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Maintenance Manual

Spectroil MOil & Fuel Analysis Spectrometers

(For Serial Numbers Starting with 6001, Modifications 6 & 7)

160 Ayer Road Littleton, MA 01460 U.S.A. • Tel. 978.486.0123 • Fax 978.486.0030email: [email protected] • web page: www.spectroinc.com

Manual Part No. M96113

Detailed Instructions for:

• Spectroil M/N-WMilitary Oil Analysis Spectrometer

• Spectroil M/C-WCommercial Oil Analysis Spectrometer

• Spectroil M/F-WFuel Analysis Spectrometer

• Spectroil M/F-LDLight Fuel Analysis Spectrometer

Table of Contents

1.0 DETAILED SYSTEM DESCRIPTION ............................................................................. 11.1 INTRODUCTION ........................................................................................................... 11.2 EXCITATION SOURCE ................................................................................................... 11.3 SAMPLE STAND .............................................................................................................. 31.4 OPTICAL SYSTEM ......................................................................................................... 71.5 COMPUTER & READOUT SYSTEMS............................................................................ 81.5.1 Control Panel ..................................................................................................................... 91.5.2 Sequential Analytical and Background Measurement ........................................................ 101.6 ACCESSORIES AND OPTIONAL PARTS .................................................................... 101.6.1 Printer ................................................................................................................................ 101.6.2 Standards ........................................................................................................................... 111.6.2.1 Wear Metal Standards ..................................................................................................... 111.6.2.1.1 Commercial Wear Metal Standards ............................................................................. 111.6.2.1.2 Military Wear Metal Standards .................................................................................... 121.6.2.2 Fuel Analysis Standards ................................................................................................... 121.6.3 Graphite Electrodes, Disc and Rod .................................................................................... 121.6.4 Rod Electrode Sharpener .................................................................................................... 131.6.5 Disposable Polyethylene Sample Holders .......................................................................... 141.6.6 Reusable Sample Holders and Covers ................................................................................ 141.6.7 External Keyboard, Video and Mouse ................................................................................. 151.6.8 Source Frequency Test Meter.............................................................................................. 151.6.9 Transit Case ....................................................................................................................... 151.6.10 Maintenance Spare Parts Kits .......................................................................................... 16

2.0 MAINTENANCE AND SERVICING INSTRUCTIONS ............................................... 172.1 FAULT ISOLATION ........................................................................................................ 182.1.1 Possible Sample Stand Faults ............................................................................................ 182.1.2 Possible Excitation Source Faults ...................................................................................... 222.1.3 Possible Optical Assembly Faults ...................................................................................... 272.1.4 Possible Computer Controller/Measurement Electronic Assembly Faults ......................... 292.1.5 Possible Main Power and Power Distribution Faults ......................................................... 322.1.6 Possible Printer Faults ...................................................................................................... 362.2 PROCEDURE TO CHECK THE FREQUENCY OF THE EXCITATION SOURCE ... 382.2.1. Auxiliary Gap Optical Fiber View ..................................................................................... 382.2.2 Auxiliary Gap Direct View ............................................................................................... 402.2.3 Detailed Description of Excitation Source Frequency ....................................................... 422.3 DARK CURRENT ELECTRONIC STABILITY TEST .................................................. 452.4 REPAIR AND REPLACEMENT PROCEDURES ........................................................... 452.4.1 Sample Stand..................................................................................................................... 452.4.1.1 Procedure to Adjust Rod Electrode Holder Slide Mechanism .......................................... 452.4.1.2 Procedure to Replace Disc Electrode Shaft, M32408 and Tracking Test .......................... 462.4.1.3 Procedure to Align Disc Electrode to Rod Electrode ........................................................ 472.4.1.4 Procedure to Adjust Sample Stand Interlock Monitor Sensitivity .................................... 472.4.1.5 Procedure to Replace Rod Electrode Holder and Gap Setting Mechanism, M31200 ....... 502.4.1.6 Procedure to Replace Disc Electrode Motor, M32101A ................................................... 50

22 December 2009 / version 3.5

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2.4.1.7 Procedure to Replace Sample Stand Exhaust Fan, M33002 ............................................. 512.4.1.8 Procedure to Replace Disc Electrode Drive Belt, M32303 ............................................... 512.4.1.9 Procedure to Replace Sample Stand Door Interlock, M33006 ......................................... 512.4.2 Excitation Source ............................................................................................................... 522.4.2.1 Procedure to Remove Combined Solid State Source Assembly, M99966 ......................... 522.4.2.2 Procedure to Replace Auxiliary Gap Tungsten Electrodes, M42004 ................................ 532.4.3 Optical System ................................................................................................................... 542.4.4 Computer and Readout System .......................................................................................... 562.4.4.1 Procedure to Replace Controller Cards ............................................................................ 562.4.4.2 Procedure to Remove Windows Readout Assembly ......................................................... 572.4.4.3 Procedure to Remove the Panel PC M68150 from Windows Readout Assembly ............. 572.4.4.4 Procedure to Remove the Panel PC M68720 from Windows Readout Assembly ............. 582.4.4.5 Procedure to Replace START or STOP Switches, M68119/M68120 .............................. 592.4.4.6 Procedure to Measure DC Power Supply Voltages ........................................................... 602.4.4.7 Procedure to Replace the Interlock Monitor Assembly, M59210 ..................................... 602.4.4.8 Procedure to Replace the Measurement and Control Circuit Card, EK0014B ................. 612.4.4.9 Procedure to Correct System File Paths ........................................................................... 622.4.5 Input Power Distribution and Accessories ......................................................................... 622.4.5.1 Procedure to Replace Electrode Sharpener Cutter Blade, M90102 .................................. 622.4.5.2 Procedure to Replace Electrode Sharpener Timer ............................................................ 632.4.5.3 Procedure to Replace Cont. Relay, M21002 and Auxiliary Contact Module, M21005 .... 632.5 SOFTWARE RESTORATION ......................................................................................... 652.5.1 Reinstalling Microsoft® Windows ® XP PRO ..................................................................... 652.5.2 Reinstalling Touch Panel Driver ........................................................................................ 702.5.3 Updating Windows® XP Settings ....................................................................................... 722.5.4 Roxio Easy CD Creator Installation .................................................................................. 742.5.5 Iomegaware Installation .................................................................................................... 752.5.6 Epson printer Driver Installation ....................................................................................... 76

3.0 ASSEMBLY PARTS LIST ................................................................................................. 793.1 PARTS LIST ILLUSTRATIONS ...................................................................................... 79

4.0 OPERATIONAL AND MAINTENANCE ILLUSTRATIONS ...................................... 1094.1 INTRODUCTION ........................................................................................................ 1094.2 ILLUSTRATIONS .......................................................................................................... 1104.2.1 Simplified Block Diagram ................................................................................................ 1114.2.2 Interconnection Wiring Block Diagram ........................................................................... 1124.2.3a. Input Power Distribution Block Diagram, Standard Spectroil M ................................... 1134.2.3b. Input Power Distribution Block Diagram, CE Version of the Spectroil M ..................... 1144.2.4a. Input Power Distribution Diagram, Standard Spectroil M............................................. 1154.2.4b. Input Power Distribution Diagram, CE Version of the Spectroil M ............................... 1164.2.5.a. Placement of Power Switching Contactor Assembly, Standard Spectroil M ................... 1174.2.5.b. Placement of Power Switching Contactor Assembly, CE Version of the Spectroil M ..... 1184.2.6.a. Regulating Power Transformer Assembly Wiring, Standard Spectroil M ....................... 1194.2.6.b. Regulating Power Transformer Assembly Wiring, CE Version of the Spectroil M ......... 1204.2.7 Sample Stand Block Diagram ........................................................................................... 1214.2.8 Excitation Source Block Diagram ..................................................................................... 122


4.2.9 Excitation Source with DC Capability for RFS Analysis Block Diagram .......................... 1234.2.10 Excitation Source / Sample Stand Schematic Diagram ................................................... 1244.2.11 Excitation Source with DC Capability for RFS Analysis / Sample Stand Schematic Diag 1254.2.12 Control Panel Assembly Block Diagram ......................................................................... 1264.2.13 Control Panel Assembly Schematic Diagram .................................................................. 1274.2.14 Connector Position for M59205 Measurement & Control Circuit Card ........................ 1284.2.15 Connector Position for M59210 Interlock & Power Monitor Circuit Card .................... 1294.2.16 Terminal Board 2 Wiring Diagram ................................................................................ 1304.2.17 Computer Controller Block Diagram ............................................................................. 1314.2.18 Computer Controller Wiring Diagram ........................................................................... 1324.2.19 Polychromator Optic Block Diagram ............................................................................. 1334.2.20 External Data Transmission Cable for External Computer with 9 Pin Serial Port .......... 1344.2.21 External Data Transmission Cable for External Computer with 25 Pin Serial Port ......... 1354.2.22 Spectroil M Dimensions and Mounting Details ............................................................. 136


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This Page is Intentionally Left Blank


List of Effective Pages

Summary of Spectroil Modifications

Modification DescriptionMod 0 Original CID version of Spectroil MMod 1 Upgrade with SFTM port and frequency adjustement potentiometerMod 2 Addition of solid state excitation ignition module and SFTM portMod 3 Upgrade to combined solid state sourceOilMWindows Upgrade to Windows hardware and softwareMod 4 Upgrade to panel PC hardware and Windows XPMod 5 CE version of the Spectroil MMod 6 CCD Optic and New Software v. 5, starting w/serial number 6001Mod 7 C.E. version of Mod. 6

Summary of OilMWindows Modification 6 Hardware and Software Manual Versions

Change Version Date DescriptionFirst Issue 3.0 7/1/07 Complete update of Mod. 5 version 2.5 manual to include CCD

optic & updated software.Change 1 3.1 10/24/07 Update for CE version, Mod. 7, changes. Addition of optic

removal procedure. Grammatical correctionsChange 2 3.2 10/31/07 More updates to Chapter 2 for CE certification.Change 3 3.3 2/18/08 Created separate Maintenance ManualChange 4 3.4 7/21/09 Major technical update & corrections. Added procedure to re-

place Interlock Monitor Assembly and Measurement & Control Circuit Card. Added 3 new diagrams.

Change 5 3.5 12/22/09 Panel PC upgrade, SFTM part number change and minor cor-rections.


Spectroil M Family of Spectrometers (Mod. 6 CCD & 7 CE) Maintenance Manual | v

vi | List of Effective Pages

Total Number of pages in this manual is 145 consisting of the following:

Section Page NumbersCover 2Table of Contents i - ivList of Effective Pages v - viiChapter 1 1 - 16Chapter 2 17--78Chapter 3 79 - 108Chapter 4 109-136

WARNING!!!High Voltages are Present During the Operation of the

Spectroil M!

Observe all Safety Precautions!

Turn OFF the Main Power Switch and unplug the SPECTROIL M before any work is performed.


Definitions

The following definitions apply to specific instructions throughout this manual.

WARNING!!!An operating procedure or practice that may cause injury if not carefully observed or

followed.

CAUTION!!! An operating procedure or practice that may cause damage to the LNF if not carefully

observed or followed

NOTE!!!An operating procedure or practice that is essential to emphasize

Software CAUTION!!!The Spectroil M computer is capable of running multiple software applications and/or operating systems. However, as designed, the computer processor is dedicated to the operation and control func-tions of the Spectroil M. Do not attempt to add any software or al-ter the original factory installed software without checking first with the Spectro Inc. Service Department.


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WARRANTY

ThewarrantyperiodoftheSpectroilMfamilyofspectrometersistwelve(12)monthsfromdateofinstallationorfifteen(15)monthsfromdateofshipment,

whicheveroccursfirst.SpectrowarrantstheSpectroilunderconditionsofopera-tionagainstdefectsofmaterialsandworkmanship.Alldefectivematerialwillbereplacedprovidingdamagewasnotcausedbyimproperuse.Warrantyappliesto

partsandlaboronly.

Note on Oil Standards

The Spectroil M series of spectrometers can be calibrated for military or commercial applications. As a rule, the Spectroil M/N-W is calibrated and standardized with D-19, D-12 and D-3 series of standards, and the Spectroil M/C-W with V-21 or S-21 series of calibration standards.

Although this manual frequently refers to the military “D” series of standards, the op-erator procedures are identical for all types of Spectroil M spectrometers. Commercial customers should substitute their equivalent “V” or “S” series of standards throughout this manual.


Figure 1-1, Spectroil M Block Diagram

Excitation

Source

Graphite

Rod and Disc

Electrodes

Oil Sample & Holder

Grating

Ana

log

to D

igita

l Con

verter

Rowland Circle

Entrance

Slit

Fiber

Optic

Cable

Readout & Control

CCD Detectors

Controller

1.0 DETAILED SYSTEM DESCRIPTION

1.1 INTRODUCTION

The Spectroil M is made up of a number of dif-ferent subsystems, each of which has its own role in the analysis. The simplified block diagram in Figure 1-1 illustrates these subsystems and each one’s relationship with the rest of the system. The paragraphs which follow will describe each of these parts of the Spectroil M in detail, discuss-ing its contribution to the overall function of the system.

1.2 EXCITATION SOURCE

The Excitation Source Assembly consists of many components which are assembled and mounted within a rectangular compartment located behind the sample excitation stand assembly. Its panels are interlocked for operator protection and are easily removed for routine maintenance and fault

Chapter 1

DetailedSystem

Description

Spectroil M Family of Spectrometers (Mod. 6 CCD & 7 CE) Maintenance Manual | 1


Auxiliary Gap1

SFTM Fiber

Capacitor C3

Resistor R2

Resistors R1 and R3

Connector J4

Inductor L1

Capacitor C2 Resistor R7

Solid State ExcitationIgnition Module

(SSEI)

Figure 1-2, Excitation Source Components Top View

isolation. The excitation source has been designed to be simple and reliable. During analysis, the ex-citation source generates the potential difference between the disc electrode and the rod electrode to create and sustain the arc discharge which re-sults in creation of the plasma. The characteristics of the excitation source, such as its capacitance, voltage level, frequency, etc., can be varied to meet the requirements of the analysis. Figure 1-2 is a view of the Excitation Source Assembly com-ponents and the following text provides a detailed description of each component’s function.

NOTE: This manual describes the latest enhanced excitation source designated as MOD 3. This is the new combined solid-state ignition and excitation source included in all new MOD 3 and MOD 4 Spectroils.

Capacitor C3 - This 10 microfarad (µfd) electro-lytic capacitor is used to accumulate the potential for the analytical excitation of the oil sample. This capacitor is charged by the regulated voltage of the M24000 regulating transformer mounted in the power distribution compartment and is con-

trolled by the operation of the K5 power contac-tor. This capacitor is charged and discharged ap-proximately 6 times at the peak of the sinusoidal waveform. The accumulated charge on this capac-itor is discharged across the analytical gap through resistor R2. Refer to Section 2.4.3 for additional technical information regarding the operation of capacitor C3 and the procedure to measure the excitation source frequency.

Inductor L1 - This inductor is an 82 µh coil that provides high voltage isolation to the components of the analytical circuit. This inductor is a passive component consisting of approximately 16 gauge wire wound around an isolated spacing tube. It isolates the high voltage from the analytical com-ponents by blocking the electromagnetic field produced by the high voltage discharge.

Solid State Excitation Ignition Module (SSEI) - A complete solid state circuit assembly which fixes the frequency of the oscillatory arc. The circuit will maintain the arc at the proper frequency even if line voltage, frequency or barometric pressure changes.

2 | Chapter 1 Detailed System Description


Figure 1-3, Front View Showing Sample Stand

Door Handle Chimney & Exhaust

Door

Window, Viewing

Resistor R2 - This is a 5 ohm, 50 watt, 1% power resistor which, in conjunction with capacitor C3, forms the R/C time constant for the discharge characteristics of the analytical waveform.

Resistor R1 & R3 - These are 50 ohm, 50 watt, 1% power resistor which is in series with the charging circuit of the analytical capacitor.

Capacitor C2 - This is a 0.0005 µfd 30K VDC high voltage capacitor which, in conjunction with the SSEI sets the frequency of the oscillatory arc.

Auxiliary Gap - The auxiliary gap is provided as the means to adjust the operating frequency of the excitation source. It is electrically in series with the analytical gap. The nominal gap distance is 0.135 inches and produces approximately 660 discharges per second. Refer to Section 7.4 for additional information regarding specific mainte-nance procedures regarding the auxiliary gap.

Auxiliary Gap Blower Fan - The excitation source assembly has a blower fan adhered to the green phenolic source component mounting plate and positioned adjacent to the auxiliary gap opening. The purpose of this blower fan to exhaust the ozone gas produced by the high voltage electrical discharge across the auxiliary gap. This fan is es-sential to ensure a reproducible discharge in any environment. The auxiliary gap fan is operational only when the contactor K5 is energized and re-mains operational for the duration of the burn cycle, which is approximately 30 seconds. There is no adjustment or maintenance required on this fan.

Resistor R7 - This is a 25 ohm, 25 watt, 5% non-inductive resistor which is electrically in series between the output of the high voltage capacitor C2 and the auxiliary gap. Its purpose is to limit the current flow of the high voltage ignition dis-charge. Since this resistor limits current flow, it will dissipate a fair amount of heat. After a couple of burns, this resistor will be hot, which is per-fectly normal.

Connector J-4 - This is the sole input source of supply voltage to the excitation source assembly M99962. Pin 1 is AC high (125 VAC regulated), pin 2 is AC low (0 VAC), and pin 3 is power earth ground.

SFTM Fiber - The fiber optic carries the image of the excitation process at auxiliary gap to the SFTM (Source Frequency Test Meter) port on the sample stand housing. The frequency of the aux-iliary gap is then measured and confirmed with the SFTM).

1.3 SAMPLE STAND

The Sample Stand is located on the right front side of the spectrometer. It is the chamber in which the oil or fuel sample is placed for analysis. It con-tains the carbon electrodes, sample table, rod elec-trode gapping mechanism and the sample stand monitoring sensors. Figure 1-3 shows a front view of the Spectroil M with the exterior sample stand parts labeled. Figure 1-4 on the next page shows an illustrated diagram of the components inside the sample stand. The paragraphs below describe the sample stand components.

Access is gained to the sample stand by placing the



Figure 1-4, Sample Stand Assembly Component Description

1. Rod Electrode, Graphite

2. Analytical Gap Adjustment Screw and

5. Disc Electrode, Graphite

4. Slide Mechanism Adjustment Screws

3. Rod Electrode Holder Mechanism

6 Rod Electrode Xmit Sensors

7. Analytical gap Receive Sensor

8. Sample Holder (Cap) Xmit Sensor

9. Disc Electrode Receive Sensor

10. Disc Electrode Shaft

11. Sample Table

12. Sample Stand Mounting Hardware Hole (4)

20. Rod Electrode Clamp Knob

22. Analytical Gap Setting Lever

21 Rod Electrode Clamp

19. Analytical Gap Xmit Sensor

18. Quartz Window and Lens Assembly

17. Rod Electrode Receive Sensor

16. Disc Electrode Xmit Sensor

15. Sample Holder Receive Sensor

Sample Holder

14. Sample Table Height Adjustment

13. Table Positioning Lever



right hand inside the door handle and pulling the door towards you. An interlock switch prevents the excitation from taking place while the door is open. The exhaust fan expels fumes from around the sample area and operates when the MODE switch is placed in the OPERATE position. The remaining components inside the sample stand are described below.

1. Rod Electrode (Graphite) - The graphite rod electrode develops an arc discharge from the tip of the rod electrode to the circumference of the disc electrode and alternately receives an arc discharge from the disc electrode surface to the tip of the rod. This is called an oscillating arc discharge. The rod is 0.243 inches (0.617 cm) in diameter and 6 inches (15.24 cm) long. Length decreases as the rod is sharpened.

2. Analytical Gap Adjustment Screw and Lock The screw is adjusted and locked to limit the up-ward travel of the slide mechanism which pro-duces an analytical gap distance of 0.090 inches between the rod and disc electrodes when the ana-lytical gap setting lever is raised and lowered to its rest position. The gap is set during factory calibra-tion to maximize light intensity. The gap should not be reset under routine circumstances.

3. Rod Electrode Holder and Slide Mechanism - The rod electrode holder clamps the rod electrode in a “V” positioning channel. This mechanism slides along the vertical axis when the analytical gap setting lever is activated thereby accurately setting the analytical gap. Its upward travel is lim-ited by the analytical gap adjustment screw.

4. Slide Mechanism Adjustment Screws - The slide mechanism must move freely along a verti-cal axis. See Section 7.6.1.1 for adjustment of the slide mechanism.

5. Disc Electrode (Graphite) - The high purity graphite disc electrode rotates through the oil sample to introduce the sample into the analytical gap for excitation. The disc is type ASTM D-2, 0.492 inches (1.25 cm) in diameter and 0.200

inches (0.508 cm) thick.

6. Rod Electrode XMIT Sensor - The presence of the rod electrode is monitored at all times to pre-vent an analytical discharge from occurring in the event that the operator fails to install and properly position the rod electrode. This monitoring sys-tem is accomplished by passing a focused beam of incandescent light from the transmitter (XMIT) to the receiver (RECEIVE). If the rod electrode is installed and properly positioned, it will inter-rupt this beam of light, confirming its presence. This component is the transmit (XMIT) sensor. This monitoring system is basically passive and does not require any alignment or adjustment, however as in all light activated systems, it should be kept clean to avoid an erroneous indication. To clean the sensors, use an ammonia-based win-dow cleaner or an optical lens cleaning solution. Clean the sensors daily, or as required depending on sample volume.

7. Analytical Gap Receive Sensor - The analyti-cal gap is monitored at all times to prevent an analytical discharge from occurring in the event that the operator fails to set a gap distance be-tween the disc and rod electrodes. This monitor-ing system is accomplished by passing a focused beam of incandescent light from the transmitter (XMIT) through the analytical gap to the receiver (RECEIVE). This component is the receive (RE-CEIVE) sensor. This monitoring system is basi-cally passive and does not require any alignment or adjustment, however as in all light activated systems, it should be kept clean to avoid an er-roneous indication. To clean the sensors, use an ammonia-based window cleaner or an optical lens cleaning solution. Clean the sensors daily, or as required depending on sample volume.

8. Sample Holder XMIT Sensor - The presence of the sample holder is monitored at all times to prevent an analytical discharge from occurring in the event that the sample holder has not been el-evated into position. This monitoring system is accomplished by passing a focused beam of in-candescent light from the transmitter (XMIT)



through the sample holder to the receiver (RE-CEIVE). If the sample holder is installed and properly positioned, it will interrupt this beam of light confirming its presence. This component is the transmit (XMIT) sensor. This monitoring sys-tem is basically passive and does not require any alignment or adjustment, however as in all light activated systems, it should be kept clean to avoid an erroneous indication. To clean the sensors, use an ammonia-based window cleaner or an optical lens cleaning solution. Clean the sensors daily, or as required depending on sample volume.

9. Disc Electrode Receive Sensor - The presence of the disc electrode is monitored at all times to pre-vent an analytical discharge from occurring in the event that the operator fails to install and properly position the disc electrode. This monitoring sys-tem is accomplished by passing a focused beam of incandescent light from the transmitter (XMIT) to the receiver (RECEIVE). If the disc electrode is installed and properly positioned, it will inter-rupt this beam of light confirming its presence. This component is the receive (RECEIVE) sensor. This monitoring system is basically passive and does not require any alignment or adjustment, however as in all light activated systems, it should be kept clean to avoid an erroneous indication. To clean the sensors, use an ammonia-based win-dow cleaner or an optical lens cleaning solution. Clean the sensors daily, or as required depending on sample volume.

10. Disc Electrode Shaft - The disc electrode shaft secures and rotates the disc electrode during the analysis. This shaft has been designed to be re-placed at the operator level. Occasionally, a disc electrode shaft will be bent through mishandling, or unable to securely mount a disc electrode be-cause of erosion of the outer diameter due to pre-vious arcing between the outer diameter of the shaft and the inner diameter of the disc electrode. In these situations, this shaft can easily be replaced by inserting a small jeweler’s screwdriver into the slotted end and turning the shaft counterclockwise until it can be pulled out of the bearing mount. Replace this shaft in the reverse of this procedure.

Check to be sure that the disc electrode is aligned to the rod by checking the tracking. Refer to Sec-tion 7.6.1.2 for a detailed description of this pro-cedure. 11. Sample Table - The sample table holds the oil sample holder, and when raised, immerses the disc electrode in the oil.

12. Sample Stand Mounting Hardware - The sample stand mounting hardware secures the sample stand to the sample excitation chamber.

13. Table Positioning Lever - The table position-ing lever raises and lowers the sample table.

14. Sample Table Height Adjustment - This threaded ring adjustment is positioned to contact the bottom of the sample stand block when the sample table is raised to the detent position. Its function is to prevent the table from being over-driven. The four 3 mm cap screws that secure the assembly can also be used for minor adjustments.

15. Sample Holder Receive Sensor - The presence of the sample holder is monitored at all times to be sure that an arc discharge will not be gener-ated across the analytical gap in the event that the sample holder has not been elevated into position. This monitoring system is accomplished by pass-ing a focused beam of incandescent light from the transmitter (XMIT) through the sample holder to the receiver (RECEIVE). This component is the receive (RECEIVE) sensor. This monitoring sys-tem is basically passive and does not require any alignment or adjustment, however as in all light activated systems, it should be kept clean to avoid an erroneous indication. To clean the sensors, use an ammonia-based window cleaner or an optical lens cleaning solution. Clean the sensors daily, or as required depending on sample volume.

16. Disc Electrode XMIT Sensor - The presence of the disc electrode is monitored at all times to pre-vent an analytical discharge from occurring in the event that the operator fails to install and properly position the disc electrode. This monitoring sys-tem is accomplished by passing a focused beam of



incandescent light from the transmitter (XMIT) to the receiver (RECEIVE). If the disc electrode is installed and properly positioned, it will inter-rupt this beam of light confirming its presence. This component is the transmit (XMIT) sensor. This monitoring system is basically passive and does not require any alignment or adjustment, however as in all light activated systems, it should be kept clean to avoid an erroneous indication. To clean the sensors, use an ammonia-based win-dow cleaner or an optical lens cleaning solution. Clean the sensors daily, or as required depending on sample volume.

17. Rod Electrode Receive Sensor - The presence of the rod electrode is monitored at all times to prevent an analytical discharge from occurring in the event that the operator fails to install and properly position the rod electrode. This monitor-ing system is accomplished by passing a focused beam of incandescent light from the transmitter (XMIT) to the receiver (RECEIVE). If the rod electrode is installed and properly positioned, it will interrupt this beam of light confirming its presence. This component is the receive (RE-CEIVE) sensor. This monitoring system is basi-cally passive and does not require any alignment or adjustment, however as in all light activated systems, it should be kept clean to avoid an er-roneous indication. To clean the sensors, use an ammonia-based window cleaner or an optical lens cleaning solution. Clean the sensors daily, or as required depending on sample volume.

18. Quartz Window and Lens Assembly - The quartz window is epoxied to the brass lens holder for ease of cleaning, and is installed to prevent oil and carbon from coating the lens. The lens col-lects light from the plasma and focuses it on the end of the optical fiber.

19. Analytical Gap Xmit Sensor - The analytical gap is monitored at all times to prevent an ana-lytical discharge from occurring in the event that the operator fails to set a gap distance between the disc and rod electrodes. This monitoring sys-tem is accomplished by passing a focused beam of

incandescent light from the transmitter (XMIT) through the analytical gap to the receiver (RE-CEIVE). This component is the transmit (XMIT) sensor. This monitoring system is basically passive and does not require any alignment or adjustment, however as in all light activated systems, it should be kept clean to avoid an erroneous indication. To clean the sensors, use an ammonia-based win-dow cleaner or an optical lens cleaning solution. Clean the sensors daily, or as required depending on sample volume.

20. Rod Electrode Clamp Knob - The black plas-tic knob is pressed to open the clamp to allow the rod electrode to be exchanged and provides insulation from the heat generated by the arc dis-charge.

21. Rod Electrode Clamp - The rod electrode clamp is held against the rod electrode holder and slide mechanism by a compression spring. Its function is to clamp the rod electrode in the po-sitioning channel of the rod electrode holder and slide mechanism. The spring is compressed when the rod electrode clamp knob is pushed inward to load the rod.

22. Analytical Gap Setting Lever - This lever is used to drive the rod electrode holder and slide mechanism downward in a vertical position. When the lever is raised to its maximum posi-tion, the slide mechanism is driven to its lowest vertical travel. At this position, the rod and disc electrodes are driven to contact each other. When the lever is lowered to the bottom of its travel, the slide mechanism with the rod electrode clamped in the positioning channel raises until its travel is stopped by the analytical gap adjustment screw. This sets the analytical gap to 0.090 inches.

1.4 OPTICAL SYSTEM

The Optical System is mounted in a light-sealed and environmentally protected temperature-sta-bilized compartment located in the bottom of the Spectroil M. The optic is a polychromator which is capable of simultaneous analysis of all the pro-



Figure 1-5, Illustrated Diagram of the Optical System

3. Diffraction Grating

4. Rowland Circle

1. Optical Fiber

2. EntranceSlit

5. CCD Detectors

grammed elements. Detailed specifications for the Spectroil M series optic are:

• Paschen-Runge mounting• Focal length: 400 mm• Holographic grating• High resolution CCD linear sensors• Wavelength range: 200-800 nm• Temperature stabilized housing• Temperature stabilized material and con-

struction• Automatic optical profile• Dynamic background correction• Shock and vibration protected

Figure 1-5 provides an illustrated example of the polychromator components and the following text will provide a detailed description of each component. For a more detailed explanation of the theory of atomic emission, please refer to Section 1.3 of the Overview & System Descrip-tion Manual3.

1. Optical Fiber - The 1 mm diameter optical fiber couples white light (containing all wave-lengths) from the analytical gap in the sample stand to the entrance slit of the polychromator optic. Optical fibers are flexible, able to transmit visible light for great distances with little loss, and offers superior optical alignment stability for mobility and laboratory applications.

2. Entrance Slit - The purpose of the entrance

slit is to form the light which exits the fiber optic into a distinct line image. This image enters the Rowland Circle in focus and begins to diverge as it projects towards the diffraction grating.

3. Diffraction Grating - The Spectroil M utilizes a holographic grating mounted on Zerodur which has 2400 lines per millimeter, and a dispersion of 8.33 Angstroms per millimeter. The grating is Paschen-Runge mounted. Its purpose is to diffract and focus the light coming from the entrance slit (containing all wavelengths) into separate compo-nents of the light onto each photomultiplier tube via an exit slit.

4. Rowland Circle - The Rowland Circle is a de-sign concept which is based on a perfect circle. If the image of a line of light enters the imaginary circle through an entrance slit and is diffracted from an optical grating having its grating surface on the circumference of the circle, the spectral lines diffracted from the grating will converge and form a perfect image of the entrance slit precisely where it exits the circle. The polychromator optic utilized in the Spectroil M employs this concept.

5.CCD Detectors - The charge-coupled device (CCD) detectors convert the light energy into electrical signals which are processed by a A/D circuit cards that are also located within the opti-cal housing. Fifteen CCD detectors are mounted on the Rowland circle in order to cover the wave-length range of the elements of interest in oil and fuel analysis. Eight CCD detectors are mounted on the top and seven on the bottom of the optical system.

1.5 COMPUTER & READOUT SYSTEMS

The analytical light, which is generated at the ana-lytical gap of the sample stand and processed in the optical system, must be converted to some form of a readout. This function is handled by the computer section of the instrument, which is located on the left side of the spectrometer and can be reached by removing the outer and left inner access panel on the top.



Figure 1-6, Spectroil M Control Panel

5. MODE Switch

1. Video Monitor & Processor

2. Keypad

7. Zip® Drive

6. CD-RW Drive

4. STOP Switch

3. START switch

8. USB Connectors (2)(Behind Cover)

The Readout System of the Spectroil M converts the electrical signals from the computer into ppm (parts per million) units which are familiar to the user. This section details the control switches of the instrument readout and the timing process in-volved throughout the analysis cycle.

1.5.1 Control Panel The control panel, Figure 1-6, is the main com-munications interface between the operator and the spectrometer. The control panel allows the operator to select and control the functions of the instrument, and to obtain the needed informa-tion from the unit regarding an analysis or any of the criteria set up in the program. The various components included on the control panel are de-scribed in the following paragraphs.

1. Video Monitor & Processor – The flat panel color monitor displays the analysis data generated by the Spectroil M, as well as all prompts, instruc-tions, and other information pertinent to the in-strument’s use. It is an integral part of a military hardened industrial grade processor which con-trols the functions of the Spectroil M.

2. Keypad – The retractable Keypad folds up for use as a standard keypad or down during trans-

port. It is environmentally sealed for maximum reliability in harsh operating environments. It is the main means of input to the instrument by the operator; the keys are in the familiar QWERTY layout, so familiar typing skills can be fully uti-lized. A numeric keypad is located to the right of the alpha keys. NOTE: The keypad is only one of the means avail-able to enter data into the Spectroil M. Additional options to enter data can be accom-plished through the touch screen and an on-screen keyboard selectable from the accessability options of the Windows®XP software.

3. Switch, START - This switch is used to initiate the analysis cycle of an oil sample. This switch is functionally in parallel with function key 9 (F9) START in the Analysis Program Screen.

4. Switch, STOP - This switch is used to stop an analysis cycle if the operator chooses to abort a burn. This switch is functionally in parallel with function key 10 (F10) STOP in the Analysis Pro-gram screen. Normally, this button is not used since the system is programmed to stop the burn automatically at a preset time.

5. Switch, MODE - This switch selects the



Figure 1-7a, Accessory Panel Connections

Printer Signal Cable Connection

Printer Power Connector Fuse F3, see Fig. 8-17

PrinterPower Connector, 125

VAC

MODE of operation for the Spectroil M. When placed in the STANDBY mode, this switch will remove the power to the rod electrode sharpener, the excitation source and the exhaust fan. When this switch is placed in the OPERATE mode, the instrument is fully operational with power ap-plied to all assemblies.

6. CD-RW Drive - This is a standard CD-RW Rewritable drive.

7. Zip® Drive - This is s standard 250 Mb Zip® re-movable drive. (A 1.44 Mb floppy drive is avail-able upon request).

8. USB Connector – Provides easy connection for USB devices.

1.5.2 Sequential Analytical and Background Measurement

The Spectroil M is designed and programmed to measure the net intensity of each analytical wave-length after correcting for variation in background intensity due to dissimilar oil matrices. This de-sign approach is necessary to compensate for the differences between the hydrocarbon base stock of the JOAP, VHG, Spectro, or CONOSTAN calibration standards and actual stock lubricants. This section will describe the hardware and soft-ware associated with background measurement and net intensity calculation.

Background radiation is an undesired by-product of the atomic emission technique. To produce atomic emission a controlled electrical arc is dis-charged through a thin layer of the oil sample. The energy of the arc instantaneously vaporizes the oil sample, thus emitting light. Even if the samples of oil were absolutely pure and free of el-emental contamination, the light produced from the arc discharge and vaporization of the sample would enter the optics for processing. Without the presence of elemental contamination, spectral lines will not be formed at the CCD detectors, but a background level of light will. The signal which flows from each CCD as a result of this light level is the background intensity for that particular oil

sample. During daily standardization at 0 ppm, the background intensity produced by the base oil standard is calibrated to produce a readout of 0 ppm.

To produce an accurate calculation of the concen-tration of any element in a used oil sample, back-ground intensity measurements must be made during the measure cycle. This is accomplished by monitoring background signals at designated pixels on the CCD detectors. These signals are used to correct the desired signals from the ele-ments present in the sample.

1.6 ACCESSORIES AND OPTIONAL PARTS

1.6.1 PrinterThe Spectroil M uses a parallel interface inkjet or high speed dot matrix printer such as the Epson LX300, LX810 or the OKIDATA 184 Turbo. The printer provides hard copy output of the data generated by the instrument. This printer is connected to the computer via a power and a sig-nal cable. . The power cable is connected to the Printer Power Connector on the Accessory Power and Signal Connector panel located on left side near the back of the instrument. The signal cable is connected to the 25 pin D-type connector la-beled LPT1 on the same panel. Refer to Figure 1-7a. for the location of these connectors on the standard Spectroil M and to Figure 1-7b. for the



Figure 1-7b, Accessory Panel Connections on CE Version of Spectroil M

Printer Signal Cable Connection

Printer Power Connector Fuse F3,

see Fig. 8-17

PrinterPower Connector, 125

VAC

location on the CE version of the Spectroil M.

A detailed description of the operating features of the printer supplied with the Spectroil M is con-tained in a manufacturer’s manual provided with each printer. Consult this manual for detailed op-erating and maintenance instructions.

1.6.2 StandardsThe Spectroil M, like all spectrometers, must be calibrated and periodically checked to confirm that it is providing an accurate analysis of an un-known oil or fuel sample. The initial instrument calibration is performed after it is manufactured, where the performance (accuracy and reproduc-ibility) becomes part of the final quality inspec-tion. In order to accurately calibrate the Spectroil M, special oil standards are required. These mul-tiple element metallo-organic oil standards are manufactured under very strict allowance toler-ances.

Regardless of the application, the Spectroil M is an instrument which compares the intensity

of the light spectrum of an unknown oil or fuel sample to the intensity of a known calibrated oil standard. The accuracy of the instrument is di-rectly dependent on the quality of the calibration standards used to produce the initial calibration curves and to perform daily recalibration. If cali-bration standards are provided with the instru-ment, they are most likely the standards that were used to generate the initial calibration curves. The quality of the Spectroil M analysis will depend on whether the operator controls the quality of the oil standards used in the daily standardization of the instrument.

NOTE: Oil standards degrade with time. Oil stan-dards are labeled with manufacture dates and may also include an expiration date. The expiration date may vary among manufacturers and their recom-mendations should always be followed.

NOTE: Oil standards must be vigorously shaken no less than 2 hours prior to use.

Fresh oil standards can be obtained from Spectro Incorporated or directly from the manufacturer.

1.6.2.1 Wear Metal Standards

1.6.2.1.1 Commercial Wear Metal Standards Depending on the application, the Spectroil M can be calibrated from 0 ppm to a maximum con-centration of 10,000 ppm. The most popular ap-plication for the Spectroil M is wear metal analy-sis, where trace element contamination is equally as important as monitoring the additive package of the oil. For most wear metal applications, an oil standard blend referred to as V21 or CS-21 (21 elements) is commonly used. Calibrating the in-strument with this standard blend for wear metal applications involves the analysis of the follow-ing oil calibration standards: 0 ppm, 10 ppm, 30 ppm, 50 ppm, 100 ppm, 300 ppm, 500 ppm and 900 ppm. For lubricant additive analysis, the level of certain elements will include the 2,500 ppm, 5,000 ppm and 10,000 ppm concentration levels.



Figure 1-8, Oil Standards, Graphite Electrodes, Sample Holders, Sample Holder Cover and Electrode Sharpener

Standard National Stock Number D3-100 1RM 9150-01-283-0249D12-5 1RM 9150-01-307-3343 D12-10 1RM 9150-00-179-5145D12-30 1RM 9150-00-179-5144D12-50 1RM 9150-00-179-5143D12-100 1RM 9150-00-179-5142D12-300 1RM 9150-00-179-5141D19-0 1RM 9150-01-179-5137

Table 1-1, Military Wear Metal Standards

1.6.2.1.2 Military Wear Metal Standards The military oil analysis program is strictly con-trolled through the Joint Oil Analysis Program Technical Support Center (JOAP-TSC) in Pen-sacola, Florida. This organization is responsible for providing and monitoring the quality of oil standards for daily operation within the military oil analysis community. Table 1-1 is a list of oil standards they manufacture.

Military oil standards have a shelf lives and should never be used after their expiration date. The shelf live will vary from one standard to the next. Prior to using a standard, check the label on the bottle to confirm that it has not expired.

The JOAP-TSC address is as follows: Joint Oil Analysis Program Technical Support Center 85 Millington Avenue, Building 3887 Pensacola, Florida USA 32508-5010

If you have any questions about JOAP stan-dards, call the JOAP-TSC at:

Commercial: 850-452-5627 DSN: 922-3191

1.6.2.2 Fuel Analysis StandardsFuel analysis applications focus on the trace ele-ment detection of such elements as sodium and potassium at the 0.5 ppm concentration and be-low. For fuels, the Spectroil M is calibrated from 0 ppm to a maximum of 500 ppm for most ele-ments. Fuel analysis standards are specially blend-ed for the gas turbine fuel analysis application. The stated concentration of the oil standard is applicable for all elements except magnesium. In

application, the recommended concentration of the inhibitive element magnesium is three times the concentration of vanadium. Therefore, cali-bration standards for the fuel analysis application will contain magnesium at three times the con-centration of the other elements in the standard.

1.6.3 Graphite Electrodes, Disc and Rod The Spectroil M is an arc emission spectrometer which incorporates the rotating graphite disc elec-trode technique. The rotating graphite disc elec-trode, Figure 1-8, provides the means by which the sample is introduced into the arc discharge to create a plasma for analysis and the rod electrode establishes the analytical gap and the arc discharge path. The shape of the graphite rod electrode and specific density of the disc electrode contribute significantly to the performance of the Spectroil M.

Since the graphite disc and rod electrodes con-tribute significantly to the quality of the analytical data, there are a few recommendations regarding the handling, preparation, and control of the elec-trodes. The disc and rod electrodes are manufac-tured and purified to strict specifications to en-sure that they do not contain unacceptable levels of trace element contamination for the elements of interest. The disc electrodes can easily become contaminated if handled improperly. The elec-trode surfaces that make up the analytical gap should never be touched with your fingers. Refer to Spectroil M Operation Manual for the recom-



Concentration Maximum MinimumRod Electrode Carbon Graphite 6.0 inches (15.24

cm) long, 0.243 inches (0.617 cm) in diameter Spectro M97009NSN 5977-00-464-8433

Sharpened on one end at a 160˚ angle to direct the arc discharge from the disc electrode

Disc Electrode Carbon Graphite 0.492 inch (1.25 cm) in diameter, 0.200 inches (0.508 cm) thick

• Military “C” Spec. Electrodes Spectro Part No. M97200 NSN 5977-00-464-8496

•Commercial Grade ElectrodesSpectro Part No. M97008

Carries the sample into the analytical gap for analysis

Table 1-2, Graphite Electrode Characteristics

mended procedure to handle and install the disc electrodes. The quality of the rod electrode shape is equally as important as the proper handling of the disc electrode. Consistent preparation of the rod electrode point will ensure that the analytical data will be reproducible. Refer to the Spectroil M Operation Manual for the recommended pro-cedure to sharpen the graphite rod electrodes.

Table 1-2 describes the characteristics of the graphite electrodes used in the Spectroil M.

All graphite disc and rod electrodes provided with the Spectroil M are of the ASTM (American So-ciety for Testing and Materials) grade which can be obtained from one of many vendors world-wide. Although these electrodes are manufactured by the same extruding process, the density of the electrodes can vary drastically from vendor to vendor.

It is strongly urged that the instrument user exer-cise caution when purchasing graphite electrodes from vendor sources other than those provided with the instrument. The specific density of the disc electrode does affect the calibration curves. Furthermore, it is advised that the instrument user avoid mixing electrode batches since specific

density may vary from batch to batch even if pro-vided by the same vendor.

1.6.4 Rod Electrode SharpenerThe Spectroil M is supplied with an accessory called the rod electrode sharpener, Part Number M90100, Figure 1-8. This accessory is required to place a smooth angular surface which is centered on the tip of a graphite rod electrode. The most common graphite rod electrode is six inches long, and each electrode can be resurfaced or sharpened approximately 20 times under normal condi-tions.

The rod electrode sharpener has been designed us-ing an induction motor which is capable of oper-ating on multiple line frequencies. This motor is designed to operate on 120 VAC 50 Hertz or 60 Hertz. This motor, running under no load condi-tions, will get hot if inadvertently left in the on position. For this reason, the rod electrode sharp-ener assembly has been designed to incorporate a timer circuit which automatically terminates the motor’s operation after approximately 5 min-utes of continuous operation. The average time required to sharpen a clean rod electrode is 10 sec-onds; therefore, 10 minutes of continuous opera-tion is ample time to prepare 60 rod electrodes,



or approximately one hour’s workload through a normal laboratory operation.

Operation of the rod electrode sharpener is sim-ple. Located on the side of the motor is a mo-mentary contact push-button switch. Pressing this switch one time will activate the timer circuit that in turn supplies operating voltage to the mo-tor. The motor will continue to operate for the full time period (approximately 3-5 minutes) and after this period has timed out, the supply voltage to the motor will automatically be removed. This operation can be repeated once more in succession without the motor reaching a temperature where it is uncomfortable to touch the motor. After two consecutive 3-5 minute operations, allow the mo-tor to cool down to room temperature (approxi-mately 10 minutes). The automatic timed opera-tion of electrode sharpener can be terminated by momentarily placing the standby/operate MODE switch in the standby position.

NOTE: Do not switch to Standby while a sample is burning.

The rod electrode sharpener has a graphite collec-tor barrel assembly which is secured to the motor mount and face plate by a rubber o-ring. After approximately 250 sharpenings, this graphite col-lector will need to be emptied. To remove this barrel assembly, locate the sharpener over a waste basket with the collector barrel pointing down-ward. Grasp the barrel with the opposite hand and rotate it while pulling it away from the motor mount and face plate. Once the o-ring disengages from the collector barrel, it will be easy to separate and empty.

While the collector barrel assembly is removed, check the rod electrode cutter head and blade. There should not be an accumulation of oil or car-bon in this area. If an oily residue is present, this is an indication that the rod electrodes are not being adequately cleaned before insertion into the elec-trode sharpener. To clean this assembly, remove the cutter blade and use general purpose spray and wipe detergent. Reassemble the cutter blade

and the graphite collector barrel assembly.

The cutter blade, part number M90102, for the rod electrode sharpener is a three-sided tungsten cutter tool commonly used in machining opera-tions. One side is capable of approximately 1000 sharpenings. The edge of a cutter is worn when the initial cut of the electrode requires an abnor-mal amount of inward pressure, and/or a smooth reflective surface cannot be achieved on the tip of the rod electrode. Refer to Section 4.1.2 on sharp-ening the rod electrode. Refer to Section 7.6.5.1 for the procedure to replace the cutter blade.

1.6.5 Disposable Polyethylene Sample Holders All instruments used for military applications have a sample stand table that has been modified to accommodate the white plastic cap from the oil sample bottle, plus the channeled aluminum boat for special applications. For those instruments that are not part of the JOAP program, a sample stand adapter is provided. Spectro Incorporated offers disposable sample holders with each Spectroil M. These sample holders are made of polyethylene plastic and are intended to be disposed of after each use. Disposable sample holders are clean and free of contamination, provided they are kept in a sealed container and are handled properly. When removing sample containers from the sealed bag, it is recommended that the operator scoop the re-quired amount of sample holders with a box or cup to avoid contaminating the inside of the sam-ple holders with the finger tips. The part number for the sample holders is M90200 and they can be reordered directly from Spectro Incorporated.

1.6.6 Reusable Sample Holders and Covers The Spectroil M is capable of analyzing low flash point samples such as light distillates and hydraulic fluids without combustion. This is accomplished by using a special sample holder made of Teflon® which is extremely dense to prevent absorption of the sample material and provides ease of clean-ing. An aluminum cover is also available. This cover will minimize the exposure of fuel vapors to oxygen and thus prevent fuel ignition during fuel analysis. These sample holders are not routinely



Figure 1-9, Source Frequency Test Meter (SFTM)

Figure 1-10, Spectroil M Transit Case

Figure 1-11, Spectroil with Transit Case Accessories and Consumables Compartment, Ready for Operation

supplied with the instrument but can be ordered directly from Spectro Incorporated. The sample holder part number is M90202 and the sample cover part number is M90204.

1.6.7 External Keyboard, Video and MouseThe Spectroil M is a self-contained and complete spectrometer system. In some operating environ-ments, such as a central laboratory or applications with extensive data entry requirements, external data output and input devices can be connected to operate with the spectrometer’s internal com-puter. A USB connector is provided on the Spec-trpoil M control panel for this purpose. See figure 1-6 for a location of the USB connectors.

1.6.8 Source Frequency Test MeterAn optional Source Frequency Test Meter (SFTM), Figure 1-9, is available to check and/or adjust the excitation source of the Spectroil M. The part number for the SFTM is M90300/N90300, NSN 6625-01-419-5538 and the need to check and/or set the excitation source frequen-cy is detailed in Section 7.4.

1.6.9 Transit CaseAn optional reusable transit case, Figures 1-10 and 1-11, is available to protect the Spectroil M during transport and to keep all the consumables and accessories together in one system.

The transit case is a complete oil analysis labo-

ratory in a deployable container. It has a shock mounted cradle design for the spectrometer and is mounted on four casters; two fixed and two that swivel and have locking brakes. The part number for the transit case is M94012. The national stock number is NSN 8145-01-434-5786.

The transit case is manufactured from a formula-tion of polyethylene for high impact strength and has outstanding resistance to high and low tem-peratures. The design provides protection from fungus, water, solvents and abrasion. Handles are provided for the removal of the cover, tie downs around the perimeter facilitate securing the case during transport, and there are openings on the



Figure 1-12, MOD Number Identification Tag

bottom for movement by forklift.

A gas cylinder lift mechanism is used to raise the spectrometer to a comfortable height (variable) for operation while inside the case. Storage for con-sumables and accessories is provided in a custom compartment which doubles as a work table.

The custom storage compartment for accessories and consumables rests on top of the spectrometer during transport. It is placed on the case cover and doubles as a work table when the spectrom-eter is in operation. The compartment contains all the accessories and consumables required for operation in a laboratory or during deployment, Figure 1-11.

1.6.10 Maintenance Spare Parts Kits In order to ensure uninterrupted operation of the Spectroil M, spare parts maintenance kits are offered as options. Contact Spectro Inc. for kit availability.

The content of the kits is predicated on the Spectroil M version that you are operating. The version of the Spectroil M is known as the modi-fication ( MOD) number. The MOD number for each Spectroil M is on a tag located beneath the serial number plate, Figure 1-12.

The MOD versions of the Spectroil M are as fol-lows:

MOD 0 - Original version of the Spectroil M. MOD 1 - Original Spectroil M/N with SFTM

Port & Source Frequency Adjustment MOD 2 - Addition of Solid State Excitation.

Ignition Module and SFTM PortMOD 3 - Addition of Combined Solid State

Source. MOD 4 - OilM Windows - Upgraded to Win-

dows® and Software and Panel PC Hardware.

MOD 5 - CE version of the Spectroil M.MOD 6 - Versions of the Spectroil M with CCD

optic and readout system. MOD 7 - CE version of the Spectroil M with

CCD optic and readout system.

The minimum complement of spares recom-mended by Spectro Incorporated for each instal-lation is the Routine Maintenance Kit. This kit contains the essential consumable items, such as fuses, electrodes, sharpener blades, etc.

The Extended Spares Kit contains additional components such as circuit boards and other sub-assemblies which are subject to wear.

The Remote Location Kit is recommended for installations with multiple instruments which are remote and/or where downtime is unacceptable.

A User Tool Kit is also available that works with all versions of the Spectroil M.



2.0 MAINTENANCE AND SERVICING INSTRUCTIONS

This chapter on maintenance and service instruc-tions for the Spectroil M is divided into five sec-tions.

Each section of this chapter is a stand-alone de-scription of tasks to be performed by personnel trained in the operation and preventive mainte-nance on the Spectroil M Oil and Fuel Analysis Spectrometer. The tasks troubleshooting fault isolation, repair and replacement and software restoration procedures.

The five main sections of this chapter are as fol-lows:

2.1 Fault Isolation - Troubleshooting charts to assist the technician in quickly locating a malfunction and making repairs or replacing components.

2.2 Procedure to Check the Frequency of the Excitation Source - Two test methods to check the excitation source frequency using the Source Frequency test Meter (SFTM).

2.3 Dark Current Electronic Stability Test - A diagnostic test to assure that the Spectroil M has achieved electronic stability.

2.4 Repair and Replacement Procedures - Step-by-step procedures for the repair, replacement, and alignment of spare parts included in maintenance kits.

2.5 Software Restoration - Instructions on replacing the original software delivered with the Spectroil M including reinstalling Windows® XP PRO, the touch panel driver and the process of configuring Windows® XP PRO for the best performance with the Spectroil M.

Chapter 2

Maintenance and Servicing Instructions



2.1 FAULT ISOLATION

This section contains troubleshooting charts to assist the technicians in quickly locating a malfunc-tion and making repairs or replacing components. The charts are divided into the main spec-trometer assemblies as follows:

2.1.1 Possible Sample Stand Faults 2.1.2 Possible Excitation Source Faults 2.1.3 Possible Optical Assembly Faults 2.1.4 Possible Computer Controller / Measurement Electronic Assembly Faults 2.1.5 Possible Main Power and Power Distribution Faults 2.1.6 Possible Printer Faults

The charts should be consulted based on the suspected location of a malfunction. Symptoms are listed in each section followed by several probable causes. Checks and tests that can be per-formed are followed by alternatives based on the test results.

WARNING: Only trained service technicians should perform some of the tests described in this sec-tion. High voltages may be present while conducting some of these tests. Observe all safety precautions.

2.1.1 Possible Sample Stand Faults

Symptom:1. The instrument will not burn when the START button is pressed. 2. The instrument burns, but disc electrode does not rotate. 3. The sample stand exhaust fan does not operate. 4. An interlock error appears on screen. 5. The rod electrode slide mechanism does not operate smoothly.

Sample Stand Symptom 1: The instrument will not burn when START button is pressed.

Probable Cause Check If Normal If Abnormal

MODE Switch is in STANDBY Mode

Check if MODE switch is in OPERATE position

The sample stand exhaust fan should be operating. Proceed to next probable cause.

Turn MODE switch to OPERATE

The software is not properly set to make a burn.

Check the bottom of the dispaly to make sure it says PPM in the Status Bar.

Proceed to next probable cause.

If the software is in a mode other than Analysis Program, refer to Chapter 5 to correct.

Sample stand monitor detects an improperly installed component in sample stand.

Interlock error will be displayed on screen. Press enter to display which sample stand component is causing the problem. This will be displayed in the upper right hand corner of the display.

Correct fault by reloading sample stand and closing the door. If interlock error still exists, refer to Symptom 4 for further fault isolation.



18 | Chapter 2 Maintenance and Servicing Instructions

F1 (2.0 slo-blo fuse) on the power connection plate of the instrument is open.

Check F1 on the power connection plate on the right side of the instrument with a multimeter.


Replace fuse with 2.0 amp slo-blo fuse, see Figure 3-16.

START switch is defective.

Press F9 (START) on the keypad or the burn icon on the display.

If the burn starts, the START switch is defective or disconnected. See Section 2.4.4.11.

If Abnormal - Proceed to next probable cause.

F4 (5.0 amp fuse) is defective.

With a multimeter, check F4 on TB2.


Replace fuse with 5.0 amp fuse.

125 volts regu-lated AC is missing or low.

Check the output on J2 on the power connection plate on the right side of the instrument with a multimeter. The voltage from pins A to B should be 125 volts AC.


If Abnormal - Refer to Section 2.1.5 for further fault isolation.

Relay K6 (OP-ERATE) is defective.

Visually check mechanical operation of the K6 relay by toggling the MODE switch from STANDBY to OPERATE.

The mechanical actuator should toggle from 0 to 1 when MODE switch is toggled from STANDBY to OPERATE. Proceed to next probable cause.

An open circuit exists between the MODE switch and Relay K6 or Relay K6 is defective. To replace, see Section 2.4.5.3.

Relay K5 (source) is defective.

Visually check mechanical operation of the K5 relay when the START button is pressed. When pressed, the mechanical actuator will toggle from 0 to 1.

Problem is most likely in the excitation source assembly. Proceed to Section 2.1.2 for further diagnosis.

The K5 relay is defective or there is an open connection between the interlock monitor and the power control assembly, M59200. Proceed to Section 2.1.5.3 for further diagnosis. To replace relay, see Section 2.4.5.3.



Sample Stand Symptom 2: The instrument burns, but disc electrode does not rotate.


Disc electrode shaft is loose.

With a screwdriver, tighten shaft in clockwise direction.

If the shaft is tight, proceed to next probable cause.

The shaft rotates clockwise with no resistance. The disc electrode drive belt or shaft pulley has come loose. Tighten or replace.

The disc electrode drive motor may be defective.

The motor should rotate when the START button is depressed.

The pulley on the motor or shaft may be loose or the drive belt is loose or missing. Tighten or replace the belt and/or shaft pulley.

The AC voltage may not be present. With an AC volt meter, measure the voltage across TB1 pins 2 and 4. The voltage should be 125 volts AC when the Start button is depressed. If the voltage is present, the motor is defective and must be replaced. See Section 2.4.1.6.

Sample Stand Symptom 3: The sample stand exhaust fan does not operate.


The MODE switch is in STANDBY

Check the position of the MODE switch.

If the MODE switch is in OPERATE, proceed to the next probable cause.

Check if the switch is disconnected from the MODE dial. If okay, turn the MODE switch to OPERATE.

No voltage to fan.

With an AC voltmeter, check the voltage across pins 1 and 2 of Wire #19 (W19). The voltage should be 125 volts AC.

The exhaust fan is binding or defective. Repair or replace. To replace fan, see Section 2.4.1.7.

Check mechanical operation of K6 relay. There may be an open circuit between K6 and the plug of W19. The K6 relay may be electrically defective. Refer to Chapter 8 for electrical schematics to troubleshoot further. To replace relay, see Section 2.4.5.3.

Probable Cause - F4 (5.0 amp fuse) on TB2 is open

Check F4 on TB2. Proceed to Section 2.1.5.5. Replace fuse with 5.0 amp fuse, see Figure 3-16.



Sample Stand Symptom 4: An interlock error appears on screen.


Rod electrode is missing.

Visually check to see if the rod electrode is installed properly. Reinstall new rod electrode.

Clean sample stand sensors. If rod and disc are properly installed, rod electrode monitor sensitivity may have to be adjusted. Refer to Section 2.4.1.4 to adjust.

If Abnormal - Install rod electrode and set gap properly. Refer to Section 4.1.4.

Electrode gap not set properly.

Visually check to see if there is a proper gap distance between rod electrode and disc electrode.

Clean sample stand sensors. If gap is properly set, analytical gap monitor sensitivity may have to be adjusted. Refer to Section 2.4.1.4 to adjust.

Reset gap between rod and disc electrodes. Refer to Section 4.1.4.

Sample error.

Visually check if sample stand table is raised properly.

Clean sample stand sensors. If sample is properly raised, sample monitor sensitivity may have to be adjusted. Refer to Section 2.4.1.4 to adjust.

Raise sample stand table to proper height.

Disc electrode missing.

Visually check if the disc electrode is installed properly.

Clean sample stand sensors. If disc is properly installed, disc electrode monitor sensitivity may have to be adjusted. Refer to Section 2.4.1.4 to adjust.

Install disc electrode properly. Refer to Section 4.1.3.

Door interlock.

Check if door is closed properly and interlock switch IS1 is mounted tight and properly positioned.

Door interlock may be defective. Replace door interlock switch IS1. To replace IS1, see Section 2.4.1.9.

Close door and/or adjust door interlock position to insure proper contact with the door frame.

Sample Stand Symptom 5: The rod electrode slide mechanism does not operate smoothly.


An obstruction is jamming the mechanism.

Visually inspect the slide mechanism. It should move smoothly along the vertical axis and be free from any obstruction or excessive wear.


Clean the slide mechanism or remove the obstruction. If loose, adjust, see Section 2.4.1.1. If worn, replace, see Section 2.4.1.5.

The slide adjustment is too tight and is causing binding.

Check the set screw adjustments on the right side of the rod electrode holder and slide mechanism for over tightness.

The rod electrode holder and slide mechanism should move freely along the vertical axis when the analytical gap setting lever is raised and lowered.

The rod electrode slide mechanism will bind, failing to move freely along the vertical axis, and coming to rest against the analytical gap adjustment screw. Adjust the set screws on the right side to permit smooth operation while minimizing the rod electrode rotational wobble. Refer to Section 2.4.1.1 for adjustment.



2.1.2 Possible Excitation Source Faults

Symptom:1. The excitation source will not arc across the analytical gap.2. An arc occurs across the analytical gap but is very weak. 3. An arc occurs across the analytical gap but holds off or is intermittent. 4. An intermittent snapping sound can be heard from the excitation source. 6. All elements have poor repeatability in all readout modes.7. The excitation source fuse F1 blows.

Excitation Source Symptom 1: The excitation source will not arc across the analytical gap.


The MODE switch is in the STANDBY position.

Visually check the position of the MODE switch. It should be in the OPERATE position.

The sample stand exhaust fan should be operating. Proceed to next probable cause.

Place the MODE switch in the OPERATE position.

The software is not properly set to make a burn

Check the bottom of the display to make sure it says PPM in the status bar.


If the software is in a mode other than PPM, refer to Section 5.4.4.3 to correct.

F1 (2.0 amp slo-blo fuse) is open.

Check F1 on the power connection plate on the right side of the instrument.



Sample stand monitor detects an improperly installed component.

Check for proper installation and positioning of sample stand components. Correct the sample stand installation and positioning error.

Clean sample stand sensors or adjust appropriate sample stand monitor. Proceed to next probable cause.

Correct the sample stand installation and positioning error.

125 Volts AC is missing or low.

Measure the voltage on J2 from pins A to B with a multimeter set to measure AC voltage.

The voltage should be 125 volts AC. Proceed to next probable cause.

Refer to Section 2.1.5 for additional troubleshooting tips.

K5 may not be electronically activating.

Visually inspect the mechanical activation of Relay K5 in the input power distribution assembly. Refer to Input Power Distribution Diagrams in Section 9.2.3 and 9.2.4 for further circuit analysis. When the START button is pressed, the mechanical actuator should move from the 0 position to the 1 position and measure the AC voltage on TB-3 on the schematic in Section 9.2.10 or 9.2.11. If the voltages on TB-3 and TB-4 are present, the problem must be within the excitation source assembly. Refer to 9.2.10 or 9.2.11 for further circuit analysis and proceed to next probable cause.

The actuator is magnetically activated, but the contacts of K5 may be defective and must be replaced or a fault may exist in the excitation source circuitry. Refer to Sample Stand Schematic Diagram on page 9-11 for further circuit analysis. Proceed to Section 2.1.4 for further fault isolation.

The energizing coil of the contactor may be defective or the energizing voltage may be missing (24 volts DC). Measure DC voltage across A1 and A2 on Relay K5 when the START button is depressed. If the voltage is present, the coil is defective and K5 should be replaced, see Section 2.4.5.3. If voltage is missing, refer to Section 2.1.4.3 for additional troubleshooting tips.



SSEI Module is defective.

Check for proper connection of P/J4 in the excitation source compartment.

Measure the AC voltage on J4, pins 1 and 2. The voltage should be 125 volts AC when the START button or F9 START is pressed.

If 125 volts is present, check fuse F1 on SSEI Assembly and replace if necessary. If fuse is ok, the SSEI module is defective. To replace the module, see Section 2.4.2.1. If 125 volts is missing, the problem lies with the associated wiring or K5 relay. To replace relay, see Section 2.4.5.3

Excitation Source Symptom 2: An arc occurs across the analytical gap but is very weak.


The analytical capacitor is defective.

There is no easy way to check this component.

The arc will be strong and consistent. After one burn, the disc will be too hot to touch.


The high voltage capacitor is defective.

There is no easy way to check this capacitor. Visually check the capacitor for signs of overheating.


Replace high voltage capacitor or entire combined solid state source, see Section 2.4.2.1.

125 Volts AC is missing or low.

Measure the voltage on J2 from pins A to B with a multimeter set to measure AC voltage.

The voltage should be 125 volts AC. Proceed to next probable cause.

Refer to Section 2.1.5 for additional troubleshooting tips.

One of the analytical resistors has failed.

In the sample stand, measure the resistance from the rod holder to the disc electrode shaft.

The resistance should be 30 +/- 1 ohm. If normal, problem is most likely due to poor electrical contact. Proceed to symptom 3.

Refer to the sample stand schematic diagram on page 9-11. Inspect and measure both resistors R1, R2 and R3 for signs of overheating and/or incorrect value. Replace if overheated or defective.



Excitation Source Symptom 3: An arc occurs across the analytical gap but holds off or is intermittent.


The frequency of the source is incorrect.

With a source frequency test meter (SFTM) check the frequency of the excitation source, see Section 2.2.

The source frequency test meter will read 54,000 +/-2000.

The Combined Solid State Source module is defective. Replace module, see Section 2.4.2.1.

Tungsten electrodes are worn in the auxiliary gap.

The electrodes should be cleaned and the ends should be round.


Remove and replace electrodes, see Section 2.4.2.2.

Auxiliary gap tungsten electrode is out of position in relation to electromagnetic deflection screw (EMDS).

The parabolic tip of the tungsten electrode closest to the back of the instrument should be equal to the tip of the EMDS, see Figure 3-13.


Shorten the auxiliary gap to 0.125 inches. If OK, problem was excess gap distance. If not OK, the source assembly is suspect. Contact Spectro Inc. Service Department.

Auxiliary gap blower fan defective or binding.

Inspect the auxiliary gap blower fan during a burn.

The fan will rotate smoothly throughout the burn.

The fan will not be turning. For MOD 3 instruments, contact Spectro Inc. For MOD 2 instruments, measure the DC voltage on CR1, it should be approximately 17 volts DC. If the voltage is present, the fan is binding or defective and the entire source assembly must be replaced, see Section 2.4.2.1. If not present, measure the input to PB1. The AC voltage should be 125 volts AC. If present, then CR1 is defective.

Poor connection to sample stand.

Check the two connections to the sample stand from the rear of the sample stand mounting plate. Refer to Sample Excitation Schematic Diagram, Section 9.2.10 or 9.2.11.

Both connections will be tight.

Tighten one or both of the connectors.

Poor electrical connection between the electrical brush and the commutator.

Remove brush from its holder and inspect commutator and brush assembly for smooth, dry, clean surface. Excercise spring loaded brush motion.

Brush will be clean and dry and move freely inside brush holder. Proceed to next probable cause.

Clean and/or replace worn components.

The disc electrode shaft has a varnish buildup where the electrode is mounted.

Visually check to see if there is black varnish buildup on the splines of the disc electrode shaft.


Replace the disc electrode shaft, see Section 2.4.1.2 or remove the varnish using an ink eraser.

The high voltage capacitor is defective.

There is no easy way to check this capacitor. Visually check the capacitor for oil leakage and cracks.

No oil is present. The arc will be consistent.

Replace combined excitation source assembly, see Section 2.4.2.1 Proceed to Section 2.1.5 for further troubleshooting procedures.



Analytical gap distance too large or too small.

Check the gap distance between the electrodes of the analytical gap. It should be 0.090 in.

Contact the Spectro Inc. Service Department.

Adjust the analytical gap distance to 0.090 inches.

Excitation Source Symptom 4: An intermittent snapping sound can be heard from the excitation source.


High voltage arc over is occurring.

With the lights out, make a burn and look for stray arcing in the excitation source assembly compartment. Repeat test several times, if necessary.

No arc should be seen anywhere in the excitation source compartment except across the auxiliary gap.

If an arc is observed, determine if this discharge is the result of the relocation of a component or wire. If so, place the wire back to its proper location. If not, determine the best course of corrective action to isolate the arc from the path of the discharge.

Excitation Source Symptom 5: All elements have poor repeatability in all readout modes. Probable Cause Check If Normal If Abnormal

Poor, or missing electrical connection between excitation source and sample stand.

In the sample stand, measure the resistance from the rod holder to the disc electrode shaft.

The resistance should be 30 +/- 1 ohm. If normal, problem is most likely due to poor electrical contact. Proceed to symptom 3.

Refer to the sample stand schematic diagram on page 9-11. Inspect and measure both resistors R1, R2 and R3 for signs of overheating and/or incorrect value. Replace if overheated or defective.



Excitation Source Symptom 6: The excitation source fuse F1 blows.


Fuse F1 is incorrectly rated.

Remove fuse and inspect for correct rating.

Fuse F1 will be a 2.0 Amp Slo-Blo 250 VAC fuse. Proceed to next probable cause.

Replace F1 with correct fuse rating, see Figure 3-14.

Input voltage and frequency parameters are incorrectly set.

Select SETUP pull-down menu and chose “Power Level “ option. Verify that the table matches the actual line voltage and frequency applied to instrument.

A short circuit exists in the wiring. Proceed to Input Power Distribution Diagram Section 9.2.4 for further circuit analysis.

Select the proper line voltage/frequency setting. Refer to Section 5.4.6.3 to select correct operating parameters.

Exhaust fan is clogged or defective.

Remove exhaust duct and inspect for sufficient exhaust flow.

Exhaust flow is sufficient to move a paper towel. Proceed to next probable cause.

No exhaust flow exists. Clean exhaust fan or replace if defective. Refer to Section 2.4.1.7.

Disc electrode motor is defective.

Remove black wire on terminal #4 of TB3 in sample stand and make a burn.

Fuse F1 still blows. Proceed to next probable cause.

Fuse F1 does not blow. Disc electrode motor is defective, replace and refer to Section 2.4.1.6.

Rod and disc electrodes shorted together in sample stand.

Check the sample stand to see that the rod and disc electrodes are properly installed.

If rod and disc electrodes are properly installed, a short circuit exists in the wiring. Proceed to Input Power Distribution Diagram Section 9.2.4 for further circuit analysis.

Correctly install disc and rod electrodes and check/adjust operation of sample stand interlock sensors, see Section 2.4.1.4



2.1.3 Possible Optical Assembly Faults

Symptom1. All elements have zero or low intensities. . 2. Auto profile cannot be found. 3. One element produces erratic results. 4. Silicon analytical data is erratic.

Optical Assembly Symptom 1. All elements have zero or low intensities.


Instrument is severely off profile.

Perform auto profile by pressing F4 or left click the profile icon.

The stored optical profile position will match the location of the optical profile knob. Proceed to next probable cause.

Proceed with next Probable Cause.

The temperature in the optical compartment has not stabilized.

If the instrument was subjected to extremely cold or hot weather in transport, it may be necessary for the optics to reach ambient stability before optical profile stability will be achieved. Verify the operating temperature reading on the Analysis Program Screen.

Optical profile will pass. Allow optics to stabilize at the required optical compartment temperature. If optical profile continues to fail, contact Spectro Incorporated Field Service for further assistance.

Optical Assembly Symptom 2 Optical profile cannot be found.


The temperature in the optical compartment has not stabilized.

If the instrument was subjected to extremely cold or hot weather in transport, it may be necessary for the optics to reach ambient stability before optical profile stability will be achieved. Verify the operating temperature reading on the Analysis Program Screen.

Optical profile will pass. Allow optics to stabilize at the required optical compartment temperature. If optical profile continues to fail, contact Spectro Incorporated Field Service for further assistance.



Optical Assembly Symptom 3: One element produces erratic results.


The optic is not on profile.

Perform optical profile. Press F4 or the profile icon to enter profile mode.

Profile position will be calculated and suspect element now produces good results.

The profile position for suspect element will cause auto profile to fail. Contact Spectro Incorporated Field Service for assistance.

The suspect element has high and/or erratic dark current output.

Perform a dark current test, see Section 5.4.8.11 to select the Dark Current program. Perform 5 dark current tests, Section 2.3.

The mean for the dark current should be less than xx and the sigma should be less than 100.

Contact Spectro Incorporated Field Service for further assistance.

Optical Assembly Symptom 4: Silicon analytical data is erratic.


Silicon contamination is present in consumables, rod electrodes, disc electrodes or sample holders.

Make 5 burns using zero (base) ppm oil. Check repeatability of suspect element against Table 4-2.

All elements meet the repeatability specifications for zero ppm oil according to table 4-2.

Systematically eliminate the possible sources of silicon contamination, starting with disc electrodes, rod electrodes, sample caps and oil standards. Check electrode sharpener, clean it and rotate the cutter blade.



2.1.4 Possible Computer Controller/Measurement Electronic Assembly Faults

Symptom:1. The excitation source will not operate. 2. There is no video on the display; the TFT display is constantly white.3. There is no video on the display; the TFT display is constantly black.4. The keyboard/mouse will not work properly. 5. The start up sequence fails. 6. Certain numbers appear when alpha characters are pressed.

Electronic Assembly Symptom 1: The excitation source will not operate.


The MODE switch is in Standby.

Visually check the position of the MODE switch.

The MODE switch will be in OPERATE.

Set the MODE switch to OPERATE position.

F1 on power connection plate is defective.

Check the 2.0 amp slo-blo fuse on the power connection plate.



START switch is defective.

Press F9 (START) on the keypad to initiate the burn sequence.

The burn cycle will begin and the source will operate. This indicates that the green START switch is defective. To replace, see Section 2.4.4.11.

The burn does not initiate and sequence counter (preburn/burn) does not count down. The fault is in the communications between the computer controller and the excitation source and not with the START switch. The software may not be in the correct state to make a burn. Shut down Windows, turn power to the instrument off with CB1 and reapply power after 30 seconds. After the software loads, repeat the test and if the excitation source burns, the problem was with the software. If the source still does not burn, proceed to the next probable cause, or the problem may be in the excitation source itself, refer to Section 2.1.2 to continue fault isolation.

Fiber optic communication cables between interface board (M58000) and I-LOK monitor board (M59200) are loose or disconnected.

Check the fiber connections on the interlock monitor board (M59200) and interface board (M58000).

The heat exchanger fans should be operating. Proceed to next probable cause.

Reconnect the fiber optic cables between both boards, repair or replace defective fibers, or isolate fault on interface board (M58000) or I-LOK monitor board (M59200). If optical cables and connectors are ok, problem is in the excitation source, proceed with Section 2.1.2 to continue fault isolation



Electronic Assembly Symptom 2: There is no video on the display; the TFT display is constantly white.


No video signal.

Turn power to the instrument off with CB1. Wait 5 seconds and reapply power to the instrument.

The screen will go black when off and return to normal when the instrumented is re-started.

The screen will go black when off and then turn white. The Panel PC is defective. replace Panel PC, see Section 2.4.4.8.

Electronic Assembly Symptom 3: There is no video on the TFT display; the display is constantly black.


No power on instrument.

Place CB1 in the up (ON) position.

Instrument will power up and TFT display will have video.

Instrument will power up, the heat exchanger and printer also turn on but the TFT display is still black. Proceed to next probable cause.

Panel PC fuse is defective

Check the Panel PC fuse, see Figure 3-16

Check to confirm the green LED on the Panel PC power supply is on.

Replace Panel PC power supply. If problem persists, replace Panel PC, see Section 2.4.4.8.

Electronic Assembly Symptom 4: The keyboard/mouse will not work properly.


The keyboard/mouse cable has become loose or is disconnected.

Check the three mini-DIN connectors; under the keyboard, in the rear of the electronic assembly and on the Panel PC.


Connector is loose or disconnected, tighten connector.

Keyboard is defective.

Turn power to instrument off with CB1. Obtain external keyboard with an mini-DIN connector and install keyboard to connector on the control panel.

All keyboard functions will operate properly. Internal keyboard or connectors are suspect. Check connector on internal keyboard. If connector is seated properly, internal keyboard is defective. Replace internal keyboard.

If external keyboard also does not work properly, problem is BIOS settings or a defective Panel PC. Contact Spectro Inc. for assistance

Pointing device (mouse) is not working properly.

Check to see if other functions with the keyboard work.

If other keyboard functions are normal, the pointing device is defective. Replace keyboard.

See first two probable causes for this symptom.



Electronic Assembly Symptom 5: The start up sequence fails.


OilM Windows start up sequence cannot locate configuration files.

Confirm that Configuration File Paths are correct. See Section 2.4.4.6.

Contact Spectro Incorporated Field Service for assistance.

Search for file location and re-create correct file path.

Electronic Assembly Symptom 6 Certain numbers appear when alpha characters are pressed.


The Numlk/Scrlk key is toggled ON.

Press the Numlk/Scrlk key one time then press any alpha key having a secondary numeric function. Example: the letter “O” is also the number “6”.

Pressing the letter “O” will type the letter “O” and not the number “6”.

The Numlk/Scrlk key is stuck in the depressed mode or the keyboard is defective.



2.1.5 Possible Main Power and Power Distribution Faults

Symptom:1. The instrument does not turn on when main power is applied. 2. The circuit breaker CB1 will not stay in the up (on) position. 3. The excitation source does not operate when MODE switch is in OPERATE position. 4. The sharpener will not operate. 5. The heat exchanger fans do not operate.

Power Symptom 1: The instrument does not turn on when main power is applied.


Source of input voltage is off.

With an AC voltmeter, check the source of line voltage.

The source of line voltage will meet the requirements of Section 2.1.4 and Table 2-2. Proceed to next probable cause.

Consult a qualified electrical contractor to provide the correct line voltage.

The main power cable is not connected to the instrument.

Check the MIL type female connector P1 is connected to J1 on the power connection plate.


Connect the power cable as per Section 2.1.3.

AC input to power supply is loose or voltage is missing.

Check the 3-pin connector CN1 on the Lambda power supply. The voltage on pins 1 and 2 should be equal to the input line voltage.

If the connection is good and the line voltage is equal to the input line voltage, the Lambda power supply is defective. To replace, see Section 2.4.4.10.

Reconnect if loose. If the voltage is missing, the problem is with the associated wiring. Refer to the Interconnection Cabling Diagram in Section 9.2.2 for further fault isolation.



Power Symptom 2: The circuit breaker CB1 will not stay in the up (on) position.


Operator is lifting on/off switch (CB1) too quickly.

Raise the on/off switch (CB1) slowly to the ON position.

Switch will stay in the up position.

Switch will fall down to the off position. Proceed to next probable cause.

One or both of the excitation source safety interlocks are tripped.

If the excitation source access panels are removed, bypass safety interlocks by pulling outward one click. If excitation source panels are on, check the 1/4 turn pawl fasteners for tightness. Then power on the instrument.

CB1 will stay in the up or on position. Proceed to next probable cause.

Bypass the interlocks or tighten the 1/4 turn pawl fasteners. If still defective, replace CB1.

There is a short circuit on the regulating transformer (M24000).

Place the circuit breaker in the ON position. Shortly after the Analysis Program appears, CB1 trips to OFF.

The regulating transformer T1 is defective. Replace.


CB1 is defective.

There is no easy way to check CB1. Replace circuit breaker.

Circuit breaker will remain in the up or on position.

Contact Spectro Incorporated Field Service for further assistance.



Power Symptom 3: The excitation source does not operate when MODE switch is in the OPERATE position.


MODE switch is defective.

The MODE switch is disconnected or defective. Remove front panel and examine switch connection. If okay, remove power and with an ohm meter, check the operation of the MODE switch.

Continuity will be measured across pins 13 and 14 when in OPERATE position. Proceed to next probable cause.

If switch is disconnected, reconnect. If continuity cannot be measured between pins 13 and 14, replace MODE switch.

F1 on power connection plate is defective.

Check the 2.0 amp slo-blo fuse on the power connection plate.



Contactor relay K6 is defective.

With a DC volt meter, measure the voltage across A1 and A2 on K6 while MODE switch is in the OPERATE position.

Voltage should be 24 volts DC. If voltage is okay, contacts of K6 relay may be defective. Refer to Input Power Distribution Block Diagram, Section 9.2.4 and Exciation Source/Sample Stand Schematic Diagram 9.2.10 or 9.2.11 for further fault isolation. Replace K6 if necessary, see Section 2.4.5.3.

If the voltage is missing, there is an open between the relay and MODE switch. Refer to Input Power Distribution Block Diagram, page 9-4 and Exciation Source/Sample Stand Schematic Diagram page 9-11.

SSEI module on Source Assembly M99966 is defective.

Check for proper connection of P/J4 in the excitation source compartment.

Measure the AC voltage on J4, pins 1 and 2. The voltage should be 125 volts AC when the START button or F9 START is pressed.

If 125 volts is present, check fuse F1 on SSEI Assembly and replace if necessary. If fuse is ok, the SSEI module is defective. To replace, see Section 2.4.2.1. If 125 volts is missing, the problem lies with the associated wiring or K5 relay. To replace relay, see Section 2.4.5.3.

Contactor relay K5 is defective.

Visually check electrical operation of K5. If OK, problem exists in excitation source assembly. Refer to Section 2.4.5.3.

When START switch is pressed, K5 should toggle from 0 to 1.

Replace contactor relay K5, see Section 2.4.5.3.



Power Symptom 4: The sharpener will not operate.

Probable Cause Check If Normal If AbnormalMODE switch is in STANDBY.

Check the position of the MODE switch.

The MODE switch should be in OPERATE position.

Switch MODE switch to OPERATE position.

Fuse F2 on power connection plate is defective.

Check 1.0 amp fuse on power connection plate.


Replace fuse with 1.0 amp fuse, see Figure 3-14.

Timer is defective.

Remove bottom plate of sharpener and measure voltage between pins 2 and 3 of the timer.

The voltage should be 125 volts AC. If present, replace the timer, see Section 2.4.5.2.

If voltage is missing, there is an open circuit between F2 and the connector.

Electrode sharpener motor is defective.

With an AC volt meter, measure the voltage between pins A and B on J2.

The voltage should be 125 volts AC. If voltage is present, replace electrode sharpener motor.

If voltage is missing, there is an open circuit between F2 and the connector.

Power Symptom 5: The heat exchanger fans do not operate.


F4 on TB2 is open.

With an ohmmeter, check 5 amp fuse on TB2.


Replace fuse with 5.0 amp fuse, see Figure 3-16.

The start-up sequence failed to complete.

Refer to Section 4.1.1, power down the instrument and then power up the instrument.

Start-up sequence completes and heat exchangers come on.

Start-up sequence is being interrupted. Refer to 2.1.4.7 for additional assistance.

P/J18 is disconnected or loose.

Check P/J18 for proper mating.

Measure voltage on P/J18. The AC voltage from pins A to B should be 125 volts AC. If voltage is present, heat exchanger is bad. Replace.

Reconnect P/J18.



2.1.6 Possible Printer Faults

Symptom:1. The printer fails to power on. 2. The printer fails to come on line. 3. The printer fails to print. 4. The printer fails to print single burns.

Printer Fault 1: The printer fails to power on.


F3 (1.5 amp) on accessory panel is open.

With an ohmmeter, check F3 on the accessory panel.


Replace F3 with a 1.5 amp fuse, see Figure 3-17.

Printer is defective.

With an AC volt meter, measure the voltage on connector J3.

The voltage will read 125 volts AC. If voltage is present, the printer is defective.

There is an open between J3 and the T1 transformer. Inspect associated wiring. See Interconnection Cabling Diagram section 9.2.2.

Printer Fault 2: The printer fails to come on line.


Printer needs to be reset.

Power down printer for 10 seconds and then power up.

Three beeps should be heard from printer. This indicates the printer is on line.

No beeps will be heard. Proceed to next probable cause.

Paper is installed improperly or is jammed.

Properly install printer paper on printer. Refer to technical manual for printer provided from original manufacturer. After printer paper installation has been corrected, power down printer for 10 seconds and then power up.

Three beeps should be heard indicating printer is on line.


Printer is defective.

Install new printer and press F5 (PRINT), the print icon or Control P to test print function.

Printer will print properly. Problem may be with the printer’s signal cable. Inspect and replace accordingly.



Printer Fault 3: The printer fails to print.

Probable Cause Check If Normal If AbnormalPrinter is not on line.

Power down for 10 seconds and then power up.

Three beeps will be heard indicating printer is on line.


Signal cable connector is loose.

If pause light is on, press once to turn off.

Pause light will go out and printer will operate properly.


Signal cable connector is loose.

Check the signal cable connection on the printer and the connection to the accessory panel for proper mating.


Re-seat signal cable on both ends.

Signal cable from CPU to the Windows accessory panel board is loose or defective.

Power down instrument and check the black Windows cable from the CPU to the connector labeled LTP1.


Re-seat signal cable or replace if necessary.

Printer Fault 4: The printer fails to print single burns.


Windows software caches up to 8 single burns per page.

Press the print icon and all burns will be printed on demand.

Refer to section 5.2.4. The print manager controls print functions and will not print one burn per page automatically.

The cache is empty



Figure 2-1, Source Frequency Test Meter (SFTM)

2.2 PROCEDURE TO CHECK THE FREQUENCY OF THE EXCITATION SOURCE

The excitation source in the Spectroil M is an oscillatory arc discharge. It has been designed to achieve excitation characteristics which produce a spectral signature to match the JOAP data base. The performance of the Spectroil M is directly dependent on the output characteristics and fre-quency of the oscillatory arc source. The follow-ing section will provide a step-by-step procedure to measure the oscillatory arc excitation source.

It is absolutely necessary to check the excitation source frequency prior to performing the JOAP monthly correlation samples. The source frequen-cy also has to be checked each time the instrument is deployed to a country where the line frequency is other than 60 Hertz, and/or to verify that no damage was incurred during transport. For a de-tailed explanation of excitation source frequency, refer to Section 2.2.3.

There are two methods to check the excitation source frequency using the Source Frequency Test Meter, Figure 2-1. The first method employs an optical fiber which views the arc discharges as they occur across the auxiliary gap. The second method measures the source frequency by directly viewing the arc discharges which occur across the auxiliary gap. Both methods work equally well, but the advantage of the first method is that it is

faster and also does not expose the operator to ar-eas with live voltage. Follow the steps listed below to check the excitation source frequency using the SFTM.

2.2.1. Auxiliary Gap Optical Fiber View

To check the excitation source frequency by mea-suring the discharges per minute across the auxil-iary gap using the SFTM, follow the steps listed below.

NOTE: This procedure should be performed by the operator once per month prior to JOAP monthly correlations, whenever the instrument is moved, or every 2,000 burns.

1. Remove the SFTM from the protective con-tainer. If this is the first time this test meter is to be used, four AA size batteries will have to be installed before it can be operated. These batteries are provided with the test meter.

2. Hold the SFTM in the right hand and with your thumb, press and hold the momentary switch located on the upper right side of the SFTM. This will turn the test meter ON and along the right side of the digital display a “0” (zero) should appear. If the image of the “0” is not clear, or if many characters simultaneously appear on the display, the CONTRAST control should be adjusted.

NOTE: Under normal circumstances, the SFTM does not require calibration. To verify calibration, point the SFTM toward a fluorescent light fixture and press and hold the Momentary Power Switch for at least 10 seconds. For power sources with 60 Hertz, the meter should read 7,200 +/- 100 and for 50 Hertz power sources, 6,000 +/- 100. If the SFTM measurement exceeds the tolerances specified, utilize the oscilloscope method.

3. Remove the threaded protective dust cover from the SFTM PORT and insert the dock-ing coupler into the SFTM PORT until it



Figure 2-2, SFTM Docked in Port for Measurement

stops. Rotate the SFTM to a convenient viewing angle. Refer to Figure 2-2.

4. Set the MODE switch on the control panel to OPERATE.

NOTE: Make four warm-up burns.

5. Prepare the sample excitation stand for a routine analysis with a new disc and rod electrode and set the analytical gap in ac-cordance with Section 2.3 of the Operator’s manual. Place a sample holder on the sample table and fill it with 0 standard oil. Raise the sample holder into the normal position. Close the sample stand door.

6. Press the START switch located on the front control panel (refer to Figure 1-6). The burn cycle will begin and the high voltage across the auxiliary gap will appear as a concen-trated stream of light. In actuality, this steam of light consists of approximately 700 high voltage discharges per second and the func-tion of the SFTM is to detect and quantify these arc discharges.

7. Press and hold the momentary power switch on the SFTM once the preburn period, displayed on the upper right hand corner of the screen (6 seconds), of the burn has been

completed. If the SFTM is properly posi-tioned to receive the light emitted across the auxiliary gap, a small red light emitting di-ode (LED) located above the digital display of the SFTM will begin to flash at a consis-tent rate. Hold the position of the SFTM steady and continue to hold the momentary power switch and monitor the consistency of the red LED to ensure that the signal is strong and consistent. Once the burn cycle is complete (30 seconds), release the momen-tary power ON switch of the SFTM and remove the SFTM from the port for a more convenient observation of the measurement.

NOTE: It is normal to observe fluctuations of approximately +/- 1000 discharges per minute (DPM) during the measurement cycle.

NOTE: If the red LED does not appear or flashed at an erratic rate, the SFTM is not in position to permit the light from the auxiliary gap to enter the test meter. Repeat the procedure until a steady flash-ing red light is obtained.

8. When the burn is complete, press and hold the MEMORY switch located on front of the SFTM one time. A number will appear momentarily, then the letters “LA” (last) will appear. This number should be ap-proximately 54,000 and represents the last measurement the SFTM made before the power switch was released. This reading is not significant for this procedure. Release the MEMORY switch to end the reading.

9. Press and hold the MEMORY switch a second time and a new number will appear. This is the number that will be used to de-termine the excitation source frequency. This number must be 54,000 +/- 2000. If the MEMORY switch is held, the letters “UP” will appear, which designates that this was the highest reading taken during the burn. If the source frequency is within this range, then proceed to step 12 of this procedure. If not, SFTM port fiber may be defective.



Check frequency with the Direct View Method, Section 2.2.2.

10. Upon completion of the source frequency check, thread the dust cover on the SFTM PORT to prevent any accumulation of debris.

11. Return the SFTM to its protective storage container.

12. This procedure is now complete.

2.2.2 Auxiliary Gap Direct View

To check the excitation source frequency by mea-suring the discharges per minute across the auxil-iary gap using the SFTM, follow the steps listed below.

WARNING: This procedure should only be per-formed by a qualified technician.

1. Remove power from the instrument by placing the main power circuit breaker CB1 to the OFF or down position, refer to Figure 2-3.

2. Remove the four Phillips head mounting screws positioned in the corners of the top trim panel. Be sure not to lose the dress washers for these panel screws; they are not captive to the screws. Remove the top trim panel.

3. To remove the top excitation source access panel (the smaller of the two panels), turn the six 1/4 turn pawl fasteners screws coun-terclockwise until the maximum travel of the screw is achieved, approximately 10 rota-tions.

CAUTION: Do not overdrive the counterclock-wise travel of these screws, stop when light resis-tance is encountered. Once all fasteners have been loosened, remove the top access panel.

NOTE: This panel has a safety interlock

switch to protect unauthorized personnel from removing this panel with power ap-plied. Only trained operators and electronic maintenance personnel are authorized to enter this compartment. To perform service in the excitation source compartment, the operator/technician must bypass this safety interlock switch.

4. To bypass the interlock switch, grasp the plunger and pull in an upward direction until the plunger moves approximately 1/4 inch. This will bypass the interlock switch function and permit power to be applied to the instrument. If either of two safety in-terlock switches are not properly positioned or bypassed, circuit breaker CB1 will fail to latch in the ON position.

5. Place the circuit breaker CB1 in the up or ON position. This will apply power to the instrument and after the computer has loaded the software and selected the proper line voltage and frequency settings for the current location, a burn can be made.

NOTE: Make four warm-up burns.

6. Prepare the sample excitation stand for a routine analysis with a new disc and rod electrode and set the analytical gap in ac-cordance with Section 2.3 of the Operator’s Manual. Pour a new sample of 0 ppm stan-dard and place this sample in position for analysis. Close the sample stand door.

7. Set the MODE switch on the control panel to OPERATE.

8. Remove the SFTM from the protective con-tainer. If this is the first time this test meter is to be used, four AA size batteries will have to be installed before it can be operated. These batteries are provided with the test meter.

9. Hold the SFTM in the right hand and with



Figure 2-3, Auxiliary Gap Assembly and Ideal Position for Source Frequency Test

your thumb, press and hold the momentary switch located on the upper right side of the SFTM, see Figure 2-1. This will turn the test meter ON and along the right side of the digital display a “0” (zero) should appear. If the image of the “0” is not clear, or if many characters simultaneously appear on the display, the CONTRAST control should be adjusted.

NOTE: Under normal circumstances, the SFTM does not require calibration. To verify calibration, point the SFTM toward a fluorescent light fixture and press and hold the Momentary Power Switch for at least 10 seconds. For power sources with 60 Hertz, the meter should read 7,200 +/- 100 and for 50 Hertz power sources, 6,000 +/- 100.

10. Locate the auxiliary gap on the excitation source component board, refer to Figure 1-2 for the location. Hold the SFTM approxi-mately 10 inches (25 cm) above the auxiliary gap with the input coupler pointing down-wards towards the auxiliary gap as shown in Figure 2-3.

Once the burn cycle begins, high voltage will be generated and distributed throughout the excitation source. Do not touch any compo-nents of the excitation source assembly while the excitation source is operating. Wait until

the burn cycle terminates before attempting to make any adjustments. Always turn the MODE switch to STANDBY before making any adjustments.

Wear safety glasses or do not look directly at the spark. The spark from the auxiliary gap could harm your eyes if stared at for pro-longed periods of time.

Only trained personnel should carry out this procedure. It is performed in an area of the Spectroil M where high voltage potentials are present.

11. Press the START switch located on the front control panel, refer to Figure 1-6. The burn cycle will begin and the high volt-age across the auxiliary gap will appear as a concentrated stream of light. In actuality, this steam of light consists of approximately 700 high voltage discharges per second and the function of the SFTM is to detect and quantify these arc discharges.

12. Press and hold the momentary power switch on the SFTM once the preburn period, displayed on the upper right hand corner of the screen (6 seconds), of the burn has been completed. If the SFTM is prop-erly positioned to receive the light emitted



across the auxiliary gap, a small red light emitting diode (LED) located above the digital display of the SFTM will begin to flash at a consistent rate. Hold the position of the SFTM steady and continue to hold the momentary power switch and monitor the consistency of the red LED to ensure that the signal is strong and consistent. Once the burn cycle is complete (30 seconds), release the momentary power ON switch of the SFTM and position it so it can be easily read.

NOTE: It is normal to observe fluctuations of approximately +/- 1000 discharges per minute (DPM) during the measurement cycle.

If the red LED does not appear or flashed at an erratic rate, the SFTM is not in position to permit the light from the auxiliary gap to enter the test meter. Repeat the procedure until a steady flashing red light is obtained.

13. When the burn is complete, press and hold the MEMORY switch located on front of the SFTM one time. A number will appear momentarily, then the letters “LA” (last) will appear. This number should be ap-proximately 54,000 and represents the last measurement the SFTM made before the power switch was released. This reading is not significant for this procedure. Release the MEMORY switch to end the reading.

14. Press and hold the MEMORY switch a second time and a new number will ap-pear. This is the number that will be used to determine the excitation source frequency. This number must be 54,000 +/- 2000. If the MEMORY switch is held, the letters “UP” will appear, which designates that this was the highest reading taken during the burn. If it is within this range, the procedure is complete and proceed with step 15. If not, the solid state ignition circuit or high volt-age capacitor may be defective, see Section 2.1.2.

NOTE: If you press and hold the MEMORY switch a third time, the number will be the lowest measured value “DN” for the burn. This reading is not significant for this proce-dure.

15. Place the MODE switch to the STANDBY position. Shut down Windows and place the circuit breaker CB1 to the down position to remove power to the instrument. Remove the main power input cable by disconnect-ing the MIL-type connector from the mat-ing receptacle.

16. Press the interlock actuator inward to reset the normal operation of the switch. This in-terlock should activate when the actuator is pressed inward to its maximum travel. Place the environmental sealing panel in position and start the six 1/4 turn pawl fasteners. Once all screws have been started, tighten all screws until they are snug, compressing the sealing gasket.

17. Install the exterior panel and secure it in position with the four Phillips head screws and dress washers.

18. Attach the main power input cable to the instrument, and plug the cable into the source of line voltage. Apply power to the instrument in accordance with all steps detailed in Section 2.1.3 of the Spectroil M Overview & Systems Description Manual.

19. This procedure is now complete.

2.2.3 Detailed Description of Excitation Source Frequency

The excitation source of the Spectroil M is an oscillating alternate current (AC) electric arc dis-charge which has been optimized for oil matrices and the JOAP data base. The excitation source is the most important subassembly of the spectrom-eter with regard to analytical performance (accu-racy, repeatability, and JOAP data correlation).



The following paragraphs will describe the func-tion of the excitation source and explain factors which affect its performance.

The excitation source has two basic functions: 1) to provide a high voltage potential to overcome the resistance offered by the air and oil between the graphite rod and disc electrodes which make up the analytical gap, and 2) to provide an ana-lytical potential capable of instantaneously vapor-izing the oil and any particles suspended in the oil medium. This is accomplished with a solid-state excitation ignition circuit (SSEI) to charge a high voltage capacitor C2 until its potential is high enough to ionize the air between the graph-ite electrodes. This ionization will appear as a high voltage arc across the analytical gap. Once the high voltage has ionized the air across the ana-lytical gap, the resistance between the gap is ef-fectively zero ohms or a short circuit to ground. This momentary (approximately 3 microsecond) short circuit to ground is all that is necessary to discharge the potential which is stored on the ana-lytical capacitor C3. This potential will instanta-neously vaporize the oil and any particles which are suspended in the oil at that one moment in time. This vaporization potential will raise the en-ergy level of the valence electron(s) of the particles and when this energy is released as it returns to the ground state, it will create atomic emission which is the basis of this technique.

This process occurs approximately 700 times per second and is referred to as the excitation source frequency. The main reasons for the relatively high excitation source frequency are twofold: 1) to provide a good statistical sampling of the particles spread across the disc electrode which is approximately 1/4 inch by 1/4 inch and 2) to raise the vaporization temperature sufficiently to vaporize the refractory elements such as Si, Al and Ti. This excitation frequency is regulated or elec-tronically controlled to ensure that the frequency remains constant over the complete burn cycle or from one oil type to the next. In order to allow the measurement of this excitation source frequency and still maintain optical alignment between the

analytical gap and the optical processing assembly, a second gap called the auxiliary gap is designed into the excitation source and this gap is in series with the analytical gap.

This excitation source frequency has become the standard for wear metal analysis, particularly in the United States Department of Defense (DoD) Joint Oil Analysis Program (JOAP). Over the last two decades, an extensive database of wear trends and maintenance guidelines have been established based on this excitation source characteristic and certain parameters, such as frequency. This da-tabase has been derived based on the results of approximately 300 fixed laboratory sites where actual mechanical system failures have been de-tected and the trend data leading up to the detec-tion of the impending failure have been analyzed to determine guidelines for appropriate corrective maintenance action. These stationary laboratories participate in a monthly data correlation program operated by the Technical Support Center of the Joint Oil Analysis Program in Pensacola, Florida. Prior to each monthly correlation data sampling or every 2000 burns, the laboratory normally has to check the excitation source frequency by us-ing an oscilloscope or SFTM. This procedure has been referred to as checking the breaks per half cycle.

The effects of the physical and environmental characteristics have virtually been eliminated by the design of the solid-state excitation igni-tion circuit (SSEI). This is accomplished by in-corporating an internally mounted ferromagnetic regulating transformer T1 which can stabilize the nominal (120 or 240 VAC) input line volt-age having +/- 10% deviation to an output of 125 VAC within +/- 3%. However, since the high voltage transformer is simply a step-up voltage de-vice having an 80:1 ratio, it is understandable that an unstable line voltage will cause the high volt-age transformer output to vary. If this occurs, the charge stored on the high voltage capacitor will also vary thus resulting in an unstable excitation source frequency. The frequency of the line volt-age is the second physical parameter which must



be compensated for. Since the excitation source frequency is modulated from the line frequency, if the line frequency changes then the excitation source frequency will automatically change. Of course, if the components which make up the high voltage ignition circuitry were to fatigue, this will change or cause an unstable excitation source fre-quency. Last to be mentioned, but most probable to occur in application is erosion of the two 3/16” tungsten electrodes which together make the aux-iliary gap. The auxiliary gap electrodes have ap-proximately 27,000 arc discharges during each 30 second analysis which originate from the parabol-ic tips. This function is slowly removing tungsten material from the tips of these electrodes, which in effect is enlarging the gap distance. As the gap distance gets larger, the resistance of the air gap is increasing and the net result is a decrease in the excitation source frequency. This is the main rea-son that the standard operating procedure in the U.S. DoD laboratories is to perform a 2000 burn check of the excitation source frequency and reset the source frequency accordingly.

The second parameter which can affect the excita-tion source frequency is the environment in which the instrument must operate. These parameters are altitude and relative humidity, and their affect are not easily remedied by design. In both cases, altitude and relative humidity, the resistance to current flow offered by the air across the auxiliary and analytical gaps can cause the excitation source to holdoff.

Holdoff occurs when the auxiliary gap has diffi-culty breaking down. This phenomenon is usu-ally identifiable by a pause in the time between the start of the burn and the countdown of the burn counter. While it is difficult to identify the actual cause of this phenomenon, it is believed to be influenced by environmental conditions. To minimize this phenomenon, a set screw has been added to the auxiliary gap, Figure 3-13, to assist in breaking down its magnetic field. Holdoff does not have an effect on analytical results unless it ex-ceeds 2 seconds. Please refer to the troubleshoot-ing section of this manual if your instrument is experiencing holdoff that exceeds two 2 seconds.

When the instrument is factory calibrated at near sea level, the excitation source is set using an oscil-loscope or the Spectro Incorporated Source Fre-quency Test Meter to the prescribed frequency. If the instrument is deployed to a higher altitude, the resistances across the gaps are reduced. With lowered resistance, the high voltage capacitor can discharge across these gaps more easily and more often within a fixed time period. The result is an increase in excitation source frequency.

When an instrument is exposed to high relative humidity, nearly the same effect occurs, how-ever, for a different reason. The percentage of moisture in the environment makes the density of air higher and therefore offers lower resistance to current flow. This allows the high voltage to conduct through the air more easily thus result-ing in an increase in excitation source frequency. This is somewhat controlled in the Spectroil M with the incorporation of a heat exchanger which stabilizes the internal environment of the instru-ment. However, there is no humidity control in the sample excitation stand.

Maintaining the correct excitation source frequen-cy is the most influential parameter to achieving good JOAP data correlation. For sake of discus-sion, let’s assume that the excitation source fre-quency of instrument #1 is set exactly correct in accordance with Section 2.2.1 or 2.2.2, and in-strument #2 is operating 20% lower than speci-fication. Both of these instruments will standard-ize without any problem because the computer will adjust the calibration curves to make all the standards from 0 to 100 ppm read correctly. Now assume that we have an oil sample containing iron wear particles. These particles range from 1 to 40 microns in size and are evenly distributed throughout the sample. Instrument #1 will totally vaporize all particles of iron from 0.1 to 5 microns but when a 30 or 50 micron particle reaches the analytical gap, only 10% will be vaporized be-cause of the excitation source frequency and the resident time in the analytical gap. The analytical result for instrument #1 may be 100 ppm. Instru-



Figure 2-4, Location of Rod Electrode Holder Slide Mechanism Adjustment Screws

Adjustment Screws

ment #2 will also vaporize all particles from 0.1 to 5 microns, but will only vaporize 2% of the par-ticles in the 30 to 40 micron range. The analytical result for instrument #2 can be perhaps as low as 70 ppm. Both instruments standardize correctly, and all standards read correctly, but they do not correlate on used oil samples because of the differ-ences in the excitation source frequency.

It is absolutely necessary to check and/or adjust the excitation source frequency prior to perform-ing the JOAP monthly correlation samples. It is also essential to check and/or adjust the excitation source frequency each and every time the instru-ment is deployed to a country where the line fre-quency is other than 60 Hertz and/or the eleva-tion or environment is different from the last time the frequency was set.

2.3 DARK CURRENT ELECTRONIC STABILITY TEST

The dark current electronic stability test is used to assure that the Spectroil M has reached elec-tronic stability. It is performed as a diagnostic test to assure that the unit is functioning properly. This test is normally not performed by the opera-tor but by qualified service personnel. The test is initiated from the password protected Tools pull down menu.

2.4 REPAIR AND REPLACEMENT PROCEDURES

This section contains procedures for the repair, re-placement and alignment of all parts included in the Spectroil M standard spare parts kits. The sec-tion is divided according to the main assemblies of the Spectroil M starting with the sample stand, excitation source, optical system, computer and readout system, software and accessories.

2.4.1 Sample Stand

The sample stand is located on the right front side

of the spectrometer. It is the chamber in which the oil or fuel sample is placed for analysis. It con-tains the carbon electrodes, sample table, rod elec-trode gapping mechanism and the sample stand monitoring sensors.

2.4.1.1 Procedure to Adjust Rod Electrode Holder Slide Mechanism

The slide mechanism is used to hold the rod elec-trode in a position which creates an analytical gap between it and the disc electrode. To produce the analytical gap distance, this slide mechanism must move along a vertical axis. In order to main-tain rod electrode alignment and good electri-cal contact for this slide mechanism, a jib plate is installed between the slide mechanism and the mounting block assembly. This jib plate must be carefully adjusted to permit free movement along the vertical axis while maintaining a good electri-cal contact. Two set screws are provided on the right side of the mounting block for this purpose, see Figure 2-4.

To adjust the movement of the rod electrode hold-er and slide mechanism, the two 5.5 mm locking nuts must be loosened. Raise the analytical gap



Figure 2-5, Set-up for Rod Centering Tracking Test

TEST FORROD CENTERING

ON DISCWIDTH

setting lever to its maximum upward position and tighten the two set screws with a 1.5 mm Allen wrench until they are snug. Lower the analytical gap setting lever. The slide mechanism will remain in the lowered position because the set screws are too tight. Alternately, loosen each set screw by 1/8th turns until the slide mechanism snaps to its raised position.

Raise and lower the analytical gap setting lever several more times to be sure that the slide mecha-nism moves freely and does not bind because it is too tight. Install a rod electrode in the holder and grasp the rod electrode clamp knob. Gently ro-tate the knob alternately in a clockwise and coun-terclockwise direction. Observe the motion of the rod electrode. If the jib plate for the rod electrode holder and slide mechanism is properly adjusted, little to no rocking motion will be observed. Do not force the rotation of this knob to observe mo-tion of the rod electrode. Some motion is obvi-ously necessary because the rod electrode holder must be free enough to move along the vertical axis.

When the slide mechanism adjustment screws have been properly adjusted, tighten the two re-taining nuts to secure their position. This proce-dure should be repeated approximately every six months depending on sample throughput.

2.4.1.2 Procedure to Replace Disc Electrode Shaft, M32408 and Tracking Test

The disc electrode shaft secures and rotates the disc electrode during the analysis. This shaft has been designed to be replaced at the operator level. Occasionally, a disc electrode shaft will be bent through mishandling or unable to securely mount a disc electrode because of erosion of the outer di-ameter due to previous arcing between the outer diameter of the shaft and the inner diameter of the disc electrode. In these situations, the shaft must be replaced and the tracking between the electrodes must be checked.

1. The shaft can easily be replaced by inserting

a small jeweler’s screwdriver into the slotted end and turning the shaft counterclockwise until it can be pulled out of the bearing mount.

2. Replace the shaft in the reverse of this pro-cedure. Next, check to be sure that the disc electrode is aligned to the rod by checking the tracking.

3. Place a new disc electrode on the shaft and drop a newly sharpened rod electrode into the holder. Do not set a gap between these electrodes.

4. With your fingers spin the disc electrode. As the disc rotates, the point of the rod will leave a track on the circumference of the disc, see Figure 2-5.

Remove the disc and determine the exact loca-tion of the rod to disc alignment. If the track is noticeably off center, the problem can be resolved as follows:



Figure 2-6, Proper Alignment of Rod Electrode to Disc Electrode Shaft

TEST FOR ROD TO DISC

SHAFT ALIGNMENT

1. See if the shaft is not screwed in all the way, if the track is slightly to the right of the nor-mal line shown on Figure 2-5.

2. Verify that the replacement shaft is the cor-rect length and part number.

3. Obtain technical assistance from Spectro Incorporated Field Service.

2.4.1.3 Procedure to Align Disc Electrode to Rod Electrode

1. Shut down Windows and remove power from the instrument by placing the main power circuit breaker CB1 to the OFF or down position.

2. Refer to Figure 3-1. To remove top exterior panel, remove the four Phillips head mount-ing screws positioned in the corners of the panel. Be sure not to lose the dress washers for these panel screws; they are not captive to the screws. Remove the trim panel.

3. Refer to Figure 3-3. Remove the smaller of the interior access panels by turning each of the 1/4 turn pawl fasteners counterclockwise until the maximum travel of the screw is reached, approximately 10 rotations.

CAUTION: Do not overdrive the CCW travel of these screws, stop when resistance is encountered. Once all fasteners have been loosened, remove the access panel.

4. Refer to Figure 3-7. Using a 3 mm Allen wrench, loosen the 4 cap screws securing the Rod Electrode and Gap Setting Mounting Assembly Base to the Component Mounting Plate.

5. With a rod electrode secured in the Rod Electrode Positioning Vee Block so that the sharpened end touches the Disc Electrode Shaft, move the Mounting Base to center the rod over the shaft end, Figure 2-6.

6. Tighten the four cap screws loosened in Step 4 to secure the Mounting Base in its new position.

7. Check the frequency of the excitation source per Section 2.2.

2.4.1.4 Procedure to Adjust Sample Stand Interlock Monitor Sensitivity

Due to transportation vibration, component fail-ure, and/or component aging, a sample stand in-terlock monitor may prevent a normal analysis cycle from initiating by displaying the message “Interlock Error” on the video display. If this were to occur and all sample stand sensors are assured to have been cleaned, it is possible that an inter-lock monitor is defective or out of adjustment. In either case, all four interlock monitors have a sensitivity control which must be adjusted to permit normal operation. Normal operation is



Figure 2-7, Location of Sample Stand Interlock Monitor Sensitivity Adjustment

SAMPLE GAP DISK ROD

Sensitivity Adjustment(Clockwise to Increase)

Sensitivity IndicatorThe following are normal operating modes when the sample stand is properly loaded with electrodes and oil sample:

• SAMPLE - OFF (dark)• GAP - ON (green)• DISK - OFF (dark)• ROD - OFF (dark)

NOTE: Red indicates marginal setting.

when the transmitted light beam is interrupted by the presence of the component which is being monitored, such as the DISC, ROD, or SAMPLE HOLDER. This is called dark operation (DO) as indicated by the small slide switch on the cor-responding interlock monitor. The exception to this rule is the GAP which, for normal operation, senses the presence of light indicating that a gap has been set between the disc and rod electrodes. This is called light operation (LO). The following procedure will provide the steps necessary to ac-complish dark operated (DO) and light operated (LO) adjustments.

1. Remove the top trim panel by removing the four Phillips head mounting screws. Be care-ful not to lose the dress washers because they are not captive to the Phillips screw and can easily become separated.

2. This will expose the two internal access panels. The readout access panel is item 2 in Figure 3-3.

3. With a slotted screwdriver, remove the readout access panel by turning the eight 1/4

turn pawl fasteners counterclockwise.

CAUTION: This is captive hardware which is permanently mounted to the panel. Turn each fastener ccw approximately 10 turns or until slight resistance is encountered.

WARNING: DO NOT OVERDRIVE THE TRAVEL OF THIS FASTENER OR IT WILL BECOME STRIPPED AND HAVE TO BE RE-PLACED FOR NORMAL OPERATION.

4. Figure 3-17 provides a top view of the com-puter controller. The interlock monitors are positioned in the upper right corner. Figure 3-22, item 1, identifies the interlock moni-tors. Familiarize yourself with the location of these blue monitors.

5. Refer to Figure 2-7 for an illustration of the interlock monitors as they are mounted in front of the Interlock Monitor and Power Control Board M59200. If one of these monitors has been determined to be defec-tive using the fault isolation tables, replace the appropriate interlock monitor.



6. With the sample stand completely empty (no disc, no rod and no sample holder), all four of the interlock monitor sensitivity indicators must be GREEN. This indicates that all interlock monitors are functioning properly. If not, consult the fault isolation tables located in Section 2.1.1.4.

7. For explanation purposes, let’s assume that an Interlock Error is being caused by the disc electrode monitor. Place a disc electrode on the disc electrode shaft. The sensitiv-ity indicator should be dark OFF. If the sensitivity adjustment is incorrectly set, the sensitivity indicator may be GREEN or RED. This indicates that the monitor is too sensitive to light.

8. Take a small jeweler’s slotted screwdriver and turn the sensitivity adjustment ccw to decrease the sensitivity until the sensitivity indicator turns from GREEN or RED to dark (OFF). Turn this sensitivity an ad-ditional 1/8 turn from the point where the sensitivity indicator changes from the RED (marginal setting) to a solid dark (OFF). Remove the disc electrode and confirm that the sensitivity indicator turns to GREEN. If the sensitivity indicator is RED (mar-ginal), turn the sensitivity adjustment CW to slightly increase the sensitivity until it is solid GREEN.

9. Remove the disc electrode and install anoth-er disc electrode and observe the sensitivity indicator. It must be dark (OFF). Remove the disc electrode and confirm that the color of the sensitivity indicator changes to GREEN. If OK, the sensitivity adjustment has been correctly set.

10. For the GAP interlock monitor which is light operated (LO), place a disc and rod electrode in position and set the analyti-cal gap. Observe the sensitivity indicator on the GAP interlock monitor. It should

be GREEN. It not, increase the sensitivity adjustment until the sensitivity indicator changes from RED to GREEN and then turn the adjustment approximately 1/8 turn beyond. Short the disc and rod electrode and observe the sensitivity indicator. It should be dark (OFF). If not, decrease the sensitiv-ity adjustment until it is dark (OFF). Reset the analytical gap several times to confirm operation both in the gapped and shorted positions.

11. Check the operation of all four interlock monitors. Remember, the GAP is light oper-ated (LO) and should be the only indica-tor to be GREEN when the sample stand is properly loaded for operation. Press the START switch and confirm that an Inter-lock Error does not inhibit the burn from initiating. If all interlock monitors are opera-tional and adjusted properly, the burn will begin. Press STOP to terminate the burn and reload the sample stand with a new disc, rod, and sample holder. Repeat this process until satisfied that all interlock monitors are working properly.

12. Take the readout access panel and confirm that all eight 1/4 turn pawl fasteners are in their maximum counterclockwise direction. If not, use a slotted screwdriver and insure that all pawls are against their maximum counterclockwise stop. Center the readout panel access panel within the frame and tighten all fasteners until the panel under each fastener begins to depress indicating that the panel is sufficiently fitted to the frame.

13. Take the top trim panel and install the four Phillips screws and dress washers. Tighten all hardware until firm but do not torque such that it deforms the dress washers.

14. The instrument is now ready to resume normal operation.



2.4.1.5 Procedure to Replace Rod Electrode Holder and Gap Setting Mechanism, M31200




CAUTION: Do not overdrive the counterclock-wise travel of these screws, stop when resistance is encountered. Once all fasteners have been loos-ened, remove the access panel.

4. Refer to Figure 3-7. Using a 1.5 mm Allen wrench, loosen the set screw securing the Electrical Contact Pin to the Analytical Gap Adjustment and Pivot Plate.

5. Refer to Figure 3-7. Using a 3 mm Allen wrench, remove the four cap screws secur-ing the Rod Electrode and Gap Setting Mounting Assembly Base to the Component Mounting Plate.

6. Remove the Rod Electrode Holder and Gap Setting Mechanism by pulling it away from the Sample Excitation Stand.

7. Attach the new Rod Electrode Holder Gap Setting Mechanism by installing the four cap screws removed in Step 5. Do not fully tighten these screws at this time.

8. Grasp the knurled thumb nut and push the Electrical Contact Pin fully into the Analytical Gap Adjustment and Pivot Plate. Tighten the set screw loosened in Step 4.

9. Follow the steps in Section 2.4.1.3 to com-plete this installation.

2.4.1.6 Procedure to Replace Disc Electrode Motor, M32101A


2. Refer to Figure 3-1. To remove top exte-rior panel, remove the four Phillips head mounting screws positioned in the corners of the panel. Be sure not to lose the dress washers for these panel screws; they are not captive to the screws. Remove the trim panel.

3. Refer to Figure 3-3. Remove the smaller of the interior access panels by turning each of the 1/4 turn pawl fasteners counterclock-wise until the maximum travel of the screw is reached, approximately 10 rotations.

CAUTION: Do not overdrive the counterclock-wise travel of these screws, stop when resistance is encountered. Once all fasteners have been loosened, remove the access panel.

4. Refer to Figure 3-10. Using a 3 mm Allen wrench, remove the three cap screws secur-ing the Disc Electrode Drive Motor to its brass standoffs.

5. Using a Phillips head screwdriver, loosen the three screws on TB-3 securing the mo-tor wires. Note the orientation of the wires to ensure the new motor is correctly con-nected.

6. Remove the old motor from the instrument.



Using a 1.5 mm Allen wrench, loosen the set screw securing the toothed sprocket to the motor shaft and remove the sprocket.

7. Attach the sprocket to the shaft of the new Disc Electrode Motor. The end of the motor shaft should be flush with the shoulder of the sprocket.

8. Install the new motor in the reverse of Steps 2-5.

2.4.1.7 Procedure to Replace Sample Stand Exhaust Fan, M33002


2. Refer to Figure 3-5. Remove the four Phil-lips head screws positioned inside the top of the Sample Excitation Stand. Remove the Exhaust Duct Mounting Housing.

3. Remove the three Phillips head screws that secure the top exhaust fan guard to the fan.

4. Remove the four Phillips head screws that secure the exhaust fan to the frame. Unplug the black wire from the side of the fan.

5. Install the new fan in the reverse of steps 2-4.

2.4.1.8 Procedure to Replace Disc Electrode Drive Belt, M32303


2. Refer to Figure 3-1. To remove top exterior panel, remove the four Phillips head mount-ing screws positioned in the corners of the panel. Be sure not to lose the dress washers

for these panel screws; they are not captive to the screws. Remove the trim panel.



4. Refer to Figure 3-11. Using a 3 mm Allen wrench, loosen the cap screw (#4 in the dia-gram) securing the base of the Idler Adjust-ment Assembly to the back of the Sample Stand Component Mounting Plate.

5. If necessary, rotate the Idler Adjustment As-sembly to allow slack to develop in the Disc Electrode Drive Belt, and remove the belt.

6. Refer to Figures 8-11 and 8-12. Install the new belt by routing it around the sprocket of the Disc Electrode Motor, the Needle Bearing of the Idler Adjustment Assembly, and the sprocket of the Disc Electrode Shaft Mounting Assembly.

7. Rotate the Idler Adjustment Assembly to take up most of the slack in the Disc Elec-trode Drive Belt. Do not over tighten the belt.

8. Tighten the cap screw loosened in step 4.

2.4.1.9 Procedure to Replace Sample Stand Door Interlock, M33006

1. Shut down Windows and remove power from the instrument by placing the main power circuit breaker CB1 to the OFF or down position. Proceed with step 2 for the Spectroil M/N-W or go to step 3 for all other models of the Spectroil M.



Figure 2-8, Spectroil M/N Sample Stand Door Interlock

Remove two nuts!

2. The Spectroil M/N-W has a cover over the interlock switch which must be removed by loosening the two nuts shown in Figure 2-8.

3. Refer to Figure 3-5. Remove electrical con-nector from the back of the Door Interlock by rotating its outer ring CCW until it separates.

4. Note the distance of the Proximity Switch to its mounting bracket. Using two adjustable wrenches, remove the two large hex nuts that secure the proximity switch.

5. Install the new proximity switch in the re-

verse of steps 1-4. Ensure the switch extends sufficiently to make adequate contact with the sample stand door without hindering door operation.

2.4.2 Excitation Source

The Excitation Source Assembly consists of many components which are assembled and mounted within a rectangular compartment located behind the sample excitation stand assembly. Its panels are interlocked for operator/maintenance protection and are easily removable for routine maintenance and fault isolation. During analysis, the excitation source generates the potential difference between the disc electrode and the rod electrode to create

and sustain the arc discharge which results in cre-ation of the plasma.

All the replacement procedures in this section re-quire the removal of the top and side access panels of the excitation source, follow the steps below to gain access to the components.


2. Refer to Figure 3-1. To remove top and right side exterior panels, remove the four Phil-lips head mounting screws positioned in the corners of each panel. Be sure not to lose the dress washers for these panel screws; they are not captive to the screws. Remove the trim panels.

3. Refer to Figure 3-3. Remove the smaller of the top interior access panels by turning each of the 1/4 turn pawl fasteners counter-clockwise until the maximum travel of the screw is reached, approximately 10 rotations.

4. Refer to Figure 3-3. Remove the right side source interior access panel by turning each of the 1/4 turn pawl fasteners counterclock-wise until the maximum travel of the screw is reached, approximately 10 rotations.


2.4.2.1 Procedure to Remove Combined Solid State Source Assembly, M99966

1. Remove the top and right side exterior pan-els, and the two interior source access panels in accordance with the four steps in Section 2.4.2.

2. Refer to Figure 2-9. Using a 3 mm Allen



Figure 2-9, Location of High Voltage Cables

P/J4

Figure 2-10. Remove SFTM Fiber

wrench, remove the cap screw securing the high voltage cable to the brass hex stock brush housing. Use a small crescent wrench to hold the brass housing to prevent it from turning. Using the thumb and forefinger, rotate counterclockwise the knurled metal thumb nut securing the auxiliary gap high voltage cable to the brass electrical contact pin, remove the thumb nut and disconnect the cable from the pin.

3. Refer to Figure 2-9. Disconnect cable W7 at P/J4. This is accomplished by grasping the connector below the excitation source component mounting plate and rotating its outer ring counterclockwise until it is freed.

4. Remove the SFTM fiber by pulling it out of the 45° bracket, Figure 2-10.

5. Using a Phillips screwdriver, remove the four 5 mm stainless steel screws from the Excita-tion Source Component Mounting Plate. Using a standard screwdriver, remove the two 5 mm nylon screws from the plate.

NOTE: The longer plastic screw feeds through a clear plastic standoff before threading into the EMI Shield Plate. This standoff is not captive to either plate. Be careful not to lose it.

6. Carefully remove the entire Excitation Source Assembly from the instrument. This can most easily be accomplished by standing at the right side of the instrument, pulling the Excitation Source towards you approxi-mately 2 inches, then tipping and sliding it forward slightly as you continue pulling it towards you. Use care to avoid catching any wires or components on the frame.

7. Install the Excitation Source Assembly in the reverse of steps 2-6.


2.4.2.2 Procedure to Replace Auxiliary Gap Tungsten Electrodes, M42004

1. Shut down Windows and remove the top exterior panel, and the top interior source access panel in accordance with the four steps in Section 2.4.2.

2. Refer to Figure 3-13. Using a 7 mm open end ignition wrench loosen the nut on each brass block. This will allow you to loosen the set screw with a 2 mm Allen wrench.

3. The two 1 in. tungsten electrodes, one in each auxiliary brass block can now be easily removed.

4. Replace the electrodes using the reverse of



Figure 2-11a, Keyboard Panel

Figure 2-11b, Keyboard Panel Hinge

Figure 2-11c, Keyboard Cable

the steps above.

5. Using a feeler gage set the auxiliary gap distance to 0.135”. Unplug the optical fiber from the 45 degree bracket mounted on the black box inductor of the excitation source. Insert the 2 mm Allen wrench into the fiber holder to indicate the view path of the fiber. Ensure the fiber would be aimed directly at the center of the auxiliary gap. When the gap is centered and set at 0.135”.

6. Plug the optical fiber into the 45 degree bracket. Reinstall the interior and exterior panels removed in Step 1.


2.4.3 Optical System

The optical system is mounted in a light sealed container located in the bottom of the Spectroil M. There are no components that can be repaired or replaced in the field. Contact Spectro for as-sistance in troubleshooting the optical system.

If it is determined that the optical system is de-fective, it must be returned to Spectro Inc. to be repaired. To gain access to the optical system, the keyboard, front and rear lower protective panels, four connectors and four nuts and screws have to be removed.

Perform the following steps to remove the optical system:

1. Shut down Windows and remove power from the instrument by placing the main power circuit breaker CB1 to the OFF and down position.

2. Remove the Keyboard Panel, Figures 2-11a and 2-11b..

3. Remove Access Panels. a. With a Phillips screwdriver, remove the

bottom front access panel. Disconnect the keyboard cable from the inside of the panel, Figure 2-11c.

b. With a Phillips screwdriver, remove the bot-tom rear access panel located beneath the heat exchanger.

4. Disengage Connectors.



Figure 2-11e, Mate-N-Lock Connectors

Figure 2-11f, Protective Cover

Figure 2-11d, DB 25 Connector

Figure 2-11g, Remove Lens and Fiber Assembly

a. Remove the DB25 connector from the EK0310 circuit card by loosening the two screws on the connector and pulling it to-wards you, Figure 2-11d.

b. Disengage the two mini “mate-n-lock” con-nectors and the larger “mate-n-lock” connec-tor, Figure 2-11e.

5. Remove the white protective cover from where the fiber enters the optic, Figure 2-11f.

6. Using a 1.5 mm Allen wrench, loosen the screw that holds the fiber in place and remove the lens and fiber assembly, Figure 2-11g

The optical system is mounted on a steel plate with four nuts and bolts, two at the rear of the instrument and two at the front. The nuts are

removed from inside the optic compartment and their bolts from underneath the instrument.

7. Using a 17 mm wrench, remove the two front nuts and the two back nuts that hold the optic to the instrument, Figures 2-11h and 2-11i.

8. Raise the instrument and place it on blocks so that you can safely get a hand beneath the instrument to remove the four bolts that secure the optic to the spectrometer frame.

9. From underneath the instrument, remove the four socket head cap screws with an 8



Figure 2-11h, Front Nuts on Optic Assemblyy

Figure 2-11i, Rear Nuts on Optic Assembly

Figure 2-11j, Remove Four Socket Head Cap Screws

mm Allen wrench, Figure 2-11j. (Figure 2-1j is provided as guidance for locating the bolts that must be found by feel unless the instrument is raised sufficiently to actually see them.)

10. The optic can now be removed from the spectrometer through the rear or front open-ing.

To replace an optic, raise the instrument and

place it on blocks again so that you can safely get a hand beneath and repeat the above steps in reverse order

2.4.4 Computer and Readout System

The computer and readout system consist of the OilM software, the readout assembly (panel PC) and the data acquisition and Ethernet controller circuit cards.

2.4.4.1 Procedure to Replace Controller Cards

The two controller circuit cards, EK0011 and EK0310 are physically located next to the Spec-troil’s optic. To remove and replace either card:

1. Shut down Windows and remove power from the instrument by placing the main power circuit breaker CB1 to the OFF and down position.

2. Remove the Keyboard Panel, Figures 2-11a and 2-11b..

3. Remove Access Panels. a. With a Phillips screwdriver, remove the

bottom front access panel. Disconnect the keyboard cable from the inside of the panel, Figure 2-11c.

b. With a Phillips screwdriver, remove the bot-tom rear access panel located beneath the heat exchanger.

4. Remove the connectors from the card you wish to replace. The EK0310 has a DB 25 connector attached to it and the EK0011 has a DB 15 connector and an Ethernet cable attached to it.

5. Slide the circuit card towards you and out of its holder.

To replace a controller circuit card, reverse the above procedure.



Figure 2-12a, Location of Windows Readout Assembly Connectors for Panel PC M68150

Parallel Input Connector

(hidden under larger

connector)

Keyboard/Mouse

Connector

USB Connectors

(2)Ethernet

Connector

P8 Connector

COM Port Connectors

(2)

PowerConnector

Mounting Screws (7)(not visible)

IDE Ribbon Cable

Yellow Disconnect Lever Locks

2.4.4.2 Procedure to Remove Windows Readout Assembly

1. The instrument must be turned OFF for this procedure. Shut down Windows and wait for the message “It is now safe to turn off the instrument” message before turning the circuit breaker, CB1, to the OFF position.

2. Refer to Figure 3-15. Remove the ten phillips head screws securing the Windows Readout Assembly (control panel) to the instrument.

3. Gently and carefully start to pull the readout assembly towards you and out of the instru-ment.

4. Slowly pull the top of the assembly forward until it is approximately level, while the bottom is resting on the frame of the instru-ment. It is not necessary, but it helps to have someone assist by holding the assembly in place.

5. Refer to Figure 2-12 and disconnect power cable from the Panel PC assembly.

6. Disconnect P8 connector by twisting apart.

7. Disconnect the two COM port cables from the Panel PC assembly.

8. Disconnect the parallel LPT input connec-tor by squeezing its sides and pulling away from the Panel PC assembly.

9. Disconnect the keyboard/mouse connector.

10. Remove the ethernet cable by squeezing on the tap at the bottom of the connector and pulling it away from the Panel PC assembly.

11. It is now possible to remove the com-plete Windows Readout assembly from the Spectroil. Carefully set it on a smooth surface to protect the video monitor.

2.4.4.3 Procedure to Remove the Panel PC M68150 from Windows Readout Assembly

The Panel PC, part number M68150 was updat-ed in August of 2009 with a new Panel PC, part number M68720. This section describes the re-placement procedure for the older Panel PC, part number M68150. The next section 2.4.4.4 de-scribes the replacement procedure for new Panel



Figure 2-12b, Location of Windows Readout Assembly Connectors for Panel PC M68720

USB Connectors

USB Connectors

Mounting Screws (2 on

each side)

P8 Connector

Red Ethernet Cable

Black Ethernet Cable

COM 1& COM 2 Connector

Power Connector

Printer Connector

Expansion Card

USB Adopter

PC. part number M68720.

To replace Panel PC part number M68150

1. Performs steps 1 through 10 in procedure 2.4.4.2 to remove the Windows Readout as-sembly (control panel) from the instrument.

2. Remove the two USB connectors from the panel PC assembly, Figure 2-12a.

3. Remove the Floppy and IDE ribbon cable connectors from the Panel PC assembly.

4. Loosen the 7 screws that hold the Panel PC assembly to the Windows Readout assembly. Note that there are two screws each, on three sides and one screw on the side closest to the CD and floppy drives.

5. When the screws have been loosened suf-ficiently, the clips to which they are attached can be disengaged from the Panel PC as-sembly.

6. The Panel PC assembly can now be safely removed from the Windows Readout as-sembly.

7. Reverse the procedure to replace the panel PC assembly.

2.4.4.4 Procedure to Remove the Panel PC M68720 from Windows Readout Assembly

To replace Panel PC part number M68720

1. Performs steps 1 through 10 in procedure 2.4.4.2 to remove the Windows Readout as-sembly (control panel) from the instrument.

2. Disconnect P8 at the black connector by twisting it approximately three turns counter clockwise, Figure 2-12b.

3. Remove the three USB connectors. Note that one connector is for the USB to PS2 adopter which is attached to the Panel PC



Figure 2-13a, Rear View of Control Panel Showing Switches and Yellow Disconnect Lever Blocks.

Disconnect Lever Blocks

Figure 2-13b, Switch Disconnect Lever

with Velcro, detach the adapter.

4. Remove red Ethernet cable.

5. Remove the black Ethernet cable.

6. Unscrew the two thumb screws on the Com 1 connector and remove the connector.

7. Unscrew the two thumb screws on the Com 2 connector and remove the connector.

8. Use a small screwdriver to loosen the two screws that hold the green power connector in its socket. Remove the power connector and cable.

9. Use a small screwdriver to loosen the two screws that hold the printer connector in its socket. Remove the printer connector and cable.

10. Remove the 5 USB cables from the Expan-sion Card.

11. Loosen the 8 screws that hold the Panel PC assembly to the Windows Readout assembly. Note that there are two screws each, on the four sides.

12. When the screws have been loosened suf-ficiently, the clips to which they are attached can be disengaged from the Panel PC as-sembly.

13. The Panel PC assembly can now be safely removed from the Windows Readout as-sembly.

14. Reverse the procedure to replace the panel PC assembly.

2.4.4.5 Procedure to Replace START or STOP Switches, M68119/M68120

1. Performs steps 1 through 10 in procedure 2.4.4.2 to remove the Windows Readout As-sembly from the instrument.

NOTE: The switches consist of two separate assem-blies, the push-button and the terminal block.

2. Make a note of the wire locations on the switch being replaced. Gently pull the wires off the terminals.

3. To remove the terminal block from a switch, pull out and remove the yellow disconnect lever lock, Figure 2-13a, to provide access to the disconnect lever.

4. Turn the disconnect lever, Figure 2-13b, in a counterclockwise direction until it locks in place (approximately 45°). Remove the terminal block from the switch.

5. The push button part of the switch can now

Disconnect Lever



Figure 2-14, Terminal Board TB-2

Figure 2-15, Row of Contacts in TB-2 for Voltage Measurements

be replaced by turning the knurled ring counterclockwise.

6. Install a replacement switch in the reverse order.

7. Install the Windows Readout Assembly in the reverse of Step 1.

2.4.4.6 Procedure to Measure DC Power Supply Voltages

The DC Power Supply is mounted on the floor of the Spectroil M just behind the control panel. It provides the direct current voltages required by the readout and control logic. The power sup-ply is mounted on the floor of the Spectroil just behind the control panel. The output voltages of the power supply can be measured on terminal board TB-2 which is located between the control panel and the power supply. The control panel must be removed to gain access to the terminal board.

CAUTION: The voltages are measured while power is applied to the instrument. This proce-dure can only be performed by qualified person-nel who are trained to work around live voltages.

1. Refer to Figure 3-15. Remove the ten phillips head screws securing the Windows Readout Assembly (control panel) to the instrument.

2. Gently and carefully start to pull the readout assembly towards you and out of the instru-ment.

3. Slowly pull the top of the assembly forward until it is approximately level, while the bottom is resting on the frame of the instru-ment. Turn the panel approximately 90 degrees so that is out of the way and there is access to TB-2, Figure 2-14. It is not neces-sary, but it helps to have someone assist by holding the assembly in place.

4. Measure the voltages according to the termi-

nal locations and specifications listed in the table. The probes are inserted in the row of contacts as shown in Figure 2-15.

Terminal“-” Probe

Terminal“+” Probe

Voltage

12 17 + 5 VDC ± 10% 8 10 +12 VDC ± 10%8 7 -12 VDC ± 10%1 3 +24 VDC ± 10%

5. Reinstall the panel removed in Step 1.

2.4.4.7 Procedure to Replace the Interlock Monitor Assembly, M59210

The interlock monitor assembly monitors sample stand settings and provides warnings if they are not correct. If defective, it can be replaced by fol-lowing the procedure below.



Standoff (2) Interlock Monitor Screw (2)

Ribbon Cable ConnectorFigure 2-16, Interlock Monitor Assembly



3. Refer to Figure 3-3. Remove the larger of the interior access panels by turning each of the 1/4 turn pawl fasteners counterclockwise until the maximum travel of the screw is reached, approximately 10 rotations.

4. Disconnect the two screws that hold the interlock monitor assembly to the circuit board, Figure 2-16.

5. Carefully remove all “Press and Pull Connec-tors” and the ribbon cable connector.

NOTE: The cable end of the connector is labeled and a corresponding label is on the circuit board.

6. Remove the two hex standoffs from the top of the circuit board and the two Phillips head screws from the bottom of the circuit board.

7. Remove the circuit board from the spectrom-eter.

8. Install a replacement circuit board by follow-ing the steps in reverse order.

2.4.4.8 Procedure to Replace the Measurement and Control Circuit Card, EK0014B

The measurement and control circuit card serves as an interface between the spectrometer control electronics and the optical assembly. If defective, it can be replaced by following the procedure be-low.




Figure 2-17, Measurement & Control Circuit Card


3. Refer to Figure 3-3. Remove the larger of the interior access panels by turning each of the 1/4 turn pawl fasteners counterclockwise until the maximum travel of the screw is reached, approximately 10 rotations.

4. Carefully remove all “Press and Pull Con-nectors”, the ribbon cable connector and the D-Sub connector, Figure 2-17.

5. Remove the four Phillips head screws that secure the circuit board.

6. Remove the circuit board from the spec-trometer.

7. Install a replacement circuit board by follow-ing the steps in reverse order.

2.4.4.9 Procedure to Correct System File Paths

When power is first applied to the Spectroil M, the software needs to locate and load four files,

a Matrix, Chip and two Binary files. This will happen in the background unless there is a prob-lem with any or all of these files. When there is a problem, a Correct Configuration File Paths screen will appear indicating that a file may be corrupted and needs to be restored, was moved, or the system just does not know where the file is located.

The screen in Figure 2-18 shows the factory de-fault locations of these files. If your screen is dif-ferent, either search your C: drive for the location of the files or type in the paths as shown in the fig-ure. Contact Spectro Inc. if the system still does not boot after the file paths have been corrected.

2.4.5 Input Power Distribution and Accessories

2.4.5.1 Procedure to Replace Electrode Sharpener Cutter Blade, M90102

The cutter blade, Figure 2-19, has three sharpened edges and can thus be used three times before it is replaced.

To replace or rotate the cutter blade to a new cut-ting edge, unplug the sharpener power connector J2 at the power connection plate. Next, remove the graphite collector barrel assembly to empty out any accumulated graphite and to expose the cutter blade, Figure 2-19.

To remove the barrel assembly, locate the sharp-ener over a waste basket with the collector barrel pointing downward. Grasp the barrel with the opposite hand and rotate it while pulling it away from the motor mount and face plate. Once the O-ring disengages the face plate, it will be easy to separate and empty. Use a flat blade screw driver to remove the #4-40 screw which mounts the cutter blade, see Figure 2-14. When replac-ing or rotating the cutter blade, be sure to place the rear edge of the cutter blade tight against the cutter head. This is the reference point to achieve the correct angle on the graphite rod electrode. Replace the barrel assembly and reconnect the sharpener to its power connector.



Figure 2-18, Default Factory File Paths

Figure 2-19, Electrode Sharpener Blade

2.4.5.2 Procedure to Replace Electrode Sharpener Timer

1. Disconnect the sharpener from the spec-trometer at P/J 2 on the power connection plate. Using a 7/64” Allen wrench, remove the four cap screws that secure the rubber feet to the sharpener base.

2. Remove the sharpener base cover to expose the internal wiring. Use an 8mm wrench to remove the nut securing the timer to the sharpener body. Pull the timer up approxi-mately 2 inches so that it clears the mount-ing screw.

3. Remove the wire(s) from one timer terminal at a time, and connect them immediately to the new timer to ensure all are connected correctly.

4. Lower the new timer over the mounting screw and replace the locking nut and wash-ers.

5. Ensure the timer adjustment is set near the mid position, and reinstall the cover and feet removed in Step 1.

6. Connect the sharpener to the spectrometer at P/J 2 and check for proper operation.

2.4.5.3 Procedure to Replace Contactor Relay, M21002 and Auxiliary Contact Module, M21005

1. Remove the top exterior panel and the source access panel in accordance with the Section 2.4.4.

2. Disconnect the power cable from the spec-trometer. This ensures no voltage will be present while replacing the contactor.

3. Using a Phillips head screwdriver, remove the Heat Exchanger Assembly from the rear of the instrument.

NOTE: The heat exchanger is heavy and must be supported while removing the mounting screws. Also, the power cable for the fan motors (P/J 18) must be disconnected prior to completely remov-ing the heat exchanger. This is done by rotating the outer ring of the P/J connector CCW until it separates.

4. Remove the Excitation Source Assembly in accordance with Section 2.4.2.1.

5. Refer to Figure 3-23. Using an 8 mm wrench, remove the five standoffs that secure



the EMI Shield Plate to the instrument frame, and remove the plate.

6. Refer also to Section 9.2.5, Placement of Power Switching Contactor Assembly, for identification of the contactor relays and auxiliary contact modules.

7. Each contactor relay, auxiliary contact module, and their associated wires should be individually labeled. If each wire connected to the component being replaced does not have a wire marker, label each wire before removing it to facilitate installation of the new component.

8. To replace an auxiliary contactor module:

a. Using a Phillips screwdriver, loosen the clamps securing each wire connected to the module, and gently pull all wires out of the module.

b. Using the thumb and forefinger to straddle the contactor, squeeze the tabs located mid-way along the bottom length of the module. This will allow the module to be pulled upward and removed.

c. Carefully pry out the rectangular white label on the old contactor and install it on the new one.

d. Orient the new contactor module over its as-sociated Contactor Relay. One end will have two alignment pins, the other only one.

e. Reconnect all wires removed in step 8.a.

f. Firmly push down on the auxiliary contactor module until it clicks into place.

g. Install the Heat Exchanger, EMI Shield Plate, and Excitation Source Assembly.

9. To replace a Contactor Relay:

a. If the contactor relay being replaced is K1 or K2, first remove the mechanical interlock by grasping it firmly with two hands and wig-gling it while pulling upward. Set it aside.

b. If the contactor relay being replaced is K3 or K4, first remove the auxiliary contactor module mounted on top of it by following step 8.b. There should be enough slack in the wires to allow access to the relay.

c. Using a flat bladed screwdriver, pry outward the clip located midway along the bottom of the relay. The relay can now be tilted back and removed from the track it is secured to.

d. Using a Phillips screwdriver, loosen the clamps securing each wire connected to the relay, and gently pull all wires out of the relay.

e. Carefully pry out the rectangular white label on the old relay and install it on the new one.

f. Reconnect all wires removed in step 9.d.

g. Orient the new relay over the track. Tilt it backward slightly, pushing downward as you then tilt it forward and it clicks into place.

h. Install the Heat Exchanger, EMI Shield Plate, and Excitation Source Assembly.

10. Reconnect the power cable and apply power to the instrument in accordance with Section 2.1.5.



Figure 2-20, Windows XP Setup

Figure 2-21 Welcome to Setup

Figure 2-22, Windows XP License Agreement

2.5 SOFTWARE RESTORATION

This section is to be used if there is a need to re-store the original software shipped with the spec-trometer. Restoring the original software may be as simple as copying one file that may be missing or corrupt, or as complex as a full restore of all files in the system. The system as described in sec-tions 2 and 4 of this manual consists of an instru-ment controller and a readout system (Pentium III™ CPU). Each of these processors use software specific to their function in the system and may, from time to time, need to be up upgraded to the latest version, or restored if the hardware were to malfunction or the software is accidentally erased or corrupted.

This section provides step-by-step instructions to restore all software used in the system. In the event of a total system reload, begin with format-ting the hard disk drive in the readout system then follow each section of this procedure. For full res-toration, you will need the Microsoft® Windows® XP PRO CD, the OILM Windows Software CD, the OILM Windows® XP Backup Zip Disk and the PPC-S123T Drive and Utility Disk. Partial software restoration should only be performed with the direction and assistance of the Service Department of Spectro Incorporated.

2.5.1 Reinstalling Microsoft® Windows ® XP PRO

Depending upon the state of the system that is being restored, these steps may vary significantly. Microsoft® has multiple levels of repair of Win-dows® XP. This section outlines the proper steps to do a complete installation of Microsoft® Win-dows® XP on an un-partitioned disk.

1. Insert the Microsoft® Windows® XP Profes-sional CD ROM into the CD disk drive and restart the computer.

2. Windows® XP Setup opens from the CD, Figure 2-20. A series of drivers and configu-ration files are loaded. This process can take

up to a few minuets to complete.

3. The “Welcome To Setup” screen opens, Fig-ure 2-21. Press “Enter” to continue.

4. Setup determines that the hard disk is either new or erased; press “C” to continue. (This screen will not appear if the drive is pre-formatted or pre-partitioned.)

5. The Windows® XP License Agreement opens, Figure 2-22. Read the entire agree-ment; use the “Page Down” button to view the next pages. If you agree with the terms of the license agreement, press “F8” to



Figure 2-23, Unpartitioned hard Disc Space

Figure 2-24, Select Format

Figure 2-25, Setup Formats Hard Disk.

Figure 2-26, Setup Initializes Configurations

Figure 2-27, Second Part of Windows Setup

continue.

6. The un-partitioned space should be high-lighted, Figure 2-23, if there are multiple drives listed select the disk you want to install Windows® XP on, then press “Enter” to continue.

7. Using the arrow keys select the “Format the partition using the NTFS file system”, Fig-ure 2-24. Press “Enter” to continue.

8. Setup performs a format of the hard disk, Figure 2-25. The time required will vary

depending upon the size of the hard disk. Expect several minutes to complete the for-mat of the disk.

9. When the format of the disk is completed Setup will start to copy files to the newly formatted disk. This process will also take several minutes.

10. Setup will initialize the Windows® XP configurations, Figure 2-26. Setup will au-tomatically restart the computer to continue installation.

11. After the restart, the second part of Win-dows® XP Setup starts, Figure 2-27. The Windows kernel is now operating and the pointing device is enabled. The mouse pointer “white arrow” will appear.

12. Setup will detect and install external devic-es connected to the system, Figure 2-28. Do not be concerned if the screen goes blank for a short time.



Figure 2-28, Setup, Installation of External Devices

Figure 2-29, Setup, Regional Settings

Figure 2-30, Setup, Personalize Your Software

Figure 2-31, Setup, Product Key

Figure 2-32, Setup, Computer Name and Administrator

13. Setup opens a “Regional Settings” window, Figure 2-29. Customize these settings as required. Using the pointing device click on the “Next” button.

14. Setup opens the “Personalize Your Soft-ware” window, Figure 2-30. Using the pointing device click on the text box to the right of Name. Type “Spectroil M” in the text box. Using the pointing device select

the next text box on the right of Organiza-tion. Type “Spectro Inc.”. Using the point-ing device click on the “Next” button.

15. Setup opens the “Your Product Key” window, Figure 2-31. Setup is looking for a unique 25-character alphanumeric prod-uct key. The key is located on the Spectroil M computer. Remove the top panel of the spectrometer and the panel beneath it. The product key is on a multi color sticker above the bar code located on the top of the computer behind the display. Using the pointing device select the first text box under Product Key. Type in the product key printed on the sticker. Using the pointing device click on the “Next” button.

16.Setup opens the ”Computer Name and Administrator Password” window, Figure 2-32. Using the pointing device select the



Figure 2-33, Setup, Date and Time

Figure 2-34, Setup, Hardware and Software

Figure 2-35, Setup, Network Settings

Figure 2-36, Setup, Workgroup or Computer Domain

text box next to Computer Name. Type “SPECTROILM”. Leave the administrator password fields blank and using the pointing device click on the Next button.

17. Setup opens the “Date and Time Settings” window, Figure 2-33. Using the pointing device change the date and time to the cur-rent date and time for your location. Using the pointing device click on the Next but-ton.

18. Setup starts copying all files needed for the system hardware, Figure 2-34. Setup next copies all of the required files for Windows® networking.

19. After the file copying is complete, setup needs to know how to setup the network connection, Figure 2-35. Using the point-ing device select the button next to Typical Settings. Using the pointing device click on the “Next” button.

20. Setup opens the “Workgroup or Computer Domain” window, Figure 2-36. Using the pointing device select the button “No, this computer is not on a network, or is on a net-work without a domain.” Using the point-ing device click on the ‘Next” button.

21. Setup is now installing all of the compo-nents of Windows® XP. This process will take several minuets to complete. Once complete, the system will restart.

22. During the first startup of Windows® XP PRO, a thank you for purchasing dialog appears. Using the pointing device, click on “Next”, Figure 2-37.

23. The “How will you connect to the internet” dialog opens, Figure 2-38. Using the point-ing device click on the option box for “Local Area Network” LAN. Using the pointing device, click on the “Next” button.



Figure 2-38, Setup, Connection to the Internet

Figure 2-37, Welcome to Microsoft WindowsFigure 2-39, Setup, Setting Up a High Speed Connection

Figure 2-340, Setup, Ready to Activate Windows

Figure 2-41, Setup, Who Will Use This Computer

24. The “Setting up high speed connection” dialog opens, Figure 2-39. Using the point-ing device select the option box “Obtain IP automatically” and also select the “Obtain DNS automatically”. Using the pointing device click on the “Next” button.

25. The “Ready to activate Windows” dialog opens, Figure 2-40. If your spectrometer is connected to the internet select “Yes, activate Windows over the internet now”. If not, select “No, remind me every few days”. Us-ing the pointing device, click on the “Next” button.

26. The “Who will use this computer?” screen appears. Figure 2-41. Next to the Your Name field, select the text box and enter “Spectro User”. Using the pointing device, click on the “Next” button.

27. The “Thank you!” screen appears, Figure

2-42. Using the pointing device, click on the “Finish” button.

WARNING: The operating system is now operat-ing properly but some devices may not be func-tioning correctly. Please follow the instructions in the next section to update device drivers.



Figure 2-42, Setup, Thank You

Figure 2-43, Start Menu

Figure 2-44, Enter Program Name

Figure 2-45, PenMount DMC9000 Install Window

2.5.2 Reinstalling Touch Panel Driver

Follow the steps outlined in this section to reinstall the touch panel driver.

1. Insert the PPC-S123T Driver and Utility disk into the CD-ROM drive. Using the Start menu, Figure 2-43, select “Run”.

2. In the Run Window, Figure 2-44, type in the text box, “D:\PPC-S123\Touch Screen\|Driver|Windows| 2000_XP\Pen-Mount Windows 2000_XP\setup.exe”. Us-ing the pointing device, click on the “OK” button.

3. The ‘PenMount DMC9000 Install Window” opens, Figure 2-45. Select “Next” to con-tinue.

4. Read the software license, Figure 2-46, select ‘I accept the terms in the license agreement” and select “Next” to continue.

5. The “Ready to install” window opens, Figure 2-47. Select “Install” to continue.

6. When the installer finishes, a system Restart window opens, Figure 2-48. Select “Yes” to restart the system.

7. Once the system has restarted, open the Control Panel using the Start Menu, Figure 2-49. Select the “Control Panel”.

8. Switch to “Category View” if necessary and select the “Performance and Maintenance” icon, Figure 2-50, by clicking on it.

9. Open the “System” Control Panel, Figure 2-51, by clicking on it.

10. Select the “Hardware” tab, Figure 2-52.



Figure 2-46, Software License

Figure 2-47, Ready to Install Window

Figure 2-48, System Restart Window

Figure 2-49, Select Control Panel

Figure 2-50, Select Performance and Maintenance

Figure 2-51, Open System Control Panel

Figure 2-52, Select Hardware Tab

Select the “Device Manager Button” by clicking on it.

11. Select the “Unknown device”, Figure 2-53 and double-click on it to open the device’s properties.

12. Click on the “Reinstall Driver” button, Figure 2-54.



Figure 2-53, Select Unknown Device

Figure 2-54, Select Reinstall Driver Figure 2-56, Select Driver

Figure 2-55, Hardware Update Window

Figure 2-57, Digital Signature

13. The “Hardware Update Window Opens”, figure 2-55. Select the “Next” button by clicking on it.

14. After the system searches for device drivers, select the first item on the list, Figure 2-56 and click “Next” to continue.

15. A “Digital Signature” warning will open, Figure 2-57. Click the “Continue Anyway” button.

16. Click on the “Finish” button, Figure 2-58. Close all open windows.

2.5.3 Updating Windows® XP Settings

These steps will take you through the process of configuring Windows® XP for the best performance with the Spectroil M.

1. Under the Start Menu, select “Settings” and select “Control Panel”, Figure 2-59.

2. On the left hand side of the screen, select “Switch to Classic View”, Figure 2-60. Double click on the Display icon.

3. Select the “Desktop” tab and select “none”



Figure 2-58, Finish Installation

Figure 2-59, Select Start, Settings Control Panel

Figure 2-60, Select Classic View

Figure 2-61, Select Desktop Tab

Figure 2-62, Select Screen Saver Tab

Figure 2-63, Change Power Settings

6. Open the “System” control panel.

7. Select the “Advanced” tab. Figure 2-64. Se-lect the “Error Reporting” button.

8. Select the “Disable Error Reporting” option, Figure 2-65 and click “OK”.

for the background, Figure 2-61.

4. Select the “Screen Saver” tab, Figure 2-62 and click on the “Power” button.

5. Change the Power Setting to always “On”and the turn off power setting to “Never”, Figure 2-63. Click OK to close the Display properties window.



Figure 2-64, Select Advanced Tab

Figure 2-66, Select Automatic Update

Figure 2-65, Select Disable Error Reporting

Figure 2-67, Taskbar and Start Menu Control Panel

Figure 2-69, Select Language

Figure 2-68, Close Control Panel

9. Select the “Automatic Update” tab, Figure 2-66. Select the ‘Turn off automatic up-dates…” option box. Select “Apply” and click on “OK” to close the window.

10. Open the “Taskbar and Start Menu” control panel, Figure 2-67. Uncheck the

“Hide Inactive Icons” check box. Click on the “OK” button to close the window.

11. Close the “Control Panel” window.

2.5.4 Roxio Easy CD Creator Installation

1. Insert the “Roxio Easy CD Creator” CD ROM into the CD drive. The setup utility will autoload. Select “Yes” to start the instal-lation, Figure 2-68.

2. Select the correct language and click on “OK”. The install Wizard will be activated, Figure 2-69.

3. The Install Shield Wizard opens, Figure 2-70. Select “Next” to continue.

4. Chose the “Complete” installation option, Figure 2-71. Select “Next” to continue,



Figure 2-70, Install Shield Wizard

Figure 2-72, Install Easy CD Creator

Figure 2-71, Select Complete Installation

Figure 2-73, Select Finish Easy CD Creator

Figure 2-74, Select No

Figure 2-75, Select Iomegaware Language

restarted, Figure 2-74. Select “No” to exit and not to restart the system.

8. Remove the “Roxio Easy CD Creator” CD ROM from the CD drive.

2.5.5 Iomegaware Installation

1. Insert the Iomegaware CD. The Iomega-ware setup will launch automatically, Figure 2-75. Select the language to continue.

2. Read the license agreement and select “Yes” to continue, Figure 2-76.

5. The Wizard is now ready to install “Easy CD Creator”, Figure 2-72. Select “Install” to continue.

6. When the Wizard completes copying files, Figure 2-73, select “Finish” to exit the in-staller.

7. The installer will request that the system be



Figure 2-76, License Agrement

Figure 2-77, Deselect All Accessories

Figure 2-78, Iomega Software Setup Figure 2-80, Epson Printer Driver Setup Window

Figure 2-79, Select Install Printer Driver Utility

3. Deselect all Accessories options, Figure 2-77. Select “Next” to continue.

4. Setup will copy all required files. When complete, setup will ask if you want to restart the system. Select the “Shutdown Later” option, Figure 2-78 and select “OK”.

5. Remove the “Iomegaware” CD ROM from the drive.

2.5.6 Epson printer Driver Installation

1. Insert the “Epson LX 300+” CD ROM in the drive.

2. Select the “Install Printer Driver Utility” line and click on the right pointing arrow to con-tinue, Figure 2-79.

3. The “Epson Printer Driver Setup” window opens, Figure 2-80. Select “OK” to con-tinue.

4. Setup completes after a short period of time, Figure 2-81. Select “OK” to continue.

5. Using the pointing device, close the window, Figure 2-82.

6. Remove the “Epson LX300+” CD ROM from the drive.



Figure 2-81, Printer Driver Setup Complete

Figure 2-82, Close Driver Setup Window

Figure 2-83, OilM Windows Install Shield Window

Figure 2-84, Destination Folder Screen

Figure 2-85, Installer Summary Screen

Figure 2-86, OilM Windows Install Completed

7. Insert the “OilMWindows” CD ROM into the drive.

8. The ‘OILM Windows Install Shield Wizard” will automatically open, Figure 2-83. Select “Next” to continue.

9. The “Destination folder” screen opens, Fig-ure 2-84. Select “Next” to continue.

10. The installer summary screen opens, Figure 2-85. Click “Install” to continue.

11. When the installation is complete, Figure 2-86, select “Finish”.

12. Using the Start Menu, select “Turn OFF Computer” using the restart option, Figure 2-87. Restart the computer to complete the process.



Figure 2-87, Select Turn Off Computer



3.0 ASSEMBLY PARTS LIST

3.1 PARTS LIST ILLUSTRATIONS

This section lists those components which are readily identifiable and can be replaced at the user level of maintenance. If parts are required, order by figure and item num-ber, nomenclature and date of instruction manual.

Figures are listed according to assemblies start-ing with the housing, excitation source, control panel, readout electronics, optics and power distribution.

Chapter 3

Assembly Parts List



1

5

3

4

6

2 (Hidden)

9

10

8

7

7

Figure 3-1, Housing Assembly, M10000

Index Nomenclature Qty Part Number 1 Housing Assembly ....................................... 1 ................................. N10000 2 Panel Exterior Left Assy ............................... 1 ................................. M13200 3 Front Panel .................................................. 1 ................................. M68608 4 Cover Front Optic ........................................ 1 ................................. M68607 5 Panel Exterior Right Assy ............................. 1 ................................. M12900 6 Panel Exterior Top Assy ................................ 1 ................................. M13100 * Mounting Hardware for all Exterior Panels * Screw, Phillips (per panel) ........................... 4 ................................. H10055 Washer, Finishing (per panel) ...................... 4 ................................. H10114 7 Vibration Mount NC2040-T6 ....................... 3 ................................. M13400 8 Screw Retractable Fastner M4 ..................... 2 ................................. M68132 9 Keyboard Shelf Support Arm ........................ 2 ................................. M68604 10 Hinge Concealed Quick-Disconnect ............. 2 ................................. M68105


80 | Chapter 3 Assembly Parts List

1

2

3

4

5 6

Figure 3-2, Housing Assembly, Rear View

Index Nomenclature Qty Part Number 1 Heat Exchanger Panel Assy ......................... 1 ................................. N12000 Screw, Phillips ........................................... 20 ................................. H10054 Washer, Flat .............................................. 20 ................................. H10086 2 Heat Exchanger ........................................... 1 ................................. M12002 3 Cover rear Optic .......................................... 1 ................................. N12800 Screw, Phillips ........................................... 19 ................................. H10054 Washer, Flat .............................................. 19 ................................. H10086 4 Heat Exchanger Filter Screen ...................... 1 ................................. M12004 5 Vibration Mount NC2060-T6 ........................ 1 ................................. M13300 Bolt, Hex ...................................................... 1 ................................. H10001 6 Vibration Mount NC2040-T6 ....................... 3 ................................. M13400 Bolt, Hex ...................................................... 3 ................................. H10001



1

2

3

4

5

6

Figure 3-3, Housing Assembly, Interior Access Panels

Index Nomenclature Qty Part Number 1 Cover Top-Source M/N Assy ........................ 1 ................................. N12500 Fastener, 1/4 turn pawl ................................ 6 ................................. H10133 2 Cover Top-Electronic M/N Assy ................... 1 ................................. N12400 Fastener, 1/4 turn pawl ................................ 8 ................................. H10133 3 Cover Left-Electronic M/N Assy .................... 1 ................................. N12300 Fastener, 1/4 turn pawl ......................... 10/12 ................................. H10133 4 Cover Left-Optic M/N assy .......................... 1 ................................. N12700 Screw, Phillips ........................................... 12 ................................. H10054 Washer, Flat .............................................. 12 ................................. H10086 5 Cover Right-Source M/N Assy ...................... 1 ................................. N12200 Fastener, 1/4 turn pawl ......................... 10/12 ................................. H10133 6 Cover Right-Optic M/N Assy ........................ 1 ................................. N12600 Screw, Phillips ........................................... 13 ................................. H10054 Washer, Flat .............................................. 13 ................................. H10086



12

3

4 (Hidden)

5

56

Figure 3-4, Sample Excitation Housing

Index Nomenclature Qty Part Number 1 Door Pull ....................................................... 1 ................................. M11007 2 Window UV & EMI Shield ............................. 1 ................................. M11003 3 Window Bezel ............................................... 1 ................................. M11002 4 Fan 92mm Sq x 25mm 115V 50/60 Hz ......... 1 ................................. M33002 5 Hinge 40 x 40mm 180 Deg Black ................. 2 ................................. M11008 6 Sample Door Trim (Spectroil M/C-W) ........... 1 ................................. M11001 Sample Door Trim Spectroil M/N-W ............. 1 ................................. N11001A



1

234

5

6

7

8 9

10

11 & 12(Hidden, access from inside)

13

14

15

16

1718

1920

Figure 3-5, Sample Excitation Stand, M30000

Index Nomenclature Qty Part Number 1 Sample Stand Plate Assy ............................ 1 ................................. M31000 2 Electrode Holder/Gapping Assy ................... 1 ................................. M31200 3 Electrode Holder V-Block Assy .................... 1 ................................. M31300 4 Analytical Gap Adjust and Set ..................... 1 ................................. M31400 5 Electrode Holder Lever Assy ....................... 1 ................................. M31500 6 Electrode Holder Bottom Plate .................... 1 ................................. M31600 7 Sample table Assy ....................................... 1 ................................. M31700 8 Fiber Optic Mount Assy Left ........................ 1 ................................. M31800 9 Fiber Optic Mount Assy Right ...................... 1 ................................. M31900 10 Shaft Disc Electrode L=82mm ...................... 1 ................................. M32408 11 Fan Filter Media 92mm 5 Pack .................... 1 ................................. M33005 12 Fan Filter Assy 92 mm Plastic ..................... 1 ................................. M33004 13 Door Catch (Spectroil M/C-W) ...................... 1 ................................. M33007 Door Catch (Spectroil M/N-W) ...................... 2 ................................. N32610 Screw, Cap ................................................ 2/4 ................................. H10006



Figure 3-5, Sample Excitation Stand, M30000 (continued)

Index Nomenclature Qty Part Number 14 Sample Door Sound Barrier ........................ 1 ................................. M11006 15 Sound barrier Top 255 x 130mm ................. 1 ................................. N33009 16 Sound barrier Left 310 x 150mm ................. 1 ................................. N33011 17 Sound barrier Right 310 x 150mm ............... 1 ................................. M33008 18 Proximity Switch IE5090 ............................... 1 ................................. M33006 Nut, Hex ........................................................ 2 ................................. H10116 19 Sample Stand Drip Tray ............................... 1 ................................. M33012 20 Gasket, Sample Stand Door (Spectroil M/C-W) 1 ................................. M11005 Gasket, Sample Stand Door (Spectroil M/N-W) . 1 ........................................N11005



1

2

3

45

6

78

9

2

2

Figure 3-6, Sample Excitation Stand, Component Mounting Plate, M31000

Index Nomenclature Qty Part Number 1 Sample Stand Plate ...................................... 1 ................................. M31001 2 Screw, Cap .................................................. 3 ................................. H10084 3 Screw, Cap ................................................... 1 ................................. H10121 4 Washer, Flat ................................................ 4 ................................. H10087 5 Washer, Locking, o-star ............................... 4 ................................. H10099 6 Oil Drip Deflector ......................................... 1 ................................. M31100 7 Screw, Cap .................................................. 3 ................................. H10005 8 Washer, Locking, o-star ............................... 3 ................................. H10097 9 Washer, Flat ................................................ 3 ................................. H10085



1011

13

14

15

16

17

18

19

20

21

22 23

1

2

34

5

6

7

8

912

24

25

26

27

28

29

Figure 3-7,Sample Excitation Stand, Rod Electrode Holder and Gap Setting Mechanism, M31200

Index Nomenclature Qty Part Number 1 Electrode Holder V-Block Base ................... 1 ................................. M31201 2 Screw, Cap ................................................... 4 ................................. H10161 3 Washer, Flat ................................................ 4 ................................. H10086 4 Washer, Locking, o-star ................................ 4 ................................. H10092 5 Electrode Holder Gib Plate .......................... 1 ................................. M31202 6 Screw, set, gap adjustment ......................... 2 ................................. H10079 7 Nut, Hex, locking, set screw ........................ 2 ................................. H10122 8 Electrode Holder V-Block ............................. 1 ................................. M31301



Figure 3-7, (continued)Sample Excitation Stand, Rod Electrode Holder and Gap Setting Mechanism, M31200

Index Nomenclature Qty Part Number

9 Electrode Holder Clamp .............................. 1 ................................. M31302 10 Spring Compression D=8 L-21 .................... 1 ................................. M31303 11 Dowel Pin .................................................... 1 ................................. M31304 12 Knob, Rod Electrode clamp ......................... 1 ................................. M31305 13 Screw, Set ................................................... 2 ................................. H10077 14 Electrode Holder Top Plate .......................... 1 ................................. M31401 15 Screw, Cap .................................................. 2 ................................. H10005 16 Electrode Holder Adjust Screw .................... 1 ................................. M31402 17 Washer, Locking, split ring ........................... 1 ................................. H10019 18 Nut, Locking, analytical gap adjustment pin 1 ................................. H10031 19 Electrode Holder Contact Rod ..................... 1 ................................. M31403 20 Screw, Set ................................................... 1 ................................. H10076 21 Nut, Thumb, knurled .................................... 2 ................................. H10045 22 Washer, Locking, o-star ................................ 1 ................................. H10092 23 Electrode Holder Gaping Lever ................... 1 ................................. M31501 24 Screw Slotted Set M4x20 DIN427 ................ 1 ................................. M31502 25 Knob Ball D=15/M4 Blk ............................... 1 ................................. M31503 26 Electrode Holder Bottom Plate ..................... 1 ................................. M31601 27 Screw, Cap ................................................... 2 ................................. H10005 28 Dowel pin DIN7-m6 M3x20 ZnST ................ 1 ................................. M31602 29 Spring OD=5 L=29.5 .................................... 1 ................................. M31603



1

2

3

4

5

6

78

9

10

11

2

Figure 3-8, Sample Excitation Stand, Sample Table Assembly, M31700

Index Nomenclature Qty Part Number 1 Sample Table Mounting Base ...................... 1 ................................. M31701 2 Screw, Cap .................................................. 4 ................................. H10161 3 Sample Table Pedestal ................................ 1 ................................. M31702 4 Sample Table Pedestal Stop Nut ................. 1 ................................. M31703 5 Sample T able Pedestal Level ..................... 1 ................................. M31704 6 Pin, Pivot, shaft elevate ............................... 1 ................................. M31706 7 Screw Slotted Set M4x10 DIN427 ............... 1 ................................. H10123 8 Spring Compression OD=5 L=12 ................. 1 ................................. M31707 9 Ball D=5mm Rust Free ................................. 1 ................................. M31708 10 Sample table................................................. 1 ................................. M31709 11 Screw, Set ................................................... 1 ................................. H10162



1

2

3

45

67

8

20 21 22 23

2

2

2

3

Figure 3-9, Sample Excitation Stand, Optic and Stand Sensor Mounts, M31800

Index Nomenclature Qty Part Number 1 Fiber Optic Mount Left .................................. 1 ................................. M31801 2 Fiber Optic HPF-T001-H (Pkg/2) ................. 8 ................................. M31802 3 Fiber Optic Mount Cover .............................. 2 ................................. M31803 4 Lens / Fiber Barrel L=15 ............................. 1 ................................. M31811 5 Set Screw ..................................................... 1 ................................. H10124 6 Lens UV Grade ............................................. 1 ................................. M31812 7 Lens Retainer / Window Assy ..................... 1 ................................. M31820 8 Fiber Optic Mount Right................................ 1 ................................. M31901



1

23

4

5

67

89

10

11 12

13

144

Figure 3-10, Sample Excitation Stand, Disc Electrode Motor Drive Assembly

Index Nomenclature Qty Part Number 1 Motor / Idler Standoff D12, 7 L...................... 1 ................................. M32001 2 Bearing Inner race 1D5XAD8XL12 .............. 1 ................................. M32002 3 Bearing needle HK0810 .............................. 1 ................................. M32003 4 Washer, Flat, drive belt guide ...................... 2 ................................. H10126 5 Motor / idler Standoff D=12. 7 ...................... 1 ................................. M32006 6 Motor Standoff D=12, 7 L=50 ....................... 2 ................................. M32004 7 Motor 120 VAC 30 RPM DB ......................... 1 ................................. M32101A 8 Screw, Cap .................................................. 6 ................................. H10124 9 Washer, Locking, o-star ............................... 3 ................................. H10092 10 Washer, Flat ................................................ 3 ................................. H10086 11 Pulley Toothed Belt ID=8mm ....................... 1 ................................. M32503 12 Bushing ID=.187” OD=8mm ........................ 1 ................................. M32201 13 Screw, Set ................................................... 1 ................................. H10072 14 Belt Toothed 6T2.5/330 ................................ 1 ................................. M32303



1

23

4

5

67

8

9

10

11

20 21 22 23

8

Figure 3-11,Sample Excitation Stand, Idler Adjustment Assembly, Disc Drive Belt, M32300

Index Nomenclature Qty Part Number 1 Belt Adjustment Idler Base .......................... 1 ................................. M32301 2 Washer, Flat ................................................ 1 ................................. H10086 3 Washer, Locking, o-star ............................... 1 ................................. H10092 4 Screw, Cap .................................................. 1 ................................. H10012 5 Standoff D=13mm L=20mm ........................ 1 ................................. M32302 6 Bearing inner race 1D5XAD8XL12 .............. 1 ................................. M32002 7 Bearing needle HK0810 .............................. 1 ................................. M32003 8 Washer, Flat, drive belt guide ...................... 2 ................................. H10126 9 Washer, Flat ................................................ 1 ................................. H10088 10 Screw, Cap .................................................. 1 ................................. H10015 11 Belt Toothed 6T2.5/330 ............................... 1 ................................. M32303



1

23

4

56

78

9

10

1112

1314

15

16

17

1819

20

91

Figure 3-12, Sample Excitation Stand, Disc Electrode Shaft Mounting Assembly, M32400 and Electrical Contact Brush Assembly, M32500

Index Nomenclature Qty Part Number 1 Commutator Housing.................................... 1 ................................. M32401 2 Washer, Flat ................................................ 2 ................................. H10086 3 Washer, Locking, o-star ............................... 2 ................................. H10092 4 Screw, Cap .................................................. 2 ................................. H10012 5 Bearing Ball ID=4 D=13 624-2Z ................... 1 ................................. M32402 6 Clip, Retaining, expansion, front bearing ..... 1 ................................. H10130 7 Oil Seal 340872 ............................................ 1 ................................. M32403 8 Commutator f/M ............................................ 1 ................................. M32404 9 Bearing Ball ID=6 OD=19 626-2Z................. 2 ................................. M32405 10 Clip, Retaining, expansion, rear bearing ..... 1 ................................. H10131 11 Pulley Toothed Belt ID=6mm ....................... 1 ................................. M32406 12 Screw, Set ................................................... 1 ................................. H10072 13 Shaft Adjust Screw M4x25mm ..................... 1 ................................. M32407 14 Nut, Hex ....................................................... 1 ................................. H10127 15 Shaft Disc Electrode L=82mm ..................... 1 ................................. M32408 16 Brush Holder................................................. 1 ................................. M32501 17 Brush Carbon w/Spring ............................... 1 ................................. M32502 18 Washer, Flat ................................................ 2 ................................. H10086 19 Washer, Locking, o-star ............................... 1 ................................. H10092 20 Screw, Cap .................................................. 1 ................................. H10012



12

3

4

5

6 78

9

10

11

12 (not shown)

13

14

15

Electromagnetic Deflection Screw

(EMDS)

Figure 3-13, Source, Solid State, Combined M99966A-RFS Source, Solid State ARFS229

Index Nomenclature Qty Part Number 1 Diode Bridge ................................................. 1 ................................. M43004 2 Resistor 50R 1% 50W .................................. 2 ................................. P10789 3 Resistor 5R 1% 50W .................................... 1 ................................. M41605 4 Capacitor 10µf 370 VDC ............................ 1 ................................. M45301 5 Cable W33 Source freq K4 to Pu ................. 1 ................................. M45302 6 Resistor Power, RH-25, 3000 ohm .............. 1 ................................. M45303 7 Cable Disc Electrode Shaft Brush ............... 1 ................................. M45304 8 Inductor Isolation , ........................................ 1 ................................. M45305 9 Cable Rod Electrode ................................... 1 ................................. M45306 10 Fan Auxiliary Gap ......................................... 1 ................................. P10169 11 Electrode Tungsten 25mm............................ 2 ................................. M41402A 12 Fiber Optic HPF-T001-H (not shown) ........... 1 ................................. M31802 13 Resistor 25R 25W Wirewound ..................... 1 ................................. M91904 14 Capacitor 50 pf 30 KV .................................. 1 ................................. M45308 15 HV Pulser f/Stand Alone Source................... 1 ................................. M99907



9

10

11

12

13

14

1

2

3

4

5

6

7

8

(Spectroil with A-RFS Only)

Figure 3-14, Sample Excitation Source

Index Nomenclature Qty Part Number 1 Source, Solid State, Combined .................... 1 ................................. M99966 2 Cable W7 Source Power LF2/P4.................. 1 ................................. M45100 3 Motor Assy ................................................... 1 ................................. M32100 4 Belt Toothed 6T2.5/330 ............................... 1 ................................. M32303 5 Brush Assy ................................................... 1 ................................. M32500 6 Brush Carbon w/Spring ............................... 1 ................................. M32502 7 Assy Disc Electrode Shaft Mounting ........... 1 ................................. M32400 8 Assy Cable Rod Electrode ........................... 1 ................................. M45306 9 Assy Cable, Disc Electrode Shaft Brush ..... 1 ................................. M45304 10 Switch Interlock 2AC59 ................................ 1 ................................. M20009 11 ID Plate Input Power..................................... 1 ................................. M29000 12 Fuse F1, 5x20mm or 6.3x32mm, 250 VAC 2.0 AMP, Type T (Time Delay) ..................... 1 ................................. M99906 13 Fuse F2, 5x20mm or 6.3x32mm, 250 VAC 1.0 AMP, Type F (Fast Acting) ...................... 1 ................................. M22004 14 ARFS Power Supply Switching Module, CE RoHS .......................... ARFS228



1

2

3

4

5

6 7

Figure 3-15, OilM Windows® Readout and Data Management System

Index Nomenclature Qty Part Number 1 Switch 16mm DPDT Maintained Toggle ................... 1 ..................... M68118 2 Switch 16mm DPDT Momentary Push Button Grn ... 1 ..................... M68119 3 Switch 16mm DPDT Momentary Push Button Red .. 1 ..................... M68120 4 Keyboard w/Cable .................................................... 1 ..................... M68156 5 Readout Panel PC ................................................... 1 ..................... M68155 6 CD ROM Drive Sim CD R-RW ................................. 1 ..................... M68101 7 Iomega Zip 250 Drive ............................................... 1 ..................... M68226 or Floppy Drive 144MB (special request) .................... 1 ..................... M62002



12

91011

12 3 45

6

7

8

Figure 3-16a, OilM Windows® Readout System Panel Open(Pre-August 2009)

Index Nomenclature Qty Part Number 1 Cable Single Floppy Interface f/PPC ............ 1 ................................. M68103 2 Readout Panel PC ........................................ 1 ................................. M68155 3 Hard Drive Slim ............................................ 1 ................................. M68121 4 Cable IDE Dual Connector f/PPC ................. 1 ................................. M68129 5 Internal Slim CD-ROM Adapter .................... 1 ................................. M68102 6 COMPACT USB 4-Port Hub ......................... 1 ................................. P10613 7 Panel Coupler USB A to Cable 1 .................. 2 ................................. M68148 8 Cable, Ethernet Crossover, 5 feet ................ 1 ................................. P10612 9 Cable LPT1 DB-25 to DB-25 ........................ 1 ................................. M68131 10 Cable Com2 Straight Thru 3’ ........................ 1 ................................. M68128 11 Cable Null Modem 44” .................................. 1 ................................. M68133 12 Fuse ATM-4 4.0A Blade ................................ 1 ................................. M68158



1

23

Figure 3-16b, OilM Windows® Readout System Panel Open(Spectroils Manufacture after August 2009)

Index Nomenclature Qty Part Number

1 Readout Panel PC ........................................ 1 ................................. M68720 2 USB to PS2 Adapter ..................................... 1 ................................. M68278 3 TKA Adapter ................................................. 1 ................................. M68213



1 2

3

4

5

Figure 3-17, OilM Windows® Readout System, Top View

Index Nomenclature Qty Part Number 1 Power Supply, 100-240V/50-60Hz 24V 3.2A 1 ................................. LF9047 2 Power Supply, NFS110-7602P ..................... 1 ................................. M59310 3 Fuse F4, 5x20mm or 6.3x32mm, 250 VAC 5.0 AMP, 3AG (Fast Acting ) (Non CE Version) ........ 1 ..................... M59400 5.0 AMP 20mm (CE Version Only) ............... 1 ................................. P10453 4 Cable, Power Supply to TB2 ........................ 1 ................................. M68172 5 Cable, Power Supply to PC Panel ................ 1 ................................. M68171



1 2 3 45

Figure 3-18 Controller Assembly, Top View

Index Nomenclature Qty Part Number 1 Fiber, Optical 0.06 M ................................................ 1 ..................... 75-190040 2 CCD Optical Assembly ............................................ 2 .................... 76-070039 3 Circuit Card EK-0310, Controller Data Acquisition ... 1 ..................... M59202 4 Circuit Card, EK-0311 DSP Ethernet Controller ...... 1 ..................... M59204 5 Circuit Card AD-Converter (inside optical assy) ....... 1 ..................... M59203



1 2 3 45

6

Figure 3-19, Circuit Board, Interlock Monitor Assembly

Index Nomenclature Qty Part Number 1 Circuit Card, I-lock & Power Monitor Assy ................ 1 ..................... M59210 2 Fiber Optic Sensor Assy GAP ................................. 1 ..................... M59126 3 Fiber Optic Sensor Assy DISC ................................ 1 ..................... M59127 4 Fiber Optic Sensor Assy ROD .................................. 1 ..................... M59128 5 Fiber Optic Sensor Assy SAMPLE ........................... 1 ..................... M59129 6 Circuit Card, Measurement & Control EK0014B ...... 1 ..................... M59205



1

2

Figure 8-23 a and b, Optical Profile Knob Assembly, Outside and Internal ViewsFigure 3-20, Optical Fiber and Entrance Slit (With & Without Cover))

Index Nomenclature Qty Part Number 1 Fiber, Optical 0.6 M ...................................... 1 ................................. 75-190040 2 CCD Optical Assembly ................................ 1 ................................ 76-070039



9

1

2

3

4(in Fuse holder)

5

78

6(in Fuse holder)

Figure 3-21a, Input Power Distribution Assembly, Panel , Standard Spectroil M

Index Nomenclature Qty Part Number 1 Instrument ID Plate Military-1 ...................... 1 ................................. M12902 2 Circuit Breaker 2P/10A 1P50A...................... 1 ................................. M22001 3 Fuse Holder 3AG Panel Mount..................... 1 ................................. M22002 4 Fuse 3AG 2.5A SLO-BLO............................ 1 ................................. MR9133 5 Fuse Holder 3AG Panel Mount..................... 1 ................................. M22002 6 Fuse 3AG 1.0A ............................................. 1 ................................. M22004 7 Connector Assy J2 Sharpener ...................... 1 ................................. N23002 8 Connector Assy J1 Main Power ................... 1 ................................. M23000 9 ID Plate Input Power..................................... 1 ................................. M29000 Power Cord W1 f/M 115 Volt (not shown) ..... 1 ................................. M25000



7

8

1

2

3

4

56

9

10

Figure 3-21b, Input Power Distribution Assembly, Panel, CE Version of Spectroil M

Index Nomenclature Qty Part Number 1 Instrument ID Plate Military-1 ...................... 1 ................................. M12902 2 Circuit Breaker 2P/10A 1P50A...................... 1 ................................. M22001 3 Fuse F1, 5x20mm or 6.3x32mm, 250 VAC 2.5 AMP, Type T (Time Delay) ..................... 1 ................................. M37050 Fuse Holder .................................................. 1 ................................. P10389 Fuse Holder Knob......................................... 1 ................................. P10389 4 Fuse F2, 5x20mm or 6.3x32mm, 250 VAC 1.0 AMP, Type F (Fast Acting) ...................... 1 ................................. P10451 Fuse Holder .................................................. 1 ................................. P10389 Fuse Holder Knob......................................... 1 ................................. P10389 5 Connector Assy J2 Sharpener ...................... 1 ................................. N23011 Connector Cap & Chain................................ 1 ................................. P01438 6 Connector Assy J1 Main Power ................... 1 ................................. M23000 Connector Cap & Chain................................ 1 ................................. P01438 7 ID Plate Input Power..................................... 1 ................................. M29100 8 Power Cord W1 ........................................... 1 ................................. M25010 9 CE Compliance Lable ................................... 1 ................................. P10460



1

2

3

4

Figure 3-22, Accessory Panel and Signal Plate Connections, Standard Spectroil M and CE Version of Spectroil M

Index Nomenclature Qty Part Number 1 IDPlatePeripheralandPower..............................1.....................................M69501 IDPlatePeripheralandPower(CEversion)........1.....................................M69502 2 PanelCouplerRJ45E-NetShielded....................1.....................................M68117 3 FuseF3,5x20mmor6.3x32mm,250VAC 1.5AMP,TypeF(FastActing)............................1.....................................P10452 FuseHolder...........................................................1.....................................M59406 FuseHolder(CEversion).....................................1.....................................P10389 FuseHolderKnob.................................................1.....................................P10389 4 Receptacle,PrinterPower.....................................1.....................................M69602 ConnectorAssemblyJ3(CEversion)...................1.....................................N72710 CapforConnectorAssembly(CEversion)..........1.....................................P10438



8 3

1

2

4

5

6

7

Figure 3-23a, Input Power Distribution Assembly, Internal View, Standard Spectroil M

Index Nomenclature Qty Part Number 1 Transformer Lenco CVS-500 125V ............. 1 ................................. M24000 2 Line Filter 10VN1 .......................................... 1 ................................. N44000 3 Capacitor 20µF 660VAC 60Hz .................... 1 ................................. M27000 4 Contactor DILEM-10-G 24V 4PNO............... 6 ................................. M21002 5 Auxiliary Contact 11 DIL EM ........................ 2 ................................. M21005 6 Circuit Breaker 2P5/10A 1P50A.................... 1 ................................. M22001 7 CCD Optical Assembly ................................ 1 ................................ 76-070039 8 Source, Solid State Comb1ned .................... 1 ................................. M99966



1

2

3

5

6

4

7 (hidden)

Figure 3-23b, Input Power Distribution Assembly, Internal View, CE Version of Spectroil M

M, M/C, M/F, M/NIndex Nomenclature Qty Part Number 1 TransformerRegulating125V(BehindPanel).....1.....................................M24002 2 LineFilter10VN1................................................1.....................................N44000 3 Capacitor20µF660VAC60Hz............................1.....................................M27000 4 ContactorDILEM-10-G24V4PNO....................6.....................................M21002 5 AuxiliaryContact11DILEM.............................2.....................................M21005 6 CircuitBreaker2P5/10A1P50A...........................1.....................................M22001 7 TimerRelay,K7....................................................1.....................................P10447



This Page is Intentionally Left Blank



4.0 OPERATIONAL AND MAINTENANCE ILLUSTRATIONS

4.1 INTRODUCTION

This section contains Spectroil M/N-W, Spectroil M/C-W, Spectroil M/F-W and Spectroil M/F-LD schematic diagrams and illustrations to assist with operational maintenance procedures.

All diagrams and illustrations are for the above Spectroil M versions with Mod. 6 (CCD optics) and Mod. 7 (CE hardware).

Chapter 4

Operational and

Maintenance Illustrations



4.2 ILLUSTRATIONS

The following diagrams are provided in this section:

Title Section#Simplified Block Diagram 4.2.1Interconnection Wiring Block Diagram 4.2.2Input Power Distribution Block Diagram 4.2.3Input Power Distribution Diagram 4.2.4Placement of Power Switching Contactor Assembly 4.2.5Regulating Power Transformer Assembly Wiring 4.2.6Sample Stand Block Diagram 4.2.7Excitation Source Block Diagram 4.2.8Excitation Source with DC Capability for RFS Analysis Block Diagram 4.2.9Excitation Source / Sample Stand Schematic Diagram 4.2.10Excitation Source for RFS Analysis / Sample Stand Schematic Diagram 4.2.11Control Panel Assembly Block Diagram 4.2.12Control Panel Assembly Schematic Diagram 4.2.13Connector Position for M59205 Measurement & Control Circuit Card 4.2.14Connector Position for M59210 Interlock & Power Monitor Circuit Card 4.2.15Terminal Board 2 Wiring Diagram 4.2.16Computer Controller Block Diagram 4.2.17Computer Controller Wiring Diagram 4.2.18Polychromator Optic Block Diagram 4.2.19External Data Transmission Cable for External Computer with 9 Pin Serial Port 4.2.20External Data Transmission Cable for External Computer with 25 Pin Serial Port 4.2.21Spectroil M Dimensions and Mounting Details 4.2.22

110 | Chapter 4 Operational and Maintenance Illustrations


400 mm POLYCROMATOROPTICAL ASSEMBLY

HEAT EXCHANGER ASSEMBLY120 VAC 50/60 HZ

EXCITATION SOURCEASSEMBLY

INCOMING POWER

READOUT PANEL ASSEMBLY

CONTROL & MEASUREMENTELECTRONICS

SAMPLE STANDASSEMBLY

K1 K2K3 K4

K5 K6

T1

POWER DISTRIBUTIONASSEMBLY

PPC P.S.+24VDC

POWER SUPPLY+12 VDC / -12 VDC+ 5 VDC / +24 VDC

VOLT & FREQDETECTION

INTERLOCKMONITORS

EK-0014MEASUREMENT/CONTROL

INTERFACE BOARD

IMPA

4.2.1 Simplified Block Diagram



EK-0

310

EK-0

011

MAI

N IN

PUT

POW

ER12

0/24

0Va

c50

/60

Hz

ELEC

TRO

DE

SHAR

PENE

R12

0VA

C50

/60

Hz

P

DOO

RSW

ITCH

IS1

EXH

AUST

FAN

M3

SAM

PLE

STA

ND

ASSY

M30

000

TODISCELECT.

TORODELECT.

W19

INPU

TPW

RD

ISTR

IBU

TIO

NAS

SYM

2000

0LF

-3

LF-4

LINE

FILT

ERLF

-1

K112

0Va

c

K4 60H

zK6

OPE

RATE

K5SO

URC

EK3 50

Hz

120/

240

REG

XFM

RT1

CIRC

UIT

BREA

KER

CB1

W9

P-4

J-4

W7

W8

LINEFILTERLF-2

TB3

K224

0Va

c

P-1J-1

P-2

J-2

P

EXC

ITAT

ION

SO

UR

CE

ASSY

M99

962

ARFSOPTIONENABLEARFSSWPS

J5J5 J20 J18 J3 J1

J22

J21

J14

J13

J11

J10

J19J16J9J12

J2J6J7J8J17

J15

DO

OR

I-LO

CK

IS1

SOU

RC

E O

N K

5

RO

BO

T O

PTIO

N-A

RM

FOR

WAR

D

RO

BO

T O

PTIO

N-S

TAR

T B

UR

N

240

VAC

K2

120

VAC

K1

60 H

Z K

4

50 H

Z K

3

SAMPLE

DO

OR

I-LO

KST

ATU

SB

IT

SOU

RC

EEN

ABLE

GAP

DISC

ROD

SEN

SOR

S A

ND

RO

BO

T FU

NC

TIO

NTC

T O

PTIO

N

120/

240

VAC

INPU

T12

0/24

0 VA

C IN

PUT

+/-1

2 VD

C

ANA

LOG

FR

EQ

ANA

LOG

VO

LT

+24

VDC

I-LO

CK&

PWR

MO

NITO

RAS

SYM

5921

0

ST1

ST2

ST1

ST5

ST20

ST6

ST19

ST18

ST17

ST7

ST8

ST21

ST22

ST29

ST9

ST10

ST23

OPT1

ST32

ST11

ST12

ST13

ST14

ST15

ST16

ST4

ST3

ST30

OPE

N

RO

BO

T EN

ABL

E

TCT

OPT

ION

TCT

OPT

ION

ARFS

EN

ABLE

TEM

P SE

NSO

R U

V O

PTIC

OPT

ION

OPE

N

ANA

LOG

FR

EQ IN

PUT

TEM

P SE

NSO

R A

IR O

PTIC

ANA

LOG

VO

LT IN

PUT

SEN

SOR

S A

ND

RO

BO

T FU

NC

TIO

N

OPT

IC S

ENSE

AN

DC

ON

TRO

L

+24

VDC

AIR

OPT

IC H

EATE

R

UV

OPT

IC H

EATE

R

DOORI-LOK

OPEN

STARTSW

STOPSW

OPEN

OPEN

OPEN

OPEN

MEA

SURE

MEN

TAN

DCO

NTRO

LEK

-001

4

FANINSIDEAIR

OPTIC

FAN

OU

TSID

EAI

R O

PTIC

FAN

FAN

RES

ISTI

VE H

EATE

RS

TEM

PER

ATU

RE

SEN

SOR

S

S.S.

MO

NITO

RRO

DEL

ECTR

ODE

S.S.

MO

NITO

RDI

SCEL

ECTR

OD

ES.

S.M

ONI

TOR

ANAL

YTIC

AL G

AP

S.S.

MO

NITO

RSA

MPL

EC

AP

K4-5

TB2-

L2

IS2-C

K6/A1CB1P3-C

123456789

1011

141516

L2L2

NN

PE

F4

PE

NN

L1L1

TB2

1213

17

J1

120/

240

Vac

POW

ERSU

PPLY

PS-1

+5Vd

c/G

ND

+/-1

2Vdc

/GND

+24V

dc/G

ND

CN1

120/

240

VacPO

WER

SUPP

LYPS

-2+2

4Vdc

/GND

OPT

OXM

IT/R

ECV

FIBE

RS

125V

AC

REG

ULA

TED

W10

85-2

65 V

AC

50/

60 H

Z (U

NR

EG)

W5

J-18

P-18 US

BUS

B

250MBZIPDRIVE

CD-ROMDRIVE

W26

W27

P-8

J-8

STAR

T/ST

OP/

MO

DESW

W31

W11

J-6P-6

W24

PRIN

TER

120

Vac

P-3J-3

LF-5

LF-6 W

17

ETH

ERNE

T

W3

W21

W25

W28

REA

DO

UT

PAN

ELAS

SEM

BLY

HEA

TEX

CH

ANG

ERA

SSY

HE-

1

W33

W1

W2

W2

W2

W16

W4

W12

W13

W15

W14

W18

W15

W23

W22

W22

W20

W2

W26

W32

EXTE

RN

ALC

ON

TRO

LLER

SER

IAL

POR

TC

OM

2

PAR

ALLE

LPO

RT

LPT

1

400

mm

POLY

CH

RO

MAT

OR

OPT

ICA

SSY

CC

D O

PTIC

ALR

EAD

OU

TAS

SY

J2

W34

PAN

ELPC

W35

4.2.2 Interconnection Wiring Block Diagram



4.2.3a. Input Power Distribution Block Diagram, Standard Spectroil M



4.2.3b. Input Power Distribution Block Diagram, CE Version of the Spectroil M



4.2.4a. Input Power Distribution Diagram, Standard Spectroil M



3 5 13

4 6 14

21 31 5 13

2 4 6 14K2

240

Vac

K1

120

Vac

31 5

2 4 6

1314 K4

60 H

z

31 5 13

2 4 6 14K3

50 H

z

3334

3334

C1

20U

F66

0V

AC

31 5 13

2 4 6 14 K6

Ope

rate

+24

Vdc

+24

Vdc

+24

Vdc

+24

Vdc +24

Vdc

12

34

56

78

910

1211

13

GN

D

T1

120/

240

Vac

Reg

ulat

ing

Xfm

r

31 5 13

2 4 6 14 K5

Sou

rce

ON

+24

Vdc

250

Vac

P1-

A

P2-

A

P3-

A

P1-

B

P2-

B

P3-

B

P1-

C

P2-

C

P3-

C

P3-

D

TO

TIM

E D

ELA

Y R

ELA

Y K

7

TO

SA

MP

LE S

TAN

DE

XH

AU

ST

FA

NF

1

FR

OM

TB

2-2

(GN

D)

FR

OM

TB

2-3

(+24

VD

C)

TO

TB

2-P

E

CN

.C.

C

N.C

.

IS2

SO

UR

CE

TO

PP

AN

EL

IS3

SO

UR

CE

SID

E P

AN

EL

PA

NE

LIN

TE

RLO

CK

S

TO

TB

2-L2

FR

OM

TB

2-L2

TO

TB

2-N

PA

RT

OF

TB

2

BLU

E T

ER

M.

W19

TO

TB

2-L1

TO

TB

2-N

AU

X C

ON

T.

AU

X C

ON

T.

FR

OM

TB

2-N

B C

LIN

EF

ILT

ER

LF1

NH

P/J

-1 A B CG

ND

W1 P

/J-2 A

FR

OM

M59

200

ST

6

FR

OM

WIN

DO

WS

RE

AD

OU

T A

SS

YM

6810

0S

5-N

.C.

F4

5.0

A25

0 V

ac

FR

OM

M59

200

ST

4

FR

OM

M59

200

ST

3

FR

OM

M59

200

ST

5

FR

OM

M59

200

ST

17

F2

1.0

A25

0 V

ac

MAIN INPUT POWER120/240 VAC, 50/60 HZ

ROD ELECTRODESHARPENER

POWER OUTPUT120 VAC, 50/60 HZ

F1

2 A

SLO

-BLO

LF3

LF4

CB

1

2122

AU

X C

ON

T.

T

O E

XC

ITA

TIO

N

SO

UR

CE

AS

SY

M

9996

2

W33

W33

3334

AU

X C

ON

T.

2122

4.2.4b. Input Power Distribution Diagram, CE Version of the Spectroil M



L11

3L2

5L3

13N

OA1

+

T12

4T2

6T3

14A2

_

01

+ -D

IL E

M-1

0-G

Klo

ckn

er

Moe

ller

NC

2133

NO

2234

11 D

IL E

M0

1

L11

3L2

5L3

13N

OA1

+

T12

4T2

6T3

14A2

_

01

+ -D

IL E

M-1

0-G

Klo

ckn

er

Moe

ller

NC

2133

NO

2234

01

L11

3L2

5L3

13N

OA1

+

T12

4T2

6T3

14A2

_

01

+ -D

IL E

M-1

0-G

Klo

ckn

er

Moe

ller

L11

3L2

5L3

13N

OA1

+

T12

4T2

6T3

14A2

_

01

+ -D

IL E

M-1

0-G

Klo

ckn

er

Moe

ller

K1K2

K3K4

L11

3L2

5L3

13N

OA1

+

T12

4T2

6T3

14A2

_

01

+ -D

IL E

M-1

0-G

Klo

ckn

er

Moe

ller

K6

L11

3L2

5L3

13N

OA1

+

T12

4T2

6T3

14A2

_

01

+ -D

IL E

M-1

0-G

Klo

ckn

er

Moe

ller

K5K5 -

SOU

RC

EK6

- O

PER

ATE

K1 -

120

VAC

K2 -

240

VAC

K3 -

50 H

Z(IN

CLU

DES

AU

XILI

ARY

CO

NTA

CTM

OD

ULE

)

K4 -

60 H

Z(IN

CLU

DES

AU

XILI

ARY

CO

NTA

CTM

OD

ULE

)

11 D

IL E

M

4.2.5.a. Placement of Power Switching Contactor Assembly, Standard Spectroil M



4.2.5.b. Placement of Power Switching Contactor Assembly, CE Version of the Spectroil M



GND 1 2 3 4 5 6 7 8 9 10 11 12 13

INPUT120V, 60HZ

TIE 1 TO 4, 2 TO 5APPLY 120V FROM 1 + 4 TO 2 + 5

INPUT120V, 50HZ

TIE 1 TO 4, 3 TO 6APPLY 120V FROM 1 + 4 TO 3 + 6

INPUT240V, 60HZ

TIE 2 TO 4APPLY 240V FROM 1 TO 5

INPUT240V, 50HZ

TIE 3 TO 4APPLY 240V FROM 1 TO 6

125 V, 50 HZ500 VA125V60 HZ500VA

CAPACITOR20 UF, 600 V 60 HZ

CAPACITOR20 UF, 600 V 50 HZ

T1120 VAC / 240 VAC, 50 HZ / 60 HZ

REGULATING TRANSFORMER ASSEMBLYCVS-500-120-240-50-60-125

P/N M24000

4.2.6.a. Regulating Power Transformer Assembly Wiring, Standard Spectroil M



Input Connect Input Line120V, 60Hz 1 to 4; 2 to 5 1 and 4120V 50Hz 1 to 4; 3 to 6 1 and 3240V, 60Hz 2 to 4 1 and 5240V, 50Hz 3 to 4 1 and 6

Output Voltage Terminals Capacitor125V, 60Hz, 500VA 7 and 8 --125V, 50Hz, 500VA 7 and 9 --

600V, 60Hz 10 and 11 20 microfarad600V, 50Hz 12 and 13 20 microfarad

20 uf 20 uf

4.2.6.b. Regulating Power Transformer Assembly Wiring, CE Version of the Spectroil M



4.2.7 Sample Stand Block Diagram



4.2.8 Excitation Source Block Diagram



4.2.9 Excitation Source with DC Capability for RFS Analysis Block Diagram



4.2.10 Excitation Source / Sample Stand Schematic Diagram



4.2.11 Excitation Source with DC Capability for RFS Analysis / Sample Stand Schematic Diagram



4.2.12 Control Panel Assembly Block Diagram



Drawing being revised, contact Spectro Inc. for latest version or an update to this manual

4.2.13 Control Panel Assembly Schematic Diagram



4.2.14 Connector Position for M59205 Measurement & Control Circuit Card

Connector Connected to:ST1 DIN Measurement Bus (DMB)ST2 Power Supply 24V DCST3ST4 D2R2 EnableST5 Heating Air OpticsST6 Heating Sulfur Optic (Optional)ST7 Door Interlock IMPA J19 ST8ST11 Analog Voltage IMPA J20ST12 Temperature Sensor Air OpticST13 Analog Frequency IMPA J18ST14ST15 Temperature Sensor Sulfur Optic (Optional)ST17 A-RFS EnableST18 Extraction Fan (Outside Optic)ST19 Agitation Fan (Inside Optic)ST20 Source Enable IMPA J16ST21 Start ButtonST22 Stop ButtonST30 TCT IMPA J22 ST32 Sensors + D2R2 IMPA J21



4.2.15 Connector Position for M59210 Interlock & Power Monitor Circuit Card

Connector Connected to:J1 AC Line Sensing inputJ2 K1 120VAC RelayJ3 +/- 12VDC InputJ4 Latching JumpersJ5 + 24VDC InputJ6 K2 240VAC RelayJ7 D2R2 StartJ8 D2R2 Sample ForwardJ9 K3 50Hz RelayJ10 Sample Sensor J11 Gap SensorJ12 K4 60HzJ13 Disc SensorJ14 Rod SensorJ15 K5 Source RelayJ16 ST19 on EK0014 (Source Enable)J17 Door InterlockJ18 Analog Frequency EK0014 ST13J19 Door Interlock signal EK0014 ST7J20 Analog Voltage EK0014 ST11J21 Sensor Signals EK0014 ST32J22 TCT Signal EK0014 ST30



1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 L2 L2 N N N PE

(GRN

)PS-

1,CN

4-4

GND

(BLK

)PS-

1,CN

4-13

+24

Vdc

(BLK

)PS-

1,CN

4-11

-12

Vdc

(GRN

)PS-

1,CN

4-5

GND

(BLK

)PS-

1,CN

4-8

+12

Vdc

(GRN

)PS-

1,CN

4-6

GND

(GRN

)PS-

1,CN

4-7

GND

(BLK

)PS-

1,CN

4-1

+5Vd

c

(BLK

)PS-

1,CN

4-2

+5Vd

c

(BLK

)PS-

1,CN

4-3

+5Vd

c

(GRN

)P8-

4G

ND(G

RN)M

5921

0IP

MA,

P5-2

GND

(BLK

) IS2

-CO

MG

ND

(BLK

)M59

210

IPM

A,P5

-1+2

4Vd

c(B

LK)C

B1P3

-C

(RED

)K6-

A1(B

LK)E

K-00

14,S

T2-1

(BLK

)P6-

4,-1

2Vd

c

(GRN

)P3-

2G

ND(G

RN)P

6-6,

GND

GRN

)P8-

11,G

ND

(GRN

)P6-

5G

ND

(BLK

)P3-

1,+1

2Vd

c(B

LK)P

6-3

,+12

Vdc

(BLK

)P8-

12,+

12Vd

c(G

RN)P

6-7,

GND

(GRN

)P6-

8, G

ND(G

RN)P

8-10

, G

ND

(BLK

)P6-

11,+

5Vd

c(B

LK)P

6-10

,+5

Vdc

(BLK

)P8-

9,+5

Vdc

(BRN

)J3-

A(B

RN)P

18-1

(BLU

)J3-

B(B

LU)P

18-2

W3

(GRN

/YEL

)PS-

1,CN

1-1

(GRN

/YEL

)P18

-3

(BRN

)M59

210

IPM

A,P1

-1

(BLU

)M59

210

IPM

A,P1

-3(B

LU)P

S-1,

CN1-

2

W4

W6

W5

TB2-

L2K4

-5

PE L1

1

2

F45.0A

(BRN

)TB2

,F4-

2

(BRN

)M20

000,

K6-1

120/

240

Vac

Reg

(BLU

)M20

000,

T1-7

(BLU

)M20

000,

PE-N

GND

(GRN

)M20

000,

LF1-

CHAS

SIS

GND

(BRN

)M20

000,

K2-1

(BLU

)M20

000,

K2-1

312

0/24

0Va

c

120/

240

Vac

NEUT

RAL

(BLU

)M20

000,

J2-B

(BLU

) M20

000,

LF2-

2

TOLA

MBD

ACO

MPU

TER

POW

ERSU

PPLY

PS-1

TOHE

ATEX

CHAN

GER

HE-1

TOI-L

OK

&PW

RM

ONI

TOR

ASSE

MBL

YM

5921

0

TOPR

INTE

R/DA

TAST

ATIO

NP-

3

L1 N

(BLU

)PS-

2,AC

NEUT

RAL

(BRN

)PS-

2,AC

LINE

(BLK

)PS-

1,CN

4-9

+12

Vdc

(GRN

)EK-

0014

ST2-

2 G

ND

(BLK

)P3-

3,-1

2Vd

c

(BLK

)P6-

2,+5

Vdc

(BLK

)P6-

12,+

5Vd

c

(GRN

/YEL

)J3-

C

(BRN

)PS-

1,CN

1-3

(GRN

/YEL

)M59

210

IPM

A,P1

-2(G

RN/Y

EL)P

S-2

FG(F

RAM

E G

ND)

4.2.16 Terminal Board 2 Wiring Diagram




4.2.17 Computer Controller Block Diagram




4.2.18 Computer Controller Wiring Diagram




4.2.19 Polychromator Optic Block Diagram



SPECTROILMODEL M

COM PORT 1

2

6

TRANSMIT 3

4

9 PIN AMPCONNECTORFEMALE


DATA TRANSMISSION SPECIFICATIONS

BAUD RATE = 9600 PARITY= NONE DATA BITS = 8 STOP BIT = 1

CLEAR TO SEND

5 5

REQ. TOSEND

3RECEIVE

DSR

2 DATAOUT

DATAIN

IBM/COMPACOR EQUIVALENT

MS-DOS SYSTEMSRS-232 SERIAL PORT

DTR

7

8

SIGNALGROUND

SIGNALGROUND

4.2.20 External Data Transmission Cable for External Computer with 9 Pin Serial Port



4.2.21 External Data Transmission Cable for External Computer with 25 Pin Serial Port



SPECTROILMODEL M

COM PORT 1

2

6

TRANSMIT 2

20



DATA TRANSMISSION SPECIFICATIONS

BAUD RATE = 9600 START BIT = 1 DATA BITS = 8 STOP BIT = 1

CLEAR TO SEND

5 7REQ. TOSEND

3RECEIVE

DSR

3 DATAOUT

DATAIN

IBM/COMPACOR EQUIVALENT

MS-DOS SYSTEMSRS-232 SERIAL PORT

DTR

7

8

4.2.22 Spectroil M Dimensions and Mounting Details



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