Carbon Dioxide

Analyser

Service Manual
Revision: B

www.ecotech.com
 EC9820 CO2 ANALYZER SERVICE MANUAL

Table of Contents

MANUAL HISTORY ....................................................................................................................................................3

SAFETY REQUIREMENTS ............................................................................................................................................4
SERVICE AND SPARE PARTS .......................................................................................................................................4
1. 0 INSTALLATION..................................................................................................................................................5
1.1 INITIAL CHECK ....................................................................................................................................................5
1.1.1 Remove the Top Cover ................................................................................................................................5
1.1.2 Service Switch .............................................................................................................................................6
1.1.3 Inspect the Components ..............................................................................................................................6
1.1.4 Reinsert Dislodged Boards..........................................................................................................................7
1.1.5 Cable Connections ......................................................................................................................................7
2. 0 THEORY OF OPERATION ...............................................................................................................................9
2.1 INSTRUMENT DESCRIPTION ................................................................................................................................10
2.1.1 Power/Microprocessor Module.................................................................................................................10
2.1.2 Sensor Module...........................................................................................................................................12
2.2 OPERATION MODES ...........................................................................................................................................16
2.2.1 Startup Mode.............................................................................................................................................16
2.2.2 Measure Modes .........................................................................................................................................18
2.2.3 Auto Zero Routines....................................................................................................................................18
3. 0 MAINTENANCE................................................................................................................................................20
3.1 MAINTENANCE SCHEDULE .................................................................................................................................20
3.2 REPLACEABLE PARTS ........................................................................................................................................21
3.2.1 Expected Life Span of Consumables .........................................................................................................22
3.3 MAINTENANCE PROCEDURES.............................................................................................................................23
3.3.1 Check Particulate Filter............................................................................................................................24
3.3.2 Particulate Filter Replacement Procedure ...............................................................................................24
3.3.3 Clean Fan Filter........................................................................................................................................25
3.3.4 Detector Signal Adjustment.......................................................................................................................26
3.3.5 Correlation Wheel/Motor/IR Source Replacement ...................................................................................27
3.3.6 IR Detector Replacement ..........................................................................................................................28
3.3.7 Leak Test Procedure .................................................................................................................................29
3.4 HIDDEN MENU ...................................................................................................................................................29
3.4.1 Pressure & Flow Calibration sub-menus..................................................................................................31
3.4.2 FACTORY DIAGNOSTICS MENU ...........................................................................................................32
3.5 PRESSURE & FLOW CALIBRATION .....................................................................................................................32
3.5.1 Pressure/Flow Calibration........................................................................................................................32
3.6 PREPROCESSOR DEVICE ID ENTRY ....................................................................................................................35
3.7 FIRMWARE UPDATE ...........................................................................................................................................36
4. 0 TROUBLESHOOTING .....................................................................................................................................39
4.1 DC POWER SUPPLY VOLTAGES .........................................................................................................................39
4.2 TROUBLESHOOTING THE EC9820 ANALYZER ....................................................................................................39
4.2.1 Preprocessor Pots Menu ...........................................................................................................................40
4.2.2 Flow Control Pots Menu (A Series only) ..................................................................................................40
4.2.3 Valve Test Menu........................................................................................................................................41
4.2.4 Event Log ..................................................................................................................................................41
4.2.5 Instrument Status.......................................................................................................................................44
4.2.6 System Temperatures ................................................................................................................................44
4.2.7 System Faults ............................................................................................................................................45
4.3 TEST FUNCTIONS ...............................................................................................................................................46
4.3.1 Optic..........................................................................................................................................................46

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EC9820 CO2 ANALYZER SERVICE MANUAL

4.3.2 Preamp......................................................................................................................................................46
4.3.3 Electric ......................................................................................................................................................46
4.3.4 Use of Diagnostic Modes ..........................................................................................................................46
4.4 TROUBLESHOOTING GUIDE ................................................................................................................................47
INDEX ........................................................................................................................................................................49

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 EC9820 CO2 ANALYZER SERVICE MANUAL

Manual History
The scope of this new manual covers the following analyzers:

ˆ EC9820 Carbon Monoxide Analyzer, 3000 ppm , PN: 98201000-101.

ˆ EC9820 Carbon Monoxide Analyzer, 1500 ppm, PN: 98201000-102
ˆ EC9820 Carbon Monoxide Analyzer, 750 ppm, PN: 98201000-103
ˆ EC9820 Carbon Monoxide Analyzer, 3000 ppm, PN: 98205000-101 Systems
ˆ EC9820 Carbon Monoxide Analyzer, 1500 ppm, PN: 98205000-102 Systems
ˆ EC9820 Carbon Monoxide Analyzer, 750 ppm, PN: 98205000-103 Systems
This instrument is manufactured by Ecotech P/L in Australia and support the new
(SMD) Microprocessor Board (Part number 98000063-4). This manual is current
for firmware version 1.18 and above.

This manual should only be used in conjunction with the EC9820 Carbon
Monoxide Analyzer, Operation Manual PN: 98207600 Rev B, April 2007

Ecotech Manual ID: MAN 0006.

Manual PN: 98207601.
Current Revision: B.
Date Released: April 2007.
Description: EC9820 Carbon Monoxide Analyzer, Service Manual,.

Revision History
Rev Date Summary Affected Pages
A September New Release for new Microprocessor Board Based All
2005 on original manuals.
B April 2007 Updated specifications, language and links within All
pdf manual created.

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EC9820 CO2 ANALYZER SERVICE MANUAL

Safety Requirements
ˆ To reduce risk of personal injury caused by electrical shock, follow all
safety notices and warnings in this documentation.
ˆ This equipment should always be used with a protective earth installed.
ˆ The EC9820 is compliant with the requirements of EN61010-1 A2:1995,
Safety Requirements for Equipment for Measurement, Control, and
Laboratory Use.
ˆ If the equipment is used for purposes not specified by the manufacturer,
the protection provided by this equipment may be impaired.
ˆ Replacement of any part should only be carried out by qualified personnel,
only using parts specified by the manufacturer. Always disconnect power
source before removing or replacing any components.
ˆ Surfaces marked with a “Caution, Hot Surface” (see internationally
recognized symbols on page 4) sticker may get hot and deliver burns.
Measure the temperature on the surface before making any contact with it.

Equipment Rating
ˆ 100-120/220-240V~ ±10%
ˆ 50/60 Hz
ˆ 250 VA max
ˆ FUSE: 5/3.15A T 250V
ˆ All wiring must be in accordance with local norms and be carried out by
experienced personnel.
Service and Spare Parts
For world wide customer service & spare parts contact ECOTECH:

Address: Ecotech Pty Ltd

1492 Ferntree Gully Rd
Knoxfield
Australia. VIC 3180

Phone: (+61) 1300 364 946

Fax: (+61) 1300 668 763

Email - Service: [email protected]

Email - Spare Parts: [email protected]

Web: www.ecotech.com.au

4 98207601 Rev B
 CHAPTER 1 INSTALLATION

1.0 Installation
1.1 Initial Check
Verify that the serial number label on the documentation and the serial number(s)
on the analyzer match.

Check to make certain your instrument arrived undamaged. If you find damage,
report it as described in the preface, on the page titled Claims for Damaged
Shipments and Shipping Discrepancies in the Operation manual.

Analyzers are shipped ready to power up. Occasionally, however, rough handling
during shipment causes dislodged PC boards, disconnected cables, or incorrectly
positioned switches. Verify that your instrument is in operating condition by
performing the following procedure.

1.1.1 Remove the Top Cover

Grasp the front top corners of the front panel and pull forward. The panel will pop
loose and pivot forward. See Figure 1. The top cover retaining hardware is then
visible as shown in Figure 2. Use a screwdriver to unscrew the two captive
screws. When the two captive screws are loosened, slide the cover backward
about 4 inches and lift the top cover straight up.

Figure 1. Opening the Front Panel

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EC9820 CO2 ANALYZER SERVICE MANUAL

1.1.2 Service Switch

Opening the front panel allows a view of the secondary panel where four switches
are visible. The position of the toggle switches for operating mode is:

DC Power ON
Pump ON
ServiceIN

The Reset switch is not a toggle switch and is only activated when pressed. It
resets the microprocessor. The pump switch is not applicable to the B-line
instrumentation because the flow is generated through the use of an external
pump.

When in the OUT position, the Service switch sets the OUT OF SERVICE bit in the
50-pin I/O interface and in the status word from the serial port. The OUT position
has no other effect on the operation or validity of the data obtained from the
analyzer. When the Service switch is set from OUT to IN, the instrument returns
to the normal operating conditions.

Figure 2. The Secondary Panel

1.1.3 Inspect the Components

Verify that the components were not damaged in shipping. If any PC boards are
dislodged or cables disconnected, follow the instructions below.

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 CHAPTER 1 INSTALLATION

1.1.4 Reinsert Dislodged Boards

The bottom edge of the boards must be held in place by the guides. The top of the
boards must be attached to the metal bulkheads by the plastic or metal studs with
spring tips.

1.1.5 Cable Connections

The cable connectors and the board connectors must be matched securely in place
for correct connection. The red indicator on each cable must be positioned at the
arrowhead mark on the board connector. Make the connection by pressing the
cable connector into the mating connector until a click is heard. Then, fold the
retainers inward to secure the connection (see Figure 3).

Figure 3. Cable Connections

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8 98207601 Rev B
 CHAPTER 2 THEORY OF OPERATION

2.0 Theory of Operation

Carbon Dioxide absorbs infrared radiation (IR) at wavelengths near 4.5 microns;
therefore, the presence and the amount of CO2 can be determined by the amount
of absorption of the IR. The EC9820 analyzer uses gas filter correlation to
compare the detailed IR absorption spectrum between the measured gas and other
gases present in the sample being analyzed. A highly concentrated sample of the
measured gas, i.e., CO2 is the filter for IR transmitted through the analyzer, thus
gas filter correlation.

The process further defined consists of radiation from the IR source encountering
a gas filter wheel alternating between CO2, N2, and a mask. The radiation passes
through a multiple pass measurement cell where the sample gas absorption
process occurs, then through a narrow-band-pass filter to limit absorption to
optical wavelengths of interest for CO2 absorption, after which it encounters the
IR detector where the amount of absorption is measured.

The N2 filter in the gas filter correlation wheel is transparent to IR and yields a
measure beam that can be absorbed by CO2 in the measurement cell. The CO2
filter in the wheel yields a beam that cannot be further attenuated by the CO2 in
the measurement cell, thus it is a reference beam. The mask creates a signal used
to determine the strength of the other two signals.

The CO2 concentration in the measurement cell absorbs the measure beam and
does not absorb the reference beam, modulating the IR radiation, or detector input
signal between the gas filters. Other gases absorb the reference and measure
beams equally and thus do not cause modulation of the detector signal. Using this
method, the system responds specifically to CO2.

The EC9820 analyzer uses the advanced digital Kalman filter. This filter provides
the best possible compromise between response time and noise reduction for the
type of signal and noise present in ambient air analyzers and their application.

Ecotech’s’ implementation of this filter enhances the analyzer’s measurement

method by making the filter time base variable depending on the change rate of
the measured value. If the signal rate is changing rapidly, the instrument is
allowed to respond quickly. When the signal is steady, a long integration time is
used to reduce noise.

The system continuously analyzes the signal and uses the appropriate filtering
time.

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EC9820 CO2 ANALYZER SERVICE MANUAL

2.1 Instrument Description

The instrument is designed in a modular format consisting of a power/
microprocessor module and a sensor module. The power/microprocessor module
contains the power supply, voltage regulators, and the system microprocessor.
The sensor module contains all components necessary to measure the pollutant
gas. The layout of the instrument is shown in the system block diagrams (Figure
4) and major component layout diagrams (Figure 5).

2.1.1 Power/Microprocessor Module

The power/microprocessor module can be described in three sections, the power
supply, the voltage regulator, and the microprocessor.

2.1.1.1 Power Supply

The power supply is a self-contained unit housed in a steel case. It is designed to
meet UL, VDE, CSA, and other regulatory requirements. It converts 99 to
264 VAC 50/60 Hz to 12 VDC power for distribution within the analyzer. The
power supply also furnishes a 250 msec power extension in the event of power
failure to allow the computer to store data before the power failure can affect it.

2.1.1.2 Voltage Regulator

The voltage regulator board regulates and distributes the different voltages needed
throughout the system: 12 VDC to +5 VDC for the digital circuitry and 12 VDC
to ±10 volts for analog circuitry. An additional +15 VDC supply is present to
power the microprocessor display supplies and analog output circuits. The voltage
regulator also furnishes a 300 msec power extension in the event of power failure
to allow the computer to store data before the power failure can affect it.

2.1.1.3 Microprocessor
The microprocessor board contains a battery backed clock/calendar and an
onboard 16-bit microprocessor (MC68HC12) operating at 16 MHz. The
microprocessor board is the control center for input and output apparatus such as
the 2 inch by 4 inch liquid crystal display (LCD), keyboard switches, the serial
ports, and the 50-pin I/O connector on the rear panel. The 50-pin I/O connector
input accepts control lines from the rear panel and sends status and failure signals
to solid state relay drivers. Support circuitry for the liquid crystal display includes
a -20 V power supply and digitally adjusted potentiometers for contrast level.

All analog voltages from the sensor assembly are digitized by the analog-to-
digital (A/D) converter for microprocessor use. Digital-to-analog (D/A)
conversion of three channels is used to send 0 to 20 mA analog signals to the
50-pin I/O connector.

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 CHAPTER 2 THEORY OF OPERATION

The microprocessor has electrically erasable ROMs which store the operating
program and internally logged data. Program upgrades can be easily made
through the serial port. The Service and Reset switches are located on the front of
the board and are accessible when the top is removed or when the front panel is
opened. The microprocessor also has provisions for USB and optional TCIP
connections through the rare panel.

Figure 4. System Block Diagram

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EC9820 CO2 ANALYZER SERVICE MANUAL

Figure 5. Major Components

2.1.2 Sensor Module

The sensor module can be divided into three areas of description: pneumatics,
optics, and electronics.

2.1.2.1 Pneumatics
The pneumatic system continuously supplies sample air to the measurement cell
at a rate that allows the sample to be measured before exiting the analyzer. The
pneumatic system flow is illustrated in Figure 6 The pump causes sample air to
be drawn into the sample inlet and through the 5 micron particulate filter.

During the startup and auto-zero cycles, the sample port is disconnected and air is
pulled into the system from then into the measurement cell. This provides the
analyzer with a stable reference of zero air to automatically correct for changes in
the measurement path.

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 CHAPTER 2 THEORY OF OPERATION

Figure 6. Pneumatic Diagram

2.1.2.1.1 Flow Control

ˆ Particulate Filter. The particulate filter is designed to remove particles
larger than 5 microns and to expose the sample to only nonreactive
materials of Kynar, Teflon, and Viton. The filtering agent is a 47 mm
diameter, 5 micron filter.
ˆ Flow Control Module. The sample flow rate is monitored by measuring
the pressure drop across a calibrated flow restrictor. The upstream
pressure of this restrictor is the sample cell pressure. Mass flow through
the restrictor is computed from the upstream and downstream pressures.
Since the pressure transducers used are temperature sensitive, they are
mounted in a temperature controlled block.
ˆ Sample Pump. The rotary vane-type pump is powered by a brushless DC
motor. Since the pump is working with a very light load, it rotates very
slowly, resulting in very little bearing or vane wear. The estimated pump
life is in excess of 5 years. The Pump speed is controlled by a DC input
voltage derived from two digital potentiometers under microprocessor
control on the flow control board. The pump speed is varied to achieve
desired sample flow rate.
ˆ Rear Fan. The fan speed is controlled by a variable input voltage derived
from a digital potentiometer under microprocessor control on the flow
control board. The fan speed is controlled to begin operating at about
30° C chassis temperature and increase its speed in a linear fashion until it
is at full operating speed about 50° C chassis temperature.

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EC9820 CO2 ANALYZER SERVICE MANUAL

2.1.2.2 Optics
The optics of the EC9820 analyzer include an IR source, an optical detector, a gas
filter correlation wheel, measurement cell, narrow-band-pass filter, IR detector,
and preamp board as described in the following paragraphs. Figure 7 illustrates
the optical path.

ˆ IR Source. The IR source is a heated resistor that generates broad-band

infrared radiation and irradiates the gas filter correlation wheel.

Figure 7. Illustrated Optical Path

ˆ Gas Filter Correlation Wheel. The gas filter correlation wheel includes
two gas filled sapphire chambers and mask areas. As the wheel rotates, the
IR beam passes through either 1) the reference chamber which is filled
with CO2, removing the CO2-sensitive wavelengths which are centered at
4.5 microns and passing the CO2-insensitive wavelengths; 2) the measure
chamber which is filled with nitrogen and passes the CO2-sensitive
wavelengths; or 3) a mask which blocks the beam. When the mask blocks
the transmission of IR, the detector generates the mask signal used as a
zero reference to determine the strengths of the other two signals. The
differences between signals are used to compute the concentration of CO2.
Figure 8 shows the gas filter correlation wheel. The wheel is mounted on a
shaft driven by a brushless DC motor.
ˆ Opto-detector. A reflective optical detector reacts to timing marks on the
periphery of the wheel and generates a signal indicating when the center of
each sector is the target of the IR source beam.

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 CHAPTER 2 THEORY OF OPERATION

Figure 8. Gas Filter Correlation Wheel

ˆ Measurement Cell. The IR next enters the multiple pass optical

measurement cell where it travels a mirror folded five meter path through
the sample gas before exiting the cell. See Figure 7.
The cell housing is kept at a controlled temperature and the thermistor
monitoring this temperature is reported as CELL TEMP on the SYSTEM
TEMPERATURES screen. This temperature is used for gas law corrections.

ˆ Narrow-Bandpass Filter. The broadband radiation from the IR source that

passes through the gas filter wheel and measurement cell is filtered again
by the narrow- band-pass filter. Only the CO2-sensitive portion of the band
centered at 4.5 microns passes through the filter. The removal of
wavelengths sensitive to other gases reduces interference.
ˆ IR Detector. The lead selenide IR detector is chilled to -20° C. When IR
centered at 4.5 microns shines on the detector, it changes the current
flowing through it. This change produces the detected signal.
2.1.2.3 Electronics
ˆ Preamplifier Board. The preamplifier (preamp) board converts the current
from the IR detector to voltage and amplifies it to a waveform containing
a reference voltage peak, measure voltage peak, and the mask voltage
valley.

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EC9820 CO2 ANALYZER SERVICE MANUAL

ˆ Preprocessor. The preprocessor contains circuitry for sampling the

amplitude of the reference and measure pulses, a regulator to keep the IR
source at constant intensity, a heater control, and miscellaneous logic to
generate test signals. The heater circuit controls the adjustable mirror plate
in the measurement cell to 50° C.
ˆ An optodecoder circuit separates detected timing marks on the gas filter
correlation wheel into logic signals for comparison of the reference and
measure pulse amplitudes. Circuitry is included to convert the pulse
amplitudes into direct current (DC) to balance the two detected DC signals
for zeroing, and to amplify the resultant signal with a programmable gain
amplifier under control of the microprocessor. The board also contains an
EAROM which contains device identification and stored setup parameters.
A switching regulator is used to step down system +12 volts power to
+6 volts for powering the IR source and the detector Peltier cooler. All
circuitry adjustments are made via the microprocessor-controlled digital
potentiometers
ˆ Flow Control PCA. The pressure/flow portion of the board contains an
absolute and a gauge pressure transducer to measure cell pressure and
control sample flow. This board also controls the pump speed, powers the
chassis fan and has a heater control circuit to heat the flow block. (A series
only).
ˆ Preamp/pressure board. The pressure/flow portion of the board contains
an absolute and a gauge pressure transducer to measure cell pressure and
detect sample flow.

2.2 Operation Modes

The analyzer operates in a number of different measurement modes. These modes
include startup, measurement, and auto-zero modes. Following is a description of
each of the operating modes.

2.2.1 Startup Mode

When the instrument is initially powered up, several components in the
instrument are automatically configured by the microprocessor and an automatic
zero is run. This process typically takes about 10 minutes. Following is a
description of the various adjustments made during the startup routine. All
adjustments are automatically performed by the microprocessor; no manual
intervention is required. During all the startup routines the cell is filled with zero
air.

2.2.1.1 Reference Self Test

The test reference and input potentiometers on the preprocessor are adjusted to
ensure response of the reference channel of the preprocessor.

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2.2.1.2 Electronic Zero Test

The test measure potentiometer on the preprocessor board is adjusted to ensure
response of the measurement channel of the preprocessor.

2.2.1.3 Reference Adjust

Reference adjust allows the input pot of the preprocessor to be adjusted for the
proper reference voltage level of 4.0 ± 0.1 volts. (The reference voltage is
proportional to the intensity of the IR signal.)

2.2.1.4 Electronic Zero Adjust

Electronic zero adjust sets the preprocessor measurement channel to minimize any
electronic or optical offset present at zero. First the cell is allowed to fill
completely with zero air. The preprocessor measure coarse zero and measure fine
zero potentiometers are then adjusted until a concentration voltage of just above
0.00 volts is obtained. This is the analyzer’s coarse zero adjustment. Once this is
set it is not readjusted until another automatic startup routine is performed or the
concentration voltage is sensed to be below -0.1 volts.

2.2.1.5 Background
Background allows the analyzer to sample zero air and measure the level of the
concentration voltage. This reading is taken as the zero signal level and this is
subtracted from any subsequent readings. This is the analyzer’s fine zero
measurement. The background is re-run nightly at midnight (unless background is
disabled), when manually selected through the CALIBRATION MENU, when a
temperature change of greater than 4°C is sensed, or when another automatic
startup routine is performed.

Note
To perform a differential background:
1. Ensure that zero air is not connected to zero port otherwise
a standard “absolute background” will be performed.
2. Connect the zero port to ambient air (outside of sampling
area) and run background readings.
3. Once this background has been performed then the analyzer
can be placed in sampling environment and proceed
sampling.
4. Ensure background air is NEVER taken from ambient air in
sampling environment; this will result in erroneous sample
readings.

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EC9820 CO2 ANALYZER SERVICE MANUAL

2.2.1.6 Sample Fill/Measure

After the background the analyzer is switched into the sample fill mode where the
reaction cell is filled with sample gas, and finally to sample measure mode when
actual gas measurement begins.

2.2.1.7 Quick-Start Routine

If the analyzer power is removed for less than two minutes, the full automatic
startup routine is replaced by a quick start routine. The analyzer is returned to its
last known operating parameters and normal operation is immediately restored.
This allows the analyzer to rapidly return to measurement mode and keeps data
loss to a minimum. If power is lost for greater than two minutes, a full automatic
restart is performed.

2.2.2 Measure Modes

2.2.2.1 Sample Measure
Sample measure is the standard operating mode of the EC9820. The cell is
continuously filled with sample gas via the main valve manifold. The IR detector
senses the IR signal from the measurement cell. This signal is amplified, and
conditioned by the preprocessor to separate reference and measure signals, which
are compared to become what is called the concentration voltage. This
concentration voltage is then used to determine gas concentrations.

2.2.2.2 Zero Measure

Zero measure allows the cell to be filled with zero air from an external zero air
source with external valves selected. Processing of the signal is identical to
measurement processing; the only difference is the source of the sample stream.

2.2.2.3 Span Measure

Span measure allows the cell to be filled with gas from an external span source.
Processing of the signal is identical to measurement processing; the only
difference is the source of the sample stream.

2.2.2.4 AZS Cycle

The analyzer can be placed in an AZS cycle mode where the sample stream is
automatically switched to zero, then span, then back to sample. Further
information on the AZS cycles is included in the EC9820 Operation Manual.

2.2.3 Auto Zero Routines

The EC9820 is an auto-zero instrument. The analyzer is allowed to periodically
sample zero air and correct for the readings obtained.

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2.2.3.1 Background
The auto-zero function (background) is performed nightly at midnight unless
BACKGROUND is DISABLED. This compensates for drift in the measurement
baseline of the analyzer. The nightly background routine is identical to the
background described in the startup routine.

2.2.3.2 Electronic Zero Adjust

Long-term negative drift may occasionally cause the measurement voltage near
zero to drift outside the range of the preprocessor measurement channel. If this
occurs, the analyzer will initiate an electronic zero adjust to reset the preprocessor
measurement coarse and fine zero adjustment. This routine is identical to the
electronic zero adjust described in the startup routine. After an electronic zero
adjust, the analyzer will perform a background to incorporate this new baseline
value.

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EC9820 CO2 ANALYZER SERVICE MANUAL

3.0 Maintenance
3.1 Maintenance Schedule
The following outlines a periodic maintenance schedule for the EC9820 analyzer.
This schedule is based on experience under normal operating conditions, and may
need to be modified to suit specific operating conditions and regulations. It is
recommended that this schedule be followed in order to maintain reliable, long-
term operation of the analyzer.

Interval1 Item Procedure Section

Weekly Inlet Particulate Filter Check/Replace Service Manual:- 3.3.1
Event Log / System Faults Check Service Manual:- 4.2.4 &
4.2.7
Precision Check Check Operation Manual:- 2.4
Monthly Fan Filter Check/Clean Service Manual:- 3.3.3
Zero / Span Calibration Perform Operation Manual:- 2.4
Clock Check Operation Manual:-2.3.3
6 Monthly Multi-point Calibration Perform Operation Manual:- 3.2
1 Year Detector Signal Adjust Service Manual:- 3.3.4
Leak Check Perform Service Manual:- 3.3.7
Flow Calibration Check / Calibrate Service Manual:- 3.5

1
Suggested intervals for normal operation and actual intervals will vary depending upon application. The user can
refer to this table as a guideline, but should develop a maintenance schedule to suit their specific requirements.

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 CHAPTER 3 MAINTENANCE

3.2 Replaceable Parts

EC9820 Analyser Spare Parts Requirements
Description Part Number Level
Filter element, 5 micron, consumable (50 each) 98000098-1 1
Infrared source 80340371 2
Filter, optical 002-057401 3
O-ring, optical filter 025-030410 3
O-ring, sapphire window 28000186 3
Extraction tool, minifit connectors 29000141-2 3
Detector 37000076 3
Pump 58500037 3
Window, sapphire 883-051600 3
PCA, Voltage Regulator 98000056 3
Display/switch assembly 98000057SP 3
PCA, Microprocessor (SMD) 98000063-4 3
PCA, 50-Pin I/O 98000066-2 3
Power supply, 115/230 VAC to 12 VDC 98000142 3
Flow control assembly 98300046SP3 3
PCA USB Board Assembly 98007502 3
PCA, Preprocessor 98200002SP 3
Preamplifier/detector assembly 98300015 3
Motor, correlation wheel 98300032 3
Reflector, optical interrupter 98300033 3
Valve manifold assembly 98300037-2 3
Source timing assembly 98200006 3
Heater/thermistor assembly 98300061 3
Correlation wheel assembly 98200017 3

Level 1: General maintenance supplies and expendables such as filters, O-rings, lamps, etc.

Level 2: Critical items that are known from experience to have a higher failure rate, such as
pumps, heaters, converters, valves, and circuit boards.

Level 3: Other miscellaneous items not included in Level 1 or 2. This level includes other spare
parts that are not expected to fail over a given time frame.

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EC9820 CO2 ANALYZER SERVICE MANUAL

Components marked with shading are essential components which need to be kept on hand at all
times.

EC9820 Analyser Spare Parts Requirements

Options and Accessories
Description Part Number
Rack mount kit with slides 98000036-2
Battery power option, 12 VDC 98000115
Filter kit, particulate, sample inlet, 5 micron 98000211-1
50-pin connector and shell kit 98000235-1
Valve manifold kit, external zero/span (EZS) 98300087
Valve, span, for external pressurized span source or gas cylinder 98301002
EC9820 Operation Manual 98207600
EC9820 Service Manual 98207601

3.2.1 Expected Life Span of Consumables

Component Minimum Typical
IR Source (98300049) 6 months 2 years

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 CHAPTER 3 MAINTENANCE

3.3 Maintenance Procedures

Following is a list of routine maintenance procedures which may be required over
the life of the analyzer.

Recommended equipment to perform maintenance:

ˆ Toolbox
ˆ Oscilloscope
ˆ Digital multimeter (DMM)
ˆ Computer or remote data terminal and connection cable for RS232
communication
ˆ Pressure transducer (absolute) and connection tubing, calibrated in torr
ˆ Flowmeter (2 slpm nominal)
ˆ Wire strippers
ˆ Soldering iron
ˆ Minifit extraction tool
ˆ Orifice removal tool
ˆ Assortment of 1/4” and 1/8” tubing and fittings
ˆ Test zero air source (CO2-free)
ˆ Test span gas source
ˆ Leak tester.

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Figure 9. Routine Maintenance Components

3.3.1 Check Particulate Filter

The inlet filter prevents particulates from entering the pneumatic components of
the EC9820. Contamination of the filter can result in degraded performance of the
EC9820, including slow response time, erroneous readings, temperature drift, and
various other problems.

Several factors affect the filter replacement schedule. In the springtime, for
example, pollens and dust might accumulate in the filter. Man-made
environmental changes such as construction dust might indicate more frequent
change, or a climate where dry, dusty conditions are normal might dictate more
frequent filter replacement than climates with few natural pollutants.

Determining the schedule for changing the filter is best developed by monitoring
the filter at weekly intervals for the first few months, then adapting the schedule
to fit the specific site.

3.3.2 Particulate Filter Replacement Procedure

Use Figure 10 as reference when performing the filter replacement procedure.

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Figure 10. Filter Replacement Procedure

1. Open the front panel to access the service switches and particulate filter.
Position the Pump switch in the secondary front panel to OFF.

2. Completely unthread the filter cap by turning it counterclockwise.

3. Pull the filter plunger out of the body, carefully resting it in a secure place.
The O-ring and filter membrane are now exposed inside the filter body.

4. Remove, inspect, and wipe down the O-ring. Replace the O-ring only if
damaged.

5. Remove, discard, and replace the old filter membrane.

6. Reinstall the O-ring over the new membrane, reinstall the plunger, and hand-
thread the cap back into place by turning it clockwise. Do not use tools.

7. Return the Pump to ON.

8. Close the front panel.

3.3.3 Clean Fan Filter

The fan filter is located on the rear of the analyzer. If this filter becomes
contaminated with dust and dirt, it may affect the cooling capacity of the analyzer.
The fan screen should be cleaned by removing it from the analyzer and blowing it
out with compressed air, or by cleaning it with mild soapy water and air drying.

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3.3.4 Detector Signal Adjustment

The detector signal must be maintained at proper intensity to ensure satisfactory
operation of the analyzer. If this signal becomes too large or too weak, the
analyzer will not be able to maintain proper reference and measurement signals,
resulting in loss of measurement capability. To perform the detector signal
adjustment:

Caution
If the detector signal is adjusted, the analyzer
will require recalibration.

Required equipment:
Oscilloscope

1. Remove the analyzer cover and connect an oscilloscope to the PAMP2VPP

test point (J5-14) on the Preprocessor PCA. Set the scope for 0.5 v/div and
2 msec/div. Synchronize the scope using the REF test point (J5-3) on the
Preprocessor PCA.

2. The detector adjustment potentiometer is accessible through the hole on the

top of the detector cover. Use an electronic tweeker to adjust the preamp
signal using for 2 volts peak-to-peak on the smaller signal (refer to Figure 11).

Figure 11. Detector Signal Adjustment

3. Verify that the two signals on the detector signal differ in amplitude by
approximately 15% (refer to Figure 11). If they differ by less than 15%, the
correlation wheel may require replacement.

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4. Disconnect the oscilloscope and reinstall the cover. If the signal was
readjusted, the analyzer should be reset and recalibrated after its startup
sequence is complete.

3.3.5 Correlation Wheel/Motor/IR Source Replacement

Refer to Figure 12.

Figure 12. Correlation Wheel/Motor/IR Source Replacement

1. Turn the analyzer off and disconnect power.

2. Disconnect the 1/4” tubing from the measurement cell inlet and outlet and all
electrical connections from the bench to the sensor tub. Remove the four
mounting screws from the bench and remove the bench from the sensor tub.

3. Remove the four screws securing the source/timing assembly to the optical
bench and remove the block from the bench.

4. Remove the correlation wheel by loosening the set screw in the side of the
wheel body (0.5 mm hex screw). Slide the correlation wheel off of the motor
shaft.

5. Remove the four screws securing the motor to the mounting plate and remove
the motor.

6. Remove the two screws that fasten the IR source into the source block.
Remove the IR source from the block.

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7. Using a minifit extraction tool, remove the two wires from the source to the
electrical connection. Remove the IR source and install the new source,
rewiring the new source in place of the old one.

8. Reinstall the IR source.

9. Reinstall the motor.

10. Reinstall the correlation wheel. When securing the correlation wheel to the
motor shaft, ensure the set screw secures to the flat face of the motor shaft.

11. Reassemble the source/timing assembly to the optical bench and reinstall the
bench in the sensor tub.

12. Perform the detector adjustment from earlier in this section. Be sure to
recalibrate the analyzer.

3.3.6 IR Detector Replacement

Refer to Figure 13.

Figure 13. IR Detector Replacement

1. Turn the analyzer off and disconnect power.

2. Disconnect the 1/4” tubing from the measurement cell inlet and outlet and all
electrical connections from the bench to the sensor tub. Remove the four
mounting screws from the bench and remove the bench from the sensor tub.

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3. Remove the four screws securing the detector cover to the detector assembly.

4. Remove the four screws securing the detector assembly to the bench.

5. Remove the detector assembly. Install the new detector in reverse order of the
above steps.

3.3.7 Leak Test Procedure

This is a test for the pneumatic system of the instrument. The display readings
will indicate whether the system is leaking.

1. Enter the TEST MENU and select OUTPUT TEST MENU, then VALVE TEST MENU;
from these items pick VALVE SEQUENCING and set to OFF.

2. Set all valves to CLOSED.

3. Press <Pg Up> to return to the OUTPUT TEST MENU and choose FLOW CONTROL
POTS.

4. Turn the Pump Switch on the secondary panel to OFF and verify FLOW: 0.00
SLPM. If it does not read 0.00 the Flow Control PCA requires recalibration.
Return the Pump Switch to ON.

5. Plug the INLET port on the rear panel.

6. Verify GAS FLOW in the FLOW CONTROL POTS screen reads 0.00. If the reading
is not 0.00, there is a leak somewhere between the valves and the flow block.

7. Set VALVE SEQUENCING to ON and then press <Exit>. Remove the plug from
the INLET port.

8. Verify that the flow returns to the original setting by observing the
INSTRUMENT STATUS menu.

The actual flow through the analyzer should be checked by turning on the pump
and connecting a flow meter to the measure inlet (ensure that the analyzer is in
SAMPLE MEASURE). Actual flow through the analyzer should be approximately
1 slpm. If flow is too low, perform the flow calibration in section 3.5 below.

3.4 Hidden Menu

The new software features of the Ecotech Microprocessor board (SMD version),
provides provisions for a hidden menu. This enables the experienced user to
access menus for maintenance purposes. These menus eliminate the need for a
portable computer to perform flow & pressure calibrations.

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To access the hidden menu, simultaneously press three keys on the front panel
from the primary screen as follows:

Up arrow (¿), <Pg Up> and Enter> (↵)

The following menu will be displayed:

HIDDEN MENU

SERIES A
ANALYZER TYPE 9820
SUB TYPE STANDARD
FLOW BLOCK TYPE STANDARD
GAS NAME ___
PRESSURE CALIBRATION MENU
FLOW CALIBRATION MENU
FACTORY DIAGNOSTICS MENU

Figure 14. Hidden Menu

SERIES
Allows the user to choose the correct series of analyzer. The options are A, B &
S. The selection must reflect the Hardware to which it is being installed. i.e. for
an EC9820 analyzer, it must be set to A, and for an EC9820B analyzer set to B, in
order to operate correctly. The S option is reserved for special system software.

ANALYSER TYPE
Allows the user to choose the correct analyzer type. The options are 9810, 9811,
9812, 9820, 9830, 9841, 9842 & 9850. The selection must reflect the
Hardware to which it is being installed. i.e. for an EC9820 analyzer, it must be set
to 9820 in order to operate correctly. The analyzer type will default to ???? if the
device type has not been set or cannot be read from the preprocessor board.

SUB TYPE
Allows the user to set the correct Hardware options for this analyzer. The options
for the EC9820 are: STANDARD, TRACE & HIGH LVL.

GAS NAME
Allows the user to set a 3 character name for the primary gas name. The name
entered here will be used to replace the primary gas name in all screens. If the
first character is a space then CO will be used as a gas name.

FLOW BLOCK TYPE

Displays the type of flow block installed. If the flow block is not connected or
calibrated, then no type will be displayed. Should be set to STANDARD.

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3.4.1 Pressure & Flow Calibration sub-menus

The pressure and flow calibration menus allow the user to manually calibrate the
pressure transducers and calibrate the flow of the flow controllers. The contents of
the pressure and flow calibration menus are described below. Note that these
parameters will vary depending on which flow block type is selected. Refer to
section 3.5 for further details.

DESIRED FLOW
Desired flow rate that the standard flow block will maintain a constant flow at.

Note
If the flow rate is changed the instrument must
be reset in order for the change to take effect.
FLOW SPAN POINT
During the flow calibration of the standard flow block, this is where the externally
measured flow rate is entered.

FLOW ZERO POINT

During the zero flow calibration of the standard flow block, this option must be
set to set and enter pressed for the zero calibration to take effect. Select cancel
to abort this operation.

FLOW TRANSDUCER DF
Selecting set, loads the factory default calibration curve into the earom on the
standard flow control board.

PRESSURE 1 HIGH
Pressure entered during ambient calibration.

PRESSURE 1 LOW
Pressure entered during low pressure calibration.

VALVE SEQUENCING
Turn the valve sequencing on or off. Same as in the Valve Test Menu. When
turned off, the appropriate valve sequence will set ready for pressure calibration.

CONTROL LOOP
When ENABLED, the microprocessor controls the pump speed (via the flow control
pots) to give the desired flow rate. When DISSABLED, the user can manually adjust
the pump speed using the flow control pots. For the standard flow block only.

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FLOW CONTROL ZERO

This flow control pot is used to manually adjust the zero flow offset voltage
during the zero calibration of the standard flow block.

PUMP SPEED COARSE/ FINE

The two flow control pots (PUMP SPEED COARSE & PUMP SPEED FINE) are
software-controlled pots which control the pumps speed on the standard flow
block.

AMBIENT PRESSURE
Current ambient pressure measured from the ISO flow controller.

GAS PRESSURE
Current gas pressure measured from the flow controller.

GAS FLOW
Current gas flow measured from the flow controller.

3.4.2 FACTORY DIAGNOSTICS MENU

This menu is for pre-release factory use only. Any modifications made within this
menu will alter instrument settings and readings. Ecotech Pty Ltd does not
guarantee the validity of any results following changes being made within this
section.

3.5 Pressure & Flow Calibration

The pressure and flow calibrations should be performed whenever a flow or
pressure reading becomes suspect, when a transducer is replaced, or can be
performed as an annual maintenance item. The pressure and flow transducer
calibration may be performed separately or together. For both procedures the
following equipment is required:

ˆ Digital Volt Meter.

ˆ Pressure transducer (absolute); calibrated in torr.
ˆ Flowmeter, 1 slpm nominal
ˆ ¼” fitting with hose to suit pressure transducer.

3.5.1 Pressure/Flow Calibration

3.5.1.1 Setup
Note

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The EC9820 analyzer should be left running for at

least one hour with the pump switched on before
this procedure is attempted. This will allow the flow
block temperature to stabilize to 50oC.

From the HIDDEN MENU, set the FLOW BLOCK TYPE TO STANDARD, and press
Enter> (↵). Press Reset on the analyzer secondary panel.

3.5.1.2 Pressure Calibration

1. From the HIDDEN MENU, select the PRESSURE CALIBRATION MENU. The menu
of Figure 15 should be displayed.

PRESSURE CALIBRATION MENU

PRESSURE 1 HIGH 743.0 TORR

PRESSURE 1 LOW 530.0 TORR

VALVE SEQUENCING ON
CONTROL LOOP ENABLED
PUMP SPEED COARSE 28

GAS PRESSURE 710.0 TORR

GAS FLOW 1.000 SLPM

Figure 15. Pressure Calibration Menu for Standard flow block

2. Verify the pump is turned off by setting the pump switch to OFF on the
secondary panel.

3. Allow 30 seconds for the pressure reading to stabilize to ambient pressure on

both the calibrated pressure transducer and the analyzer. This reading (in
TORR) should be the ambient pressure. Set this value as PRESSURE 1 HIGH
in the PRESSURE CALIBRATION MENU and then press Enter> (↵).

Note
To convert from millibar to TORR, multiply the
pressure by 0.75.

4. Set the CONTROL LOOP TO DISABLED, and press Enter> (↵).This will disable
the flow control loop.

5. Connect the calibrated pressure transducer to the sample inlet on the rear
panel of the analyzer.

6. Turn the pump ON from the secondary panel.

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EC9820 CO2 ANALYZER SERVICE MANUAL

7. Set the PUMP SPEED COARSE to 99 and press Enter> (↵).

8. Allow approximately 1 minute for the pressure to drop to a stable reading.

This reading should be typically 100 to 200 torr lower than the ambient
pressure (depending upon the capacity of the pump).

9. Set this reading (in TORR) as PRESSURE 1 LOW in the PRESSURE

CALIBRATION MENU and press Enter> (↵).

10. Disconnect the pressure transducer from the inlet and turn the pump OFF.

11. To verify that the pressure transducers on the standard flow control board are
calibrated, view the GAS PRESSURE reading in the PRESSURE CALIBRATION
MENU. it should be at ambient pressure +/- 2 TORR.

This completes the pressure transducer calibration procedure.

3.5.1.3 Flow Calibration

1. From the HIDDEN MENU, select the FLOW CALIBRATION MENU. The menu of
Figure 16 should be displayed.

FLOW CALIBRATION MENU

DESIRED FLOW 1.00 SLPM

FLOW CONTROL ZERO 81
FLOW TRANSDUCER DF CANCEL
CONTROL LOOP ENABLED
VALVE SEQUENCING ON
FLOW ZERO POINT CANCEL
FLOW SPAN POINT 1.000 SLPM
PUMP SPEED COARSE 28
PUMP SPEED FINE 7
GAS PRESSURE 710.0 TORR
GAS FLOW 1.000 SLPM

Figure 16. Flow Calibration Menu for Standard flow block

2. Verify the pump is turned OFF .and the CONTROL LOOP is DISABLED in the
FLOW CALIBRATION MENU.

3. Load the linearization table into the flow control board EAROM by setting
FLOW TRANSDUCER DF to SET and pressing Enter> (↵). The linearization
table contains the following parameters:

Flow points: 0, 0.5, 1.75, 2.5, 3.25, 3.75.

Voltage points: 0, 0.13, 0.91, 1.783, 2.5, 3.478.

34 98207601 Rev B
 CHAPTER 3 MAINTENANCE

4. Connect the calibrated flow meter to the sample inlet on the rear panel of the
analyzer. With the pump turned off, verify that there is no flow.

5. Connect a Digital Volt Meter (DVM) to the FLOW test point on the Flow
Control PCA. TP1 is the 0V connection, and pin 5 of the J2 connector is the
FLOW test point. The Digital Volt Meter should be set to the 2V DC range.

6. Adjust the FLOW CONTROL ZERO pot until the DVM reads slightly positive (0
to 0.5 VDC), then press <Enter>.

7. Set the FLOW ZERO POINT to SET and press Enter> (↵). The GAS FLOW
should now read 0.000 SLPM.

8. Disconnect the DVM.

9. Turn the analyzer pump ON and verify the CONTROL LOOP is still
DISABLED.

10. From FLOW CALIBRATION MENU use the PUMP SPEED COARSE and PUMP
SPEED FINE pots to adjust the measured flow (external flowmeter) to as close
as possible to 1.00 SLPM.

Note
If the analyzer attempts to automatically change the
pot position during adjustment then repeat step 9.

11. Record the average measured flow from the flowmeter and enter it into the
FLOW SPAN POINT and press Enter> (↵).

12. Set the DESIRED FLOW to 1.00 SLPM and press Enter> (↵).

13. Press Reset on the analyzer and allow the flow to stabilize. Verify the
flowmeter reading is now 1.0 ±0.05 SLPM.

Note
After the instrument startup is complete, verify the
gas pressure is slightly below actual ambient
pressure (approximately 10 - 20 torr). The gas
pressure and gas flow readings may not bet updated
during the startup routine.

This completes the flow transducer calibration procedure.

3.6 Preprocessor Device ID Entry

This procedure is only required if the microprocessor is not reading the device ID
from the preprocessor board, or if the preprocessor board has been replaced.

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EC9820 CO2 ANALYZER SERVICE MANUAL

1. From the HIDDN MENU set the SERIES to A then press Enter> (↵).

2. Set the ANALYSER TYPE to 9820 and press Enter> (↵).

3. Press Reset on the analyzer secondary panel. The display should now display
9820 CO ANALYZER.

4. You may need to erase memory after this procedure to avoid any problems.

This completes the analyzer device type programming.

3.7 Firmware Update

As improvements are made to the EC9800 series analyzers, these can be easily
passed on to the user by updating the firmware (software operating within the
Microprocessor board).

To update your EC9800 Analyzer, download the Firmware Updater Software.

Install this software on a Windows based computer with a COM port. To do this,
run the downloaded file 'setup.exe' by double clicking on it, then follow the
installation screens to install.

Next, download the required software version for your 9800 analyzer from those
listed at the bottom of this page (e.g. V1.00.0002), by right clicking on the link,
and choosing 'Save Target As', and saving the .sx file on your computer. You will
need to select save as type 'All Files' in the download window.

To update the firmware on the analyzer:

1. Run 'Firmware Updater' from the 'Start - Programs - Ecotech - Firmware

Updater' menu.

2. Connect the 9800 analyzer to the computer using a standard serial cable (you
can connect to either the Multidrop port on the back of the analyzer, or the
service port on the front of the analyzer).

3. Select 'Serial Port' and the COM Port on the computer from those listed on
the Firmware Update screen.

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Figure 17 Firmware Update communication settings screenshot

4. Click Next

5. Enter the full path and file name of the firmware (.sx) file you downloaded.
e.g. - C:\TEMP\V1.03.0001.SX assuming the file was saved to C:\TEMP.

Figure 18. Firmware Update firmware selection screenshot

6. Click Next

7. Tick the boxes as shown in the figure below.

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EC9820 CO2 ANALYZER SERVICE MANUAL

Figure 19. Firmware Update operations screenshot

8. Ensure the analyzer is switched off using the switch under the front panel.

9. Click 'Start'.

10. Switch the analyzer on.

11. The Firmware Updater window will show each step as the firmware is
uploaded. DO NOT turn the analyzer off until the 'Close' button is enabled as
shown below, and the Analyzer is operating as usual again.

Figure 20. Firmware Update completion screenshot

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4.0 Troubleshooting
4.1 DC Power Supply Voltages
Before consulting the troubleshooting section, verify that the DC power supply
voltages are present and within the specifications given for each printed circuit
board listed in the following table. Circuit board illustrations indicating the test
points and other component locations immediately follow the Troubleshooting
Guide.

Table 1. Troubleshooting Voltages

PCB Supply DVM(-) DVM(+) Response
Microprocessor +12V GOOD* TP1 (PGND) TP2 +20 ±0.5 v
-10 v TP3 -10 ±0.5 v
-20 v TP4 -20 ±0.5 v
Voltage Reg. +12 v TP7 (AGND) TP9 +12 ±0.5 v
+10 v TP8 +10 ±0.5 v
-10 v TP6 -10 ±0.5 v
+5 v TP4 +5 ±0.25 v
Preprocessor +12 v TP2 (AGND) J2-1, J2-6 +12 ±0.5 v
+5 v J2-3 +5 ±0.25 v
+10 v J2-4 +10 ±0.5 v
+1 v (COOLER) J5-5 +1 ±0.3 v
+6 v (SOURCE) J3-3 +6 ±0.3 v
Flow Control +5VL TP1 (AGND) J2-1 +5 ±0.25V
+4.5VB J2-4 +4.5 ±0.25V
+12V J2-8 +12 ±0.5V

* The +12V GOOD test point is a 5 volt status output from the power supply to
indicate that the Mains supply is within the correct operating range.

4.2 Troubleshooting the EC9820 Analyzer

Because of the sophisticated design of the EC9820 analyzer, a significant amount
of information about the condition of the system is available on the front panel
display. You can therefore troubleshoot an operating instrument without opening
the front cover.

The most useful menus in terms of troubleshooting are:

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EC9820 CO2 ANALYZER SERVICE MANUAL

ˆ PREPROCESSOR POTS
ˆ VALVE TEST MENU
ˆ EVENT LOG
ˆ INSTRUMENT STATUS
ˆ SYSTEM TEMPERATURES
ˆ SYSTEM FAULTS.
These menus provide information that may indicate a failure or an operational
problem. If instrument performance appears to have changed dramatically, the
component that is causing the problem can possibly be determined, thereby
speeding up the corrective process. It may assist the operator to periodically check
and record these parameters to establish an operational history of the analyzer. In
addition, information from this section may be requested by the Ecotech Service
Support personnel when assistance is required.

4.2.1 Preprocessor Pots Menu

PREPROCESSOR POTS

MEASURE COARSE ZERO : 67 (50-80)

MEASURE FINE ZERO : 4 (1-99)
INPUT : 42
REFERENCE GAIN : 0
TEST MEASURE : 0

REF. VOLTAGE 3.70 - 4.30 VOLTS

CO 0 - 200 PPM
CONC. VOLTAGE 0 - 4.5 VOLTS

Figure 21. Preprocessor Pots and Ranges

The PREPROCESSOR POTS screen displays the potentiometer settings associated

with several components, variables, or signals on the preprocessor board. Figure
21 illustrates a typical screen for an instrument that is operating normally. The
value of the potentiometer settings is somewhat arbitrary and differences in the
examples shown here and the values displayed on an operating instrument should
not be construed as a definite indicator of a problem. Potentiometer settings of 99
and 0, however, represent the extreme limits of the potentiometer range and may
be reason to suspect a problem, except for TEST MEASURE, which is zero unless
changed by the operator.

4.2.2 Flow Control Pots Menu (A Series only)

The FLOW CONTROL POTS screen displays the potentiometer settings associated
with several components, variables, or signals on the A series Flow Control
board. Figure 22 illustrates a typical test screen for an instrument that is operating
normally. Like the PREPROCESSOR POTS, the value of the potentiometer settings is
somewhat arbitrary. Potentiometer settings 99 and 0, however, represent the

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extreme limits of the potentiometer range and may be reason to suspect a

problem.

FLOW CONTROL POTS

FLOW CONTROL ZERO : 81 (50 –90)

FAN SPEED CONTROL : 16 (0 - 99)
PUMP SPEED FINE : 85 (0 - 99)
PUMP SPEED COARSE : 62 (20 - 60)

GAS FLOW 1.000 SLPM

GAS PRESSURE 585.6 TORR

Figure 22. Flow Control Pots Range

4.2.3 Valve Test Menu

VALVE TEST MENU

INT. VALVE #1 : OPEN

INT. VALVE #2 : CLOSED
INT. VALVE #3 : CLOSED
EXT. MEASURE : CLOSED
EXT. ZERO GAS : CLOSED
EXT. SPAN GAS : CLOSED
AUX. VALVE #1 : CLOSED
AUX. VALVE #2 : CLOSED
VALVE SEQUENCING : ON

Figure 23. Valve Test Menu

The VALVE TEST MENU (see Figure 23) displays the current status of each valve
in the instrument. This menu can be particularly useful in correcting flow
problems in the machine. The valves can be opened and closed from this menu,
thus allowing the operator to determine whether valves are operating correctly.
Valve sequencing must be ON in order for correct gas measurement to be
accomplished.

4.2.4 Event Log

Upon noting a possible operational problem, examine the EVENT LOG menu to
determine whether the microprocessor is reporting a system failure or problem.

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Should the EVENT LOG indicate an error, it will also provide information as to the
portion or component of the instrument which is at fault.

Event Log Messages

Message Description Action
RAM CHECKSUM Checksum of memory at Battery failure or system
FAILURE power down differs from software error. If error
checksum at restart. persists, call Ecotech
Customer Service for
instructions.
EAROM X DATA ERROR EROM designated X Check pressure board cable
Y detected error at location connections and pressure
Y. board.
SERVICE SWITCH Unit taken out of service Return analyzer to service
ACTIVATED from front panel. using the front panel
switch.
LCD DISPLAY BUSY LCD constantly busy Check display cable
indicates hardware failure connection, display board,
in display. and microprocessor board.
A/D CONVERSION A/D returned busy status Normal at startup. If failure
ERROR persists, replace
microprocessor.
SYSTEM POWER Power removed from No action required.
FAILURE system.
SYSTEM POWER Power applied to system. No action required.
RESTORED
ZERO POT LIMITED Zero voltage controller Reset analyzer, check zero
TO 0 OR 99 reached limits before air source.
voltage reached set point.
INPUT POT LIMITED Input controller reached Check IR source.
TO 0 OR 99 limits before reference
voltage reached set point.
ZERO FLOW Instrument flow has gone The pump has failed or a
to zero. flow obstruction has
occurred. Replace pump, or
clear obstruction.
SPAN RATIO <0.75 After AZS cycle, ratio of Instrument span has drifted
requested span to measured beyond acceptable limits.
span is <0.75. Recalibrate.
SPAN RATIO >1.25 After AZS cycle, ratio of Instrument span has drifted
requested span to measured beyond acceptable limits.
span is >1.25. Recalibrate.

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Event Log Messages

Message Description Action
ELECTRONIC ZERO An analyzer electronic zero Normal after reset or power
ADJUST cycle was initiated. failure. If not associated
with these, check zero air
supply.
BACKGROUND CYCLE Background cycle started. No action required.
The value of the result of
the previous background is
stored here.
RESET DETECTION Reset button pressed or Unless the reset was not
watchdog timer caused initiated by the user, no
reset. action is required.
AZS CYCLE AZS cycle started. No action required.
CHOPPER WHEEL Indicates that the chopper Check chopper motor,
ERROR wheel is not operating opto-interrupter and
correctly. chopper wheel.
DATA LOGGING MEM Occurs if unable to write to Battery failure or system
FAIL datalogging memory. software error. If error
persists, call Ecotech
Customer Service for
instructions.
CONTROL LOOP Occurs when Control Loop No action required.
RESTARTED has been disabled, and then
automatically enabled after
the main screen has been
visible for the last 1
minute.
CHASSIS TEMP. Occurs if chassis No action required.
THRESHOLD temp varies by 4C,
then 3 successive
backgrounds will
be performed each
hour.
VALVE SEQUENCING Occurs when valve No action required.
RESTARTED sequencing has been
disabled, and then
automatically enabled after
the main screen has been
visible for the last 1
minute.

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4.2.5 Instrument Status

INSTRUMENT STATUS

GAS FLOW : 0.9 - 1.3 SLPM

GAS PRESSURE : 430 - 800 TORR
REF. VOLTAGE : 3.80 - 4.20 VOLTS
CONC. VOLTAGE : 0 - 4.50 VOLTS
ANALOG SUPPLY : 11.6 - 12.2 VOLTS
DIGITAL SUPPLY : 4.8 - 5.2 VOLTS

VERSION 1.11.0002 EXIT

Figure 24. Instrument Status and Ranges

The INSTRUMENT STATUS screen provides information about several critical

parameters in the EC9820. If any of the parameters displayed on the INSTRUMENT
STATUS screen vary significantly from the values shown in Figure 24, the fault or
operational problem is probably related. This is also true if one of the parameters
is demonstrating a rapid change or is oscillating strongly around the desired
setpoint. For more information on the operational limits and fault messages, refer
to the table in section 4.2.7 System Faults.

Several of the parameters displayed on the INSTRUMENT STATUS screen are

affected by the potentiometer settings on the PREPROCESSOR POTS screen. If a
parameter is out of the normal operating range, make note of the parameter value,
proceed to the applicable menu, and examine the pertinent potentiometer settings.

4.2.6 System Temperatures

SYSTEM TEMPERATURES

CELL TEMP. : 47 - 53 DEG C

CONV. TEMP. : 87 - 93 DEG C
CHASSIS TEMP. : 15 - 55 DEG C
FLOW TEMP. : 45 - 55 DEG c
COOLER TEMP. : 1.0 - 1.2 VOLTS
MIRROR TEMP. : 47 - 53 DEG C

EXIT

Figure 25. System Temperatures and Tolerances

The SYSTEM TEMPERATURES screen provides the temperatures of the

measurement cell, the chassis temperature, and the thermoelectric cooler
temperature used to cool the detector. Figure 25 contains the nominal values that
should be displayed on this screen. If any of the parameters are outside the
acceptable ranges, a significant problem among these components is strongly
indicated. For more information on the operational limits and fault messages,
refer to the table in section 4.2.7 System Faults.

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4.2.7 System Faults

The SYSTEM FAULTS display provides pass/fail indications for various parameters
that are continually monitored. These parameters must be within acceptable
operating ranges in order to display PASS. If FAIL is indicated, this indicates a
major failure in that area. If the instrument is in startup mode, START will be
displayed.

Note
The SYSTEM FAULTS screen only indicates PASS or
FAIL for the various analyzer parameters, and is
meant to indicate major failures. Desired operating
ranges are indicated in the INSTRUMENT STATUS
and SYSTEM TEMPERATURE ranges section. If
analyzer readings are not within these ranges, it
could indicate deterioration of certain assemblies
within the analyzer, or minor failures.

The following table lists the possible system fault messages that are displayed on
the primary screen if a major failure occurs. If a fault message is displayed, use
the troubleshooting guide to find the possible cause of the fault.

System Fault Messages

Message Description/Failure Limits
OUT OF SERVICE Indicates the Service switch is in the OFF position. Unless the
analyzer is being serviced, this switch should be in the IN position.
ZERO FLOW Indicates that the sample flow is less than 0.1 slpm.
(A series)
LAMP/SOURCE Indicates that the source voltage is not within the acceptable limits. A
FAILURE fault is indicated if the cooler voltage falls below 0.5 volts.

CHOPPER WHEEL Indicates that the chopper (correlation) wheel is not rotating.
FAILURE
COOLER FAILURE Indicates that the cooler temperature or voltage is not within the
acceptable limits. A fault is indicated if the cooler voltage is above
1.5 volts.
REFERENCE Indicates that the reference voltage is not within the acceptable limits.
VOLTAGE OUT OF A fault is indicated if the reference voltage is below 3 volts or above
RANGE 4.5 volts.
12 VOLT SUPPLY Indicates that the 12 volt supply voltage is not within the acceptable
FAILURE limits. A fault is indicated if the 12 volt supply voltage is below
11.1 volts or above 14.3 volts.

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System Fault Messages

Message Description/Failure Limits
CELL Indicates that the cell temperature is not within the acceptable limits.
TEMPERATURE A fault is indicated if the cell temperature is below 35° C or above
FAILURE 60° C.
CONVERTER Indicates that the converter temperature is not within the acceptable
TEMPERATURE limits. A fault is indicated if the converter temperature is below 80° C
FAILURE or above 100° C.
MIRROR Indicates that the mirror temperature is not within the acceptable
TEMPERATURE limits. A fault is indicated if the mirror temperature is below 35° C or
FAILURE above 60° C.
FLOW BLOCK TEMP Indicates the flow block temperature is not within acceptable limits.
A fault is indicated if the flow temperature is below 35° C or above
60° C.
START UP Indicates that the analyzer is in start-up mode. Usually after power-up
SEQUENCE ACTIVE or reset.

4.3 Test Functions

The following lists the available diagnostic modes in the EC9820 under the TEST
MENU:

4.3.1 Optic
Not supported.

4.3.2 Preamp
The preamp test function generates an electronic test signal which is applied to
the input of the IR detector preamp. This simulates an input from the detector and
is then processed as if it were an actual signal. This test is used to verify the
operation of the detector.

4.3.3 Electric
The electric test function generates an electronic test signal which is applied to the
input of the preprocessor. This simulates a reference and measure input to the
preprocessor and is then processed as if it were an actual signal. This test is used
to verify the operation of the preprocessor board reference and measure channels.

4.3.4 Use of Diagnostic Modes

The diagnostic mode is actuated by selecting DIAGNOSTIC MODE: ELECTRIC or
PREAMP, and adjusting the test measure or test reference potentiometer until a
response (simulated concentration or reference) is noted. Response to tests will
vary depending upon individual analyzer parameters. These tests are typically
pass/fail (response or no response).

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4.4 Troubleshooting Guide

Use this troubleshooting guide to find the symptom, then follow in order the
possible causes and fault isolation/solutions until the problem is discovered and
take the action described.

If you cannot identify the problem, contact Ecotech at the locations given in
the front of this manual.

System Troubleshooting Table

Symptom Possible Cause Fault Isolation/Solution
1. No display/ AC power 1. Verify that the line cord is connected.
instrument dead 2. Check that the power supply fuse is not open.
The fuse should be 5A (115 v) or 3A (230 v).
3. Verify that the voltage switch is in the proper
position.
2. No display Contrast Set or adjust the display contract by
maladjusted simultaneously pressing two keys on the front
panel as follows:
- Contrast: Press Up Arrow (¿) and <Select> for
darker contrast, Down Arrow (À) and <Select> for
lighter contrast.
DC power 1. Verify the cable connection from the power
supply to the Vreg board.
2. Check the Vreg board for correct voltages as
listed in the troubleshooting voltages table in
section 4.1 above. If incorrect voltages are found,
replace the power supply.
3. Check Microprocessor test points listed in the
Troubleshooting Voltages table in section 4.1.
Display Check the interface cable between the display and
J6 on the microprocessor board.
Bad Display or 1. Replace the front panel display.
microprocessor 2. Replace the microprocessor board.
board
3. A bad cable is unlikely, but if you suspect it,
perform a pin-for-pin continuity test using an
ohmmeter.
3. Zero Flow Pump failed Replace the pump.
Filter Check the particulate filter. Replace if dirty or
plugged.
Flow control Recalibrate the flow control assembly.
assembly
Pressurized Rx Cell Ensure Sample and Zero inlets are maintained at
ambient pressure.
4. Noisy or Leaks A leak dilutes the sample stream and causes low
unstable readings span readings and noise. See the leak test
procedure in section 3.3.7 above.

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System Troubleshooting Table

Symptom Possible Cause Fault Isolation/Solution
IR source weak or Adjust the detector signal. If you are unable to
noisy detector. obtain an acceptable reading, replace the source or
detector.
Cell Heater/Mirror A failed temperature control allows the instrument
Heater zero to drift with ambient temperature. Verify that
the cell temperature and mirror temp are 50° ±3° C
and stable
(±0.3° C).
5. Low span Span setting Adjust the span using the calibration procedure in
the EC9820 Operation Manual.
No flow See the zero flow symptom in this table.
Correlation Wheel Check the preprocessor pots/measure coarse zero
Leak setting. If it is below 50, replace the correlation
wheel.
Leaks A leak dilutes the sample stream and causes low
span readings and noise. See the leak test
procedure in section 3.3.7 above.
6. No response to Leaks A leak dilutes the sample stream and causes low
span gas span readings and noise. See the leak test
procedure in section 3.3.7 above.
No flow See the zero flow symptom in this table.
Correlation Wheel Check the preprocessor pots/measure coarse zero
Leak setting. If it is below 50, replace the correlation
wheel.
Software lockup 1. Observe whether ECOTECH GLOBE on the
display is turning.
2. Verify that other menus can be selected.
3. Press the Reset button on the secondary panel.
4. Check that D5 HEART BEAT LED is flashing
on the Microprocessor Board
7. Zero drift Leak A leak dilutes the sample stream and causes low
span readings and noise. See the leak test
procedure in section 3.3.7 above.
8. Unstable flow Failed pressure Recalibrate flow/pressure board. Replace board if
or pressure board symptoms persist.
readings
9. Instrument Reference voltage Perform detector signal check and adjustment.
stuck in reference
adjust
10. Response time Low Flow Check sample flow with flow meter. It should be
not at specified 0.8 to 1.2 slpm at STP. Replace inlet filter, SS
value filter, or orifice if it is not.

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System Troubleshooting Table

Symptom Possible Cause Fault Isolation/Solution
11. Analyzer Preprocessor ID set 1. Check J5 connector on Microprocessor.
displays BAD wrong 2. Check J4 connector on Preprocessor.
I.D.
ANALYZER 3. Reprogram device ID.
4. Replace Preprocessor

INDEX

Illustrations, Pneumatic Diagram ............................13

C
Illustrations, Preprocessor Pots and Ranges ............40
Cable Connections (illustration) ................................7 Illustrations, System Block Diagram .......................11
Correlation wheel ....................................................14 Illustrations, System Temperatures and Tolerances 44
Correlation wheel replacement ................................27 Illustrations, Valve Test Menu ................................41
Correlation Wheel/Motor/IR Source Replacement Installation .................................................................5
(illustration) ........................................................27 Instrument Status and Ranges (illustration).............44
Instrument Status Ranges (illustration)........30, 33, 34
D Instrument Status screen ..........................................44
DATA LOGGING...................................................43 IR detector ...............................................................15
Detector signal adjustment ......................................26 IR detector replacement...........................................28
Detector Signal Adjustment (illustration)................26 IR source..................................................................14
Diagnostic modes ....................................................46 IR source replacement .............................................27
E L
Electric test function................................................46 Leak test...................................................................29
Event Log ................................................................42
M
F Maintenance, periodic .............................................20
Fan filter cleaning....................................................25 Maintenance, routine ...............................................23
Filter maintenance ...................................................24 Major Components (illustration) .............................12
Filter, narrow bandpass............................................15 Measurement cell.....................................................15
Flow/Pressure board calibration ........................30, 31 Microprocessor board ..............................................10
Motor replacement...................................................27
G
N
Gas filter correlation wheel .....................................14
Gas Filter Correlation Wheel (illustration) ..............15 Narrow bandpass filter.............................................15
I O
Illustrations, Cable Connections................................7 Opening the Front Panel (illustration) .......................5
Illustrations, Correlation Wheel/Motor/IR Source Optical detector........................................................15
Replacement .......................................................27 Optical Path (illustration) ........................................14
Illustrations, Detector Signal Adjustment................26 Optics system components ......................................14
Illustrations, Gas Filter Correlation Wheel..............15 Optodecoder circuit .................................................16
Illustrations, Instrument Status and Ranges.............44
P
Illustrations, Instrument Status Ranges .......30, 33, 34
Illustrations, IR Detector Replacement....................28 Particulate filter maintenance ..................................24
Illustrations, Major Components .............................12 Periodic maintenance...............................................20
Illustrations, Opening the Front Panel .......................5 Pneumatic Diagram (illustration) ............................13
Illustrations, Optical Path ........................................14 Power/microprocessor module ................................10

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Preamp test function ................................................46 System Temperatures and Tolerances (illustration) 44

Preamp/Pressure board ............................................16 System Temperatures screen ...................................44
Preamplifier board ...................................................16
T
Preprocessor board ..................................................16
Preprocessor Pots and Ranges (illustration) ............40 TCIP ........................................................................11
Preprocessor Pots Menu ..........................................40 Theory of operation ...................................................9
Troubleshooting.................................................39, 47
R
U
Replaceable parts.....................................................39
Routine maintenance ...............................................23 USB ...................................................................11, 21
S V
Sensor module .........................................................12 Valve Test Menu .....................................................41
Service switches ........................................................6 Valve Test Menu (illustration).................................41
Spare parts ...............................................................39 Voltage Regulator board..........................................10
System Faults display ..............................................45

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