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Weathering Instrumentation Products Ci3000+ Ci4000 Ci5000 Weather-Ometer ®® Instrument Service Guide Doc. No. 07-7030-00 Revision 0 November 10, 1999 Table Of Contents 1.0 INTRODUCTION 11 2.0 WARNINGS AND PRECAUTIONS 12 3.0 3.1 3.2 REQUIRED TOOLS AND NIST TRACEABILITY Required Tools NIST Traceability 13 13 13 4.0 4.1 4.2 4.2.1 4.2.2 4.2.3 4.2.4 4.3 4.4 DATA PANEL SERVICE AND SETUP PAGES Accessing the Service Pages Service Page Functions PID Loop Parameters – Page 91 Manual Calibration – Page 92 Manual Checkout: Discretes – Page 93 Manual Checkout: Analogs – Page 94 Data Panel Control Pages Data Panel Error Messages 14 14 14 14 14 15 15 15 17 5.0 TROUBLESHOOTING PROCEDURES - QUICK GUIDE 19 5.1 Power-up Malfunctions 5.1.1 Description 5.1.2 Troubleshooting Guide 5.1.3 Troubleshooting Flow Chart 5.1.4 Troubleshooting Procedure 5.1.5 Power Component Configuration 20 20 23 24 25 26 5.2 Xenon Lamp and Irradiance Malfunctions 5.2.1 Description 5.2.2 Troubleshooting Guide 5.2.3 Troubleshooting Flow Chart – Lamp Ignition Failure 5.2.4 Troubleshooting Flow Chart – Irradiance High or Low 5.2.5 Troubleshooting Flow Chart – 2-Sun Irradiance Considerations 5.2.6 Troubleshooting Procedure – Lamp Ignition Failure (Ignitor) 5.2.7 Troubleshooting Procedure – Irradiance High or Low (Watt. Regulator) 5.2.8 Troubleshooting Procedure – 2-Sun Irradiance Considerations 29 29 34 35 36 37 38 39 42 5.3 Humidification Malfunctions 5.3.1 Description 5.3.2 Troubleshooting Guide 5.3.3 Troubleshooting Flow Chart – Humidification Failure 5.3.4 Troubleshooting Flow Charts – RH Control and Sensing Errors 5.3.5 Troubleshooting Procedure – Humidification Failure 5.3.6 Troubleshooting Procedure – RH Control and Sensing Errors 5.3.6.1 RH Reading is 0% or 100% 44 44 45 46 47 48 50 51 Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 2 Table Of Contents List of Figures Figure 5.1–1 Booster Transformer T1 Figure 5.1–2 Main Reactor L1 Figure 5.1–3 Auxiliary Reactor L2 Figure 5.1–4 Isolation Transformer T2 Figure 5.1–5 Chamber Safety Thermostat S4 Figure 5.1–6 Ci3000+ Power Component Configuration Guide Figure 5.1–7 Ci4000 Power Component Configuration Guide Figure 5.1–8 Ci5000 Power Component Configuration Guide Figure 5.2–1 Ci3000+ Xenon Lamp Circuit Figure 5.2–2 Ci4000 Xenon Lamp Circuit Figure 5.2–3 Ci5000 Xenon Lamp Circuit Figure 5.2–4 Xenon Lamp Assembly Guide Figure 5.2–5 Ci3000+ Xenon Lamp Ignitor Figure 5.2–6 Ci4000 Xenon Lamp Ignitor Figure 5.2–7 Ci5000 Xenon Lamp Ignitor Figure 5.2–8 Chamber Overtemperature Thermostat Figure 5.2–9 Xenon Lamp Wattage Regulator Figure 5.2–10 Wattage Regulator Power LED Figure 5.2–11 Wattage Regulator Output LED Figure 5.2–12 One and Two Sun Circuit Block Diagram Figure 5.3–1 Humidification System Plumbing Diagram Figure 5.3–2 Air Pressure Regulator Bowl Drain Valve Figure 5.3–3 Humidification Nozzle (rear panel) Figure 5.3–4 Humidification Nozzle Detail Figure 5.3–5 Humidifier Water Line Filter Figure 5.3–6 Humidification Block Diagram Figure 5.3–7 Humidification Solenoid Valve Locations Figure 5.3–8 Humidification Water Control Relay Q1 Figure 5.3–9 Humidity PC Board Jumpers Figure 5.3–10 APC1 Filter PC Board Figure 5.4–1 Chamber Safety Thermostat S4 Figure 5.4–2 Chamber Overtemperature Alarm Figure 5.4–3 Chamber Temperature Transmitter Figure 5.4–4 Air Heater Control Relay Q2 Figure 5.5–1 Xenon Lamp Cooling System Electrical Block Diagram Figure 5.5–2 CS-6 Lamp Cooling System Plumbing Diagram (Ci3000+) Figure 5.5–3 CS-6 Lamp Cooling System Plumbing Diagram (Ci4000/Ci5000) Figure 5.5–4 CS-6 Lamp Cooling System Figure 5.5–5 Testing the Flow Switch Figure 5.5–6 CS-6 Pump Shaft Coupling Figure 5.6–1 Lenze 8200 Blower Controller Figure 5.6–2 Blower System Electrical Block Diagram Figure 5.6–3 Blower Wheel Mounting Figure 5.6–4 Lenze Display and Input Select Jumper Figure 5.7–1 Black Sensor Transmitter & Collector Ring (Ci4000/Ci5000) Figure 5.7–2 Black Sensor Transmitter & Collector Ring (Ci3000+) Figure 5.7–3 Temperature Control Systems Electrical Block Diagrams Figure 5.7–4 Blower Controller and Chamber Temp. Transmitter (Ci4/Ci5) 21 21 21 22 25 26 27 28 30 31 32 33 38 38 38 38 40 40 41 42 44 48 48 48 48 49 49 50 50 51 52 52 55 56 59 60 61 62 67 67 69 69 73 75 78 78 79 80 Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 7 Table Of Contents List of Figures (cont.) Figure 8.3–6 CS-6 Circulator Pump and Motor Figure 8.3–7 Circulator Pump/Motor Coupling Figure 8.3–8 CS-6 Pump/Motor Details Figure 8.3–9 Ci3000+ and Ci4000 Rack Motors Figure 8.3–10 Ci5000 Rack Motor & Controller Figure 8.3–11 Rack Drive Gear Alignment Figure 8.3–12 Ci4000 Rack Motor Wiring Diagram Figure 8.4–1 Rack & Specimen Spray Solenoid Valves 184 184 184 185 185 185 186 186 Figure 8.4–2 CS-6 and Humidification Solenoid Valves Figure 8.5–1 Rack Speed Controller (Ci5000) Figure 8.5–2 Water Resistivity Monitor Figure 8.5–3 Transmitter Locations Figure 8.5–4 Chamber Overtemperature Alarm Figure 8.5–5 Lamp Water Temperature Controller Figure 8.5–6 Blower Motor Controller Figure 8.5–7 Lenze Display and Input Select Jumper Figure 8.5–8 AFE Data Panel Mark I (early Ci4000) Figure 8.5–9 AFE Data Panel Mark II Figure 8.5–10 Typical PLC Module (side view) Figure 8.5–11 PLC0 Fuse Figure 8.6–1 Ci4000 Xenon Lamp Ignitor Figure 8.6–2 Ci5000 Xenon Lamp Ignitor Figure 8.6–3 Ci4000 Ignitor Terminal Figure 8.6–4 Ci4000 Ignitor Sealing Washers Figure 8.7–1 Xenon Lamp Wattage Regulator Figure 8.7–2 Wattage Regulator Trimpots Figure 8.8–1 CS-6 Reservoir Tank Figure 8.8–2 Level Switch Float Orientation (Dry) Figure 8.9–1 Ci4000 Air Heater Figure 8.9–2 Ci4000 Rack Hub Figure 8.9–3 Ci5000 Rack Hub Figure 8.9–4 Air Heater Terminals Figure 8.10–1 Collector Ring Figure 8.11–1 Rack Bearings Figure 8.11–2 Rack Driveshaft Components Figure 8.11–3 Ci5000 Rack Hub Figure 8.12–1 Chart Recorder Terminals Figure 8.12–1 Chart Recorder Electrical Diagram 186 187 187 187 188 189 190 190 193 193 194 195 196 196 196 196 197 197 198 198 198 198 198 200 200 201 201 201 202 202 List of Tables Table 5.6 – 1 Lenze 8200 Blower Motor Controller Setup Codes Table 5.13–1 PLC6 Indicator Light Legend Table 8.5–1 Lenze 8200 Blower Motor Controller Setup Codes 77 124 192 Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 10 1.0 INTRODUCTION This manual provides instructions for the troubleshooting, calibration, maintenance and repair or replacement of all applicable systems and components of the Ci3000 + , Ci4000 and Ci5000 Weather-Ometers. These procedures should be performed only by a qualified service technician. Specifications may be subject to change without notification. Observe Precautions Before conducting any procedures, read the warnings and precautions in Section 2.0. Doing so will help ensure your safety and minimize the potential for damage to the instrument. Beforehand, always read the procedure that you will be conducting to become familiar with the steps involved, tools required and safety precautions. Topics Covered This manual covers the following topics: n Troubleshooting Power-up Malfunctions Xenon Lamp & Power Circuit Malfunctions Humidification Malfunctions Chamber Overtemperature Malfunctions CS-6 Lamp Cooling System Malfunctions Blower System Malfunctions Temperature Control Malfunctions Specimen Rack Drive Malfunctions Water Spray Malfunctions Water Resistivity Monitor Malfunctions Optional Chart Recorder Malfunctions Data Panel Malfunctions PLC (Programmable Logic Controller) Malfunctions Optional Data Acquisition System Malfunctions Reference Material Test Malfunctions (SRM) n Calibration Black Sensor (BPT and BST) Chamber (dry bulb) Sensor Relative Humidity Lamp Wattage Lamp Irradiance Air valve (Damper) Rack Speed Control Resistivity Monitor Lamp & Rack Alignment n Maintenance Lamp Water Fitting Gasket Lamp Outer Filter Cleaning Light Rod End Cleaning Lamp Burner Socket Inspection Test Chamber Cleaning Demineralizer Cartridge Replacement Flow Switch Filter Screen Cleaning Lamp Water Reservoir Cleaning Light Monitor Filter Replacement Inlet Air Filter Cleaning Humidifier Water Filter Cleaning Humidifier - Inspection, Cleaning & Adjustment Air Regulator Oil Trap Cleaning Lamp, Rack & Light Rod Alignment n Component Replacement Relay Replacement Sensor Replacement Electric Motor Replacement Solenoid Valve Replacement Controller and Transmitter Replacement Ignitor Replacement Wattage Regulator Replacement CS-6 Cooling Coil & Level Switches Air Heater Replacement Collector Ring Replacement Rack Bearing Replacement Chart Recorder Replacement Data Panel and Software Downloading n Appendix A – PLC and Data Panel Software Configuration B – Optional Yokogawa Chart Recorder Manual C – Component Parts Lists The Troubleshooting section is designed not only to help you pinpoint and verify malfunctions, but to provide a basic explanation of operating principles of the various instrument subsystems. Electrical block diagrams, while simplified, include accurate component wiring designations. Additional Questions If you have questions or encounter problems that are not addressed in this manual, please contact Atlas Service at (773) 327-4520, or send a fax to (773) 327-5787, Chicago, Illinois U.S.A. Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 11 5.0 TROUBLESHOOTING PROCEDURES 5.2 Xenon Lamp and Irradiance Control Malfunctions 5.2.1 Description Irradiance is provided by the xenon lamp system which is comprised of the xenon lamp and power supply components that include the booster transformer T1, igniter L3, main reactor L1, auxiliary reactor L2 and wattage regulator AR1. Lamp malfunctions can result from numerous causes. Ignition of the lamp can be prevented by a damaged or disconnected lamp, a CS-6 malfunction, such as low or lost water flow, or by the malfunction of a lamp circuit component. Low lamp irradiance output is often the result of burner or lamp filter aging, or expired interference filters in the light monitor. This section focuses on troubleshooting of the lamp assembly, lamp circuit components and the light monitor. For CS-6 troubleshooting, refer to Section 5.5. The Ci3000+ has a 4500 watt xenon lamp capable of operating from 1700 to 4500 watts. The 6500 watt xenon lamp in the Ci4000 is capable of operating within the range of 2500 to 7400 watts. The 12,000 watt lamp in the Ci5000 operates within the range of 4000 to 14000 watts. The xenon lamp receives its high-voltage ignition pulse from the igniter, which drops out of the circuit after the lamp is operating steadily. The instrument is designed to provide three ignition attempts before an ignition failure message is displayed on Data Panel MAIN page 1. At minimum wattage, the lamp receives its power from the main reactor only. At higher wattage levels, the auxiliary reactor and wattage regulator (in series with the main reactor) contribute additional power and provide precision wattage control. Irradiance control is provided by the light monitor which continuously monitors lamp output and provides a voltage signal to the PLC. The PLC then increases or decreases lamp wattage to maintain a stable irradiance level. Lamp wattage is continuously monitored by the wattage transducer A1 which provides a voltage signal to the PLC. Lamp cooling is provided by the CS-6 lamp cooling system which pumps filtered D.I. water through the xenon lamp. Heat is extracted from the cooling water by a tap water coil in the CS-6 reservoir tank. In locations where tap water is expensive or its temperature is too high, an optional LiquiAir unit or a refrigeration unit may be present to provide cooling of the lamp water. 65000W Xenon Lamp Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 29 C1-2 CB2-1 4 C1-2 BOOSTER TRANSFORMER T1 IGNITION PULSE RELAY K3 XENON CIRCUIT BREAKER CB1 3 4 TP2 6 32 31 34 33 PLC5-10 2 PLC5 ANALOG INPUT MODULE IGNITOR L3b PLC5-8 1 7 WATTAGE TRANSDUCER RELAY K9 L1-2 PLC6-7 PLC6-19 AUX. 1 REACTOR L2 L1-1 RELAY COIL SWITCHING SOURCE AND PLC INDICATOR LIGHTS PLC TERMINAL PLC3-2 PLC3-3 PLC3-7 PLC3-17 LED# A1 A2 A5 B5 30 NOTE: WHEN PLC LED IS ON PLC CONTACT IS CLOSED TO PROVIDE VOLTAGE TO RELAY. 1 (+) PLC6 ANALOG OUTPUT MODULE L1-1 RELAY K1 K3 K5 K9 9 3 2 6 A1-5 A1-1 6 IGNITION PULSE RELAY 5 K3 APC1 L1-2 XENON LAMP RELAY K1 5 4 L1-2 L1-2 MAIN REACTOR L1 A1b WATTAGE TRANSDUCER 1 C1-1 1 1 BLEEDER RESISTOR 20K OHM 20W 10 APC1 A1-4 (+) 3 4 AMPLIFIER RELAY K5 2 1 REAR PCB FRONT PCB 5 X3 (15V) X2 (30V) A1-2 F1 FUSE INTERNAL .062A 250V TP1 IGNITION CAPACITOR C1 40 mfd WATTAGE TRANSDUCER 2 A1a (COIL) 2 WATTAGE TRANSDUCER RELAY K9 1 3 3 X1 CB2-2 2 IGNITION CIRCUIT BREAKER CB2 WATTAGE 4 TRANSDUCER RELAY 3 K9 IGNITOR 5 L3a XENON LAMP 2 XE 1 500 OHM XENON LAMP RELAY K1 K1-4 2 Figure 5.2 – 1 Ci3000+ Xenon Lamp Circuit Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 XENON CIRCUIT BREAKER CB1 4 RESISTOR 3 WATTAGE REGULATOR AR1 2 3 IGNITION CIRCUIT BREAKER CB2 3 4 5.0 TROUBLESHOOTING PROCEDURES 2 5.2 Xenon Lamp and Irradiance Control Malfunctions 1 5.2.1 Description (cont.) Ci3000+ 4 1 4 IGNITOR L3a 3 BOOSTER TRANSFORMER T1 5 XENON LAMP XE 1 C2 C3 TB2-2 MAIN REACTOR L1 1 6 A1-5 32 31 IGNITION PULSE RELAY K3 34 33 PLC5-10 PLC5 ANALOG INPUT MODULE 2 IGNITOR L3b 1 7 7 2 3 1 (+) PLC6-7 PLC6 ANALOG OUTPUT MODULE 2 PLC6-19 2 3 4 IGNITION CIRCUIT BREAKER CB2 4 3 AMPLIFIER RELAY K5 L1-1 L1-1 RELAY COIL SWITCHING SOURCE AND PLC INDICATOR LIGHTS RELAY K1 K3 K5 K9 PLC TERMINAL PLC3-2 PLC3-3 PLC3-7 PLC3-17 5 PLC5-8 WATTAGE REGULATOR AR1 AUX. 1 REACTOR L2 6 RESISTOR R4 1.8K OHM 2W APC1 REAR PCB FRONT PCB 5 4 A1-1 WATTAGE TRANSDUCER RELAY K9 TB2-2 WATTAGE 10 TRANSDUCER RELAY 9 K9 APC1 A1-4 (+) A1b WATTAGE TRANSDUCER L1-2 L1-2 2 3 TP2 6 3 XENON LAMP RELAY K1 A1-2 F1 FUSE INTERNAL .062A 250V 4 3 CB2-2 3 WATTAGE TRANSDUCER A1a (COIL) C3-1 XENON CIRCUIT BREAKER CB1 1 IGNITION PULSE RELAY K3 1 BOOST CAP. RELAY 4 K4 TP1 C1-1 TB2-2 C2-1 VOLTAGE BOOST CAPACITORS (40 MFD) BLEEDER RESISTOR 56K OHM IGNITION CAPACITOR C1 2 C3-2 2 3 56Κ Ω 56Κ Ω C2-2 C1-2 4 500 OHM 2 WATTAGE TRANSDUCER RELAY K9 2 IGNITION CIRCUIT BREAKER CB2 RESISTOR 3 XENON LAMP RELAY K1 LED# A1 A2 A5 B5 31 NOTE: WHEN PLC LED IS ON PLC CONTACT IS CLOSED TO PROVIDE VOLTAGE TO RELAY. 5.0 TROUBLESHOOTING PROCEDURES 2 XENON CIRCUIT BREAKER CB1 Figure 5.2 – 2 Ci4000 Xenon Lamp Circuit Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 1 5.2 Xenon Lamp and Irradiance Control Malfunctions 5.2.1 Description (cont.) Ci4000 K1-4 11 3 BOOSTER TRANSFORMER T1 R 2 1 10 8 W IGNITION CAP. RELAY K3 BLEEDER RESISTOR 56K OHM 6 7 34 A1-5 PLC5-10 6 PLC5 ANALOG INPUT MODULE 33 APC1 w/b 5 IGNITOR L3 brn 3 w/b 4 blk 2 1 TB6-1 TB6-1 WATTAGE TRANSDUCER 1 A1a (COIL) 2 6 7 3 K4 2-SUN 4 WATTAGE REGULATOR AR1 2 AUX. 1 REACTOR L2 3 4 AMPLIFIER RELAY K5 L1-1 RELAY COIL SWITCHING SOURCE AND PLC INDICATOR LIGHTS 32 RELAY K1 K3 K5 K9 PLC TERMINAL LED# PLC3-2 A1 PLC3-3 A2 PLC3-7 A5 PLC3-17 B5 NOTE: WHEN PLC LED IS ON PLC CONTACT IS CLOSED TO PROVIDE VOLTAGE TO RELAY. 3 REAR PCB FRONT PCB 3 7 WATTAGE TRANSDUCER RELAY K9 2 7 IGNITION PULSE RELAY K3 4 MAIN 4 REACTOR HI L1 LOW COM 60Hz T1-1 6 4 31 1 LOW 4 FUSE 63 mA 1SLO-BLO 32 PLC5-8 K15 1-SUN 3 2 A1-4 (+) 2 TP 2 3 XENON LAMP RELAY K1 10 WATTAGE TRANSDUCER RELAY K9 APC1 1 STEP DOWN TRANSFORMER T3 2 9 TP 1 12 IGNITION CAPACITOR C1 (80 MFD) XENON CIRCUIT BREAKER CB1 WATTAGE TRANSDUCER A1b 3 1 IGNITION CIRCUIT BREAKER CB2 3 4 CB2-2 2 HIGH VOLTAGE TRANSFORMER T4 XENON LAMP XE 1 500 OHM IGNITOR 7 5 L3 WATTAGE TRANSDUCER RELAY K9 460V 230V 2 Figure 5.2 – 3 Ci5000 Xenon Lamp Circuit Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 XENON LAMP RELAY K1 XENON CIRCUIT BREAKER CB1 CB2-1 RESISTOR 4 HIGH VOLTAGE TRANSFORMER T4 3 1 (+) PLC6-7 PLC6 ANALOG OUTPUT MODULE 2 PLC6-19 IGNITION CIRCUIT BREAKER CB2 3 4 5.0 TROUBLESHOOTING PROCEDURES 2 5.2 Xenon Lamp and Irradiance Control Malfunctions 1 5.2.1 Description (cont.) Ci5000 Lamp Electrode Correct Incorrect End View of Lamp Inner Filter Union Ring Union Ring Lower Filter Housing Washer Burner Socket Union Ring Union Ring Union Ring Union Ring Spring Alignment Pin Outer Filter Outer Filter Xenon Burner Alignment Pin Washer Union Ring Union Ring Union Ring Union Ring Union Ring Mounting Ring Sealing Washer Upper Filter Housing Pin Burner Base Union Ring Install the two sealing washers onto the outer filter ends if none are in place. Connect the upper filter housing to the outer filter. Be sure to match the alignment pin and hole. Gently hand tighten. Hold the lamp sideways, and slowly slide the inner filter into the outer filter. Do NOT drop the inner filter in place or damage may occur. Check that the spring inside the lower filter housing tube is in place. Connect the lower filter housing to the outer filter. Gently hand tighten the union ring. Turn the lamp upside down. Check that the sealing washer is in place on the burner base. Slide the burner up into the burner socket. Look down through the lower filter housing to ensure that the burner tip is inside the burner socket. 33 Figure 5.2–4 Xenon Lamp Assembly Guide Check that the burner tip is inside the socket as shown. Gently hand tighten the union ring. Clean the outer filter with an optical cleaner or a 1:1 mixture of alcohol and acetone. Hold the lamp by the upper or lower filter housing only. Lamp Water Fitting Check that there is a sealing washer inside the lamp water fitting. Connect the lamp and rotate it until the alignment pin falls into place. Gently hand tighten the mounting ring. 5.0 TROUBLESHOOTING PROCEDURES Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 Burner Socket 5.2 Xenon Lamp and Irradiance Control Malfunctions (cont.) Burner Tip Must Not Be Visible Beside Socket 5.0 TROUBLESHOOTING PROCEDURES 5.2 Xenon Lamp and Irradiance Control Malfunctions (cont.) 5.2.2 Troubleshooting Guide MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION Lamp fails to ignite Chamber door open or switch failure Xenon lamp/ignition breakers off Lamp assembled/installed incorrectly Lamp ignitor lead off or loose Light rod dirty or damaged Light monitor malfunction Lamp burner socket damaged Low lamp starting voltage CS-6 cooling water flow low Ignitor malfunction Relay failure in lamp circuit PLC malfunction Close door or check switch. Turn on circuit-breakers. Check lamp. Check lead connections. Inspect/clean light rod. Check filters & photodiodes. Inspect/replace (Sec. 7.2.4). Check/adjust taps on T1 and L1. Check CS-6 (see Section 5.5) Conduct procedure in 5.2.6. Conduct procedure in 5.2.6. Conduct procedure in 5.2.6. Lamp output is high/low Burner is near end of life Lamp filters expired Burner tip/socket damaged Incorrect irradiance calibration Interference filters expired Light rod is misaligned Wattage regulator malfunction Replace xenon burner. Replace lamp filters. Inspect/replace socket or burner. Recalibrate (Section 6.9). Check/replace filters (Sec. 7.2.9). Align light rod (Secs. 7.2.14 & .15) Conduct procedure in 5.2.7. Lamp will not operate above 1-Sun level (Ci5000 only) 1-Sun or 2-Sun relay failure Perform procedure 5.2.8. Lamp operating at excessive wattage Burner is near end of life Lamp filters expired Burner tip/socket damaged Incorrect irradiance calibration Interference filters expired Light rod is misaligned Wattage regulator malfunction Replace xenon burner. Replace lamp filters. Inspect/replace socket or burner. Recalibrate (Section 6.9). Check/replace filters (Sec. 7.2.9). Align per Section 7.2.14 or 7.2.15. Conduct procedure in 5.2.7. No wattage display Blown fuse F1 on A1 transducer A1 wattage transducer board failure Check fuse. Check board output w/ lamp on. Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 34 5.0 TROUBLESHOOTING PROCEDURES 5.2 Xenon Lamp and Irradiance Control Malfunctions (cont.) 5.2.3 Troubleshooting Flow Chart - Lamp Ignition Failure 1) Confirm Xenon and Ignition circuit-breakers are on. 2) Check lamp for age, damage, proper installation and ignitor lead connections. “Lamp Water Temperature High” “Lamp Water Flow is Low” Check CS-6 cooling system (Section 5.5). 3) Check for messages on Data Panel MAIN page 1. Messages displayed 4) Initiate standard test no. 1. Ignition pulse is audible “Chamber Temperature is High” Reset chamber safety thermostat S4 in electronics drawer. Install calibrated lamp and attempt ignition. Ignition pulse is not audible 5) Check for line voltage to ignitor during pulse. Voltage is present No voltage present 6) Check for continuity between relay terminals K3-5 & K3-6 (Ci3 & Ci4) or K3-6 & K3-7 (Ci5)*. On Ci3000+ and Ci4000, replace ignitor. On Ci5000 check 1&2-Sun relays K15 and K4. Continuity Check voltage at breaker CB2. If no voltage, replace breaker. Voltage is present Coil has failed. Replace relay K3. Lamp ignites Lamp does not ignite Previous lamp is malfunctioning. Inspect for damage. Check burner socket. Measure line voltage and check transformer taps. Set T1 lamp voltage boost to next higher selection (see Section 5.1.5). Also check light rod cleanliness/integrity and light monitor filters and photodiodes (Sec. 7.2.9). No Continuity 7) Check for 24Vac at relay K3 coil during pulse. No voltage present Continuity If LED A2 on PLC3 module is on during pulse, replace PLC3 module. If the LED is off, download software program to PLC (see Appendix A & Sec. 5.13.5). 9) Check for 24Vac at TB3-7 & TB3-9 (Ci4) or TB3-5 & TB3-8 (Ci5). Check breaker CB5 and T2 output at T2-X3 & T2-X4. 8) Check for continuity at terminals PLC3-1 and PLC3-3 during pulse. No continuity No voltage Replace failed breaker or transformer T2. *Ci3 denote Ci3000+ Ci4 denotes Ci4000 Ci5 denotes Ci5000 Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 35 5.0 TROUBLESHOOTING PROCEDURES 5.2 Xenon Lamp and Irradiance Control Malfunctions (cont.) 5.2.4 Troubleshooting Flow Chart - Irradiance High or Low 1) Perform Wattage Calibration and Irradiance Calibration procedures. 2) Initiate standard test no. 1. 3) Confirm light monitor output at PLC5-11 & -13 (or at PLC5-12 & -14 for 2nd light sensor). No output Check light monitor filters & photocells (Sec. 7.2.9). 4) Initiate custom wattage-controlled test at minimum lamp wattage. 5) Observe upper green Power LED on wattage regulator. LED is off 6) Check drive current signal to wattage regulator terminal AR1-1. Should be approx. 4mA. Current is zero or well above 4mA Continuity R4 is open-circuited or wattage regulator failed. No continuity Check for 24Vac across relay K9 coil terminals. Check for continuity at relay K9 (K9-9 & K9-10). Potential PLC6 module failure. Confirm below. Voltage present Replace relay K9. 7) Initiate custom midrange wattage test at: Ci3-3000W, Ci4 – 5000W Ci5 – 8000W 8) Observe lower green Output LED on wattage regulator. Drive current is still 4mA, zero or unstable No voltage present LED dim or off & drive current well above 4mA Replace PLC6 Analog Output module (see Section 5.13.8 first). If B5 LED on PLC3 is on, replace PLC3. If LED is off, download software to PLC. If operation not restored, replace PLC3. See Section 5.13.5. Replace the wattage regulator. Run mid-range wattage test again. Drive signal should be approximately 9 to 11mA. Drive current in range Run standard test no. 1 and confirm stable irradiance within test tolerance. Drive current still zero or out of range. Replace the CPU module of the PLC (see Sec. 5.13.3). Run midrange wattage test again and check drive signal current. Drive current in range Reinstall old PLC6 module & confirm operation by running standard test no. 1. Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 36 5.0 TROUBLESHOOTING PROCEDURES 5.2 Xenon Lamp and Irradiance Control Malfunctions (cont.) 5.2.5 Troubleshooting Flow Chart - 2-Sun Irradiance Considerations (Ci5000 only) 1) Create and initiate a custom 2-Sun test. 2) Check for rack speed of 10 RPM. Rack at 1 RPM 3) Check for continuity between K14 relay terminals K14-3 and K14-4. Continuity No continuity 4) Check for 24Vac at K14 coil terminals K14-1 and K14-2. 5) With K14 operating properly, check for voltage between ground and K4 relay terminal K4-3. No voltage Relay K14 or A14 rack speed controller is malfunctioning. Check for 0 volts between ground and relay K15 terminal K15-3. If voltage present, K15 or K14 is stuck closed. Replace bad relay. If A8 LED on PLC3 is on, replace PLC3. If LED is off, download software to PLC. If operation not restored, replace PLC3. See Section 5.13.5. Voltage present Replace relay K14. Voltage present Relay K4 is o.k. No voltage present Check for 24Vac at K4 coil terminals K4-1 and K4-2. If no voltage is present, replace K4. If voltage is present, replace PLC3 Logic Output module (see Sec. 5.13.5 first). Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 37 5.0 TROUBLESHOOTING PROCEDURES 5.2 Xenon Lamp and Irradiance Control Malfunctions (cont.) 5.2.6 Troubleshooting Procedure – Lamp Ignition Failure (Ignitor) 2) Confirm that the Xenon Lamp and Ignition circuit-breakers are turned on. 3) Check for messages on the Data Panel MAIN page 1 Messages display. A) Check the CS-6 lamp cooling system (Sec. 5.5) if one of these messages appears: Ignitor LS-8 Light Monitor Lamp Water Temperature High Lamp Water Flow is Low B) If the message “Chamber Temperature is High” is displayed, reset the chamber safety thermostat (S4) inside the electronics drawer. Press the red reset button on the thermostat. Figure 5.2 – 5 Ci3000 + Lamp Ignitor & LS-8 S4 Figure 5.2 – 8 Chamber Overtemperature Thermostat Figure 5.2 – 6 Ci4000 Xenon Lamp Ignitor 4) Initiate standard test no. 1 to attempt lamp ignition. 5) If the ignition start pulse is audible (up to 4 attempts), but the lamp will not ignite, the problem is either the lamp itself or low lamp-circuit voltage. Figure 5.2 – 7 Ci5000 Xenon Lamp Ignitor 1) Ensure that the xenon lamp is properly installed and that the ignitor lead is firmly secured to the lamp electrode. Also ensure that the lamp lead connection to the ignitor terminal is secure and free of corrosion. A) Install the calibrated reference lamp and initiate the test. If the lamp lights, then the previously installed xenon lamp is malfunctioning. Examine it for damage, burner tip and socket damage or corrosion. Check the burner age as recorded on the Xenon Burner Warranty Log card. The lamp may be at the end of its life (1200 hours or more). B) If the calibration lamp will not ignite, measure line voltage to the instrument and Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 38 5.0 TROUBLESHOOTING PROCEDURES 5.2 Xenon Lamp and Irradiance Control Malfunctions (cont.) 5.2.6 Troubleshooting Procedure – Lamp Ignition Failure (Ignitor) (cont.) check the transformer tap connections as described in Section 5.1.1. Set the T1 booster transformer lead T1-3 to the next higher lamp boost voltage terminal. Re-attempt lamp ignition. If the lamp still does not ignite, continue below. Also check the light rod for cleanliness and damage. Confirm the LS-8 light sensor interference filters have not expired and that the photodiodes are functional (Sec. 7.2.9). CAUTION: SHOCK HAZARD. Conduct step 6 below with meter leads clipped onto the specified terminals. DO NOT hold probes onto the terminals during lamp ignition or electric shock and injury may result. Note: In the steps below you must shut the instrument off with the front panel power switch after each attempt at igniting the lamp. This will reset the lamp starting circuit. 6) Check voltage to the ignitor: Connect a voltmeter (with clip leads) to terminals L3-1 and L3-2. Attempt lamp ignition while watching the meter. The meter should indicate line voltage (230V or 480V) during the ignition pulse. A) If line voltage is present during the ignition pulse, the ignitor has failed. Replace it (see Section 8.6). B) If no voltage is present, continue below. 7) Check relay K3 operation: During an ignition attempt, check for continuity between the terminals of Ignition Pulse Relay K3. There should be continuity for 1 second during each ignition pulse between terminals: Ci3/4000 - Terminals K3-5 and K3-6 Ci5000 - Terminals K3-6 and K3-7 A) If there is continuity across the K3 contacts during the ignition pulse, then there is a problem with the line voltage supply to the relay. Check wiring to the relay and voltage at the CB2 Ignition circuit-breaker terminals CB2-2 and CB3-4. There should be line voltage between each terminal and ground. If not, replace the circuit-breaker. B) If the relay does not activate, its coil is bad or the PLC is not sending it an activation signal or the 24Vac supply to the PLC is bad. B1) Check for 24Vac on the relay coil during the ignition pulse. If 24Vac is present, the coil is bad. Replace the relay (see Section 8.1). B2) During the ignition pulse, check for continuity between terminals PLC3-1 and PLC3-3. If there is no continuity, and the A2 LED on PLC3 is on, replace the module (see Section 5.13.5 first). If A2 is off, download the PLC software program to the PLC. B3) Check for continuous 24Vac across: Ci3/4000 – TB3-7 and TB3-9 Ci5000 – TB3-5 and TB3-8 This is the 24Vac supply to the 24Vac control circuit. If 24Vac is not present, check circuitbreaker CB5 and the 24Vac output of the isolation transformer T2 at terminals T2-X3 and T2-X4. Replace the failed breaker or transformer. 5.2.7 Troubleshooting Procedure – Irradiance Low or High (Wattage Regulator) To maintain an accurate and stable irradiance level during a test, the PLC receives a signal from the light monitor (at PLC5-11/-13 or PLC2-12/-14), compares it to the irradiance setpoint reference, and then alters its output (at PLC6-7/-19) to increase or decrease wattage regulator output. Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 39 5.0 TROUBLESHOOTING PROCEDURES 5.2 Xenon Lamp and Irradiance Control Malfunctions (cont.) 5.2.7 Troubleshooting Procedure – Irradiance Low or High (Wattage Regulator) (cont.) This drive signal is applied to terminals AR1-1 and AR1-2 of the wattage regulator AR1. terminals PLC5-11 and PLC5-13 (or at terminals PLC5-12 and PLC5-14 if the optional sensor is installed and is controlling irradiance). A) If no voltage is present, there is a problem with the light sensor wiring, interference filter or the photocell. Check each of these before continuing (See Section 7.2.9). B) If the signal is present, the light monitor is functioning properly. 4) Shut off all power to the instrument at the wallmounted disconnect switch. 5) Disconnect the AR1-1 lead from the wattage regulator and connect an ammeter in series with Power LED Figure 5.2 – 9 Xenon Lamp Wattage Regulator Troubleshooting consists of first confirming light monitor operation and its output signal to the PLC. Then the instrument is operated at constant wattage and the PLC output signal to the wattage regulator is checked. If a stable drive signal is present, but lamp operation is erratic or out of wattage tolerance, it is likely that the wattage regulator is malfunctioning. 1) Perform the Wattage Calibration (Sec. 6.8) and then the Irradiance Calibration (Sec. 6.9) to eliminate calibration as a contributive factor. 2) Initiate standard test no. 1 SAE J-1885. Set it up so the lamp will operate for 30 minutes. 3) With the lamp operating, confirm that the voltage signal from the light monitor is present at the PLC Figure 5.2 – 10 Wattage Regulator Power LED the lead and terminal AR1-1. This will allow measurement of the 4-20mA drive signal from the PLC to the wattage regulator. 6) Apply power to the instrument. Initiate a custom test using wattage control rather than irradiance control. Set the wattage level to minimum for the lamp type in use (1700 watts for Ci3000+, 2500 watts for Ci4000, 4000 watts for Ci5000). Set the test duration to 30 minutes. 7) Observe the LED indicator lights on the wattage regulator. With power on and the xenon lamp operating, the upper green lamp should be on indicating that the regulator is receiving power. Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 40 5.0 TROUBLESHOOTING PROCEDURES 5.2 Xenon Lamp and Irradiance Control Malfunctions (cont.) 5.2.7 Troubleshooting Procedure – Irradiance Low or High (Wattage Regulator) (cont.) A) If the LED is off, check for continuity across terminals K9-9 and K9-10 of relay K9. If there is continuity, then resistor R4 (Ci4 only) is open-circuited or the wattage regulator has failed. Replace the regulator per Section 8.7. with the PLC Analog Output PLC6 module. (This will be checked in a later step.) 9) Stop the wattage test and alter it to the midrange operating wattage level shown below. Ci3000+ – 3000 watts Ci4000 – 5000 watts Ci5000 – 8000 watts 10) Initiate the new test to ignite the lamp. 11) Observe the green LED indicator light on the lower circuit board of the wattage regulator. This is the output indicator and becomes brighter as output increases. It should be on brightly. Soft Start LED A) If the LED is very dim or off, and the ammeter reading is well above 4mA, there is a problem with the wattage regulator output. Replace the regulator (Section 8.7). Output LED B) If the ammeter reading is zero, still at 4mA or is unstable, there is a problem with the PLC Analog Output PLC6 module or the PLC CPU (PID settings, corrupt PLC software or CPU failure). Figure 5.2 – 11 Wattage Regulator Output LED B) Check for 24Vac volts across the K9 relay coil terminals K9-1 and K9-2. B1) If voltage is present, and there is no continuity between terminals K9-9 and K9-10, replace relay K9 per Section 8.1. B2) If voltage is not present, and the B5 LED on PLC3 is on, replace the PLC3 module (see Section 5.13.5). If B5 is off, download the software program to the PLC. If this fails to restore operation, replace PLC3. 8) Observe the ammeter on the AR1-1 terminal. It should display a reading of approximately 4mA. A) If the ammeter reading is zero, or well above 4mA, there is potentially a problem B1) Replace the PLC6 module (see Sec. 5.13.8 first). Run the mid-range wattage test again. Check the level and stability of the ammeter reading. It should be very stable and approximately 5 to 10 mA. B2) If replacement of the PLC6 module does not correct the problem, download the custom programs from the PLC to a laptop computer and replace the CPU module of the PLC (see Sections 5.13 and Appendix A). Upload the custom programs and the correct PLC operating software. Run the mid-range wattage test again and observe the ammeter reading for stability. If this corrects the problem, reinstall the old PLC6 module and confirm operation. Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 41 5.0 TROUBLESHOOTING PROCEDURES 1) Program a custom, 2-sun irradiance test with the parameters shown below. 5.2 Xenon Lamp and Irradiance Control Malfunctions (cont.) Test List (Data Panel page 6) Select an unused Custom test. Press F6, the test number and Enter three times. Press F2. 5.2.8 Troubleshooting Procedure – 2-Sun Irradiance Considerations If the xenon lamp in the Ci5000 fails to operate at higher (2-Sun) irradiance levels, there may be a malfunction of the 1-Sun or 2-Sun relays, or the components driving them (Fig. 5.2–9). Additionally, if the error message “Test Irrad. Not Match with Filters” appears on the screen at the start of a test, it indicates that the irradiance level chosen is in the 2-Sun range and you must recalibrate the lamp for this irradiance level. 2-Sun irradiance levels are defined as follows: 0.70 W/m2 or higher @ 340 nm filter 1.40 W/m2 or higher @ 420 nm filter 75.0 W/m2 or higher @ 300-400 nm filter At 1-Sun irradiance levels, the rack rotates at 1 RPM. At 2-Sun levels it rotates at 10 RPM. Relay K14 switches the input to the rack speed controller. Conduct the procedure below to determine the cause of 2-Sun operation failure. L3 IGNITOR PLC3 LOGIC OUTPUT MODULE L3-12 K3-3 A8 A14 RACK MOTOR SPEED CONTROL K14-1 TB6-1 TB3-9 K14-2 K14-4 N.C. K14 N.C. RACK SPEED RELAY K14-11 K15-1 K14-3 K15-2 C O I L 4 R2 10K 3 LOW COM TB2-2 Test List (Data Panel page 6) Press F8. Press F5, the custom test number and Enter three times to load the new custom test. Run/Stop Segment (Data Panel page 3) Test Duration 0 hours 30 min LOW HI 2) Press F4 on RUN/STOP page 3 to start the test. CAUTION: SHOCK HAZARD In the procedures below, you must check for voltages at live electrical terminals. Avoid contact with component terminals and wear insulated gloves to prevent electrical shock. K15 ONE SUN RELAY TB3-11 A14-S2 L1 MAIN REACTOR Segment (cont.) (Data Panel page 9) Set sprays to off. 3 COIL K14-9 A14-S1 L2-2 Segment (Data Panel page 8) Segment Number 1 Light or Dark Light Time or Irradiance 30 min. Irradiance 1.50 W/m2 Black Temp. 80 °C Chamber (DB) Temp. 60 °C Relative Humidity 0% PLC3-10 24Vac TB3-5 TB3-6 TB3-7 A14-S3 TB6-1 Test Criteria (Data Panel page 7) Total Segments 1 Duration Units Time Black Sensor BPT Black Temp. Active Yes Radiation@filter 340 nm Chamber Temp. Active No K4 TWO SUN RELAY C O I L K4-1 PLC3-5 A4 PLC3 LOGIC OUTPUT MODULE K4-2 4 TB3-8 24Vac Figure 5.2 – 12 One and Two Sun Circuit Block Diagram 3) When the Ci5000 is running a test at 2-Sun irradiance level, the rack should be rotating at 10 RPM. Check rack speed. If it is rotating at 1 RPM, relay K14 or the rack speed control A14 is malfunctioning (see Section 5.8). Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 42 5.0 TROUBLESHOOTING PROCEDURES 5.2 Xenon Lamp and Irradiance Control Malfunctions (cont.) 5.2.8 Troubleshooting Procedure – 2-Sun Irradiance Considerations (cont.) In 2-Sun mode, PLC3 de-energizes (closes) the 2-Sun relay K4. It also energizes relay K14 causing the 1-Sun relay relay K15 to open. K14 also causes closure of contacts A14-S2 and A14-S3 of the A14 rack speed control board to provide 10 RPM rack rotation (see Fig. 5.2–9). 3) Check for continuity between terminals K14-3 and K14-4. A) If there is continuity, relay K14 is likely operating properly. Check for voltage between ground and terminal K15-3 of relay K15. It should be 0 volts. If voltage is present, K15 is stuck closed or contacts K14-9 and K14-11 of relay K14 are stuck closed. Replace the malfunctioning relay (Sec. 8.1). B) If there is no continuity, check for 24Vac at the K14 coil terminals K14-1 and K14-2. If voltage is present, replace K14. If no voltage is present, and the A8 indicator light on PLC3 is off, download the software program to the PLC. If indicator light A8 is on, replace the PLC3 Logic Output module (see Section 5.13.5 first). 4) With relay K14 operating properly, check for voltage between ground and terminal K4-3 of relay K4. A) If voltage is present, K4 is o.k. B) If voltage is not present, check for 24Vac at the K4 coil terminals K4-1 and K4-2. If voltage is present, the PLC3 Logic Output module is malfunctioning. Replace it (see Section 5.13.5 first). If voltage is not present, relay K4 is stuck open. Replace K4 (Sec. 8.1). Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 43 8.0 REPAIR & REPLACEMENT PROCEDURES Light Rod Connector 8.2 Sensor Replacement (cont.) 8.2.7 Light Monitor Photodiodes Optional Channel 2 Interference Filter (300-400nm shown) Capsule Cover The LS-8 Light Monitor, used on the Ci5000, Enhanced Ci4000and Ci3000+, includes one or two capsules that contain an interference filter and a photodiode. Light from the xenon lamp is transmitted to the photodiode via the quartz light rod. The photodiode produces a microampere (µA) output proportional to the light intensity it receives passing through the interference filter. Channel 1 Interference Filter (340/420nm shown) Channel 1 Capsule & Photodiode A10 In all three light monitors, the types of photodiodes used are the same, but their mountings differ. Ci3000+, Ci5000 & Enhanced Ci4000 Light Sensor A13 Photodiode Sensor Cell #2 Photodiode Part Numbers 340nm 420 nm 300-400 nm 09-3515-00 09-3515-00 09-3493-00 Ci3+, Ci5 & Ci4000 09-3529-00* 09-3530-00* Enhanced 09-3531-00* Older Ci4000 *LS-8 capsule assembly including photodiode Leads for code jumpering Interference Filter Channel 2 Capsule & Photodiode A13 Beam Splitter (not present on single bandwidth units) Older Ci4000 instruments have either a single light sensor in a sheetmetal enclosure or an optional dual band sensor in a machined aluminum housing. Note: The photodiode used with a 340 or 420nm narrow-band interference filter is different than the one used with a 300400nm wide-band filter. Do not mix them. O-Ring Filter Housing Light Path O-ring Housing Cover Interference Filter (Note orientation of arrow) Filter Housing and Beam Splitter Interference Filter (Note orientation of arrow) A10 Photodiode Sensor Cell #1 O-Ring Older Ci4000 Dual Bandwidth Light Sensor Photodiode Figure 8.2 – 7 LS-8 Light Sensor Capsule Assembly Figure 8.2 – 8 Dual Bandwidth Light Sensors Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 180 8.0 REPAIR & REPLACEMENT PROCEDURES 8.2.8 Chamber Overtemperature Thermostat 8.2.7 Light Monitor Photodiodes (cont.) This thermostat is accessed from inside the electronics drawer (but may be easier to replace by removing the right-side access panel). Chamber Wall 8.2 Sensor Replacement (cont.) Sensor Housing Reset Interference Filter (Note orientation of arrow) A10 Photodiode Sensor Cell Filter Housing Cap Sensor Housing Cover DO NOT remove screws in this location Figure 8.2 – 9 Older Ci4000 Single Bandwidth Light Sensor Guidelines Figure 8.2 – 10 Chamber Overtemp. Thermostat S4 Guidelines 1) The face of the thermostat must be in contact with the exterior wall of the test chamber. Apply a small amount of silicon thermal grease to the face of the thermostat when mounting a new one. (Thermal grease is commonly used in the electronics industry when mounting transistors to heat sinks to improve thermal transfer.) 2) Apply sealant to the mounting screws. The screws extend into the test chamber and could allow leakage without sealant in place. 1) The photodiode is fragile. Handle it with care and avoid touching its front window. If you do, clean it with alcohol or optical cleaner and a soft cloth. This applies to the interference filters as well. 8.2.9 Chamber Overtemperature Sensor (Older Ci4000 only) 2) Always ensure that the direction arrow on the 340 or 420nm filter is pointing toward the photodiode (direction of light travel) when assembling the light sensor. The 300-400nm filter may be installed either way. On some of the early Ci4000 instruments, a Chamber Overtemperature alarm was included beside the Lamp Cooling Water Controller in the top section. It has an RTD temperature sensor mounted in the test chamber. 3) DO NOT attempt to install a photodiode normally used with the 340/420nm filter in place of the one used with the 300-400nm filter, or vice versa. The spectral response of each is different and will result in erroneous readings. Replace the three-wire sensor by disconnecting it 0000 from the back of the alarm. Remove the old sensor from the test chamber Eurotherm 92 taking note of its insertion Chamber Overtemperature Figure 8.2–11 Chamber depth in its mounting. Install Overtemperature Alarm the new sensor. AL1 RESET AL2 Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 181 INDEX Symbols 2-Sun Irradiance Levels 90 2-Sun Irradiance Test 42 6-Channel Chart Recorder 109 A Access Panel Removal 134 Air Filter Cleaning 165 Air Heater Element Resistance Values 89 Element Terminals 88 Power Ratings 81 Air Heater Control Relay Q2 56 Air Regulator Oil Trap Cleaning 165 Air Valve (Damper) Troubleshooting 88 Alignment Lamp/Rack/Light Rod 168 APC1 Filter PC Board 51 Atlas Fax Number 11 Auxiliary Reactor L2 21 B Bearings Specimen Rack 201 Black Panel Sensor Circuit Calibration 138 Sensor Check Procedure 137 Transmitters/Collector Ring 78 Black Standard Panel Circuit Calibration 138 Error Messages 18. See also Sensor: Temperature: Error Message Sensor Check Procedure 137 Blower Error Message 17 Blower Controller 69 Blower Controller Code List 77 Blower System Blower Wheel Mounting 73 Chamber Overtemp. 17 Controller Code Listing 77 Controller Error Messages 70 Controller Indicator Lights 70 Controller Keypad Functions 75 Controller Programming 76 Electrical Diagram 69 Malfunction Troubleshooting 69 Motor Controller Input Jumper 75 Blower Wheel Mounting 73 BP Transmitters & Collector Rings 78 Burner Socket Maintenance 158 C Calibration 134 Black Sensor Check 137 Black Sensor Circuit 138 Calibration Schedule 136 Chamber Sensor Check 141 Chamber Sensor Circuit 143 Ci5000 Rack Speed 154 Component Locations 134 Damper Calibration 153 Irradiance Calibration 151 Procedures 134 Relative Humidity 146, 147 Water Resistivity Monitor 156 Wattage Calibration 148 Chamber Dry Bulb (DB) Error Message 18. See also Sensors: Temperature: Error Message Sensor Check 141 Temp. Sensor Locations 142 Transmitter Location 141 Transmitter Terminals 141 Chart Recorder 109 Channel Assignments 109 Electrical Diagram 112 Error Messages - Fatal 112 LIST Printout 109 Malfunction Troubleshooting 109 mR1000 Manual 205 Recorder Replacement 202 Chart Recorder Block Diagram 112 Control Panel. See Data Panel: Error Messages CS-6 Lamp Cooling System Demineralizer Cartridge Replacement 160 Electrical Diagram 59 Flow Switch Filter Cleaning 160 Flow Switch Testing 67 Malfunction Troubleshooting 59 Plumbing Diagram 60 Pump/Motor Coupling 67 Reservoir Cleaning 162 Reservoir Diagram 62 CS-6 Pump Shaft Coupling 67 D Damper Calibration 153 Chamber overtemp. 17 Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 231 INDEX Safety Thermostat 23 Photo of 25 Tools Required 13 Transformer, Reactor Config. 20 Configuration Guides 26 Transformer T1 21 W Water Control Relay Q1 50 Water Resistivity Monitor 104 Calibration 156 Malfunction Troubleshooting 104 Sensor Cleaning 108 Water Spray Systems 99 Electrical Diagrams 103 Malfunction Troubleshooting 99 Plumbing (Ci3+) 100 Plumbing (Ci4, Ci5) 99 Water Solenoid Valves 100 Wattage Setting Minimum 40 Wattage Calibration 148 Wattage Powermeter Connections, calibration 148 Wattage Regulators 40 X Xenon Lamp 1 & 2-Sun Relays 42 Alignment (Ci3+) 171 Alignment (Ci4, Ci5) 168 Assembly Guide 33 Burner Socket 158 Circuit Drawings 30 CS-6 Cooling System 59 Error Messages 17 Ignitors (photos) 38 Malfunction Troubleshooting 29 Min. Wattage Setting 40 Operating Ranges 29 Outer Filter Cleaning 158 Water Flow Switch 67 Wattage Regulators (photos) 40 Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 234