Casella Evolution CM2010 User manual

Internal Zero and Span Module for
Evolution Series
CM2010 Ozone Analyser
Service Manual
RegentHouse,WolseleyRoad
Kempston,Bedford
EnglandMK427JY
Tel:[phone]
Fax:[phone]
[e-mail]
HB4014-02 Printed in the UK
Mar - 2011

EVOLUTION SERIES CM2010 OZONE ANALYSER
2 HB4014-02
Contents
1Installation ........................................................................................................................................3
2Theory of Operation.........................................................................................................................5
2.1 IZS Description ............................................................................................................................................5
Generator Chamber.....................................................................................................................................5
Zero Air Scrubber.........................................................................................................................................5
Pneumatic Valves ........................................................................................................................................5
Pneumatic Fittings and Tubing ....................................................................................................................5
IZS Control PCA............................................................................................................................................5
3Service...............................................................................................................................................9
3.1 Periodic Maintenance...................................................................................................................................9
Check Zero Air Scrubber ............................................................................................................................10
Charcoal Replacement...............................................................................................................................10
Disposable Filtration Unit (DFU) Replacement..........................................................................................11
Purge Filter and Orifice..............................................................................................................................11
Flow Test....................................................................................................................................................12
Leak Test....................................................................................................................................................12
3.2 Replaceable Parts......................................................................................................................................12
3.3 Troubleshooting .........................................................................................................................................13
DC Power Supply Voltages.........................................................................................................................13
Troubleshooting Guide..............................................................................................................................13
3.4 Routine Maintenance.................................................................................................................................14
Lamp Adjustment ......................................................................................................................................14
Lamp Replacement....................................................................................................................................15
Generator Cleaning....................................................................................................................................15
4Circuit Diagrams ............................................................................................................................16

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1 Installation
This section contains a diagram outlining the installation of the IZS module. If the IZS module has al-
ready been installed, disregard this section.
If required, install the IZS module as shown in Figure 1-1 and Figure 1-2 below.
Figure 1-1 CM2010 IZS Installation

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Figure 1-2 CM2010 IZS Plumbing

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2 Theory of Operation
The CM2010 IZS uses the principle of UV irradiation of oxygen molecules to produce ozone. Oxygen
absorbs ultraviolet light whose wavelength is approximately 185 nanometres (nm). The energy at this
wavelength is sufficient to separate the oxygen molecule into two atoms. The oxygen atoms then react
with oxygen molecules to form ozone.
A mercury vapour lamp is used as the source of 185 nm light. This lamp differs from lamps used for
ozone measurement in the type of glass used in the lamp envelope. The envelope of an ozone-
producing lamp is transparent to 185 nm light, and a measurement lamp is opaque to 185 nm light.
Zero air is pulled through the disposable filtration unit (DFU) to introduce particulate and ozone-free air
to the IZS and the ozone generating chamber. In the chamber, oxygen in the air is irradiated by a mer-
cury vapour lamp and a constant number of ozone molecules per unit time are produced.
The actual amount of ozone produced depends on the flow rate through the chamber and the intensity
of the UV light in the generating chamber. During span, the air flow rate in the chamber is the same as
the analyser flow rate. The intensity of the UV is regulated by the IZS Control PCA, under control of the
Microprocessor PCA, and is proportional to the amount of current through the UV lamp. The UV lamp is
kept on at all times to maintain thermal stability, but current through the lamp may be altered through
the course of a calibration cycle to produce different ozone concentrations.
When ZERO is selected, the analyser sample stream is switched to draw air directly from the zero air
scrubber. When SPAN is selected, the analyser sample stream is selected to monitor the output of the
ozone generating chamber. A continuous, low-volume purge flow is provided to the span chamber. This
prevents saturation of the air in the generating chamber from continuous exposure to UV energy.
2.1 IZS Description
The IZS module is composed of a generator chamber with heaters and a UV lamp, a zero air scrubber,
pneumatic fittings and tubing, and the IZS Control PCA.
Generator Chamber
The generator chamber is constructed of machined aluminium. Zero air is passed through a quartz
glass tube and past the UV lamp. The quartz tube is transparent to UV energy, so zero air is irradiated
by the UV lamp producing ozone. The chamber body and lamp are kept at a constant temperature by
the heater/thermistor assembly, thus ensuring stable span concentrations.
Zero Air Scrubber
The zero air scrubber is a canister filled with activated charcoal. Activated charcoal removes O3from
the ambient air, providing a clean zero air source for zero measurements and ozone generation. The
output of this canister is filtered through a DFU to remove any particulate contamination.
Pneumatic Valves
The sample, zero, and span gas streams are switched by a three-valve manifold.
Pneumatic Fittings and Tubing
All pneumatic fittings used in the IZS module are made from Kynar; the tubing is Teflon. These materi-
als are chemically non-reactive to the gases generated by the IZS module.
IZS Control PCA
The IZS Control PCA contains circuitry for temperature control of the generation chamber, a driver cir-
cuit for the ozone generating lamp, and circuitry to monitor temperatures and lamp current.

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Figure 2-1 Pneumatic diagram

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Figure 2-2 Major components

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Figure 2-3 System block diagram

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3 Service
This section includes periodic maintenance procedures, a list of replaceable parts, a troubleshooting
voltages table, and a troubleshooting guide.
3.1 Periodic Maintenance
The table below outlines a periodic maintenance schedule for the CM2010 IZS module. This schedule
is based on experience under normal operating conditions, and may need to be modified to suit specific
operating conditions.
Table 3-1 Routine maintenance
Interval1
Item
Procedure
6 months
Zero Air Scrubber
Check/Replace2
1 year
DFU Filter
Replace
Purge Filter/Orifice
Clean/Replace
Flow/Leak Check
Perform
1Suggested intervals for normal operation, and actual intervals will vary depending upon application.
This table can be used as a guideline, but the user should develop a maintenance schedule to suit
their specific requirements.
2Replacement interval determined by ambient pollutant levels.
Figure 3-1 Maintenance components

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Check Zero Air Scrubber
The zero air supply is critical to the operation of the CM2010 analyser and the IZS module. Poor zero
air can result in numerous problems (for example, inaccurate measurements near zero and span drift).
Check the quality of the zero air system by challenging the analyser with a known good zero air source
(such as commercially available Ultra Zero Air) or a known good charcoal scrubber. To check the zero
air system, perform the following procedure.
Required Equipment: Test zero air supply
1. From the CALIBRATION MENU, put the analyser in CAL. MODE: ZERO. This allows the ana-
lyser to sample zero air from the zero air scrubber. Allow the analyser to sample for
approximately 15 minutes.
2. Record the front panel O3reading as the initial value.
3. Connect the challenge zero air to the Sample inlet of the analyser. Be sure the inlet pressure is
maintained at ambient pressure.
4. From the CALIBRATION MENU, select CAL. MODE: MEASURE and press the <Enter> key.
This allows the analyser to sample the challenge zero air. Allow the analyser to sample for
15 minutes.
5. Record the front panel O3reading as the challenge value.
6. Compare the initial O3value and the challenge value. They should agree within 0.002 PPM. If
the initial value is more positive than the challenge value, recharge or replace the zero air
scrubber.
7. Disconnect the challenge zero air and reconnect the sample line to the Sample inlet of the ana-
lyser. Verify that the analyser is in the Sample Measure mode.
The life span of a zero air scrubber typically depends on the amount of pollutant it is required to scrub.
Closely monitor the performance of the zero air system after initial installation and note when the zero
air begins to degrade. This interval can be used as the baseline for establishing a zero air maintenance
schedule.
Table 3-2 Charcoal replacement schedule
Average Ambient O3Concentration
Charcoal Replacement Interval
0 to 30 ppb
12 Months
30 to 100 ppb
6 Months
> 100 ppb
1 Month
Charcoal Replacement
1. Turn the analyser pump off.
2. Disconnect the pneumatic fitting from the top of the scrubber and DFU. Loosen the Velcro strap
securing the scrubber and remove the scrubber from the analyser.
3. Unscrew the scrubber cap and remove the plastic insert, metal screen, and felt pad. Pour the
charcoal out of the scrubber and refill with fresh charcoal.
4. Replace the felt pad, metal screen, plastic insert, and canister lid.

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5. Reinstall the scrubber in the analyser. Secure the Velcro strap and reconnect the pneumatic fit-
ting.
6. Turn the analyser pump back on.
Disposable Filtration Unit (DFU) Replacement
The zero air from the scrubber is filtered by the disposable filtration unit (DFU) to prevent contamination
of the pneumatics and reaction cell. Failure of the DFU could result in poor zero readings or loss of
purge/supply air to the IZS. This filter is connected to the top of the charcoal scrubber. Replace the filter
annually or whenever it begins to discolour.
To replace the filter:
1. Turn off the pump.
2. Remove and retain the Kynar nuts from both ends of the DFU.
3. Remove and replace the DFU, ensuring that the direction of flow is correct.
4. Reinstall the Kynar nuts, ensuring that the ferrules are properly installed in the nuts.
5. Turn on the pump.
Purge Filter and Orifice
The purge orifice ensures that sufficient air is continuously drawn through the span chamber to prevent
saturation of the permeation chamber with O3. Replace the filter and check and clean the orifice to en-
sure proper operation.
Recommended Equipment: Orifice/filter removal tool (P/N 98000190)
1. Turn off the pump.
2. The purge filter is in one arm of the Kynar tee connected to the outlet of the span chamber. Us-
ing the orifice removal tool, remove and replace the filter. Be sure to use a new O-ring when
installing the new filter, and orient the filter with its threaded port facing outward.
3. The purge orifice is in one arm of the Kynar tee connected to the exhaust line inside the rear of
the analyser. Using the orifice removal tool, remove and clean or replace the orifice. Be sure to
use a new O-ring when reinstalling the orifice, and orient the orifice with its threaded port facing
outward.
4. Turn on the pump.
5. Perform the flow test described below after cleaning or replacing the filter or orifice.

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Flow Test
Perform a flow test of the IZS module whenever a pneumatic components are replaced or whenever
corrective maintenance is performed.
Required Equipment: Flow meter (0.50 slpm nominal)
1. From the CALIBRATION MENU, select CAL MODE: MEASURE.
2. Connect the flow meter to the inlet (bottom) of the zero air scrubber. Verify a flow of 0.04
0.02 slpm.
3. From the CALIBRATION MENU, select CAL MODE: SPAN. Verify a flow of 0.50 0.10 slpm.
4. Disconnect the flow meter.
Leak Test
Perform a leak test of the IZS module whenever corrective maintenance is performed. To perform a
leak check, plug the inlet (bottom) of the zero air scrubber and check according to the instructions in the
CM2010 Service Manual. Due to the small size of the purge orifice, it will take additional time to evacu-
ate the IZS pneumatics (up to 20 minutes).
3.2 Replaceable Parts
CM2010 IZS Module Spare Parts Requirements
Description
Part Number
Level
Filtration unit, disposable
036-040180
1
O-ring, quartz tube
25000442-111
1
O-ring, orifice and sintered filter
25000447-007
1
Fitting, reducing, 1/2 inch to 1/8 inch
28280802-12
1
Charcoal, activated, 2 pound bulk container
850-056500
1
Scrubber, zero air
855-005604
1
Orifice, 3 mil (purge)
98000180-01
1
Filter, sintered
98000181-1
1
Tube, quartz
98107014-1
1
Heater thermisor assembly
98107017-1-SP
1
Lamp, ultraviolet, normal level
98110012
1
Lamp, ultraviolet, low level
98110012-2
1
Lamp, ultraviolet, high level
98110012-3
1
PCA, Internal Zero/Span Control
98110036-3-SP
1
Valve manifold
98300037-SP
1

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3.3 Troubleshooting
DC Power Supply Voltages
Before consulting the troubleshooting section below, verify that the DC power supply voltages on the
Heater Control PCA are present and within the specifications given for each voltage listed in the follow-
ing table.
Table 3-3 DC Power supply voltages
Voltage
DMM (–)
DMM (+)
Response
+12 V
AGND (TP4)
J1-22
+12 ±0.5 V
+10 V
AGND (TP4)
TP3
+10 0.2 V
-10 V
AGND (TP4)
TP1
-10 0.2 V
+5 VR
AGND (TP4)
J4-15
+5 ±0.25 V
Troubleshooting Guide
Use this troubleshooting guide to find the symptom, then follow in order the possible causes and solu-
tions. When the problem is identified, take the corrective action recommended. If you cannot identify
the problem, E-mail technical support –[e-mail].
Symptom
Possible Cause
Solution
The DC voltages in Table 3-3
DC Power supply voltag-
esabove are not present.
Power cable not connected.
Verify that the IZS control cable is
connected to Vreg connector J5.
Failed IZS Control PCA.
Replace the IZS Control PCA.
Low span.
Bad calibration.
Re-calibrate the O3generator.
Dirty quartz tube.
Clean the quartz tube.
High flow.
Check flow (refer to “Flow Test”
section).
Bad lamp.
Replace the UV lamp (refer to
“Lamp Replacement” on page 15).
Failed IZS Control PCA.
Replace the IZS Control PCA
High span.
Bad calibration.
Re-calibrate the O3generator. Re-
fer to the CM2010 IZS Module
Operation Instructions.
Low flow.
Check flow (refer to “Flow Test”
section).

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Symptom
Possible Cause
Solution
Unstable span readings.
Bad zero air.
Check the zero air supply (refer to
“Zero Air Scrubber” on page Error!
Bookmark not defined.) and re-
place DFU filter.
Leak.
Perform a leak check.
Loss of purge flow through the
generator.
Verify a purge flow of approximately
35 cc/min. (refer to “Flow Test”). If
flow is low, replace the purge filter,
orifice, or DFU.
Unstable analyser flow.
Check analyser flow and verify
stability over time.
Dirty generator quartz tube.
Clean the quartz tube (refer to
“Generator Cleaning”).
Unstable generator chamber
temperature.
Verify that O3lamp temperature is
50 °C 5 °C and stable. If not, re-
place the heater/thermistor or the
IZS Control PCA.
Bad UV lamp.
Replace the UV lamp (refer to
“Lamp Replacement”).
Failed IZS Control PCA
Replace the IZS Control PCA.
Lamp current does not go to
maximum when GEN LAMP:
CALIBRATE is selected
analyser not in CAL. MODE:
SPAN.
Select CAL. MODE: SPAN in the
CALIBRATION MENU.
3.4 Routine Maintenance
Lamp Adjustment
The physical position of the lamp can be adjusted to achieve higher or lower concentrations of O3 if
desired by the operator. Adjust the lamp as follows:
1. From the CALIBRATION MENU, select CAL MODE: SPAN.
2. From the O3 GEN. MENU, select GEN. LAMP: CALIBRATE and press <Enter>. Verify that the
LAMP CURRENT increases to around 7 mA.
3. Allow the analyser to run in Calibrate mode for about 5 minutes. This allows the lamp to reach
operating temperature and stabilize.
4. Loosen the set screw securing the UV lamp and adjust the lamp (rotate and slide in and out of
the generator body) until the desired O3output is achieved. Allow enough time for the output to
stabilize after each adjustment.
Note: This will now be the maximum value that the UV lamp can achieve.
5. Secure the set screw.
6. Select GEN. LAMP: OPERATE and press <Enter>.
7. Recalibrate the O3generator. Refer to the CM2010 IZS Module Operation Instructions.

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Lamp Replacement
Over time the UV lamp output degrades. This may cause the O3generator output to become unstable
or too low. Replace the UV lamp as follows:
1. Turn the analyser off.
2. Loosen the set screw securing the UV lamp into the generator body.
3. Disconnect the UV lamp electrical connector from the IZS Control PCA.
4. Slide the UV lamp out of the generator body.
5. Install the new lamp in the generator body.
6. Connect the UV lamp electrical connector to the IZS Control PCA.
7. Turn the analyser on and allow it to stabilize.
8. Perform the UV lamp adjustment procedure. Refer to Lamp Replacement section.
Generator Cleaning
The quartz tube inside the O3generator is where the actual production of ozone takes place. Over time,
the tube may become contaminated or dirty, resulting in noisy or low output values from the O3genera-
tor. Clean the tube as follows:
WARNING:
The quartz tube is fragile. Exercise extreme care during han-
dling.
1. Turn the analyser off.
2. Disconnect the inlet and outlet tubing from the O3generator.
3. Remove the fitting from the front end of the O3generator and slide the quartz tube out the rear
of the generator housing.
4. Clean the quartz tube using a mild soap or alcohol. Avoid leaving dirt, lint, or fingerprints on the
body of the quartz tube. Allow the tube to air dry before installation.
5. Reinstall the quartz tube in the generator body and reinstall the fitting on the front of the tube.
The fitting must be tightly secured, but be careful not to crack the quartz tube.
6. Reconnect the inlet and outlet tubing.
7. Leak test the IZS module. Refer to Leak Test on page 12.
8. Turn the analyser on and allow it to stabilize.
9. Recalibrate the ozone generator. Refer to the CM2010 IZS Module Operation Instructions.

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4 Circuit Diagrams