6. airnet ii service manual

8/19/2019 6. Airnet II Service Manual

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September 23, 2009

IRNET ® II

P RTICLE COUNTERService Manual

Author: Jerry Swinford

www.pmeasuring.com


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September 23, 2009Page ii

Airnet ® is a registered trademark of Particle Measuring Systems, Inc.Molex ® is a registered trademark of Molex Corporation

All trademarks appearing in this manual are the property of their respective owners.

DO NOT REPRODUCE OR DISTRIBUTECONFIDENTIAL INFORMATION

FOR INTERNAL PMS USE ONLY This confidential document contains proprietary information, which is protected bycopyright. All rights are reserved. No part of this document may be reproduced,distributed, or transmitted in any form without the prior written consent of ParticleMeasuring Systems. The information contained in this document is subject to changewithout notice.

© 2009 by Particle Measuring Systems, Inc.All Rights Reserved


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Table of Contents

1 PURPOSE ................................................................................................................... 1

2 INTRODUCTION ...................................................................................................... 2

3 RELATED DOCUMENTS........................................................................................ 3

4 AIRNET II FEATURES ............................................................................................ 4

4.1 Connector Panel ................................................................................................................................ 4

4.2 Status & Activity LEDs .................................................................................................................... 5

4.3 Flow Pressure Sensors ...................................................................................................................... 5

5 SYSTEM COMPONENTS ........................................................................................ 6

5.1 Processor Board (1000013669) ........................................................................................................ 7 5.1.1 Connector Pinouts ....................................................................................................................... 7

5.1.1.1 CO12....................................................................................................................................... 7 5.1.1.2 CO3 Detector Board ............................................................................................................... 8 5.1.1.3 CO10 4-20mA Board .............................................................................................................. 8 5.1.1.4 CO11 Pulses ........................................................................................................................... 8 5.1.1.5 CO6 RS-232 ........................................................................................................................... 9 5.1.1.6 CO8 Ethernet .......................................................................................................................... 9 5.1.1.7 CO7 BDM .............................................................................................................................. 9 5.1.1.8 CO9 Power & Thresholds ....................................................................................................... 9

5.1.2 Power Supplies ......................................................................................................................... 10 5.1.2.1 Power over Ethernet (PoE) ................................................................................................... 10

5.2 Detector Board (1000013676) ........................................................................................................ 10

5.3 Laser Board (1000013943) ............................................................................................................. 11

5.4 4-20 mA Board (1000013684) ........................................................................................................ 11

5.5 Cabling ............................................................................................................................................ 12

6 DISASSEMBLY ....................................................................................................... 13

7 ASSEMBLY .............................................................................................................. 15

8 TEST POINTS .......................................................................................................... 16

8.1 Processor Board .............................................................................................................................. 16


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8.2 Laser Board ..................................................................................................................................... 16

8.3 Detector Board ................................................................................................................................ 16

8.4 4-20mA Board ................................................................................................................................. 17

9 COMPONENT REPLACEMENT PROCEDURES ............................................. 18

9.1 Processor Board (1000013669) ...................................................................................................... 18

9.2 Detector Board (1000013676) ........................................................................................................ 18

9.3 Laser Board (1000013943) ............................................................................................................. 18

9.4 4-20 mA Board (1000013684) ........................................................................................................ 18

10 TROUBLE SHOOTING ...................................................................................... 19

10.1 Power ............................................................................................................................................... 19 10.1.1 +5V ........................................................................................................................................... 19 10.1.2 +3.3V ........................................................................................................................................ 19 10.1.3 +1.8V ........................................................................................................................................ 19 10.1.4 +12V ......................................................................................................................................... 19 10.1.5 -12V .......................................................................................................................................... 19

10.2 Ethernet ........................................................................................................................................... 19

10.3 Laser ................................................................................................................................................ 19

11 SERIAL COMMANDS ........................................................................................ 20

12 APPENDIX ............................................................................................................ 21

12.1 Processor Board .............................................................................................................................. 21 12.1.1.1 Processor ........................................................................................................................... 21 12.1.1.2 FLASH ............................................................................................................................. 21 12.1.1.3 SDRAM ............................................................................................................................ 21 12.1.1.4 EEPROM .......................................................................................................................... 21 12.1.1.5 Ethernet Controller ........................................................................................................... 21 12.1.1.6 Serial Ports ........................................................................................................................ 21 12.1.1.7 4 – 20mA Outputs (Optional) ........................................................................................... 21 12.1.1.8 BDM Port ......................................................................................................................... 21

12.2 Power over Ethernet (PoE) ............................................................................................................ 21 12.2.1 Power Up Sequence .................................................................................................................. 22

12.3 Additional Equipment .................................................................................................................... 22


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1 PurposeThe purpose of this document is to give a high level description of how the Airnet ® II Particle Counter operates and to

provide troubleshooting and service information. This manual does not cover the Airnet II calibration.


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2 IntroductionThe Airnet II is an aerosol particle counter. It operates from either an external DC power supply or from Power overEthernet (PoE). The instrument has an RS-232 interface, Ethernet interface, and three 4-20 mA output channels.


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3 Related DocumentsL:\Engineering\Release\Firmware\AirNet_II\PMS_Documentation\AirNetII_Command_Summary.doc


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4 Airnet II Features

4.1 Connector PanelThe connector panel on the Airnet II comes in two versions, one with the cutout for the optional 4-20mA board and one without.

With 4-20mA option Without 4-20mA option

With 4-20mA option Without 4-20mA option


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5 System Components

Transimpedance Amp

Op AmpBaseline Restore

Detector

Op Amp

BNC31 ‐221 ‐RFX

LaserModule

+5V

3V Reference ATM Press

Sensor

Pulses

X H P - 2

X H P - 5

X H P - 4

B 4 B - X

H - A

( L F ) ( S N )

Main Board

Laser Board

Detector Board

Front Panel

Date Drawn: September 22, 2009Drawn By: Jerry Swinford

-12V+5V +12V

+3.3V+1.8V

Particle Threshold 1 & 2Baseline Restore Threshold

LTC2604CGN

CH1 Clock

CH2 Clock

Particle Threshold 1

Status

EthernetConnector

6339191-4

-48V

0V

Power InputThreshold Output

Connector39-30-0060

-48V

0V

CDBH

CDBHD1100

H2019NL

Threshold 1

Threshold 2

Pulses

-12V+5V

Particle Threshold 2

Baseline Restore Threshold

PORLTC1728ES5-5

I 2C

Address

Data

Control

+12V

S 2 B - X

H - A

2 0 R - J

M D S S

- G - 1 - T

F

B 5 B - X

H - A

( L F ) ( S N )

+3.3V

RS-232Connector

FRJAE-666

RS-232Transceiver

ISL4221EIRZ

+3.3V+3.3V

Option Configuration Bit 0

Option Configuration Bit 1

2 0 P S

- J M D S S

- G - 1 - T

F

Spare Digital Input

SPI Data

SPI Clock

Optional 4-20 mA Board

D/A

D/A

D/A 4 - 2 0 m

A O u

t p u t

C o n n e c

t o r

4 3 0 4 5 - 0

6 1 1

4-20 mA Board

4-20 mA_Latch

Spare_Latch

SPI Data

SPI Clock

Thresh_Latch

4-20 mA_Latch

Spare_Latch

Spare Digital Input

2 0 R - J

M D S S

- G - 1 - T

F

2 0 P S

- J M D S S

- G - 1 - T

F

+5V

Laser On

Line FilterBNX022-01L

SurgeProtection

+24V

0V

+5V

ADCReference

MAX15006

-12V+5V +12V

FlowPressure Sensor A/D

AD124S051CIMM

BNCH PressSensor

Diff PressSensor

+12V

5V Reference

4.096VReference

Power PC

MPC875CVR80


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The Airnet II electronics is made up of a Processor board, Detector board, Laser board, and an optional 4-20 mA board.The DC power supplies are on the Processor board. The Detector board and the optional 4-20 mA board are connected tothe processor board by board-to-board connectors. The Laser board is connected to the Processor board by a cable.

5.1 Processor Board (1000013669)

Processor Board (1000013669)

The Processor board interfaces to and controls the rest of the system components. The major components of the Processor board are:

• FLASH memory for System firmware• SDRAM for System memory• EEPROM memory for System configuration• D/A to set thresholds and baseline restore• Serial interfaces (RS-232 & SPI)• Ethernet Interface• Power supplies (PoE and system power)

5.1.1 Connector PinoutsThere are eight connectors on the Processor board.

Ref Des Description Mfr P/NCO3 Detector Board, Board-to-board Connector JST 20R-JMDSS-G-1-TF(LF)(SN)CO6 RS-232 Connector Amphenol FRJAE-666CO7 Background Debug (BDM) Connector Samtec TSM-105-01-L-DVCO8 Ethernet Connector AMP 6339191-4CO9 Power Input and Threshold Voltage Output Connector Molex 39-30-0060

CO10 4-20mA Board, Board-to-board Connector JST 20R-JMDSS-G-1-TF(LF)(SN)CO11 Pulse Output Cable Connector JST B2B-XH-AM(LF)(SN)CO12 Laser Board Cable Connector JST B5B-XH-AM(LF)(SN)

5.1.1.1 CO12

Pin Number Description1 +5V2 -12V3 Ground4 Laser Status5 #Laser_On


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5.1.1.2 CO3 Detector Board

Pin Number Description1 +5V2 Differential Pressure3 +5V4 Bench Pressure

5 Ground6 Ground7 +12V8 Baseline Restore9 +12V

10 Ground11 Ground12 Ground13 -12V14 Atmospheric Pressure15 -12V16 Ground17 Ground18 Ground19 Ground20 Pulses

5.1.1.3 CO10 4-20mA Board

Pin Number Description1 #Busy2 V_Bus3 Ground4 V_Bus5 Spare_Latch

6 #HRESET7 Ground8 Ground9 Optional Board Configuration Bit 0

10 4-20mA_Latch11 Ground12 Ground13 Optional Board Configuration Bit 014 4-20_SPICK15 Ground16 SPIMOSI17 Spare_SPICK18 SPIMISO19 Ground20 Spare Input (PE23)

5.1.1.4 CO11 Pulses

Pin Number Description1 Pulses (Center)2 Ground (Ring)


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5.1.1.5 CO6 RS-232

Pin Number Description1 Shorted to pins 4 & 5 with a capacitor to ground2 TxD3 RxD4 Shorted to pins 1 & 5 with a capacitor to ground

5 Shorted to pins 1 & 4 with a capacitor to ground6 Ground

5.1.1.6 CO8 Ethernet

Pin Number Description1 Tx+ (PoE)2 Tx- (PoE)3 Rx+ (PoE)4 Shorted to pin 5 (PoE)5 Shorted to pin 4 (PoE)6 Rx- (PoE)

7 Shorted to pin 8 (PoE)8 Shorted to pin 7 (PoE)9 Yellow LED Cathode

10 Yellow LED Anode11 Green LED Cathode12 Green LED Anode

5.1.1.7 CO7 BDM

Pin Number Description1 VFLS02 #SRESET3 Ground4 DSCK5 Ground6 VFLS17 #HRESET8 DSDI9 Pulled up to +3.3V

10 DSDO

5.1.1.8 CO9 Power & Thresholds

Pin Number Description1 +24VDC In2 Channel 1 Threshold3 Channel 2 Threshold4 0VDC5 Ground6 Ground


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5.1.2 Power SuppliesThe Airnet II power supplies are on the processor board. The instrument can be powered from an external +24VDC supplyor via Power over Ethernet (PoE). The DC voltages that are produced are: +5V, +3.3V, +1.8V, and ± 12V. The PoEstandard does not dictate the polarity of the DC voltage supplied over the Ethernet cable. Therefore, the PoE supply has

bridge rectifiers on the input. A bridge rectifier was also added to the +24V input so that the instrument will not bedamaged if the +24V power is wired backwards.

5.1.2.1 Power over Ethernet (PoE)The PoE supply produces +12VDC. This is connected through a diode to the V_Bus (a.k.a. Raw_DC) that is used to

produce all of the system voltages. The external +24VDC is also connected to V_Bus through a diode. When the +24VDCis being used to power the instrument, the PoE circuit will be disabled. If a Power Sourcing Equipment (PSE) device suchas a PoE Ethernet switch is connected it will go through the PoE negotiation sequence and be denied. I believe it maycontinue to try this negotiation sequence forever. So, if PoE is available it is not recommended to power the instrumentwith the external +24VDC. The Airnet II is a Class 0 PD.

There is more detailed information about PoE in general in the Appendix.

5.2 Detector Board (1000013676)The Detector board does the particle detection and sends particle pulses to the Processor board. The Detector board also has

pressure sensors that are used for monitoring the flow. The outputs of these sensors are sent to the Processor board wherethey are measured with an A/D converter.


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Detector Board (1000013676) and Board-to-Board Connector

5.3 Laser Board (1000013943)The Laser board drives the solid state laser. The Laser board is connected to the Processor board by the LEM cable(1000013724).

Laser Board (1000013943) and Cable (1000013724)

5.4 4-20 mA Board (1000013684)The 4-20 mA board is optional. It connects to the Processor board via a board-to-board connector. It has three channels,two particle channels and one for status.

4-20 mA Board (1000013684)


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The 4-20mA board is mounted in the Airnet II with two socket head cap screws. The length of these screws is critical. Ifone of the screws is too long it will break the differential pressure sensor on the Detector board.

5.5 CablingThere are two cables in the Airnet II. One cable connects the Processor board to the Laser board. The other cable connectsto the Processor board to a BNC connector on the rear of the Airnet II.

PMS P/N Description1000013724 Processor board to Laser board cable (LEM)1000013725 Processor board to Pulse BNC cable (Pulse)

Pulse Cable (1000013725)


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6 DisassemblyThe bottom of the case is held on by the four feet.

1. Remove the four feet by unscrewing the socket head capscrews with a hex wrench.

Socket head cap screws in feet

2. With the bottom removed, the cover can be removed byremoving the four socket head cap screws in the fourcorners.

Socket head cap screws

3. Lift off the top of the case.


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4. Remove the Processor board by removing the four sockethead cap screws in the four corners.

Remove Processor Board

5. Remove the tubing from the pressure sensor on the Detector board. Remove the two socket head caps screws. Removethe Detector board.

The pressure sensors can be damaged easily. Therefore, thetubing should only be removed if it is necessary.

Remove Detector Board

6. The 4-20mA board is removed by removing the two sockethead cap screws.

Remove 4-20mA Board


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7 AssemblyAssembling the Airnet II has a few critical steps.

1. The length of the socket head cap screws used to mount the4-20mA board is critical. If the screw protrudes too farthrough the mounting bracket it will damage the differential

pressure sensor on the Detector board.

Socket head cap screw length

Socket head cap screw length Socket head cap screw length

2. Care must be taken when mounting the Processor board. Ifthe board-to-board connectors are not properly aligned whenthe Processor board is pressed down, the connector on theDetector board and/or the 4-20mA board will be damaged.

Board-to-board connectors


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8 Test Points

8.1 Processor Board

TP Signal Name Description7 Baseline Restore Threshold Baseline restore voltage for Detector board8 CH1_THRESH Particle channel 1 threshold voltage9 CH2_THRESH Particle channel 2 threshold voltage

10 +1.8VDC +1.8V power for processor chip11 +3.3V +3.3V power

12, 14 GND System ground13 D Ground for PoE circuit. Connected to system ground through C14615 L_STATUS Status output from Laser board17 CH2CLK Channel 2 particle pulses going to counter18 CH1CLK Channel 1 particle pulses going to counter19 ADC IN4 Spare input to A/D converter20 DAC4_OUT Spare output from D/A converter

8.2 Laser BoardThere are no test points on the analog board.

8.3

Detector BoardThere are four test points on the analog board.

TP Signal Name Description1 Photodiode Anode Photodiode Anode2 Photodiode Cathode Photodiode Cathode3 +12VDC +12VDC4 -12VDC -12VDC


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8.4 4-20mA BoardThere are eleven test points on the 4-20mA board.

TP Signal Name Description1 GND Ground2 GND Ground3 V_OUT_C D/A output for 4-20mA channel 3 (0 to +5VDC)

4 V_OUT_B D/A output for 4-20mA channel 2 (0 to +5VDC)5 V_OUT_A D/A output for 4-20mA channel 1 (0 to +5VDC)6 #HRESET System reset7 4-20mA_Latch SPI latch to D/A8 4-20_SPICK SPI clock9 SPIMOSI SPI serial data

10 V_Bus Raw power from Processor board11 V_OUT_D Spare D/A output (0 to +5VDC)


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9 Component Replacement Procedures

9.1 Processor Board (1000013669)The Processor board contains the D/A that sets the thresholds and the baseline restore voltage. It contains the A/D thatmeasures the pressure sensors. Both of these devices have precision voltage references. The value of these references may

be different on the new Processor board. This may affect the flow setting and the calibration. If the Processor board isreplaced, run setup and calibration.

9.2 Detector Board (1000013676)If the Detector board is replaced, run flow and calibration.

9.3 Laser Board (1000013943)If the Laser board is replaced, run calibration.

9.4 4-20 mA Board (1000013684)If the 4-20mA board is replaced, nothing else is required.


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10 Trouble Shooting

10.1 PowerThe Airnet II can be powered from either an external +24VDC supply or from a PoE switch. It is possible that the Airnet IIcan function from the +24VDC input and not from the PoE input. This would indicate that the PoE circuit is faulty but therest of the supplies are OK. There is a Power LED (D21) on the Processor board. If it is not illuminated then the +3.3Vsupply is faulty. If it is illuminated it does not guarantee that the rest of the supplies are OK. All of the voltages must beverified with a meter.

10.1.1 +5VThe +5V can be verified by measuring pin 1 on CO12 (Laser cable connector).

10.1.2 +3.3VThe +3.3V is OK if D21 is illuminated or measuring TP11.

10.1.3 +1.8VThe +1.8V can be verified by measuring TP10.

10.1.4 +12VThe +12V can be verified by measuring pin 8 on U43.

10.1.5 -12VThe -12V can be verified by measuring pin 2 on CO12 (Laser cable connector).

10.2 EthernetThe Ethernet circuit and connector are on the Processor board. If it is determined that the Ethernet problem is a hardware

problem then the Processor board must be replaced.

10.3 LaserThe firmware will turn the laser off if the air flow is not correct. This can be checked by measuring the #Laser_On signal.

This is a low true signal, which means that if the firmware is telling the laser to be on, #Laser_On will measure about 0V.This signal is on CO12 pin 5.


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11 Serial CommandsThe serial commands are described in the “AirNetII PMS/OPC command summary” document.


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12 Appendix

12.1 Processor BoardThe major components of the Processor board are described below.

12.1.1.1 ProcessorThe processor is a Freescale MPC875.

12.1.1.2 FLASHThe system firmware is stored in the FLASH. The FLASH is two PC28F256M29EW parts. These are 16-bit wide 256 Mbit

parts. This is 64 Mbytes of FLASH. The address space of the FLASH is from 0xF0000000 to 0xF3FFFFFF.

12.1.1.3 SDRAMThe SDRAM system memory is one Micron MT48LC4M32B2B5-6 part. This a 32-bit wide 128 Mb part. This is 16Mbytes of SDRAM. The address space of the SDRAM is 0x00000000 to 0x00FFFFFF.

12.1.1.4 EEPROMThe EEPROM is used to store system parameters. There are 32 kbits. The EEPROM is accessed via the SPI bus.

12.1.1.5 Ethernet ControllerThe Ethernet Controller is accessed via the Media Independent Interface (MII). D34 on the Processor board is a bi-colorLED. The Green portion of the LED indicates the speed of the link (10/100) and the Red portion of the LED indicateswhether the link is half duplex or full duplex.

12.1.1.6 Serial PortsThere is one RS-232 serial port and the SPI serial interface.

12.1.1.6.1 SPI InterfaceThe SPI interface is used within the instrument. The processor controls the EEPROM, the optional 4-20mA output D/A, thethreshold D/A, and the pressure sensor A/D via the SPI interface.

12.1.1.6.2 RS-232The RJ-11 connector on the Processor board is for the RS-232 port.

12.1.1.7 4 – 20mA Outputs (Optional)If the Airnet II has 4-20mA outputs, the optional 4-20mA board is installed.

12.1.1.8 BDM PortThe Background Debug Port (BDM) is used to view and / or modify the internal memory, registers, and peripherals on anyof the processor buses.

12.2 Power over Ethernet (PoE)IEEE802.3af is the standard that defines PoE. There are two basic components to PoE, the Powered Device (PD) and thePower Sourcing Equipment (PSE). The standard requires the use of CAT 3 cable at a minimum. The cable has four twisted

pairs. The PSE provides 44-57VDC over two of the four pairs, either the two spare pairs or the two data pairs. Since thestandard does not specify which pairs are to be used, the PD must accept power from either set of wire pairs.


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12.2.1 Power Up SequenceTo ensure that power is not applied to an Ethernet device that is not a PD, the standard requires the PSE to look for a 25k Ω resistance (signature resistance) on the wire pairs that will be powered. Therefore, the PD must provide this resistance as

part of the power up sequence. The standard also specifies five classes of power levels.

Class Usage Maximum Power Levels at Input of PD (Watt)0 Default 0.44 – 12.94

1 Optional 0.44 3.842 Optional 3.84 6.493 Optional 6.49 12.954 Reserved

The PD has a power classification resistor that is detected by the PSE. This allows the PSE to determine how many devicesit can power. If the total available power is 100W and each of the PDs are class 3, the PSE can power seven. If the PDs areclass 1 then the PSE can power twenty six.

12.3 Additional EquipmentIn addition to the standard accessories, there are some items that may be useful.

Mfr. P/N Description

SL Power LS15RB2401J04 Input: PoE Output: 11.4W, +24VDC (for powering old Airnet in PoE installation)PMS 1000014175 Adapter cable for powering Airnet II from Airnet power supplyPMS 1000014176 Adapter cable for connecting Airnet II 4-20mA outputs to old Airnet installationPMS 1000014177 Adapter cable for powering old Airnet from Airnet II power supplyPMS 1000014178 Adapter cable for connecting old Airnet 4-20mA outputs to Airnet II installation

SL Power PW183RB Desktop style universal 30 Watt IEEE802.3af compliant PoE power supplyDell PowerConnect 3524P 24 port PoE Ethernet switch, 370W for the 24 PoE ports