RAAS Troubleshooting Guide. Confirm that the power switch to the unit is in the on position.

Transcription

1 RAAS Troubleshooting Guide 1 Power Out Confirm that the power switch to the unit is in the on position. - The power switch is located to the lower left on the interior of the cabinet. It is a large black rocker type switch. A red color at on end of the switch should be clearly visible when the unit is turned on. Refer to Andersen Instruments RAAS operators manual, Figure on page 3-16.(see photo # 1) Photo # 1 Confirm that the unit is configured for the proper voltage. - Locate the voltage selection switch directly above the power switch. This switch must be on 115 volts. Refer to Andersen Instruments RAAS operators manual, Figure on page 3-16.(see photo # 1) Confirm that the power cord is properly plugged into the outlet. -The end of the power wire should have a three-prong plug. Does the plug have all three prongs? 1

2 Confirm that there is power to the outlet. -Use an outlet tester to determine if there is proper voltage. The two yellow lights on the tester should be lit for proper voltage. If any other combinations of lights are on, call your supervisor for assistance. -If the unit is connected to the outlet via an extension cord, check to insure that the extension cord is conduct power. Use an outlet tester to determine if there is proper voltage. See the description above for use of the voltage tester. Confirm that the circuit breaker is in the on position. - Locate the circuit breaker that controls the electrical circuit the sampler is using. This may or may not be labeled on the door of the circuit box. - If the breaker is in the off position, reset the breaker and turn it to the on position. If the breaker will not stay in the on position, there is a short circuit in the line. Call your supervisor for assistance. If the circuit breaker is in the on position, check wire connections from the sampler power supply to the printed circuit boards. If all of the connections appear to OK, replace the power supply printed circuit board (see the procedure for replacing the power supply board). 2 Automation Control Failures Automation control refers to the operation of the filter stage (vertical motion) and the filter cassette tray (horizontal motion). The monitor screen indicates that there is a Failure of the Automation Controller This message only tells the operator that there has been a failure somewhere in the automation control. It will not lead the operator to the specific cause of the failure. It is possible to have a failure of a component in the automation control and not have an error message generated. The following section describes possible automation control problems and their solutions. - If the monitor screen is showing a message that says, Failure Automation Controller. Select Cancel on the 2

3 keypad. This should allow the sampler to begin initialization. - Observe the initialization process to determine which motion is affected. See Technical bulletin # 6 for detailed information on the initialization process. If the operator receives the error message during the vertical phase, begin looking for stage control problems. If the error message is generated while the filter stage should be rotating, look for rotational problems. Filter Stage will not move up or down. During initialization or loading and unloading, the filter stage will not go through its full range of motion. Filter stage begins to move and then suddenly stops. - Turn sampler off and on. - Confirm that the locking collar to the vertical drive motor is tight and is positioned correctly (see technical bulletin # 8 for more details)(see photo # 2). - Inspect the toothed belt. Replace if worn. - Inspect the orange o-ring connecting the filter drive gear to the vertical encoder. Replace if worn.(see photo # 3) - Inspect wiring connection of vertical encoder to the automation control board. - Reboot the sampler. Before rebooting, download the five minute averages to a laptop computer (refer to the download procedure provided). - Replace the vertical encoder (see the section 12) Replace the automation control board (refer to technical bulletin # 19 for specific details)(see photo # 4 & 5). Photo # 2 Photo # 3 3

4 Photo 4 Photo # 5 Filter stage will not completely seat the filter cassette against the impactor housing. - Turn the power to the sampler off and on. Does the stage fully seat the filter into the impactor? - Reboot the sampler. Before rebooting the sampler, download the five-minute averages from the sampler s memory. - After rebooting, observe the filter stage as it raises toward the impactor. When the stage reaches the filter tray, it should slow down and push the filter completely into the impactor and stop.(see photo # 6) - If the stage does not slow its motion when it reaches the filter stage, replace the vertical encoder. - Check the condition of vertical drive motor. The motor shaft should be perpendicular to the base of the sampler. If it appears to be bent, replace the motor.(see photo # 7). Photo # 6 Photo # 7 4

5 Filter stage lowers to the bottom of the stage assembly and does not stop. - Turn the power off and on. Observe the initialization process to determine if the problem has been resolved. - If the problem persists, check the wire connection for the magnetic reed switch at the base of the filter stage assembly. There is a connection to the automation control board. (see photo # 8) - Disconnect the switch wire from the control board. - Place a magnet on top of the reed switch. - Using a multi-purpose tester, check if the circuit is closed. If the circuit is open replace the magnet attached to the filter stage. - Replace the switch. - If the circuit is closed, replace the automation control board (refer to technical bulletin # 19)(see photo # 9). Photo # 8 Photo # 9 5

6 Filter stage raises the filter into the impactor and the vertical drive motor continues to run. Toothed belt pops on vertical drive gear pulley. - Turn sampler off and on. - Inspect the orange o-ring between filter stage drive wheel and vertical encoder. Replace if necessary. - Inspect toothed belt for wear. Replace if necessary. Inspect the vertical drive gear. (refer to technical bulletin # 8 for additional information)(see photo # 10). Replace vertical encoder. Refer to part replacement procedure for vertical encoder(see photo # 11) - Replace automation control board. (refer to technical bulletin # 19 for additional information)(see photo #12 & 13). Photo # 10 Photo # 11 Photo # 12 Photo #13 6

7 Filter tray rotates for 2.5 seconds and then stops. - Check the locking collar on the rotational drive pulley. Make sure the collar is tight (see photo #10). - Check the condition of o-rings on the rotational drive pulley. Replace if worn, cracked or shredded. - Check the condition of o-ring from rotational drive pulley to rotational drive motor. Replace the o-ring if necessary (see photo # 14). - Check the position of the magnetic sensor. Determine if the sensor is touching the filter tray. Make sure the sensor is tightly secured (see photo # 15). - Determine if the filter tray is touching the filter tray guide bars. The filter tray should not touch the bars. If the filter tray is touching, check the adjustment of the filter tray drive roller. See Technical Bulletin # 5 for specific instructions. - Check wire connections from the rotational encoder to the automation control board. - Replace the rotational encoder (refer to technical bulletin # 10 for instructions for replacing the encoder) (see photo # 16). - Replace the automation control board (see photos # 12 & 13). - Replace the cable connecting the automation control board to the rotational encoder. Photo 14 7

8 Photo # 15 Photo # 16 Filter stage drive belt pops while filter stage is lowered or raised. - Replace the toothed belt. - Adjust the vertical drive gear. See Technical Bulletin # 8 for specific instructions (see photo # 10). - Inspect vertical drive motor shaft. The shaft should be perpendicular to the base of the sampler cabinet. If the shaft appears to be bent, replace the motor. - **Never use vacuum grease on the toothed belt. This is not a fix and can be a possible source of contamination. Torn or ground up orange o-rings on filter tray pulley. - This situation indicates that the filter tray has been jammed and cannot properly rotate. - Check filter tray to find the cause of the jamb. It is most likely a filter cassette that has popped open under the impactor. This prevents the filter tray from rotating. - Tighten locking collar to drive pulley. - Replace the two orange o-rings on the drive pulley (see photo # 14). - The o-rings on the rotational encoder pulley may appear to ground up or shredded. They are probably in good shape. What you are seeing is shredded o-ring from the drive pulley that has deposited on the rotational pulley. This deposit must be removed before checking condition of rotational encoder pulley o-rings. Replace o-rings if necessary. 8

9 Filter tray will not stop at the programmed position. - Turn sampler power off and on. - Check the condition of the magnets in the filter tray. Insure that all of the magnets are in place. If a magnet has fallen out, do not attempt to reinstall the magnet. Replace the entire filter tray. The old tray should be sent back to the vendor. There should be 9 magnets. See Technical Bulletin # 9 for specific instructions. - Check position of magnetic sensor (see photo # 15). Adjust sensor as close to the filter tray as possible. Be certain that the sensor does not touch the filter tray. Check the wire connection of the sensor to the automation control board. - Initialize the sampler. Listen to the sound of the tray as it rotates. The motor should shift speeds as each magnet passes under the magnet sensor. Listen to the sound of the motor as the filter tray rotates. From position # 1, there should be 9 motor speed changes. When it approaches position # 1, the tray should hesitate twice because there are two magnets at this location. - Program sampler to load position eight. If this loads correctly the magnet sensor is working properly. - Check the condition of the orange o-ring between the rotational encoder and the tray pulley. Does it appear to be worn, cracked, broken, missing? Replace the o-ring. - Check the locking collar securing the rotational encoder pulley at the filter tray. The pulley can be loose and not turn properly. This situation will not allow the rotational encoder to turn and will not detect the position of the filter tray. - Check the wire connections from the rotational encoder to the automation control board. Look for loose connections or broken wires. - Replace the rotational encoder. See technical bulletin # 10 for specific instructions (see photo # 16). - Replace the automation control board (sequential board) (see photos # 12 & 13). 9

10 3 Leak check failures Sampler flow should be below 0.08 L/M to pass the leak check. In cold weather, the pump needs to warm up to operating temp before attempting a leak check. Run verify flow a few minutes before attempting leak check. Perform an external and internal leak check to determine which side of the filter stage the leak is on. - Check o-rings for cracks, breaks and wear marks. - Insure that air tubing fits tightly onto all tubing fittings. - Insure that tubing fittings are threaded tightly and the sealing tape is in good condition. - Two common sources of air leaks are the o-rings on the filter stage and the air fitting on the rear of the filter stage (see photo # 17). Photo # 17 10

11 Pump appears to bog down, during a leak check. Level of sound pump generates decreases. Pump power decreases in percent power and pump finally stops. - In cold weather, the pump needs to warm up to operating temp before attempting a leak check. Run verify flow a few minutes before attempting leak check. - Check to insure the inline fuse to the pump is good (see photo # 18). If the pump was running during the first part of the leak check, the in-line fuse is suspect. As the pump decreases in power, the load on the circuit increases. The in-line burns up to protect the circuits in the power supply. - Pump bypass solenoid valve may not be opening to allow a flow of air to reach the pump (see photos # 19 & 20). Place a finger on the inlet of the solenoid to determine if air is entering the valve. If it has been determined that air is not entering the valve, replace the valve. - Recalibrate sampler. In Line Fuse Photo # 18 Photo # 19 Pump/ DGM Assembly Photo # 20 11

12 After a leak check is completed, a window appears indicating that the unit is depressurizing and to please wait. The window never disappears until you select cancel and manually depressurize via the leak check adapter. -The leak check solenoid valve could have failed to open so the pressure is not relieved. Before selecting the cancel key, open the leak check adapter to relieve the pressure. If after the pressure has been released, the unit begins to operate normally, the solenoid valve maybe suspect. - Replace the leak check solenoid valve. - A bad calibration of the meter drop pressure sensor may be the cause of this problem. Calibrate temperatures, barometric pressure and meter drop pressure. - If these parameters cannot be successfully calibrated, replace the DGM printed circuit board and recalibrate temperatures, barometric pressure and meter drop ( see photo # 21). - If calibration is successful or the DGM board has been replaced, perform a leak check to determine if the problem has been resolved. After the problem has been resolved, a full calibration of the sampler must be performed. Photo # 21 12

13 4 Pump Problems: Pump is not running: -Confirm that there is power to the sampler and it is turned on. (Refer to section # 1) - Be certain that the option you have chosen needs the pump to run (i.e. leak check, verify flow.). -Check for loose or frayed wire connections from pump/motor assembly to power supply. -Check socket and pin connections on the pump wire connectors. This connects the pump to the power supply. Make sure the socket connections are tight against the pins. If not, use a small screwdriver to push the socket connectors together. Check in-line fuse on pump. Replace fuse if blown. -Check braided ground wire connection to the pump /DGM assembly. This connection must be tight at both ends of ground wire. - Replace the dry gas meter printed circuit board. - Unplug the pump wire connection at the power supply. Perform a verify flow operation. Using a voltmeter, determine if there is a voltage output from the power supply. It should be 12 vdc. Cancel the verify flow operation. -If there is 12 volts dc, replace the motor. -If there is no voltage, replace the power supply printed circuit board. (Refer to the power supply printed circuit board procedure listed under Power Out ) Pump runs continuously: -Turn power off and then back on. If the pump continues to run -Download five-minute averages from sampler and then reboot. If the pump continues to run -Turn power off to the sampler. -Access the electronics cabinet from the rear of the sampler. -Identify the dry gas meter printed circuit board (refer to Andersen technical bulletin # 19 for location. -Unplug the connection from the DGM circuit board to the power supply. (There will be three cable connections that are in the center of the board. Unplug the connection on the right.) -Turn the sampler on. If the pump does not run, replace the DGM circuit board. If the pump continues to run, replace the power supply printed circuit board. In either case, turn the sampler off before replacing any boards. 13

14 -If this still does not correct the problem, call the office for technical help. The next step would be to replace the main processor board. Do not replace this board unless technical support at the office advises its replacement. Pump runs intermittently - Check socket and pin connections on the pump wire connectors. This connects the pump to the power supply. Make sure the socket connections are tight against the pins. If not, use a small screwdriver to push the socket connectors together. Pump speed runs erratically (high and low) during verify flow or sample run. - Check for air leaks in the air train. Refer to section, Leaks in the System, described below. - Perform external leak check. Refer to RAAS operators manual Section Recalibrate the sampler. - Check cable connections between the DGM encoder and the DGM circuit board. - Replace the DGM encoder. If the DGM encoder is replaced, a full calibration of the sampler is necessary. - Check condition of rubber seals on inlet and outlet for the dry gas meter. It is possible that the seal has deteriorated and contaminated the interior of the dry gas meter. Pump appears to bog down during a leak check. Level of sound pump generates decreases. Pump power decreases in percent power and finally shuts off. - In cold weather, the pump needs to warm up to operating temp before attempting a leak check. Run verify flow a few minutes before attempting leak check. - Check to insure the inline fuse to the pump is good. - Pump bypass solenoid valve may not be opening to allow a flow of air to reach the pump. Place a finger on the inlet of the solenoid to determine if air is entering the valve. If it has been determined that air is not entering the valve, replace the valve. - Recalibrate sampler. 14

15 Pump power increasing well above 50% during verify flow and sampling. During the normal operation of the sampler, the pump power may be above 50%. This varies from sampler to sampler. Pump power can be as high as 69% and still be in the range of normal operation. If the pump power is higher than 69%, this may indicate an air leak in the system or the pump is beginning to fail. - Perform an external leak check. - Refer to the section Leaks in the System to determine where possible air leaks can occur. - Recalibrate all 4 thermocouples, barometric pressure and meter drop pressure. - Check the operation of the leak check solenoid valve. The valve should be closed during verify flow and during sampling. If the valve is open, replace the valve/solenoid unit. - Check cable connections from DGM encoder to DGM circuit board. - Replace the DGM encoder. If the DGM encoder is replaced, a full calibration of the sampler is necessary. - Replace the DGM circuit board. If the DGM circuit board is replaced, a full calibration of the sampler is necessary. Pump is running, but the monitor screen indicates there is no flow. There is probably a communications problem between the dry gas meter and the dry gas meter board. The first thing to check is the cable connections between the dry gas meter encoder and the dry gas meter board. The cable consists of two pieces that are connected together at the back wall of the instrument. The connection uses four pins that insert into sockets. Check to insure that the sockets make connection with the pins. Sometimes the sockets become spread apart and the pin does not make a good connection. Use a small jeweler s screwdriver to force the socket back together. The second thing to check is the position of the pins and sockets in the plastic connectors. Insure that the pins and sockets are firmly seated in the connector. They should extend far enough in the connector to make a firm connection with its mate. 15

16 - Replace the dry gas meter encoder. If the DGM encoder is replaced, a full calibration of the sampler is necessary. - Replace the dry gas meter printed circuit board. Calibrate the board before deciding if the repair was successful. If the board is replaced, a full calibration of the sampler is necessary. 5 Calibration Issues The screen displays SAT, (out of range) when trying to calibrate a temperature sensor. - Make sure the temperature calibrator (TEGAM) is being used properly. There are two ports on the calibrator. One is for sensing temperature; the other is to simulate a temperature. Make sure the connection is made to the T2 port. Be sure the calibrator is set up to measure for type K thermocouples and the temperature is measured in degrees Celsius. Check the manufacturer s documentation for the proper use of the calibrator. - Check for a bad thermocouple connection, even if it is not the channel being calibrated. Ensure that all thermocouples are securely plugged in to the calibration panel. The temperature displayed by the RAAS system and the calibration equipment does not agree. - Ensure that the calibrator is functioning properly. Refer to the manufacturer s documentation for proper use. - Be sure the calibrator is set up to measure for type K thermocouples and the temperature is measured in degrees Celsius. - Recalibrate the temperature sensor. The screen displays SAT when trying to calibrate a pressure sensor. - Be sure that the pressure being applied is within the proper range. The range for the barometric pressure sensor is 600 to 800 mm Hg. The range for the meter drop is 0 to 200 mm Hg. 16

17 - If the system has the leak check adapter installed, make sure it is in the open position. The pressure displayed by the RAAS system does not agree with the calibration equipment. - Ensure that the calibration equipment is operating properly. - If you are calibrating the meter drop pressure sensor, make sure that you are comparing the correct the correct pressure values. When using an absolute measurement device, the barometric pressure must be subtracted to find the differential pressure. - Re-calibrate the sensor in question. The middle value of the flow calibration is out of range. - Check for air leaks. Refer to the troubleshooting section entitled Checking for air leaks - Recalibrate the sampler. Ambient or meter drop pressure cannot be calibrated. - Determine that the pressure calibration device is functioning properly. Ensure that the battery is good condition. Use a new battery if there is any doubt of its condition. - Check for obstructions in the tubing connecting the pressure calibration device to the syringe and sampler. Check the connections of the tubing. - Check tubing to the DGM printed circuit board and the FTPTP boards for obstructions and fit at their connections. - Check wire connections to the DGM and FTPTP boards. - Replace the DGM printed circuit board and calibrate the board. - Replace the FTPTP board and calibrate the board. 6 Temperatures out of range, Spikes in temperatures No Temperature Flags - Inspect temperature boards. Look for loose or broken wires. Inspect for cracks or breaks in the thermocouple wires or the yellow wires making connections from the thermocouples to the temperature boards (see photo # ). - Inspect thermocouple connections to inner wall of sampler. 17

18 - Inspect thermocouple. Use a TEGAM to determine if the thermocouple is working properly. Compare this temperature value with the thermocouple supplied with the calibration kit. If a sampler thermocouple is out of range (>2 C), recalibrate for temperatures. - Replace the thermocouple. - Recalibrate the temperature boards. - Replace the temperature board for the affected thermocouple and calibrate the board. - Determine if cabinet fan is working properly - Determine if magnetic switch to fan is working properly. - According to the manufacturer of the RAAS, large Max Dif. numbers are not a problem unless there is a flag. These large numbers can be attributed to power spikes, cold fronts or software glitches. 7 Leaks in the System- Where to look for leaks - Perform internal and external leak checks - Does the external leak check pass? YES or NO Is the leak check adapter closed? - Does the internal leak check pass? YES or NO Is the leak check adapter plate secure in the filter cassette? - Check the position of the filter stage. Insure that the stage has properly sealed the filter cassette to the impactor. - Check snubber jars. Are they tightly screwed closed? If they appear to be cracked on broken, replace the seals. - Check the fittings and hoses connected to the pump and dry gas meter. Determine that hoses fit tightly to the fittings and hose clamps are firmly locked in place. Be sure the T fitting leading into the pump is tight. - Check the air fitting connection to the filter stage. If it is loose, disassemble. Remove the Teflon tape and inspect the threads on the fitting. If the fitting is damaged, replace the fitting. Make sure to use new Teflon tape during assembly. - Check the thermocouple o-ring at the dry gas meter. Replace the o-ring if it is damaged. Apply silicone grease to the o-ring before reassembly. - Locate the leak check solenoid valve. During verify flow and active sampling, this valve should be closed. Perform a verify flow operation and determine if there is air entering the valve inlet. - Check the diaphragm on the sampler pump. Check for tears or rips in the diaphragm. 18

19 - Refer to Andersen Instruments RAAS operator s manual Appendix D, page D-6 for a diagram of the leak check solenoid valve and pump assembly. 8 Cold Weather Kit Heater The cold weather kit heater has been set to turn on at a preset temperature of 10 C. This heater is supplied to warm the diaphragm pump during cold weather (>10 C) conditions. Refer to technical bulletin # 16 for additional information Heater is always on. - Observe the four-position switch located on the front of the heater. All four positions on the switch. They should all be in the down position. - Unplug the power wire leading to the power supply. Re-attach and determine if the heater is still on. - Replace the heater. Heater will not come on. Cabinet temperature is below 10 C. - Determine that thermocouples are operating properly. Recalibrate thermocouples if necessary. - Replace the heater. If replacing the heater does not solve the problem, follow the next procedure. Remember that the cabinet temperature must be less than 10 C for the heater to operate. - Unplug the heater cable at the power supply. - Using a multimeter/voltmeter determine if there is power to the heater (the voltage should be 110 volts). The cabinet temperature must be less than 10 C. - Replace the heater if the voltage is 110 volts. - If the voltage is less than 110 volts, call the office for additional help. 9 Cabinet Fan Cabinet fan does not operate. - Turn the sampler off and on. - Allow the sampler to initialize. - Close the door to the sampler and observe the operation of the cabinet fan. Remember that the operation of the cabinet fan requires that the cabinet temperature be 5 C more than the 19

20 10 Data Logging ambient temperature. Be certain this condition exists before deciding the fan is not working properly. - Determine that the thermocouples are functioning properly. Recalibrate if necessary. - Check the alignment of the cabinet door fan switch with the magnet attached to the cabinet door. The magnet should be in close proximity to the switch when the cabinet door is closed. - Using a hand held magnet try to close the circuit to the switch. Bring the magnet close to the switch. The hand held magnet can directly touch the switch. Observe the function of the cabinet fan. - Turn off the power to the sampler. - Locate the wire connection for the fan power supply. It is located at the top of the power supply cabinet in the front of the sampler. Remove the wire connection for the fan. - Connect a 12-volt power supply to the fan wire. Observe the operation of the fan. - If the fan does not work, replace the fan (refer to section # 12) - Remove the intake filter and electronics cabinet panel. Locate the wire connection from the fan switch to the DGM printed circuit board (see technical bulletin # 19 for location of the connection). - Disconnect the fan wire connection. - Close the front door of the sampler. - Using an alligator clip, jump the fan connections on the DGM board. If the fan works, proceed to the next step. If the fan does not work, replace the DGM board. - Calibrate the DGM board. - Attach a multimeter to the wire connection. With the front door to the sampler closed, check the multimeter to determine if the circuit is closed. If the multimeter indicates the circuit is open, try the procedure again using the hand held magnet. If the multimeter still indicates an open circuit, replace the fan switch. Refer to the DataLink Operator s Manual for additional information on the proper use of the datalink system. Page 1-2 describes the meaning of the status LED s. Red light appears when trying to do a download from the sampler. - Remove the datalink from the RS-232 port. Wait seconds and try reconnecting. - If this does not resolve the problem, use a new datalink. Inform your supervisor about the defective datalink. 20

21 11 Other Considerations Before inspecting or replacing electrical wires, encoders or printed circuit boards, turn the power off to the sampler. If the power is not turned off, there is a possibility that you can do serious harm to your body as well as the sampler. Sometimes the sampler becomes confused during an operation. Turn the sampler off and then back on. This sometimes clears the problem. If the decision is made to reboot the sampler, the site operator must download all of the five-minute averages before it is rebooted. Make sure the calibration values have been archived before rebooting. Refer to Andersen operator s manual section Rebooting the sampler clears the memory of all stored information except for archived calibration values. The rotational encoder senses the rotation of the filter tray. Its signal helps the sampler determine the filter tray position. The vertical encoder determines the position of the filter stage. When the stage drives up, it will slow down as it makes contact with the filter stage. If it does not slow down, the encoder is faulty and needs to be replaced. The dry gas meter encoder determines airflow from the dry gas meter. It sends a signal to the dry gas meter printed circuit board. When electrical problems are suspected, the first thing to check is the cable connections. Make sure the plugs are firmly attached to their associated connection. Check to insure that the sockets make connection with the pins. Sometimes the sockets become spread apart and the pin does not make a good connection. This is especially true of the cables for the dry gas meter encoder to the dry gas meter printed circuit board. Use a small jeweler s screwdriver to force the socket back together. The second thing to check is the position of the pins and sockets in the plastic connectors. Insure that the pins and sockets are firmly seated in the connector. They should extend far enough in the connector to make a firm connection with its mate. 12 Part Replacement Procedures Rotation Encoder - Unload the filter tray - Turn the power off to the sampler 21

22 - Remove the back panel - Locate the rotational encoder. Refer to photo #. - Remove the orange o-ring connecting the encoder to the rotational encoder pulley. - Loosen the setscrew on the shaft collar that holds the pulley on the rotational encoder. - Remove the pulley and shaft collar. - Disconnect the signal cable from the top of the rotational encoder. - Remove the nut and washer from the encoder and remove the encoder. - Replace the old encoder with a new unit. - Reinstall the washer and nut and tighten the nut. - Reinstall the pulley and shaft collar. There should be a slight gap (about the thickness of a quarter) between the top of the shaft collar and the end of the thread on the encoder. - Tighten the setscrew on the shaft collar. - Reinstall the orange o-ring on the rotational encoder pulley. - Reconnect the signal cable to the top of the encoder. - Load the filter tray. - Turn the sampler power on. - Observe proper operation. Dry Gas Meter Encoder - Turn off the unit - Remove the front door - Locate the pump/motor dry gas meter assembly (see photo # ) - Remove the four screws securing the pump/dry gas meter assembly to the inside of the sampler. The screws are located under the cabinet. - Disconnect the dry gas meter temperature thermocouple from the dry gas meter. - Disconnect the meter drop pressure tubing. - Disconnect the sampling train tubing from the right hand snubber jar. - Disconnect the dry gas meter encoder cable from the back of the interior wall of the cabinet. - Disconnect all of the wiring cables from the sampler power supply. This includes heater, leak check solenoid valve and pump motor cable. - Slide the pump/dry gas meter assembly out through the front of the cabinet. - Locate the cover surrounding the dry gas meter encoder (refer to photo 3 ). 22

23 - Remove the two screws on each side of the cover and remove the cover. - Locate the dry gas meter encoder. - Disconnect the wiring cable from the encoder. - Remove the four screws securing the encoder. - Locate the tubing connecting the encoder to the dry gas meter. Grasp the tubing and gently detach it from the shaft of the dry gas meter. - Remove the tubing from the shaft of the dry gas meter encoder. - Replace the old encoder with a new unit. - Install the tubing onto the shaft of the new encoder. Make sure the tubing does not make contact with the encoder body. - Attach the other end of the tubing onto the shaft of the dry gas meter. Make sure the tubing does not make contact with the dry gas meter. - Secure the encoder to the frame. - Re-attach the wiring cable to the encoder. - Install the encoder cover. - Slide the pump/dry gas meter assembly, back into the sampler cabinet. - Re-attach the wiring cables for the pump, heater and leak check solenoid to the power supply. - Re-attach the dry gas meter encoder cable to the back wall of the cabinet. - Re-attach the tubing for meter drop pressure and sampling train. - Re-attach the dry gas meter thermocouple. - Install the four screws securing the pump/dry gas meter assembly to the sampler cabinet. - Turn power on to the sampler. - Calibrate the sampler. - Observe proper operation. Vertical Encoder - Refer to Andersen Instruments RAAS operators manual, Appendix-D page D-8.(see photo # ) - Turn power off to the sampler. - Remove the front door of the sampler. - Remove the back panel. - Remove the panel to the electronics compartment. - Remove filter tray - Remove the impactor assembly - Remove retaining pin holding drive shaft to filter stage 23

24 - Unscrew the drive shaft and remove - Remove the retaining screws holding the drive gear top plate - Lift drive gear top mount - Remove drive gear toothed belt and vertical drive encoder o- ring. - Remove the vertical drive encoder pulley - Remove the six screws holding the filter stage assembly plate to the sampler body. - Remove the two screws retaining the filter stage guide bars. They are located below the filter stage assembly plate. - Remove fastener and washer holding the vertical encoder to the filter stage assembly plate. - Remove filter stage thermocouple - Remove the tubing - The filter stage reed switch does not need to be removed. - Slide filter stage off of the plate. Move it to the side of the sampler. - Lift back of filter stage assembly plate and remove encoder. - Disconnect wire to the automation control board. - Place the new encoder into the hole in the filter stage assembly plate. Be sure to align pin from encoder into hole in filter stage assembly plate. Secure with lock washer and nut. - Connect the encoder wire to the automation control board. - Align the filter stage assembly plate with the six mounting holes and secure with screws. - Move the filter stage into position on filter stage assembly plate. Install the two screws securing the filter stage guide bar. - Install the tubing and thermocouple to the stage. - Install the vertical drive encoder pulley. - Install the vertical drive gear beneath the filter stage. - Loosely lay the orange vertical drive encoder o-ring and the toothed belt into position on the drive gear. - Install top mount on the drive gear using the two mounting screws. - Install the drive shaft through the drive gear into the filter stage. Secure the drive screw to the filter stage with the threaded pin (see appendix-d, RAAS operators manual). - Install the orange vertical encoder o-ring from the drive gear to the vertical encoder pulley. - Install the toothed belt to the vertical drive motor pulley. Adjust the pulley if necessary (see technical bulletin # 8 for instructions). - Install the electronics cabinet door. - Install the filter back onto the sampler cabinet. - Install the impactor assembly. - Install the filter tray. 24

25 - Install the sampler front door. - Turn the power on to the sampler. - Observe proper operation of sampler during initialization. Removing cabinet heater - Turn sampler off - Remove the front door of the sampler. - Locate the pump/motor dry gas meter assembly. - Remove the four screws securing the assembly. They are located beneath the sampler cabinet. - Disconnect the cables for the pump/motor assembly, heater and leak check solenoid valve from the power supply. - Disconnect the cable for the DGM encoder. It is connected to the rear wall of the sampler. - Slide the pump/motor dry gas meter assembly forward 4-5 inches. This should allow for enough room to remove the four screws securing the heater to the base plate. The screws can be located beneath the base plate. - Replace the heater. - Secure the heater with four screws. - Slide the assembly back into the sampler cabinet. - Reconnect the cables for the heater, pump/motor assembly and leak check solenoid valve to the power supply cabinet. - Reconnect the DGM encoder cable to the rear wall of the sampler cabinet. - Secure the pump/motor dry gas meter assembly to the sampler cabinet with four screws. - Install the front door to the cabinet. - Turn power on to the sampler and observe proper function of the heater. Removing cabinet fan - Turn sampler off - Remove cabinet door - Remove filter tray and impactor - Remove inlet head and downtube - Remove ambient thermocouple radiation shield - Remove the four screws retaining the top of the sampler cabinet. They are located inside the cabinet. - Carefully slide the thermocouple out of the cabinet top. - Remove the top of the cabinet. - Remove the four screws securing the top of the filter cabinet. 25

26 - Remove the four screws securing the lower portion of the filter cabinet. - Remove the four screws securing the front of the fan cabinet. - Remove the cable to the rotational encoder. - Remove the rotational encoder.( See procedure) - Remove the rotational drive motor pulley - Remove the three screws retaining the rotational motor. - Remove the rotational motor and let it rest inside the cabinet next to the filter stage assembly. - Disconnect inactive thermocouple from its location. - Slide fan cabinet towards the back of the sampler. - Remove the four screws securing the fan to the fan cabinet. You will need to hold the retaining nuts with a pair of pliers while using a screwdriver to loosen the screws. - Disconnect the fan wire. - Replace the fan. - Connect the fan wire to the fan. - Secure the fan to the cabinet with the four screws and retaining nuts. - Slide the fan cabinet back into the sampler. - Connect the inactive thermocouple to its original location. - Secure the fan cabinet to the sampler. There will be 12 screws. Start with the screws securing the front of the cabinet. They can be reached through the front of the sampler. Do not tighten any of the screws until they are all in place. - Install rotational drive motor and pulley. - Install the orange o-ring connecting the motor to the pulley. - Install the rotational encoder. Align the pin from the encoder into the hole on the mounting plate. - Install the sampler top cover to the cabinet. Make sure the ambient thermocouple is threaded through the hole in the side of the cover. Secure with four screws. - Attach the ambient thermocouple radiation shield to the sampler. - Attach the ambient thermocouple to the radiation shield. - Install downtube and inlet head. - Install impactor and filter tray. - Install Sampler door. - Turn power on and allow sampler to initialize. - Close the door to the sampler to allow the fan to operate. Replacing the power supply printed circuit board. - Before attempting this procedure, call your supervisor for assistance 26

27 - Unplug the sampler from its power source. - To access the power supply printed circuit board, the power supply cabinet must be removed from the sampler. - Remove the intake filter assembly from the rear of the sampler. - Remove the panel covering the electronics. - Remove the two screws attaching the power supply cabinet to the sampler cabinet (refer to technical bulletin #19 for location of the screws). - Unplug the two cables connected to the power supply board. - Move to the front of the sampler. Unplug the power wires connecting the power supply to the heater, pump/motor assembly and leak check solenoid valve. Remove the four screws attaching the power supply cabinet to the sampler. They are located beneath the sampler. - Remove the locking ring securing the power cord to the cabinet. - Remove the power supply cabinet from the sampler. It may be necessary to remove the dry gas meter/ pump assembly in order to remove the power supply from the cabinet. - Remove the screws attaching the power supply cover. Open the power supply cabinet and locate the power supply printed circuit board. - Remove all wire connections that are attached to the board. Remove the screws securing the printed circuit board to the cabinet. - Replace the board, reinstall the screws securing the board and make the wire connections. - Replace the power supply cabinet into the sampler. - Install the six screws securing the power supply cabinet the sampler. - Reconnect the two cables to the power supply printed circuit board. - Install the pump/motor assembly if it has been removed. - Attach the meter drop and air train hoses. - Reconnect the wires for the pump/motor, heater and leak check solenoid valve. Reconnect the DGM encoder cable to the back wall of the sampler. - Reinstall the door to the electronics cabinet at the rear of the sampler. - Reinstall the intake filter assembly. 27

28 - Turn power on to the sampler and observe proper function. Securing front door hinges Top door hinge - Use the unload filter option to lower the filter stage. - Turn the sampler off. - Remove the sampler front door. - Remove the filter tray and impactor assembly. - Remove the inlet assembly and downtube. - Remove the top of the sampler. There are four screws securing the top. They are located inside the sampler. - Remove the ambient thermocouple from the radiation shield. - Remove the radiation shield for the ambient thermocouple. - Lift the sampler top up and remove the ambient thermocouple from the top. - Locate the screws securing the top door hinge. - Using a long screwdriver (18-24 inches long), tighten the two screws. - Reassemble the sampler top and reinstall all parts. Lower Door Hinge - Turn the power off to the sampler. - Remove the front door from the hinges. - Remove the four screws securing the pump/motor dry gas meter assembly. - Push the assembly to the back interior wall of the cabinet. - Tighten the two hinge screws using a stubby Phillips head screwdriver. - Slide the pump/motor dry gas meter assembly back into position and secure with four screws. - Install front door. 28