Page 2: Service Manual
We ask the users of this Service Manual bring to our attention any possible mistakes. We would also appreciate any suggestions for supplements and improvements to this Service Manual. CAUTION ! Before opening this device, always unplug the main power ! © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 0.1-2...
Page 3: Table Of Contents
Pneumatics ....................2.6-1 Pressure regulation ..................2.7-1 Closing cone, adjustment................2.8-1 Linearisation....................2.9-1 2.10 Programming the balance................2.10-1 2.11 ........................2.11-1 2.12 Induction generator control ................2.12-1 2.13 Diagnostic printous..................2.13-1 2.14 Setting check up...................2.14-1 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 0.1-3...
Page 4 Preventive Maintenance checklist ..............3.21-1 MISCELLANEOUS Ordering numbers ..................4.1-1 Wiring and gas flow diagrams .................4.2-1 Starting through external key ................4.3-1 External report of analysis condition..............4.4-1 Spare parts kits ....................4.5-1 Maintenance CS-800..................4.5-1 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 0.1-4...
Page 6: 0.1 Overview Of The Cs-800 Modifications
0.1 Overview of the CS-800 modifications: Up to S/N0766xxxxxx The CS-800 analysers are equipped with a flow sensor with optical elements and with the corresponding board HF-3 and HF-4. 0,75mm ² 5 0 V A C Cataly st C oil...
Page 7 black 10l/h 180l/h controlled controlled 3 00 10 0 Infrared cell rack In ducti on cell bl ack Fur nac e black yellow 10l/h Oxygen stop valve Dust filter 0,35 bar black Flow 5 psi regulating valve Pressure Pressure regulator regulator 0.35bar 5psi...
Page 9 From S/N 0767xxxxxx The CS-800 is equipped with a flow sensor employing a pressure transducer, and with the corresponding boards HF-41 and later the HF-42. These boards also offer: ■ Current limit for the induction furnace ( on board HF 41/42 adjustment ) ■...
Page 10 Electronic rack 12800 CS 800 Signal and control HF 41 wit hout R13 gr/ rs gr/r s Gas fl ow Gener ator 70 cm 70 cm Bypas s val ve 70 cm 70 cm Shut tl e val ve 70 cm 70 cm Out fl ow valv e 70 cm...
Page 11 Exhaust valve black 10l/h 180l/h controlled controlled Infrared cell rack In ductio n cell black Fu rn ace black cell yellow 10l/h Oxygen stop valve Dust filter 0,5 bar black Flow 7, 5 psi regulating valve Pressure Pressure regulator regulator 0.5bar 7.5psi 1,5 bar...
Page 12 The wiring has also changed. It has been modified to be used with the IR-4, and the four IR-cell rack. As the 4-cell software was not available, the CS-800 was equipped with the still available with the 3-range IR-cell using an adapter and the 3-cell software up to SN / 1079xxxx.
Page 13 Close/Start Open/End of analysis Pressed Not pressed flow Outflow valve no flow no flow Lance valve flow Chamber flow valve no flow Furn. bypassed Bypass valve Furnace flow Pressure switch piston up Pneumatic valve piston down GENERATOR Nur durch Nullinie ; sonst t=0 continous flow flow Carrier gas...
Page 14 23.01.2002 yellow grey 30. 4. 2001 Datum Name Benennung: green gez.: 14. 7. 2000 Knipp 27. 3. 2001 CS-800 CS-2000 orange gepr.: Polemitis 14. 7. 2000 pink 5. 3. 2001 Signalleitung für IR-4 20. 9. 2000 black 18. 9. 2000 Zeichnungs-Nr.:...
Page 15 Alte Zelle-neuer Analysator- pink Polemitis gepr.: 18. 9.2000 -alte Software Zeichnungs-Nr.: black 1 2 0 6 8 violett Mainstr. 85 Block 20 Bez.: D-41469 Neuss geändert am: white © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 0.1-14...
Page 16 From S/N 1080xxxxxx The CS-800 is equipped with the four IR-cell rack. All electronic boards as well as the chopper motor ARE DIFFERENT to those of the previous 3-range IR-cell. The software changed to the four IR-range version !!! The gas saving mode is available and selectable in the PC software PLOTCS.
Page 17 No v oltage as long as the LE D is OFF 06255 06640 10pin plug s w s w Temperat ur e ge/gn sensor D-15 plug pin 9 ge/gn 1-14-4- 1 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 0.1-16...
Page 18 Chopper housing 2+15 0 . 5 ² x 2 2 c m I R s o u r c e bl ue 6+19 1 . 7 5 - 7 V D C br own I R s o u r c e 0 .
Page 19 Datum Name Benennung: gez.: 10.7.2000 Knipp Chopper m otor and IR source gepr.: Polemitis 10.7.2000 Zeichnungs-Nr.: 06660 Mainstr. 85 Block 20 Bez.: geändert am: gepr.: D-41469 Neuss © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 0.1-18...
Page 20 Cable c onec tion TH 62 - NR 32 (15 037 ) ge pr.: 26.08.2000 Polemitis Zeichnungs-Nr.: 06645 Mainstr. 85 Block 20 Bez.: D-41469 Neuss geändert am: © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 0.1-19...
Page 21 3 x 0. 14mm² x 55c m 10 x 0.14mm² x 35cm blu e brown yel low grey Name Datum Benennung: green CS-800 CS-2000 gez.: 19.07.2004 Sanda orange Signalleitung für IR-4- gepr.: Polemitis 19.07.2004 pin k UNI 1.3 Version bla ck 23.08.2004...
Page 22 From end of the year 2007 the CS-800 is equipped with the new pneumatics. 60525 60525 60350 60360 60566 Feder 06/8-10cm 60500 silver Pis ton 26618 Feder 60240 06/8-10cm 60635 26319 60522 60240 Cushioning 60522 26618 60513 60635 26319 60631...
Page 23: Faults
Asking for detectors, preamplifiers and boards. Without following this diagram is useless. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.1-1...
Page 24: Gas Flow Too High Or Too Low
V6 B lock age after the R eplac e th e r egul ating valve V6 va lve V 6 s ee 1- 02-1 -0 S © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.2-1...
Page 25 µA ba r 1-02-1-1 S Panel meter indicating the control of the gas regulation valve Gas flow meter 300 l/h Oxygen pressure gauge Compressed air pressure gauge © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.2-2...
Page 26: The Gas Flow Rate Fluctuates
1.5 bar down to 1.4 bar but not lower. If it goes much lower, it means that the incoming oxygen is restricted on the way from the bottle to the analyser. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.3-1...
Page 27: No Combustion
7 of the 50 pin see 1. 4 plug. Replace t he Replace the electr onic dr iver, Check accor ding board HF41/42 see 1. 6 1.15 1-4S © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.4-1...
Page 28 50 pin plugs that haven’t been properly inserted are a frequent problem. Tighten the screws of the plug properly, to ensure a proper connection to the board. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.4-2...
Page 29 Set the power switch to pos. 1 before removing the tube, although it would be best to completely turn off the device and unplug the power cord. O h m © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.4-3...
Page 30 If the current does not increase, it means that the generator does not take power, for example due to a broken grid resietor. The rectifier ( 1 ) could also be faulty! © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.4-4...
Page 31 PC screen) there is no combustion to see in the furnace then STOP the generator by pressing the STOP button or by clicking STOP on the screen depending on which software and hardware you use. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.4-5...
Page 32 (steel or iron chips) will have visible signs of starting burning. But if you wait up to the end of the analysis cycle in order to check whether there was combustion, it could be already too late for the tube due to overheating. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.4-5...
Page 33 If the current does not increase, it means that the generator does not take power, for example due to a broken grid resietor. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.4-5...
Page 34: Bad Combustion
This normally does not occur suddenly, it is rather a long process. Replace the tube Replace inadequate contact points in the oscillating circuit, see 1. 4 Replace worn power controls, see 1. 4 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.5-1...
Page 35: Electronic Drivers Malfunctioning
; pneumatic valve for furnace, see 2. 6 IC c: Purging valve V3, see 7and 4. 2 IC d: By-pass valve V4, see 4. 2 Generator „start“ signal, see 1. 4 1.24 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.6-1...
Page 36: The Furnace Does Not Close
The furnace floor goes up, when valve ( V7 ) receives 24 VDC. The 24 V DC comes from the electronic unit; if not, replace the electronic drivers, 1. 6 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.7-1...
Page 37: The Analysis Takes Too Long
If the problem remains, this number can be increased stepwise until the problem is solved. The threshold level can only be set in the low carbon channel. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.8-1...
Page 38 At least 10 V DC for a 3 channel device at rectifier At least 8 V DC for a 2 channel device At least 6 V DC for a 1 channel device © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.8-2...
Page 39 V DC for 4 channel device 4 Soldering location for 4 channel device ( 1,75 Volts DC for each IR source ) 8 Always connected ( common ) © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.8-3...
Page 40 The power voltage sinks below 180 VAC: Even a momentary drop in the in the voltage is enough to cause problems. Use a voltage stabiliser. See 3.15 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.8-4...
Page 41: Development Of Dust When Closing The Furnace
This can easily be checked when removing the tube ( 3 ). The nozzle should have an internal diameter of 1 mm. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.9-1...
Page 42: Erratic Results
3. 9 The base line of the detector is unstable, due through insufficient main voltage ( less than 200 V AC ). Connect a stabiliser, see 3.15 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.10-1...
Page 43: The Results Are Always 0.0000% Or 00.0 Ppm
IR path is very dirty If after replacing the detector the fault still exists, then reinstall the old detectors IR path is very dirty 1-11 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.11-1...
Page 44: Beeper Responding
24 V supply for the solenoid valves faulty ■ No balance attached ( when analyser operating without PC ) At request, beeper can be made to respond every time when an analysis is complete. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.12-1...
Page 45: The Life Time Of The Combustion Tube Is Too Short
2 . 1 5 m m 1 - 2 1 - 1 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.13-1...
Page 46 Ch ec k t he wirin g s ee 4. 2 t ha n 6 kOh m Rep la ce the TH6 1/ 62 1 - 14 - 1 S © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.14-1...
Page 47 One of the contact threads ( 2 ) could have failed, or one of the connections ( 3 ) could be disconnected. A look inside the plug ( 4 ) is recommended. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.14-2...
Page 48: The Fuse Burns Out At The Beginning Of Combustion
Otherwise, replace the transformer. The cables ( 4 ) and ( 5 ) are then reconnected. The cable ( 7 ) is unscrewed and removed from the capacitor ( 8 ) © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.15-1...
Page 49 The cable ( 7 ) therefore should be laid so that its end is at least 10 cm away from the nearest object ! If, after pressing < START > and GEN, the fuse is blown, then replace the rectifier ( 9 ) 1-15-2 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.15-2...
Page 50 If the tube needs to be replaced ( 8 ) ■ Loosen the screw ( 9 ), pull out the heat sink ( 10 ) upwards ! Pull out the tube ( 8 ) upwards! © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.15-3...
Page 51: The Fuse Blows At The End Of The Analysis
4 - 6 b a r (6 0 -9 0 p si ) 1 - 1 5 Replace the TRIAC! ( To locate the triac, see 4. 1 - 4 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.16-1...
Page 52: Large Collection Of Dust When Opening The Furnace
24 V / 20 mA. One of the valves ( V1 ) or ( V2 ) is sticking, preferable valve ( V1 ) Clean the valves, see 3.13 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.17-1...
Page 53: No Or Low Oxygen Pressure
For changing the paper filter, Operation Manual 7. On the rear-side of the analyser: The contents of the gas cleaning furnace could be worn out and clogged. Operation Manual 7. 2 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.18-1...
Page 54 The pressure switch does not close, see 2. 2 The furnace closes too slowly, adjust according to 2. 6 The furnace does not close, see 1. 7 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.18-2...
Page 55: Saved Data Are Lost
EPROM’s are the current values. Therefore, you should note down any linearity factors that you enter through the keyboard, in case the accumulator becomes empty. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.19-1...
Page 56: Noise Or Drift Of The Infrared Baseline
A fault on the circuit board IR 21, replace, see 3. 3 The power supply fluctuates, 3. 3 3. 4 The IR source is defective, 3. 2 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.20-1...
Page 57: Dust In The Oxygen Carrying Tube When The Furnace Opens
When the valve is incorrectly mounted, the oxygen flow will be blocked. 1 -21 -1 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.21-1...
Page 58: The Word Eltra Appears On The Display
This only happens when the power supply to the electronic is turned on. The electronic unit can function down to a minimum main voltage of only 160 V. If, during the operation the word "ELTRA" appears on the display, then the voltage has sunken below 160 V.
Page 59: The Oxygen Pressure Falls When The Furnace Opens
, or the electronic unit is defect, see If the voltage on the valve ( V2 ) is correct, then the valve itself is defect, see 3.13. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.23-1...
Page 60: Combustion Without Pressing " Start
"START" and without "GEN" on the display, there is only 0,5 V DC on TP9 ( instead of 1 2V DC ). Replace the electronic drivers, see © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.24-1...
Page 61 220V T P1 2 TP 5 T P 9 T P1 TP1 5 TP16 TP17 TP18 TP19 TP20 HF42 GN D +12V +20V +24V -12V +5V 1-24-2-0 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.24-2...
Page 62: The Crucible Cracks Or Melts
Excessive sample and / or accelerator weight. The use of a “sample or accelerator” that requires lower generation power. In this case reduce the generator power, see 2.12 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.25-1...
Page 63: The Analysis Doesn't Start
There are two reasons for the above fault: Insufficient oxygen pressure ( below 1 bar ), see 1.18 The infrared zero- baseline deviates too much from zero, see © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.26-1...
Page 64: Vibrations On Setting
When blowing compressed air, the rotary speed of the blower can exceed the limit of operation causing damage to the bearings and the shaft. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.27-1...
Page 65: 1.28 The Analysis Cycle Stops Only 25 Seconds After Start
2. The infrared cell is damaged. Do the IR-test. See 2. 3 Make sure that you take a sample with relatively high carbon to provide a clear visible high peak to about 3 to 8 volts. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.28-1...
Page 66: 1.29 The Chopper Motor Doesn`t Rotate
Silicon grease is also good for this purpose and it is also available in laboratories, however it could be very difficult for grease to penetrate the space between shaft and bearings. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.29-1...
Page 67: High Carbon Results Are Erretic
If you feel a remarkable restriction, replace it by a new one. With a new filter the air should pass practically free without any restriction. Filter housing Blow by keeping the filter inside. 1-31 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.30-1...
Page 68 The panel meter ( 4 ) must indicate between 30 and 70 µA. Check and if necessary readjust the pressure regulator ( PR3 ) in front of the flow regulating valve. See ■ Jumper settings: © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.1-1...
Page 69 Flow sensor From the IR-paths To the IR-paths 0 10 Flow regulating valve yellow + 2 0 V +12V TP17 TP10 green 1 2 V + 5 V TP11 Reference Oxygen flow +15V +20V TP20 Relay board TP18 HF 42 TP17 flow adjustment...
Page 70 The HF 42 board drives the flow regulating valve ( V6 ) in such way, to provide a constant and accurate gas flow. The µA meter ( 4 ) shows the rate, at which the flow valve ( V6 ) is driven „open“. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.1-3...
Page 71 Remark: Due to a few failures of the flow sensors, almost exclusively on the CS-800 at customers who regularly treat their samples with acid, we concluded that the reason of the failures should be of chemical nature i.e. acids and Schutze`s Reagent damage the sensor.
Page 72: Pressure Switch
If zero volts are measured when the pressure is at 1 bar ( 15 psi ), the screw ( 1 ) should be turned clockwise until the voltage goes to 24 V. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.2-1...
Page 73: Infrared Zero-Baseline, Control And Adjustment
( power switch on setting 1 ) for at least one hour, better would be two hours, and the oxygen flowed for about 10 to 15 minutes ( Power switch on setting 2 ). © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.3-1...
Page 74 3.11 13 / 14 / 15 / 16 Pre-amplifiers 17 / 18 / 19 / 20 Adjusters 21 / 22 / 23 / 24 Zero fine adjustment © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.3-2...
Page 75 When reinstalling the infrared cell into the analyser, you must pay attention to the colour markings of the tubes and their connections. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.3-3...
Page 76: Ir-Source Voltage Setting
IR-source measured on the a.m. test point. If the voltage of C is too low, either the transformer is not correctly connected, or the rectifier R is out of order. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.4-1...
Page 77: Temperature Regulation Of The Ir-Cell
The opposite happens when the temperature in the laboratory goes higher. The IR- cell heaters need less power to keep the temperature constant, so that the voltage will become lower. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.5-1...
Page 78 5.35 V DC present between TP2 an TP3. If the fault still remains, despite adjusting the TH 62, then check the board NR 32, according to the following instructions. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.5-2...
Page 79 If there is no voltage between 4 and 5, then the NR 32 is faulty. Replace it, according ■ The above sentences, extend to the board TH 62. From there they feed the heating elements. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.5-3...
Page 80 The modulated signal further drives and power stage of the NR 32 board; the power signal returns to the TH 62 board, from there it finally goes to the heater elements. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.5-4...
Page 81 TH62 -06630- 3 4 5 6 7 NR32 -15038- PW M 200V DC 3 4 5 6 8 9 10 +24V +200V Temperature 200V DC sensor voltage stabilizer IR-Temp.-Test output to PC about + 12V 300VDC CAUTION: High voltage on NR32 Heating elements 2-5-3...
Page 82: Pneumatics
Adjust the furnace downwards speed with screw ( 5 ), it must be within a reasonable limit. Adjust lower cushioning ( 7 ), so that the furnace opens without banging at the bottom. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.6-1...
Page 83 Magnetic switch of the pneumatic cylinder: Cylinder model with one Cylinder model with two slot pre-adjust 15 mm as above. slots pre-adjust 25 mm as above. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.6-2...
Page 84: Check The Following
■ If the piston goes down, then adjust the switch lower. 2 - 1 1 - 2 2 - 1 1 - 2 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.6-3...
Page 85: Pressure Regulation
Ensure that the flow shown on the flow meter ( 5 ) shows between 180 and 200 l/h; if not, adjust according to µA 1 -0 2 -1 -1 S © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.7-1...
Page 86 ( 1 ), as indicated above. Pull and rotate the knob of the pressure regulator ( PR3 ), until the correct pressure is shown on the gauge. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.7-2...
Page 87 The vibration stopped at the level of 1 bar. The volt meter ( 4 ) started moving to ist maximum at 0,3 bar. Therefore: 1 bar + 0,3 bar = 0.65 bar on the gauge ( 1 ) with PR3 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.7-3...
Page 88: Closing Cone, Adjustment
The screws ( 8 ) should be properly fastened ( with a wrench ) The screws ( 9 ) should only be tightened by hand © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.8-1...
Page 89: Linearisation
Channel 1 : Carbon ( low ) linearisation factor Approximate value 23000: 0.197%C 400 mg 0.151%C 500 mg 0.100%C 500 mg 0.067%C 500 mg 0.023%C 500 mg The standard for successive calibration is 0.151%C © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.9-1...
Page 90 10 ) < New Factor > < Enter > 11 ) < Nr > < New Factor > < Enter > 12 ) Repeat from # 1 ) © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.9-2...
Page 91: Programming The Balance
The balance supplied by Eltra is a Sartorius, model CP 64. The balance is programmed ( always with 3 Digits ) in our company, in order to establish a good communication with the analyser.
Page 93: Induction Generator Control
Connect a digital multi meter on TP1 ( TP15 is GND ) Start the analysis, adjusting P2 until 6.3 volts DC are on TP1 (for copper analysis adjust 1.2 volts DC). Adjust only, while the furnace is active. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.12-1...
Page 94 11,1 10,5 Setpoint ( V ) Generator power vs. setpoint 3000 2500 2410 2156 2000 1920 1682 1510 1500 1188 1000 40 62 Setpoint ( V ) © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.12-2...
Page 95: Diagnostic Printous
The printer port must be activated, with : < Menu > < 3 > < 1 > < Enter > This report should be faxed to ELTRA if interpretation or further instructions are needed. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800...
Page 96: Setting Check
Conclude this section, by pressing CAUTION! Do not press any other key instead of Enter, otherwise the linearisation factor will be affected and the analyser will be totally inaccurate. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.14-1...
Page 97 The following information is printed out: The serial No. of the analyser The internal software version The calibration factors for each measuring range The linearity factor The blank value The comparator level © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.14-2...
Page 98: Service
Reconnect the plugs ( 17 ) of the preamplifiers ( 6 ), in case they were removed. After reinstallation, adjustments according to 2. 3 are highly recommended. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.1-1...
Page 100 Above sample weights for Metals and Alloys are just guidelines. For more accurate information please turn to Operation Manual 3.3 „Applications“ The following materials are used as Non Metals: cement, stone, soils, etc. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.1-3...
Page 101 A and B are correct, C, D, E and F are wrong. Avoid moving the IR-source back and forth, try placing it correctly the first time. After re-assembling the infrared cell, adjust according to 2. 3 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.2-1...
Page 102: Infrared Electronics
The IR 41-circuit board is malfunctioning, when the correct signal can be measured at test point 1; while the signal at test point 6 cannot be adjusted to zero, see © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.3-1...
Page 103: Infrared Power Supply
The front panel is now completely loose and can be exchanged. The new power supply unit ( 1 ) is installed in the reverse order. It is suggested that the adjustments now be made according to © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.4-1...
Page 104 2. The heating wire is not very elastic, therefore do not move it back and forth, rather, you should correctly position it the first time © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.5-1...
Page 105 Each end of the IR-source cables ( 3 ) will then be soldered to each one of these groups. Polarity is irrelevant. Afterwards, the chopper blade is refastened. Reassemble in the reverse order. After installing, the infrared cell should be adjusted, see 2. 3 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.5-2...
Page 106: Infrared Temperature Regulation
3. 4 Disconnect plug ( 2 ) Remove the four nuts ( 3 ) Re-assemble in reverse order. Make adjusts to the unit, according to 2. 5 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.6-1...
Page 107 Solder the cables ( 4 ) CAUTION ! screw the probes in very gently, the threads are of aluminium. After replacing the temperature sensor, adjust according to 2. 5 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.6-2...
Page 108: Leak Checking
( 43 ) again. If the pressure is stable then the leakage will found in the furnace. ■ If the pressure still decreases, then the leakage is to found inside the analyser. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.7-1...
Page 109 Viton Viton Viton Polyamid 6/4x1 Polyamid 6/4x1 Infrar ed ce ll ra ck Viton 6/4x1 cell Viton Viton Viton Vi ton Teflon T eflon Tefl on Polyamid 6/4x1 PVC 7/4x1.5 Teflon 7/4x1.5 Viton Viton PVC 7/4x1.5 Viton Viton...
Page 110 Reverse valve ( V2 ), check for 24 VDC on input pins ATTENTION: do not cause a short circuit while measuring! If the voltages on V2, V3, or V4 are wrong, then replace the electronic drivers, see © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.7-3...
Page 111: Replacing Eproms
EPROMs, will be deleted. CAUTION: The analyzer has to be recalibrated, or an application has EPROM EPROM to be recalled from the application memory. 18065 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.8-1...
Page 112: Clearing Memory
Detach the power plug ( 1 ) from the electronic unit Press the reset key ( 2 ) on the base plate of the electronic unit for 30 seconds Restore the unit to its original condition Recalibrate. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.9-1...
Page 113: Electronic Reset
Disconnect the cable ( 1 ) from the electronic unit for 10 seconds and plug back in. 1 80 65 3 - 9 ■ Should the problem remain: 3. 9 " Clearing Memory " © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.10-1...
Page 114: Coding Ir-Ranges
S e c t i o n s o f I R - 4 e l e c t r o n i c b o a r d © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.11-1...
Page 115 L o w ca rb o n T h e s e co n d 2 0 0 mm p a t h l o n g e st p a t h h e r e H ig h ca r b o n 6 mm p a t h Th e s h o rt e s t p a t h h e re...
Page 116 IR-path: carbon low 05067 IR-path: carbon high 05068 IR-path: sulphur 06741 Printed circuit board IR-41 06032 Infrared receiver with CO filter 06034 Infrared receiver with SO filter © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.12-1...
Page 117: Cleaning The Solenoid Valves
( 3 ), as well as the armature ( 5 ) and re-assemble the solenoid valve. With the furnace closed and renewed oxygen pressure, check to ensure that the solenoid valve is sealed, see 3. 7 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.13-1...
Page 118: Replacing The Flow Sensor
Pay particular attention to the position of the tubes ( 5 ), ( 6 ), ( 10 ) and ( 11 ). Adjust according to 2. 1 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.14-1...
Page 119: Installing An Ac-Power Stabiliser
It is advisable to check the power of the above devices before ordering a stabilizer. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.15-1...
Page 120: Additional Safety Features For Furnace Pneumatics (Optional)
By adding a solenoid valve ( 8 ) and connecting the coil directly to 220 V AC, the piston won’t change position in case of a power failure. If the piston was down, it will remain down; if it was up, it will remain up. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.16-1...
Page 121: Installing A Halogen Trap
3.17 Installing a halogen trap: 3.17 Left hand side panel Inside view 48070 ø5 ø8 Rubber ring ø5 ø5 36710 3-20-1 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.17-1...
Page 122: Gas Saving Mode
T P 4 T P12 TP 5 Co ntin uo us flow T P 9 T P 1 TP16 TP17 TP 18 TP19 TP20 H F 4 2 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.18-1...
Page 123: 3.19 3.19 Upgrade For Copper Analysis Without Accelerators
Copper sample up to 20 g, or as much Copper sample the crucible can accommodate. If the Copper sample has the form of grains or drillings, the standard CS-800 ( CS-2000 ) can do the job. The condition is: The furnace control board should have a HF-42 with the corresponding jumper setting for The correct control mode.
Page 124 J o i n t c o n n e c t i o n f o r S i n C u 4 -1 - 5 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.19-2...
Page 125: Upgrading Of Analysers With Electronic Rack For Using The New Windows Software
This means replacement of the wiring, new HF board, new upper furnace part with two oxygen inlets and modifications of the tubing and new flow sensor in the IR-cell. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.20-1...
Page 126: 3.21 Preventive Maintenance Checklist
5. check of the chopper purge flow 6. check of the induction furnace a) measurement of the power/capacity and if necessary adjust b) check of the pneumatic and if necessary adjust. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.21-1...
Page 127: Miscellaneous
05020 Chopper blade 05030 Chopper blade holder 05064 Chopper motor 05048 Infrared source ( emitter ) 70280 O-ring 70330 O-ring 75120 Spring 75130 Retaining washer 75190 Washer © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.1-1...
Page 128 Threaded rod ( advice the length ) 05275 Infrared preamplifier 06210 IR-cable 06670 IR-zero adjustment board 06741 Infrared electronics board 15207 Gas flow sensor 70180 O-ring 70330 O-ring 77510 Heaters for IR-cell © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.1-2...
Page 129 72020 72020 Pressure gauge 77430 Panel meter 100 µA 70230 78010 Main power switch b ar 78040 Button for leakage test 70230 20045 11045 11185 70230 11120 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.1-3...
Page 130 Inlet pressure regulator 11495 Purge pressure regulator 12016 Gas flow and furnace control board HF 42 12044 Transformer 16100 Power supply board NK 31 18467 Microcontroller board UNI © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.1-3...
Page 131 Exhaust muffler 11376 Fixing plate for 11822 11492 Pressure regulator 11822 Pnematic valve block 12045 Transformer 12080 Rectifier 12100 Transformer 13850 Centrifugal blower 77050 TRIAC 77135 Capacitor © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.1-4...
Page 132 Co il cooling 26319 60631 60635 26618 60558 26319 Hollow screw 26618 Valve block 60234 Pneumatic valve 60240 Silencer 60513 Fiting 60522 Fiting 60631 Closure 60635 Seal © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.1-5...
Page 133 77210 Oscillator tube 77322 Capacitorr 77330 Capacitor 77335 Capacitor 77333 Filter 77345(13261; 13262; 77340; 77341; 77342) Capacitor 77350 Capacitor 100 nF 77489 Bracket 77600 Resistor 77610 Resistor © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.1-5...
Page 134 Cleaning brush for radiation shield 14026 76002 Washer 76003 70390 76003 Wing nut 76005 Knurled nut 90150 90150 Crucibles 14168 14200 71031 14210 14170 71010 14180 14185 14150 14220 14009 B9-1-3 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.1-6...
Page 135 Metal tube 1 4 0 2 1 70120 7 5 1 5 0 1 4 0 5 1 1 4 0 4 5 1 4 0 7 2 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.1-7...
Page 136 Oxygen purifying furnace: 21120 21010 21010 Heather section 21120 Quartz tube 70380 O-Ring 70380 4-1-9 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.1-8...
Page 137 CS 800 Main power wiring, right hand side bl ue br o wn ye llow RF filter gr e y Feed gr e en FILTER throug h or a ng e cap aci tor pi nk re d F 1 1 .1 2 6 / 3 6 bl ack vio le tt wh ite...
Page 138 blue brow n yellow grey C o o l i n g f a n green orange 1 1 0 3 5 1 2 0 4 4 pink N K 3 1 black 1 6 1 1 0 violett white 2 2 0 V A C D u s t t r a p h e a t e r 0 , 7 5²...
Page 139: Valve Wiring
Shuttle valve Purging valve Bypass valve Oxygen valve Regulating valve Pneumatic valve Coil cooling valve Outlet valve Pressure switch over valve for furnace lift Pressure switch Panel meter © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.2-3...
Page 140 30. 4. 2001 Datum Name Benennung: gr ee n gez.: 14. 7. 2000 Knipp 27. 3. 2001 CS-800 CS-2000 or an ge gepr.: 5. 3. 2001 14. 7. 2000 Polemitis pink Signalleitung für IR-4 r ed 20. 9. 2000 blac k 18.
Page 141 LE D is OFF 06255 06640 10pi n plug s w s w Temperatu re ge/gn sensor D-15 pl ug pi n 9 ge/gn 1-14-4-1 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.2-5...
Page 142 Chopper housing 0 . 5 ² x 2 2 c m I R s o u r c e 2+15 blue 6+19 1 . 7 5 - 7 V D C brown I R s o u r c e 0 .
Page 143 Name Datum Benennung: gez.: 10.7.2000 Knipp Chopper motor and IR source gepr.: 10.7.2000 Polemitis Zeichnungs-Nr.: 06660 Mainstr. 85 Block 20 D-41469 Neuss Bez.: geändert am: gepr.: © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.2-7...
Page 144 25.08.2000 Knipp Cable cone ction TH 62 - NR 32 (15037) Polemitis gepr.: 26.08.2000 Zeichnungs-Nr.: 06 645 Mainstr. 85 Block 20 Bez.: D-41469 Neuss geändert am: © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.2-8...
Page 145 IR-4 which is described in this manual. The adapter of the drawing below is used to adapt the new IR-rack to the CS-800 analyser. The drawings of the previous rack wiring can be found in the following 5 pages, these are the older models.
Page 146 0 61 75 According to the number of channels see 13-pin plug connector 25-pin plug Transformer Energy filter Heating elements Temperature sensor According to the number of channels, see © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.2-10...
Page 147 1 x g r 0 . 2 5 ² x 2 5 c m I R 2 1 0 62 0 0 C-signal S-signal Control voltage Control voltage Control signal for low channel Regulating voltage for low channel © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.2-11...
Page 148 Chopper motor and IR source p i n k r e d b l a c k v i o l e t t 06190 w h i t e © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.2-12...
Page 149: Cable Connection
Cable connection TH 61 - NR 32 (15037) 06090 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.2-13...
Page 151 Analyzer-PC grey yellow green brown wh ite shield CAUTION! Connect the shield on both connector frames. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.2-15...
Page 154 ( zero volts between its two leads ). After a short delay by the software, V2, V3 and V4 will be de-energised. The closed furnace condition is now reached. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.2-18...
Page 155 I R Th e rm o s ta t i c co n t r o l I R S i g n a l S R e g u l a ti n g v a l ve I NP UT S IR S i g n a l C O xy g e n f l o w ( De t e ct o r si g n a l s )
Page 156: Starting Through External Key
For this purpose, remove the case of the 96-pin plug and connect a wire to the key ( pins 17a to 26a ). ( All carry +24 volts ) The second wire is connected to pin 5C. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.3-1...
Page 157 To do this, remove the cover of the 96-pin connector and attach a relay wire to 17a to 26a ( all carry +24 volts ). ■ The second wire is attached to pin 24B. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.4-1...
Page 158: Spare Parts Kits
Tube black id = 6 od = 9 90290 Copper oxide 100g 11062 Reagent tubes 160 x 16mm 21120 Quartz tube for purification furnace 15083 Gasflow meter 15 l/h © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.5-1...
Page 159 20040 Catalyst tube 200 x 16mm 80925 Sets of fuses 11115 Plastic tube 75mm 11120 Paper filter holder 11370 Gasflow regulating valve 11400 Pressure outlet solenoid valve © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.5-2...
Page 160 77350 Capacitor 1µF/50V 77600 Grid resistor 77610 Resistor 14080 Cleaning mechanism rod 75122 Spring 75130 Safety ring 20000 Catalyst furnace 11490 Pressure regulator 15116 Gas flow sensor © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.5-3...
Page 161 Check if the 96-pole plug at the back of the CS 800 is firmly plugged in. Check if all the warning labels are still attached to the side-panels. Calibration of all measuring ranges. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.6-1...
Page 163 We ask the users of this Service Manual bring to our attention any possible mistakes. We would also appreciate any suggestions for supplements and improvements to this Service Manual. CAUTION ! Before opening this device, always unplug the main power ! © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 0.1-2...
Page 164 Pneumatics ....................2.6-1 Pressure regulation ..................2.7-1 Closing cone, adjustment................2.8-1 Linearisation....................2.9-1 2.10 Programming the balance................2.10-1 2.11 ........................2.11-1 2.12 Induction generator control ................2.12-1 2.13 Diagnostic printous..................2.13-1 2.14 Setting check up...................2.14-1 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 0.1-3...
Page 165 Preventive Maintenance checklist ..............3.21-1 MISCELLANEOUS Ordering numbers ..................4.1-1 Wiring and gas flow diagrams .................4.2-1 Starting through external key ................4.3-1 External report of analysis condition..............4.4-1 Spare parts kits ....................4.5-1 Maintenance CS-800..................4.5-1 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 0.1-4...
Page 167: 0.1 Overview Of The Cs-800 Modifications
0.1 Overview of the CS-800 modifications: Up to S/N0766xxxxxx The CS-800 analysers are equipped with a flow sensor with optical elements and with the corresponding board HF-3 and HF-4. 0,75mm ² 5 0 V A C Cataly st C oil...
Page 168 black 10l/h 180l/h controlled controlled 3 00 10 0 Infrared cell rack In ducti on cell bl ack Fur nac e black yellow 10l/h Oxygen stop valve Dust filter 0,35 bar black Flow 5 psi regulating valve Pressure Pressure regulator regulator 0.35bar 5psi...
Page 170 From S/N 0767xxxxxx The CS-800 is equipped with a flow sensor employing a pressure transducer, and with the corresponding boards HF-41 and later the HF-42. These boards also offer: ■ Current limit for the induction furnace ( on board HF 41/42 adjustment ) ■...
Page 171 Electronic rack 12800 CS 800 Signal and control HF 41 wit hout R13 gr/ rs gr/r s Gas fl ow Gener ator 70 cm 70 cm Bypas s val ve 70 cm 70 cm Shut tl e val ve 70 cm 70 cm Out fl ow valv e 70 cm...
Page 172 Exhaust valve black 10l/h 180l/h controlled controlled Infrared cell rack In ductio n cell black Fu rn ace black cell yellow 10l/h Oxygen stop valve Dust filter 0,5 bar black Flow 7, 5 psi regulating valve Pressure Pressure regulator regulator 0.5bar 7.5psi 1,5 bar...
Page 173 The wiring has also changed. It has been modified to be used with the IR-4, and the four IR-cell rack. As the 4-cell software was not available, the CS-800 was equipped with the still available with the 3-range IR-cell using an adapter and the 3-cell software up to SN / 1079xxxx.
Page 174 Close/Start Open/End of analysis Pressed Not pressed flow Outflow valve no flow no flow Lance valve flow Chamber flow valve no flow Furn. bypassed Bypass valve Furnace flow Pressure switch piston up Pneumatic valve piston down GENERATOR Nur durch Nullinie ; sonst t=0 continous flow flow Carrier gas...
Page 175 23.01.2002 yellow grey 30. 4. 2001 Datum Name Benennung: green gez.: 14. 7. 2000 Knipp 27. 3. 2001 CS-800 CS-2000 orange gepr.: Polemitis 14. 7. 2000 pink 5. 3. 2001 Signalleitung für IR-4 20. 9. 2000 black 18. 9. 2000 Zeichnungs-Nr.:...
Page 176 Alte Zelle-neuer Analysator- pink Polemitis gepr.: 18. 9.2000 -alte Software Zeichnungs-Nr.: black 1 2 0 6 8 violett Mainstr. 85 Block 20 Bez.: D-41469 Neuss geändert am: white © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 0.1-14...
Page 177 From S/N 1080xxxxxx The CS-800 is equipped with the four IR-cell rack. All electronic boards as well as the chopper motor ARE DIFFERENT to those of the previous 3-range IR-cell. The software changed to the four IR-range version !!! The gas saving mode is available and selectable in the PC software PLOTCS.
Page 178 No v oltage as long as the LE D is OFF 06255 06640 10pin plug s w s w Temperat ur e ge/gn sensor D-15 plug pin 9 ge/gn 1-14-4- 1 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 0.1-16...
Page 179 Chopper housing 2+15 0 . 5 ² x 2 2 c m I R s o u r c e bl ue 6+19 1 . 7 5 - 7 V D C br own I R s o u r c e 0 .
Page 180 Datum Name Benennung: gez.: 10.7.2000 Knipp Chopper m otor and IR source gepr.: Polemitis 10.7.2000 Zeichnungs-Nr.: 06660 Mainstr. 85 Block 20 Bez.: geändert am: gepr.: D-41469 Neuss © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 0.1-18...
Page 181 Cable c onec tion TH 62 - NR 32 (15 037 ) ge pr.: 26.08.2000 Polemitis Zeichnungs-Nr.: 06645 Mainstr. 85 Block 20 Bez.: D-41469 Neuss geändert am: © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 0.1-19...
Page 182 3 x 0. 14mm² x 55c m 10 x 0.14mm² x 35cm blu e brown yel low grey Name Datum Benennung: green CS-800 CS-2000 gez.: 19.07.2004 Sanda orange Signalleitung für IR-4- gepr.: Polemitis 19.07.2004 pin k UNI 1.3 Version bla ck 23.08.2004...
Page 183 From end of the year 2007 the CS-800 is equipped with the new pneumatics. 60525 60525 60350 60360 60566 Feder 06/8-10cm 60500 silver Pis ton 26618 Feder 60240 06/8-10cm 60635 26319 60522 60240 Cushioning 60522 26618 60513 60635 26319 60631...
Page 184: Faults
Asking for detectors, preamplifiers and boards. Without following this diagram is useless. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.1-1...
Page 185: Gas Flow Too High Or Too Low
V6 B lock age after the R eplac e th e r egul ating valve V6 va lve V 6 s ee 1- 02-1 -0 S © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.2-1...
Page 186 µA ba r 1-02-1-1 S Panel meter indicating the control of the gas regulation valve Gas flow meter 300 l/h Oxygen pressure gauge Compressed air pressure gauge © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.2-2...
Page 187: The Gas Flow Rate Fluctuates
1.5 bar down to 1.4 bar but not lower. If it goes much lower, it means that the incoming oxygen is restricted on the way from the bottle to the analyser. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.3-1...
Page 188: No Combustion
7 of the 50 pin see 1. 4 plug. Replace t he Replace the electr onic dr iver, Check accor ding board HF41/42 see 1. 6 1.15 1-4S © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.4-1...
Page 189 50 pin plugs that haven’t been properly inserted are a frequent problem. Tighten the screws of the plug properly, to ensure a proper connection to the board. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.4-2...
Page 190 Set the power switch to pos. 1 before removing the tube, although it would be best to completely turn off the device and unplug the power cord. O h m © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.4-3...
Page 191 If the current does not increase, it means that the generator does not take power, for example due to a broken grid resietor. The rectifier ( 1 ) could also be faulty! © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.4-4...
Page 192 PC screen) there is no combustion to see in the furnace then STOP the generator by pressing the STOP button or by clicking STOP on the screen depending on which software and hardware you use. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.4-5...
Page 193 (steel or iron chips) will have visible signs of starting burning. But if you wait up to the end of the analysis cycle in order to check whether there was combustion, it could be already too late for the tube due to overheating. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.4-5...
Page 194 If the current does not increase, it means that the generator does not take power, for example due to a broken grid resietor. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.4-5...
Page 195: Bad Combustion
This normally does not occur suddenly, it is rather a long process. Replace the tube Replace inadequate contact points in the oscillating circuit, see 1. 4 Replace worn power controls, see 1. 4 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.5-1...
Page 196: Electronic Drivers Malfunctioning
; pneumatic valve for furnace, see 2. 6 IC c: Purging valve V3, see 7and 4. 2 IC d: By-pass valve V4, see 4. 2 Generator „start“ signal, see 1. 4 1.24 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.6-1...
Page 197: The Furnace Does Not Close
The furnace floor goes up, when valve ( V7 ) receives 24 VDC. The 24 V DC comes from the electronic unit; if not, replace the electronic drivers, 1. 6 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.7-1...
Page 198: The Analysis Takes Too Long
If the problem remains, this number can be increased stepwise until the problem is solved. The threshold level can only be set in the low carbon channel. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.8-1...
Page 199 At least 10 V DC for a 3 channel device at rectifier At least 8 V DC for a 2 channel device At least 6 V DC for a 1 channel device © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.8-2...
Page 200 V DC for 4 channel device 4 Soldering location for 4 channel device ( 1,75 Volts DC for each IR source ) 8 Always connected ( common ) © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.8-3...
Page 201 The power voltage sinks below 180 VAC: Even a momentary drop in the in the voltage is enough to cause problems. Use a voltage stabiliser. See 3.15 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.8-4...
Page 202: Development Of Dust When Closing The Furnace
This can easily be checked when removing the tube ( 3 ). The nozzle should have an internal diameter of 1 mm. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.9-1...
Page 203: Erratic Results
3. 9 The base line of the detector is unstable, due through insufficient main voltage ( less than 200 V AC ). Connect a stabiliser, see 3.15 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.10-1...
Page 204: The Results Are Always 0.0000% Or 00.0 Ppm
IR path is very dirty If after replacing the detector the fault still exists, then reinstall the old detectors IR path is very dirty 1-11 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.11-1...
Page 205: Beeper Responding
24 V supply for the solenoid valves faulty ■ No balance attached ( when analyser operating without PC ) At request, beeper can be made to respond every time when an analysis is complete. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.12-1...
Page 207 Ch ec k t he wirin g s ee 4. 2 t ha n 6 kOh m Rep la ce the TH6 1/ 62 1 - 14 - 1 S © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.14-1...
Page 208 One of the contact threads ( 2 ) could have failed, or one of the connections ( 3 ) could be disconnected. A look inside the plug ( 4 ) is recommended. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.14-2...
Page 209: The Fuse Burns Out At The Beginning Of Combustion
Otherwise, replace the transformer. The cables ( 4 ) and ( 5 ) are then reconnected. The cable ( 7 ) is unscrewed and removed from the capacitor ( 8 ) © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.15-1...
Page 210 The cable ( 7 ) therefore should be laid so that its end is at least 10 cm away from the nearest object ! If, after pressing < START > and GEN, the fuse is blown, then replace the rectifier ( 9 ) 1-15-2 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.15-2...
Page 211 If the tube needs to be replaced ( 8 ) ■ Loosen the screw ( 9 ), pull out the heat sink ( 10 ) upwards ! Pull out the tube ( 8 ) upwards! © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.15-3...
Page 212: The Fuse Blows At The End Of The Analysis
4 - 6 b a r (6 0 -9 0 p si ) 1 - 1 5 Replace the TRIAC! ( To locate the triac, see 4. 1 - 4 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.16-1...
Page 213: Large Collection Of Dust When Opening The Furnace
24 V / 20 mA. One of the valves ( V1 ) or ( V2 ) is sticking, preferable valve ( V1 ) Clean the valves, see 3.13 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.17-1...
Page 214: No Or Low Oxygen Pressure
For changing the paper filter, Operation Manual 7. On the rear-side of the analyser: The contents of the gas cleaning furnace could be worn out and clogged. Operation Manual 7. 2 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.18-1...
Page 215 The pressure switch does not close, see 2. 2 The furnace closes too slowly, adjust according to 2. 6 The furnace does not close, see 1. 7 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.18-2...
Page 216: Saved Data Are Lost
EPROM’s are the current values. Therefore, you should note down any linearity factors that you enter through the keyboard, in case the accumulator becomes empty. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.19-1...
Page 217: Noise Or Drift Of The Infrared Baseline
A fault on the circuit board IR 21, replace, see 3. 3 The power supply fluctuates, 3. 3 3. 4 The IR source is defective, 3. 2 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.20-1...
Page 218: Dust In The Oxygen Carrying Tube When The Furnace Opens
When the valve is incorrectly mounted, the oxygen flow will be blocked. 1 -21 -1 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.21-1...
Page 219: The Word Eltra Appears On The Display
This only happens when the power supply to the electronic is turned on. The electronic unit can function down to a minimum main voltage of only 160 V. If, during the operation the word "ELTRA" appears on the display, then the voltage has sunken below 160 V.
Page 220: The Oxygen Pressure Falls When The Furnace Opens
, or the electronic unit is defect, see If the voltage on the valve ( V2 ) is correct, then the valve itself is defect, see 3.13. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.23-1...
Page 221: Combustion Without Pressing " Start
"START" and without "GEN" on the display, there is only 0,5 V DC on TP9 ( instead of 1 2V DC ). Replace the electronic drivers, see © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.24-1...
Page 222 220V T P1 2 TP 5 T P 9 T P1 TP1 5 TP16 TP17 TP18 TP19 TP20 HF42 GN D +12V +20V +24V -12V +5V 1-24-2-0 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.24-2...
Page 223: The Crucible Cracks Or Melts
Excessive sample and / or accelerator weight. The use of a “sample or accelerator” that requires lower generation power. In this case reduce the generator power, see 2.12 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.25-1...
Page 224: The Analysis Doesn't Start
There are two reasons for the above fault: Insufficient oxygen pressure ( below 1 bar ), see 1.18 The infrared zero- baseline deviates too much from zero, see © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.26-1...
Page 225: Vibrations On Setting
When blowing compressed air, the rotary speed of the blower can exceed the limit of operation causing damage to the bearings and the shaft. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.27-1...
Page 226: 1.28 The Analysis Cycle Stops Only 25 Seconds After Start
2. The infrared cell is damaged. Do the IR-test. See 2. 3 Make sure that you take a sample with relatively high carbon to provide a clear visible high peak to about 3 to 8 volts. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.28-1...
Page 227: 1.29 The Chopper Motor Doesn`t Rotate
Silicon grease is also good for this purpose and it is also available in laboratories, however it could be very difficult for grease to penetrate the space between shaft and bearings. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.29-1...
Page 228: High Carbon Results Are Erretic
If you feel a remarkable restriction, replace it by a new one. With a new filter the air should pass practically free without any restriction. Filter housing Blow by keeping the filter inside. 1-31 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 1.30-1...
Page 229: Adjustment, Test And Function Explanations
The panel meter ( 4 ) must indicate between 30 and 70 µA. Check and if necessary readjust the pressure regulator ( PR3 ) in front of the flow regulating valve. See ■ Jumper settings: © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.1-1...
Page 230 Flow sensor From the IR-paths To the IR-paths 0 10 Flow regulating valve yellow + 2 0 V +12V TP17 TP10 green 1 2 V + 5 V TP11 Reference Oxygen flow +15V +20V TP20 Relay board TP18 HF 42 TP17 flow adjustment...
Page 231 The HF 42 board drives the flow regulating valve ( V6 ) in such way, to provide a constant and accurate gas flow. The µA meter ( 4 ) shows the rate, at which the flow valve ( V6 ) is driven „open“. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.1-3...
Page 232 Remark: Due to a few failures of the flow sensors, almost exclusively on the CS-800 at customers who regularly treat their samples with acid, we concluded that the reason of the failures should be of chemical nature i.e. acids and Schutze`s Reagent damage the sensor.
Page 233: Pressure Switch
If zero volts are measured when the pressure is at 1 bar ( 15 psi ), the screw ( 1 ) should be turned clockwise until the voltage goes to 24 V. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.2-1...
Page 234: Infrared Zero-Baseline, Control And Adjustment
( power switch on setting 1 ) for at least one hour, better would be two hours, and the oxygen flowed for about 10 to 15 minutes ( Power switch on setting 2 ). © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.3-1...
Page 235 3.11 13 / 14 / 15 / 16 Pre-amplifiers 17 / 18 / 19 / 20 Adjusters 21 / 22 / 23 / 24 Zero fine adjustment © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.3-2...
Page 236 When reinstalling the infrared cell into the analyser, you must pay attention to the colour markings of the tubes and their connections. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.3-3...
Page 237: Ir-Source Voltage Setting
IR-source measured on the a.m. test point. If the voltage of C is too low, either the transformer is not correctly connected, or the rectifier R is out of order. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.4-1...
Page 238: Temperature Regulation Of The Ir-Cell
The opposite happens when the temperature in the laboratory goes higher. The IR- cell heaters need less power to keep the temperature constant, so that the voltage will become lower. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.5-1...
Page 239 5.35 V DC present between TP2 an TP3. If the fault still remains, despite adjusting the TH 62, then check the board NR 32, according to the following instructions. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.5-2...
Page 240 If there is no voltage between 4 and 5, then the NR 32 is faulty. Replace it, according ■ The above sentences, extend to the board TH 62. From there they feed the heating elements. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.5-3...
Page 241 The modulated signal further drives and power stage of the NR 32 board; the power signal returns to the TH 62 board, from there it finally goes to the heater elements. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.5-4...
Page 242 TH62 -06630- 3 4 5 6 7 NR32 -15038- PW M 200V DC 3 4 5 6 8 9 10 +24V +200V Temperature 200V DC sensor voltage stabilizer IR-Temp.-Test output to PC about + 12V 300VDC CAUTION: High voltage on NR32 Heating elements 2-5-3...
Page 243: Pneumatics
Adjust the furnace downwards speed with screw ( 5 ), it must be within a reasonable limit. Adjust lower cushioning ( 7 ), so that the furnace opens without banging at the bottom. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.6-1...
Page 244 Magnetic switch of the pneumatic cylinder: Cylinder model with one Cylinder model with two slot pre-adjust 15 mm as above. slots pre-adjust 25 mm as above. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.6-2...
Page 245 ■ If the piston goes down, then adjust the switch lower. 2 - 1 1 - 2 2 - 1 1 - 2 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.6-3...
Page 246: Pressure Regulation
Ensure that the flow shown on the flow meter ( 5 ) shows between 180 and 200 l/h; if not, adjust according to µA 1 -0 2 -1 -1 S © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.7-1...
Page 247 ( 1 ), as indicated above. Pull and rotate the knob of the pressure regulator ( PR3 ), until the correct pressure is shown on the gauge. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.7-2...
Page 248 The vibration stopped at the level of 1 bar. The volt meter ( 4 ) started moving to ist maximum at 0,3 bar. Therefore: 1 bar + 0,3 bar = 0.65 bar on the gauge ( 1 ) with PR3 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.7-3...
Page 249: Closing Cone, Adjustment
The screws ( 8 ) should be properly fastened ( with a wrench ) The screws ( 9 ) should only be tightened by hand © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.8-1...
Page 250: Linearisation
Channel 1 : Carbon ( low ) linearisation factor Approximate value 23000: 0.197%C 400 mg 0.151%C 500 mg 0.100%C 500 mg 0.067%C 500 mg 0.023%C 500 mg The standard for successive calibration is 0.151%C © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.9-1...
Page 251 10 ) < New Factor > < Enter > 11 ) < Nr > < New Factor > < Enter > 12 ) Repeat from # 1 ) © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.9-2...
Page 252: Programming The Balance
The balance supplied by Eltra is a Sartorius, model CP 64. The balance is programmed ( always with 3 Digits ) in our company, in order to establish a good communication with the analyser.
Page 254: Induction Generator Control
Connect a digital multi meter on TP1 ( TP15 is GND ) Start the analysis, adjusting P2 until 6.3 volts DC are on TP1 (for copper analysis adjust 1.2 volts DC). Adjust only, while the furnace is active. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.12-1...
Page 255 11,1 10,5 Setpoint ( V ) Generator power vs. setpoint 3000 2500 2410 2156 2000 1920 1682 1510 1500 1188 1000 40 62 Setpoint ( V ) © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.12-2...
Page 256 The printer port must be activated, with : < Menu > < 3 > < 1 > < Enter > This report should be faxed to ELTRA if interpretation or further instructions are needed. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800...
Page 257: Setting Check
Conclude this section, by pressing CAUTION! Do not press any other key instead of Enter, otherwise the linearisation factor will be affected and the analyser will be totally inaccurate. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.14-1...
Page 258 The following information is printed out: The serial No. of the analyser The internal software version The calibration factors for each measuring range The linearity factor The blank value The comparator level © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 2.14-2...
Page 259: Service
Reconnect the plugs ( 17 ) of the preamplifiers ( 6 ), in case they were removed. After reinstallation, adjustments according to 2. 3 are highly recommended. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.1-1...
Page 261 Above sample weights for Metals and Alloys are just guidelines. For more accurate information please turn to Operation Manual 3.3 „Applications“ The following materials are used as Non Metals: cement, stone, soils, etc. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.1-3...
Page 262: Ir-Source
A and B are correct, C, D, E and F are wrong. Avoid moving the IR-source back and forth, try placing it correctly the first time. After re-assembling the infrared cell, adjust according to 2. 3 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.2-1...
Page 263: Infrared Electronics
The IR 41-circuit board is malfunctioning, when the correct signal can be measured at test point 1; while the signal at test point 6 cannot be adjusted to zero, see © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.3-1...
Page 264: Infrared Power Supply
The front panel is now completely loose and can be exchanged. The new power supply unit ( 1 ) is installed in the reverse order. It is suggested that the adjustments now be made according to © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.4-1...
Page 265 2. The heating wire is not very elastic, therefore do not move it back and forth, rather, you should correctly position it the first time © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.5-1...
Page 266 Each end of the IR-source cables ( 3 ) will then be soldered to each one of these groups. Polarity is irrelevant. Afterwards, the chopper blade is refastened. Reassemble in the reverse order. After installing, the infrared cell should be adjusted, see 2. 3 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.5-2...
Page 267: Infrared Temperature Regulation
3. 4 Disconnect plug ( 2 ) Remove the four nuts ( 3 ) Re-assemble in reverse order. Make adjusts to the unit, according to 2. 5 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.6-1...
Page 268 Solder the cables ( 4 ) CAUTION ! screw the probes in very gently, the threads are of aluminium. After replacing the temperature sensor, adjust according to 2. 5 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.6-2...
Page 269: Leak Checking
( 43 ) again. If the pressure is stable then the leakage will found in the furnace. ■ If the pressure still decreases, then the leakage is to found inside the analyser. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.7-1...
Page 270 Viton Viton Viton Polyamid 6/4x1 Polyamid 6/4x1 Infrar ed ce ll ra ck Viton 6/4x1 cell Viton Viton Viton Vi ton Teflon T eflon Tefl on Polyamid 6/4x1 PVC 7/4x1.5 Teflon 7/4x1.5 Viton Viton PVC 7/4x1.5 Viton Viton...
Page 271 Reverse valve ( V2 ), check for 24 VDC on input pins ATTENTION: do not cause a short circuit while measuring! If the voltages on V2, V3, or V4 are wrong, then replace the electronic drivers, see © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.7-3...
Page 272: Replacing Eproms
EPROMs, will be deleted. CAUTION: The analyzer has to be recalibrated, or an application has EPROM EPROM to be recalled from the application memory. 18065 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.8-1...
Page 273: Clearing Memory
Detach the power plug ( 1 ) from the electronic unit Press the reset key ( 2 ) on the base plate of the electronic unit for 30 seconds Restore the unit to its original condition Recalibrate. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.9-1...
Page 274: Electronic Reset
Disconnect the cable ( 1 ) from the electronic unit for 10 seconds and plug back in. 1 80 65 3 - 9 ■ Should the problem remain: 3. 9 " Clearing Memory " © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.10-1...
Page 275: Coding Ir-Ranges
S e c t i o n s o f I R - 4 e l e c t r o n i c b o a r d © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.11-1...
Page 276 L o w ca rb o n T h e s e co n d 2 0 0 mm p a t h l o n g e st p a t h h e r e H ig h ca r b o n 6 mm p a t h Th e s h o rt e s t p a t h h e re...
Page 277 IR-path: carbon low 05067 IR-path: carbon high 05068 IR-path: sulphur 06741 Printed circuit board IR-41 06032 Infrared receiver with CO filter 06034 Infrared receiver with SO filter © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.12-1...
Page 278: Cleaning The Solenoid Valves
( 3 ), as well as the armature ( 5 ) and re-assemble the solenoid valve. With the furnace closed and renewed oxygen pressure, check to ensure that the solenoid valve is sealed, see 3. 7 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.13-1...
Page 279: Replacing The Flow Sensor
Pay particular attention to the position of the tubes ( 5 ), ( 6 ), ( 10 ) and ( 11 ). Adjust according to 2. 1 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.14-1...
Page 280: Installing An Ac-Power Stabiliser
It is advisable to check the power of the above devices before ordering a stabilizer. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.15-1...
Page 281: Additional Safety Features For Furnace Pneumatics (Optional)
By adding a solenoid valve ( 8 ) and connecting the coil directly to 220 V AC, the piston won’t change position in case of a power failure. If the piston was down, it will remain down; if it was up, it will remain up. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.16-1...
Page 282: Installing A Halogen Trap
3.17 Installing a halogen trap: 3.17 Left hand side panel Inside view 48070 ø5 ø8 Rubber ring ø5 ø5 36710 3-20-1 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.17-1...
Page 283: Gas Saving Mode
T P 4 T P12 TP 5 Co ntin uo us flow T P 9 T P 1 TP16 TP17 TP 18 TP19 TP20 H F 4 2 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.18-1...
Page 284: 3.19 3.19 Upgrade For Copper Analysis Without Accelerators
Copper sample up to 20 g, or as much Copper sample the crucible can accommodate. If the Copper sample has the form of grains or drillings, the standard CS-800 ( CS-2000 ) can do the job. The condition is: The furnace control board should have a HF-42 with the corresponding jumper setting for The correct control mode.
Page 285 J o i n t c o n n e c t i o n f o r S i n C u 4 -1 - 5 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.19-2...
Page 286: Upgrading Of Analysers With Electronic Rack For Using The New Windows Software
This means replacement of the wiring, new HF board, new upper furnace part with two oxygen inlets and modifications of the tubing and new flow sensor in the IR-cell. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.20-1...
Page 287: 3.21 Preventive Maintenance Checklist
5. check of the chopper purge flow 6. check of the induction furnace a) measurement of the power/capacity and if necessary adjust b) check of the pneumatic and if necessary adjust. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 3.21-1...
Page 288: Miscellaneous
05020 Chopper blade 05030 Chopper blade holder 05064 Chopper motor 05048 Infrared source ( emitter ) 70280 O-ring 70330 O-ring 75120 Spring 75130 Retaining washer 75190 Washer © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.1-1...
Page 289 Threaded rod ( advice the length ) 05275 Infrared preamplifier 06210 IR-cable 06670 IR-zero adjustment board 06741 Infrared electronics board 15207 Gas flow sensor 70180 O-ring 70330 O-ring 77510 Heaters for IR-cell © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.1-2...
Page 290 72020 72020 Pressure gauge 77430 Panel meter 100 µA 70230 78010 Main power switch b ar 78040 Button for leakage test 70230 20045 11045 11185 70230 11120 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.1-3...
Page 291 Inlet pressure regulator 11495 Purge pressure regulator 12016 Gas flow and furnace control board HF 42 12044 Transformer 16100 Power supply board NK 31 18467 Microcontroller board UNI © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.1-3...
Page 292 Exhaust muffler 11376 Fixing plate for 11822 11492 Pressure regulator 11822 Pnematic valve block 12045 Transformer 12080 Rectifier 12100 Transformer 13850 Centrifugal blower 77050 TRIAC 77135 Capacitor © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.1-4...
Page 293 Co il cooling 26319 60631 60635 26618 60558 26319 Hollow screw 26618 Valve block 60234 Pneumatic valve 60240 Silencer 60513 Fiting 60522 Fiting 60631 Closure 60635 Seal © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.1-5...
Page 294 77210 Oscillator tube 77322 Capacitorr 77330 Capacitor 77335 Capacitor 77333 Filter 77345(13261; 13262; 77340; 77341; 77342) Capacitor 77350 Capacitor 100 nF 77489 Bracket 77600 Resistor 77610 Resistor © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.1-5...
Page 295 Cleaning brush for radiation shield 14026 76002 Washer 76003 70390 76003 Wing nut 76005 Knurled nut 90150 90150 Crucibles 14168 14200 71031 14210 14170 71010 14180 14185 14150 14220 14009 B9-1-3 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.1-6...
Page 296 Metal tube 1 4 0 2 1 70120 7 5 1 5 0 1 4 0 5 1 1 4 0 4 5 1 4 0 7 2 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.1-7...
Page 297 Oxygen purifying furnace: 21120 21010 21010 Heather section 21120 Quartz tube 70380 O-Ring 70380 4-1-9 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.1-8...
Page 298 CS 800 Main power wiring, right hand side bl ue br o wn ye llow RF filter gr e y Feed gr e en FILTER throug h or a ng e cap aci tor pi nk re d F 1 1 .1 2 6 / 3 6 bl ack vio le tt wh ite...
Page 299 blue brow n yellow grey C o o l i n g f a n green orange 1 1 0 3 5 1 2 0 4 4 pink N K 3 1 black 1 6 1 1 0 violett white 2 2 0 V A C D u s t t r a p h e a t e r 0 , 7 5²...
Page 300 Shuttle valve Purging valve Bypass valve Oxygen valve Regulating valve Pneumatic valve Coil cooling valve Outlet valve Pressure switch over valve for furnace lift Pressure switch Panel meter © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.2-3...
Page 301 30. 4. 2001 Datum Name Benennung: gr ee n gez.: 14. 7. 2000 Knipp 27. 3. 2001 CS-800 CS-2000 or an ge gepr.: 5. 3. 2001 14. 7. 2000 Polemitis pink Signalleitung für IR-4 r ed 20. 9. 2000 blac k 18.
Page 302 LE D is OFF 06255 06640 10pi n plug s w s w Temperatu re ge/gn sensor D-15 pl ug pi n 9 ge/gn 1-14-4-1 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.2-5...
Page 303 Chopper housing 0 . 5 ² x 2 2 c m I R s o u r c e 2+15 blue 6+19 1 . 7 5 - 7 V D C brown I R s o u r c e 0 .
Page 304 Name Datum Benennung: gez.: 10.7.2000 Knipp Chopper motor and IR source gepr.: 10.7.2000 Polemitis Zeichnungs-Nr.: 06660 Mainstr. 85 Block 20 D-41469 Neuss Bez.: geändert am: gepr.: © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.2-7...
Page 305 25.08.2000 Knipp Cable cone ction TH 62 - NR 32 (15037) Polemitis gepr.: 26.08.2000 Zeichnungs-Nr.: 06 645 Mainstr. 85 Block 20 Bez.: D-41469 Neuss geändert am: © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.2-8...
Page 306 IR-4 which is described in this manual. The adapter of the drawing below is used to adapt the new IR-rack to the CS-800 analyser. The drawings of the previous rack wiring can be found in the following 5 pages, these are the older models.
Page 307 0 61 75 According to the number of channels see 13-pin plug connector 25-pin plug Transformer Energy filter Heating elements Temperature sensor According to the number of channels, see © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.2-10...
Page 308 1 x g r 0 . 2 5 ² x 2 5 c m I R 2 1 0 62 0 0 C-signal S-signal Control voltage Control voltage Control signal for low channel Regulating voltage for low channel © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.2-11...
Page 309 Chopper motor and IR source p i n k r e d b l a c k v i o l e t t 06190 w h i t e © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.2-12...
Page 310 Cable connection TH 61 - NR 32 (15037) 06090 © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.2-13...
Page 312 Analyzer-PC grey yellow green brown wh ite shield CAUTION! Connect the shield on both connector frames. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.2-15...
Page 315 ( zero volts between its two leads ). After a short delay by the software, V2, V3 and V4 will be de-energised. The closed furnace condition is now reached. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.2-18...
Page 316 I R Th e rm o s ta t i c co n t r o l I R S i g n a l S R e g u l a ti n g v a l ve I NP UT S IR S i g n a l C O xy g e n f l o w ( De t e ct o r si g n a l s )
Page 317: Starting Through External Key
For this purpose, remove the case of the 96-pin plug and connect a wire to the key ( pins 17a to 26a ). ( All carry +24 volts ) The second wire is connected to pin 5C. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.3-1...
Page 318 To do this, remove the cover of the 96-pin connector and attach a relay wire to 17a to 26a ( all carry +24 volts ). ■ The second wire is attached to pin 24B. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.4-1...
Page 319: Spare Parts Kits
Tube black id = 6 od = 9 90290 Copper oxide 100g 11062 Reagent tubes 160 x 16mm 21120 Quartz tube for purification furnace 15083 Gasflow meter 15 l/h © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.5-1...
Page 320 20040 Catalyst tube 200 x 16mm 80925 Sets of fuses 11115 Plastic tube 75mm 11120 Paper filter holder 11370 Gasflow regulating valve 11400 Pressure outlet solenoid valve © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.5-2...
Page 321 77350 Capacitor 1µF/50V 77600 Grid resistor 77610 Resistor 14080 Cleaning mechanism rod 75122 Spring 75130 Safety ring 20000 Catalyst furnace 11490 Pressure regulator 15116 Gas flow sensor © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.5-3...
Page 322 Check if the 96-pole plug at the back of the CS 800 is firmly plugged in. Check if all the warning labels are still attached to the side-panels. Calibration of all measuring ranges. © 2002 by ELTRA GmbH Germany–- January 2002 - Service Manual CS-800 4.6-1...

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