Service Manual

CS-2000 Carbon / Sulfur Determinator

Translation

© Eltra GmbH, 42781 Haan, Retsch-Allee 1-5, Germany | 08.08.2016 Version 0001
Copyright
© Copyright by
Eltra GmbH
Retsch-Allee 1-5
D-42781 Haan
Germany

2
Table of Contents
1 Notes on service instructions 7
1.1 Explanations of the Safety Instructions 7
2 Discharging the oscillator 8
3 Faults 12
3.1 Check base lines 12
3.2 Fluctuating gas flow 13
3.3 No combustion 18
3.3.1 Induction furnace operation 18
3.3.2 Resistance furnace operation 27
3.4 Bad combustion 27
3.4.1 Induction furnace operation 27
3.4.2 Resistance furnace operation 28
3.5 Furnace does not close 30
3.6 Analysis takes too long 32
3.6.1 RF-interference on the IR-cell, or on the electronic units 33
3.6.2 Additional reasons for excessive analysis duration 34
3.6.3 One of the IR-sources is unstable 34
3.6.4 The power voltage sinks below 180 VAC 34
3.7 Development of dust when closing the furnace 35
3.8 Erratic results 35
3.9 The results are always 0.0000% or 00.0ppm: 37
3.10 No oxygen flow 38
3.10.1 Induction furnace operation 38
3.10.2 Other faults 39
3.10.3 Resistance furnace operation 39
3.11 IR-cell temperature control is out of range 39
3.12 Breaker turns off at the beginning of combustion 39
3.13 Breaker turns off at the end of the analysis 43
3.14 Dustcloud when opening the furnace 44
3.15 No or low oxygen pressure 45
3.16 Waiting for stability message 47
3.17 Combustion tube breaks frequently 48
3.18 Oxygen pressure falls when the furnace opens 49
3.19 Combustion without starting analysis 50
3.20 Crucible or boat cracks or melts 52
3.20.1 Induction furnace 52
3.20.2 Resitance furnace 52
3.21 Oxygen pressure goes up very slowly 52
3.22 Pump voltage too high 54
3.23 Resistance furnace takes too long to warm up 58
3.24 Negative drift after start 59
3.25 Resistance furnace completly cold or too hot 60
3.26 Fumes in the resistance furnace 61
3.27 Resistance furnace doesn`t reach full temperature 62
3.28 Unstable resistance furnace temperatur 62
3.29 Dust or soot from the resistance furnace 63

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 3.30 Vibrations in induction furnace mode 64
3.31 Analysis cycle stops too early 64
3.32 Chopper motor doesn‘t rotate 65
3.33 Sample burns but no peak on the screen 65
3.34 IR signal does not come down to the base line at the end of analysis 66
4 Adjustments 70
4.1 Gas flow controller-adjustment and jumper settings 70
4.1.1 Flow controller for induction furnace operation 70
4.1.2 Flow controller for resistance furnace operation 73
4.2 Infrared base line adjustments 75
4.2.1 Infrared cell modification - general information 75
4.2.2 General test points 78
4.2.3 Test points IR-ranges 79
4.2.4 Base line adjustments. 80
4.2.5 Infrared cell board IRC1.x sections assignment 80
4.2.6 Voltage of a base line is too high (higher than 9.5V) 81
4.3 IR source voltage setting 83
4.4 Infrared cell temperature regulation 84
4.5 Pneumatics 86
4.6 Pressure regulation 90
4.7 Closing cone adjustment 92
4.8 Linearity correction 93
4.9 Induction generator control 94
4.10 Resistance furnace 96
4.10.1 Setting the furnace regulation card TH 43 / TH 44 96
4.10.2 Furnace regulation board TH 43 / TH 44 97
4.11 Thermocouple testing 98
5 Service 99
5.1 IR-paths, cleaning and replacing 99
5.2 Infrared electronics 100
5.2.1 Removing the IRC-board 100
5.2.2 Changing the IR-source 101
5.3 Chopper 102
5.4 Leak checking 104
5.5 Solenoid valves cleaning 108
5.6 Flow sensor replacement 110
5.7 Gas pump replacement 111
5.8 Thermocouple replacement 112
5.9 Gas saving mode 114
5.10 Gas saving also for resistance furnace 115
5.11 Furnace pneumatics - additional safety features (optional) 116
5.12 Halogen trap - installing 117
6 Miscellaneous 118
6.1 Ordering numbers 118
6.1.1 Front side 118
6.1.2 Left hand side 120
6.1.3 Right hand side 122

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 6.1.4 Induction furnace 124
6.1.5 Furnace cleaning 126
6.1.6 Oscillating circuit 127
6.1.7 Infrared cell 129
6.1.8 Chopper 131
6.1.9 Resistance furnace 132
6.1.10 Oxygen purifying furnace 134
6.1.11 Dust trap 135
6.2 Wiring diagrams 137
6.2.1 Right hand side power wiring 137
6.2.2 Left hand side power wiring 138
6.2.3 Valve wiring 139
6.2.4 Control signal wiring 140
6.2.5 IR-current supply, old version 141
6.2.6 IR-cell internal signals 142
6.2.7 Amplitude circle 143
6.3 Gas flow diagrams 144
6.3.1 Gas flow for induction furnace when furnace is closed 144
6.3.2 Gas flow for induction furnace when furnace is open 145
6.3.3 Gas flow for resistance furnace 146
6.3.4 Valve contolling 147
6.4 Spare parts kits 148
6.4.1 Common spare parts kti for all analysers 148
6.4.2 Spare Parts kit for CS2000 (including spare parts kits CS800 and HTF540) 150
6.5 Maintenance 152
7 Approved methodologies to which Eltra instruments conform 153
7.1 Inorganic materials (Metals) 153
7.2 Organic materials (Oil, Coal, foodstuffs) 154
8 Disposal 155
9 Index 156

5
Notes on service instructions

6
Notes on service instructions

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1 Notes on service instructions

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1.1 Explanations of the Safety Instructions

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In this Operating Manual we give you the following safety warnings

Mortal injury may result from failing to heed these safety warnings. We give you the following
warnings and corresponding content.

DANGER

Type of danger / personal injury

Source of danger
– Possible consequences if the dangers are not observed.
• Instructions on how the dangers are to be avoided.

We also use the following signal word box in the text or in the instructions on action to be taken:
DANGER

Serious injury may result from failing to heed these safety warnings. We give you the following
warnings and corresponding content.

WARNING
Type of danger / personal injury
Source of danger
– Possible consequences if the dangers are not observed.
• Instructions on how the dangers are to be avoided.

We also use the following signal word box in the text or in the instructions on action to be taken:
WARNING

Moderate or mild injury may result from failing to heed these safety warnings. We give you
the following warnings and corresponding content.

CAUTION
Type of danger / personal injury
Source of danger
– Possible consequences if the dangers are not observed.
• Instructions on how the dangers are to be avoided.

We also use the following signal word box in the text or in the instructions on action to be taken:
CAUTION

In the event of possible property damage we inform you with the word “Instructions” and the
corresponding content.

7
 Discharging the oscillator

NOTICE

Nature of the property damage

Source of property damage
– Possible consequences if the instructions are not observed.
• Instructions on how the dangers are to be avoided.

We also use the following signal word in the text or in the instructions on action to be taken:
NOTICE

2 Discharging the oscillator

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In order to carry out work on the oscillator of the CS800/2000, it is necessary to ensure that the
oscillator has no stored energy. This is achieved by short circuiting the various potentials.

Attention:
This activity may only be carried out by a qualified electrician with sound knowledge of the
CS800/2000 devices.
Only the Eltra discharge set (Order Number 11001-2005) may be used for discharging. The
discharge set must always be inspected for visible faults before use.

1000V insulating gloves (order number 8840-0453) must be worn during the discharging
process to prevent an electric shock.

The protective measure is only effective if the discharge set and the insulating gloves are
always worn together.

Discharge set: 11001-2005 Insulating gloves 1000V: 88400-0453

8
Discharging the oscillator

Implementation:
Disconnect the mains plug.
Use a multimeter to check that the device is
voltage-free

Remove the housing cover on the device and

disconnect the GND connector

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 Discharging the oscillator

The clamp is attached to the mounting bracket of

the oscillator

In order to guarantee a safe GND connection

between the crocodile clip and the device ground,
a multimeter is used to ensures that the transition
resistance of the set to the device ground is low
(R<1 Ohm).

To do this, one of the measuring tip on the

multimeter is held on the protective earth of the
device. The other measuring tip is connected to
the tip of the discharge set.

Attention!
The oscillator cover must be removed carefully to
expose the transformer connectors

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Discharging the oscillator

Attention!
The measuring tip is now held first on the left-hand
and then on the right-hand 4.4 KV connector of the
transformer for approx. 5s

It is necessary to ensure that the tip stays on each

contact for the full 5s.

Attention!
All marked components inside the oscillator are short circuited to ground using the measuring tip.

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 Faults

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3 Faults
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3.1 Check base lines

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When this message appears on the PC screen, at least one of the base lines is either over
+9.5Volts or below -9.5 Volts.
In order to read the base line voltages of all IR cells available, click on “base lines”

Fig. 1: Base line button

A window appears at the right upper end of the screen showing the base lines moving from the
left to the right (time coordinate). In the middle of the right end of this base lines window, there
is a small button. After clicking on it, a new window appears, displaying the base line voltages,
described as “Inputs” and their “Averages”.
The description “Inputs” is made from the software point of view. The outputs of the cells are
inputs for the microcontroller board and for the software.
It is advisable to watch the figures under “Inputs”. Do not observe the “Averages” because the
response is delayed when the base lines change. This is a disadvantage when adjusting the
base lines.

Fig. 2: : Activating Inputs and Averages Window

Fig. 3: Inputs and Averages Window

If any of the “Inputs” or “Averages” is over 9.5V, adjust a voltage of about 6 to 7V.
See chapter 3.2 “Infrared base line adjustment”.
The adjustment is preferably made when having carrier gas flow through the cells.

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Faults

Notice
The IR cells have normally base lines adjusted to about 8V and the peak comes down during
analysis, respectively during IR absorption by the measuring gas.
In case of golden paths, in the first couple of months after being in operation, the base line may
goes up, which means that the paths become more reflective during this period. Therefore, the
base lines of golden paths should be initially set rather at 5 or 6 volts instead of 8 volts. In the
first couple of months the base lines go up, but the growing slows down and growing
contamination finally causes the base line to start coming down.
The initial base line adjustment at 5 to 6 volts, prevents the maximum base line value from
reaching 9.5V, where the error message “Check base line” appears. Note that this message is
just a warning. The analyzer is not prevented from carrying out further analyses. As long as the
base line remains below 10V, the results are correct.
If a base line is below -9.5V, an adjustment should be done as advised above. If this is not
possible, then most probably there is a fault or a very strong contamination. See chapter 4.1 “IR
paths cleaning”. In case of contamination, all cells available should have very low voltages,
even negative ones.
If all available cells are below -9.5V there is most probably a fault that is common for all cells
like no rotating chopper motor or a faulty infrared source. See chapter 2.35 “The chopper
motor doesn’t rotate” and 3.3 “IR source voltage setting”.
See also Chapter 3.4 “Analysis takes too long / RF-interference on the IR-cell, or on the
electronic units”
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3.2 Fluctuating gas flow

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Fig. 4: Fluctuating gas flow

The flow rate is electronically controlled; therefore there should be no significant variation from
the set value.

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 Faults

In case of a fault however, a control of the flow rate is no longer possible and the gas flow
fluctuates. This can be caused, for example, by an excessive obstruction of the gas flow system
or by a faulty component that needs to be replaced.
See the next pages of this chapter and chapter 3.1 “Gas flow controller adjustment and
jumper settings”
Mostly, the problem lies in the saturation of the dust trap or of the chemicals.
In case the flow becomes lower and the regulating valve or the pump voltage goes higher
during combustion, it is obvious that the flow regulator is working. Therefore the problem must
be a restricted oxygen supply. When the accelerators start burning they take a lot of oxygen, so
that the pressure in the furnace goes down, and as a result for this the flow may also go down

List of fault reasons in order of probability: (Details to the above points)

Induction furnace Resistance furnace
1. Blocked metal dust filter 1. Blocked chemicals
2. Blocked chemicals 2. Blocked furnace outlet
3. Blocked paper filters 3. Too low oxygen pressure
4. Blocked lance hole over the crucible. 4. The outlet tap of the oxygen bottle is
not properly open
5. Blocked hole of the ceramic heat 5. A heavy item is placed on the plastic
shield tube of the oxygen supply
6. Too low oxygen pressure 6. Twisted plastic tube inside the
analyzer
7. The outlet tap of the oxygen bottle is 7. Blocked dust filter cartridge
not properly open
8. Faulty oxygen regulator 8. Blocked fittings
9. Contaminated or corroded solenoid 9. Blocked flow sensor assembly
valve
10. Bent plastic tube of oxygen supply 10. Electronic problem
11. A heavy item is placed on the plastic 11. Weak gas pump
tube of the oxygen supply
12. Twisted plastic tube inside the
analyzer
13. The oxygen supply is interchanged
with the compressed air supply
14. Blocked dust filter cartridge
15. Blocked flow sensor assembly
16. Electronic problem
Blocked metal dust filter:
Clean the metal dust filter according to the operation manual.
Caution: Even if the filter may be brushed and cleaned in ultrasonic cleaner, some day will not
be able to be cleaned any more. The filter doesn't last forever.

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Faults

Check by removing the filter with the dust filter housing. See chapter: “High carbon results are
erratic”.
Don’t remove the filter from its housing.
Turn the filter housing upside down and try to blow air through the smaller whole (about 16mm
diameter) of the filter housing.
If you feel a remarkable restriction, replace the filter by a new one. With a new filter the air
should pass practically free without any restriction.
Blocked chemicals:
The grains of magnesium perchlorate as well as of sodium hydroxide have to move when
knocking on their glass tube. If they are cloggy, they are completely depleted and they have to
be replaced. When the glass tube is turned upside down, the grains should fall off. If a screw
driver is needed to stab the grains free, the chemicals had to be replaced much earlier.
Blocked paper filters:
The paper filters are small so that they are frequently forgotten or neglected, although they can
block the flow when they are not replaced for long.
Blocked lance hole over the crucible:
The hole in the ceramic heat shield over the crucible in the induction furnace can be restricted
or blocked.
Clean by using the brass brush as described in the operation manual. If this may not be enough
then clean the hole by using a piece of wire or a pipe cleaner.
Blocked furnace outlet:
For induction furnace, unscrew the cap-nut at the furnace outlet and remove the plastic tube.
Pass through the fitting a pipe cleaner. Open the furnace in order to be sure that the pipe
cleaner has passed thru the fitting reaching the furnace area.
Completely remove the plastic tube by unscrewing the left hand cap-nut on the dust filter
assembly. Clean this fitting the same way like before. If necessary clean the plastic tube as well.
In case of resistance furnace operation clean the furnace outlet as shown below.

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 Faults

Push the tube (1) through the upper glass tube assembly (2), pass it through the tube (3) up to
the inside of the dust trap box (4).
This should be done when the glass tube has to be removed anyway, for replacing the
magnesium perchlorate (anhydrone). See also operation manual, chapter “Dust cleaning”.
Too low oxygen pressure:
Check the oxygen gauge (6). The reading should be 1.5 bar (22.5psi). If the pressure is too low,
it can be adjusted by pulling and turning clockwise the knob of the pressure regulator on the
rear panel of the analyzer. It is placed on the left hand side and the knob is accessible from
inside the analyzer. An adjustment is possible provided that there is sufficient pressure at the
input of this pressure regulator.
Outlet tap of the oxygen bottle is not properly open:
It is important to properly open the small tap at the outlet of the pressure regulator of the oxygen
bottle. If this outlet tap of the regulator is not properly open, you may have enough pressure at
the analyzer when there is no or little oxygen demand. But when the oxygen demand grows, for
example at the beginning of combustion in the
induction furnace when the sample needs a lot of oxygen to burn, the pressure may drop to a
very low level if not enough oxygen can be supplied to the analyzer at the moment of high
oxygen demand. The same problem will appear during furnace purging before or after the
analysis, depending on the actual settings in the software.
Contaminated or corroded solenoid valve:
In case of exceptional materials like ores, solenoid valves can be contaminated up to the extent
of failing. This depends mainly on the amount of sulfur and moisture in the sample. The most
affected valves are the outflow valve V1 and the bypass valve V4 in as well as the valves
switching from Induction to resistance furnace V11 and V12. See chapter “Gas flow system”.
The resistance furnace operation can only contaminate V11 and V12. The valves can be
cleaned.
Faulty oxygen regulator:
A faulty oxygen regulator can of course cause a similar problem when it does not keep the
pressure level at moments of higher oxygen consumption.
Bent plastic tube of oxygen supply:
When the plastic tube supplying oxygen from the bottle to the analyzer is bent, there will be the
same problem like described in the above two subjects. There will be too low oxygen pressure
in the analyzer, especially at moments of high oxygen consumption, like when burning samples
or purging the furnace.
Oxygen supply is interchanged with the compressed air supply:
In case of reported bad combustion, check for correct connection of oxygen and compressed air
supply. Compressed air in the induction furnace will provide combustion but a bad one, because
of only 20% of oxygen existing in the air. Therefore the peaks are low and long, consisting of
more than one peak, looking like mountains.
CAUTION Oxygen to the compressed air inlet can lead to the explosion of the pneumatic
cylinder.
Blocked dust filter cartridge:
The dust filter cartridge is on the front panel so that contamination is visible for the operator. In
the gas flow circuit, this dust cartridge is connected after the metal filter and its following glass
tube with magnesium perchlorate, so that the carrier gas passing through the cartridge is
already filtered.

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Faults

Blocked fittings:
This case is very unlikely to happen in case of induction furnace operation, because the
analyzed materials in question are inorganic materials like metals and ceramics, so that they
don’t create fumes, volatiles and moisture. Even cement analysis is not as critical as organics
analysis. In case of analysis of materials causing major contamination, mainly when analyzing
organic materials in the resistance furnace, the fittings of the IR cells can be blocked so that
they have to be cleaned. See chapter “IR paths cleaning and replacing”.
Also fittings elsewhere can be blocked, like the fittings for plastic tubes on the reagent glass-
tube holders.
Blocked flow sensor assembly:
If the flow sensor is blocked, it should normally be replaced.
For those who may decide to clean them - please read the description about cleaning. Chapter
“Flow sensor replacing / cleaning”.
Electronic reasons for flow problems:
The flow controller consists of 3 components.
Induction furnace operation
1. The flow sensor
2. The board HF-42 (The lower half of the board only).
3. The proportional valve V6 (see chapter “Gas flow system”).
4. Interferences from the induction generator. See chapter “Analysis takes too long / RF-
interference on the IR-cell, or on the electronic units”.
The electronic devices involved in the flow regulation are the board HF-42 and the flow sensor.
The only influence of the PC and of the microcontroller on the flow, is the start/stop the flow, for
example to start it when oxygen pressure available, to stop it in case of gas saving mode etc.
For chasing flow problems, there is a possibility to avoid any involvement of the PC and of the
microcontroller, by setting a jumper on the HF-42. To do this, move the jumper of J3 from A1-A2
to B3-B4. See chapter “Gas flow controller and jumper settings”.

DANGER G0002

Mortal danger from electric shock

Exposed power contacts - High Voltage
- An electric shock can cause injuries in the form of burns and
cardiac arrhythmia, respiratory arrest or cardiac arrest.
• Disconnect the mains power plug before opening the
analyzer’s cabinet.

17
 Faults

Fig. 5: HF-42

Fig. 6: Jumper position for gas saving mode

Fig. 7: Jumper position for continuous flow

In this case there is continuous flow when the main power switch is on Position 2.
Resistance furnace operation:
1. The flow sensor (same sensor also used in induction operation)
2. The electronic board PC-2 (see chapter “Gas flow controller and jumper settings”).
3. The gas pump (see chapter “Gas flow system”).
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3.3 No combustion
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3.3.1 Induction furnace operation

After clicking START of analysis or pressing F5 but the sample doesn’t burn, check the reports
in the “status window” on the pc screen.
The following describes how to proceed depending on the displayed message
No oxygen pressure
See Chapter “No or low oxygen pressure”

18
Faults

No flow
If this message permanently remains in the “status window”, check the flow on the lower flow
meter (Rotameter). The ball has to be in the range of 180 L/h. If it is in this range, then click on
the “device state” window icon.

Fig. 8: device state window icon

Check the graph for L/h. (See software helps). If the vertical bar is not in the middle of the base
line then calibrate the flow in the software as follows.
Pre-purging
If this message permanently remains in the “status window”, click the icon of the “configuration
window”.

Fig. 9: configuration window icon

The duration of pre-purging is possibly entered much too long. Reasonable values are between
1 and 5 seconds, maximum 10 sec for very low carbon analysis.
Waiting for stability
If this message permanently remains in the “status window”, the infrared cell base lines are not
stable or out of range. Click the Base line Icon and check.

Fig. 10: Base line icon

Integration delay
The message “Integration delay” appears for as many seconds as entered in the “configuration
window”. Reasonable range is something between zero and 5 seconds. When the integration
delay starts, the induction generator starts at the same time. In other words, the software starts
the integration delay and the generator at the same time. This is valid also when the integration
delay is set to zero seconds. In this case, the generator is started but “Integration delay does
not appear in the status window. The status window displays then the next message of its
sequence, which is “Analyzing”.
Analyzing
When “Analyzing” appears in the status window, it means that definitely the command for
starting combustion is given by the software, so that if still there is no combustion, there must be
probably a hardware reason for this fault.
After starting analysis, the word “Analyzing” appears in the configuration window.
The command from the microcontroller to start the generator is not received

19
 Faults

Fig. 11: Measurements on TP9

1. Measurements on TP9
– a signal of about 0.5 V should turn the generator on,
– a signal of about 12 V should turn the generator off.
If 12 V are measured, despite "Analyzing" appearing on the display, then the microcontroller
board is defective or the connection from the HF 42 circuit board, pin 7 is loose.

Fig. 12: TP13 test point

When the command for the generator is received ( 0.5 V DC ), the triac triggering pulses must
appear on the TP13 test point. If there is no oscilloscope available you can test this with a digital
voltmeter. The displayed value depends on what type of digital voltmeter you have. There must
be a voltage increase on TP13, once the word "Analyzing" has appeared on the display, or once
0.5 V are present on TP9. When no voltage increase occurs on TP13 , despite having 0.5 V on
TP9; the HF 42 circuit board is defective.
NOTICE
After replacing the HF 42 board, make sure that the 50 pin plug is properly inserted. It takes a
lot of force to push in 50 pins at once. 50 pin plugs that haven’t been properly inserted are a

20
Faults

frequent problem. Tighten the screws of the plug properly, to ensure a proper connection to the
board.

2. Checking the generator tube

DANGER
Mortal danger from electric shock
Exposed power contacts - High Voltage
Ensure that the power switch is at position 3.
Check if the filament of the generator tube glows:
This can be easily checked:
Through the air vent holes of the furnace, the reflected light of the glowing filaments (heater of
the cathode) should be visible.

Fig. 13: Air vent holes of the furnace

3. The filament of the generator tube doesn’t glow

Check the voltage of the filament, on the transformer, there should be 10 V AC on the
secondary. If not, then measure 220 V AC on the primary, leads 2-3.
NOTICE
Set the power switch to pos. 1 before removing the tube, although it would be best to
completely turn off the device and unplug the power cord.

DANGER
Mortal danger from electric shock
Exposed power contacts - High Voltage
Before touching any components or wiring, make sure the capacitors are discharged.

21
 Faults

10 VAC

220 VAC
(between contact 2
and 3)

Fig. 14: Measurements

Check whether the filament is faulty, at the filament connections, only 1 Ohm must be
measured. A very high or infinitive resistance means that the filament is burnt through and the
tube needs to be replaced.

22
Faults

4. Checking the primary voltage on the high voltage transformer

DANGER
Mortal danger from electric shock
Exposed power contacts - High Voltage
When checking for induction power, always keep the furnace closed!
On the primary side of the high voltage transformer, you should be able to measure about 210 V
AC; if not, the triac is possibly defective.
The filament voltage can be also measured as shown below. A direct measurement at the
tube’s socket rules out eventual interruptions on the way of the voltage from the transformer to
the socket.

Fig. 15: Measurements - high voltage transformer

Once there is voltage on the transformer the triac must be OK. A relatively low voltage on the
transformer could be a result of too high current so that the HF-42 board reduces the phase
angle. IF so there is most probably a faulty component in the oscillator circuit preventing it from
oscillating so that the oscillator tube takes a high DC current.
NOTICE
This can damage the tube. Therefore when you start for testing whether there is combustion
keep your finger on the STOP button. If the sample does not start burning about 3 seconds after
the generator starts, then immediately stop the analysis.
One thing that will give further evidence is the current taken by the analyzer from the mains
power.
If the current goes up to a level of about 10A, then a faulty component prevents oscillations so
that the tube takes all this power causing overheating of the tube within several seconds.
If the current does not increase, it means that the generator does not take power, for example
due to a broken grid resistor.
In case the transformer has 210 V AC on the primary coil and there is still no combustion, check
the windings of the transformer as follows:
– switch off the analyzer and disconnect the main power plug.
– Measure the resistance of the primary coil.
– It must be extremely low, about 0.8 Ohms between the
– screws labeled 0 and 270.
– Measure the resistance of the secondary coil between the two screws on the –
ceramic insulators where the wires of the rectifier are connected.
– The resistance is approximately 322 Ohms.

23
 Faults

5. The rectifier could also be faulty

Checking the high frequency generator

DANGER
Mortal danger from electric shock
Exposed power contacts - High Voltage
Never try to measure the voltage here!
Due to high voltage in the range of 7000 Volts (amplitude), there should be no measurement on
the rectifier under power. If no spare rectifier available to exchange, then test by using a scope
according to the following drawing.

220 VAC
Insulating
transformer

220 VAC
Adjustable
transformer

Rectifier

about
4000 Ω

Fig. 16: Rectifier

24
Faults

10

11
6

1
2

Fig. 17: Draft high frequency generator (1-4-4 + 1-4-5S)

As there is high voltage (5000V) and high frequency (19.2MHz) present, a measurement would
be very difficult and, above all, very dangerous. Before the generator cover plate is unscrewed,
the device should be turned off or, better, the power plug pulled out.
DANGER
Mortal danger from electric shock
Exposed power contacts - High Voltage
Before touching any components or wiring, make sure the capacitors are discharged.
You should check the connections in the oscillator circuit to ensure all screws are turned tightly,
especially all the cap screws on the combustion coil.
The electrical connections and resistors should be checked with an ohmmeter. If the resistor
2.7K / 100W (3) is open circuit, then there is no oscillation, but also no power consumption.
The tube doesn't take any current at all. The parts e.g. tube and rectifier should be replaced one
by one.
6. The ground connection of the tube’s cathode is interrupted.
The cathode of the oscillator tube is connected to the ground. The cathode is connected with
one of the two leads of the filament inside the tube. So, one of the two filament plugs on the
socket is connected to the chassis having this way a ground connection

25
 Faults

The filament lead (socket) connected to the chassis, is the upper one of the two which are
connected to the multimeter. The grownd connection is done by using a small copper sheet. It is
on one side soldered to the socket and on the other end it is fixed on the chassis with a screw.

Fig. 18: Socket top view

7. Loud buzzing sound when the generator turns on

If during integration (combustion period) the high voltage transformer is making exceptionally
loud buzzing sound when the generator turns on, also when running the furnace empty still the
loud buzzing appears, this means that obviously for some reason, the triggering of the triac has
changed.
If you are sure that the noise appears only during integration period (combustion period) then
the problem could be in the generator. The unusually loud noise could be due to current
limitation by phase angle control.
The oscillator tube may not be oscillating due to a tube fault so that it takes a very high DC
current causing the current limit circuit to reduce the phase angle. Replace the tube. This is also
the easiest thing to try so that it can be done by the customer.
NOTICE
The oscillator tube can be damaged due to overheating if for some other reason the new tube
may not be able to oscillate. For testing after installing the new tube, put crucible with sample
and accelerators into the furnace like you use to do with every normal analysis. After starting
analysis watch carefully the furnace to see the light of the burning sample/accelerators. If a
couple of seconds after generator start (transformer noise, base lines for peak on the PC
screen) there is no combustion to see in the furnace then STOP the generator by clicking STOP
on the screen.
NOTICE
When testing for induction power, always test with closed furnace.
NOTICE
When looking to find out whether there is combustion or not, STOP the analysis cycle about 3
seconds after it started. If there are oscillations, after 3 seconds the sample (steel or iron chips)
will have visible signs of starting burning. But if you wait up to the end of the analysis cycle in
order to check whether there was combustion, it could be already too late for the tube due to
overheating.
When there are no oscillations, the tube takes a high DC current, so that after several seconds,
the anode of the tube starts glowing from the lower end. This can be visible when the
environment is not bright or it is dark.
It is practically not possible to do any measurements on the generator due to very high voltage
and due to high frequency in the oscillator (in case of functioning). So we have to solve the
problems by looking and trying.

26
Faults

One reason could be the resistor (8) having a short circuit. Normally its resistance has the value
of 200K.
One more possibility is a faulty capacitor. Check the capacitors, mainly the one on top (7) of the
oscillator circuit which is connecting the anode of the tube with the oscillator circuit. Check also
the grid capacitor (6) which is placed underneath the oscillator chassis. Try to find out whether
they are broken by applying a reasonable force on them to see whether they are still in one
piece.
Check also the other, bigger capacitors (9), (10) and (11) however if one of them was faulty,
most probably the fuses would blow.
3.3.2 Resistance furnace operation
See Chapter 2.4.2 “IResitance furnace operation”.
Pos : 3.8 /0025 Ü bersc hriften/ELTR A 1.1 Ü bersc hriften/11 Bad combusti on ELTRA @ 6\mod_1368608656440_9.doc x @ 40248 @ 2 @ 1

3.4 Bad combustion

Pos : 3.9 /0010 ELTR A/0015 s er vice_i nstr uctions /CS- 2000_s er vic e/05F aul ts_C S-2000/0520 M odul Bad combusti on @ 9\mod_1425539443621_9.doc x @ 74129 @ 33 @ 1

3.4.1 Induction furnace operation

In most cases the reasons for bad combustion are:
– Problems with the flow
– The Generator (oscillator) tube is not powerful enough anymore. Norma lly this does
not occur suddenly. It is rather a long process.
(Part number 77210)
– The contacts of the tube are bad.
Some more hints:

Fig. 19: bypass valves

The bypass valve V4 (28) is either falsely activated during combustion, or the plunger jams. In
this case, the oxygen flows through the bypass valve into the IR-cell and not through the
furnace. The furnace remains nonetheless under oxygen pressure.

27
 Faults

– Measure the voltage to the bypass valve V4 (28)

24 Volts DC while the furnace is open is normal.
Zero volts when the furnace is closed is normal.
– Clean the valves
3.4.2 Resistance furnace operation
No combustion:
The operating temperature is mostly 1350°C so that it is easy to recognize by looking into the
furnace, whether the furnace is hot or not.
Caution For looking into the furnace be sure to wear protective glasses and to hold radiation
absorbing glass in front of your eyes.
In case the furnace is hot but still there are doubts about the true of the temperature, the
resistance furnace temperature can be measured by entering a thermocouple connected to
appropriate digital thermometer.

Fig. 20: Temperature control

The tip of the thermocouple should be in the middle of the hot zone where the combustion boat
use to be. The thermocouple must be long enough in order to make sure that the junction of the
thermocouple wires to the cable does not become hot. A thermocouple length of 50 cm is
appropriate. In case the furnace temperature is over 1000°C the thermocouple has to be of type
S. It is not usual to have it in this length available. If a 300mm type S thermocouple is available,
a compromise is to enter the tip up to the beginning of the hot zone to prevent the junction
temperature of the cable from overheating. If this is not available then set the furnace
temperature to 1000°C and check with a long type K or N thermocouple.
In case the resistance furnace is completely cold:
- check the set temperature. If there is nothing shown on the display, then check the
availability of mains power. Take a look at the breaker on the back of the furnace and at
the breaker of the power line.
- If the display shows the right “Set point” and the displayed actual “Furnace temperature”
is displayed very low but corresponding to the real furnace temperature, most probably
the heating elements are worn out and broken so that they have to be replaced. See

28
Faults

operation manual chapter “Replacing the heating elements”. If you want to be sure that
the heating elements are broken, then measure the voltage on the wires to the heating
elements.

Fig. 21: Measuring the voltage

– If the voltage is 230VAC heating elements but the furnace is cold, the heating elements
are broken. See chapter “The resistance furnace is completely cold or too hot”.
- In case the “Set point” is shown correctly but the “Furnace temperature” shows “-1”
without any other following digits, the thermocouple is defective (interrupted). Replace the
thermocouple. See chapter “Thermocouple replacement”.
Bad combustion:
– The furnace temperature is too low, see chapters “Resistance furnace doesn’t reach
full temperature” and “The resistance furnace is too cold or too hot.”
– The sample contains a substance that doesn’t burn easily.
Some materials contain sulfur compounds which are very difficult to burn, i.e. they need
higher temperature than 1550°C to properly burn in a reasonable time.
An improvement can be achieved by adding accelerators, such as iron phosphate to
coal samples that contain pyrites, or vanadium pentoxide to cement samples.
For materials which require such high temperatures to burn, we recommend induction
furnace analysis.
– No oxygen flow, see chapter “No oxygen flow”

29
 Faults

Pos : 3.10 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 T he furnac e does not cl os e ELTR A @ 6\mod_1368610904372_9.doc x @ 40292 @ 2 @ 1

3.5 Furnace does not close

Pos : 3.11 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0530 M odul T he inducti on fur nace does not cl ose @ 9\mod_1425539561623_9.doc x @ 74153 @ @ 1

V7
4

V10

7
V8
12

13
14

15

11190

Fig. 22: Pneumatics (schematically)

30
Faults

15

V7

12

V10
V8

Fig. 23: Pneumatics (photo)

If there is little or no compressed air pressure, the furnace cannot close.
This pressure is shown on gauge (13), on the front-side of the analyzer.
It must be between 4 to 6 bar (60 to 90psi).
The screw (2) must be turned counter-clockwise, as much as possible.
Adjust regulator (8), so that the furnace floor can rise completely, without shaking; while a
person still can stop the moving furnace floor with only one hand.
This is a safety precaution.
Repeat above instruction, until the adjustment is completed. Now, the upward speed is fast
enough, yet safe for the operator. The pressure regulator (8) is found on the inside, on the right-
side section of the analyzer, installed on the rear panel.
One of the pneumatic valves (V7) or (V10) (or both) is malfunctioning.
The magnetic coil of the pneumatic valve (V7) or (V10) is not powered. The furnace floor goes
up, when valve (V10) receives 24 VDC.

31
 Faults

Pos : 3.12 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 Anal ys edauer zu lang - The anal ysis takes too long ELTR A @ 6\mod_1368613082100_9.doc x @ 40314 @ 2 @ 1

3.6 Analysis takes too long

Pos : 3.13 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0535 M odul T he anal ysis takes too l ong @ 9\mod_1425539613183_9.doc x @ 74165 @ 3444 @ 1

Fig. 24: Analysis time

The analysis respectively the combustion, takes normally a maximum of 100 seconds. At the
beginning of combustion, the IR-cells signals start going up on the computer screen, reaching a
peak maximum depending on the C resp. S concentrations in the sample. When the signal
comes down, the analysis will be terminated when the signal has reached a comparator level.
The value of this comparator level is entered in the configuration window of the software.
If, for some reason, the signal may not come down to the comparator level, the analysis is
terminated when the maximum analysis time expires. This time is also entered in the
configuration window.
The analysis stops also when the maximum analysis time expires before the signal comes down
to the comparator level.
The meaning of setting a maximum analysis time is to protect the induction generator from
overheating, in case the signal may not come down to the comparator level. One reason why
the signal not to come down to the comparator level is that Hydrocarbons from the oxygen burn
on the hot crucible, preventing the IR-signal from coming down to zero resp. down to the
comparator level. One more reason is a too low comparator level, so that a small positive drift of
the base line during analysis makes the base line higher than the comparator level at the end of
the combustion. In such cases, the comparator level should be set higher.
The comparator level value entered into the configuration window is a minimum value which
increases according to the peak maximum of each analysis. During combustion, the software
takes the peak maximum to add to the entered comparator value an additional amount
depending on the actual peak maximum.

32
 Faults

3.6.1 RF-interference on the IR-cell, or on the electronic units

If the generator's high frequency disrupts the electronic units or the infrared cell, then the base
line on the PC monitor appears jerky.

DANGER
Mortal danger from electric shock
Exposed power contacts - High Voltage

2
1

3
1
5
9
2
10
6
11
12

1
7

Fig. 25: Draft high frequency generator (1-4-4 + 1-4-5S)

The causes
– The screws (1) are not tightened properly, or not all 22 of them are
screwed in.
– The cap nuts (2) are not tightened properly or not all 14 are in place.
– The cover (3) does not seal properly with the plates (4) and (5) or with the contract
straps behind it, on the front panel (6)
– One or both filters (7) are not OK
– The filter (11) can also be damaged in this way.
– When the ground strip (12) is not connected after removal or replacement of the oscillator
the filters (7) will defect. In this case the drift appears after the generator is started. In
order to find out whether is high frequency interference, carefully disconnect a primary
wire of the high voltage transformer. If the drift remains the same after starting analysis
cycle, then high frequency interference is excluded.
– The capacitor (9) is out of order
– The capacitor (10) is out of order. This is however less likely.

33
 Faults

In case of failure of this capacitor, most probably the fuses blow.

3.6.2 Additional reasons for excessive analysis duration

– Dirty dust trap, see Operation Manual chapter “Cleaning the dust trap”
– Saturated chemicals, see Operation Manual “Filling the reagent tubes”
– Cotton, glass or quartz wool is pressed too tight.
– The oxygen is not pure, or the catalyst furnace is faulty or cold, or the copper oxide is
depleted, see Operation Manual “Filling the reagent tubes”
– The temperature of the infrared cell is not yet stable. Either it is not switched on for at
least 1 hour, or the oxygen flow has not yet been running for 10 to 15 minutes ( power
switch on setting 2 ), see Operation Manual “Main power connections” and “Work
breaks”
– The thermostatic control of the infrared cell is defective, see “IR thermostatic control “
– Excessive combustion temperature, resulting in high blanks from the crucible (CO2).

3.6.3 One of the IR-sources is unstable

– Small resistance changes of one or more IR-sources can cause the
current to vary, thus affecting the intensity of the IR-radiation.
This problem will affect all the channels, due to the fact that the IR-sources are all
connected in series.
In order to find out whether this problem is present or not, an analysis cycle should be run
without a sample or a crucible. The baseline of the IR-cells can then be monitored on the
PC screen. See “Software helps”
The baselines should be quite stable. The drift within the usual time of analysis should be
in the range of 2 to 5mv, depending on the path lengths.
Remark Drift is the average of the noise.
Due to the fact that the IR sources are connected in series, if one of them is damaged, a
typical effect is that all base lines drift simultaneously in the same direction, with
occasionally changing slope from positive to negative. However the same effect appears
in case of faulty power supply when the IR source voltage drifts up and down. This is
however less likely.
It is difficult, in case of such problem, to find which IR-source is faulty and it is therefore
easier to replace them all.
– A window of an IR-path is not gastight. The measuring gases pass through the leakage,
either into the chopper housing or to the IR-detector. In this case the typical effect is that
the base line does not come down to the initial starting level at the end of analysis, but it
remains at a constant level over the base line.
Perform a leakage test of the IR-paths. Replace the faulty IR-path. See chapter “IR path
cleaning and replacing”
– The infrared power supply is defective, so that the voltage stabilisation does not function.
– The Infrared electronics are faulty. See chapter “Infrared electronics”

3.6.4 The power voltage sinks below 180 VAC

– Even a momentary drop in the voltage is enough to cause problems.
Use a voltage stabilizer.

34
Faults

Pos : 3.14 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 D evelopment of dus t when cl osing the fur nac e ELTR @ 6 \mod_1368620567231_9.doc x @ 40336 @ 2 @ 1

3.7 Development of dust when closing the furnace

Pos : 3.15 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0540 M odul D evelopment of dus t when cl osing the fur nac e @ 9\mod_1425539653510_9.doc x @ 74177 @ @ 1

Fig. 26: Gas-flow diagram - furnace closed

This happens when there is no restrictor in the left hand fitting of the valve V3 or when the
internal diameter of the restrictor is too large. This can easily be checked when removing the
connected tube.
The restrictor should have an internal diameter of 1 mm.
See draft “Gas-flow diagram - furnace closed”
in the chapter “Modification Overview”.
The sample material is causing dust:
This will be caused mainly through tin analysis. Tin causes a light grey dust. The same problem
appears when tin is used as accelerator. Therefore using tin as accelerator should be avoided.
Also the tungsten – tin mixture shouldn’t be used. Almost all different materials can be analyzed
without the need of tin accelerators.
See Operation Manual chapter “Applications”.
Usage of other materials:
Cast-iron causes brown dust during the analysis.
When the dust is yellow, too much tungsten is used as accelerator. If the dust is brown, too
much iron accelerator is used.
See Operation Manual chapter“Applications”.
Pos : 3.16 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 Erratic res ults @ 8\mod_1396882131370_9.doc x @ 60214 @ 2 @ 1

3.8 Erratic results

Pos : 3.17 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0545 M odul Erratic res ults @ 9\mod_1425539699891_9.doc x @ 74189 @ @ 1

There are a lot of different reasons for this

– Saturated chemicals or clogged dust filter
– Heterogeneous samples
– Leakage
– Flow problems
– The electronic noise or drift of the infrared signal
– It can happen quite often that the combustion start is delayed and the analysis
time is too long
– Incomplete or bad combustion
– Too high blank value for the crucible and tungsten. This will be especially noticeable,
mostly though, in the low carbon channel
– Widely different weights of sample and accelerator (tungsten)

35
 Faults

High carbon results are erratic:

Even if the filter may be brushed and cleaned in ultrasonic cleaner, someday will not be able to
be cleaned any more. Filters don’t last forever.
Clean the filter and make some analyzes again. Should the results still be erratic, replace it by a
new one.
Sulfur results are not repeatable::
When the Sulfur results are not stable, but the carbon results are good, there are two possible
reasons
– The magnesium perchlorate (anhydrone) is saturated.
Replace the complete contents of the glass tube after the corresponding furnace.
– There is sulphuric acid in the combustion tube of the resistance furnace. Replace the
combustion tube, see chapter “Replacing the combustion tube”

4
5

If the combustion tube (4) was in use for a very long time and many samples with high Sulfur
were analyzed, then sulfuric acid may build up in the rear-side of the combustion tube.
When the heated tube is removed together with the connector (5), a brown fluid can be seen in
the ceramic tube.
During the analysis, some SO2 is trapped in this fluid, causing non
repeatable results. It is recommended to clean the furnace outlet tube.

36
Faults

Pos : 3.18 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 Ergebniss e si nd 0,0% oder 00,0ppm ELTR A @ 6 \mod_1368621911416_9.doc x @ 40380 @ 2 @ 1

3.9 The results are always 0.0000% or 00.0ppm:

Pos : 3.19 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0555 M odul T he res ults ar e al ways 0.0000% or 00.0ppm @ 9\mod_1425539815442_9.doc x @ 74213 @ @ 1

Pos : 3.20 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 N o oxygen flow @ 7\mod_1380623315133_9.doc x @ 49429 @ 2 @ 1

37
 Faults

3.10 No oxygen flow

Pos : 3.21 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0560 M odul N o oxygen flow @ 9\mod_1425539875300_9.doc x @ 74225 @ 333 @ 1

3.10.1 Induction furnace operation

- No oxygen pressure. See corresponding chapter “No oxygen pressure”
- The software is in the gas saving mode. If this is the case, the flow will be restored when
the mouse is moved or when a key is pressed like F4 for entering the sample weight or
F2 for opening and closing the furnace.
- Bent plastic tube. See chapter “Fluctuating gas flow”
- Faulty flow sensor, flow control board or valve. See chapter “Gas flow controller”
- The tubes of the flow sensor are interchanged (input <--¬¬> output).
See chapter “Gas flow diagrams”
– The outflow valve V1 does not close. Open the left-side panel of the analyzer. When the
furnace is closed (the lift is up), no oxygen should be flowing out of the lower (free)
opening of the valve. See chapter “Gas flow diagrams”. This can be checked by putting
your finger under the lower opening of the valve. If the valve does not close correctly, you
will feel a strong oxygen pressure. The voltage across the leads of the outflow valve V1
should be 0 Volt. If this is the case then the plunger of this valve jams. The valve should
be cleaned (see chapter “Cleaning the solenoid valves”) or be replaced. If the voltage
on the outflow valve is permanently at 24 V, switch off the analyzer, exit the software and
restart.

38
Faults

3.10.2 Other faults

– The screw for the upper furnace cushioning is too tight, see chapter “Pneumatics”
– The pressure switch does not close. Measure the voltage across its leads. Zero volts with
pressure, 24 VDC without pressure.
– The furnace closes too slowly, adjust according to chapter “Pneumatics”
– The furnace does not close: see chapter “The induction furnace does not close”

3.10.3 Resistance furnace operation

– Check the oxygen pressure on the upper pressure gauge. The pressure should be about
1,5 bar (22 psi). If lower, see Chapter “No or low oxygen pressure”
– Check the pump voltage in the “Device state window”.
Pos : 3.22 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 IR-c ell temper ature c ontrol is out of r ange ELTR A @ 6\mod_1368687694553_9.doc x @ 40448 @ 2 @ 1

3.11 IR-cell temperature control is out of range

Pos : 3.23 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0565 M odul IR temperatur e c ontrol out of range @ 9\mod_1425539916703_9.doc x @ 74237 @ 3 @ 1

If in the device state the graphs of IR-temperature °C or %IR are not in the green area, adjust
the temperature. See chapter “IR-cell temperature control”.

Fig. 27: Device state

– Thermostatic control reports 0% or 100% power:
The percentage of power required by the thermostatic control is displayed in the Device State

Window . The power is 100% after switching on from cold while heating up. It takes about
30 minutes for the temperature to reach the set point. In stable condition, the power required
should be between 30 and 70%.
If the value is less than 30%, adjust a higher temperature set point. If the value is over 70%
without any tendency for coming down to lower values, adjust a lower set point.
Pos : 3.24 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 Breaker turns off at the begi nni ng of c ombusti on ELTR A @ 6 \mod_1368688648887_9.doc x @ 40470 @ 2 @ 1

3.12 Breaker turns off at the beginning of combustion

Pos : 3.25 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0570 M odul Breaker turns off at th beginning of c umbustion @ 9\mod_1425539992083_9.doc x @ 74249 @ @ 1

If the circuit breaker turns off at the beginning of combustion then:

– Unplug the analyzer mains power plug.
– Switch on the breaker.

39
 Faults

DANGER
Mortal danger from electric shock
Exposed power contacts - High Voltage
Make sure all capacitors are discharged

Fig. 28: Transformer

– Disconnect the cables (1) from the primary side of the transformer (2) and connect the
cables (1) to a 220 V light bulb (3) which is inserted to a socket. An ordinary desk lamp
can serve for this purpose. In case only 110 V light bulbs are available, connect two of
them in series.
NOTE
Be careful that no short circuit occurs!

After the cables (1) have been connected, plug the analyzer to the mains power again.
– Set the power switch to pos. 3
– Enter a weight manually (for example, 500 mg).
– Press START
– The word "Analyzing" should appear in the status window.
If not, but "Waiting for stability" appears instead, the reason is that after restarting the
device and the oxygen flow, the infrared base line is drifting. In order to save time, there
is a possibility to start the cycle without waiting for stability.
– Quit by pressing STOP
– Go to the "power user" level and click on the button "Stable".
– The analysis cycle starts then without waiting for base line stability of the cells.

40
Faults

When "Analyzing" appears on the status window, the light bulb should glow; this does not
happen suddenly, but gradually (soft start).
Within a few seconds, the light bulb will gradually change from dark to fully bright.
– If not, but the lamp becomes immediately bright like switching on with a switch, replace
the board HF-42.
– If the light is not fully bright but dim and flickering, replace the triac (6).
If yes (O.K.), unplug the mains power plug and reconnect the power cables (1) to the
transformer (2).
Unplug the power plug and reconnect the cables (1).
When reconnecting the power cables (1), do not let these wires be close to the connectors for
the cables (4) and (5). Otherwise the high voltage can create sparks.
The cables (4) and (5) should be unscrewed from the transformer and placed away from it.

DANGER
Mortal danger from electric shock
Exposed power contacts - High Voltage
After the generator starts the cable carries a voltage of about 7000 Volts!
– Plug in the mains power plug to power the analyzer.
A new analysis should be started. When "Analyzing" appears and the fuse is not damaged as
well as the mains power current didn't exceed 10 A (RMS), then the transformer is functioning
properly.
Otherwise, replace the transformer. The cables (4) and (5) are then reconnected.
If the problem still remains:
– Unplug the analyzer from the mains power.
– The cable (7) is unscrewed and removed from the capacitor (8)
After the generator starts (Analyzing) the cable (7) carries a voltage of about 7000 Volts! The
cable (7) therefore should be laid so that its end is at least 10 cm away from the nearest object!
If, after pressing START and after "Analyzing" appears, the breaker turns off, then replace the
rectifier (9).

Further causes could be found in the oscillator circuit

Because of the high voltage (7000 volts) and the high frequency (19.5 MHz), it is difficult to
make measurements without any special measuring instruments.
Thus, the analyzer needs to be turned off, and the power plug disconnected.

DANGER
Mortal danger from electric shock
Exposed power contacts - High Voltage
Make sure all capacitors are discharged

41
 Faults

10

5 9

1
11

12

Fig. 29: Draft 11001-9002 (1-15-3-1S)

– Check that all the screws and soldering connections have a good contact.
– If the resistor 200 K (11) is a short circuit, then the fuse will blow when starting the
generator.
– Check that all power conductors and copper bands are placed far enough away from
any objects!
– The wire (1) and the copper band (2), for example, should be placed.
far away from the plate (3).
– The power cable (4) should have a maximum distance from any surrounding object.
– The copper band (5) should be placed as far as possible away, from the capacitor (6)!
This is why the copper band (5) should always be bent around the insulator (7).
– If the tube (8) needs to be replaced, loosen the screw (9) and pull out the heat sink (10)
upwards ! Pull out the tube (8) upwards!

42
Faults

Fig. 30: Capacitor and insulator

Pos : 3.26 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 Breaker turns off at the end of the anal ysis ELTR A @ 6\mod_1368692228547_9.doc x @ 40492 @ 2 @ 1

3.13 Breaker turns off at the end of the analysis

Pos : 3.27 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0575 M odul Breaker turns off at the end of anal ysis @ 9\mod_1425540062314_9.doc x @ 74261 @ @ 1

Causes:
The triac is malfunctioning.
The so-called Latch-up effect causes the triac to remain conductive in one direction after
triggering. The transformer is then acting as a short circuit because it is fed with a DC voltage!
– Replace the TRIAC.

Pos : 3.28 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 D ustcl oud when openi ng the furnace @ 9\mod_1425546854305_9.doc x @ 74956 @ 2 @ 1

43
 Faults

3.14 Dustcloud when opening the furnace

Pos : 3.29 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0580 M odul D ustcl oud when openi ng the furnace @ 9\mod_1425540118802_9.doc x @ 74273 @ @ 1

Fig. 31: Valves

After pressing the key to open the furnace, the valves (V1) and (V2) are energized. This means
that they have across their coils 24V DC coming from the electronic unit.
Valve (V2) closes the oxygen supply to the furnace.
Valve (V1) opens, releasing the pressure from the furnace through the dust trap (3), through the
moisture trap (4) and through the filter cartridge (1) into the open air (in the direction of the
arrow).
Following this, the pneumatic valve shuts and the furnace opens (lift downwards). When dust
comes out of the furnace after this process this will cause, that the pressure in the furnace is not
sufficiently reduced.
The causes:
– Too much dust in the dust trap (3),
(a few hundred analyses without cleaning)
– Saturated moisture trap (4)
– Clogged paper filter in the moisture trap (4)

44
Faults

– Clogged filter cartridge (1 and 2) (this would be unlikely though)

– One of the valves (V1) or (V2) receives no power (24V DC)
NOTE
The valve (V1) will only be supplied with voltage (24V DC) until the lift has reached the bottom
position, then it will be switched off.
One of the valves (V1) or (V2) jumps, most likely valve (V1)
– Clean the valves.
Pos : 3.30 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 N o or low oxyg en pr ess ure ELTRA @ 6\mod_1368695090291_9.doc x @ 41086 @ 2 @ 1

3.15 No or low oxygen pressure

Pos : 3.31 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0585 M odul N o or low oxyg en pr ess ure @ 9\mod_1425540163981_9.doc x @ 74285 @ 33344 @ 1

Possible faults:

3
2

Fig. 32: Front panel

45
 Faults

After starting an analysis”, the following message appears: "no oxygen pressure".
If this message permanently remains in the “status window”, then check
– Is the power switch (1) set on position 3?
– The pressure on the oxygen gauge (2) may be too low. 1.5bar is normal (22psi). The
pressure remains constant when the furnace is closed, and it sinks during the upward
movement of the furnace floor.
– Check the oxygen pressure in the supply line or tank. 4 to 6 bar (60 to 90psi)
showing on the pressure gauge is normal.
– Check if the pressure gauge for compressed air (5) shows 4 to 6 bar (60 to 90 psi).
– Check if the cock (3) is properly shut, or else the O-ring (4) will not seal Check if the
O-ring (4) is in a good condition.
– Check if the combustion tube is broken or cracked.
– Do leakage check. See chapter: “Leak checking”.
– Check if the chemicals are saturated and have become hard.
– The paper filter could also be the cause. For changing the paper filter, read the
operating manual.
– See chapter “Fluctuating gas flow”
– The contents of the gas cleaning furnace could be worn out and clogged.

Oxygen solenoid valve (V5) may be defective:

– Open the left-side panel of the analyzer.
– Unscrew the upper tube (1). The oxygen should rush out when the power switch is set
to pos. 3
If not:
– There may be no oxygen supplied.

Fig. 33: Terminal of the solenoid coil

– 220V AC is not measured on the terminal (2) of the solenoid coil.
– The solenoid valve is clogged.

46
Faults

– Clean the solenoid valve, see chapter “Cleaning solenoid valves”.

If the fault is still present, then:
– Switch off the power, (set the power switch to position 0).
– Pull out the socket (2) from the coil and measure the coil resistance. 3.3K is normal.
Outflow valve does not close:

Fig. 34: Outflow valve

Open the left-side panel of the analyzer. When the furnace is closed (the lift is up), no oxygen
should be flowing out of the lower (free) opening of the valve (1) (in the direction of the arrow).
This can be checked by putting your finger under the lower opening of the valve. If the valve
does not close correctly, you will feel a strong
oxygen pressure. The power supply to the valve ( V1 ) should be 0 Volt. If this is the case then
the outflow valve ( V1 ) should be cleaned see chapter “Cleaning solenoid valves”.

The voltage on the outflow valve is constantly at 24 V:

– Switch off the analyzer, exit the software and restart.

Other faults:
– The screw for the upper furnace cushioning is too tight, see chapter “Pneumatics”.
– The pressure switch does not close, see chapter “Pressure switch”.
– The furnace closes too slowly, adjust according to chapter “Pneumatics”.
– The furnace does not close: see chapter “The induction furnace does not close”.
Pos : 3.32 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 Waiting for s tability mess age @ 9\mod_1421835931277_9.doc x @ 72389 @ 2 @ 1

3.16 Waiting for stability message

Pos : 3.33 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0590 M odul Waiting for s tability @ 9\mod_1425540207023_9.doc x @ 74297 @ @ 1

When this message appears in the status window after starting analysis, it means that the base
lines are not within the "deviation-limit", set in the "configuration" window. A usual value is 10mV
and the set time is 20 seconds. By setting the voltage and the time, both criteria for base line
stability are considered, the noise and the drift.
Reasons for instability:
1. Too low deviation value
One reason for the above message is that the deviation value in the configuration window is too
low, so that a higher value should be entered. The levels of noise of all cells are not necessarily
identical. Longer cells have normally higher noise than shorter ones and the sensors
themselves have noise level deviations between exemplars. The deviation can be increased in
the Configuration window, Base lines. Usual value is are 10mV / 20 seconds.

47
 Faults

2. Too high noise

One more reason could be exceptionally high noise. The base lines and the level of their noise
can be seen on the screen when clicking on the base lines icon (with three waves).
Reasons for noise are:
– The infrared detector, replace, see chapter “IR paths cleaning and replacing” and
“Infrared base lines”.
– The pre-amplifier, replace it, see chapter “Infrared electronics”.
– A fault on the IR circuit board IRC-1, replace it, see chapter “Infrared electronics”..
– The IR source is defective, see chapter “The analysis takes too long” and “IR sources”.
– The microcontroller board.
– The power supply fluctuates, see chapter “Infrared electronics”.
In case of a module (rack) of more than one IR-cell, mostly only one of the base lines has too
high noise while the others have noise in normal range. In order to localize whether the noise is
created by the sensor, preamplifier or the corresponding section of the IRC board, interchange
the preamp connector of the noisy range with another one on the IRC board. If the noise moves
to the other range on the PC screen (base line color), this means that the noise is created by
the sensor or preamplifier.
In this case replace first the sensor as the more probable reason and if this doesn't help,
replace the preamplifier.
NOTE
Don't forget to connect the interchanged connectors to the original position again.
– If the noise is created by the IRC board, change it.
3. Too high drift
Another reason for report of instability is a too high drift of at least one cell, so that the signal of
one cell reaches the end of the set window (mV).
A drift can be due to temperature changes of the IR cell. It happens when the cell temperature
is still not stable after switching on the power. When switching on the power after long break so
that the cell is cold, allow the cell at least 30 minutes to stabilize the temperature. This has to be
taken into consideration when checking the base line stability.
When starting the oxygen flow (power switch on position 3), the cell takes about 5 minutes to
stabilize when restarting the oxygen flow after long time without flow (but with uninterrupted
power).
Pos : 3.34 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 C ombusti on tube breaks freq uentl y @ 6\mod_1368628553320_9.doc x @ 40424 @ 2 @ 1

3.17 Combustion tube breaks frequently

Pos : 3.35 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0605 M odul C ombusti on tube ser vic e life too s hor t @ 9\mod_1425540856869_9.doc x @ 74333 @ @ 1

Induction furnace:
– The sample weight or the weight of the accelerator is too high.
– Don’t use copper as accelerator.
Resistance furnace:
– The furnace temperature is too high. Usual operation temperature are 1350°C.The higher
the temperature the shorter the service expectancy of the ceramic tube.
– The faster the furnace heats up, the higher the stress for the combustion tube. A
compromise is to lower the current limit of the heating up current.
See chapter “Resistance furnace”. in this manual

48
Faults

Pos : 3.36 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 Oxygen pres sur e falls when the fur nac e opens ELTRA @ 6\mod_1368705931127_9.doc x @ 41187 @ 2 @ 1

3.18 Oxygen pressure falls when the furnace opens

Pos : 3.37 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0606 M odul Oxygen pres sur e falls when the i nducti on furnac e opens @ 9 \mod_1426585710647_9.doc x @ 75806 @ @ 1

Fig. 35: Pressure gauge

Regardless of whether the furnace is opened or closed,
the oxygen pressure shown on the pressure gauge ( 2 ) must remain 1.5 bar ( 22.5 psi )
constant.
If, however, the oxygen pressure falls when the furnace is open, then
either the valve ( V2 ) is defective or its control is incorrect.

Fig. 36: Valves

49
 Faults

When the furnace is open, the valve ( V2 ) should have 23 V DC on its magnetic coil.
When the furnace is closed, the voltage should be at zero volts.
– If the voltage on the valve ( V2 ) remains at 23 V DC, no matter whether the furnace is
opened or closed, then there is an electronic problem.
– If the valve voltage always stays at zero, then either the wiring is broken, see chapter
“Wiring diagrams” or the electronic unit is defective.
– If the voltage on the valve ( V2 ) is correct, then the valve itself is defective, see chapter
“Cleaning the solenoid valves”.
Pos : 3.38 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 C ombusti on without starting anal ysis ELTR A @ 6 \mod_1368706920531_9.doc x @ 41209 @ 2 @ 1

3.19 Combustion without starting analysis

Pos : 3.39 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0610 M odul C ombusti on without starting anal ysis @ 9\mod_1425540917709_9.doc x @ 74345 @ @ 1

Induction furnace operation:

In this case, the combustion of the sample begins immediately after the sample enters the
furnace area and before having pressed F5 to start analysis. Should the combustion start just
after closing the furnace then there is a serious fault

Fig. 37: Power switch

The power switch should be set immediately to pos. 1, in order to avoid any overheating of the
generator.
NOTE
Always keep the furnace closed while testing availability of induction power.

50
Faults

Fig. 38: Microcontroller board TP9

NOTICE
When software starts the generator, the voltage on the multimeter should change from 12VDC
to 0.5VDC. The generator is again OFF when this voltage goes again to 12VDC.
The drivers of the microcontroller board are out of order, when the combustion starts without
pressing F5 or clicking START and when without "Analyzing" on the screen, there is only 0,5V
DC or lower on TP9 ( instead of 12V DC ). Replace the electronic drivers

Fig. 39: Microcontroller board TP13

51
 Faults

When the pulses at TP13 are present without starting analysis and with 12 V DC at TP9, then
the circuit board HF 42 is out of order.
If no scope is available, the pulses can be detected by using a voltmeter.
Normal values are about 0 V AC without pulses, and about 1 V AC with pulses.
This indicated value can be different, depending on the type of the voltmeter used.
If this AC voltage is practically zero but even though the generator is powered, the next possible
reason: The triac is faulty (short circuit), and has to be replaced.

Fig. 40: Circuit board HF 42

Pos : 3.40 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 Cr ucibl e or boat cr ac ks or melts ELTRA @ 6 \mod_1368708007091_9.doc x @ 41231 @ 2 @ 1

3.20 Crucible or boat cracks or melts

Pos : 3.41 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0615 M odul Cr ucibl e cr ac ks or melts @ 9\mod_1425540955461_9.doc x @ 74357 @ 33 @ 1

3.20.1 Induction furnace

One reason could be that the quality of the crucible is bad. Use a better quality.
Another reason could be that the furnace temperature is too high, due to:
– Excessive main voltage.
– Excessive sample and / or accelerator weight.
– The use of a "sample or accelerator" that requires lower generator power.
In this case reduce the generator power in case of induction furnace. See chapter „Induction
generator control“.

3.20.2 Resitance furnace

In case of resistance furnace, the boat melts when there is excessive amount of metal in the
combustion boat. The dangerous thing is that the molted metal destroys not only the boat but
also the combustion tube, finally dropping thru the tube on the thermocouple. It is then very hard
to remove the deformed tube from the furnace even after breaking it in two.
Pos : 3.42 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 Oxygen pres sur e goes up ver y sl owl y @ 9 \mod_1425548475420_9.doc x @ 74976 @ 2 @ 1

3.21 Oxygen pressure goes up very slowly

Pos : 3.43 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0620Modul T he oxyg en pr ess ure g oes up ver y slowl y @ 9\mod_1425540999219_9.doc x @ 74369 @ @ 1

When using induction furnace operation:

After the button has been pressed to close the furnace (or to start the analysis by closing the
furnace first ), the oxygen gauge (6) should reach the normal level of
1,5 bar within a couple of seconds after the furnace has closed.
If this takes longer:
Then the problem is most probably outside the analyser.

52
Faults

Either the plastic tube supplying oxygen to the analyzer is squashed, or the oxygen regulator is
not properly open.

Fig. 41: Oxygen gauge

Fig. 42: Oxygen regulator

Pos : 3.44 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 Pump voltage too high @ 9\mod_1425548769110_9.doc x @ 74988 @ 2 @ 1

53
 Faults

3.22 Pump voltage too high

Pos : 3.45 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0625 M odul Pump voltage too high @ 9\mod_1425541043383_9.doc x @ 74381 @ @ 1

Only for resistance furnace operation:

Check the pump voltage in the device status window. Normal value is around 7 VDC. The
maximum possible value is 24 VDC. The pump voltage should be in any case much lower than
24V in order to have margin to compensate growing restriction of the flow due to growing
saturation of the chemicals. Values over 10V or even up to 15V are not critical. In case of higher
voltages it is advisable to replace the magnesium perchlorate. And if this doesn’t help, check for
restrictions due to contamination.
A typical example for this fault could be a combined partial blockage of the glass tube (22) and
of the combustion tube outlet (36).
Make sure that the chemicals are not saturated and that the combustion tube is not blocked.
Usually, these faults caused by contamination occur due to frequent analyzing of samples that
produce a lot of dust, and after a prolonged use of the combustion tube

Fig. 43: Front of CS-2000

54
55
14 31
Faults

3
2
1
9

32 36
29
10

24

Carrier gas inlet

21
30

Pressure regulator
Pressure regulator
22 33
35
20
28
5

27
11
25
19 37
23 12

26
3
34
6
7
2

16 38
38 4
1 17
18 13 15
 Faults

4 Bypass valve V4
5 Oxygen valve V5
6 Flow regulating valve V6
7 Purge valve V3
8 ----
9 Exhaust valve V9
10 Valve V10
11 Solenoid valve V11
12 Solenoid valve V12
13 Solenoid valve V13
14 Gas outlet
15 Lance valve V2
16 Pressure switch
17 Oxygen pressure gauge 1,5 bar
18 Restrictor
19 Restrictor
20 Carrier gas flow meter
21 IR purge flow meter
22 Moisture trap after the furnace
23 CO2 / H2O – purification trap
24 Catalyst furnace
25 SO3 - trap
26 H2O – trap
27 Dust filter
28 IR-cell
29 Gas pump
30 Attenuator before the pump
31 Attenuator after the pump
32 Resistance furnace
33 Induction firnace
34 Furnace input flow meter
35 Furnace inlet-oxygen
36 Furnace outlet measuring gas
37 Flow sensor
Detailed explanation of the faults indicated in the flow diagram
1. Blockage of the lower connection of the glass tube (22)
The bore hole of the lower connection of the glass tube (22) can get blocked when there
isn’t enough quartz wool at the bottom end of the glass tube (22) enabling fine particles of
the magnesium perchlorate to fall into the bore blocking it. It is therefore absolutely
important to fill the glass tubes exactly according to the Instructions. See Operation
Manual “Filling the reagent tubes”.
Holes of other reagent tube connectors need to be cleaned from inside and outside of the
analyzer, due to the fact that the passage is not straight, but vertical outside and
horizontal inside the analyzer.

56
Faults

CAUTION Switch off the mains power when handling inside the analyzer.
If a tube fitting is blocked, then the tube may be blocked as well.
Therefore the tube needs to be cleaned or replaced, otherwise the contamination could reach
the IR-cell as well.
2. The IR-cell is blocked
This fault is caused mainly by a kink in one of the tubes.
A blockage due to contamination may appear in one of the fittings of the IR paths, where
is a minimum diameter in the gas flow, compared to the inner diameter of the tubes.
3. Leakage
Not only blockages of the flow can cause the pump to run with full power, but also
leakages between the flow sensor (37) and the pump (29) can cause the pump to run at
maximum power.
Occasionally, the cover of the attenuator (30) (see also below) is not properly sealed, or
the gas flow meter (20) has a crack at the fittings for the tube connections. Disconnect
the gas flow gauge and check for cracks.
4. Blockage in the lower connection of the thick glass tube (22)
If there is not enough quartz wool used underneath the magnesium perchlorate, fine
particles fall down to the glass fitting causing blockage in its hole.
– Remove the glass tube (22). See operation manual “Filling the reagent tubes”.
– Remove the tube from the lower fitting.
– Clean the hole by passing a wire or a pipe cleaner.
5. Cotton wool is dirty
Another possibility could be that the cotton wool inside the glass (30) is very dirty.
CAUTION Don’t interchange the tubes of the glasses

Fig. 44: Gas pump/ Attenuator

The end of the tube inside the glass must be free. It shouldn’t be blocked by cotton wool. The
same applies for the fitting at the outlet of the glass.
The tubes of the pump are connected to the short fittings of the glass.

57
 Faults

35331 without cotton wool

35330 with cotton wool
6. Furnace
Clean according to the Operation Manual

4
5

Fig. 45: Resistance furnace

Pos : 3.46 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 R esistance furnace takes too long to war m up @ 9\mod_1425549194106_9.doc x @ 75000 @ 2 @ 1

3.23 Resistance furnace takes too long to warm up

Pos : 3.47 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0630 M odul R esistance furnace takes too long to war m up @ 9\mod_1425541083085_9.doc x @ 74393 @ @ 1

Normal warm-up time: from room temperature to 1300°C, in 15-20 min unless the current limit
on the board is set for lower heating-up current.
Faulty heating elements:
Investigate the problem the following way:
Set the temperature to maximum value and measure the voltage across the heating elements.

58
Faults

Fig. 46: Voltage across the heating elements

Fig. 47: Voltage across the heating elements

– Set the measuring range of a voltmeter to 1000 V AC. If the measured voltage is close to
220 V AC, then the heating elements are faulty.
– Replace the heating elements. See description in the operation manual.
– the measured voltage is much lower than 220 V AC, then the set value for the current
limit is too low, see chapter “Resistance furnace”.
A fault on the board TH-44 is also in question.
Pos : 3.48 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 N egati ve drift after start @ 9 \mod_1425549543984_9.doc x @ 75022 @ 2 @ 1

3.24 Negative drift after start

Pos : 3.49 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0635 M odule Neg ati ve drift after s tart @ 9\mod_1425541130275_9.doc x @ 74405 @ @ 1

This problem can appear in resistance furnace operation, when some material from previous
samples, fall off the combustion boat when shifted into the furnace. Then, when removing the
boat out of the furnace, the hot combustion boat may touch and burn this material, causing an
unwanted small peak on the base line.
If the following analysis is started while the base line is still above zero, then the electronics will
take this level as base line at the beginning of analysis so that the base line drifts negative when
that small peak comes down.
A problem of the IR-cell itself can be ruled out, when running a few blank analyses by just
entering manually a sample weight into the memory and pressing “START”, without inserting
any sample into the furnace. If the base line doesn’t show a negative drift, then the IR-cell is
O.K.

59
 Faults

Pos : 3.50 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 R esistance furnace c ompl etl y c ol d or too hot @ 9\mod_1425625509164_9.doc x @ 75116 @ 2 @ 1

3.25 Resistance furnace completly cold or too hot

Pos : 3.51 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0640 M odule Resistanc e fur nac e completel y col d or too hot @ 9\mod_1425541165983_9.doc x @ 74417 @ @ 1

Fig. 48: Furnace temperature problem

Pos : 3.52 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 F umes in the resis tanc e furnac e @ 9 \mod_1425626045991_9.doc x @ 75128 @ 2 @ 1

60
Faults

3.26 Fumes in the resistance furnace

Pos : 3.53 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0645 M odul F umes in the resis tanc e furnac e @ 9\mod_1425541226464_9.doc x @ 74429 @ @ 1

CAUTION! Never turn on the oxygen flow, when fumes come out of the furnace, or else
there can be an EXPLOSION!
Wait for at least 15 minutes, until the smoke has disappeared from the furnace before turning
on the oxygen supply!

When smoke comes out of the resistance furnace front, mostly the reason is that a sample is
entered into the hot zone of the furnace without having oxygen flow. If at that moment the
oxygen flow is restored, the gases in the furnace will ignite and explode with a loud bang and
with a flame shooting out of the combustion tube.
The explosive gases consist of carbon monoxide from carbon in the sample and (very little)
oxygen from the air which was in the combustion tube and of volatiles driven out of the sample
by the temperature without burning due to missing of oxygen.

Other possible reasons:

– It is a sign of bad combustion. See chapter “Bad combustion”.
– The furnace temperature is too low.
– No oxygen flow. See chapter “No oxygen flow”.
– The pressure switch is faulty.
– The oxygen inlet valve V5 is faulty. See chapter “Wiring diagrams”. Check for pressure
response. Unscrew the lower tube (1). The oxygen must exit the valve when the mains
power switch is set to pos. 2.

O2
6

7 VAC

5 2
220 VAC
4
3 2

1 1-15-3

If not:
– There is no voltage (220 V) on the leads (2) of the coil (4.)
– The valve is blocked. Clean the valve by
a) closing the oxygen supply,
b) setting the mains switch to pos. 0

61
 Faults

c) clean the valve according to chapter “Cleaning solenoid valves”.

If the fault still remains, then:

– Switch off the power (pos. 0).
– Disconnect plug ( 2 ) from the coil ( 4 ) and measure the resistance. 3.3 K for 220VAC
valves is a normal value.
Pos : 3.54 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 R esistance furnace doesn` t reac h full temper ature @ 9\mod_1425626188856_9.doc x @ 75140 @ 2 @ 1

3.27 Resistance furnace doesn`t reach full temperature

Pos : 3.55 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0650 M odul R esistance furnace does n`t reac h full temper ature @ 9\mod_1425541312124_9.doc x @ 74441 @ @ 1

– The heating elements are used up. See chapter “Bad combustion”.
– The furnace is faulty. See Chapters “No combustion”, “Resistance furnace”,
“Resistance furnace doesn’t reach full temperature”, “The resistance furnace is too
cold or too hot” and “Resistance furnace takes too long to warm up”.
Pos : 3.56 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 U nstable r esistance furnace temperatur @ 9\mod_1425626418438_9.doc x @ 75152 @ 2 @ 1

3.28 Unstable resistance furnace temperatur

Pos : 3.57 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0655 M odul U nstable r esistance furnace temperatur e @ 9\mod_1425541401855_9.doc x @ 74453 @ @ 1

– The heating elements are used up, and the required temperature can only hardly be
reached so that there are no reserves of power, to properly regulate the temperature at a
stable level. See chapter “Resistance furnace doesn’t reach full temperature”. To
confirm this fault, set the temperature to a much lower value. If the temperature cannot
reach the new higher level, it is obvious that the unstable temperature was at maximum
level of temperature the heaters can reach.
– The temperature control board TH 43/44 is faulty. Replace the TH 43/44 board and adjust
according to chapter “Resistance furnace”.
– The thermocouple is faulty. See chapter “Thermocouple testing”.

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Faults

Pos : 3.58 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 D ust or s oot from the r esistance fur nace @ 9\mod_1425626621251_9.doc x @ 75164 @ 2 @ 1

3.29 Dust or soot from the resistance furnace

Pos : 3.59 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0660 M odul D ust or s oot from the r esistance furnace @ 9\mod_1425541504144_9.doc x @ 74477 @ @ 1

Fig 49: Front CS-2000

The sample has been inserted into the furnace too quickly:
– See Operation Manual chapter “Applications / Coal analysis”.
The sample weight is too high:
– If a sample burns explosively, then there could be a shortage of oxygen. This can cause
some soot or oil vapors that pass through the hot zone of the furnace without burning. It
is necessary to reduce the weight of the sample, e.g. to 100mg or even to 50mg. If the
weight reduction doesn’t help, then operate differently by shifting the boat slowly towards
the beginning of the hot zone of the furnace. Leave the boat there and allow the sample
to start burning. Towards the end of the combustion, move the boat to the middle of the
hot zone, in order to obtain a complete combustion. See Operation Manual “Applications
/ Oil analysis”.
The sample is metallic:
– Perform analysis by using the induction furnace. See Operation Manual.

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 Faults

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3.30 Vibrations in induction furnace mode

Pos : 3.61 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0665 M odul Vibr ations in i nduc tion furnac e mode @ 9\mod_1425541546467_9.doc x @ 74489 @ @ 1

If the Analyzer vibrates when the mains power switch is turned to position 3, the reason is dust
accumulation on the blades of the oscillator’s blower. The vibrations are caused by dust on the
blades causing eccentrical rotations.

DANGER
Mortal danger from electric shock
Clean it carefully with a vacuum cleaner, if necessary:

Vacuum cleaning

Vacuum cleaning

Fig. 50: Oscillator blower cleaning

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3.31 Analysis cycle stops too early

Pos : 3.63 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0670 M odul T he anal ysis c ycle stops too earl y @ 9\mod_1425541597042_9.doc x @ 74501 @ @ 1

The minimum analysis time is set too short in the configuration window, so that the analysis time
expires before the peak starts coming up. Normally the peak starts about 6 to 8 seconds after
the start of combustion. If the minimum analysis time is set for example to 4 seconds, the
analysis may be terminated before the peak starts. If the minimum analysis time is set far over 8
seconds, the peak starts before the minimum time expires. Due to the IR signal being then
higher than the comparator level, the analysis continues until the IR signal comes down to the
comparator level, unless the maximum analysis time expires earlier. If so, it is advisable to
increase the maximum analysis time in order to integrate the whole peak.

64
Faults

Especially in case of resistance furnace operation, the peak of hard-to-burn samples starts
coming up quite late. In such cases, the minimum analysis time should be set to about 60
seconds.
If after prolongation of the minimum analysis time to a reasonable value, a peak still doesn't
appear, possible reasons for the fault are:
– No combustion. See chapter “No combustion”.
– There is no gas flow. See chapter “No flow”.
– There is gas flow, but bypassing the furnace. See chapter “Sample burns but no peak
on the screen“.
– The IR cell is faulty. See chapter “Check base lines“.
Pos : 3.64 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 C hopper motor does n‘t r otate ELTR A @ 6\mod_1368709089073_9.doc x @ 41319 @ 2 @ 1

3.32 Chopper motor doesn‘t rotate

Pos : 3.65 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0675 M odul T he c hopper motor does n`t rotate @ 9\mod_1425541638117_0.doc x @ 74513 @ @ 1

The rotation of the chopper motor needs to be checked in case of problems only, like when
there are no combustion peaks on the screen or the IR signals are minus -10V (take care,
minus) displayed on the PC screen in the window “inputs”.

In order to check whether the chopper motor is rotating, the easiest way is to remove an IR
path. See chapter “IR-paths, cleaning and replacing”. Mostly, the easiest path to remove is
the shortest one. Then, the chopper blade can be seen thru the hole of the chopper housing,
which becomes free (open) after removing the path.

The reason of failure can be a faulty motor but also the controlling electronics of the motor may
have become defective. If so, the motor or the IRC board has to be replaced. Before replacing,
check at least the voltages on the board, mainly the supply voltage of 24VDC. See chapter
“Infrared cell adjustments”.
For replacing the chopper see chapter “Chopper”.
Pos : 3.66 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 Sample burns but no peak on the s creen @ 7\mod_1381400077047_9.doc x @ 49828 @ 2 @ 1

3.33 Sample burns but no peak on the screen

Pos : 3.67 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0680 M odul Sample burns but no peak on the s creen @ 9\mod_1425541684636_9.doc x @ 74525 @ @ 1

When the analysis cycle is carried out normally and the sample is burned but no peak on the
screen, possible reasons are the following:
- The IR cell could be faulty. Check the base lines. See chapters “Check base lines” and
“Infrared cell adjustments”. If the base lines look normal, the IR cell can be regarded as
ruled out. If the base lines are practically at zero volts, the cell is faulty or without power.
(24VDC). See chapter “Bad combustion”.
- The plunger of bypass valve V4 jams. See chapter “Cleaning solenoid valves”.

This is related to induction operation only:

This may happen in case of induction furnace operation. There is gas flow, but bypassing the
furnace, so that there is gas flow shown on the flow meter and by the flow sensor on the screen,
but no gas flow thru the induction furnace. In this case the bypass valve V4 jams, causing the
oxygen flow to bypass the furnace like in case of open furnace. See chapter “Gas flow
system”.

The furnace has though oxygen pressure but without having oxygen flow. Due to oxygen being
present, the metal sample and accelerator(s) burn, because there is availability of oxygen in the
furnace, coming thru the chamber valve V3 and/or thru the lance valve V2. In case of metal

65
 Faults

analysis, the burned sample in the crucible looks like normally combusted sample. If so, check
the bypass valve V4. See chapter “Cleaning Solenoid valves”.
Pos : 3.68 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 IR signal does not c ome down to the base line at the end of anal ysis @ 7\mod_1381404509510_9.doc x @ 49850 @ 2 @ 1

3.34 IR signal does not come down to the base line at the end of analysis
Pos : 3.69 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/05Faults _C S-2000/0685 M odul IR signal does not c ome down to the base line @ 9\mod_1425541763229_9.doc x @ 74537 @ 3333 @ 1

There are several different reasons for this effect

1. Long combustion of a very low carbon sample:

Fig. 51: Programm screenshot (graph example 1)

It appears like a long tailing at the end of the peak. It appears in the low carbon range only and
the distance to the base line is in the range of 10 to 50mV. Depending on the blanks of the
crucibles and on the oxygen purity, the level of the tailing can be as high as 100mV. When the
burning is extremely long, the level of the low carbon tailing even starts to grow.
Possible solutions:
- Reduce the analysis time
- Increase the comparator level of the low carbon range,
- Reduce the generator time.

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Faults

2. Copper oxide has a bad quality:

Fig. 52: Programm screenshot (graph example 2)

Memory effects of the copper oxide can cause tailing of the low carbon range in the level of 10
to 50 mV. However the tailing level does not grow due to faulty copper oxide.
Possible solution:
- Replace the copper oxide
3. Path window is not sealed or it is broken
If the faulty window is on the chopper housing side, all available cells have a tailing due to
combustion gases entering the chopper housing causing permanent IR absorption for all cells
available.
If the faulty window is on the IR sensor side, there is tailing of the damaged cell only.
Solution:
-Replace the part having the faulty window.
Replacing the window only, is rather tricky because the window should be available, the faulty
window must be removed, the surface for gluing new window must be cleaned from old glue
and rests of the broken window, there must be glue available being suitable to glue windows
(two components glue) and time should also be available to wait until the glue is solid.

67
 Faults

4. Flow stops during analysis

Fig. 53: Programm screenshot (graph example 3)

In such case all base lines remain high, keeping their level which they had at the moment the
flow stops. Therefore the voltages of the horizontal continuation of the base lines can be high,
depending on the voltage level of each peak at the moment the flow stopped.
Possible reasons why the flow may stop during combustion:
– The lance valve V2 jams.
At the beginning of analysis, the oxygen is supplied to the furnace by the chamber valve
V3 during T2 and T3 for the time (seconds) set in the software (configuration window).
After expiring of T2 and T3, V3 closes the oxygen to normally continue being supplied by
the lance valve V2 until the end of analysis. But if V2 blocks there is no flow any more so
that the combustion gases remain in the IR paths constantly absorbing IR Radiation.
In this case the shape of the IR signals is repeatable as long as T2 and T3 remain
unchanged, unless V2 sometimes jams occasionally.
– Loose wire connection to the flow regulating valve V6.
In this case it is not likely to have repeatable shape of the IR signal.
– The 50-pin connector of the HF-42 is not properly connected.
Fix the connector’s screws.
– The flow control board HF-42 is faulty.
– For some reason the software goes to the gas saving mode

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Faults

Fig. 54: Programm screenshot (graph example 4)

In this case, the flow blockage was not permanent. This can happen for example when the
plunger of the valve V2 may shake due to contamination, enabling occasionally more or less or
no flow at all, during one combustion.

Pos : 4 /0010 ELTR A/------- Seitenumbruc h ----------- @ 6\mod_1368796429449_0.doc x @ 41468 @ @ 1

69
 Adjustments

Pos : 5.1 /0025 Ü bersc hriften/ELTR A 1. Ü berschriften/1 Adj ustments eltr a @ 8 \mod_1396882697255_9.doc x @ 60262 @ 1 @ 1

4 Adjustments
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4.1 Gas flow controller-adjustment and jumper settings

Pos : 5.3 /0010 ELTR A/0015 s er vice_i nstr uctions /CS- 2000_s er vic e/10Adj ustments _CS- 2000/1005 Modul Gas flow contr oller adj ustments and j umper s ettings @ 9\mod_1425542321719_9.doc x @ 74562 @ 344 @ 1

4.1.1 Flow controller for induction furnace operation

Gas flow controller adjustment

Fig. 55: Gas flow controller

– Set the flow rate with P1 of the HF 42, to about 180 l/h. Observe the flow rate on the
lower flow meter of the analyzer. Wait until the value is stable.
The output of the flow sensor is on TP10 of the HF 42 board; TP15 is GND. With a flow of
180 l/h, the voltage is about 2.5 - 3V.
NOTE: without flow, the output voltage of the sensor is not 0V but about 0.6V.
– Adjust with P3 until the voltage on TP7 is 5V.
On TP8, the activity of the pulse width modulator can be checked.
The output voltage to the gas flow regulation valve can be measured on TP3.
With a constant flow of about 180 l/h, it should be between 5 and 15 volts.
– Check and if necessary readjust the pressure regulator (PR3) in front of the flow
regulating valve.

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Adjustments

Jumper settings:

Fig. 56: Jumper settings

The connector J2 is for selecting different options for the induction generator control. By default,
one jumper is set in the factory at the position “current control” connecting the pins B1-B2 and a
second jumper is set to connect B3-B4 for “On board power adjustment”.
The connector J3 is for selecting options for the oxygen flow. The factory setting of the jumper is
for “External flow enable”, by connecting the pins A1-A2. In this case, the microcontroller board
can start and stop the flow enabling gas saving mode.
When moving the jumper to B1-B2 for “On board flow enable”, the flow will start and stop with
the analysis begin and the analysis end, in other words, there is flow only during analysis. This
can be interesting for older analyzers without gas saving function in their software, when they
are used in automations running analyses only once in a while with long and regular idling
period between analyses, for example 15 minutes
At position “Continuous flow” when the jumper connects B3-B4, there is continuous flow as long
as the mains power switch is set to position 2. The continuous flow position is useful in case of
looking to solve flow problems, because the flow is always enabled

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 Adjustments

Fig. 57: Gas flow regulation

The flow controller mainly consists of the following components:

72
Adjustments

– The flow sensor (1)

– The flow regulating valve (V6)
– The flow control board HF 42
The flow sensor measures the gas flow rate, and converts its flow rate into an electrical signal
(DC voltage).
The HF 42 board compares this flow value with the flow value set by P1.
The signal resulting from the comparator controls a pulse width modulator.
Its output can be seen on TP 8, TP 15 is GND.
The pulse width modulated signal controls a power transistor, which drives the flow regulating
valve.
The duty cycle of the output signal determines the average DC voltage on the valve. In normal
operation with a flow of about 180 l/h and with not depleted chemicals, the DC voltage across
the valve coil is around 10V. This voltage can be measured between TP3 and TP17. This
voltage on the valve has the value needed at any moment for keeping the flow constant, in
other words for keeping the sensor voltage equal to the value set with P1.

4.1.2 Flow controller for resistance furnace operation

The flow sensor is common for both, induction and resistance furnace operation.
The sensor output is connected to both:
To the input of the HF42 board controlling the regulating valve V6 in induction operation and to
the input of the pump control board PC-1.3 controlling the pump in resistance furnace operation.
See chapter “Wiring diagrams” and “Gas flow diagram”.

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 Adjustments

Fig. 58: Gas flow regulation

Caution: This board is installed in the analyzer upside down. The above schematic shows the
components side of the board, which is the lower side of the board in the analyzer.

Test points explanations:

TP1–TP2: AC voltage across the pump coil
TP3: GND for measuring DC voltages on P4, P5, P6.
TP4: Start/stop controling of the pump by the UNI board. 5VDC means no start command.
0.5VDC means, the command for the pump to start is available.
TP5: DC Voltage corresponding (proportional) to the pump voltage. This voltage is used for
displaying the pump voltage on the PC screen. The voltage displayed on the screen is
recalculated and it is higher than what is measured on TP5. The maximum pump voltage
displayed on the screen is 24V. This can be verified by squeezing a plastic tube causing the
pump to run at maximum voltage.
One of the reasons why the voltage on TP5 is kept at lower level, is that the analog inputs of the
microcontroller board has a maximum input voltage of 10V.

In normal operation the pump voltage is displayed in the “device state window” lies
between 5V to 8V.
TP6: Flow sensor output voltage. This voltage is displayed on the PC screen in the “device

state window” next to the flow rate in L/h.

R6: Flow rate adjustment. The flow rate can be adjusted by turning this trimmer, clockwise for
higher and counter clockwise for lower flow rate.

R13: Pump frequency adjustment. The pumping frequency of the pump can be adjusted by
turning this trimmer, clockwise for higher and counter clockwise for lower pump frequency. The
pumps are basically designed for 50 Hz operation. The pump frequency has a factory
adjustment so that it is not advisable to change it.
X1: Flow sensor connector FD9.
Pin 2: Sensor output
Pin 3: GND
Pin 5: +12V
X2: Connector to UNI board.
Pin 1: Sensor output / TP6
Pin 2: Input for flow start command/TP4. 12V means no flow. 0.5V for flow.
X3: 24V power supply.
Pin (middle) +24V. Outer contact GND.
X4: Pump connector.
Alternating 24V square voltage voltage/TP1 – TP2. Frequency adjustable by R13.
The duty cycle of this square voltage defines the power of the pump.
JP1: The pins 1 and GND must be connected with a jumper for late analyzers.
Older analyzers work also with a jumper, however the pump and flow voltages in the device
state window are more stable without jumper.
For details about wiring see chapter “Wiring diagrams”.

74
Adjustments

Remark:
Due to a few failures of the flow sensors, almost exclusively with users who analyse samples
with high sulphur and high moisture or regularly treat their samples with acid, we concluded that
the reason of the failures should be of chemical nature i.e. sulphuric acid and other acids
damage the sensor.
The solution is to prevent the analysis gases to get in contact with the sensors. Therefore the
sensor ports are connected with long tubes to the gas flow system. There is no gas flow through
the sensor tubes but only the pressure is sensed by the sensor.
In case of failure of a previous version sensor, it is advisable to replace it by the new version. In
this case the part numbers of the complete assemblies should be used for ordering. In case the
analyzer has already the new version sensor, the order should include the spare part number.
See drawings below and chapter “Ordering numbers”.

Fig. 59: New flow sensor

Fig. 60: Old flow sensor

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4.2 Infrared base line adjustments

Pos : 5.5 /0010 ELTR A/0015 s er vice_i nstr uctions /CS- 2000_s er vic e/10Adj ustments _CS- 2000/1010 Modul Infrar ed bas eline @ 9\mod_1425542384792_9.doc x @ 74574 @ 334434 @ 1

4.2.1 Infrared cell modification - general information

Eltra has changed the IR cell design. This modification makes the cells less susceptible to
contamination problems and makes the calibration more stable. The changes are:
The IR-4 board is modified so that now the output voltage of the cell is adjusted at 8V instead of
zero.
The voltage of each source remains unchanged at 1.75 volts as it used to be.
After this modification the peaks you see on the screen and the output voltage of the IR cell are
two different things.
The Peaks on the screen look the same way like they used to look before starting from zero
(base line) and going up positive.

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 Adjustments

The outputs of the IR cells (IR base lines) are factory set at 8V when the paths are new and
clean. The peaks come down starting from 8V coming down to a minimum voltage (at the peak
maximum) and they go back to the 8V baseline after completion of combustion. The 8V IR-base
line is obtained through preamplifier adjustment only.
In real operation, with growing contamination resulting in gradually weakened radiation reaching
the detector, the IR cell output base lines will move down to levels below 8V depending on the
grade of contamination. The (negative output) peaks of the cell will also change to smaller
amplitude.
The base line is not regulated any more.
Due to a recalculation formula, the base lines on the screen are always zero volts, the peaks
are positive and they are always of equal amplitude and surface (for same sample and same
weight) regardless the path contamination, regardless the cell base line level, and regardless
the cell output peak amplitude. Consequently the integrated value (of the peak on the screen)
remains the same and of course also the analyses results remain constant at any grade of
contamination.
– When loading the UNI software select from now on "New cell" mode.

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Adjustments

Fig. 61: IRC 1.3

77
 Adjustments

4.2.2 General test points

Supply voltages and thermostatic control circuit
TP 1: GND
TP 7: IR source voltage
TP 12: + 5V supply
TP 13: Heating transistors control voltage
TP 26: IR temperature actual value
TP 27: +24V supply
TP 28: IR temperature set point
Supply voltages for IR signal processing circuit
TP 6: +12V
TP 21: -12V

Fig. 62: Mainboard (Cut-out) IR-Cell – general test points

78
Adjustments

4.2.3 Test points IR-ranges

Fig. 63: Test points IR-ranges

Supply voltages for IR signal processing circuit
TP 15: +5V reference
TP 20: Analog GND
Outputs (base lines about 8VDC. For golden paths adjust 6VDC)
TP 22: Output section [1]
TP 25: Output section [2]
TP 24: Output section [3]

79
 Adjustments

TP 23: Output section [4]

4.2.4 Base line adjustments.

See also chapter “Check base lines”.
When the IR module (rack) is removed from the analyzer, it can be powered on the desk by a
24VDC power supply connected to J1 of the IRC board. The power supply should normally be
capable to supply a current of 5A.
If a lower current power supply available, in order to prevent the temperature control from taking
high current from the power supply, set a jumper to position 2 of the connector J1. In this case a
24V / 1A power supply will be enough.
CAUTION:
Remember to remove the jumper from position 2 before reinstalling the IR module into the
analyzer, otherwise the thermostatic control will not work.
4.2.5 Infrared cell board IRC1.x sections assignment

board sections [4] [3] [2] [1]

4 cells IR module Hi S Lo S Hi C Lo C
3 cells IR module S Hi C Lo C
3 cells IR module Hi S Lo S C
2 cells IR module S C
2 cells IR module Hi C Lo C
2 cells IR module Hi S Lo S
1 cell IR module C
1 cell IR module S
Explanations
– Lo C: Low carbon range (long C path)
– Hi C: High carbon range (short C path)
– Lo S: Low sulfur range (long S path)
– Hi S: High sulfur range (short S path)
– C: single carbon range (single C path)
– S: single sulfur range (single S path)
The preamplifier connectors of the cells are of course connected to the corresponding sections
according to the above assignment list. (4-pin module connectors).

Example
A three cell module with a low carbon, a high carbon and a sulfur cell has
– the low carbon signal on section [1], the LoC preamp is on X1
– the high carbon signal on section [2], the HiC preamp is on X2
– the Sulfur cell signal on section [3], the S preamp is on X3

The base line adjustments are done by adjusting the gain of the preamplifier of each IR cell in
the IR module (rack). The gain adjustment is done by turning the trimmer which is inside of each
preamplifier. The base line voltages can be measured on the following test points:

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Adjustments

Outputs (base lines about 8VDC)

TP 22: Output section [1]
TP 25: Output section [2]
TP 24: Output section [3]
TP 23: Output section [4]
TP 20: Analog GND
NOTICE
Use a very thin screwdriver. With a big screwdriver, the trimmer can be mechanically destroyed
before you feel it. The screwdriver should never get in touch with the hole resp. the housing of
the preamp, otherwise the trimmer may be mechanically stressed and break.

4.2.6 Voltage of a base line is too high (higher than 9.5V)

The optimal value for the base lines of the IR-paths is about 8V. Golden paths have the effect to
become more reflective in the first few months of their operation. To compensate this effect, the
original value of the golden paths base line should be adjusted at 5 V. In case of a long golden
paths (300mm) having sensors including on-chip preamplifier, the cell output sometimes cannot
be adjusted down to the required 5 to 6V by turning counter clockwise the trimmer in the
preamplifier. (Outputs: TP22 to TP25 against AGND = TP20).
In this case the IR sources voltage has to be reduced until you get a base line of the troubled
golden cell down to about 5 to 6V. You will then need to increase the gain of the other cells
preamps to get their base lines back to the range of 8V.
Source voltage – reducing
1. Take the IR cell out of the analyser.
2. Power the cell by an external 24VDC power supply connected to J1 of the IRC board.
3. If the external power supply cannot supply 5A then set a jumper on position 2 (Test °C) of
JP1 in order to switch off the temperature control so that a power supply of 1A is
adequate. If a jumper is available on position 3 or 4 (Analysis), this jumper can be moved
to position 2. The positions 3 and 4 are simply parking positions for jumpers to simply be
available when needed. There are no tracks connected on the pins of the (Analysis)
positions 3 and 4 of JP1.
4. Make sure that the gain of the preamplifier in question is adjusted to a minimum
gain. To do this, turn its trimmer counter clockwise up to the end of trimmer range.
These trimmers have a maximum of 20 turns. When the end of range has been reached,
you can hear a gently silent click with each turn. It is not possible to feel any
mechanical resistance on the screw driver.
5. Measure the actual source voltage between on TP7 against GND=TP1 and note the
value.
6. Turn the potentiometer R80 of the IRC board counter clockwise up to the end of its range.
(Maximum gear range = 20 turns).
7. Switch off resp. disconnect the power supply.
8. Move the jumper of JP2 to position 5.
9. Connect the 24V power again.
10. Connect the multimeter to the cell output which has to be adjusted.
11. Wait for the sources to warm up until the output voltage will almost reach its maximum
value.
12. Turn the trimmer R80 slowly clockwise until the base line of the cell in question has
reached 8V. In case of a clean golden path, adjust between 5V and 6V instead of 8V.

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 Adjustments

13. Adjust the outputs of other cells (not golden paths) to have between 7 to 8V by adjusting
the gains of their preamplifiers.
14. Set the jumper of the JP1 from position 2 (Test °C) to Position 3 (Analysis).
15. Install the IR module into the analyzer.
16. Allow sufficient time for the base lines to stabilize.
NOTICE It is necessary to turn slowly in order for the IR sources to stabilize their temperature
with increasing IR source voltage.
– Adjust the other cells of the module (if any) at 8V baselines or 5V to 6V in case of clean
golden paths.
– Install the IR module into the analyzer. Allow sufficient time for the base lines to stabilize.
– Start gas flow and check the base lines again. If any of them is significantly over 8V then
readjust.
Drift too large
– Check the temperature regulation.
– Unstable power supply.
– Defective IR-source.
NOTICE If it is shown on the display that the infrared cell's output voltage is over 10 volts then
there is a serious defect.

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Adjustments

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4.3 IR source voltage setting

Pos : 5.7 /0010 ELTR A/0015 s er vice_i nstr uctions /CS- 2000_s er vic e/10Adj ustments _CS- 2000/1015 Modul IR-s ourc e voltage s etting @ 9\mod_1425542423232_9.doc x @ 74586 @ @ 1

Fig. 64: IR source voltage setting

The jumper JP2 is for setting voltages of the IR sources. All available sources in an IR cell are
connected in series. Normally the voltage of each source is 1.75 VDC. The total voltage of all
available cells can be measured on test point TP7 against TP1=GND.
Caution: In case of adjusting resp. changing the IR source voltage, the base lines take a few
minutes to stabilize at a new level.
In case of problems with adjusting the base line see chapters “Infrared cell adjustments” and
“Infrared power supply”.

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 Adjustments

Pos : 5.8 /0025 Ü bersc hriften/ELTR A 1.1 Ü bersc hriften/11 Infrar ed cell temper ature regul ati on ELTRA @ 6\mod_1369641998919_9.doc x @ 42289 @ 2 @ 1

4.4 Infrared cell temperature regulation

Pos : 5.9 /0010 ELTR A/0015 s er vice_i nstr uctions /CS- 2000_s er vic e/10Adj ustments _CS- 2000/1020 Modul IR ther mos tatic c ontrol @ 9\mod_1425542463669_9.doc x @ 74598 @ @ 1

IR cell temperature control

Fig. 65: IR cell temperature control

TP28 is the test point for measuring the set point of the IR temperature against TP1=GND.
At 3000 mV the temperature is 27°C growing with 10 mv /°C.
Examples:
3.10V  37°C
3.30V  57°C
This is the adjustable temperature range of the cell in normal cases. This temperature range is
adjustable when there is a jumper set on position 6-Lo temperature of JP1 and mainly there is
no jumper on position 5-Hi Temp of JP1. In other words, when no jumper is set, this
temperature range is already by default. A jumper in position 6-Lo Temp will keep this range, so
there is no difference, but the jumper will be available when a jumper is elsewhere really
needed.
3.73V 100°C
3.98V 125°C
This temperature range is available for heated paths only. They are the paths for measuring
water resp. hydrogen in the analyzers CW and CHS and possibly later in CHNS analyzers. In

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Adjustments

order to have the temperature adjustable in the above range, a jumper has to be set on position
5-Hi Temp. of JP1.
The temperature is set by turning the pot and measuring the set value on
The actual value of the temperature is measured on TP26.
Caution: After changing the temperature set point, it takes some time until the actual
temperature value is stabilized at the new set level.

Fig. 66: Trimmer

This is the trimmer in the IR cell module for adjusting the cell temperature. It is accessible with a
screw driver from outside the cell. There is no need to remove the cell block module from the
analyzer’s cabinet in order to adjust the temperature
Modifications for higher sensitivity (gain) in the low sulphur range:
For LS: R101=47k R100 = 3M
4.1 x Standard gain
Recalculation factor = 92.664
For double the normal sensitivity: R101=180k
1.92 x standard gain
Recalculation factor = 39.5
For standard gain.
Recalculation factor = 20.59

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 Adjustments

Pos : 5.10 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 Pneumatic s ELTR A @ 6\mod_1369229118822_9.doc x @ 41844 @ 2 @ 1

4.5 Pneumatics
Pos : 5.11 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/10Adjustments_C S-2000/1025 Modul Pneumatics @ 9\mod_1425542494387_9.doc x @ 74610 @ 3 @ 1

Fig. 67: Pneumatics parts

Pneumatics parts showing the location of the pneumatic valves V7, V8 and V10 as well as the
position of the pressure regulator 8

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Adjustments

5
3

6 10

7 11
12
14
13

15

Fig. 68: Pneumatic parts

1 Furnace closing cone

2 Upper cushioning
3 Magnetic switch
4 Magnetic switch holder

87
 Adjustments

5 Adjusting screw
6 Pneumatic cylinder
7 Lower cushioning
8 Pressure regulator
9 Piston valve
10 Cushioning valve
11 Coil cooling valve
12 Coil cooling adjustment
13 Pressure gauge
14 Combustion coil
15 Muffler
Pneumatics adjusting for correct furnace movement:
When closing the furnace, the piston moves.
Open the right side panel of the analyzer to find the pneumatic valves (9 / V7), (10 / V10) and
(11 / V8) as well as the pressure regulator (8).
- Turn the restrictor (12) clockwise up to the end for complete restriction.
- Check the pressure on gauge (13) to be between 4-6 bar (60-85psi).
- Press F2 to open the furnace.
- Pull to unlock and then rotate the knob of the pressure regulator (8) counter clockwise for
minimum pressure (zero pressure).
- Turn the screw (5) counter clockwise until the magnetic switch support (4) is free to move
up and down on the cylinder (6).
- Shift the magnetic switch upwards up to the end of its adjusting range.
- Press F2 for closing the furnace. The furnace closing cone (1) won’t yet move or move
very slowly.
- Turn clockwise the knob of the pressure regulator (8) until the closing cone (1) can rise
smoothly (without shaking) up to the upper end of its stroke. To do this, open and close
the furnace (F2) as often as needed. Take software delays into account.
- The pressure should be only as high as necessary and low enough for a person to be
able to stop by hand the cone from rising.
- Push the knob to lock the pressure regulator (8).
- When the furnace is closed, slowly shift the magnetic switch (3) with its support (4)
downwards until it just switches on. This can be recognized due to the clicking of a
pneumatic valve (10/V10) and the piston moving then slightly higher.
- Make a marking on the cylinder (6) at the upper end of the magnetic switch holder (4).
- Shift the switch with holder downwards until the magnetic switch is off (A valve clicks and
the piston slightly moves downwards).
- Make a second marking on the cylinder (6) at the upper end of the switch holder (4).
- Adjust the switch holder (4) to have the upper end in the middle of the two markings.
- Open the furnace and then close it again (F2) to verify the correctness of the adjustment.
- Adjust the lower cushioning (7), so that the furnace opens without the piston banging at
the bottom.

88
Adjustments

- Click on “Communication test”-“Digital outputs”, on the 9th button counting from the left,
to energize the coil cooling valve (11/V8), or start analysis cycle.
- Turn the restrictor (12) counter clockwise until the pressure on the gauge (13) is reduced
by about 0.2 to 0.3 bar (3 to 4 psi) when the coil cooling valve (11/V8) is open.
- Fix the locknut of the restrictor (12).
REMARK:
In case of using valuable gas for operating the pneumatics, the restrictor (12) should be
adjusted for lower flow by turning it clockwise. It can even be completely closed by turning it
clockwise up to the end of its range.
The flow adjusted with this restrictor is for cooling the combustion coil to ensure very long
service life. According to our experience, the combustion coils of our analyzers don’t need
replacement, even after years of operation.

Check the following :

– Open the furnace ( piston down ).
– Hold the piston down by pressing on the horizontal bar of the furnace. ( with the fingers)
– Press the key to close the furnace.
– Allow the piston to go up very slowly by controlling the force of your fingers.
If not possible do the pneumatics adjustment, see pages before.
– About 5 mm before the piston reaches its highest position the force will increase.
– With your fingers press down firmly to make sure that the piston can not be pushed
down.
– If the piston starts vibrating by moving up and down with full force, then adjust the switch
higher.
– If the piston goes down, then adjust the switch lower.

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 Adjustments

Fig. 69: Adjusting correct furnace movement

Pos : 5.12 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 Press ure regul ati on ELTR A @ 6 \mod_1369298860002_9.doc x @ 41930 @ 2 @ 1

4.6 Pressure regulation

Pos : 5.13 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/10Adjustments_C S-2000/1030 M odul Pres sur e reg ulators @ 9\mod_1425542522280_9.doc x @ 74622 @ @ 1

Inlet pressure

Fig. 70: PR1

PR1 is the inlet oxygen regulator, and is situated inside the analyzer, on the rear panel.
The outlet pressure needs to be set to 1.5bar (22.5psi).

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Adjustments

– Pull and rotate the knob of the regulator, until the pressure gauge (6) shows the correct
value.
– Ensure that the flow shown on the flow meter (5) shows between 180 and 200l/h; if
not, adjust according to the related chapter.

Fig. 71: Front side

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 Adjustments

Purge pressure

1 1
1.5

0.5 2

bar

0 2.5

PR2

Fig. 72: PR2

PR2 is the pressure regulator for the purging system of the IR-cell and it is situated inside the
analyzer, just behind the left-side of the panel. It is positioned horizontally.
– The oxygen pressure at the outlet of the PR2 should be 0.35 bar (5psi). The pressure can
be checked by applying a T-piece on the outlet of the pressure regulator, and connecting
a pressure gauge (1), as indicated above.
– Pull and rotate the knob of the pressure regulator (PR2), until the correct pressure is
shown on the gauge.
Pos : 5.14 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 Cl osing c one adjustment ELTR A @ 6 \mod_1369381713916_9.doc x @ 42030 @ 2 @ 1

4.7 Closing cone adjustment

Pos : 5.15 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/10Adjustments_C S-2000/1035 M odul Cl osing cone @ 9\mod_1425542547459_9.doc x @ 74634 @ @ 1

– Ensure that the shaft (1) is securely fastened to the (1). (engineers wrench size 17).
– In order to adjust the cone, the screws (4) should be loosened so that the cone (3) moves
horizontally on the bar (2).
– Close the furnace ( with the lift upwards ).
– Tighten the screws (4).
– The cone is now positioned correctly.
– The screws (5), (6), (7), must now be well tightened in this order.
– The screws (8) should be properly fastened (with a wrench).
– The screws (9) should be tightened by hand only.

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Adjustments

Fig. 73: Closing cone

Pos : 5.16 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 Linearity c orrecti on @ 9\mod_1425629238672_9.doc x @ 75212 @ 2 @ 1

4.8 Linearity correction

Pos : 5.17 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/10Adjustments_C S-2000/1040 M odul Linearity c orrec tion @ 9\mod_1425542573090_9.doc x @ 74646 @ @ 1

See „Software helps“!

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 Adjustments

Pos : 5.18 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 Induction g enerator c ontrol ELTRA @ 6\mod_1369387490836_9.doc x @ 42096 @ 2 @ 1

4.9 Induction generator control

Pos : 5.19 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/10Adjustments_C S-2000/1050 M odul Induction g enerator contr ol @ 9\mod_1425542716597_9.doc x @ 74670 @ @ 1

TP13 TP14
TP10
TP11
J2
TP6
TP2 TP7 TP8

J3
TP4
TP5 TP12
TP3
TP9

TP1 TP15 TP16 TP17 TP18 TP19 TP20

P1 P 2 P3 GND +12V +20V +24V -12V +5V HF42 12016

Fig. 74: HF 42

Fig. 75: Jumper settings HF 42

Current control:
The current control provides a safer and more accurate control of the furnace intensity.
– Set the jumper J2 to B1-B2. .
– Connect a digital multi meter on TP1 (TP15 is GND).
Adjust only, while the furnace is active:
– Start the analysis, adjusting P2 until 6.3V DC is reached on TP1 (for copper analysis,
adjust 1.2V DC).

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Adjustments

The following diagrams show the relationship between the set value (adjustment with P2 on the
HF 42 board) and the generator parameters.

Fig. 76: Diagram Generator current vs. setpoint

Fig. 77: Diagram Generator power vs. setpoint

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 Adjustments

Pos : 5.20 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 R esistance furnace @ 9\mod_1425629579658_9.doc x @ 75224 @ 2 @ 1

4.10 Resistance furnace

Pos : 5.21 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/10Adjustments_C S-2000/1055 M odul R esistanc e furnac e @ 9\mod_1425542751105_9.doc x @ 74682 @ 33 @ 1

4.10.1 Setting the furnace regulation card TH 43 / TH 44

Fig. 78: Setting the furnace reulation card

1) Connect jumper J4 to A1 B1.

2) Disconnect plugs J2 and J3.
3) Turn trimmer P4 anticlockwise to the end-stop.
4) Set the power switch to pos. 2.
5) Measure about +15 V on pin 4 of the IC1; TP3 = GND.
6) Measure about +5 V on pin 14 of the IC 1.
7) Measure about –5 V on pin 11 of the IC 1.
8) Reconnect J2 and J3.
9) Turn the potentiometer on the front panel clockwise until maximum setting is reached.
10) Set the toggle switch to position set point .
11) Adjust with P1 to 1550 mV ( maximum ) on TP4 ( to be measured with a digital DVM ).
12) Set the trimmer to a value of 1550 on the LCD display.
13) Set the toggle switch to actual value ( furnace temperature ).
14) With P3 set the room temperature on the LCD display.
15) Set toggle switch back to set point.
16) Adjust set point to 1250°C.
17) Set toggle switch back to actual value.
18) Connect jumper J4 to A2 B2.
19) Adjust with P4 the max. AC current. For this purpose measure the current of the main
power with an external amperemeter. Adjust 20A.
CAUTION! Use a true RMS meter
20) Measure the voltage of the thermocouple on TP1, using an external multimeter with a
resolution of 0.01 mV.
21) By means of P2, set a value on the LCD display which relates to the value on the
multimeter; e.g. if the multimeter shows 11,30 mV, then the LCD display must show
1130°C. Once the furnace temperature is stable at the set temperature of 1250°C, the
multimeter must show 12.50 mV and the LCD display must show 1250°C. Repeat the
adjustments, in case the readings deviate.

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Adjustments

Replacement of the TH 43 board:

once the TH 43 board has been replaced, it is necessary to perform the above adjustments, to
avoid errors due to the tolerance of any component in the furnace.

4.10.2 Furnace regulation board TH 43 / TH 44

Description of its function:

NTC TP6
J5/9
Mains L

Temp.compensation Current
limitation
+15V
J5/8

TP1 TP10 TP12

J2/9
Linearisation
Heater
Thermocouple
elements
J2/10

J2/1 ACTUAL TEMPERATURE VALUE

J5/6
Furnace
Thyristor
temperature
drive
display J2/2 TEMPERATURE SET POINT J5/5
Mains N
TP5 +15V

+15V
TP2 +5V
TP4
max.
J2/5 setpoint
TP7

Furnace J2/4 -5V

temperature TP3
setting
J2/13

2-6-3

Fig. 79: Furnace regulation board TH 43/TH 44

The TH 43 or TH 44 control board regulates the furnace power, first by comparing the
temperature set point with the actual furnace temperature, then by sending the appropriate
signal to the thyristor drive unit.
The output voltage of the thermocouple (actual furnace temperature) can be read at TP1. Its
range is about 13 mV at 1300°C.
The output voltage versus temperature characteristic of a thermocouple is not perfectly linear. A
linearisation unit therefore, has been included in the above circuit.
Once linearized and amplified, the furnace temperature voltage can be read on TP10. The
temperature set point, which is adjustable with the potentiometer on the furnace, is compared
with the actual furnace temperature voltage.
The resultant voltage (on TP12) is then fed to the thyristor drive unit, thus increasing or
decreasing the furnace voltage.
A current limitation circuit keeps the furnace current within safe limits.
Either the temperature set point or the actual temperature can be digitally displayed, depending
on the switch setting on the furnace.

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 Adjustments

Pos : 5.22 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 T her moc ouple testi ng @ 9\mod_1425629857432_9.doc x @ 75276 @ 2 @ 1

4.11 Thermocouple testing

Pos : 5.23 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/10Adjustments_C S-2000/1060 M odul T hermoc oupl e testi ng @ 9\mod_1425542792773_9.doc x @ 74694 @ @ 1

TH43
36907
TP2
J1 1

TP3
TP5
TP4

AB
8
7
1 2
6 TP7 A
J2 5
B
4 1 2
3
2
1
J3 TP11

TP12
TP6
TP1

J5

P1 P2 P3 P4 2-15

OHM

Fig. 80: Thermocouple testing

Disconnect the plug J1 from the board TH 43 and measure the resistance of the thermocouple
with a digital multimeter, range 100 Ohm.
The resistance must be very low, about 0,5 Ohm.
If the resistance is very high or infinite, then the thermocouple is faulty and must be replaced.
Pos : 6 /0010 ELTR A/------- Seitenumbruc h ----------- @ 6\mod_1368796429449_0.doc x @ 41468 @ @ 1

98
Service

Pos : 7.1 /0025 Ü bersc hriften/ELTR A 1. Ü berschriften/1 Ser vic e @ 6\mod_1369640568215_9.doc x @ 42168 @ 1 @ 1

5 Service
Pos : 7.2 /0025 Ü bersc hriften/ELTR A 1.1 Ü bersc hriften/11 IR-paths, cleaning and r epl acing ELTRA @ 6\mod_1369640666897_9.doc x @ 42179 @ 2 @ 1

5.1 IR-paths, cleaning and replacing

Pos : 7.3 /0010 ELTR A/0015 s er vice_i nstr uctions /CS- 2000_s er vic e/15 Ser vice_CS- 2000/1505 Modul IR- paths , cl eaning and replaci ng @ 9\mod_1425543299696_9.doc x @ 74706 @ @ 1

– Remove the plastic tubes from the IR-paths (gas inlet / outlet).
– Unscrew the rings with windows on both ends of the paths and remove it for cleaning
purposes (screws M 2.5 in the following schematics).
– After disassembly check the two windows for damage.
– For cleaning the path use the cleaning brush for golden IR-paths, see picture below.

Fig. 81: Golden IR-Path

Fig. 82: Cleaning brush for golden IR-Path

– Assembly of the paths in the reverse order.
– After reinstallation, adjustments according to chapter “Infrared base line “and “Infrared
power supply” are highly recommended.
– Check the calibration and if necessary calibrate. See operation manual.
List of available infrared paths for the CS-2000 see chapter “Ordering numbers”.
The following schematic is to help to make sure that the tubing is done correctly after
reinstalling the cleaned paths.

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 Service

Fig. 83: The tubing

When reinstalling the infrared cell unit in the analyzer, pay attention to the color markings of the
tubes and their fittings.
Pos : 7.4 /0025 Ü bersc hriften/ELTR A 1.1 Ü bersc hriften/11 Infrar ed el ectr onics ELTR A @ 6 \mod_1369640821864_9.doc x @ 42223 @ 2 @ 1

5.2 Infrared electronics

Pos : 7.5 /0010 ELTR A/0015 s er vice_i nstr uctions /CS- 2000_s er vic e/15 Ser vice_CS- 2000/1510 Modul IR- elec tronics @ 9\mod_1425543339476_9.doc x @ 74718 @ 33 @ 1

5.2.1 Removing the IRC-board

Fig. 84: IRC 1.4+

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Service

– The plugs ( 1 / 2 / 3 / 4 / 5 / 6 ) should be unplugged.

– The 10 screws ( 7 and 8 ) should be removed.
See also chapters “Infrared baseline adjustments”, “IR source voltage setting” and “Infrared
power supply”

5.2.2 Changing the IR-source

Fig. 85: Infrared source replacement

REMARK
– The IR sources (2) are fastened with the screws (3).
To install or removing the IR-source (2), the complete chopper motor assembly (1),
together with the mounted paths and pre-amplifier, should be removed from the infrared
unit. See chapter “IR paths cleaning and replacing”.
– The chopper motor housing (1) does not necessarily need to be unscrewed.
– In order to remove the IR-source, unscrew the nuts (4) with a (5.5 mm wrench).
– Unsolder the old IR source and solder the new one.
– Before re-assembling, check the position of the IR-source (2) and, if necessary, center
the position of the source in the source housing before reassembling. See graphics
below.
CAUTION
The wire of the IR source is hard, therefore do not move it back and forth. The wires of the
source can break when bending. Rather be careful to correctly position the source with one
attempt only.
For more details see chapter “Chopper”.

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 Service

NOTICE
The position of the IR sources in their housing has to be as shown in the graphics A and B.
Correct: Wrong:

5 5 5
5

B C D

A 6 5 5
5

E F
5
33--22--11

Fig. 86: IR sources in their housing

If the position of a source is wrong, the radiation reaching the IR sensor is lower than when the
source is in the right position. It may happen that after transportation due to a strong shock that
the base lines are not in the right level due to the sources being not in the right position any
more. For correct base lines see chapter “Infrared cell adjustments”.
(Take care in case of previous IR cell models having a base line around zero volts.)
For correcting the position of bent IR sources use a thin forceps or carefully push them to the
right central position by using a thin screw driver. Take care not to bend the wires too far. They
are quite hard so that when bending back and forth they may break.
In case of changing a source, the wires must be very properly soldered because the resistance
of a source is below one Ohm.
All IR sources for all available cells in a module are connected in series.
For adjusting the IR source voltage see chapter “IR-source voltage setting”.
Pos : 7.6 /0025 Ü bersc hriften/ELTR A 1.1 Ü bersc hriften/11 C hopper ELTR A @ 6\mod_1369641924960_9.doc x @ 42267 @ 2 @ 1

5.3 Chopper
Pos : 7.7 /0010 ELTR A/0015 s er vice_i nstr uctions /CS- 2000_s er vic e/15 Ser vice_CS- 2000/1520 Modul C hopper @ 9\mod_1425543409739_9.doc x @ 74742 @ @ 1

Motor replacement:
The replacement motors are supplied with their wires already soldered on a 9-pin plug, so that
in case of replacing a chopper motor, only the two wires of the IR sources have to be soldered
on the connector.

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Service

Fig. 87: Chopper motor replacement

The chopper blade (1) is fastened to the motor (2). The chopper blade must be removed first in
order to dismount the motor (2) from the mounting plate (3)
Disassemble in the following order:
1. safety ring (4)
2. the washer(s) (5) ( there could be two )
3. the chopper blade (1)
4. the cylinder (6)
5. the spring (7)

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 Service

Fig. 88: Chopper

– Disassemble the plug (1) by removing the two screws (2).
– The cables (3) of the IR source (4) are then unsoldered from plug (1)
– Unscrew the nuts (5)
– Install the new motor (6)
– The IR source cables (3) are then soldered to the plug (1)
CAUTION
Due to the high current for the infrared cell; it is important that the soldering here is done
accurately, because two pins inside the plug (1) will be soldered together to form one group.
There are two such groups in one plug.
Each end of the IR-source cables (3) will then be soldered to each one of these groups. The
polarity is irrelevant.
– Afterwards, the chopper blade is refastened.
– Reassemble in the reverse order.
– After installing, the infrared cell should be adjusted, see chapter “Infrared base line
adjustment”.
Pos : 7.8 /0025 Ü bersc hriften/ELTR A 1.1 Ü bersc hriften/11 Leak c hec ki ng ELTR A @ 6\mod_1369642077339_9.doc x @ 42311 @ 2 @ 1

5.4 Leak checking

Pos : 7.9 /0010 ELTR A/0015 s er vice_i nstr uctions /CS- 2000_s er vic e/15 Ser vice_CS- 2000/1525 Modul Leak c hec ki ng @ 9\mod_1425543451001_9.doc x @ 74754 @ 33 @ 1

Fig. 89: Leak checking

– Set the power switch (1) to pos. 3.
– Close the furnace.
– Press and hold the button (2).
The entire system is checked for leaks.

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Service

– After pressing the button, the pressure drops on gauge (3) for about 5 seconds and then
it remains constant. Watch it for about a minute. If there is no pressure drop any more,
the complete gas system is seal so that the leakage test is successfully completed.
– Keep holding the button (2) for about one minute. Should there be a continuous pressure
drop, then release the button (2), open the furnace, press and hold the button (2) again. If
the pressure with open furnace remains stable then the leakage is in the furnace area. To
the furnace area belong also the metal dust trap (6), the tube (5) and the moisture trap (7)
underneath the metal filter, the dust filter cartridge on the front panel and the outflow
valve V1.
1. Leakage in the furnace area:
According to experience over years, leakages are almost exclusively in the furnace area. Most
common reasons in the order of probability are: (see graphic below).
- The combustion tube (12) has a crack or a hole due major accumulation of splashes from
the analyzed samples. See graphic below.
- The two small O-rings (9) sealing the top of the furnace are damaged, deformed or dusty.
- The palm grip (8) is not in the right position so that the O-ring, sealing the upper end of
the filter housing, is not properly pressed against the filter housing. Rotate to the right
position (maximum force on the O-ring).
- The O-rings (10) sealing the combustion tube are very unlikely to leak, provided that the
winged nuts fixing the furnace closure are driven normally by fingers. The use of
excessive force is not needed and not recommended.
- The O-ring (11) sealing the furnace with the closing cone is very reliable as well. Only if it
is burned by a hot crucible when taking the crucible from the pedestal, there may be a
sealing problem.
- The tube (5) can be damaged due to aging and pressure.
- The moisture trap underneath the metal filter can be not seal when the glass tube may
crack when fitting it.
- The plunger of the outflow valve V1 jams due to contamination. See chapter “Cleaning
solenoid valves” and “Wiring and gas flow diagrams”.
- The dust filter cartridge is leaking. Either one of the small O-rings sealing the cartridge
leads is not seal or one of the hexagon socket screws on the front of the supporting
fittings is not properly fixed.

9 10

8
10
12

5 11 b7-10-1

105
 Service

Fig. 90: Leak check induction furnace

– Open the furnace and check again. If the pressure decreases when checking with open
furnace, then the leakage is not in the furnace area but elsewhere in the analyzer.
Most probable reasons:
– An infrared path is not seal, for example due to an infrared window with a crack or with
not properly sealing glue.
– The lower flow meter may be not seal due to a crack.
2. Leakage outside the furnace area:
Localizing a leakage outside the furnace area with open furnace in induction
mode:
– When pressing the button (2), the gauge (3) shows a pressure drop lasting for one minute
(see details above) while the furnace is open, then localize the leakage, according to the
sequence below.
Keep the furnace opened, squeeze the following tubes tightly, while pressing and holding the
button (2). If there is no pressure drop any more when squeezing the corresponding tube, the
leakage is in the place shown in the table below:

106
Service

Fig. 91: Tubes to squeeze

107
 Service

Tube to squeeze: Leak location:

13 Exhaust valve (V9)
14 Flow meter (25)
15 CO2-Paths (26)
16 SO3-Trap (27) or oxidizing furnace
tube (28)
17 SO2-Path (29) or flow sensor (30)
18 Regulator valve (V6)
20 Bypass valve (V4), check for 24 V
DC on the coil
21 Purge valve (V3), check for 0 V DC
on the coil
22 Lance valve (V2), check for 24 V DC
on the coil

ATTENTION do not cause a short circuit while measuring, otherwise the drivers will be
destroyed. See chapter “Electronic drivers malfunctioning”.
– If the voltages on V2, V3, or V4 are wrong, then replace the electronic drivers.

Pos : 7.10 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 Sol enoi d val ves cleaning ELTR A @ 6\mod_1369643206541_9.doc x @ 42465 @ 2 @ 1

5.5 Solenoid valves cleaning

Pos : 7.11 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/15 Ser vic e_C S-2000/1530 Modul Cleani ng s olenoi d val ves @ 9\mod_1425543480470_9.doc x @ 74766 @ @ 1

1
7 2

7 2

3
3

4
4

5
5

6 6
3-13-1

Fig. 92: Solenoid valve 2/2

108
 Service

1
2

7 2

3
3

4
4

5
5

6 6
3-13-1

Fig. 93: Solenoid valve 3/2

– Turn the power switch to pos.0.
– Unplug the main power plug as well.
– Remove the connector (7).
– Unscrew the nut (1).
– Remove the coil (2) (only with the 2/2 valve).
– Unscrew counter-clockwise the hexagon screw on the plunger housing.
– Remove the plunger (5) (only with the 2/2 valve)
Caution Do not lose the spring (4)!
– With oxygen pressure or compressed air, clean the inside of the plunger housing(3), as
well as the plunger (5) and re-assemble the solenoid valve. With the furnace closed and
renewed oxygen pressure, check to ensure that the solenoid valve is sealed.

109
 Service

Pos : 7.12 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 Fl ow s ensor r epl ac ement Eltr a @ 8 \mod_1396941567775_9.doc x @ 60384 @ 2 @ 1

5.6 Flow sensor replacement

Pos : 7.13 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/15 Ser vic e_C S-2000/1535 Modul Flow sens or replac ement @ 9\mod_1425543539438_9.doc x @ 74778 @ @ 1

11
9
10

1 7

6
Fig. 94: Flow sensor(3-14)

– Set the power switch to pos. 0.

– Remove the left side panel of the analyzer’s cabinet.
– Remove the tubes (10) and (11) at the bottom-side of the infrared module.
– Remove the plastic tubes from the left hand side of the IR module.
– Remove the two plugs from the left hand side of the IR module.
– Remove the screw fixing the IR module in the analyzer. Take the infrared module out of
the analyzer.
– Remove the two tubes (5) and (6) from the flow sensor (9).
CAUTION They shouldn’t be interchanged when reassembling! In case of doubt see chapter
“IR-paths cleaning and replacing”
– Remove the two screws (7) underneath the flow sensor.
– Remove the old flow sensor (9) and install a new one.
– Reassemble the infrared rack in reverse order.
– Pay particular attention to the position of the tubes (5), (6), (10) and (11). In case of doubt
see chapter “IR-paths cleaning and replacing”
– Adjust the flow sensor. See chapter “Gas flow controller” where is written:
“Set the flow rate with P1 of the HF 42, to about 180 l/h. Observe the flow rate on the lower flow
meter of the analyzer. Wait until the value is stable.”

110
Service

Pos : 7.14 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 Gas pump replacement Eltra @ 8\mod_1396941649931_9.doc x @ 60396 @ 2 @ 1

5.7 Gas pump replacement

Pos : 7.15 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/15 Ser vic e_C S-2000/1540 Modul Gas pump r epl ac ement @ 9\mod_1425543580653_9.doc x @ 74790 @ @ 1

Fig. 95: Gas pump

– Switch off the analyzer and disconnect the mains power plug.
– Disconnect plug (1) of the pump from the socket X4 on the board (2).
– Disconnect the tubes (3) and (4) from the pump (5).
– Remove the pump from the supporting panel (6) by pulling the four rubber buffers (7).
(If necessary they can be cut).
– Reinstall a new pump in reverse order.
REMARK
For installing a new pump, the rubber buffers (7) of the new pump have to be pulled down from
underneath the supporting panel (6) by using slim pliers. If suitable pliers not available, the
board (2) can be removed by unscrewing the four nuts (8).

111
 Service

Pos : 7.16 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 T her moc ouple replac ement @ 9 \mod_1425632233953_9.doc x @ 75300 @ 2 @ 1

5.8 Thermocouple replacement

Pos : 7.17 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/15 Ser vic e_C S-2000/1545 Modul Ther moc oupl e r epl acement @ 9\mod_1425543624115_9.doc x @ 74802 @ @ 1

77450
36720
77507
36242
36288
36288 77525
75140 70380
90155 36101
36620
70380
36465
90162

70410
36242

36445

36665 36283
36914
Viton 4x1 Länge:65cm
36975 36908
zum unteren Glasanschluß

Viton 3x1 Länge:85cm

TH44/36904
TH43/36907 36799

36217
36216 36350

Fig. 96: Thermocouple replacement

– Remove the side panel of the furnace which does not carry the moisture trap. In case of
CS-2000 it is the left hand panel.
– Shift the furnace to the front for about 10 cm over the edge of the desk where it is placed
on.

– Disconnect the chinch connector of the thermocouple cable from the temperature control
board.

112
Service

Fig. 97: Chinch connector of thermocouple

– Hold the spring (36665) which is holding the thermocouple in place, to slide along the
thermocouple while pulling it down out of the furnace.

Fig. 98: Spring (36665) which is holding the thermocouple in place

Fig. 99: Pulling the thermocouple down out of the furnace

113
 Service

– If you want to check the thermocouple, see chapter “Thermocouple testing”.

– Install a new thermocouple in reverse order.
CAUTION
Take care of the spring (36665) to be in place again, preventing the thermocouple from sliding
How to set the jumpers for gas saving mode: down.
Take care to install the thermocouple with its top touching the combustion tube.
How to set This
CAUTION: the jumpers
option isfor gas saving
funtional with mode:
EPROMs
Pos : 7.18 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 Gas s aving mode ELTRA @ 6\mod_1369643654807_9.doc x @ 42575 @ 2 @ 1

5.9 Gas saving mode

CAUTION:
If theNOTICE
analyser This has option the isHffuntional with EPROMs
Pos : 7.19 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/15 Ser vic e_C S-2000/1550 Modul Gas s avi ng mode @ 9\mod_1425543657717_9.doc x @ 74814 @ @ 1

41 board:
Set the jumpers
This option is functional jumper
with EPROMS. to conect A1 with A2 on J2
If theIf the
analyser
analyzer has thehas the Hf 41 board:
HF41 board:
Set the
– jumpers
Set the jumper to jumper
connect A1 withto conect
A2 on J2 A1 with A2 on J2 TP10
TP13 TP14

TP11

TP13 TP14
TP10
TP2 TP7 TP8
TP6 TP11
HF41: J2
I C 1

A B
TP2 TP7 TP8 External A1 B1 On board
TP3 TP4 TP6 J2
TP5 HF41:
flow enable A2 J2 B2 flow enable
I C 1

On board A3 A B B3 Continuous
TP12 power adjust.
External A
A14 B4
B 1 flowboard
On
TP3 TP4
J2
flow enable A2 B2 flow enable
TP5
TP9
On board A3 B3 Continuous
TP12 power adjust. A4 B4 flow

TP1 TP9
TP15 TP16 TP17 TP18 TP19 TP20

HF41 12008
TP1

TP15 TP16 TP17 TP18 TP19 TP20

HF41 12008

Fig. 1: HF41 board jumper setting for gas saving mode

If theIf the
analyser has the Hf 42 board:
analyzer has the HF42 board:
Set the Set jumpers jumper A1 withto conect A1 with A2 on J3
If the– analyser the jumper to connect
has the HfA2 on
42J3 board:
Set the jumpers T P 1 0 jumper to conect A1 with A2 on J3
TP 1 3 TP14
TP11
J2
TP 1 3 TP14
TP6 TP10
TP 2 TP7 TTPP81 1
HF42: J3
J2 A B
TP6 External A1 B1 On board
TP 2 TJP
37 TP8 flow enable
TP4 HF42:
flow enable A2 J3 B2
TP5 TP12
A3 A B B3 Continuous
TP3 External A
A14 B1
B 4 flowboard
On
J3 flow enable A2 flow enable
TP4 TP9 B2
TP5 TP12 B3
A3 Continuous
TP3 A4 B4 flow
TP9

TP1 TP16 TP17 TP18 TP19 TP20

P1 P2 P3 HF42

TP1 TP16 TP17 TP18 TP19 TP20

Fig. 2: HF42 board jumper
P1 P2 P3
setting for gas saving mode
HF42

114
Service

Pos : 7.20 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 Gas s aving also for resis tanc e furnac e @ 9\mod_1425632688373_9.doc x @ 75312 @ 2 @ 1

5.10 Gas saving also for resistance furnace

Pos : 7.21 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/15 Ser vic e_C S-2000/1555 Modul Gas s avi ng for resis tanc e furnac e @ 9\mod_1425543689791_9.doc x @ 74826 @ @ 1

If this feature is required, the CS-2000 can be upgraded as follows. But the customer must take
care to have oxygen flow first before entering the sample into the furnace. The flow is restored
as soon as any button on the PC-keyboard is pressed. For example taking a sample weight.

If an organic sample is entered into the furnace without oxygen flow and the flow is
subsequently restored, it may lead to a very intensive ignition. Therefore, the gas saving feature
for the resistance furnace operation should only be installed after the customer’s consent to
take full responsibility for entering a sample into the furnace only after the flow is restored.
The modifications are shown in the following schematics. For full
Details, see chapter „Wiring diagrams“.
1. Install a solenoid valve No. 01160 in the analyzer’s cabinet.

Pressure
regulator

Schematic 1
PR1 0.5
1
1 .5

2
1 , 5 b a r / 2 2 p si
200l/h

bar
0 2.5

Oxygen inlet
2-4 bar
30-60 psi

230VAC
Gas saving for
resistance furnace V13
operation Pressure switch

01160 3-21-1

Fig. 100: Gas saving for resistance furnace operation

2. Connect the valve in the tube leading to the resistance furnace inlet (close one port of the
T-piece of the valve, like already done for V3).

Fig. 101: Gas saving for resistance furnace operation

3. Connect a cable to pin 49 of the 50-pin plug to the board HF-42.

115
 Service

Fig. 102: Gas saving for resistance furnace operation

4. Connect the coil of 01160 as shown in schematic
Pos : 7.22 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 F urnac e pneumatic s - additi onal s afety featur es (opti onal) ELTR A @ 6\mod_1369643455549_9.doc x @ 42531 @ 2 @ 1

5.11 Furnace pneumatics - additional safety features (optional)

Pos : 7.23 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/15 Ser vic e_C S-2000/1560 Modul Fur nac e pneumatics - addi tional safety features ( optional) @ 9\mod_1425543730507_9.doc x @ 74838 @ @ 1

The furnace doesn’t change position in case of a power failure.

Fig. 103: Furnace power failure

By adding a solenoid valve (8) and connecting the coil directly to 220V AC, the piston won’t
change position in case of a power failure. If the piston was down, it will remain down; if it was
up, it will remain up.
Pos : 7.24 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 H alog en trap - i nstalling ELTR A @ 6\mod_1369643531895_9.doc x @ 42553 @ 2 @ 1

116
Service

5.12 Halogen trap - installing

Pos : 7.25 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/15 Ser vic e_C S-2000/1565 Modul Installing a halog en trap @ 9\mod_1425543807540_9.doc x @ 74850 @ @ 1

Eltra analyzers don’t need any halogen trap when they are equipped with golden paths. However, in case a
user may insist in a halogen trap, the installation can be done as follows:

Fig. 104: Halogen trap installation

Pos : 8 /0010 ELTR A/------- Seitenumbruc h ----------- @ 6\mod_1368796429449_0.doc x @ 41468 @ @ 1

117
 Miscellaneous

Pos : 9.1 /0025 Ü bersc hriften/ELTR A 1. Ü berschriften/1 Misc ellaneous ELTRA @ 6\mod_1370352969876_9.doc x @ 42719 @ 1 @ 1

6 Miscellaneous
Pos : 9.2 /0025 Ü bersc hriften/ELTR A 1.1 Ü bersc hriften/11 Ordering numbers ELTR A @ 6\mod_1373449838307_9.doc x @ 43582 @ 2 @ 1

6.1 Ordering numbers

Pos : 9.3 /0010 ELTR A/0015 s er vice_i nstr uctions /CS- 2000_s er vic e/20 Mis cell aneous _CS- 2000/2005 M odul Or deri ng numbers @ 9\mod_1425543891671_9.doc x @ 74862 @ 33333333333 @ 1

6.1.1 Front side

Fig. 105: Front side view

118
Miscellaneous

Part No. Description

11042 Upper tube holder
11045 Lower tube holder
11062 Reagent tube
11064 Reagent tube
11091 Dust trap mechanism
11105 Metal dust filter
11110 Filter housing

11115 Furnace outlet tube

11120 Paper filter holder
11185 Paper filters

11480 Adjustable restrictor

15083 Gas flow indicator 15 l/h
15087 Gas flow indicator 300 l/h
20000 Catalyst furnace

20036 Upper tube holder

20040 Catalyst tube

20045 Lower tube holder

70150 O-ring
70210 O-ring
70230 O-ring
70320 O-ring
70350 O-ring
70370 O-ring

71036 Cleaning brush for filter

72010 Pressure gauge 2,5 bar

72020 Pressure gauge 10 bar

78017 Main power switch
78040 Button for leakage test

119
 Miscellaneous

6.1.2 Left hand side

Fig. 106: Left hand side view

120
Miscellaneous

Part No. Description

11180 Dust filter cartridge
11370- Gas flow regulating valve
2001
11390 Oxygen solenoid valve
11400 Pressure outlet solenoid valve
11415 Oxygen stop solenoid valve
11415 Lance valve
11430 Purge solenoid valve
11440 Bypass solenoid valve
11490 Pressure regulator
11492 Inlet pressure regulator
11495 Purge pressure regulator
12016 Gas flow and furnace control board HF 42
12044 Transformer
15268 Pump control board PC

15270 Gas pump

16110 Power supply board NK 31

24250 Valve V10

25190 Valve V11

24260 Valve V13

24265 Valve V12
24285 Board CS20
35336 Attenuator volume

121
 Miscellaneous

6.1.3 Right hand side

Fig. 107: Right hand side view

122
Miscellaneous

Part No. Description

11190 Exhaust muffler
11376 Fixing plate for 11822
11492 Pressure regulator
11822 Pnematic valve block
12045 Transformer
12080 Rectifier
12100 Transformer

13850 Centrifugal blower

77050 TRIAC
77135 Capacitor

123
 Miscellaneous

6.1.4 Induction furnace

Fig. 108: Induction furnace

Part No. Description

13067 Combustion coil

14009 Pneumatic cylinder for furnace lift
14021 Upper furnace lock
14026 Lower furnace lock
14030 Upper furnace plate

14035 Lower furnace plate

14090 Bearing
14100 Mounting rod

124
Miscellaneous

14110 Threaded rod

14120 Furnace cover
14130 Combustion tube
14150 Lower log
14160 Upper log
14161 Lower knurled nut
14165 Upper knurled nut
14168 Pedestal

14170 Pedestal mount

14180 Furnace closure
14185 Tray

14200 Metal tube

14210 Threaded rod
14220 Cylinder support
70380 O-ring

70390 O-ring
71010 Cleaning brush for pedestal

71031 Cleaning brush for radiation shield

76002 Washer
76003 Wing nut
76005 Knurled nut
90150 Crucibles

125
 Miscellaneous

6.1.5 Furnace cleaning

Fig. 109: Furnace cleaning mechanism

Part No. Description

14014 Complete furnace cleaning assembly unit:

14021 Upper furnace lock
14045 Cleaning brush for combustion tube
14051 Brush holder
14072 Ceramic heat shield for brush
14080 Cleaning mechanism Rod
14160 Upper log
70120 O-ring
75122 Spring
75130 Safety spring
75150 Metal tube

126
Miscellaneous

6.1.6 Oscillating circuit

Fig. 110: Oscillating circuit

Part No. Description

13060 Protection sheet

13081 Capacitor support

13090 Upper coil connector

13100 Lower coil connector

13122 Capacitor connector

13130 Capacitor connector

13140 Ground connector
13151 Anode connector and heat sink

13160 Coil heat sink

13170 Radiation shield
13175 Insulator
13210 Grid choke

127
 Miscellaneous

13220 Anode choke

13250 Chassis support
13260 High voltage filter
13270 Resistor
77140 HF-filter
77210 Oscillator tube
77322 Capacitorr
77330 Capacitor

77335 Capacitor
77333 Filter
77345 (13261; 13262; 77340; 77341; 77342) Capacitor

77350 Capacitor 100 nF

77489 Bracket
77600 Resistor
77610 Resistor

128
Miscellaneous

6.1.7 Infrared cell

Fig. 111: Infrared cell

129
 Miscellaneous

Fig. 112: Golden path

Part No. Description

05008 IR fitting

05064 Chopper motor

05175 Gas conditioner

05250 IR-housing holder

05270 Threaded rod ( advice the length )

05278 IR pre-amplifier V4
05279 IR pre-amplifier
05350 IR front panel
05465 IR path ring with window (source side)
05469 IR path cone with window (detector side)
05479 Chopperassembly, 1 channel
05488 Chopperassembly, 4 channels

05492 Chopperassembly, 3 channels

05496 Chopperassembly, 2 channels
05502-0100 Golden IR-path 100mm
05502-0120 Golden IR-path 120mm
05502-0140 Golden IR-path 140mm
05502-0170 Golden IR-path 170mm

05502-0200 Golden IR-path 200mm

05502-0275 Golden IR-path 275mm
05502-0295 Golden IR-path 295mm

05527 IR path 1-3mm

130
Miscellaneous

06730 IRC 1 channel

06731 IRC 2 channel
06732 IRC 3 channel
06733 IRC 4 channel
089330263 Cylinder screw 84 M2
15209 Flow meter
704120 O-ring

6.1.8 Chopper

Fig. 113: Chopper

Part No. Description

05020 Chopper blade

05030 Chopper blade holder

05064 Chopper motor

05048 Infrared source (emitter)

131
 Miscellaneous

05049 Double source

70280 O-ring

70330 O-ring

75120 Spring

75130 Retaining washer

75190 Washer

6.1.9 Resistance furnace

Fig. 114: Resistance furnace

Part No. Description

36101 Boat stop
36216 Combustion boat insertion stick

36217 Combustion boat removing stick

36242 Ceramic plate
36283 Heating element connector
36288 Heating element connector

132
Miscellaneous

36445 Front panel for the combustion boat

36465 Ceran plate
36620 Dust trap
36665 Spring
36799 Cooling fan
36907* Temperature control board TH 43 / TH 44
36908 Cable for TH 43 / TH 44
36914 Thermocouple

36975 LCD – display DVM 2

70380 O-ring
70410 O-ring

75140 Coil spring washer

77450 Temperature switch
77507 Ceramic tube
77525 Heating elements, 4 pcs

90155 Combustion boats

90162 Combustion tube
* Note:
36907 Temperature control board TH 43 is an older version.
36904 Temperature control board TH 44 is a newer version and fully
compatible

133
 Miscellaneous

Fig. 115: Ordering Numbers resistance furnace

Part No. Description
36720 Teflon tube
36725 Teflon tube for 36720

6.1.10 Oxygen purifying furnace

Fig. 116: Oxygen purifying furnace

Part No. Description
21010 Heather section
21120 Quartz tube
70380 O-ring

134
Miscellaneous

6.1.11 Dust trap

Optional for metal analysis

Fig. 117: Dust trap

Part No. Description

70320 O-Ring
70350 O-Ring
07370 O-Ring
11091 Dust trap mechanism

135
 Miscellaneous

11093 Filter plate

11105 Metal dust filter
11110 Filter housing
36751-
Panel
3001
36752 Filter housing support

136
Miscellaneous

Pos : 9.4 /0025 Ü bersc hriften/ELTR A 1.1 Ü bersc hriften/11 Wiring di agrams Eltra @ 8\mod_1399966125802_9.doc x @ 60786 @ 2 @ 1

6.2 Wiring diagrams

Pos : 9.5 /0010 ELTR A/0015 s er vice_i nstr uctions /CS- 2000_s er vic e/20 Mis cell aneous _CS- 2000/2010 M odul Wiring diagrams @ 9\mod_1425543931731_9.doc x @ 74874 @ 3333333 @ 1

6.2.1 Right hand side power wiring

137
 Miscellaneous

Fig:. 118: Rightt hand side power wiring

6.2.2 Left hand side power wiring

See figure „control signal

wiring“

138
Miscellaneous

Fig. 119: Left hand side power wiring

6.2.3 Valve wiring

139
 Miscellaneous

Fig. 120: Valve wiring

6.2.4 Control signal wiring

Fig. 121: Control signal wiring

140
Miscellaneous

6.2.5 IR-current supply, old version

bl blue
br brown
ge yellow
gr grey
gn green

3+16
2+15
or orange

22
21

11
17
25
rs pink
rt red
sw black

sw

sw
bl

br
bl

gr
vi
vi violett
ws white
Je nach Anzahl der IR-Zellen
According to the
number of IR cells
Heaters
200VDC as long
as the LED is on.
No voltage as long
as the LED is OFF

8 7 6 5 4 3 2 1

06255

PRI SEC
06640
10pin plug
1 2 3 4 5 6 7 8

sw sw
br bl
1 2 3 4 5 6 7 8 9 10
rt rt
rt br gn
gr
vi
gr

sw sw

rt
sw sw

Temperature
ge/gn sensor

rt
D-15 plug pin 9
ge/gn

1-14-4-1

Fig. 122: IR-current supply, old version

141
 Miscellaneous

6.2.6 IR-cell internal signals

Fig. 123: IR-current supply, new version

142
143
7kV
Miscellaneous

6.2.7 Amplitude circle

500pF 100pF
600pF

22/10W 500pF

500pF
600pF

100k/50W

2k7/100W
100nF

100nF

F11.126/36

Amplitude circle
1µF 1µF
12085
 Miscellaneous

Pos : 9.6 /0025 Ü bersc hriften/ELTR A 1.1 Ü bersc hriften/11 Gas fl ow diagrams El tra @ 8\mod_1396942447930_9.doc x @ 60504 @ 2 @ 1

6.3 Gas flow diagrams

Pos : 9.7 /0010 ELTR A/0015 s er vice_i nstr uctions /CS- 2000_s er vic e/20 Mis cell aneous _CS- 2000/2015 M odule Gas fl ow diagrams @ 9\mod_1425543960513_9.doc x @ 74886 @ 3333 @ 1

6.3.1 Gas flow for induction furnace when furnace is closed

144
Miscellaneous

6.3.2 Gas flow for induction furnace when furnace is open

145
 Miscellaneous

6.3.3 Gas flow for resistance furnace

146
Miscellaneous

6.3.4 Valve contolling

147
 Miscellaneous

Pos : 9.8 /0025 Ü bersc hriften/ELTR A 1.1 Ü bersc hriften/11 Spar e parts kits @ 7\mod_1382427709237_9.doc x @ 50008 @ 2 @ 1

6.4 Spare parts kits

Pos : 9.9 /0010 ELTR A/0015 s er vice_i nstr uctions /CS- 2000_s er vic e/20 Mis cell aneous _CS- 2000/2020 M odul Spare parts ki ts @ 9\mod_1425543989561_9.doc x @ 74898 @ 33 @ 1

6.4.1 Common spare parts kti for all analysers

quantity
Number

description
Part

05048 Infrared source (emitter) 1

05060 Reflector 1
05064 Chopper motor 1
05067 IR path for high carbon 1
05068 IR path for sulphur 1
05150 IR path connector with window source side 1
05160 IR path connector with window detector side 1
05260 IR path tube (80 to 320 mm) 1
05278 Infrared preamplifier for 3 pins 1
05279 Infrared preamplifier for 4 pins
06032 Infrared detector with CO2 filter 1
06034 Infrared detector with SO2 filter 1
06058 IR Temperature control board TH61 1
06421 Infrared power supply assembly IR13 1
06630 IR Temperature control board TH62 1
06733 IRC board for 4 channels 1
11035 Cooling fan 1
11062 Reagent tubes 160 x 16mm 2
11064 Reagent tubes 280mm x 16mm 2
11380 Pneumatic valve 1
11390 Oxygen solenoid valve 1
11408 Pressure switch 1
11480 Adjustable flow restrictor 1
11492 Inlet pressure regulator 1
15037 IR Temperature regulation board NR32 1
15063 Gasflow sensor 300 l/h 1
15083 Gas flow meter 15 l/h 1
15087 Gasflow meter 300 l/h 1

148
Miscellaneous

15095 Gasflow meter 600 l/h 1

15098 Gas flow control board FC 21 1
16110 Power supply board NK 32 1
16114 Power supply 24V 5A
18173 PC-cable 1
18454 Balance cable 1
21120 Quartz tube for purification furnace 1
35310 Pressure switch 1
70120 O-ring 3.4 x 1.9 VT furnace cleaning rods (CS 800) 1
and for furnace platform
70150 O-ring 6 x 2.5 VT 1
70210 O-ring 8 x 3.5 VT for catalyst tube (CS 800) 1
and for reagent tube (OH/ON 900)
70230 O-ring 9 x 3 VT for reagent tubes and dust filter 1
70280 O-ring 18 x 2 VT for chopper motor 2
70285 O-ring 19 x 3 VT for furnace ON/OH 900 (top) 1
70320 O-ring 20 x 5 VT for dust filter (CS 800) 1
for furnace glass tube (CS 500)
For reagent tube (HTF540) 2
70330 O-ring 21 x 2 VT for infrared source 6
70350 O-ring 29 x 5 VT for dust filter (CS 800) 1
70370 O ring 34 x 3 VT for dust filter (CS 800) 1
70380 O-ring 35 x 5 VT for combustion tube (CS 800) 2
and for furnace internal (CS 500)
70390 O-ring 38 x 5 VT for furnace (CS 800) 1
70405 O-ring 47.2x 5.7 VT for furnace closure ON/OH 1
70410 O-ring 48 x 3 VT for furnace internal (CS 500) 1
70415 O-ring 62 x 3 VT for furnace ON/OH 900 (centre) 1
70425 O-ring 90 x 2.5 VT for furnace ON/OH (bottom) 1
72010 Pressure gauge 2,5 bar (37.5 psi) 1
72020 Gauge 10 bar/140 psi 1
73020 Tube transparent 5m
73030 Tube black id = 4 od = 5 5m
73040 Tube black id = 6 od = 9 1m
75120 Spring 1
75130 Retaining washer 1

149
 Miscellaneous

75190 Washer 1
77140 HF-filter 250 V 1
78010 Mains power switch 1
90290 Copper oxide 100g
92610 Tube of grease 1

6.4.2 Spare Parts kit for CS2000 (including spare parts kits CS800 and HTF540)

quantity
Number

description
Part

05390 Heatsink 1
09090 Reagent tube 1
11105 Metal dust filter 1
11115 Plastic tube 75mm
11120 Paper filter holder 1
11180 Dust filter cartridge 1
11185 Paper filters 10
11370- Gasflow regulating valve 1
2001
11400 Pressure outlet solenoid valve 1
11410 Oxygen stop solenoid valve 1
11430 Purge solenoid valve 1
11440 Bypass solenoid valve 1
11470 One way valve 1
11490 Pressure regulator 1
12005 Gasflow and furnace control board HF3 1
12016 Gasflow and furnace control board HF42 1
12080 Rectifier 1
13067 Combustion coil 1
13175 Insulator 1
13260 High voltage filter 1
13262 Capacitor 700 pF/40KV 1
13270 Resistor 1
14045 Cleaning brush for combustion tube 1
14072 Ceramic heat shield for brush 1

150
Miscellaneous

14080 Cleaning mechanism rod 1

14130 Combustion tube l=145 id=32 od=36 mm 2
14168 Pedestal 1
15208 Gas flow sensor 1
20000 Catalyst furnace 1
20040 Catalyst tube 200 x 16mm 1
35070 Ventilator frame 1
35355 Lower reagent tube connector 1
36101 Boat stop 1
36216 Combustion boat insertion stick 1
36217 Combustion boat removing stick 1
36242 Ceramic plate 2
36283 Heating element connector 1
36288 Heating element connector 1
36445 Front panel for the combustion boat 1
36465 Ceran plate 1
36620 Dust trap 1
36665 Spring 1
36700 Upper reagent tube connector 1
36720 Teflon tube 1
36725 Teflon tube for 36720 1
36798 Transformer 1
36799 Cooling fan 1
* 36907 Temperature control board TH 43 / TH 44 1
36908 Cable for TH 43 / TH 44 1
36914 Thermocouple 1
36975 LCD – display DVM 2 1
75122 Spring 1
75130 Safety ring 1
75140 Coil spring washer 1
77050 Triac 1
77135 Capacitor 2µF for blower (at the generator unit) 1
77210 Oscillator tube 1
77322 Capacitor 100 pF/30KVA 1
77333 10V/10A filter 2

151
 Miscellaneous

77350 Capacitor 1µF/50V 2

77450 Temperature switch 1
77507 Ceramic tube 1/8
77525 Heating elements 4
77600 Grid resistor 1
77610 Resistor 1
80925 Sets of fuses 3
88400- Gas pump VP-6035S
0283
90155 Combustion boats
90162 Combustion tube 1
90220 Tungsten 2500g
90260 Iron chips 908g
92400 Steel standards (advice %C and %S) 100g
*NOTE:
36907 Temperatur control board TH43 is an older version 1
36904 Temperatur control board TH43 is a newer version and fully 1
compatible

Pos : 9.10 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften11 Mai ntenanc e (2015- 12- 03 07:57:57) @ 7\mod_1383121708299_9.doc x @ 50516 @ 2 @ 1

6.5 Maintenance
Pos : 9.11 /0010 ELTR A/0015 s ervic e_ins truc tions/C S-2000_s er vice/20 Misc ellaneous_CS-2000/2025 Modul Mai ntenanc e C S-2000 @ 9\mod_1425544021010_9.doc x @ 74910 @ @ 1

– Is the furnace closure cone still properly fixed? See chapter “Closing cone”.
– Check whether the imprint of all the O-rings is at least of 2 mm thickness.
– Is the inlet pressure regulator set on 1,5 bar ( 22.5 psi )? See chapter “Pressure
regulators”.
– Is the other two pressure regulator set on 0,35 bar ( 5 psi )?
– Check for leaks. See chapter “Leak checking”.
– Is the gas flow rate correct? See chapter “Gas flow controller”.
– Pressure switch: change over at about 1 bar? Measure across the leads. See chapter
“No or low oxygen pressure”.
– Does the thermostatic control work correctly? See chapter “IR thermostatic control”.
– Check the infrared baseline. See chapter “Infrared base line”.
– Check whether all the screws of the generator housing are tight.
– Check whether all four „high voltage“ stickers are still in place.
– Check whether all plugs in the analyzer are properly plugged in.
– Check whether all the warning labels are still attached to the side-panels.
– Calibration of all measuring ranges.

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152
Approved methodologies to which Eltra instruments conform

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7 Approved methodologies to which Eltra instruments conform

Pos : 11.2 /0025 Übersc hriften/ELTRA 1.1 Übersc hriften/11 Inorganic ma teri als (Metals) @ 7\mod_1388733469039_9.doc x @ 54002 @ 2 @ 1

7.1 Inorganic materials (Metals)

Pos : 11.3 /0010 ELTR A/0099 Geräteneutr al/Standar d M odule El tra/9903 Standard M odul Inorganic materi als (Nor m) _Neu @ 7\mod_1388733026204_9.doc x @ 53979 @ @ 1

Norm Elements Materials Instruments

CS-800
DIN EN ISO 9556:2002-04 C Steel and Iron
CS-2000
ISO 4935:1989 CS-800
S Steel and Iron
DIN EN 24935:1992-07 CS-2000
CS-800
CS-2000
ASTM E 1019:2011 C,N,O,S Steel, Iron, Nickel / Cobalt Alloys ON-900
OH-900
ONH-2000
CS-800
CS-2000
ASTM E 1587:2010 C,N,O,S Refined Nickel ON-900
OH-900
ONH-2000
ON-900
ASTM E 1409:2013 N,O Titanium and Titanium Alloys OH-900
ONH-2000
ON-900
ASTM E 1569:2009 O Tantalum OH-900
ONH-2000
OH-900
ASTM E 1447:2009 H Titanium and Titanium Alloys
ONH-2000
CS-580
Metal Bearing Ores and Related
ASTM E1915 - 13 C,S CS-800
Materials (i.e. tailings, waste rock)
CS-2000
CS-800
UOP703 - 09 C Catalysts
CS-2000
CS-800
ASTM E 1941:2010 C Refractory and Reactive Metals
CS-2000
ASTM E2575 - 08 O Copper ONH
ONH 2000
DIN EN ISO 15351 N Steel
ON900
ISO 22963 O Titan ONH serie
ISO 17053 O Steel/Iron ONH serie

153
 Approved methodologies to which Eltra instruments conform

CS 800
DIN EN ISO 15349-2 C Steel
CS 2000
CS 800
ISO 13902 S Steel/Iron
CS 2000
CS 800
ISO 4689-3 S Iron ore
CS 2000
CS 800
ISO 7524 C Nickel
CS 2000
CS 800
DIN EN 27526 S Nickel
CS 2000
CS 800
DIN EN ISO 15350 C,S Steel / Iron
CS 2000
DIN EN ISO 3690 H Steel H 500
ON 900
DIN EN ISO 10720 N Steel
ONH 2000
CS 800
ISO 10719 C Steel
CS 2000

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7.2 Organic materials (Oil, Coal, foodstuffs)

Pos : 11.5 /0010 ELTR A/0099 Geräteneutr al/Standar d M odule El tra/9904 Standard M odul Organic materi als (Nor m)_N eu @ 7 \mod_1388672707117_9.doc x @ 53919 @ @ 1

Norm Elements Materials Instruments

CS-580
ASTM D 1552:2008 S Oil and Petrolium Products
CS-2000
CS-580
ASTM D 4239:2013; S Coal and Coke
CS-2000
CS-580
ASTM D 5016:2008 S Coal and Coke Ash
CS-2000
CS-580
ASTM D 1619:2011 S Carbon Black
CS-2000
CS-580
DIN EN 13137:2001-12 C Waste
CS-2000
CS-580
DIN ISO 10694:1996-08 C Soil samples
CS-2000
TGA
Loss On Ignition
ASTM D 7348:2013 Combustion Residues Auto TGA
(LOI)
Thermo Chain
CS 580
ISO 15178 S Soil CS 800
CS 2000

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154
Disposal

Pos : 13.1 /0025 Übersc hriften/1. Übersc hriften/1 Ents orgung @ 0\mod_1234258746831_9.doc x @ 6173 @ 1 @ 1

8 Disposal
Pos : 13.2 /0005 RET SCH/0000 Ger äteneutral/M odul eEnts orgung General (2015-10-21 11:05:55) @ 0\mod_1234269404935_9.doc x @ 6180 @ @ 1

Please observe the respective statutory requirements with respect to disposal.

Information on disposal of electrical and electronic machines in the European Community.
Within the European Community the disposal of electrically operated devices is regulated by
national provisions that are based on the EU Directive 2002/96/EC on Waste Electrical and
Electronic Equipment (WEEE).
Accordingly, all machines supplied after 13.08.2005 in the business-to-business area to which
this product is classified, may no longer be disposed of with municipal or household waste. To
document this they have the following label:

Fig. 3: Disposal label

Since the disposal regulations within the EU may differ from country to country we would
request you to consult your supplier.

=== Ende der Liste für T extmar ke Inhalt ===

155
 Index

9 Index

% Checking the generator tube ............................. 21

%IR .....................................................................39 Checking the primary voltage on the high voltage
0 transformer ..................................................... 23
0.0000% ..............................................................37 Chinch connector of thermocouple .................. 113
00.0ppm ..............................................................37 Chopper ........................................... 102, 104, 131
1 Chopper motor doesn‘t rotate ............................ 65
Chopper motor replacement ............................ 103
1-4-4....................................................................33
circuit board HF 42 ............................................. 52
1-4-5S .................................................................33
Cleaning brush ................................................... 99
A
Closing cone ...................................................... 93
a restricted oxygen supply ..................................14
Closing cone adjustment ................................... 92
Activating Inputs and Averages Window ............12
Combustion tube breaks frequently ................... 48
Adjusting correct furnace movement ..................90
Combustion tube induction furnace ................... 48
Adjustments ........................................................70
Combustion tube resistance furnace ................. 48
Air vent holes of the furnace ...............................21
Combustion without starting analysis ................ 50
Analysis cicle stops too early ..............................64
Command to start the generator is not received 19
Analysis takes too long .......................................32
configuration window icon .................................. 19
Analysis time .......................................................32
Contaminated or corroded solenoid valve ......... 16
Analyzing ............................................................19
Control signal wiring ......................................... 140
Approved methodologies to which Eltra
instruments conform......................................153 Copper oxide bad quality ................................... 67
Averages .............................................................12 Copper oxide has a bad quality ......................... 67
B Crucible or boat cracks or melts ........................ 52
D
Bad combustion ............................................27, 29
base line .............................................................75 Development of dust when closing the furnace . 35
Base line adjustments.........................................80 deviation value too low....................................... 47
Base line button ..................................................12 Deviation value too low ...................................... 47
Base line icon .....................................................19 Device state ....................................................... 39
Base line window ................................................12 device state window icon ................................... 19
Bent plastic tube of oxygen supply .....................16 Diagram Generator current vs. setpoint............. 95
Blocked chemicals ........................................14, 15 Diagram Generator power vs. setpoint .............. 95
Blocked dust filter cartridge ................................16 Discharging the oscillator ..................................... 8
Blocked fittings ....................................................17 Disposal ........................................................... 155
Blocked flow sensor assembly ...........................17 Disposal label ................................................... 155
Blocked furnace outlet ..................................14, 15 Draft 11001-9002 (1-15-3-1S) ........................... 42
Blocked lance hole over the crucible ..................15 Draft high frequency generator (1-4-4 + 1-4-5S)
.................................................................. 25, 33
Blocked metal dust filter......................................14
Drift too high ....................................................... 48
Blocked paper filters .....................................14, 15
Drift too large ..................................................... 82
Breaker turns off .................................................39
Dust or soot from the resistance furnace ........... 63
Breaker turns off at the end of the analysis ........43
Dust trap .......................................................... 135
bypass valves .....................................................27
Dustcloud when opening the furnace ................ 44
C
E
C 39
Electronic problem Induction furnace operation 17
Capacitor and insulator .......................................43
Electronic problem resistance furnace operation18
Check base lines ................................................12
Electronic reasons for flow problems ................. 17

156
Index

Erratic results ......................................................35 HF-42 ................................................................. 18

exceptionally high noise......................................48 HF42 board ...................................................... 114
Explanations of the safety instructions ................. 7 jumper setting - gas saving mode ................ 114
F Hi C .................................................................... 80
Faults ..................................................................12 Hi S .................................................................... 80
Faulty oxygen regulator ......................................16 High carbon results are erratic ........................... 36
Flow sensor replacement..................................110 High frequency generator (1-4-4 + 1-4-5S) ....... 33
Flow sensor(3-14) .............................................110 Higher sensitivity (gain)...................................... 85
Flow stops during analysis..................................68 I
Fluctuating gas flow ............................................13 Induction furnace ............................................. 124
Fluctuating gas flow fault reasons ......................14 Induction generator control ................................ 94
Front panel .........................................................45 Infrared base line adjustments ........................... 75
Front CS-2000 ....................................................63 Infrared cell ...................................................... 129
Front of CS-2000 ................................................54 Infrared cell modification - general information .. 75
Front side ............................................................91 Infrared cell temperature regulation ................... 84
Front side view ..................................................118 Infrared electronics .......................................... 100
Fumes in the resistance furnace ........................61 Infrared source replacement ............................ 101
Furnace cleaning mechanism ...........................126 Inorganic materials (Metals) ............................ 153
Furnace pneumatics - additional safety features Inputs ................................................................. 12
(optional) .......................................................116 Inputs and Averages Window ............................ 12
Furnace power failure .......................................116 Instability reasons .............................................. 47
Furnace regulation board TH 43/TH 44 ..............97 Integration delay ................................................ 19
Furnace temperature problem ............................60 IR cell temperature control ................................. 84
G IR signal
Gas flow controller ..............................................70 does not come down to the base line at the end
of analysis ................................................... 66
Gas flow controller adjustment and jumper
settings ............................................................70 IR source voltage setting ................................... 83
Gas flow diagrams ............................................144 IR sources in their housing .............................. 102
Gas flow regulation .......................................72, 74 IR -temperature .................................................. 39
Gas pump .........................................................111 IRC 1.3 ............................................................... 77
Gas pump replacement ....................................111 IRC 1.4 ............................................................. 100
Gas pump/ Attenuator.........................................57 IRC1.x ................................................................ 80
Gas saving also for resistance furnace ............115 IRC-1.x ............................................................... 48
Gas saving for resistance furnace operation ... 115, IR-cell board IRC1.x sections assignment ......... 80
116 IR-Cell general test points ................................. 78
Gas saving mode ..............................................114 IR-cell temperature control is out of range......... 39
Gas-flow diagram - furnace closed .....................35 IR-current supply, new version ........................ 142
Golden IR-Path ...................................................99 IR-current supply, old version .......................... 141
Golden path ......................................................130 IR-paths, cleaning and replacing ....................... 99
Ground connection of the tube’s cathode is J
interrupted .......................................................25 J2 ....................................................................... 94
H Jumper position for continuous flow .................. 18
Halogen trap - installing ....................................117 Jumper position for gas saving mode ................ 18
Halogen trap installation ...................................117 jumper setting .................................................. 114
Heating elements ................................................29 Jumper settings .................................................. 71
HF 42 ..................................................................94 Jumper settings HF 42 ....................................... 94
HF41 board .......................................................114 L
jumper setting - gas saving mode .............114
Latch-up effect ................................................... 43
HF42 ...................................................................20

157
 Index

Leak check induction furnace ...........................106 Outflow valve ..................................................... 47

Leak checking ...................................................104 Outflow valve does not close ............................. 47
Leakage in the furnace area .............................105 Outlet tap not properly open .............................. 14
Leakage outside the furnace area ....................106 Outlet tap of the oxygen bottle is not properly
Left hand side power wiring ..............................139 open................................................................ 16
Left hand side view ...........................................120 Outputs (base lines about 8VDC. For golden
paths adjust 6VDC) ........................................ 79
Linearity correction .............................................93
Oxygen
Lo C ....................................................................80
no flow ............................................................ 38
Lo S.....................................................................80
Oxygen gauge .................................................... 53
LoC preamp ........................................................80
Oxygen pressure falls when the furnace opens 49
Long C path ........................................................80
Oxygen pressure goes up very slowly ............... 52
Long S path ........................................................80
Oxygen purifying furnace ................................. 134
Loud buzzing sound when the generator turns on
Oxygen regulator ......................................... 53, 90
........................................................................26
Oxygen solenoid valve (V5) may be defective .. 46
Low carbon sample too long combustion of a very
........................................................................66 Oxygen supply is interchanged with the
compressed air supply ................................... 16
Lower sulphur range ...........................................85
P
M
Path window broken........................................... 67
Maintenance .....................................................152
Path window not sealed ..................................... 67
Measurements ....................................................22
Pin 7 ................................................................... 20
Measurements - high voltage transformer ..........23
Pneumatic parts ................................................. 87
Measurements on TP9 .......................................20
Pneumatics ........................................................ 86
Measuring the voltage ........................................29
Pneumatics (photo) ............................................ 31
microcontroller board TP13 ................................51
Pneumatics (schematically) ............................... 30
microcontroller board TP9 ..................................51
Pneumatics adjusting for correct furnace
Miscellaneous ...................................................118
movement ....................................................... 88
Moderate or mild injury ......................................... 7
Pneumatics parts ............................................... 86
Mortal injury .......................................................... 7
power supply fluctuates ..................................... 48
N
Power switch ...................................................... 50
Negative drift after start ......................................59 PR1 .................................................................... 90
New flow sensor .................................................75 PR2 .................................................................... 92
No combustion ..............................................18, 28 Preamplifier ........................................................ 80
No combustion induction furnace operation .......18 Pre-purging ........................................................ 19
No cumbustion resistance furnace operatio .......27 Pressure gauge .................................................. 49
No flow ................................................................19 Pressure regulation ............................................ 90
No or low oxygen pressure .................................45 Programm screenshot (graph example 1) ......... 66
No oxygen pressure ............................................18 Programm screenshot (graph example 2) ......... 67
Noise reasons .....................................................48 Programm screenshot (graph example 3) ......... 68
Noise too high .....................................................48 Programm screenshot (graph example 4) ......... 69
Notes on service instructions ................................ 7 property damage .................................................. 7
O Pump voltage attenuator cotton wool dirty......... 57
Old flow sensor ...................................................75 Pump voltage blockage lower connection glas
Ordering numbers .............................................118 tube................................................................. 56
Ordering Numbers resistance furnace ..............134 Pump voltage furnace ........................................ 58
Organic materials (Oil, Coal, foodstuffs)...........154 Pump voltage IR-cell is blocked......................... 57
Oscillating circuit ...............................................127 Pump voltage leakage ....................................... 57
Oscillator .............................................................64 Pump voltage too high ....................................... 54
Oscillator blower cleaning ...................................64 Pump voltage too high faults ............................. 56

158
Index

R Test points (general)

Reason for instability ..........................................47 IR-Cell ............................................................ 78
Rectifier ...............................................................24 Test points IR-ranges......................................... 79
Rectifier could be faulty ......................................24 TH 43 ........................................................... 96, 97
Removing the IRC-board ..................................100 TH 44 ........................................................... 96, 97
Resistance furnace ...............................58, 96, 132 The filament of the generator tube doesn’t glow 21
Resistance furnace completly cold or too hot .....60 The furnace does not close ............................... 30
Resistance furnace doesn`t reach full temperature The results are always 0.0000% or 00.0ppm: ... 37
........................................................................62 The tubing ........................................................ 100
Resistance furnace takes too long to warm up ..58 Thermocouple replacement ............................. 112
Right hand side view.........................................122 Thermocouple testing ........................................ 98
Rightt hand side power wiring ..........................138 Thermostatic control reports 0% or 100% power39
S Too high noise ................................................... 48
Safety warnings .................................................... 7 Too low deviation value ..................................... 47
Sample burns but no peak on the screen ...........65 Too low oxygen pressure ............................. 14, 16
serious injury ......................................................... 7 TP13................................................................... 20
Service ................................................................99 TP13 test point ................................................... 20
Setting the furnace reulation card .......................96 TP9..................................................................... 20
Short C path ........................................................80 Transformer ....................................................... 40
Short S path ........................................................80 TRIAC ................................................................ 43
Single C path ......................................................80 Triac malfunctioning ........................................... 43
Single carbon range............................................80 Trimmer .............................................................. 85
Single S path ......................................................80 Tubes to squeeze ............................................ 107
Single sulfur range ..............................................80 U
Socket top view ...................................................26 Unstable resistance furnace temperatur ............ 62
Solenoid valve 2/2 ...........................................108 V
Solenoid valves cleaning ..................................108 Valve wiring ...................................................... 140
Source voltage Valves .......................................................... 44, 49
rducing.............................................................81 Vibrations ........................................................... 64
Spare parts kits .................................................148 Vibrations in induction furnace mode................. 64
Spring (36665) which is holding the thermocouple Voltage
in place ..........................................................113 base-line is too high ....................................... 81
Sulfur results are not repeatable ........................36 Higher than 9.5V ............................................ 81
Supply voltages and thermostatic control circuit 78 Voltage across the heating elements ................. 59
Supply voltages for IR signal processing circuit 78, Voltage on the outflow valve is constantly at 24 V
79 ........................................................................ 47
T W
Temperature control resistance furnace .............28 Waiting for stability ....................................... 19, 47
Terminal of the solenoid coil ...............................46 Wiring diagrams ............................................... 137

159
Copyright
© Copyright by
Eltra GmbH
Retsch-Allee 1-5
D-42781 Haan
Germany