IR3000 Field Service Manual

2

3

Table of Contents

1. Installation Drawings & Guidelines 4 6. Diagnostic Program 341.1 Pneumatic Sampler 6 6.1 Installation 341.2 2 Flange Window 8 6.2 Adjust Prime Mirror 34

2. Basic Communications 10 7. Troubleshooting 352.1 1 PC Configuration 10 7.1 LED’s / Test Points 352.2 RS-232 10 7.2 Comm Errors 362.3 Cable Assy. pin out (Ethernet) 102.4 Cable Assy. pin out (RS-232) 12

3. Instrument Configuration Software 133.1 Main Page (Connect to the NIRG) 133.2 2 Setup 14

3.2.1 Downloading Firmware 143.3 Measurement Configuration 15

3.3.1 Measurement Options 153.3.2 Integration Start Positions 163.3.3 Integration Width 163.3.4 Median Filter 163.3.5 mples to Average 163.3.6 Auto Gain Control 163.3.7 Auto Zero Control 16

3.4 Product Code Configuration 173.4.1 General Parameters 173.4.2 Calibration Coefficients 183.4.3 Filtering 18

3.5 Fieldbus Configuration 203.6 6 Serial/4-20mA Configuration 213.7 7 Ethernet Configuration 223.8 Calibration Program 23

3.8.1 Calibration Procedure 243.8.2 Calibration Data Table 243.8.3 Offset Method 243.8.4 inear Regression 24

4. Operator Interface and Remote Display (LED) 264.1 Reloading the Operating System 264.2 LCD Recalibration 264.3 Configuring the OI panel 274.4 Electrical 274.5 Updating Software 284.6 Updating Software (from Internet) 284.7 Scaling a Remote Display (DPM) 29

5. R/R of Mechanical Assemblies 305.1 Motherboard/Rabbit/Filter Wheel 30

5.1.1 Replacement of Motherboard Assy. 325.2 Power Supply 325.3 Detector 325.4 4 Lamp 33

4

The IR-3000 includes two (2) removable mounting brackets. These brackets may be configured in numerous ways to provide flexible mounting options. The most common configuration, the one provided from the factory, is a vertical mounting with the two mounting clamps positioned on the connector-end of the gauge. Figure 1 illustrates this mounting configuration.

Mounting brackets are designed to clamp on a diameter of 1.25” – 1.3” (~32mm) metal bar. Due to the many variables associated with any process environment, it may be more convenient to use a horizontal mounting bar. In this case the mounting clamps need to be relocated using the four mounting holes on the top of the instrument housing. The four holes form a square pattern, allowing clamps to be mounted in either of two positions, at 90° orientation. Figure 1 shows several possible mounting configurations.

Figure 1 Gauge Mounting Configurations

The most important mounting consideration is the distance from product to sensor. Although the gauge will operate effectively in many applications at distances of 4” – 24” (100mm – 600mm), the optimum distance for most applications is 6” – 10” (150mm – 250mm) or 2” – 6” from end of light tube.

The sensor may be equipped with an air-purge nozzle (light tube option) approximately 4” (100mm) long. This nozzle is generally recommended to keep gauge window clean, even when not using air.

5

Highly reflective products, such as glossy paper, produce first surface reflections detrimental to measurement. Setting the gauge at a slight angle from vertical may easily eliminate these reflections. Typically an angle of 15° - 20° from vertical is recommended.

Figure 2 Sensor Outline

6

1.1 Installing the Pneumatic Sampler

Figure 3 Installation Drawing-Pneumatic Sampler

If a pneumatic sampler option is supplied, it will take the place of the air purge light tube. Mounting hardware as well as other necessary parts (flange, etc.) for installation are provided. An additional 3-pin connector will be installed on the bottom of the sensor to provide power to the solenoid.

Sampling time and other measurement parameters are configured from the Measurement Configuration page using the MoistTech software.

7

Figure 4 Outline Drawing-Pneumatic Sampler

8

1.2 Flange Window Mounting Configuration

Figure 5 Use of Mounting Bracket for Flange Window

9

Figure 6 Flange Window

10

2 Communicating with the NIRG

2.1 Configuring PC for Ethernet Communication

Ethernet communications allow a means of interfacing a gauge to a PC or a network using TCP/IP protocol. The advantage of Ethernet is speed of data transfer and distance of transmission. The following procedure documents a single gauge communicating directly with a PC using a CAT5E crossover cable. In this simple link, it is necessary to give both gauge and computer fixed IP addresses. This procedure is for a Windows XP operating system; others may vary slightly.

1. From the Control Panel go to ‘Network Connections’.2. Select Local Area Connection and go to ‘Properties’

3. A window titled “Local Area Connection Properties” is displayed. Scroll down and double click on Internet Protocol (TCP/IP) or highlight this selection and press ‘Properties’.

4. Select the option to “always use the following IP address”. Initially you should use the address 192.168.0.94 and Subnet Mask 255.255.255.0 (default), unless the gauge’s IP address has already been changed. In this case a suitable IP address must be used.

5. Click OK and exit all previously opened windows.6. Failure to establish communications at this point may require additional configuration which is

outlined in Chapter 7.

2.2 Communicating via RS232

An alternative to using TCP/IP is communicating with the gauge through the serial port. There is no configuration required for this method other than standard COM port settings (19200, 8, N,1, N). Cable assembly is outlined in Section 2.4.

2.3 Ethernet Cable Assembly

Figure 7 Ethernet Crossover Cable

Position Color1 Wht/Org2 Org3 Wht/Grn4 Blue5 Wht/Blu6 Grn7 Wht/Brn8 Brown

11

Ethernet Cable Instructions:

1. Pull the cable off the reel to the desired length and cut it. If you are pulling cables through holes, its easier to attach the RJ-45 plugs after the cable is pulled. The total length of wire segments between a PC and a hub or between two PC's cannot exceed 100 Meters (328 feet) for 100BASE- TX and 300 Meters for 10BASE-T.

2. Start on one end and strip the cable jacket off (about 1") using a stripper or a knife. Be extra careful not to nick the wires, otherwise you will need to start over.

3. Spread, untwist the pairs, and arrange the wires in the order of the desired cable end. Flatten the end between your thumb and forefinger. Trim the ends of the wires so they are even with one another, leaving only 1/2" in wire length. If it is longer than 1/2" it will be out-of-spec and susceptible to crosstalk. Flatten and insure there are no spaces between wires.

4. Hold the RJ-45 plug with the clip facing down or away from you. Push the wires firmly into the plug. Inspect each wire is flat even at the front of the plug. Check the order of the wires. Double check again. Check that the jacket is fitted right against the stop of the plug. Carefully hold the wire and firmly crimp the RJ-45 with the crimper.

5. Check the color orientation, check that the crimped connection is not about to come apart, and check to see if the wires are flat against the front of the plug. If even one of these is incorrect, you will have to start over. Test the Ethernet cable.

Ethernet Cable Tips: A straight-thru cable has identical wiring at each end. A crossover cable has different wiring at each end. A straight thru cable is used to connect a device to a hub. A crossover is used to connect two Ethernet devices without a hub or for connecting two hubs. A crossover has one end with the Orange set of wires switched with the Green set. Odd numbered pins are always striped; even numbered pins are always solid colored. Looking at the RJ-45 with the clip facing away from you, Brown is always on the right, and pin 1

is on the left. No more than 1/2" of the Ethernet cable should be untwisted otherwise it will be susceptible to

crosstalk. Do not deform, do not bend, do not stretch, do not staple, do not run parallel with power cables,

and do not run Ethernet cables near noise inducing components (motors, fluorescent lights, etc.)

Ethernet Connector (lower right on sensor end)

Most modern systems are auto-polarizing. Use 568A above, if not.

Figure 8 Ethernet Connector

Use a cable diameter for the connector cable clamp of 4.5 mm (.175") to 7.5 mm (.300").

12

Figure 9 Ethernet Bulgin Connector Assembly

2.4 Cable Assembly: RS 232/485 (lower left on sensor end)

Figure 9 Serial Connector 7 pin

For RS 232 connections: pins 5, 6 and 7 are used. For RS 422 connections: pins 1,2,3,4 and 7 are used. For RS 485 connections: pins 3, 4 and 7 are used. Use a cable diameter for the connector cable clamp of 4.5 mm (.175") to 7.5 mm (.300").

Position

Signal Name1 IP+2 IP-3 OP+4 OP-5 RxD 2326 TxD 2327 Gnd

Figure 10 Main Page

13

3 Instrument Configuration Software

A compact disc is included with the gauge. This CD contains various software to facilitate sensor configuration. PC configuration software is contained in a folder labeled ‘IR3000 Configuration’. From this folder, run Setup.exe and follow installation instructions. At the completion of installation, an icon will be placed on the desktop. Double click this icon to run the application and display the screen shown in Figure 10. (There is also a “readme.txt” file on the disk with installation instructions for all software applications.)

If any earlier versions of MoistTech software are installed, they should be detected during the setup procedure and removed. It is recommended to remove any earlier known versions prior to setup.

Figure 10 Main Page

3.1 Operator Page

All gauges connected to the host PC will be displayed in the “Gauge List”. To communicate with a specific gauge, add it into the Selected Gauge window by double clicking on the name in the Gauge List and then press ‘Connect’. The same applies if you will be communicating through the serial port- select the appropriate COM port and then press connect. At this point the information fields immediately right of the ‘Connect’ button should display the appropriate data associated with the connected gauge.

The home screen has several features for monitoring the gauge readings. Four digital displays enable one to simultaneously monitor the measurement of three different constituents in addition to product temperature. The trend plot also displays online readings from each constituent.

14

There is also a DATA-LOGGING feature on the Main page, which can store sample data directly into an Excel file. Pressing the red ‘Enable Logging’ button will open a window where you can create and name the file. Once the file is named, press ‘Open’ to activate this function. To begin data collection you must press the ‘Start’ button. The program will continue to record until the user disables logging or until the application has been closed closed.

The ‘Active Product Code’ is also set from the Main page.

3.2 Setup

Figure 11 Setup Page

This screen allows you to do such things as change the engineering password, save a master file containing all parameters for the selected gauge, update firmware, and set the display resolution for the Main screen. The auto connect feature stores the gauge ID that was last connected to, and will attempt to connect again to that ID at start-up.

When an online gauge is set up as a lab unit, the operator and location strings are assigned from here.

3.2.1 Downloading Firmware

1. Connect to the gauge over Ethernet and log in as Engineer to update the firmware.2. Press the ‘Browse’ button and locate source file RCM3000_VER_2_XX.bin for the older

processor or RCM3200_VER_2.XX.bin for the new processor. There is an auto-detect feature built in to the software that will use the Hardware Revision code to identify which processor is installed.

3. Make your selection and then press ‘Download Firmware’. This process takes about 1 minute.

Figure 12 Measure Configuration Page

15

3.3 Measurement Configuration

Most of the parameters on this page are set by the factory and should not be adjusted. They are only visible when logged in as Manufacturer. When logged in as an Engineer you have the ability to configure a variety of measurement methods to choose from depending on the application.

Figure 12 Measurement Configuration

3.3.1 Measurement Methods

1. Continuous - In this mode the gauge processes readings continually and updates its outputs accordingly.

2. Signal Gated - In this mode the gauge waits for a digital input to be asserted to take measurements. When the signal is negated, the gauge calculates the average of all the readings and generates an output. The output is held until new measurement is required.

3. Auto Gated - Similar to signal gated, but a certain moisture level enables gating. A threshold is programmed and the ‘Auto-Gate trigger’ is selectable for greater or less than this threshold.

4. Timed Sampling - This is used when a sampling device is attached to the gauge. Programmable functions for this mode include fill time, measurement duration, and purge.

5. Gated Timed - In this mode, an external logic input enables measurement for a timed interval.

16

Batch Mode – This can be applied to all measurement modes except for continuous. The measurement will be averaged during the period that the “gate” is active. The average value will be displayed when the gate is inactive.

Peak Mode – This can be applied to all measurement modes. Only the peak (highest) value measured is displayed instead of the average.

Measurement Basis: Wet or Dry?

In certain applications the customer prefers to record measurements on a “dry basis”

Calibration can only be done using wet basis data. Therefore, the gauge must first be programmed for wet basis measurement and then calibrated. Once recalibration is complete, SEND the new coefficients and then return to the Measurement Configuration page, switch to dry basis measurement, and SEND.

The formula for converting dry basis data is: MW = MD / (MD+1)

*Do not make changes to the following measurement parameters without first consulting the factory.

3.3.2 Integration Start Positions

Each wheel rotation generates exactly 512 Analog – Digital conversions, numbered 0 … 511. The readings contain the eight / twelve measurement ‘bumps’ together with transition areas where the data cannot be accurately attributed to a particular filter. This set of eight / twelve parameters specify where to start integrating for each ‘bump’.

3.3.3 Integration Width

This specifies the number of A2D readings to include in the integration. Together, with the ‘Integration Start Positions’ parameters, the samples to use for integration are completely defined.

3.3.4 Median Filter Size

The measurement system generates a new reading every wheel rotation. Each new reading is fed into a median filter whose job it is to remove outlier values. The larger the median filter, the greater the outlier rejection, but the longer the transport delay. Valid ranges for this parameter are odd numbers from 3 … 31

3.3.5 Samples to Average

The output of the median filter is fed into a type of averaging filter. This class of filter generates an output for every N inputs. The larger N is made, the greater the filtering action, but the slower the update rate. N is typically a power of two, so that valid decimation rates are 4, 8, 16, 32, 64.

3.3.6 Auto Gain Control (AGC)

The AGC Upper and Lower Action Limits set the threshold for when gain control is to be applied. If the sample peak goes outside of this window, AGC will adjust the amplitude of the signal.

3.3.7 Auto Zero Control (AZC)

Defines the entire signal range of the absorption band and sets the baseline.

17

3.4 Product Code Configuration

Product codes consist of all adjustable parameters on a per product basis. These parameters fall into four categories:

General Calibration Coefficients Filter Factors Constituent Names

3.4.1 General Parameters

From this page you can stipulate the percent moisture that corresponds to 4mA and 20mA respectively as well as the Auto Gate trip level.

The reference compensation coefficient or parameter K that appears in the main linearization equation can be adjusted to minimize the influence of product color on measurement.

0 K 1

⎡[ K Ref1 ( 1 k) Ref2] ⎤⎡

Meas p ⎤x ⎢ ⎥⎣ Meas ⎦⎣KRef1p (1 K)Ref2p ⎦

Figure 13 Product Code General Parameters

This screen can also be used to set the level of moisture than corresponds to the 4-20mA outputs respectively.

3.4.2 Product Specific Parameters

Coefficient ‘A’ is always zero, unless a logarithmic curve fit is used.

18

Coefficient ‘B’ is the slope of the calibration line. A higher ‘b’ value increases instrument sensitivity to moisture. In most cases the instrument will be pre-calibrated prior to shipping and a suitable ‘b’ value will be installed.

Coefficient ‘C’ is an offset coefficient and may be positive or negative. When the instrument-displayed values are compared to laboratory analyses (“grab samples”), the ‘c’ coefficient is used to correct for an average bias in the instrument

One can view and change coefficients stored for each product code and constituent. Pressing the ‘Load all Products’ button will download the calibration coefficients from the active product code into the remaining 49 product codes.

Figure 14 Product Specific Parameters (Calibration Coefficients)

3.4.3 Filtering

There are three levels of signal filtering within the gauge. Wheel rotation averaging is factory set for a specific application and effectively determines the sample update rate. If this needs to be changed, consult the factory for instructions. Median filtering is another factory set parameter and should only be changed by a factory-authorized technician.

The third filtering technique is ‘Damping’ and is user programmable. Damping performs a running average on the real-time data. For example, if a damping value of 10 is chosen, then a software buffer is generated containing the last 10 sample updates. The instrument value displayed is the average of the data in the buffer. The sample update rate is not affected by the damping value, but the displayed value is a running average of the last ‘n’ samples. Damping has a smoothing effect on the instrument response, but will slow the response to moisture changes. Large step changes in a process are unusual, but may happen during transitional periods such as process start-ups. With heavy damping, a step change will take time to reach a final value.

The IR-3000 also contains a programmable filter band where any moisture changes within this band have damping applied. Changes exceeding the filter band bypass the damping function. In this way, small, steady state fluctuations are smoothed by damping, but major disturbances are immediately displayed.

19

(a) Raw Signal – No Damping

Damping = 15 samples Filter Band = 10

(b) Damped Signal

Damping = 15 samples Filter Band = 1

(c) Damped Signal with Narrow Filter Band

Figure 14 Effects of Damping/Filter Band

20

3.5 Fieldbus Configuration

This page enables you to set the node address and baud rate when interfacing with a DeviceNet network. On a Profibus network, only the node address is required and the valid range is 0-126. Some implementations of Profibus support automatic node assignment in which case this parameter is not needed.

Figure 15 Fieldbus Configuration

Profibus Ribbon for 9-pin Sub-D Connector

9 pin Sub-D Signal Anybus Signal Motherboard8-pin Header (J8)

1 - - -2 - - -3 B-Line, Positive RS485 RxD/TxD FB2 74 RTS FB3 65 GND BUS FB5 46 +5V BUS FB6 37 - - -8 A-Line, Negative RS485 RxD/TxD FB-1 89 - - -

DeviceNet Connector

Bulgin 6-pin Connector Signal Motherboard8-pin Header (J8)

1 V- 42 CAN_L 73 SHIELD 24 CAN_H 85 V+ 36 - -

21

3.6 Serial and Analog Output Configuration

For digital communications the first parameter that must be defined is the protocol to be used. The choices are Gauge-Link or Modbus RTU.

For Gauge-Link, the communication parameters are fixed at 19200 (baud rate), 8 (data bits), N (parity), and 1 (stop bits). The only parameters that must be set are the Hardware Mode RS232/422 (Full Duplex) or RS485 (Half Duplex), and the slave address.

The Modbus RTU protocol defines the configuration parameters that are required. Namely:

Hardware Mode Baud Rate: 9600/19200/38400. The link will use 8-N-2 for other parameters per the Modbus spec NIRG’s slave address, which is a 1byte value. Certain addresses are reserved.

Follow link to download Interface Documents for AnyBus, Modbus TCP (Ethernet), Modbus RTU (Serial), and ProfiNet.

www.ir3000.beaufortcay.com Reference Chapter 2.4 for cable pin outs.

The 4-20mA Configuration page also allocates the measured constituents to specific analog outputs. There are three isolated, self-powered 4-20mA outputs on the IR3000.

Figure 16 4-20mA Connector

Figure 17 Serial/4-20mA Configuration screen

Position Signal Name1 #1 Positive2 #1 Negative3 #2 Positive4 #2 Negative5 #3 Positive6 #3 Negative

22

3.7 Ethernet Configuration

The most powerful communications feature is the TCP/IP Ethernet port. This feature is standard on all IR- 3000 series instruments and provides the highest data speed with the most comprehensive data access.

Many factory networks use fixed IP addresses. In this case, an IT professional should assign the addresses for the gauge and PC.

If the sensor is connected to a DHCP server-based network, then the DHCP box must be flagged in the Ethernet configuration screen for the gauge and in the Network Settings for the PC. Dynamic Host Configuration Protocol (DHCP) basically assigns suitable IP addresses to all devices on the network at time of start up.

To run the Diagnostics Program, the UDP box should be checked and the appropriate IP address of the receiving PC should be entered in the UDP address box.

Figure 18 shows the default configuration for the IR3000. These will be the parameters used when first connecting a PC to the gauge using TCP/CP but can be modified from this page to be put on any network.

Figure 18 Ethernet Configuration

23

3.8 Calibration Program

Today’s computers and sophisticated software have made available very powerful statistical packages. The calibration program supplied with the IR3000 uses such a package. Care should be exercised in the use of these statistical tools as lack of understanding may lead to misuse or wrongful conclusions.

The graphic display provides a means of visually assessing data; possibly rejecting bad data points and determining what function may be best suited to linearizing the data. Samples should be taken over as wide a range of moisture values as possible, covering the entire operating range at that measurement point in the process. If it is not possible to deliberately vary process conditions to cover the desired (maximum) moisture range, then an initial calibration should be carried out within the operating limits. This calibration may be updated and refined as samples are added covering a wider spread. If seasonal variations affect product moisture, then complete calibration may only be obtained over the entire season.

Figure 20 Calibration Program

The calibration program provides the means of acquiring sample data corresponding to physical samples taken for laboratory analysis. Statistical analysis determines calibration coefficients and correlation and standard error displays for more critical analysis.

Pre-existing calibration data files may be loaded and appended with newly acquired samples. Complete data files may be stored in PC memory, or calibration coefficients may be saved to PC calibration (product code) files or directly downloaded to the gauge.

24

3.8.1 Procedure

First determine which method of calibration is to be used- Linear of Offset. Select the “Calibration Mode” using the drop down menu located above the data table.

The calibration procedure comprises pressing the ‘Start Sampling’ button in the upper portion of screen, taking a sample from the process in close proximity to the gauge, and then pressing the ‘stop sampling’ button. Each time this button is pressed, it will toggle between start and stop. After taking a sample, the ‘store sample’ button will be highlighted and the average instrument reading between start and stop sampling is displayed. Pressing this button will store this value in the table to the right. Each sample has an associated time and date stamp to facilitate sample matching.

The physical sample obtained from the process should also be immediately sealed in an airtight container with time and date written on the container.

Where possible, two people are preferred for sample collection. One person located at the PC initiates the gauge data acquisition while a second person grabs a representative sample from the process.

3.8.2 Calibration Data Table

The left side of the calibration screen shows a calibration data table containing data acquired from the gauge during the calibration procedure. This includes: the date and time sample is taken, the gauge reading, and the X factor. An additional column contains laboratory data, which is manually entered following laboratory analysis. It is also possible to remove points from the equation by temporarily disabling them or you deleting them permanently. Once a sample has been deleted it cannot be recovered.

3.8.3 Offset Method of Calibration

The simplest calibration is the ‘offset’ method. This method assumes that the gauge has been previously calibrated and the calibration slope is approximately right. After inputting the samples to the calibration table and having performed a laboratory analysis on the corresponding samples, the laboratory values may be inserted into the table. Locating the cursor over the appropriate lab value, highlight that value, and enter the new lab value. When all lab values have been entered into the table, press the ‘Recalculate Coefficients’ button. The average instrument and lab values are calculated and the ‘c’ coefficient is updated according to the average error. Nothing is changed in the instrument until the ‘Send Coefficients’ button is pressed.

3.8.4 Linear Regression

Linear regression is a statistical program that establishes the direct correlation between two data series. A correlation coefficient indicates the quality of correlation. This value is between 0 and 1, with 1 being a perfect correlation. In addition to determining the quality of fit, the regression program calculates the slope and intercept of the calibration line. These two values are the ‘b’ and ‘c’ coefficients respectively.

MO

IST

U

MO

IST

U

15

10

5

5 10 15INSTRUMENT

Effect of Coefficient 'c' on OffsetFigure 22

15

10

5

5 10 15INSTRUMENT

Effect of Coefficient 'b' on SlopeFigure 21

25

To calibrate gauge using Linear Method:

Use the drop down menu in the upper center box and select ‘Linear’. Sampling is performed using the calibration program exactly as in the offset method

After pressing ‘Recalculate Coefficients’, both ‘b’ and ‘c’ will change.

A linear regression should only be performed on data with an adequate range, typically at least a 2% absolute range, and with at least three samples.

Running a linear regression on static product samples is often a good way of establishing a slope. When the instrument is then placed on-line, the offset method may used to bring the results into the correct range.

Figure 23 HTML

26

4 Operator Interface / Remote Digital Display

This chapter describes how to reload the operating system in the event of a software malfunction, and how to configure the display panel for communication with the NIRG. If a remote digital panel meter (DPM) is being used, a procedure for adjusting the range is at the end of this chapter.

4.1 Reloading the Operating System

You will need to hard-wire a cable (see Fig 25, Electrical) using one male and one female DB9 connector at each end.

1. Remove the lid of the enclosure to access back side of display panel.

2. Plug the male end of the cable into COM3 and female end to your PC.

3. Move DIP SW3 to the on position.

4. Open your computer’s HyperTerminal to run the display’s Boot Loader mode.

5. Power on the display. Immediately press the space bar on your computer’s keyboard to temporarily time out the connection to allow for configuration.

6. Pressing 5 will enable ‘Download RAM image into FLASH’ however this step may not be required. The status of this function will be displayed at the end of line 5. (Figure 23)

7. Press ‘D’ to download the binary image. This will commence the write to FLASH.

8. When the download is complete the Boot Loader screen will display “jumping to image…”. Also, the display panel’s operating system will begin to reboot. Once the reboot is complete, power the unit off and return DIP SW3 to the off position.

9. Keep unit open and proceed to section 4.2 LCD Recalibration.

4.2 LCD Recalibration

1. Move DIP SW1 into the “on” position and apply power to unit.2. Follow cross hairs on screen to recalibrate and press ‘Enter’ when done.3. Move DIP SW1 into the “off” position.4. Secure the lid of the enclosure and proceed to Configuration.

An LCD recalibration can be performed at any time without opening the unit. Run “cecp.exe” (ref. Section 4.3, Step 4) and select recalibrate. Then, save to the registry.

27

4.3 Configuration

The following procedure documents how to configure the display panel for use with the NIRG.

1. Set the IP address by clicking the START button. Go to Settings / Network & Dial-Up Connections. Select the Local Area Connection (CS89501). Choose to specify an IP address and enter in 192.168.0.10, Subnet Mask 255.255.255.0. Click OK and return to Desktop screen.

2. To hide the Taskbar. Press the START button and go to Settings / Taskbar and Start Menu…Check the box labeled ‘Auto Hide’ and un-check the box ‘Always on Top’

3. Press START, go to Programs / Windows Explorer. Open the directory ‘StorageCard’ and copy the folder ‘StartUp’. Go back to Windows Explorer, open directory called NORFlash and paste ‘StartUP’ into here. Doing this programs the MoistTech Configuration software to boot automatically when unit is powered up.

4. Save all changes to the registry . Click the START button and select “Run…” Type “cecp.exe” and press OK. Scroll over to “Save” tab and click button ‘Save Registry’.

4.4 Electrical

If the display does not turn on within 2 seconds of power up, remove power immediately. Check the wiring to ensure proper connections. An internal fuse (1A) on the display will prevent damage if the polarity of DC power is incorrect.

Figure 24 OFM40-240 OI power supply unit

Male Signal Name Female5 GND 57 Transmit 28 Receive 3

Figure 25 COM3 cable pin out

28

4.5 Updating the operator interface executable file

1. Open the enclosure and remove the FLASH disk from the back of the display.2. Load the disk into a FLASH r/w drive and choose to “Open a folder to view files.”3. Overwrite by copying the entire new IR3000 directory into the folder.4. Carefully replace FLASH disk into the back of the display ensuring the protruded edge is faced

toward the ports.

4.6 Updating the operator interface executable file from the Internet

In the event that you need an updated version of the OI software and cannot receive the file through email, the executable can be downloaded directly from the programmer’s website using the following instructions.

1. Configure the display for DHCP by navigating to the Local Area Connection properties and selecting the option to “obtain an IP address automatically”. Then save this change to the registry.

2. Connect the display’s Ethernet port to a hub or router where it can connect to the Internet via DHCP then restart the display.

3. Exit from the MoistTech Configuration software: from the Main tab-select Close, then enter the exit password.

4. Open WIN CE file explorer and navigate to \StorageCard\IR3000\. Delete filesIR2004OperatorInterface and GaugeData001.

5. Open WIN CE Internet Explorer and go to www.ir3000.beaufortcay.com.

6. Locate and click on the Operator Interface Cabinet File to download the software.

7. A window will open asking if you want to run the file or save it to disk. Select “save to disk”. The OK button isn’t accessible so you’ll have to make your selection by using the Input Panel. Open the input panel and press Return (Enter).

8. A “save as” window will appear. Navigate to \StorageCard\IR3000 and hit Return on the input panel to download the file: IR2004operatorinterface.exe. Select yes to overwrite existing file if required.

9. To start the new application, reboot the display.

10. To connect to a gauge you will have to reconfigure the display’s IP settings assigning the unit a fixed IP address. Save to registry .

29

4.7 Scaling the Remote Display

If the application’s moisture range has been specified, the display will be scaled prior to shipment from the factory. In the event the moisture level exceeds that range, or a tighter resolution is desired use the following procedure. Be sure to record original calibration coefficients before proceeding .

DPM setup:1. Open the enclosure by loosening the four cover screws.2. Loosen the two display mounting screws to access the rear of PCB.3. Locate the zero and span adjustments as per Figure 26.

Set the range using a PC and analogue controls:1. Navigate to your Product Code Specific Parameters.2. Set coefficients a, b, and c to zero. SEND to gauge.3. Adjust the zero offset (DPM) until display reads 0.0.4. Set coeff. c to value corresponding to max range (c=20 represents 20% H2O). SEND to gauge.5. Adjust the span (DPM) until display reads max range (i.e. 20.0).6. Repeat steps 2-5 until range is accurate over full scale.7. Change the calibration coefficients back to their original values and SEND to gauge.8. Replace all hardware and secure the DPM enclosure.

Figure 26 Digital Panel Meter

30

5 Removal/Replacement of Mechanical Parts

When possible take the gauge be taken off-line before doing any maintenance.

Required tools for working on the NIRG:

13mm Crescent Wrench (mounting brackets) 5mm Allen Key (side panels) 4mm Allen Key (optical bench) 5/64” Allen Key (internal hardware) 1/16” Allen Key (internal hardware)

5.1 Motherboard/Rabbit Processor/Filter Wheel

1. Remove the right and left side panels. Mounting hardware secures board from both sides.

2. Remove the three screws that secure the board to the optical bench. (Figure 27, 28)

Mains Power Plug (J3)

Figure 27 Motor Mounting Screw (1) Figure 28 PCB Alignment Screws (2)

3. Slide the PCB and filter wheel assembly out as a unit to access the cable assemblies.

Serial Connector (J5)

(Detector cable)

4-20mA Conn. (J11, J30, J31)

Figure 29 Main PCB Assy.

31

4. Unplug the serial connector, 4-20 output connectors (x3), Mains cable, and detector. Use extreme care when unplugging the detector so as to not damage the wires.

Detector Cable (J15, J18)

Figure 30

5. Once these connectors have been removed, slide the entire assembly out of the track to accessthe remaining connectors. Unplug the power, lamp, and Ethernet connectors.

Lamp (J12)

Power (J14)

Ethernet

Figure 31

Rabbit Processor

Filter Wheel Assy.

Figure 32 Motherboard Assembly

6. To remove the Rabbit processor you must first detach the filter wheel assembly from the board by unplugging the motor cable, slot switch, and mounting hardware.

* Use caution when removing the Rabbit processor so as not to bend the pins.

* Never touch the NIR filters with your hands. Oil in the skin will etch away the IR filter, causing leakage.

32

5.1.1 Replacement of the Motherboard Assembly

1. Replace the Rabbit processor first. (It will not fit into socket with filter wheel assy. installed.)

2. Insert the motor ribbon cable and clamp it down. Mount the filter wheel assembly to the board with two screws.

3. Plug slot switch in at J29.

4. Slide the motherboard assembly half way into the filter wheel track and plug in all connectors that were removed prior to extraction:

Ethernet Mains Lamp Power (5, 15V) Serial 4-20mA (x3)

5. Secure the motor mount screw and the PCB alignment screws.

5.2 Power Supply Unit R/R

1. Remove the optical bench mounting hardware (4 screws) found on the bottom of the enclosure.2. Position the optical bench so that you can remove the two power supply mounting screws.

PSU hardware

Figure 33

3. Unplug the cables and remove power supply.4. Install the new power supply, plug in cables, and replace mounting hardware.5. Secure the optical bench to enclosure.

33

5.3 Detector R/R

1. Take the optical bench out of enclosure by removing the four screws from the bottom of the enclosure. Disconnect Mains from power supply, the Ethernet and Serial connections,and the 4-20mA connectors.2. Remove the dome mirror (2 screws).3. Unplug the detector cable from the motherboard and detach bulkhead assembly (4 screws).3. Detach the detector mounting block by removing the two screws on the back side of the bulkhead assembly.4. Remove the entire detector pre-amp board from mounting block (2 screws.)

Ground

Figure 31 Bulkhead Assy. Figure 32 Detector Pre-Amp Board

5. Replace the detector pre-amp board on 1/8” spacers. Be sure hardware passes through spacers before securing to avoid damaging board.6. Reassemble bulkhead assembly and attach it to the optical bench.7. Connect the detector cable.8. Secure the optical bench in enclosure.

5.4 Lamp R/R

1. Remove the optical bench from enclosure.2. Loosen the set screw in lamp mounting block.3. Slide the lamp up and out of block and disconnect from motherboard.4. Insert the new lamp as shown in Figure 33 and connect to motherboard. Alignment markings

should be parallel with stand-off.5. Tighten set screw and reinstall the optical bench in enclosure.

Figure 33 Lamp Alignment

34

6 Diagnostics Program

MoistTech has a comprehensive diagnostics program to run on the LAN. This program uses UDP (User Datagram Protocol), which differs from TCP/IP in that it largely ignores errors, but provides a very rapid transfer of large blocks of data.

To run diagnostics program, the UDP box on the Ethernet Configuration screen should be checked, and the appropriate IP address of the receiving PC should be entered in the UDP address box. Then press ‘SEND’.

6.1 Installation

1. Open appropriate directory and run setup.exe2. Follow the prompts for installation.3. Once setup is complete navigate to C:\Program Files\NIRG. Copy NIRG.exe to the desktop

where it is easily accessible.

6.2 Adjusting the Prime Mirror

The prime mirror controls the amount of compensating light directed onto the detector.

1. Remove the side cover from the enclosure, and locate the set screw holding the mirror in the block. Loosen the screw (Figure 35) so that the mirror is free to rotate within the block. The newer model IR3000 has a prime mirror that is designed to slide in and out of the block. This type is identified by the white line that runs horizontally along the adjustment knob and the groove cut into the shaft of the mirror. The mirror in the IR2004 rotates side to side versus sliding in and out.

2. With the diagnostic dump switched on, go to the Measurement Diagnostics page to view the absorption waveform. Place a sample of the material beneath the gauge and adjust the prime mirror using the knob until the peaks Ref.1 Prime and Ref. 1 are the same amplitude (height). When the mirror is set, lock it into place making sure the peaks don’t shift when doing so.

Figure 34 Measurement Diagnostics Page

Set Screw

35

Figure 34 Measurement Diagnostics Page (Absorption Band)

3

7 Field Troubleshooting

To prevent overlooking the obvious, always use a methodical approach when troubleshooting. Never make assumptions.

First perform a basic systems check:

Power on Motor turning Lamp source on “0” displayed

7.1 LED’s and Test Points

There is a seven segment display on the front of the motherboard that will give a good indication to the fundamental operations of the gauge. The error codes apply in all measurement modes.

Continuous

0 – Measure (OK)

Timed Sampling

0 – Measure

Signal Gated

0 – switch open (measure)1 – Wheel Lock error 2 – AZC error3 – AGC error

4 – Fill cup 6 - Purge

7 – Switch closed (hold)

Error Codes:

The number “1” may appear briefly when viewing/changing parameters within the gauge. This does not indicate that there is a problem, just that the gauge is processing data.

In the event that the gauge cannot lock the wheel on to the Mains frequency a “1” will be displayed indefinitely indicating a problem. If this happens go to the Manufacturing tab in the Configuration Software and verify that the correct Mains frequency has been selected for that region. Use the drop down menu, select the appropriate setting, and press SEND. A gauge reboot is required after making changes under Manufacturing.

When a “2” or a “3” is displayed this normally indicates a problem with the initial setup of the gauge. Most likely the Prime Mirror inside the instrument hasn’t been properly balanced for the application. Use the diagnostics program to verify proper setup.

If the AGC/AZC error persists, you can use an oscilloscope to determine whether the detector or the PCB is at fault. A clean waveform at TP 45 generally rules out the detector as the source. Probe TP 46 to see the waveform after amplification and possibly isolate the Main board as the problem.

Possible causes for AGC error on Main board:

Soldered bus wire at U31 broken off Jumper between R82 & R93 Detector cable

R82, R93

U31

Test Points

TP54

Grd

TP70

TP48

TP44 TP46 TP45Grd

3

Test Points – Main PCB

TP 44 Final Detector Signal

TP 45 Detector’s Raw Signal

TP 46 AGC after amplification

TP 48 DC offset (1.6V)

TP 54 Slot Switch 3V peak pulse train

TP 70 Phase Locked Loop (1.5 – 3.5 V)

Figure 36 Test Points

Other LED’s:

D1 Isolated 5V solid greenD2 End of cycle flashing redD3 Slot Interrupts flashing orangeD4 Samples Averaged flashing yellowD7 5V power solid greenD8 3.3V power solid green

7.2 Ethernet Communication Problems

In the event you can’t connect to the NIRG, use the following guidelines to correct the problem.

1. Use only a CAT5E Crossover cable

2. Assign an appropriate fixed IP address to your PC.

3. Check for a positive connection between you PC and the gauge (indicated by a green LED at the LAN port and also on the Rabbit.

4. Configure your PC’s Firewall and/or Anti-Virus software to allow the MoistTech applications to runn freely on your computer.

a. Navigate to your Control Panel (Start-Settings-Control Panel) and select “Windows Firewall.” Click on the Exceptions tab and check the box next to IR3000 Configuration (also NIRG.exe for diagnostics.) If the programs aren’t listed click “Add Program…” and make your selection from this list.

b. All Anti-Virus programs vary slightly however each has built in features that will allow you to communicate with the MoistTech software over the LAN connection.

5. Connect through the COM port and verify Ethernet configuration for the gauge. If connecting point to point ensure DHCP has not been enabled.