the detection of substances subject to the RoHS Directive a...

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Page 5: ...Procedure 2 2 System Plumbing Connections 2 2 Startup Procedure 2 3 CHAPTER 3 OPERATION 3 1 Electronics 3 1 Relay Board 3 1 Switch Board 3 3 Rear Terminal Board 3 4 Gauges 3 6 Flow Description 3 7 Subassemblies 3 8 CHAPTER 4 CALIBRATION 4 1 Equipment Required 4 1 Dilution Probe 4 1 Probe Technique 4 2 Single Dilution Configuration 4 2 Dilution Calculations 4 3 ...

Page 6: ...t 5 2 Precision Orifice Check 5 3 Span Solenoid Valve Check 5 3 Flow Leak Check 5 4 Spare Parts 5 4 Service Locations 5 5 CHAPTER 6 TROUBLESHOOTING 6 1 Troubleshooting Guide 6 1 APPENDIX A WARRANTY A 1 APPENDIX B SCHEMATICS B 1 LV200 AC Wiring Schematic B 1 Main Control Relay Board B 2 200L Switch Board Dual and Single B 3 Terminal Board B 4 ...

Page 7: ...System Line Connections 2 3 2 4 Dilution Probe 2 5 2 5 Sonic Orifice Assembly 2 6 3 1 Relay Board Assembly 3 2 3 2 Switch Board Assembly 3 3 3 3 Rear Terminal Board 3 4 3 4 Rear Terminal Status and Remote Activation 3 5 3 5 Gauge Locations 3 6 3 6 Plumbing Diagram 3 7 3 8 Case Bottom Assembly Layout 3 8 5 4 Span Valve Manifold Assembly 5 3 ...

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Page 9: ...vii LIST OF TABLES Table Page 4 1 Critical Orifice Sizes 4 3 5 1 Replacement Parts 5 1 ...

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Page 11: ...ffluents by mixing the exhaust gases with pressurized regulated zero air at a known dilution ratio This method meets the requirements pertained in the E P A CFR Title 40 Part 60 A critical orifice is affixed to the probe which draws the sample or span gas through to mix with the pressure being delivered from the instrument s controller unit The critical orifice selection determines which dilution ...

Page 12: ... Zero and up to 5 spans Physical Dimensions 17 W x 7 H x 23 D Weight 29 lbs Any alteration modification or republication of this instruction manual or any alteration or modification to the Thermo Environmental Instrument product without the express written consent of Thermo Environmental Instruments Inc is expressly prohibited nullifies our warranty obligations and bars our liability for any damag...

Page 13: ...ng the bottom in the rear UNPACKING The Model 200L Single Dilution Probe Controller is shipped complete in one container If upon receipt of the controller there is obvious damage to the shipping container notify the carrier immediately and hold for inspection The carrier and not Thermo Environmental Instruments Inc is responsible for any damage incurred during shipment Follow the procedure below t...

Page 14: ...ms System documentation will be issued if the unit is supplied as a component of a larger systems Before powering up of the Model 200L Single Dilution Probe Controller make sure the proper transformer configuration is correct for the proper outlet Identify the rear panel for appropriate outlet labeling The transformer is marked accordingly to identify if the transformer is for 110 AC or 220 AC The...

Page 15: ...n turn The Model 200L Single Dilution Probe Controller is now ready to be installed either in a rack assembly or for test bench purposes With the unit placed in a secured location the lines to the unit can be connected Figure 2 3 illustrates a common connection to a rack system for a Model 200L Single Dilution Probe Controller Four major plumbing connection lines and the system plumbing configurat...

Page 16: ...d to approximately 40 psig by a dilution air regulator The desired dilution ratio is determined after reviewing the application data This dilution air is delivered to the sample probe A high performance venturi in the probe provides the vacuum that draws the sample through the critical orifice This sample is mixed with the dilution air and transported through the sample transport bundle to the sel...

Page 17: ...Chapter 2 Installation 2 5 Figure 2 4 Dilution Probe ...

Page 18: ...rifice against a glass frit The glass critical orifice is attached to the dilution nozzle heat exchanger section with a graphite ferrule and nut The mantel section is carefully threaded onto the dilution nozzle heat exchanger Figure 2 5 Sonic Orifice Assembly CAUTION This is a very fine threaded section and requires anti seize compound on the threads since this section will be located in the zone ...

Page 19: ...controller can be activated remotely by a data acquisition unit or by solid state relay configurations RELAY BOARD The relay board supplies 24 Volts to the solenoid valves depending upon the position of the switch The relay board is part of the regulator relay board assembly Figure 3 1 Three ribbon cables are attached to the relay board One of the cable assemblies is connected to the switch board ...

Page 20: ...Chapter 3 Operation 3 2 62P715 Figure 3 1 Relay Board Assembly ...

Page 21: ...path for the 24 Volts DC to the solid state relays from the relay board Assembly The rotary switch behind the switch board assembly shown in Figure 3 2 uses two adjustable locking washers to select from zero sample and 5 span valves Figure 3 2 Switch Board Assembly ...

Page 22: ...ent from the Rear Terminal Board for remote activation from a data acquisition system or relay contact configurations In order to activate for zero or the 5 span valves 24 Volts DC is delivered to the appropriate terminal connection from a dry contact closed state All valves are in the de energized state with both lines to the solenoid valve at a zero volt potential Figure 3 3 Rear Terminal Board ...

Page 23: ... board assembly J9 from the relay board provides the status contacts for zero air and one to five span gas valves The connections for the status and remote activation are illustrated in Figure 3 4 NU Not Used NO Normally Open NC Normally Closed Figure 3 4 Rear Terminal Status and Remote Activation ...

Page 24: ...rmed if this pressure is below 30 psig The vacuum gauge should read from 17 to 22 inches Hg at sea level The zero air gauge should be set to 20 psig Refer to the troubleshooting section for leak checking the instrument The vacuum gauge corresponds to the setting of the high pressure air adjustment for the selection of the dilution orifice The span zero rotometer shown in Figure 2 1 should read 2 5...

Page 25: ...e dilution probe The configuration will be determined by site application and the customer s request or requirements Figure 3 6 is a flow diagram Figure 3 6 Plumbing Diagram The flow diagram illustrates a standard single configuration Some controllers may not follow the standard configuration depending upon customer requirements If this is the case refer to the system documentation or attached add...

Page 26: ...ES The subassemblies shown in Figure 3 7 are available from Thermo Environmental Spare Parts Department The subassemblies allow the customer to replace inoperable parts and troubleshoot efficiently Figure 3 7 Case Bottom Assembly Layout ...

Page 27: ...approved gas manufacturer s Certified Reference Material CRM A recommended protocol for certifying NO gas cylinders against a NO SRM or CRM is given in the Quality Assurance Handbook The NO gas cylinder should be recertified on a regular basis determined by the local quality control program DILUTION PROBE There are four lines to the dilution probe The lines are dilution air calibration line dilute...

Page 28: ...to Table 4 1 for specific data for the size of the critical orifice Table 4 1 Pyrex Critical Orifice Sizes Orifice Size Nominal Dilution Ratio P N 20 mil min 200 1 6944 50 mil min 100 1 6945 100 mil min 50 1 6946 150 mil min 20 1 6947 After the appropriate critical orifice is determined the adjustment for the Model 200L Single Dilution Probe Controller can be made Connect the analyzer unit to the ...

Page 29: ...take longer with sample line lengths over 200 feet 61 meters The dilution ratio may swing in either direction from the previous adjustment before actually stabilizing Care should be taken when adjusting the dilution air regulator It is better to adjust the dilution air regulator a little rather than in quarter turns increments especially if the readings are near the expected value Once the right a...

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Page 31: ...tic wrist strap that is properly connected to earth ground note that when the analyzer is unplugged the chassis is not at earth ground If an antistatic wrist strap is not available be sure to touch a grounded metal object before touching any internal components Carefully observe the instructions in each procedure Remove the power cord from the unit when any of the assemblies are replaced REPLACEME...

Page 32: ...ectors to the numbered locations on the relay board Apply power to the unit and make sure the relay board is working properly by switching all the selection points SWITCH BOARD REPLACEMENT Figure 3 2 Equipment required New Switch Board Assy Part No 14669 Nut Driver or Adjustable Wrench Flat Tip Screwdriver Slide the unit from the rack cabinet and remove the cover so that the switch board assemblie...

Page 33: ...cal orifice to draw from while providing a reasonable lag time through the sample line SPAN SOLENOID VALVE CHECK The valves can be checked by using air flow applied to the common port of the valve Use the plumbing diagram associated with the type of controller supplied with the instrument Figure 5 1 shows the components of the span valve manifold assembly 62P718 Figure 5 1 Span Valve Manifold Asse...

Page 34: ...sig of pressure through the line and then shut off the valve to keep the pressure suspended in the line Wait for about two minutes and monitor the pressure reading to see if it drops If the valve was shut off at 50 psig and stays at 48 psig for two minutes the line has no leaks If the pressure drops below 48 psig and continues to fall the line either needs to be replaced or the fittings are not ti...

Page 35: ...S For additional assistance Environmental Instruments Division has service available from exclusive distributors worldwide Contact one of the phone numbers below for product support and technical information 866 282 0430 Toll Free 508 520 0430 International ...

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Page 37: ...pondence with the factory please note the serial number of the controller unit TROUBLESHOOTING GUIDE MALFUNCTION POSSIBLE CAUSE ACTION Does not start up No power Check that the unit is plugged into the power source 115 or 220 VAC Check unit fuse Power supply Check that the voltage from the transformer is approximately 20 AC Electronics Check that all boards and defective connectors are seated prop...

Page 38: ...tles Replace the bottles to external components are listed incorrectly Zero air system Check plant instrument air or compressor system Solenoid valves are Replace the valves not switching Valve will not switch Isolate If it is the Replace the defective Relay board Assy or Board Assembly Switch Board Assy ...

Page 39: ...ial Authorization RMA which may include biohazard decontamination procedures and other product specific handling instructions and c then if applicable Buyer may return the defective Products to Seller with all costs prepaid by Buyer Replacement parts may be new or refurbished at the election of Seller All replaced parts shall become the property of Seller Shipment to Buyer of repaired or replaceme...

Page 40: ... Seller s then prevailing time and materials rates ANY INSTALLATION MAINTENANCE REPAIR SERVICE RELOCATION OR ALTERATION TO OR OF OR OTHER TAMPERING WITH THE PRODUCTS PERFORMED BY ANY PERSON OR ENTITY OTHER THAN SELLER WITHOUT SELLER S PRIOR WRITTEN APPROVAL OR ANY USE OF REPLACEMENT PARTS NOT SUPPLIED BY SELLER SHALL IMMEDIATELY VOID AND CANCEL ALL WARRANTIES WITH RESPECT TO THE AFFECTED PRODUCTS ...

Page 41: ...B 1 APPENDIX B SCHEMATICS ...

Page 42: ...APPENDIX B SCHEMATICS B 2 ...

Page 43: ...APPENDIX B SCHEMATICS B 3 ...

Page 44: ...APPENDIX B SCHEMATICS B 4 ...

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