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

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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
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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

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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
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............................................................................................................................................. 127

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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

©Copyright MAC Instruments 2005. All Rights Reserved. MAC155 Rev. 12
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Figure 30 – General Menu Display ..................................................................... 55
Figure 31 – Time Set Menu ................................................................................ 56
Figure 32 – Auto CalCheck Time Set Menu ....................................................... 57
Figure 33 – Display Brightness Selection Menu ................................................. 57
Figure 34 – Analog Output Range Selection Menu ............................................ 58
Figure 35 - Probe MBV Range Selection Menu.................................................. 58
Figure 36 - Maintenance Relay Setup Menu ...................................................... 59
Figure 37 – PLC Interface Setup Menu .............................................................. 59
Figure 38 - MODBUS RTU Address setup ......................................................... 60
Figure 39 - MODBUS address setup 1 ............................................................... 60
Figure 40 - MODBUS address setup 2 ............................................................... 60
Figure 41 - MODBUS RTU Baud rate setup....................................................... 61
Figure 42 - MODBUS Baud rate select............................................................... 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 100° Menu ..................................................... 64
Figure 48 – Force Cond Temp to 130° Menu ..................................................... 65
Figure 49 – Force Probe into Calibration Menu.................................................. 66
Figure 50 – Force Probe to Verify Calibration .................................................... 67
Figure 51 – Force Probe Maintenance Mode ..................................................... 67
Figure 52 - PLC Interface ................................................................................... 68
Figure 53 - Initial Login Address ......................................................................... 73
Figure 54 - Login Screen .................................................................................... 73
Figure 55 - Mac155 Normal Operation Screen................................................... 74
Figure 56 - MAC155 Time Setup Menu .............................................................. 75
Figure 57 - MAC155 Time Setup Menu .............................................................. 76
Figure 58 - MAC155 CalCheck Mode................................................................. 77
Figure 59 - MAC155 Time Setup Menu .............................................................. 78
Figure 60 - General Configuration Menu ............................................................ 79
Figure 61 - Alarm Email Setup Menu.................................................................. 80
Figure 62 - MAC155 Time Setup Menu .............................................................. 82

MAC155 Rev. 12 ©Copyright MAC Instruments 2005. All Rights Reserved.
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Figure 63 - MAC155 Time 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
Tables
Table 1 – DC Power Conductor Size vs. Length ................................................ 14
Table 2 – Main Board Status Indicators ............................................................. 30

©Copyright MAC Instruments 2005. All Rights Reserved. MAC155 Rev. 12
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MAC155 Rev. 12 ©Copyright MAC Instruments 2005. All Rights Reserved.
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SYMBOL DEFINITIONS
Risk of Dangerous Condition
Documentation needs to be referenced to explain danger in detail.
Hot Surface
Contact 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 Terminal
Provides termination point for unit protective earth (ground)
connection. Only one wire is allowed on screw or stud.
LImportant Note
Information following this symbol requires special attention.

©Copyright MAC Instruments 2005. All Rights Reserved. MAC155 Rev. 12
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©Copyright MAC Instruments 2005. All Rights Reserved. MAC155 Rev. 12
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OVERVIEW
GENERAL
Always maintain AC power to the MAC155 Probe when the probe is
in place in the instrument port and the monitored equipment is
operating, (generating typical moisture).
There are no operator serviceable parts inside The MAC155 Probe
or Controller. Removal of the cover will increase the risk of electric
shock and contact of surfaces that can cause burns. Only trained
personnel familiar with this type of equipment and the hazards
involved should remove the covers.
The MAC155 is intended for use in continuously monitoring the water vapor
level in a stack or duct.
The MAC155 consists of two parts; a probe that mounts to a port on the stack
or duct that is being monitored, 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 do a calibration
sequence if the range is changed. The unit is shipped preset and calibrated to
the range indicated on the order. Refer to the blue factory configuration sheet
that was shipped with the unit for range information.
The MAC155 controller supplies AC and DC power to the probe. The probe
and controller communicate via an isolated RS485 serial port.
The % moisture level is displayed on the controller front panel and is
available as a 4–20ma or a 0–20mA analog signal at the rear of the controller.
4mA or 0mA represents 0% moisture by volume (MBV) and 20mA represents
100% MBV. The analog output can be forced to 0%, 25%, 50% 75% and 100%
of full scale using the pushbuttons on the front of the controller. This allows
testing of data logging equipment.

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The accuracy of the MAC155 is ± 1% of full scale over 20% to 100% of the
full scale range. The accuracy is reduced to some extent below 20% of full
scale.
The MAC155 contains a built in sensor calibration system that makes it
possible to do a daily two point calibration check. The calibration gas is
generated by mixing water vapor from an internal water reservoir with air in the
proper ratio. The probe is then swamped with this calibration gas so that the
sensor is totally immersed in the internally generated reference gas. The
calibration points are 40% and 80% of full scale.
The internal water reservoir holds 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 once per year.
THEORY OF OPERATION
The MAC155 Probe contains a proprietary high temperature capacitive
sensor that responds to the partial pressure of the water vapor that is dissolved
in the atmosphere that is being monitored. An absolute pressure sensor
measures the total pressure at the moisture sensor. The percent of water vapor
by volume is then calculated by the internal processor using the following
equation:
% water vapor by volume = (water vapor partial pressure / total pressure) X 100
The total pressure is a function of the altitude above sea level, fluctuations of
barometric pressure with weather, and changes in operating conditions of the
equipment feeding the stack
.

©Copyright MAC Instruments 2005. All Rights Reserved. MAC155 Rev. 12
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SENSOR CALIBRATOR
The MAC155 Probe contains an internal calibrator that generates a reference
gas of 40% and 80% of the selected full scale range (Refer to the MAC155
specification sheet). The reference gas can be used to verify the calibration or it
can be used to calibrate the MAC155 Probe at these two 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 generate the
water vapor that is in the reference gas stream. The tank holds enough water for
more than a year of normal operation. The water tank has a built in water level
detector that provides a “Low Water” alarm when the water level is low. Refer to
the “OPERATION” section of this manual for information about filling the tank.
Figure 1 – MAC155 Probe Water Tank
Fill Plug

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CONDENSER
The gas stream from the water tank is fed to the condenser. The condenser
causes moisture from the gas stream to condense until the gas stream leaving
the condenser is at the required percent of moisture 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 reference gas to flow to the sensor.
CALIBRATION PUMP
The calibration pump starts to run when the instrument is in the
“CALIBRATION OR CALIBRATION CHECK” modes. This pump runs at twice
the speed of the sampling pump to assure that the barrel and sensor is flooded
with the reference gas.