MAC MAC155L User manual

©Copyright MAC Instruments 2005. All Rights Reserved. MAC155 Rev. 12
Instruction Manual
for the
MAC155L
&
MAC155H
Moisture Analyzer

©Copyright MAC Instruments 2005. All Rights Reserved. MAC155 Rev. 12
Instruction Manual
for the
MAC155L
&
MAC155H
Moisture Analyzer

©Copyright MAC Instruments 2005. All Rights Reserved. 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

MAC155 Rev. 12 ©Copyright MAC Instruments 2005. All Rights Reserved.
Pg ii
WATER FILLING / FLUSHING KIT........................................................................................ 24
FILLING WATER TANK.........................................................................................................25
WATER TANK FLUSHING ....................................................................................................26
START UP ............................................................................................................................. 28
STATUS INDICATORS.......................................................................................................... 29
AUTOMATIC CALIBRATION CHECK ...................................................................................31
MAINTENANCE ............................................................................................. 33
FILTER / EXTENSION TUBE ................................................................................................33
INSTALLING THE FILTER .............................................................................................33
WATER TANK........................................................................................................................ 36
SAMPLING PUMP ................................................................................................................. 37
CALIBRATION PUMP............................................................................................................38
PERISTALTIC PUMP TUBING REPLACEMENT.................................................................. 39
TROUBLE SHOOTING................................................................................... 43
MECHANICAL TESTS...........................................................................................................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 Indicators.....................................................................................................50
Electrical Tests – Probe ......................................................................................................... 51
+/– 15V Power ................................................................................................................51
+5V Digital Power...........................................................................................................52
+5V Analog Power..........................................................................................................52
Status Indicators.............................................................................................................52
CONTROLLER MENU NAVIGATION ............................................................ 55
GENERAL MENU OPERATION ............................................................................................55
SETUP MENU........................................................................................................................ 56
TIME SET .......................................................................................................................56
SET AUTO CALCHECK TIME .......................................................................................57
DISPLAY BRIGHTNESS SELECTION ..........................................................................57
ANALOG OUTPUT RANGE SELECTION ..................................................................... 58
PROBE MBV RANGE SELECTION............................................................................... 58
MAINTENANCE RELAY SET UP ..................................................................................59
PLC INTERFACE SET UP (Option) ...............................................................................59
MODBUS RTU ADDRESS SET UP (Option)................................................................. 60

©Copyright MAC Instruments 2005. All Rights Reserved. MAC155 Rev. 12
Pg iii
MODBUS RTU BAUD RATE SET UP (Option) .............................................................61
DIAGNOSTIC MENU ............................................................................................................. 62
FORCED OUTPUT SIGNAL .......................................................................................... 62
MANUAL CAL PUMP OPERATION ............................................................................... 63
FORCED FILTER BLOW BACK .................................................................................... 63
MANUAL CASE HTR OPERATION ............................................................................... 64
FORCE COND TEMP 100°............................................................................................ 64
FORCE COND TEMP 130°............................................................................................ 65
MAINTENANCE MENU .........................................................................................................66
MANUAL CALIBRATION MODE.................................................................................... 66
MANUAL CALIBRATION CHECK MODE ...................................................................... 67
MANUAL PROBE MAINTENANCE MODE.................................................................... 67
PLC INTERFACE CONTROLLER OPTION ................................................... 68
PLC INTERFACE SETUP...................................................................................................... 69
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 ......................................................................................... 74
TIME SET-UP ........................................................................................................................ 75
CALIBRATE OPERATION SCREEN..................................................................................... 76
CALCHECK OPERATION SCREEN ..................................................................................... 77
IN MAINTENANCE OPERATION SCREEN .......................................................................... 78
GENERAL CONFIGURATION MENU ................................................................................... 79
ALARM EMAIL SETUP.......................................................................................................... 79
Email To: ........................................................................................................................ 80
Email From: ....................................................................................................................80
Email Subject:................................................................................................................. 80
Email Server: .................................................................................................................. 81
Outgoing Email Server Requires Authorization.............................................................. 81
Email Server User Name:............................................................................................... 81
Email Server Password: ................................................................................................. 81
Email Alarm Status Active: ............................................................................................. 81
MAC155 PROBE MOISTURE SCALE SELECTION ............................................................. 82
NETWORK CONFIGURATION MENU.................................................................................. 82
NETWORK ADDRESS CONFIGURATION ........................................................................... 83

MAC155 Rev. 12 ©Copyright MAC Instruments 2005. All Rights Reserved.
Pg iv
USERNAME AND PASSWORD SET-UP..............................................................................84
AUTOMATIC CALCHECK TIME SET-UP .............................................................................84
MODBUS RTU CONTROLLER OPTION ....................................................... 86
Overview ................................................................................................................................86
Modbus Setup ........................................................................................................................ 86
Modbus Coil & Register Data.................................................................................................86
Controller Inputs .............................................................................................................86
Controller Outputs ..........................................................................................................87
Drawings........................................................................................................ 88
Mounting Outline .................................................................................................................... 88
Typical Installation.................................................................................................................. 91
Mounting Adapters ................................................................................................................. 93
Wall Mount Remote Sampling Probe Outline ........................................................................95
Wall Mount Remote Sampling 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
PLC Interface Wiring Diagram (continued) ..........................................................................111
Probe to Controller Wiring....................................................................................................113
Probe to Controller Wiring (230V)........................................................................................115
Probe to Controller Wiring (Remote Probe Power)..............................................................117
Probe to Controller Wiring (With Fiber Optic Communications) .......................................... 119
Probe to Controller Wiring (230V With Remote CD Power) ................................................ 123
Probe Junction Box Outline Drawing ...................................................................................125
Controller Fiber Optic Converter Outline.............................................................................. 127
Controller Fiber Optic Converter Outline.............................................................................. 127

©Copyright MAC Instruments 2005. All Rights Reserved. MAC155 Rev. 12
Pg v
............................................................................................................................................. 127

MAC155 Rev. 12 ©Copyright MAC Instruments 2005. All Rights Reserved.
Pg vi
Figures and Tables
Figures
Figure 1 – MAC155 Probe Water Tank ................................................................ 3
Figure 2 – Extension Tube cut to 12 inch/ 30cm .................................................. 5
Figure 3 – MAC155 Probe Compressed Air Input ................................................ 7
Figure 4 – MAC155 Probe Mounting .................................................................... 9
Figure 5 – Typical MAC155 Probe Installation ................................................... 10
Figure 6 – Typical Mounting Adapter.................................................................. 11
Figure 7 – MAC155 Probe Connectors .............................................................. 13
Figure 8 – Filter Blow Back Compressed Air Input............................................. 17
Figure 9 – Rear Connections of MAC155 Controller .......................................... 18
Figure 10 – Controller I/O Pin Designations ....................................................... 18
Figure 11 – Controller to 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 Tank ........................................................................... 26
Figure 17– Draining Water Tank ........................................................................ 27
Figure 18 – Normal Display................................................................................ 29
Figure 19 – Main Board Status Indicators .......................................................... 29
Figure 20 – ±15V Power Supply Status Indicators ............................................. 31
Figure 21 – +5V Power Supply Status Indicator................................................. 31
Figure 22 – MAC155 Probe Filter Parts ............................................................. 35
Figure 23 – Probe Filter Partially Assembled ..................................................... 35
Figure 24 – Peristaltic Pump stand-in Tubing..................................................... 39
Figure 25 – Peristaltic Pump Assembly.............................................................. 39
Figure 26 – Peristaltic Pump Housing ................................................................ 40
Figure 27 – Disassembled Peristaltic Pump Housing......................................... 40
Figure 28 – AC Input Fuse Location................................................................... 49
Figure 29 – Probe Fuse Location on Controller.................................................. 49