PINSSAR DPMRA01.A User manual

DPM Reader
Service Manual for Model
DPMRA01.A

PIN-M-02 DPMRA01.A Service Manual
16/12/2019 Page 2 of 96
Document Change Record
Revision
Date
Change Note
1.0
xx/xx/2019
Draft
2.0
16/12/2019
Full revision, and accuracy Disclaimer added
Notice:
The information contained in this document is subject to change without notice.
While every care is taken to ensure the accuracy of the information and statements
made in this document, Pinssar (Aust) PTY LTD, or any other associated or related
company, makes no representation or warranties about its accuracy, reliability,
completeness or suitability for any particular purpose and disclaims all responsibility
and all liability (including without limitation, liability in negligence) for all expenses,
losses, damages (including indirect or consequential damage) and costs which you
might incur as a result of the information and statements made in in this document
being inaccurate or incomplete in any way and for any reason.
© 2019 PINSSAR Pty. Ltd. All rights reserved. Reproduction, adaption or translation
without prior permission is prohibited except as allowed under copyright laws.

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Table of Contents
1General........................................................................................................ 7
1.1 Parts provided............................................................................................. 8
1.2 Parts not supplied with this DPM Reader.................................................... 8
2Cautions and Warnings ............................................................................... 8
2.1 Caution........................................................................................................ 8
2.2 Mains Voltage ............................................................................................. 9
2.3 Laser......................................................................................................... 10
2.4 Earthing..................................................................................................... 10
3System Overview....................................................................................... 11
4Scope of Service Manual........................................................................... 12
5Service Safety ........................................................................................... 13
5.1 Safety Control Level’s (SCL’s) .................................................................. 15
5.1.1 SCL Levels 1 Electric Shock Caution ................................................. 16
5.1.2 Cooling Fan........................................................................................ 16
5.1.3 In-Line Air Heater ............................................................................... 16
5.1.4 Pinch Value ........................................................................................ 17
5.1.5 Blower................................................................................................. 17
5.1.6 Silicon vacuum air tubes..................................................................... 17
5.2 Locations and safety warnings on each component.................................. 17
5.2.1 DPM Reader Layout and Locations of Warnings................................ 17
5.2.2 240VAC Mains Caution Areas............................................................ 17
5.2.3 Battery and DC Caution Areas ........................................................... 17
5.2.4 Laser light Caution.............................................................................. 17
5.2.5 Heat generating components.............................................................. 18
6DPM Reader Servicing.............................................................................. 19
6.1 Tools required........................................................................................... 19
6.2 Bolt Torque Settings.................................................................................. 19
6.3 Accessing the Internal Components.......................................................... 20
6.4 Regular Interval Servicing......................................................................... 20
6.5 External high humidity and dust filter (05-0795) maintenance .................. 20
6.5.1 05-0795 External High Humidity Filter Removal................................. 20

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6.5.2 Draining filter housing.........................................................................21
6.5.3 Cleaning fine mesh metal filter (100976)............................................ 22
6.6 Internal clean air filter cartridge replacement ............................................ 22
6.6.1 100974 Replacement Filter Internal.................................................... 22
6.7 Cyclone Filter Maintenance....................................................................... 23
6.8 05-0772 Measurement Chamber Replacement ........................................ 24
7Electrical Safety Testing............................................................................ 26
8Visual Inspection ....................................................................................... 27
8.1.1 Stage 1 –External Visual Inspection.................................................. 29
8.1.2 Stage 2 –Internal Visual Inspection................................................... 31
9Fault Condition Diagnostics and Repair .................................................... 38
9.1 05-0788 Left Gear Plate Assembly Components...................................... 39
9.1.1 Wireless Modem Router Fault Diagnostics and Replacement............ 39
9.1.1.1 Wireless Modem Router status ..............................................................................39
9.1.1.2 Checking SIM card extension adapter insertion onto the Wireless Modem Router41
9.1.1.3 Accessing the SIM card reader extension adaptor .................................................41
9.1.1.4 SIM Card slot located on the Wireless Modem Router ..........................................41
9.1.1.5 Replacing Wireless Modem Router SmartFlex module ..........................................42
9.1.2 FAN fault servicing ............................................................................. 44
9.1.2.1 Fan operation diagnostics.......................................................................................44
9.1.2.2 Checking fan’s cable connection.............................................................................44
9.1.3 05-0790 Fan Assembly....................................................................... 45
9.1.4 112204 Battery Replacement............................................................. 46
9.1.5 Isolation Switch Fault Servicing.......................................................... 46
9.1.5.1 Test Switch Function...............................................................................................46
9.1.5.2 Check switches for physical damage.......................................................................47
9.1.5.3 Replacing Isolation Switch ......................................................................................47
9.1.6 80358 Power Supply Unit (PSU) Fault Finding................................... 48
9.1.6.1 Check connections ..................................................................................................48
9.1.6.2 Electrical test...........................................................................................................48
9.1.6.3 80358 Power Supply Unit Replacement .................................................................49
9.1.7 97-0017 Power Distribution Board (PDB)........................................... 50
9.1.7.1 Check connections ..................................................................................................50
9.1.7.2 Electrical test...........................................................................................................50

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9.1.7.3 Power Distribution Board (PDB) Replacement ...................................................... 51
9.1.8 80359 Pico UPS................................................................................. 52
9.1.8.1 Check Connections..................................................................................................52
9.1.8.2 Pico UPS Replacement ............................................................................................52
9.1.9 Red Lion............................................................................................. 53
9.1.10 Compact Flash Card........................................................................... 54
9.1.11 112212 Phoenix Contact Relays ........................................................ 55
9.2 05-0788 Right Gear Plate Assembly Components.................................... 57
9.2.1 05-0793 DPM Carrier Board............................................................... 57
9.2.2 05-0792 Blower Fault Servicing.......................................................... 59
9.2.2.1 Diagnosing Blower Fault .........................................................................................59
9.2.2.2 Replacing Blower.....................................................................................................59
9.2.3 05-0796 Pinch Valve Fault Servicing.................................................. 60
9.2.3.1 Check Pinch Valve Connection................................................................................60
9.2.3.2 Replacing Pinch Valve .............................................................................................61
9.2.4 100977 Tee Piece and Holder Replacement...................................... 61
9.2.5 05-0785 Air Heater Assembly Replacement....................................... 63
9.2.6 05-0791 Air Flow Sensor Assembly Replacement.............................. 64
9.2.7 Blower Speed Controller Replacement............................................... 64
9.3 Enclosure mounted components............................................................... 65
9.3.1 Power Button Fault Servicing ............................................................. 65
9.3.1.1 Check connections ..................................................................................................65
9.3.1.2 Electrical test...........................................................................................................66
9.3.1.3 Power Button replacement.....................................................................................66
9.3.2 100900 Pressure Relief Valve Replacement...................................... 67
9.3.3 05-0816 Cyclone Assembly Replacement.......................................... 68
9.3.4 05-0809 Exit Valve Replacement ....................................................... 69
9.3.5 112199 Antenna Replacement........................................................... 69
9.3.6 98-1173 Temperature Sensor Replacement....................................... 70
9.4 Wiring Looms –98-1112 Rev A ................................................................ 72
9.4.1 Wiring list............................................................................................ 73
10 Additional Electrical Troubleshooting Checks............................................ 74
11 HMI Introduction........................................................................................ 76

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11.1 Red Lion HMI.........................................................................................76
11.2 HMI Navigation ...................................................................................... 77
11.3 Placing the system in standby mode...................................................... 78
12 Fault Finding Using the HMI...................................................................... 79
12.1 Valve...................................................................................................... 79
12.2 Heater.................................................................................................... 81
12.3 Amplifier................................................................................................. 82
12.4 Sensor ................................................................................................... 83
12.5 Laser...................................................................................................... 85
12.6 Blower.................................................................................................... 86
12.7 Ambient Temperature............................................................................ 87
12.8 Pressure ................................................................................................ 88
12.9 PSU ....................................................................................................... 89
12.10 Battery ................................................................................................... 90
12.11 LED........................................................................................................ 91
13 Operating Log Guide ................................................................................. 93
13.1 Log Table............................................................................................... 93
13.2 Blower RPM........................................................................................... 93
13.3 Dark Light Reading................................................................................ 93
13.4 Sample Status........................................................................................ 94
14 FAQ’s ........................................................................................................ 95

PIN-M-02 DPMRA01.A Service Manual
Copyright © Pinssar (Aust) Pty Ltd 2019. The PINSSAR logo is a registered trademark of Pinssar Pty Ltd
Page 7 of 96
1 General
The DPM Reader model number DPMRA01.A is designed for vertical mounting onto a
flat surface. The Reader is a stand-alone device with USB, Ethernet and Wireless
connectivity. Limited AC Mains fail battery back-up is provided using an internal Lithium
Ion Phosphate battery.
FIGURE 1-PICTURE OF THE DPM READER

PIN-M-02 DPMRA01.A Service Manual
Copyright © Pinssar (Aust) Pty Ltd 2019. The PINSSAR logo is a registered trademark of Pinssar Pty Ltd
Page 8 of 96
1.1 Parts provided
Part Number
Description
Qty
DPMRA01.A
DPM Reader 655Hx600Wx250D c/w S/S
Enclosure
1
98-1149
USB Jumper cable (900mm length)
1
90545
Ethernet Jumper cable CAT5e (1.5m length)
1
111750
Ethernet Cable Gland
1
98-1353
AC Mains power cord (1m length) Aust. plug
1
112693
Door Access Key (Square profile)
1
100969
PTFE Tape
1
AFD11759 Rev 3.1
Installation Manual
1
AFD11758 Rev 1.1
Calibration Certificate
1
Warranty Certificate
1
Tech Service Qualification Statement
1
Terms & Conditions of Sale-Pinssar Holdings
1
1.2 Parts not supplied with this DPM Reader
•Wall mounting bolts (+/- 10mm x 4)
2 Cautions and Warnings
2.1 Caution
Please read the installation manual thoroughly before installation. Incorrect operation
could result in death or serious injury.
The DPM Reader DPMRA01.A weighs approximately 32Kg and is considered a two
person lift packed or unpacked. Care must be taken carrying the unit. The reader
contains sensitive electronic measuring equipment which will be damaged if the unit is
dropped from any height or excessively vibrated during transportation.
Installation is only to be done by trained personnel who have been sufficiently briefed
on the installation requirements and aspects of this DPM DPMRA01.A Reader.
The DPM Reader DPMRA01.A is designed for covered area, indoor use and operation.
Do not install the DPM Reader in any position of direct sunlight, corrosive environments
or high temperatures in excess of the stated operational temperature range. Please
ensure the moisture and dust environment of the installation is in accordance with the
stated IP rating of the DPM Reader.

PIN-M-02 DPMRA01.A Service Manual
Copyright © Pinssar (Aust) Pty Ltd 2019. The PINSSAR logo is a registered trademark of Pinssar Pty Ltd
Page 9 of 96
The DPM Reader is not intrinsically safe. Do not operate or maintain the DPM Reader
in any environments classified as hazardous as it may ignite flammable gases. The
Reader contains a single internally mounted Lithium Iron Phosphate battery pack with
a rating of 12.8VDC 6.4AH (81.9WH).
Any devices that connect to the data ports must comply with clause 4.7 of AS/NZS
60950.1.
2.2 Mains Voltage
All electrical work should be carried out in accordance with the state, federal or
applicable national electrical wiring codes and regulations.
The AC Mains electrical point into which the reader is to be connected, must have been
installed by a qualified electrician. The provided AC mains cable with special connector
interface for termination into the enclosure is one (1) meter in length and therefore we
recommend that the power socket dedicated to the DPM Reader should be installed
within 500mm of the left-hand side of theenclosure. The socket should be wired through
a suitable circuit breaker via an RCD device.
Two labelled isolation switches are provided on the left-hand side of the DPM Reader.
One is to isolate the AC mains, the other is to isolate the internal battery DC source
during service or whilst being transported. An additional LED illuminated low profile
power switch is located on the same side as the isolator switches, labelled POWER
which powers the internally mounted PLC and electronics.
Access into the DPM Reader is intended for suitable electrically qualified service
personal ONLY. Although an access key is provided with the DPM DPMRA01.A Reader,
there is no requirement to open the hinged door on the reader whilst installing the
reader.
Please be aware that if the access door is opened for any reason, DIRECT
exposure to live AC Mains contact points will be a very real danger.

PIN-M-02 DPMRA01.A Service Manual
Copyright © Pinssar (Aust) Pty Ltd 2019. The PINSSAR logo is a registered trademark of Pinssar Pty Ltd
Page 10 of 96
2.3 Laser
The internal measurement laser scattering chamber houses a Class 3B laser.
There is no requirement to open the enclosure to gain access to the laser scattering
measurement chamber during the installation process, however should the laser
scattering measurement chamber be dissembled in the field for any reason, you may
be exposed to the laser beam causing possible injury to the unprotected eye. Avoid
visual contact with the laser beam.
2.4 Earthing
The mains earth is connected via the mains cable and respective earth pin.