Atlas Weather-Ometer Ci3000+ User manual

Ci3000+
Ci4000
Ci5000
Weather-Ometer®
Instrument
Service Guide
Weathering
Instrumentation Products
Doc. No. 07-7030-00
Revision 0
November 10, 1999
Weather-Ometer®
Ci3000+
Ci4000
Ci5000

Ci3000+/ Ci4000 / Ci5000 Weather-Ometer®Service Guide Doc. No. 07-7030-00 Rev. 0 2
Table Of Contents
1.0 INTRODUCTION 11
2.0 WARNINGS AND PRECAUTIONS 12
3.0 REQUIRED TOOLS AND NIST TRACEABILITY 13
3.1 Required Tools 13
3.2 NIST Traceability 13
4.0 DATA PANEL SERVICE AND SETUP PAGES 14
4.1 Accessing the Service Pages 14
4.2 Service Page Functions 14
4.2.1 PID Loop Parameters – Page 91 14
4.2.2 Manual Calibration – Page 92 14
4.2.3 Manual Checkout: Discretes – Page 93 15
4.2.4 Manual Checkout: Analogs – Page 94 15
4.3 Data Panel Control Pages 15
4.4 Data Panel Error Messages 17
5.0 TROUBLESHOOTING PROCEDURES - QUICK GUIDE 19
5.1 Power-up Malfunctions 20
5.1.1 Description 20
5.1.2 Troubleshooting Guide 23
5.1.3 Troubleshooting Flow Chart 24
5.1.4 Troubleshooting Procedure 25
5.1.5 Power Component Configuration 26
5.2 Xenon Lamp and Irradiance Malfunctions 29
5.2.1 Description 29
5.2.2 Troubleshooting Guide 34
5.2.3 Troubleshooting Flow Chart – Lamp Ignition Failure 35
5.2.4 Troubleshooting Flow Chart – Irradiance High or Low 36
5.2.5 Troubleshooting Flow Chart – 2-Sun Irradiance Considerations 37
5.2.6 Troubleshooting Procedure – Lamp Ignition Failure (Ignitor) 38
5.2.7 Troubleshooting Procedure – Irradiance High or Low (Watt. Regulator) 39
5.2.8 Troubleshooting Procedure – 2-Sun Irradiance Considerations 42
5.3 Humidification Malfunctions 44
5.3.1 Description 44
5.3.2 Troubleshooting Guide 45
5.3.3 Troubleshooting Flow Chart – Humidification Failure 46
5.3.4 Troubleshooting Flow Charts – RH Control and Sensing Errors 47
5.3.5 Troubleshooting Procedure – Humidification Failure 48
5.3.6 Troubleshooting Procedure – RH Control and Sensing Errors 50
5.3.6.1 RH Reading is 0% or 100% 51

Ci3000+/ Ci4000 / Ci5000 Weather-Ometer®Service Guide Doc. No. 07-7030-00 Rev. 0 7
Table Of Contents
List of Figures
Figure 5.1–1 Booster Transformer T1 21
Figure 5.1–2 Main Reactor L1 21
Figure 5.1–3 Auxiliary Reactor L2 21
Figure 5.1–4 Isolation Transformer T2 22
Figure 5.1–5 Chamber Safety Thermostat S4 25
Figure 5.1–6 Ci3000+Power Component Configuration Guide 26
Figure 5.1–7 Ci4000 Power Component Configuration Guide 27
Figure 5.1–8 Ci5000 Power Component Configuration Guide 28
Figure 5.2–1 Ci3000+Xenon Lamp Circuit 30
Figure 5.2–2 Ci4000 Xenon Lamp Circuit 31
Figure 5.2–3 Ci5000 Xenon Lamp Circuit 32
Figure 5.2–4 Xenon Lamp Assembly Guide 33
Figure 5.2–5 Ci3000+Xenon Lamp Ignitor 38
Figure 5.2–6 Ci4000 Xenon Lamp Ignitor 38
Figure 5.2–7 Ci5000 Xenon Lamp Ignitor 38
Figure 5.2–8 Chamber Overtemperature Thermostat 38
Figure 5.2–9 Xenon Lamp Wattage Regulator 40
Figure 5.2–10 Wattage Regulator Power LED 40
Figure 5.2–11 Wattage Regulator Output LED 41
Figure 5.2–12 One and Two Sun Circuit Block Diagram 42
Figure 5.3–1 Humidification System Plumbing Diagram 44
Figure 5.3–2 Air Pressure Regulator Bowl Drain Valve 48
Figure 5.3–3 Humidification Nozzle (rear panel) 48
Figure 5.3–4 Humidification Nozzle Detail 48
Figure 5.3–5 Humidifier Water Line Filter 48
Figure 5.3–6 Humidification Block Diagram 49
Figure 5.3–7 Humidification Solenoid Valve Locations 49
Figure 5.3–8 Humidification Water Control Relay Q1 50
Figure 5.3–9 Humidity PC Board Jumpers 50
Figure 5.3–10 APC1 Filter PC Board 51
Figure 5.4–1 Chamber Safety Thermostat S4 52
Figure 5.4–2 Chamber Overtemperature Alarm 52
Figure 5.4–3 Chamber Temperature Transmitter 55
Figure 5.4–4 Air Heater Control Relay Q2 56
Figure 5.5–1 Xenon Lamp Cooling System Electrical Block Diagram 59
Figure 5.5–2 CS-6 Lamp Cooling System Plumbing Diagram (Ci3000+)60
Figure 5.5–3 CS-6 Lamp Cooling System Plumbing Diagram (Ci4000/Ci5000)61
Figure 5.5–4 CS-6 Lamp Cooling System 62
Figure 5.5–5 Testing the Flow Switch 67
Figure 5.5–6 CS-6 Pump Shaft Coupling 67
Figure 5.6–1 Lenze 8200 Blower Controller 69
Figure 5.6–2 Blower System Electrical Block Diagram 69
Figure 5.6–3 Blower Wheel Mounting 73
Figure 5.6–4 Lenze Display and Input Select Jumper 75
Figure 5.7–1 Black Sensor Transmitter & Collector Ring (Ci4000/Ci5000) 78
Figure 5.7–2 Black Sensor Transmitter & Collector Ring (Ci3000+)78
Figure 5.7–3 Temperature Control Systems Electrical Block Diagrams 79
Figure 5.7–4 Blower Controller and Chamber Temp. Transmitter (Ci4/Ci5) 80

Ci3000+/ Ci4000 / Ci5000 Weather-Ometer®Service Guide Doc. No. 07-7030-00 Rev. 0 10
Table Of Contents
List of Figures (cont.)
Figure 8.3–6 CS-6 Circulator Pump and Motor 184
Figure 8.3–7 Circulator Pump/Motor Coupling 184
Figure 8.3–8 CS-6 Pump/Motor Details 184
Figure 8.3–9 Ci3000+and Ci4000 Rack Motors 185
Figure 8.3–10 Ci5000 Rack Motor & Controller 185
Figure 8.3–11 Rack Drive Gear Alignment 185
Figure 8.3–12 Ci4000 Rack Motor Wiring Diagram 186
Figure 8.4–1 Rack & Specimen Spray Solenoid Valves 186
Figure 8.4–2 CS-6 and Humidification Solenoid Valves 186
Figure 8.5–1 Rack Speed Controller (Ci5000) 187
Figure 8.5–2 Water Resistivity Monitor 187
Figure 8.5–3 Transmitter Locations 187
Figure 8.5–4 Chamber Overtemperature Alarm 188
Figure 8.5–5 Lamp Water Temperature Controller 189
Figure 8.5–6 Blower Motor Controller 190
Figure 8.5–7 Lenze Display and Input Select Jumper 190
Figure 8.5–8 AFE Data Panel Mark I (early Ci4000) 193
Figure 8.5–9 AFE Data Panel Mark II 193
Figure 8.5–10 Typical PLC Module (side view) 194
Figure 8.5–11 PLC0 Fuse 195
Figure 8.6–1 Ci4000 Xenon Lamp Ignitor 196
Figure 8.6–2 Ci5000 Xenon Lamp Ignitor 196
Figure 8.6–3 Ci4000 Ignitor Terminal 196
Figure 8.6–4 Ci4000 Ignitor Sealing Washers 196
Figure 8.7–1 Xenon Lamp Wattage Regulator 197
Figure 8.7–2 Wattage Regulator Trimpots 197
Figure 8.8–1 CS-6 Reservoir Tank 198
Figure 8.8–2 Level Switch Float Orientation (Dry) 198
Figure 8.9–1 Ci4000 Air Heater 198
Figure 8.9–2 Ci4000 Rack Hub 198
Figure 8.9–3 Ci5000 Rack Hub 198
Figure 8.9–4 Air Heater Terminals 200
Figure 8.10–1 Collector Ring 200
Figure 8.11–1 Rack Bearings 201
Figure 8.11–2 Rack Driveshaft Components 201
Figure 8.11–3 Ci5000 Rack Hub 201
Figure 8.12–1 Chart Recorder Terminals 202
Figure 8.12–1 Chart Recorder Electrical Diagram 202
List of Tables
Table 5.6 – 1 Lenze 8200 Blower Motor Controller Setup Codes 77
Table 5.13–1 PLC6 Indicator Light Legend 124
Table 8.5–1 Lenze 8200 Blower Motor Controller Setup Codes 192

Ci3000+/ Ci4000 / Ci5000 Weather-Ometer®Service Guide Doc. No. 07-7030-00 Rev. 0 11
1.0 INTRODUCTION
This manual provides instructions for the trouble-
shooting, calibration, maintenance and repair or
replacement of all applicable systems and com-
ponents of the Ci3000+, Ci4000 and Ci5000
Weather-Ometers. These procedures should be
performed only by a qualified service technician.
Specifications may be subject to change without
notification.
Observe Precautions
Beforeconductinganyprocedures,readthewarn-
ings and precautions in Section 2.0. Doing so will
help ensure your safety and minimize the poten-
tial for damage to the instrument. Beforehand,
always read the procedure that you will be con-
ductingtobecomefamiliarwiththestepsinvolved,
tools required and safety precautions.
Topics Covered
This manual covers the following topics:
nTroubleshooting
Power-up Malfunctions
Xenon Lamp & Power Circuit Malfunctions
Humidification Malfunctions
Chamber Overtemperature Malfunctions
CS-6 Lamp Cooling System Malfunctions
Blower System Malfunctions
Temperature Control Malfunctions
Specimen Rack Drive Malfunctions
Water Spray Malfunctions
Water Resistivity Monitor Malfunctions
Optional Chart Recorder Malfunctions
Data Panel Malfunctions
PLC (Programmable Logic Controller)
Malfunctions
Optional Data Acquisition System Malfunctions
Reference Material Test Malfunctions (SRM)
nCalibration
Black Sensor (BPT and BST)
Chamber (dry bulb) Sensor
Relative Humidity
Lamp Wattage
Lamp Irradiance
Air valve (Damper)
Rack Speed Control
Resistivity Monitor
Lamp & Rack Alignment
nMaintenance
Lamp Water Fitting Gasket
Lamp Outer Filter Cleaning
Light Rod End Cleaning
Lamp Burner Socket Inspection
Test Chamber Cleaning
Demineralizer Cartridge Replacement
Flow Switch Filter Screen Cleaning
Lamp Water Reservoir Cleaning
Light Monitor Filter Replacement
Inlet Air Filter Cleaning
Humidifier Water Filter Cleaning
Humidifier - Inspection, Cleaning & Adjustment
Air Regulator Oil Trap Cleaning
Lamp, Rack & Light Rod Alignment
nComponent Replacement
Relay Replacement
Sensor Replacement
Electric Motor Replacement
Solenoid Valve Replacement
Controller and Transmitter Replacement
Ignitor Replacement
Wattage Regulator Replacement
CS-6 Cooling Coil & Level Switches
Air Heater Replacement
Collector Ring Replacement
Rack Bearing Replacement
Chart Recorder Replacement
Data Panel and Software Downloading
nAppendix
A – PLC and Data Panel Software Configuration
B – Optional Yokogawa Chart Recorder Manual
C – Component Parts Lists
The Troubleshooting section is designed not only
to help you pinpoint and verify malfunctions, but
to provide a basic explanation of operating
principles of the various instrument subsystems.
Electricalblock diagrams,whilesimplified,include
accurate component wiring designations.
Additional Questions
If you have questions or encounter problems that
are not addressed in this manual, please contact
Atlas Service at [phone], or send a fax to
[phone], Chicago, Illinois U.S.A.

Ci3000+/ Ci4000 / Ci5000 Weather-Ometer®Service Guide Doc. No. 07-7030-00 Rev. 0 29
5.0 TROUBLESHOOTING PROCEDURES
5.2 Xenon Lamp and Irradiance
Control Malfunctions
5.2.1 Description
Irradiance is provided by the xenon lamp system
which is comprised of the xenon lamp and power
supply components that include the booster
transformer T1, igniter L3, main reactor L1,
auxiliary reactor L2 and wattage regulator AR1.
TheCi3000+hasa4500wattxenon lamp capable
of operating from 1700 to 4500 watts. The 6500
watt xenon lamp in the Ci4000 is capable of
operating within the range of 2500 to 7400 watts.
The12,000wattlampintheCi5000operateswithin
the range of 4000 to 14000 watts.
The xenon lamp receives its high-voltage ignition
pulsefromtheigniter,whichdropsoutofthecircuit
afterthelampis operating steadily.Theinstrument
is designed to provide three ignition attempts
before an ignition failure message is displayed on
Data Panel MAIN page 1.
At minimum wattage, the lamp receives its power
fromthemainreactoronly.Athigher wattagelevels,
the auxiliary reactor and wattage regulator (in
series with the main reactor) contribute additional
power and provide precision wattage control.
Irradiance control is provided by the light monitor
which continuously monitors lamp output and
providesavoltagesignalto thePLC.ThePLCthen
increases or decreases lamp wattage to maintain
a stable irradiance level. Lamp wattage is
continuouslymonitoredbythe wattage transducer
A1 which provides a voltage signal to the PLC.
Lampcooling is providedbytheCS-6lampcooling
systemwhich pumps filtered D.I. water throughthe
xenon lamp. Heat is extracted from the cooling
waterby atapwatercoil intheCS-6reservoir tank.
In locations where tap water is expensive or its
temperature is too high, an optional LiquiAir unit
or a refrigeration unit may be present to provide
cooling of the lamp water.
Lamp malfunctions can result from numerous
causes. Ignition of the lamp can be prevented by
a damaged or disconnected lamp, a CS-6
malfunction, such as low or lost water flow, or by
the malfunction of a lamp circuit component. Low
lamp irradiance output is often the result of burner
or lamp filter aging, or expired interference filters
in the light monitor. This section focuses on
troubleshootingofthelampassembly, lamp circuit
components and the light monitor. For CS-6
troubleshooting, refer to Section 5.5.
65000W Xenon Lamp

Ci3000+/ Ci4000 / Ci5000 Weather-Ometer®Service Guide Doc. No. 07-7030-00 Rev. 0 30
5.0 TROUBLESHOOTING PROCEDURES
5.2 Xenon Lamp and Irradiance Control Malfunctions 5.2.1 Description (cont.)
3 4
MAIN
REACTOR
L1
L1-2
XENON
LAMP
XE
5
4
21
1
2
1
53
BOOSTER
TRANSFORMER
T1
X3 (15V) X2 (30V)
3 4
X1
L1-1
56
K1-4
L1-1
IGNITOR
L3a
3
2
L1-2
12
WATTAGE
TRANSDUCER
A1a (COIL)
L1-2
AUX.
REACTOR
L2
1
2
12
C1-2 CB2-1
67
L1-2
WATTAGE
REGULATOR
AR1
3
2
REAR PCB
FRONT PCB
2
PLC6-7
PLC6-19
1 (+)
IGNITION
PULSE
RELAY
K3
6
1
3 4
5
2
IGNITOR
L3b
PLC6
ANALOG OUTPUT
MODULE
WATTAGE
TRANS-
DUCER
RELAY
K9
4
3
F1
FUSE
INTERNAL
.062A
250V
TP1
TP2
A1-2
A1-1 A1-5
APC1
32 31
APC1
34 33 PLC5-8
A1-4
(+)
PLC5-10
A1b
WATTAGE
TRANSDUCER
1
9
10
WATTAGE
TRANS-
DUCER
RELAY
K9
RESISTOR
500 OHM
PLC5
ANALOG INPUT
MODULE
CB2-2
AMPLIFIER
RELAY
K5
34
XENON
LAMP
RELAY
K1
IGNITION
CIRCUIT
BREAKER
CB2
WATTAGE
TRANSDUCER
RELAY
K9
XENON
CIRCUIT
BREAKER
CB1
XENON
CIRCUIT
BREAKER
CB1
XENON
LAMP
RELAY
K1
IGNITION
CIRCUIT
BREAKER
CB2
2
1
4
3
IGNITION
PULSE
RELAY
K3
C1-2
C1-1
BLEEDER
RESISTOR
20K OHM
20W
IGNITION
CAPACITOR
C1
40 mfd
RELAY PLC TERMINAL LED#
K1 PLC3-2 A1
K3 PLC3-3 A2
K5 PLC3-7 A5
K9 PLC3-17 B5
RELAY COIL SWITCHING SOURCE
AND PLC INDICATOR LIGHTS
NOTE: WHEN PLC LED IS ON PLC CONTACT
IS CLOSED TO PROVIDE VOLTAGE TO RELAY.
Figure 5.2–1 Ci3000+Xenon Lamp Circuit
Ci3000+

Ci3000+/ Ci4000 / Ci5000 Weather-Ometer®Service Guide Doc. No. 07-7030-00 Rev. 0 31
5.0 TROUBLESHOOTING PROCEDURES
MAIN
REACTOR
L1
AUX.
REACTOR
L2
IGNITION
PULSE
RELAY
K3 WATTAGE
TRANSDUCER
RELAY
K9
AMPLIFIER
RELAY
K5
XENON
LAMP
RELAY
K1
XENON
LAMP
XE
4
5 3
2
1
2
1
67
34
4
3
1
2
1
L1-1
2
56
F1
FUSE
INTERNAL
.062A
250V
TP1 A1-2
A1-5
APC1
32 31
APC1
34 33 PLC5-8
A1-4
(+)
PLC5-10
A1b
WATTAGE
TRANSDUCER
RESISTOR
500 OHM
PLC5
ANALOG INPUT
MODULE
TP2 A1-1
1 2
WATTAGE
TRANS-
DUCER
RELAY
K9
4
3
C1-2
C1-1
WATTAGE
REGULATOR
AR1
REAR PCB
FRONT PCB
2
PLC6-7
PLC6-19
1 (+)
PLC6
ANALOG OUTPUT
MODULE
7
32
10
9
CB2-2
IGNITION
CIRCUIT
BREAKER
CB2
34
IGNITION
PULSE
RELAY
K3
6
5
2
1
BLEEDER
RESISTOR
56K OHM
34
3
4
C2 C3
BOOST
CAP. RELAY
K4
56Κ Ω 56Κ Ω
XENON
CIRCUIT
BREAKER
CB1
12
3 4
BOOSTER
TRANSFORMER
T1
2 3
1
XENON
CIRCUIT
BREAKER
CB1
XENON
LAMP
RELAY
K1
C2-1
VOLTAGE
BOOST
CAPACITORS
(40 MFD)
C3-1
C3-2
C2-2
TB2-2
L1-2 L1-2
IGNITOR
L3a
IGNITOR
L3b
WATTAGE
TRANSDUCER
A1a (COIL)
IGNITION
CIRCUIT
BREAKER
CB2
WATTAGE
TRANS-
DUCER
RELAY
K9
RESISTOR
R4
1.8K OHM
2W
TB2-2TB2-2
IGNITION
CAPACITOR
C1
L1-1
RELAY PLC TERMINAL LED#
K1 PLC3-2 A1
K3 PLC3-3 A2
K5 PLC3-7 A5
K9 PLC3-17 B5
RELAY COIL SWITCHING SOURCE
AND PLC INDICATOR LIGHTS
NOTE: WHEN PLC LED IS ON PLC CONTACT
IS CLOSED TO PROVIDE VOLTAGE TO RELAY.
Figure 5.2–2 Ci4000 Xenon Lamp Circuit
5.2 Xenon Lamp and Irradiance Control Malfunctions 5.2.1 Description (cont.)
Ci4000

Ci3000+/ Ci4000 / Ci5000 Weather-Ometer®Service Guide Doc. No. 07-7030-00 Rev. 0 32
5.0 TROUBLESHOOTING PROCEDURES
AUX.
REACTOR
L2
IGNITOR
L3
XENON
LAMP
XE
HIGH VOLTAGE
TRANSFORMER T4
STEP DOWN
TRANSFORMER
T3
IGNITION
CAP. RELAY
K3
WATTAGE
TRANS-
DUCER
RELAY
K9
3 4
3
4
2
1
4
3
11
52
1
10
7
8
346712L1-1
4
34
1
MAIN
REACTOR
L1
76
TB6-1
12
LOW
HI
LOW COM
4 3 3
4
K15
1-SUN
K4
2-SUN
60Hz
TB6-1
W
R
2
WATTAGE
REGULATOR
AR1
REAR PCB
FRONT PCB
2
PLC6-7
PLC6-19
1 (+)
PLC6
ANALOG OUTPUT
MODULE
2
13
460V 230V
TP 2
TP 1
1
2
FUSE
63 mA
SLO-BLO
RESISTOR
500 OHM
A1-5
APC1
34 33 PLC5-8
APC1
32 31
A1-4
(+)
PLC5-10
PLC5
ANALOG INPUT
MODULE
12
IGNITION
CIRCUIT
BREAKER
CB2
IGNITION
PULSE
RELAY
K3
IGNITOR
L3
HIGH VOLTAGE
TRANSFORMER T4
6
7
5
3
4
2
1
6
w/b
brn
w/b
blk
3 4
9
10
3
2
7
BLEEDER
RESISTOR
56K OHM
IGNITION
CAPACITOR
C1
(80 MFD)
WATTAGE
TRANSDUCER
A1a (COIL)
WATTAGE
TRANS-
DUCER
A1b
K1-4 CB2-1 CB2-2
BOOSTER
TRANSFORMER
T1
12
2 3
1
T1-1
WATTAGE
TRANSDUCER
RELAY
K9
AMPLIFIER
RELAY
K5
XENON
LAMP
RELAY
K1
IGNITION
CIRCUIT
BREAKER
CB2
XENON
CIRCUIT
BREAKER
CB1
WATTAGE
TRANS-
DUCER
RELAY
K9
XENON
CIRCUIT
BREAKER
CB1
XENON
LAMP
RELAY
K1
RELAY PLC TERMINAL LED#
K1 PLC3-2 A1
K3 PLC3-3 A2
K5 PLC3-7 A5
K9 PLC3-17 B5
RELAY COIL SWITCHING SOURCE
AND PLC INDICATOR LIGHTS
NOTE: WHEN PLC LED IS ON PLC CONTACT
IS CLOSED TO PROVIDE VOLTAGE TO RELAY.
Figure 5.2–3 Ci5000 Xenon Lamp Circuit
5.2 Xenon Lamp and Irradiance Control Malfunctions 5.2.1 Description (cont.)
Ci5000

Ci3000+/ Ci4000 / Ci5000 Weather-Ometer®Service Guide Doc. No. 07-7030-00 Rev. 0 33
5.0 TROUBLESHOOTING PROCEDURES
Figure 5.2–4 Xenon Lamp Assembly Guide
Burner Tip Must Not Be
Visible Beside Socket
End View of Lamp
Incorrect
Correct
Union Ring
Union Ring
Union Ring
Union Ring
Mounting Ring
Lamp
Water
Fitting
Union Ring
Union Ring
Outer
Filter
Union Ring
Union Ring
Union Ring
Inner
Filter
Lower
Filter
Housing
Union Ring
Spring
Burner
Socket
Burner
Socket
Upper
Filter
Housing
Sealing
Washer
Union Ring
Xenon
Burner
Burner
Base
Union Ring
Alignment
Pin
Alignment
Pin
Washer
Washer
Pin
Install the two
sealing washers
onto the outer
filter ends if none
are in place.
Check that the burner tip
is inside the socket as
shown. Gently hand
tighten the union ring.
Clean the outer filter with
an optical cleaner or a 1:1
mixture of alcohol and
acetone. Hold the lamp by
the upper or lower filter
housing only.
Check that there is a
sealing washer inside the
lamp water fitting.
Connect the lamp and
rotate it until the
alignment pin falls into
place. Gently hand
tighten the mounting ring.
Connect the upper
filter housing to the
outer filter. Be sure
to match the
alignment pin and
hole. Gently hand
tighten.
Hold the lamp
sideways, and
slowly slide the
inner filter into the
outer filter. Do NOT
drop the inner filter
in place or damage
may occur.
Check that the spring
inside the lower filter
housing tube is in place.
Connect the lower filter
housing to the outer filter.
Gently hand tighten the
union ring.
Turn the lamp upside
down. Check that the
sealing washer is in
place on the burner
base. Slide the
burner up into the
burner socket. Look
down through the
lower filter housing to
ensure that the
burner tip is inside
the burner socket.
Lamp Electrode
Outer
Filter
5.2 Xenon Lamp and Irradiance Control Malfunctions (cont.)

Ci3000+/ Ci4000 / Ci5000 Weather-Ometer®Service Guide Doc. No. 07-7030-00 Rev. 0 34
5.0 TROUBLESHOOTING PROCEDURES
5.2 Xenon Lamp and Irradiance Control Malfunctions (cont.)
5.2.2 Troubleshooting Guide
MALFUNCTION PROBABLE CAUSE CORRECTIVE ACTION
Lamp fails to ignite Chamber door open or switch failure Close door or check switch.
Xenon lamp/ignition breakers off Turn on circuit-breakers.
Lamp assembled/installed incorrectly Check lamp.
Lamp ignitor lead off or loose Check lead connections.
Light rod dirty or damaged Inspect/clean light rod.
Light monitor malfunction Check filters & photodiodes.
Lamp burner socket damaged Inspect/replace (Sec. 7.2.4).
Low lamp starting voltage Check/adjust taps on T1 and L1.
CS-6 cooling water flow low Check CS-6 (see Section 5.5)
Ignitor malfunction Conduct procedure in 5.2.6.
Relay failure in lamp circuit Conduct procedure in 5.2.6.
PLC malfunction Conduct procedure in 5.2.6.
Lamp output is high/low Burner is near end of life Replace xenon burner.
Lamp filters expired Replace lamp filters.
Burner tip/socket damaged Inspect/replace socket or burner.
Incorrect irradiance calibration Recalibrate (Section 6.9).
Interference filters expired Check/replace filters (Sec. 7.2.9).
Light rod is misaligned Align light rod (Secs. 7.2.14 & .15)
Wattage regulator malfunction Conduct procedure in 5.2.7.
Lamp will not operate 1-Sun or 2-Sun relay failure Perform procedure 5.2.8.
above 1-Sun level
(Ci5000 only)
Lamp operating at Burner is near end of life Replace xenon burner.
excessive wattage Lamp filters expired Replace lamp filters.
Burner tip/socket damaged Inspect/replace socket or burner.
Incorrect irradiance calibration Recalibrate (Section 6.9).
Interference filters expired Check/replace filters (Sec. 7.2.9).
Light rod is misaligned Align per Section 7.2.14 or 7.2.15.
Wattage regulator malfunction Conduct procedure in 5.2.7.
No wattage display Blown fuse F1 on A1 transducer Check fuse.
A1 wattage transducer board failure Check board output w/ lamp on.

Ci3000+/ Ci4000 / Ci5000 Weather-Ometer®Service Guide Doc. No. 07-7030-00 Rev. 0 35
5.0 TROUBLESHOOTING PROCEDURES
5.2 Xenon Lamp and Irradiance Control Malfunctions (cont.)
5.2.3Troubleshooting Flow Chart - Lamp Ignition Failure
3) Check for messages
on Data Panel MAIN
page 1.
2) Check lamp for age,
damage, proper installa-
tion and ignitor lead con-
nections.
5) Check for line voltage
to ignitor during pulse.
1) Confirm Xenon and
Ignition circuit-breakers
are on.
6) Check for continuity
between relay terminals
K3-5 & K3-6 (Ci3 & Ci4)
or K3-6 & K3-7 (Ci5)*.
4) Initiate standard test
no. 1.
7) Check for 24Vac at
relayK3coil duringpulse.
8) Check for continuity at
terminals PLC3-1 and
PLC3-3 during pulse.
Messages
displayed
“Lamp Water Temperature High”
“Lamp Water Flow is Low”
Check CS-6 cooling system
(Section 5.5).
“Chamber Temperature is High”
Reset chamber safety thermo-
stat S4 in electronics drawer.
Ignition pulse
is audible Install calibrated lamp
and attempt ignition. Lamp
ignites
Lamp does
not ignite
Previous lamp is malfunc-
tioning. Inspect for dam-
age. Check burner socket.
Measure line voltage and
check transformer taps.
Set T1 lamp voltage boost
to next higher selection
(see Section 5.1.5).
Also check light rod clean-
liness/integrity and light
monitor filters and photo-
diodes (Sec. 7.2.9).
Ignition pulse
is not audible
Voltage is
present On Ci3000+and Ci4000,
replace ignitor. On
Ci5000 check 1&2-Sun
relays K15 and K4.
No voltage
present
Continuity
No
Continuity
Check voltage at breaker
CB2. If no voltage, replace
breaker.
Voltage is
present
No voltage
present
Coil has failed. Replace
relay K3.
No
continuity
Continuity
IfLED A2 onPLC3 module
is on during pulse, replace
PLC3 module. If the LED
is off, download software
program to PLC (see
AppendixA & Sec.5.13.5).
9) Check for 24Vac at
TB3-7 & TB3-9 (Ci4) or
TB3-5 & TB3-8 (Ci5). No voltage CheckbreakerCB5 and T2
output at T2-X3 & T2-X4. Replace failed breaker or transformer T2.
*Ci3 denote Ci3000+
Ci4 denotes Ci4000
Ci5 denotes Ci5000

Ci3000+/ Ci4000 / Ci5000 Weather-Ometer®Service Guide Doc. No. 07-7030-00 Rev. 0 36
5.0 TROUBLESHOOTING PROCEDURES
5.2 Xenon Lamp and Irradiance Control Malfunctions (cont.)
5.2.4Troubleshooting Flow Chart - Irradiance High or Low
3) Confirm light monitor
output at PLC5-11 & -13
(or at PLC5-12 & -14 for
2nd light sensor).
2) Initiate standard test
no. 1.
5) Observe upper green
Power LED on wattage
regulator.
1) Perform Wattage Cali-
bration and Irradiance
Calibration procedures.
6) Check drive current
signal to wattage regu-
lator terminal AR1-1.
Should be approx. 4mA.
4) Initiate custom watt-
age-controlled test at
minimum lamp wattage.
No output
Current is
zero or well
above 4mA
Potential PLC6 module
failure. Confirm below.
Check light monitor filters
& photocells (Sec. 7.2.9).
LED is off Check for continuity at
relay K9 (K9-9 & K9-10).
Continuity R4 is open-circuited or
wattage regulator failed.
No
continuity Check for 24Vac across
relay K9 coil terminals.
Voltage
present No voltage present
Replace
relay K9.
If B5 LED on PLC3 is
on, replace PLC3. If
LED is off, download
software to PLC. If
operation not restored,
replace PLC3. See
Section 5.13.5.
7) Initiate custom mid-
range wattage test at:
Ci3-3000W,Ci4 – 5000W
Ci5 – 8000W
8) Observe lower green
Output LED on wattage
regulator.
LED dim or
off & drive
current well
above 4mA
Replace the wattage
regulator.
Drive
current is
still 4mA,
zero or
unstable
Replace PLC6 Analog
Output module (see
Section 5.13.8 first).
Run mid-range wattage
test again. Drive signal
should be approximately
9 to 11mA.
Drive
current in
range
Drive current
still zero or
out of range.
Replace the CPU
module of the PLC (see
Sec. 5.13.3). Run mid-
range wattage test
again and check drive
signal current.
Run standard test no.
1 and confirm stable
irradiance within test
tolerance.
Drive
current in
range
Reinstall old PLC6
module & confirm
operation by running
standard test no. 1.

Ci3000+/ Ci4000 / Ci5000 Weather-Ometer®Service Guide Doc. No. 07-7030-00 Rev. 0 37
5.0 TROUBLESHOOTING PROCEDURES
5.2 Xenon Lamp and Irradiance Control Malfunctions (cont.)
5.2.5Troubleshooting Flow Chart - 2-Sun Irradiance Considerations (Ci5000 only)
2) Check for rack speed
of 10 RPM. Rack at
1 RPM
No
continuity
Relay K14 or A14 rack
speed controller is
malfunctioning.
3) Check for continuity
betweenK14 relay termi-
nals K14-3 and K14-4. Continuity Check for 0 volts between
ground and relay K15
terminal K15-3. If voltage
present, K15 or K14 is
stuck closed. Replace bad
relay.
4) Check for 24Vac at
K14 coil terminals K14-1
and K14-2. Voltage
present
No voltage
Replace relay K14.
5) With K14 operating
properly, check for volt-
age between ground and
K4 relay terminal K4-3. No voltage
present
Voltage
present Relay K4 is o.k.
Check for 24Vac at K4
coil terminals K4-1 and
K4-2. If no voltage is
present, replace K4. If
voltage is present, re-
place PLC3 Logic Output
module (see Sec. 5.13.5
first).
1) Create and initiate a
custom 2-Sun test.
If A8 LED on PLC3 is
on, replace PLC3. If
LED is off, download
software to PLC. If
operation not restored,
replace PLC3. See
Section 5.13.5.

Ci3000+/ Ci4000 / Ci5000 Weather-Ometer®Service Guide Doc. No. 07-7030-00 Rev. 0 38
5.0 TROUBLESHOOTING PROCEDURES
5.2 Xenon Lamp and Irradiance
Control Malfunctions (cont.)
5.2.6 Troubleshooting Procedure –
Lamp Ignition Failure (Ignitor)
1)Ensure that thexenonlampisproperly installed
and that the ignitor lead is firmly secured to the
lamp electrode. Also ensure that the lamp lead
connection to the ignitor terminal is secure and
free of corrosion.
2) Confirm that the Xenon Lamp and Ignition
circuit-breakers are turned on.
3) Check for messages on the Data Panel MAIN
page 1 Messages display.
A) Check the CS-6 lamp cooling system
(Sec.5.5)ifoneofthesemessagesappears:
Lamp Water Temperature High
Lamp Water Flow is Low
B) If the message “Chamber Temperature is
High” is displayed, reset the chamber safety
thermostat(S4)insidetheelectronicsdrawer.
Pressthe red reset button on thethermostat.
4) Initiate standard test no.1 to attempt lamp
ignition.
5) If the ignition start pulse is audible (up to 4
attempts), but the lamp will not ignite, the problem
is either the lamp itself or low lamp-circuit voltage.
A) Install the calibrated reference lamp and
initiate the test. If the lamp lights, then the
previously installed xenon lamp is
malfunctioning. Examine it for damage,
burner tip and socket damage or corrosion.
Check the burner age as recorded on the
Xenon Burner Warranty Log card. The lamp
may be at the end of its life (1200 hours or
more).
B) If the calibration lamp will not ignite,
measure line voltage to the instrument and
Figure 5.2–8 Chamber Overtemperature Thermostat
S4
Figure 5.2–6 Ci4000 Xenon Lamp Ignitor
Figure 5.2–7 Ci5000 Xenon Lamp Ignitor
Figure 5.2–5 Ci3000+Lamp Ignitor & LS-8
Ignitor LS-8
Light
Monitor

Ci3000+/ Ci4000 / Ci5000 Weather-Ometer®Service Guide Doc. No. 07-7030-00 Rev. 0 39
5.0 TROUBLESHOOTING PROCEDURES
check the transformer tap connections as
describedinSection5.1.1.SettheT1booster
transformerleadT1-3tothenexthigherlamp
boost voltage terminal. Re-attempt lamp
ignition. If the lamp still does not ignite,
continue below.
Also check the light rod for cleanliness and
damage. Confirm the LS-8 light sensor
interferencefilters have not expired andthat
the photodiodes are functional (Sec. 7.2.9).
CAUTION: SHOCK HAZARD.
Conduct step 6 below with
meter leads clipped onto the
specified terminals. DO NOT hold probes
onto the terminals during lamp ignition or
electric shock and injury may result.
Note: In the steps below you must shut the
instrument off with the front panel power
switchaftereachattemptatignitingthelamp.
This will reset the lamp starting circuit.
6)Checkvoltagetotheignitor:Connectavoltmeter
(withclip leads)toterminalsL3-1 andL3-2.Attempt
lamp ignition while watching the meter. The meter
shouldindicatelinevoltage(230Vor480V)during
the ignition pulse.
A)Ifline voltage is present during the ignition
pulse, the ignitor has failed. Replace it (see
Section 8.6).
B) If no voltage is present, continue below.
7) Check relay K3 operation: During an ignition
attempt,checkforcontinuitybetween theterminals
of Ignition Pulse Relay K3. There should be
continuity for 1 second during each ignition pulse
between terminals:
5.2 Xenon Lamp and Irradiance
Control Malfunctions (cont.)
5.2.6 Troubleshooting Procedure –
Lamp Ignition Failure (Ignitor) (cont.)
Ci3/4000 - Terminals K3-5 and K3-6
Ci5000 - Terminals K3-6 and K3-7
A)IfthereiscontinuityacrosstheK3contacts
during the ignition pulse, then there is a
problem with the line voltage supply to the
relay. Check wiring to the relay and voltage
at the CB2 Ignition circuit-breaker terminals
CB2-2 and CB3-4. There should be line
voltage between each terminal and ground.
If not, replace the circuit-breaker.
B) If the relay does not activate, its coil is
badorthePLCis not sending it an activation
signalorthe24VacsupplytothePLCisbad.
B1) Check for 24Vac on the relay coil during
theignition pulse. If24Vacispresent,thecoil
is bad. Replace the relay (see Section 8.1).
B2) During the ignition pulse, check for
continuity between terminals PLC3-1 and
PLC3-3. If there is no continuity, and the A2
LEDonPLC3ison,replacethe module (see
Section 5.13.5 first). If A2 is off, download
the PLC software program to the PLC.
B3) Check for continuous 24Vac across:
Ci3/4000 – TB3-7 and TB3-9
Ci5000 – TB3-5 and TB3-8
Thisisthe 24Vac supply to the 24Vac control
circuit. If 24Vac is not present, check circuit-
breaker CB5 and the 24Vac output of the
isolation transformer T2 at terminals
T2-X3andT2-X4.Replacethe failedbreaker
or transformer.
5.2.7 Troubleshooting Procedure – Irradiance
Low or High (Wattage Regulator)
Tomaintain anaccurateandstableirradiance level
during a test, the PLC receives a signal from the
light monitor (at PLC5-11/-13 or PLC2-12/-14),
compares it to the irradiance setpoint reference,
and then alters its output (at PLC6-7/-19) to
increase or decrease wattage regulator output.

Ci3000+/ Ci4000 / Ci5000 Weather-Ometer®Service Guide Doc. No. 07-7030-00 Rev. 0 40
5.0 TROUBLESHOOTING PROCEDURES
Thisdrivesignal is applied to terminals AR1-1 and
AR1-2 of the wattage regulator AR1.
Troubleshooting consists of first confirming light
monitoroperationanditsoutputsignalto the PLC.
Then the instrument is operated at constant
wattage and the PLC output signal to the wattage
regulator is checked. If a stable drive signal is
present, but lamp operation is erratic or out of
wattage tolerance, it is likely that the wattage
regulator is malfunctioning.
1) Perform the Wattage Calibration (Sec. 6.8) and
then the Irradiance Calibration (Sec. 6.9) to
eliminate calibration as a contributive factor.
2) Initiate standard test no. 1 SAE J-1885. Set it
up so the lamp will operate for 30 minutes.
3)With the lampoperating,confirmthatthevoltage
signal from the light monitor is present at the PLC
5.2 Xenon Lamp and Irradiance
Control Malfunctions (cont.)
5.2.7 Troubleshooting Procedure – Irradiance
Low or High (Wattage Regulator) (cont.)
terminals PLC5-11 and PLC5-13 (or at terminals
PLC5-12 and PLC5-14 if the optional sensor is
installed and is controlling irradiance).
A)Ifnovoltageis present, there is a problem
withthelightsensorwiring,interferencefilter
orthephotocell. Check each of thesebefore
continuing (See Section 7.2.9).
B) If the signal is present, the light monitor is
functioning properly.
4) Shut off all power to the instrument at the wall-
mounted disconnect switch.
5) Disconnect the AR1-1 lead from the wattage
regulator and connect an ammeter in series with
the lead and terminal AR1-1. This will allow
measurement of the 4-20mA drive signal from the
PLC to the wattage regulator.
6)Apply power to the instrument. Initiate a custom
test using wattage control rather than irradiance
control. Set the wattage level to minimum for the
lamp type in use (1700 watts for Ci3000+, 2500
watts for Ci4000, 4000 watts for Ci5000). Set the
test duration to 30 minutes.
7)Observe the LEDindicatorlightsonthe wattage
regulator. With power on and the xenon lamp
operating, the upper green lamp should be on
indicating that the regulator is receiving power.
Figure 5.2–10 Wattage Regulator Power LED
Power
LED
Figure 5.2–9 Xenon Lamp Wattage Regulator

Ci3000+/ Ci4000 / Ci5000 Weather-Ometer®Service Guide Doc. No. 07-7030-00 Rev. 0 41
5.0 TROUBLESHOOTING PROCEDURES
A)If the LEDisoff,check for continuityacross
terminalsK9-9andK9-10 ofrelayK9.Ifthere
is continuity, then resistor R4 (Ci4 only) is
open-circuited or the wattage regulator has
failed.Replacethe regulator per Section 8.7.
B)Check for 24Vac voltsacross the K9relay
coil terminals K9-1 and K9-2.
B1) If voltage is present, and there is no
continuity between terminals K9-9 and
K9-10, replace relay K9 per Section 8.1.
B2) If voltage is not present, and the B5
LED on PLC3 is on, replace the PLC3
module (see Section 5.13.5). If B5 is off,
download the software program to the
PLC. If this fails to restore operation,
replace PLC3.
8) Observe the ammeter on the AR1-1 terminal. It
should display a reading of approximately 4mA.
A) If the ammeter reading is zero, or well
above 4mA, there is potentially a problem
5.2 Xenon Lamp and Irradiance
Control Malfunctions (cont.)
5.2.7 Troubleshooting Procedure – Irradiance
Low or High (Wattage Regulator) (cont.)
Figure 5.2–11 Wattage Regulator Output LED
Soft
Start
LED
Output
LED
with the PLC Analog Output PLC6 module.
(This will be checked in a later step.)
9) Stop the wattage test and alter it to the mid-
range operating wattage level shown below.
Ci3000+– 3000 watts
Ci4000 – 5000 watts
Ci5000 – 8000 watts
10) Initiate the new test to ignite the lamp.
11) Observe the green LED indicator light on the
lower circuit board of the wattage regulator. This
is the output indicator and becomes brighter as
output increases. It should be on brightly.
A) If the LED is very dim or off, and the
ammeter reading is well above 4mA, there
is a problem with the wattage regulator
output. Replace the regulator (Section 8.7).
B)Iftheammeterreading iszero,still at4mA
or is unstable, there is a problem with the
PLCAnalogOutputPLC6moduleorthePLC
CPU (PID settings, corrupt PLC software or
CPU failure).
B1) Replace the PLC6 module (see Sec.
5.13.8 first). Run the mid-range wattage
test again. Check the level and stability
of the ammeter reading. It should be very
stable and approximately 5 to 10 mA.
B2) If replacement of the PLC6 module
does not correct the problem, download
the custom programs from the PLC to a
laptop computer and replace the CPU
moduleofthePLC(seeSections5.13and
Appendix A). Upload the custom pro-
grams and the correct PLC operating
software.Runthemid-range wattage test
again and observe the ammeter reading
for stability. If this corrects the problem,
reinstallthe old PLC6moduleandconfirm
operation.

Ci3000+/ Ci4000 / Ci5000 Weather-Ometer®Service Guide Doc. No. 07-7030-00 Rev. 0 42
5.0 TROUBLESHOOTING PROCEDURES
If the xenon lamp in the Ci5000 fails to operate at
higher (2-Sun) irradiance levels, there may be a
malfunction of the 1-Sun or 2-Sun relays, or the
componentsdrivingthem(Fig.5.2–9).Additionally,
if the error message “Test Irrad. Not Match with
Filters”appearsonthe screen at the start of atest,
it indicates that the irradiance level chosen is in
the2-Sun rangeandyoumustrecalibratethelamp
for this irradiance level.
2-Sun irradiance levels are defined as follows:
0.70 W/m2or higher @ 340 nm filter
1.40 W/m2or higher @ 420 nm filter
75.0 W/m2or higher @ 300-400 nm filter
At 1-Sun irradiance levels, the rack rotates at 1
RPM. At 2-Sun levels it rotates at 10 RPM. Relay
K14switchestheinputtothe rack speed controller.
Conduct the procedure below to determine the
cause of 2-Sun operation failure.
5.2 Xenon Lamp and Irradiance
Control Malfunctions (cont.)
5.2.8 Troubleshooting Procedure – 2-Sun
Irradiance Considerations
1) Program a custom, 2-sun irradiance test with
the parameters shown below.
Test List (Data Panel page 6)
Select an unused Custom test. Press F6, the test
number and Enter three times. Press F2.
Test Criteria (Data Panel page 7)
Total Segments 1
Duration Units Time
Black Sensor BPT
Black Temp. Active Yes
Radiation@filter 340 nm
Chamber Temp. Active No
Segment (Data Panel page 8)
Segment Number 1
Light or Dark Light
Time or Irradiance 30 min.
Irradiance 1.50 W/m2
Black Temp. 80 °C
Chamber (DB) Temp. 60 °C
Relative Humidity 0 %
Segment (cont.) (Data Panel page 9)
Set sprays to off.
Test List (Data Panel page 6)
Press F8. Press F5, the custom test number and
Enter three times to load the new custom test.
Run/Stop Segment (Data Panel page 3)
Test Duration 0 hours 30 min
2) Press F4 on RUN/STOP page 3 to start the test.
CAUTION: SHOCK HAZARD
In the procedures below, you
must check for voltages at live
electrical terminals. Avoid
contact with component terminals and
wearinsulated gloves to prevent electrical
shock.
3) When the Ci5000 is running a test at
2-Sun irradiance level, the rack should be rotating
at 10 RPM. Check rack speed. If it is rotating at 1
RPM, relay K14 or the rack speed control A14 is
malfunctioning (see Section 5.8).
3
4
C
O
I
L
K15
ONE
SUN
RELAY
TB3-11
COIL
K14
RACK
SPEED
RELAY
A14-S2
A14-S1 R2
10K
A14-S3 K14-3K14-4
K14-9
K14-1 K14-2 TB3-9
K15-2
K15-1
L1
MAIN
REACTOR C
O
I
L
K4
TWO
SUN
RELAY
3
4
K4-1
K4-2
L3
IGNITOR
L2-2K3-3
TB6-1
24Vac
TB3-5
TB3-6
TB3-7
PLC3-10
L3-12
TB6-1
K14-11
LOW
HI
PLC3-5
LOW COM
A14
RACK
MOTOR
SPEED
CONTROL
TB3-8
24Vac
N.C.N.C.
TB2-2
PLC3
LOGIC
OUTPUT
MODULE
A8
PLC3
LOGIC
OUTPUT
MODULE
A4
Figure 5.2–12 One and Two Sun Circuit Block Diagram

Ci3000+/ Ci4000 / Ci5000 Weather-Ometer®Service Guide Doc. No. 07-7030-00 Rev. 0 43
5.0 TROUBLESHOOTING PROCEDURES
In 2-Sun mode, PLC3 de-energizes (closes) the
2-SunrelayK4.It alsoenergizesrelayK14causing
the1-SunrelayrelayK15 toopen.K14alsocauses
closureofcontacts A14-S2 and A14-S3 of the A14
rack speed control board to provide 10 RPM rack
rotation (see Fig. 5.2–9).
3) Check for continuity between terminals K14-3
and K14-4.
A) If there is continuity, relay K14 is likely
operating properly. Check for voltage
between ground and terminal K15-3 of relay
K15.Itshouldbe0volts.Ifvoltageispresent,
K15 is stuck closed or contacts K14-9 and
K14-11 of relay K14 are stuck closed.
Replace the malfunctioning relay (Sec. 8.1).
B)If there is no continuity,check for24Vac
at the K14 coil terminals K14-1 and K14-2. If
voltageispresent,replaceK14.Ifnovoltage
ispresent, andtheA8indicator lightonPLC3
is off, download the software program to the
PLC. If indicator light A8 is on, replace the
PLC3 Logic Output module (see Section
5.13.5 first).
4) With relay K14 operating properly, check for
voltagebetween groundandterminalK4-3 of relay
K4.
A) If voltage is present, K4 is o.k.
B) If voltage is not present, check for 24Vac
at the K4 coil terminals K4-1 and K4-2. If
voltage is present, the PLC3 Logic Output
module is malfunctioning. Replace it (see
Section5.13.5 first). If voltage is notpresent,
relay K4 is stuck open. Replace K4 (Sec.
8.1).
5.2 Xenon Lamp and Irradiance
Control Malfunctions (cont.)
5.2.8 Troubleshooting Procedure – 2-Sun
Irradiance Considerations (cont.)