Service Manual Author: Jerry Swinford
www.pmeasuring.com
September 23, 2009
Airnet® is a registered trademark of Particle Measuring Systems, Inc. Molex® is a registered trademark of Molex Corporation
All trademarks appearing in this manual are the property of their respective owners.
DO NOT REPRODUCE OR DISTRIBUTE CONFIDENTIAL CONFIDENTIA L INFORMATION FOR INTERNAL PMS USE ONLY This confidential document contains proprietary information, which is protected by copyright. All rights are reserved. No part of this document may be reproduced, distributed, or transmitted in any form without the prior written consent of Particle Measuring Systems. The information contained in this document is subject to change without notice. © 2009 by Particle Measuring Systems, Inc. All Rights Reserved
September 23, 2009 Page ii
Table of Contents 1
PURPOSE .................................................................................................... ............... 1
2
INTRODUCTION...................................................................................................... 2
3
RELATED DOCUMENTS........................................................................................ 3
4
AIRNET II FEATURES .................................................. .......................................... 4
4.1
Connector Panel................................................................................................................................ 4
4.2
Status & Activity LEDs .................................................................................................................... 5
4.3
Flow Pressure Sensors ...................................................................................................................... 5
5
SYSTEM COMPONENTS ................................................ ........................................ 6
5.1 Processor Board (1000013669) ........................................................................................................ 7 5.1.1 Connector Pinouts....................................................................................................................... 7 5.1.1.1 CO12....................................................................................................................................... 7 5.1.1.2 CO3 Detector Board ............................................................................................................... 8 5.1.1.3 CO10 4-20mA Board.............................................................................................................. 8 5.1.1.4 CO11 Pulses ........................................................................................................................... 8 5.1.1.5 CO6 RS-232 ........................................................................................................................... 9 5.1.1.6 CO8 Ethernet .......................................................................................................................... 9 5.1.1.7 CO7 BDM .............................................................................................................................. 9 5.1.1.8 CO9 Power & Thresholds ....................................................................................................... 9 5.1.2 Power Supplies ......................................................................................................................... 10 5.1.2.1 Power over Ethernet (PoE) ................................................................................................... 10 5.2
Detector Board (1000013676) ........................................................................................................ 10
5.3
Laser Board (1000013943) ............................................................................................................. 11
5.4
4-20 mA Board (1000013684) ........................................................................................................ 11
5.5
Cabling ............................................................................................................................................ 12
6
DISASSEMBLY ................................................................................................. ...... 13
7
ASSEMBLY .............................................................................................................. 15
8
TEST POINTS .......................................................................................................... 16
8.1
Processor Board .............................................................................................................................. 16
September 23, 2009 Page iii
8.2
Laser Board..................................................................................................................................... 16
8.3
Detector Board ................................................................................................................................ 16
8.4
4-20mA Board ................................................................................................................................. 17
9
COMPONENT REPLACEMENT PROCEDURES............................................. 18
9.1
Processor Board (1000013669) ...................................................................................................... 18
9.2
Detector Board (1000013676) ........................................................................................................ 18
9.3
Laser Board (1000013943) ............................................................................................................. 18
9.4
4-20 mA Board (1000013684) ........................................................................................................ 18
10
TROUBLE SHOOTING .............................................. ........................................ 19
10.1 Power ............................................................................................................................................... 19 10.1.1 +5V ........................................................................................................................................... 19 10.1.2 +3.3V ........................................................................................................................................ 19 10.1.3 +1.8V ........................................................................................................................................ 19 10.1.4 +12V ......................................................................................................................................... 19 10.1.5 -12V .......................................................................................................................................... 19 10.2
Ethernet ........................................................................................................................................... 19
10.3
Laser ................................................................................................................................................ 19
11
SERIAL COMMANDS .................................................................................... .... 20
12
APPENDIX ............................................................................................................ 21
12.1
Processor Board .............................................................................................................................. 21 12.1.1.1 Processor........................................................................................................................... 21 12.1.1.2 FLASH ............................................................................................................................. 21 12.1.1.3 SDRAM ............................................................................................................................ 21 12.1.1.4 EEPROM .......................................................................................................................... 21 12.1.1.5 Ethernet Controller ........................................................................................................... 21 12.1.1.6 Serial Ports........................................................................................................................ 21 12.1.1.7 4 – 20mA Outputs (Optional) ........................................................................................... 21 12.1.1.8 BDM Port ......................................................................................................................... 21
12.2 Power over Ethernet (PoE) ............................................................................................................ 21 12.2.1 Power Up Sequence.................................................................................................................. 22 12.3
Additional Equipment .................................................................................................................... 22
September 23, 2009 Page iv
1 Purpose The purpose of this document is to give a high level description of how the Airnet® II Particle Counter operates and to provide troubleshooting and service information. This manual does not cover the Airnet II calibration.
September 23, 2009 Page 1
2 Introduction The Airnet II is an aerosol particle counter. It operates from either an external DC power supply or from Power over Ethernet (PoE). The instrument has an RS-232 interface, Ethernet interface, and three 4-20 mA output channels.
September 23, 2009 Page 2
3 Related Documents L:\Engineering\Release\Firmware\AirNet_II\PMS_Documentation\AirNetII_Command_Summary.doc
September 23, 2009 Page 3
4 Airnet II Features 4.1 Connector Panel The connector panel on the Airnet II comes in two versions, one with the cutout for the optional 4-20mA board and one without.
With 4-20mA option
Without 4-20mA option
With 4-20mA option
Without 4-20mA option
September 23, 2009 Page 4
4.2 Status & Activity LEDs The Airnet II has two LEDs, one for status and one for activity indication. They are both located on the Processor board. The top case has one light pipe for each LED. The activity LED is green and the status LED is bi-color (Red/Green/Both).
4.3 Flow Pressure Sensors The pressure sensors are located on the Detector board. The differential pressure sensor and the bench pressure sensor have tubes connected to the. The atmospheric pressure sensor does not have a tube attached.
September 23, 2009 Page 5
5 System Components
-48V
+3.3V +3.3V
CDBHD1100
4-20 mA Board D/A t u p r t o 1 u t 1 6 O c 0 e 5 A n 4 0 m n o 3 4 0 C 2 4
D/A Spare Digital Input D/A
SBM1040
F F T - T 1 - 1 G - G S S S S D D M M J - J S R P 0 0 2 2
Raw DC 320uF
Si3440 Ethernet Connector
H2019NL
0V
6339191-4
Power Over Ethernet Controller
SPI Data SPI Clock
-48V
100k
0.1
LTC4267-3
4-20 mA_Latch BA5516
Spare_Latch
60.4k
Optional 4-20 mA Board 0V
CDBHD1100 PS2911
+24V Power Input Threshold Output Connector 39-30-0060
2200pF 250 VAC
Line Filter
Surge Protection
0V
CDBHD1100
BNX022-01L
Threshold 1 Threshold 2
Laser Board
+5V POR
Laser Module
) N S ( ) F 4 L ( P A - H H X X B 4 B
) N S ( ) F 5 - L P ( A H X H X B 5 B
+5V
-12V
+5V
+1.8V
LTC1728ES5-5
+1.8V
+3.3V
+3.3V
+5V +3.3V
+12V Triple DC/DC Converter
-12V
DC/DC Converter LT3873
LT3507
+1.8V
Option Configuration Bit 0 Option Configuration Bit 1
Laser On
+3.3V +3.3V
Status
25 MHz Osc CWX813-25.0M
MII Interface
Detector Board
Detector
Op Amp
Op Amp
Diff Press Sensor
Activity LED
ADC Reference
-12V
HSMF-C165
Status LED
Flow Pressure Sensor A/D
HSMF-C165
+3.3V
AD124S05 1CIMM
10 MHz Osc
+3.3V
CWX813-10.0M
Power PC +12V
EEPROM 32 kbits
I2C +3.3V
+5V BNCH Press Sensor
+12V
Particle Threshold 2
Baseline Restore Threshold
ATM Press Sensor
24AA32A -ISNG
4.096V Reference
-12V
Particle Threshold 1
+5V
3V Reference
+12V
MAX15006
F F T - T 1 - 1 G - G S S S S D D M M J - J S R P 0 0 2 2
+12V
5V Reference
+5V
Pulses
Baseline Restore
BCM5221
Reset
+5V
Transimpedance Amp
Ethernet I/F
FLASH 32 Mbits x2
SPI Clock Thresh_Latch
Particle Threshold 1 & 2 Baseline Restore Threshold
4-20 mA_Latch
LTC2604CGN
Address
Spare_Latch
Data
PC28F256M29EWH
32
32
+3.3V
Spare Digital Input SPI Data Control
SDRAM 128 Mbits
CH1 Clock
MT48LC4M32B2B5-6
A 2 - H P X H B X 2 S
BDM Connector
+3.3V
BNC 31‐221‐RFX
Drawn By: Jerry Swinford Date Drawn: September 22, 2009
CH2 Clock
Pulses
Main Board
RS-232 Connector FRJAE-666
RS-232 Transceiver
TSM-105-01-L-DV
MPC875CVR80
ISL4221EIRZ
Front Panel
September 23, 2009 Page 6
The Airnet II electronics is made up of a Processor board, Detector board, Laser board, and an optional 4-20 mA board. The DC power supplies are on the Processor board. The Detector board and the optional 4-20 mA board are connected to the processor board by board-to-board connectors. The Laser board is connected to the Processor board by a cable.
5.1 Processor Board (1000013669)
Processor Board (1000013669) The Processor board interfaces to and controls the rest of the system components. The major components of the Processor board are: FLASH memory for System firmware SDRAM for System memory EEPROM memory for System configuration D/A to set thresholds and baseline restore Serial interfaces (RS-232 & SPI) Ethernet Interface Power supplies (PoE and system power) • • • • • • •
5.1.1
Connector Pinouts
There are eight connectors on the Processor board. Ref Des CO3 CO6 CO7 CO8 CO9 CO10 CO11 CO12
Description Detector Board, Board-to-board Connector RS-232 Connector Background Debug (BDM) Connector Ethernet Connector Power Input and Threshold Voltage Output Connector 4-20mA Board, Board-to-board Connector Pulse Output Cable Connector Laser Board Cable Connector
Mfr JST Amphenol Samtec AMP Molex JST JST JST
P/N 20R-JMDSS-G-1-TF(LF)(SN) FRJAE-666 TSM-105-01-L-DV 6339191-4 39-30-0060 20R-JMDSS-G-1-TF(LF)(SN) B2B-XH-AM(LF)(SN) B5B-XH-AM(LF)(SN)
5.1.1.1 CO12 Pin Number 1 2 3 4 5
Description +5V -12V Ground Laser Status #Laser_On September 23, 2009
Page 7
5.1.1.2 CO3 Detector Board Pin Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Description +5V Differential Pressure +5V Bench Pressure Ground Ground +12V Baseline Restore +12V Ground Ground Ground -12V Atmospheric Pressure -12V Ground Ground Ground Ground Pulses
5.1.1.3 CO10 4-20mA Board Pin Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Description #Busy V_Bus Ground V_Bus Spare_Latch #HRESET Ground Ground Optional Board Configuration Bit 0 4-20mA_Latch Ground Ground Optional Board Configuration Bit 0 4-20_SPICK Ground SPIMOSI Spare_SPICK SPIMISO Ground Spare Input (PE23)
5.1.1.4 CO11 Pulses Pin Number 1 2
Description Pulses (Center) Ground (Ring)
September 23, 2009 Page 8
5.1.1.5 CO6 RS-232 Pin Number 1 2 3 4 5 6
Description Shorted to pins 4 & 5 with a capacitor to ground TxD RxD Shorted to pins 1 & 5 with a capacitor to ground Shorted to pins 1 & 4 with a capacitor to ground Ground
5.1.1.6 CO8 Ethernet Pin Number 1 2 3 4 5 6 7 8 9 10 11 12
Description Tx+ (PoE) Tx- (PoE) Rx+ (PoE) Shorted to pin 5 (PoE) Shorted to pin 4 (PoE) Rx- (PoE) Shorted to pin 8 (PoE) Shorted to pin 7 (PoE) Yellow LED Cathode Yellow LED Anode Green LED Cathode Green LED Anode
5.1.1.7 CO7 BDM Pin Number 1 2 3 4 5 6 7 8 9 10
Description VFLS0 #SRESET Ground DSCK Ground VFLS1 #HRESET DSDI Pulled up to +3.3V DSDO
5.1.1.8 CO9 Power & Thresholds Pin Number 1 2 3 4 5 6
Description +24VDC In Channel 1 Threshold Channel 2 Threshold 0VDC Ground Ground
September 23, 2009 Page 9
5.1.2
Power Supplies
The Airnet II power supplies are on the processor board. The instrument can be powered from an external +24VDC supply or via Power over Ethernet (PoE). The DC voltages that are produced are: +5V, +3.3V, +1.8V, and ±12V. The PoE standard does not dictate the polarity of the DC voltage supplied over the Ethernet cable. Therefore, the PoE supply has bridge rectifiers on the input. A bridge rectifier was also added to the +24V input so that the instrument will not be damaged if the +24V power is wired backwards.
5.1.2.1 Power over Ethernet (PoE) The PoE supply produces +12VDC. This is connected through a diode to the V_Bus (a.k.a. Raw_DC) that is used to produce all of the system voltages. The external +24VDC is also connected to V_Bus through a diode. When the +24VDC is being used to power the instrument, the PoE circuit will be disabled. If a Power Sourcing Equipment (PSE) device such as a PoE Ethernet switch is connected it will go through the PoE negotiation sequence and be denied. I believe it may continue to try this negotiation sequence forever. So, if PoE is available it is not recommended to power the instrument with the external +24VDC. The Airnet II is a Class 0 PD. There is more detailed information about PoE in general in the Appendix.
5.2 Detector Board (1000013676) The Detector board does the particle detection and sends particle pulses to the Processor board. The Detector board also has pressure sensors that are used for monitoring the flow. The outputs of these sensors are sent to the Processor board where they are measured with an A/D converter.
September 23, 2009 Page 10
Detector Board (1000013676) and Board-to-Board Connector
5.3 Laser Board (1000013943) The Laser board drives the solid state laser. The Laser board is connected to the Processor board by the LEM cable (1000013724).
Laser Board (1000013943) and Cable (1000013724)
5.4 4-20 mA Board (1000013684) The 4-20 mA board is optional. It connects to the Processor board via a board-to-board connector. It has three channels, two particle channels and one for status.
4-20 mA Board (1000013684)
September 23, 2009 Page 11
The 4-20mA board is mounted in the Airnet II with two socket head cap screws. The length of these screws is critical. If one of the screws is too long it will break the differential pressure sensor on the Detector board.
5.5 Cabling There are two cables in the Airnet II. One cable connects the Processor board to the Laser board. The other cable connects to the Processor board to a BNC connector on the rear of the Airnet II.
PMS P/N 1000013724 1000013725
Description Processor board to Laser board cable (LEM) Processor board to Pulse BNC cable (Pulse)
Pulse Cable (1000013725)
September 23, 2009 Page 12
6 Disassembly The bottom of the case is held on by the four feet. 1.
Remove the four feet by unscrewing the socket head cap screws with a hex wrench.
Socket head cap screws in feet 2.
With the bottom removed, the cover can be removed by removing the four socket head cap screws in the four corners.
Socket head cap screws 3.
Lift off the top of the case.
September 23, 2009 Page 13
4.
Remove the Processor board by removing the four socket head cap screws in the four corners.
Remove Processor Board 5.
Remove the tubing from the pressure sensor on the Detector board. Remove the two socket head caps screws. Remove the Detector board. The pressure sensors can be damaged easily. Therefore, the tubing should only be removed if it is necessary.
Remove Detector Board 6.
The 4-20mA board is removed by removing the two socket head cap screws.
Remove 4-20mA Board
September 23, 2009 Page 14
7 Assembly Assembling the Airnet II has a few critical steps. 1.
The length of the socket head cap screws used to mount the 4-20mA board is critical. If the screw protrudes too far through the mounting bracket it will damage the differential pressure sensor on the Detector board.
Socket head cap screw length
Socket head cap screw length 2.
Socket head cap screw length
Care must be taken when mounting the Processor board. If the board-to-board connectors are not properly aligned when the Processor board is pressed down, the connector on the Detector board and/or the 4-20mA board will be damaged.
Board-to-board connectors
September 23, 2009 Page 15
8 Test Points 8.1 Processor Board TP 7 8 9 10 11 12, 14 13 15 17 18 19 20
Signal Name Baseline Restore Threshold CH1_THRESH CH2_THRESH +1.8VDC +3.3V GND D L_STATUS CH2CLK CH1CLK ADC IN4 DAC4_OUT
Description Baseline restore voltage for Detector board Particle channel 1 threshold voltage Particle channel 2 threshold voltage +1.8V power for processor chip +3.3V power System ground Ground for PoE circuit. Connected to system ground through C146 Status output from Laser board Channel 2 particle pulses going to counter Channel 1 particle pulses going to counter Spare input to A/D converter Spare output from D/A converter
8.2 Laser Board There are no test points on the analog board.
8.3 Detector Board There are four test points on the analog board. TP 1 2 3 4
Signal Name Photodiode Anode Photodiode Cathode +12VDC -12VDC
Description Photodiode Anode Photodiode Cathode +12VDC -12VDC
September 23, 2009 Page 16
8.4 4-20mA Board There are eleven test points on the 4-20mA board. TP 1 2 3 4 5 6 7 8 9 10 11
Signal Name GND GND V_OUT_C V_OUT_B V_OUT_A #HRESET 4-20mA_Latch 4-20_SPICK SPIMOSI V_Bus V_OUT_D
Description Ground Ground D/A output for 4-20mA channel 3 (0 to +5VDC) D/A output for 4-20mA channel 2 (0 to +5VDC) D/A output for 4-20mA channel 1 (0 to +5VDC) System reset SPI latch to D/A SPI clock SPI serial data Raw power from Processor board Spare D/A output (0 to +5VDC)
September 23, 2009 Page 17
9 Component Replacement Procedures 9.1 Processor Board (1000013669) The Processor board contains the D/A that sets the thresholds and the baseline restore voltage. It contains the A/D that measures the pressure sensors. Both of these devices have precision voltage references. The value of these references may be different on the new Processor board. This may affect the flow setting and the calibration. If the Processor board is replaced, run setup and calibration.
9.2 Detector Board (1000013676) If the Detector board is replaced, run flow and calibration.
9.3 Laser Board (1000013943) If the Laser board is replaced, run calibration.
9.4 4-20 mA Board (1000013684) If the 4-20mA board is replaced, nothing else is required.
September 23, 2009 Page 18
10 Trouble Shooting 10.1 Power The Airnet II can be powered from either an external +24VDC supply or from a PoE switch. It is possible that the Airnet II can function from the +24VDC input and not from the PoE input. This would indicate that the PoE circuit is faulty but the rest of the supplies are OK. There is a Power LED (D21) on the Processor board. If it is not illuminated then the +3.3V supply is faulty. If it is illuminated it does not guarantee that the rest of the supplies are OK. All of the voltages must be verified with a meter.
10.1.1 +5V The +5V can be verified by measuring pin 1 on CO12 (Laser cable connector).
10.1.2 +3.3V The +3.3V is OK if D21 is illuminated or measuring TP11.
10.1.3 +1.8V The +1.8V can be verified by measuring TP10.
10.1.4 +12V The +12V can be verified by measuring pin 8 on U43.
10.1.5 -12V The -12V can be verified by measuring pin 2 on CO12 (Laser cable connector).
10.2 Ethernet The Ethernet circuit and connector are on the Processor board. If it is determined that the Ethernet problem is a hardware problem then the Processor board must be replaced.
10.3 Laser The firmware will turn the laser off if the air flow is not correct. This can be checked by measuring the #Laser_On signal. This is a low true signal, which means that if the firmware is telling the laser to be on, #Laser_On will measure about 0V. This signal is on CO12 pin 5.
September 23, 2009 Page 19
11 Serial Commands The serial commands are described in the “AirNetII PMS/OPC command summary” document.
September 23, 2009 Page 20
12 Appendix 12.1 Processor Board The major components of the Processor board are described below.
12.1.1.1
Processor
The processor is a Freescale MPC875.
12.1.1.2
FLASH
The system firmware is stored in the FLASH. The FLASH is two PC28F256M29EW parts. These are 16-bit wide 256 Mbit parts. This is 64 Mbytes of FLASH. The address space of the FLASH is from 0xF0000000 to 0xF3FFFFFF.
12.1.1.3
SDRAM
The SDRAM system memory is one Micron MT48LC4M32B2B5-6 part. This a 32-bit wide 128 Mb part. This is 16 Mbytes of SDRAM. The address space of the SDRAM is 0x00000000 to 0x00FFFFFF.
12.1.1.4
EEPROM
The EEPROM is used to store system parameters. There are 32 kbits. The EEPROM is accessed via the SPI bus.
12.1.1.5
Ethernet Controller
The Ethernet Controller is accessed via the Media Independent Interface (MII). D34 on the Processor board is a bi-color LED. The Green portion of the LED indicates the speed of the link (10/100) and the Red portion of the LED indicates whether the link is half duplex or full duplex.
12.1.1.6
Serial Ports
There is one RS-232 serial port and the SPI serial interface.
12.1.1.6.1
SPI Interface
The SPI interface is used within the instrument. The processor controls the EEPROM, the optional 4-20mA output D/A, the threshold D/A, and the pressure sensor A/D via the SPI interface.
12.1.1.6.2
RS-232
The RJ-11 connector on the Processor board is for the RS-232 port.
12.1.1.7
4 – 20mA Outputs (Optional)
If the Airnet II has 4-20mA outputs, the optional 4-20mA board is installed.
12.1.1.8
BDM Port
The Background Debug Port (BDM) is used to view and / or modify the internal memory, registers, and peripherals on any of the processor buses.
12.2 Power over Ethernet (PoE) IEEE802.3af is the standard that defines PoE. There are two basic components to PoE, the Powered Device (PD) and the Power Sourcing Equipment (PSE). The standard requires the use of CAT 3 cable at a minimum. The cable has four twisted pairs. The PSE provides 44-57VDC over two of the four pairs, either the two spare pairs or the two data pairs. Since the standard does not specify which pairs are to be used, the PD must accept power from either set of wire pairs.
September 23, 2009 Page 21
12.2.1 Power Up Sequence To ensure that power is not applied to an Ethernet device that is not a PD, the standard requires the PSE to look for a 25k Ω resistance (signature resistance) on the wire pairs that will be powered. Therefore, the PD must provide this resistance as part of the power up sequence. The standard also specifies five classes of power levels. Class 0 1 2 3 4
Usage Default Optional Optional Optional Reserved
Maximum Power Levels at Input of PD (Watt) 0.44 – 12.94 0.44 3.84 3.84 6.49 6.49 12.95
The PD has a power classification resistor that is detected by the PSE. This allows the PSE to determine how many devices it can power. If the total available power is 100W and each of the PDs are class 3, the PSE can power seven. If the PDs are class 1 then the PSE can power twenty six.
12.3 Additional Equipment In addition to the standard accessories, there are some items that may be useful. Mfr. SL Power PMS PMS PMS PMS SL Power Dell
P/N LS15RB2401J04 1000014175 1000014176 1000014177 1000014178 PW183RB PowerConnect 3524P
Description Input: PoE Output: 11.4W, +24VDC (for powering old Airnet in PoE installation) Adapter cable for powering Airnet II from Airnet power supply Adapter cable for connecting Airnet II 4-20mA outputs to old Airnet installation Adapter cable for powering old Airnet from Airnet II power supply Adapter cable for connecting old Airnet 4-20mA outputs to Airnet II installation Desktop style universal 30 Watt IEEE802.3af compliant PoE power supply 24 port PoE Ethernet switch, 370W for the 24 PoE ports
September 23, 2009 Page 22
