MAC MAC155L Instruction Manual Download

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MAC155 Rev. 12

Pg i

Table of Contents

Figures and Tables......................................................................................... vi

Figures .................................................................................................................................... vi

Tables ....................................................................................................................................viii

OVERVIEW....................................................................................................... 1

GENERAL ................................................................................................................................ 1

THEORY OF OPERATION......................................................................................................2

SENSOR CALIBRATOR..........................................................................................................3

WATER TANK .................................................................................................................. 3

CONDENSER................................................................................................................... 4

CALIBRATION VALVE.....................................................................................................4

CALIBRATION PUMP ...................................................................................................... 4

PROBE OPTIONS ............................................................................................ 5

EXTENSION TUBE.................................................................................................................. 5

CASE HEATER........................................................................................................................ 5

CASE COOL ............................................................................................................................ 6

FILTER BLOW BACK .............................................................................................................. 6

INSTALLATION ................................................................................................ 9

MOUNTING ADAPTER .........................................................................................................11

WALL MOUNT REMOTE SAMPLING PROBE (OPTION) .................................................... 12

PROBE WIRING .................................................................................................................... 12

PROBE JUNCTION BOX....................................................................................................... 15

MAC155 PROBE JUNCTION BOX OPTION......................................................................... 15

MAC155 CONTROLLER FIBER OPTIC CONVERTER JUNCTION BOX OPTION

............ 16

PROBE INSERTION..............................................................................................................16

FILTER BLOW BACK AIR SUPPLY – OPTION .................................................................... 17

CONTROLLER WIRING ........................................................................................................ 18

PROBE TO CONTROLLER WIRING............................................................................. 18

CURRENT LOOP WIRING ............................................................................................19

MAINTENANCE MODE CONTACT ............................................................................... 20

LOCAL ALARM CONTACTS ......................................................................................... 21

RS485 COMMUNICATIONS.......................................................................................... 21

OPERATION ................................................................................................... 23

GENERAL .............................................................................................................................. 23

WATER TANK PREPARATION............................................................................................. 23

Summary of Contents for MAC155L

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Page 5: ...5 CASE COOL 6 FILTER BLOW BACK 6 INSTALLATION 9 MOUNTING ADAPTER 11 WALL MOUNT REMOTE SAMPLING PROBE OPTION 12 PROBE WIRING 12 PROBE JUNCTION BOX 15 MAC155 PROBE JUNCTION BOX OPTION 15 MAC155 CONTROL...

Page 6: ...S 45 M1 Test of sample gas flow path 45 M2 Test of reference gas flow path 46 M3 Sampling pump test 47 M4 Calibration pump test 48 Electrical Tests Controller 48 Power Supplies 50 LED Status Indicator...

Page 7: ...9 PLC INTERFACE OUTPUTS 69 PLC INTERFACE INPUTS 71 ETHERNET CONTROLLER OPTION 72 INITIAL SETUP 72 Hardware Requirements 72 Communication with Controller 72 CONTROLLER LOGIN 72 NORMAL OPERATION SCREEN...

Page 8: ...mpling Probe Mounting Hole Layout 97 Probe Assembly 99 Controller Outline 101 Controller Assembly 120V 103 Probe Main Board Layout 105 Controller Main Board Layout 107 PLC Interface Wiring Diagram 109...

Page 10: ...Probe Connectors 18 Figure 12 Controller PE GND stud 19 Figure 13 MAC155 0 5V Operation 20 Figure 14 Water Level Sensor Location 24 Figure 15 Water Filling Flushing Kit 25 Figure 16 Filling Water Tan...

Page 11: ...lect 61 Figure 43 Forced Analog Output Menu 62 Figure 44 Force Calibration Pump ON Menu 63 Figure 45 Force Blow Back Sol ON Menu 63 Figure 46 Forced Case Heater Menu 64 Figure 47 Force Cond Temp to 10...

Page 12: ...ime Setup Menu 83 Figure 64 MAC155 Time Setup Menu 83 Figure 65 MAC155 Time Setup Menu 84 Figure 66 MAC155 Time Setup Menu 85 Figure 67 Modbus 8bit Input Word 87 Figure 68 Modbus 8bit Output Word 87 T...

Page 14: ...t with surface could cause burns Risk of electric shock High voltage is present which could cause electric shock Consult Service Manual Read manual before performing any operation Protective Conductor...

Page 16: ......

Page 17: ...onitored and a controller which is typically located in a control room The MAC155 has multiple ranges which are user selectable using the display and pushbuttons on the controller It is necessary to d...

Page 18: ...s approximately 17 ounces 500mL of distilled water Under normal operating conditions the water will last for over a year It is recommended however that the reservoir be drained and re filled at least...

Page 19: ...o points The calibrator consists of the following pieces of hardware Water Tank Condenser Calibration Valve Calibration Pump WATER TANK The water tank holds a supply of distilled water that is used to...

Page 20: ...by volume level CALIBRATION VALVE The calibration valve is normally closed when the instrument is in the RUN mode The calibration valve opens in the CALIBRATION OR CALIBRATION CHECK modes to allow the...

Page 21: ...nsion tube is to draw the sample atmosphere at a point well away from the wall of the stack or duct The 3 foot 0 9 meter extension tube can be cut to any desired length Figure 2 Extension Tube cut to...

Page 22: ...should be implemented This option requires the user to supply a source of 10 psi 69kPa clean dry and oil free air into the 0 170 barbed hose fitting on the MAC155 case see figure 3 FILTER BLOW BACK Th...

Page 23: ...ed Air Input It is required to provide clean dry instrument air for the compressed air input Failure to do so may result in damage to the moisture sensor which is not covered under the warranty LWhen...

Page 25: ...connections are made through two waterproof NEMA 4 IP 65 connectors Although the MAC155 Probe is suitable for outdoor installation it should not be mounted where it would be exposed to direct sun lig...

Page 27: ...ng cap is to cover the hole in the mounting adapter if the MAC155 Probe is removed The clamp is used to hold either the sealing cap or the MAC155 Probe in place A Teflon gasket is also provided with t...

Page 28: ...hole layout for mounting the probe The probe should be mounted to the wall or panel using 4 fillister head screws PROBE WIRING The MAC155 is powered by a nominal 120 VAC 50 60 HZ 3A max power source T...

Page 29: ...nded termination point The PE stud should be terminated before any other connections to the unit are made with a 14 gauge 2 5mm2 or larger wire It is not permitted to terminate more than one wire on t...

Page 30: ...truments 2005 All Rights Reserved Pg 14 Maximum length of Wires One Way Wire Size AWG Nom Size mm2 150 Feet 12 4 mm2 240 Feet 10 6 mm2 400 Feet 8 10 mm2 600 Feet 6 16 mm2 1000 Feet 4 25 mm2 Table 1 DC...

Page 31: ...ective to mount DC power supplies near the MAC155 probe In some cases it is also desirable to obtain AC power from a source close to the MAC155 probe rather than running it from the MAC155 Controller...

Page 32: ...measuring approximately 7 5 X 7 5 X 2 5 The 6 conductor I O cable connects between the controller and the terminal strip in the fiber optic converter junction box The I O cable supplies 15V DC power...

Page 33: ...nserted into the adapter by placing the gasket over the probe barrel and then inserting the probe barrel into the mounting flange adapter Insertion into the mounting flange adapter requires an assista...

Page 34: ...troller I O Pin Designations PROBE TO CONTROLLER WIRING Using the supplied cables connect the controller to the probe The rear of the controller provides the appropriate connections The wiring to the...

Page 35: ...panel of the controller via a menu and pushbuttons Refer to the Setup section for the controller 0 TO 10V OR 0 TO 5V OPERATION The current loop configuration provides a high degree of immunity from in...

Page 36: ...NTENANCE MODE CONTACT The maintenance mode relay contact Normally Closed is wired to terminals on the rear of the controller When power is applied to the MAC155 this contact opens The contact can also...

Page 37: ...circuit must match the output of the solid state relay contacts RS485 COMMUNICATIONS The RS 485 port is provided on the rear of the controller to implement communications to external devices The exte...

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Page 39: ...the MAC155 is not in operation when the monitored equipment is in operation remove the MAC155 from the mounting tube and seal the mounting tube with the sealing cap provided WATER TANK PREPARATION Be...

Page 40: ...ensor If the water level falls below a minimum level the Low Water alarm will be activated L The Low Water alarm signal indicates that service to the water tank is required WATER FILLING FLUSHING KIT...

Page 41: ...on a level surface and open the cover Remove the plug by releasing the retention lever and pulling the plug straight out Place the drip prevention tube over the fill port Use the funnel and fill the...

Page 42: ...ter from the tank Draining is performed by first removing the fill plug then disconnecting the tubing that comes from the tank to the calibration pump at the calibration pump end and connecting the si...

Page 44: ...d from the ground pin of the power connector to a proper earth ground Also check that the AC voltage is correct 120 VAC 50 60 HZ or 240 VAC 50 60 Hz and is connected to the correct pins of the power c...

Page 45: ...pump will stop running and there will be no status messages displayed on the screen Figure 18 Normal Display STATUS INDICATORS There are nine LED s on the main board that indicate the status of variou...

Page 46: ...indicates power off Note case heater is an option ON OR OFF Case Cool Power to case cool solenoid status ON indicates power on OFF indicates power off Note case cool is an option ON OR OFF Water Leve...

Page 47: ...155 can be placed into a calibration check once every 24 hours The time this function will activate is determined by the setting in the controller A time setting of 0 00 will disable the automatic cal...

Page 49: ...thin the MAC155 Probe that may require maintenance or even replacement from time to time FILTER EXTENSION TUBE INSTALLING THE FILTER 1 Remove the filter cover 2 Remove the compression spring 3 Slide t...

Page 50: ...n should be used This option automatically cleans the filter by blowing user supplied compressed air in the reverse direction through the filter once per day during the calibration check In order to m...

Page 51: ...ed they should not be blown from the filter with compressed air but should instead be allowed to evaporate in a well ventilated area far removed from sources of ignition If compressed air were used a...

Page 52: ...should be drained flushed and refilled at least once per year Read the OPERATION section in this manual for information about filling the tank When it is time to re fill the water tank proceed as fol...

Page 53: ...revolution every 4 seconds This low speed combined with the sturdy construction of the pump assures a long life A new pump can produce a vacuum of approximately 8 psi 55 kP The pump will perform prope...

Page 54: ...e sampling pump to assure that the sensor is flooded with the calibration gas The calibration pump can be tested in the same way as the sampling pump The pump will work properly as long as it can main...

Page 55: ...v 12 Pg 39 PERISTALTIC PUMP TUBING REPLACEMENT Figure 24 Peristaltic Pump stand in Tubing 6 Remove the two screws holding the plastic head assembly and remove the assembly from the motor Figure 25 Per...

Page 56: ...quired and remove the old tubing by pulling the white cam wheel and tubing out of the plastic housing Figure 26 Peristaltic Pump Housing Figure 27 Disassembled Peristaltic Pump Housing 8 Wrap the new...

Page 57: ...ing Insert the two screws through the holes in the housing and place the two black rubber washers over the ends of the screws to hold them in place 10 Mount the housing onto the motor Note that the fl...

Page 59: ...n be thought of as the Moisture Analyzer Additional equipment in the MAC155 Probe is there only for checking the calibration of the Moisture Analyzer The equipment that is used to check the calibratio...

Page 60: ...t containing tubing fittings and tubing is included with the MAC155 Probe to facilitate connections of the test gauge to the MAC155 Probe Do NOT use a liquid filled manometer when testing differential...

Page 61: ...oved and blown out as described in the maintenance section of this manual The silicone rubber tubing running from the sensor module to the sampling pump should be removed and tested for blockage Repla...

Page 62: ...h The components in the reference gas flow path are the calibration pump the water tank the condenser the calibration valve and the barrel It is highly unlikely that the flow path for the reference ga...

Page 63: ...M3 If the calibration pump is working properly and the water tank tubes and fill plug are not leaking the reference gas must flow into the barrel when the pump runs M3 Sampling pump test A new pump ca...

Page 64: ...ent and place it in the calibration check mode Note the reading on the vacuum gauge If it is at least 2 psi vacuum the calibration pump is operating properly 4 Disconnect electrical power disconnect t...

Page 65: ...v 12 Pg 49 Figure 28 AC Input Fuse Location Other fuses located on the back of the controller are for the 120V AC power and the 15V DC power feeding the probe Figure 29 Probe Fuse Location on Controll...

Page 66: ...o supplies DC power to the MAC155 probe in addition to the remaining 15V supply Each power supply has a green LED which indicates if voltage is present on the output The power supplies have a current...

Page 67: ...ne 9 LED s to aid in diagnosing potential problems with the MAC155 probe The probe receives 120V AC power and 15V DC power from the MAC155 controller Fuses for these lines are located on the back of t...

Page 68: ...here is no LED indicator to represent this supply due to the nature of the low current output available Test points are available for the 5V analog supply at the tope edge of the main board just below...

Page 69: ...ature is below 45 F 7 C If the probe is equipped with the case heater option 120V AC power is applied to the case heater when ever the LED is ON Filter Blow Back The Blow Back LED comes on for 2 sec w...

Page 71: ...ntroller s display To enter the menu system press the lower pushbutton indicated by a black cap Upon pressing this button the controller will enter the general menu display Three different menu select...

Page 72: ...the clock one minute If the minute pushbutton is continuously pressed the clock will auto increment 1 minute approximately of a second Setting the Hours Pressing the Red pushbutton will increment the...

Page 73: ...per 24hr time period Set the Auto CalCheck Time using the same method as described in the Time Set Menu Setting a time of 0 00 will disable the Auto CalCheck Figure 32 Auto CalCheck Time Set Menu DISP...

Page 74: ...s two different current loop scales Scale 1 4 20mA Scale 2 0 20mA The default level is 4 20mA PROBE MBV RANGE SELECTION Figure 35 Probe MBV Range Selection Menu The MAC155 L menu provides two differen...

Page 75: ...wer must be removed from the MAC155 and then reapplied MAINTENANCE RELAY SET UP Figure 36 Maintenance Relay Setup Menu This menu is to enable the maintenance contacts to close during calibration and c...

Page 76: ...ting the MODBUS RTU slave address for the MAC155 After pressing enter the following screen will appear Figure 39 MODBUS address setup 1 Press the INCREMENT or DECREMENT buttons to select the 1st digit...

Page 77: ...Option Figure 41 MODBUS RTU Baud rate setup This menu item is used to set the desired baud rate for MODBUS RTU communications Pressing ENTER will bring up the following display Figure 42 MODBUS Baud...

Page 78: ...Range 4 0 mA 0 20 8 0 mA 25 40 12 0 mA 50 60 16 0 mA 75 80 20 0 mA 100 100 Example using above table a 15 full scale instrument 50 of full scale is 7 5 MBV This output signal will be present on the an...

Page 79: ...at the previously set value until the enable button is pressed or until the diagnostic menu is exited MANUAL CAL PUMP OPERATION Figure 44 Force Calibration Pump ON Menu Pressing the Enable pushbutton...

Page 80: ...EXIT pushbutton is disabled until the DISABLE button is pressed MANUAL CASE HTR OPERATION Figure 46 Forced Case Heater Menu If the MAC155 Probe is equipped with the case heater option the case heater...

Page 81: ...the EXIT button before the DISABLE button will result in no change in the display since the EXIT button is disabled during this forced condition FORCE COND TEMP 130 Figure 48 Force Cond Temp to 130 Me...

Page 82: ...eriod of 12 minutes When the calibrator has finished generating the low and high calibration points the new calibration values are stored in the MAC155 Probe and then returns to normal operation Verif...

Page 83: ...generate a calibration gas stream of 80 of full scale for a period of 11 minutes At the end of that period the MAC155 Probe returns to the normal mode The calibration of the probe is left unchanged MA...

Page 84: ...nd six outputs are available to interface to a PLC LEDs indicate if signals are present on the inputs and outputs There is also a bi color STATUS LED that provides information with respect to the comm...

Page 85: ...relay LOW WATER OUTPUT If the probe generates a LOW WATER Alarm a dry relay contact will close and the RED LOW WATER LED will illuminate confirming the activation of the relay The PLC Interface will a...

Page 86: ...will illuminate confirming the activation of the relay This relay output will be active any time the Local Alarm Relay is active The exception to this is if there is a loss of communications between...

Page 87: ...t signal should be applied for a minimum of 10 seconds to ensure the PLC interface has communicated the request to the controller MAINTENANCE Applying 24VDC to this input will place the MAC155 into a...

Page 88: ...a personal computer with a network interface card web browser and active network connection Connection directly to the controller requires the same hardware with the addition requirement of a 10Base T...

Page 89: ...After pressing enter you should be greeted with a pop up login box The default username MAC155 and password MAC155 need to be entered to proceed to the normal operation web page The user name and pass...

Page 90: ...first area that may need attention is the MAC155 Time If the time was not set using the controller s menu system it can be set at this time This is accomplished by clicking on the Set MAC155 Time butt...

Page 91: ...MAC155 Time Set button will present the Change MAC155 Time web page The current time and date will be visible Note any discrepancies between the actual time and the MAC155 time Click on any boxes that...

Page 92: ...cation the controller received the command without error The Calibration mode causes the calibrator section of the MAC155 Probe to generate a calibration gas stream of 40 of full scale moisture by vol...

Page 93: ...ed when refreshing the page and viewing the Mode text box Upon completion of the calibration mode Normal will be displayed in the text box CALCHECK OPERATION SCREEN Figure 58 MAC155 CalCheck Mode Pres...

Page 94: ...ENANCE OPERATION SCREEN Figure 59 MAC155 Time Setup Menu The In Maintenance mode can be executed by clicking on the Maintenance button The probe will stay in the in maintenance mode until cancelled by...

Page 95: ...fects the alarm reporting and operation of the MAC155 Each menu is explained in further detail following this description Figure 60 General Configuration Menu ALARM EMAIL SETUP A MAC155 controller equ...

Page 96: ...ield is the desired email address that will be placed in the Email From field This does not have to be a valid email address Email Subject This field contains the subject of the email The default is M...

Page 97: ...res a login to send email this check box will need to be checked so the username and password are sent when connecting to an email server Email Server User Name This field contains the user name requi...

Page 98: ...L determines which scales will be available in the drop down menu Figure 62 MAC155 Time Setup Menu NETWORK CONFIGURATION MENU Clicking the Network Configuration Menu button from the main menu will lo...

Page 99: ...DRESS CONFIGURATION This menu changes the default IP address of the MAC155 to an IP address that is compatible with your network Initial connection to the MAC155 using the default IP address of 192 16...

Page 100: ...o a calibration check once every 24 hours The time this function will activate is determined by the setting in the controller The default time is 0 00 The MAC155 can be placed into a calibration check...

Page 102: ...during communications The baud rate of the RS 485 serial communications must be set to the common baud rate of the master Modbus Setup The baud rate and slave number must be configured for correct Mod...

Page 103: ...and Calibration check modes will return to Run mode after the 22 minute calibration or calibration check process Controller Outputs The MAC155 recognizes Function 01 Read Coil Status This function sho...

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Page 115: ...struments 2005 All Rights Reserved MAC155 Rev 12 Pg 99 Probe Assembly CAL SOL Valve Condenser Main Board Water Level Switch Fill Port Case Heater CAL Pump Sample Pump Water Tank Sensor Head Fitting Bl...

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MAC MAC155L, Instruction Manual

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