Service Manual

multi EA 4000
Elemental Analyzer

1
Manufacturer Analytik Jena AG
Konrad-Zuse-Str.1
07745 Jena  Germany
Phone + 49 3641 / 77 70
Fax + 49 3641 / 77 92 79
Email [email protected]

Service Analytik Jena AG

Service & Support Center
Konrad-Zuse-Straße 1
07745 Jena  Germany
Phone: +49 3641 / 77 7402
Fax: +49 3641 / 77 7449
E-mail: [email protected]

Internet: ww.analytik-jena.com

General information http://www.analytik-jena.com

Copyrights and multi EA and multiWin are registered trademarks of Analytik Jena AG in Germany.
Trademarks Microsoft and Windows are registered trademarks of Microsoft Corp.
The identification with ® or TM is omitted in this manual.

Documentation number 01.17

Edition

Implementation of the Analytik Jena AG

Service Documentation

© Copyright 2017, Analytik Jena AG

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HTS1500 Contents

Contents
1 Basic Information............................................................................................................. 7
1.1 Service Manual Notes ................................................................................................. 7
1.2 Intended use ............................................................................................................... 7
1.3 Warranty and liability.................................................................................................. 8

2 Safety instructions ........................................................................................................... 9

2.1 General notes .............................................................................................................. 9
2.2 Safety markings on the device .................................................................................... 9
2.2.1 Handling hazardous substances .................................................................................. 9
2.2.2 Chemical resistance of the device ............................................................................... 9
2.3 Safety instructions for maintenance and repair ........................................................ 10
2.4 Behavior during emergencies.................................................................................... 10

3 System design ................................................................................................................ 11

3.1 Comprehensive overview .......................................................................................... 11
3.2 Basic device ............................................................................................................... 11
3.2.1 Combustion system ................................................................................................... 11
3.2.2 Pneumatic and Hose System ..................................................................................... 12
3.2.3 Components for sample gas drying and cleaning ...................................................... 13
3.2.4 Indicator and control elements, connections ............................................................ 14
3.3 Block schema configuration ...................................................................................... 17

4 Installation and commissioning ................................................................................... 19

4.1 Environmental conditions ......................................................................................... 19
4.2 Energy supply ............................................................................................................ 19
4.3 Gas supply ................................................................................................................. 20
4.4 Installation of the device ........................................................................................... 20

5 Preparation for service .................................................................................................. 21

5.1 Service position 1 (left side panel) ............................................................................ 21
5.2 Service position 2 (right side panel) ......................................................................... 22
5.3 Installation of furnace cartridge and heating elements ............................................ 23
5.4 Remove the heating elements and furnace cartridge ............................................... 27
5.5 Exchange of heating elements .................................................................................. 29
5.6 Exchange of thermocouple ....................................................................................... 30

6 Control electronic ........................................................................................................... 31

6.1 Block schema ............................................................................................................ 32
6.2 Power supply ............................................................................................................. 33
6.2.1 Test of power supply ................................................................................................. 33
6.2.2 Exchange of main power supply ............................................................................... 34
6.2.3 Exchange of power supply for temperature control .................................................. 34
6.3 Temperature control electronic ................................................................................. 34
6.3.1 Adjustment of temperature control (comparator) .................................................... 35
6.3.2 Exchange of temperature control PCB ...................................................................... 35
6.4 Gas control system .................................................................................................... 36
6.4.1 Flow schema ............................................................................................................. 37
6.5 Check of external communication ............................................................................. 38
6.5.1 Test of HTS 1500 via RS232 ..................................................................................... 38
6.5.2 Testing the interface (HT furnace) with service program ......................................... 40
6.5.3 Testing the hardware in the furnace module HTS 1500 ........................................... 41
6.5.4 Preparation of service PC for debug connection (USB driver installation) ................ 42
6.5.5 Test of HTS 1500 in operation mode (multiWin) via debug connection................... 42
6.5.6 Commands HTS 1500 (overview about the output of service interface) .................. 43
6.6 Firmware ................................................................................................................... 43
6.6.1 Firmware update ....................................................................................................... 44

7 Maintenance and care ................................................................................................... 45

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Figures Device name

7.1 Recomended service intervals during preventive maintenance ................................ 45

8 Spare parts ...................................................................................................................... 46

9 Recommended tools for service.................................................................................... 48

10 Transportating the device ............................................................................................. 49

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HTS1500 Contents

Figures
Fig. 1 Horizontal furnace of the basic device multi EA 4000 ................................ 12
Fig. 2 Flow meters at the basic device multi EA 4000 ........................................... 13
Fig. 3 Dust trap at the combustion furnace ............................................................ 13
Fig. 4 Inline filter ...................................................................................................... 14
Fig. 5 Drying tube and halogen absorber ............................................................... 14
Fig. 6 Status indicators at the basic device multi EA 4000 ................................... 15
Fig. 7 Control elements behind the front doors of the multi EA 4000 ................. 15
Fig. 8 Connections on the right-hand side of the multi EA 4000 ......................... 16
Fig. 9 Connections on the rear of the multi EA 4000 ............................................ 16
Fig. 10 Block schema CS ............................................................................................. 17
Fig. 11 Block schema Cl .............................................................................................. 17
Fig. 12 Block schema CS-Cl ........................................................................................ 18
Fig. 13 Block schema CS-TIC auto ............................................................................. 18
Fig. 14 View left side .................................................................................................. 21
Fig. 15 View right side ................................................................................................ 22
Fig. 16 View furnace ................................................................................................... 22
Fig. 17 Disconnecting heating elements ................................................................... 29
Fig. 18 Removing heating elements ......................................................................... 30
Fig. 19 Heating elements ........................................................................................... 30
Fig. 20 Block schema HTS 1500 ................................................................................ 32
Fig. 21 Voltages control PCB ...................................................................................... 33
Fig. 22 Adjustment temperature control .................................................................. 35
Fig. 23 Flow schema HTS 1500 ................................................................................. 37
Fig. 24 Check of external communication................................................................. 38
Fig. 25 Connect the service program – HTS 1500.................................................... 38
Fig. 26 service program: Select the temperature controller .................................... 39
Fig. 27 Query the firmware version of the temperature controller......................... 39
Fig. 28 Simulation of HT 1500 interface (independent from the installed furnace
type HT 1500 or HTS 1500) ......................................................................... 40
Fig. 29 Select simulation HTS 1500 .......................................................................... 40
Fig. 30 Simulation HTS 1500..................................................................................... 41
Fig. 31 Null modem cable (702-011.032) assignment (COM) (female 9 pin -
female 9 pin) .................................................................................................. 41
Fig. 33 maintenance service intervals ....................................................................... 45

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Figures Device name

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HTS1500 Basic Information

1 Basic Information

1.1 Service Manual Notes

Contents The service manual informs about the service and function of the HTS 1500, provides
the necessary know-how for the safe servicing of the device and connected
components to authorized service persons. The service manual further includes notes
on the maintenance of the equipment.

Conventions Instructions for action which occur in chronological order are numbered and combined
into action units and furnished with the corresponding results.
Safety notes are indicated by safety symbols and signal words. The type and source of
the danger, as well as the consequences, are stated together with notes on preventing
the danger.
The software elements are indicated as follows:
 Program terms are identified with small caps (e.g. menu FILE).
 Buttons are shown by square brackets (e.g. [OK])
 Menu items are separated by arrows (e.g. FILE  OPEN)

Safety symbols and The service manual uses the following symbols and signal words to indicate hazards or
signal words used instructions. The safety instructions are always placed before an action.

DANGER!
This symbol alerts you to a dangerous situation. Failure to avoid this situation will
result in serious or fatal injury.

WARNING
This symbol alerts you to a dangerous situation. Failure to avoid this situation can
result in serious or fatal injury.

CAUTION
This symbol alerts you to a dangerous situation. Failure to avoid this situation can
result in minor or medium injury.

Notice
This symbol contains information on procedures and other facts which do not result in
personal injury.

1.2 Intended use

The HTS 1500 is a high temperature furnace module, which is used only in
combination with the elemental analyzer multi EA 4000. The furnace temperature can

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Basic Information HTS 1500

be setup inside the software up to 1500 °C and is controlled via the firmware controller
of detection unit.

1.3 Warranty and liability

The warranty and liability periods comply with the legal requirements and the
provisions in the General Terms and Conditions of Analytik Jena AG.
Deviations from the intended use described in this user manual will result in
limitations of warranty and liability in the event of damage. Damage to wearing parts
or breakage of glass are not included in the warranty.
Warranty and liability claims are excluded for personal injury and property damage if
resulting from one or several of the following causes:
 use of the device other than intended
 improper commissioning, operation and servicing of the device
 modifications to the equipment without prior consultation with Analytik Jena AG
 operation of the device with faulty safety equipment or improperly fitted safety and
protection equipment
 inadequate monitoring of the equipment components subject to wear
 use of other than original spare parts, wearing parts or consumables
 improper repairs
 faults due to the non-observance of this service manual

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HTS1500 Safety instructions

2 Safety instructions

2.1 General notes

For your own safety and to ensure error-free and safe operation of the device, please
read this chapter carefully before using the appliance.
Observe all safety notes listed in this user manual and all messages and notes
displayed by the control and analysis program on the monitor.
Besides the safety instructions in this user manual and the local safety regulations that
apply to the operation of the device, the general applicable regulations regarding
accident prevention, occupational health and safety and environmental protection
have to be observed and complied with.
References to potential dangers do not replace the work protection regulations which
must be observed.

2.2 Safety markings on the device

Warnings and notice symbols have been attached to the device which must always be
observed.
Damaged or missing warning and notice symbols can cause incorrect actions leading to
personal injury or material damage! The symbol labels must not be removed!
Damaged symbol labels must be replaced without delay!

2.2.1 Handling hazardous substances

Even when the device is used as intended, the risk of damage to health when handling
hazardous substances cannot be excluded. The operator is solely responsible for
ensuring compliance with all safety requirements to protect individuals and property
when handling radioactive, infectious, toxic, caustic, flammable and other hazardous
substances.
Control the handling of hazardous substances in accordance with the safety category
of the lab, the details in the manufacturer safety data sheets and additional national
and international regulations (WHO, "Laboratory Biosafety Manual").
Wear personal protective equipment when working at the device.
Observe all notices on the cleaning and decontamination of the device.

2.2.2 Chemical resistance of the device

Aggressive substances may damage the device. Although the materials used are
resistant to most commonly used substances, material damage from aggressive
substances cannot be excluded.
Before using aggressive substances (e.g., acids, bases or organic solutions), check
whether the materials that are in direct contact with the substances are resistant to
them.

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Safety instructions HTS 1500

2.3 Safety instructions for maintenance and repair

The analyzer is always serviced by the authorized service engineer of Analytik Jena AG
or its authorized and trained specialist personnel.

Improper service and maintenance by unauthorized persons can damage the analyzer
seriously and endanger the operator of the multi EA 4000 system. The operator may
generally only carry out the tasks listed in the related chapter of user manual.

For cleaning of the device and the autosampler FPG 48/ Manual Boat Drive the
operator is responsible for establishing appropriate safety precautions – particularly in
terms of contaminated and infectious materials.
The HTS 1500 should be only moved during service after removing of the heating
elements.

The following has to be observed:

 The exterior of the analyzer may only be cleaned with a damp, not dripping, cloth
after the analyzer has been switched off.
 Any service and repair work at the analyzer may usually only be carried out in the
switched-off condition (unless stated otherwise).
 Service tasks and the replacement of system components (removal of the
combustion tube, service of the dust trap) must only be carried out after a
sufficiently long cooling down phase.
 Only use original accessories and original replacement parts from Analytik Jena AG.
The notes in the chapter "Service and care" must be observed.
 All protective equipment must be reinstalled correctly immediately after
completion of the service and repair work and be checked for operation!

2.4 Behavior during emergencies

The analyzer must be switched off by means of the means of the main switches (each
module and the furnace module HTS 1500), which are located at the rear panel of the
modules and the mains plug must be disconnected from the mains outlet in case of
dangerous situations or accidents. If the mains to the HTS 1500 was interrupted
(switched off or unplugged), there is a danger for overheating of the housing, because
of the not operating air circulation (fans)!

Because a rapid response can save lives during an emergency, the following has to be
ensured:

 The operating staff must be familiar with the location of safety equipment,
accident and danger alarms as well as first aid and rescue equipment as well as
their handling.
 All equipment for first aid (first-aid kit, eyewash bottles, stretcher, etc.) as well as
equipment for firefighting (fire extinguishers) must be within reach and easy to
access. All equipment has to be in a sound condition and should be checked
regularly.

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HTS1500 System design

3 System design

3.1 Comprehensive overview

The analyzer multi EA 4000 is of modular design. The basic device (combustion unit)
is combined with one or two detector modules and optional accessories for sample
digestion and automation:
 Basic device (HTS 1500)
 Carbon and/or sulfur module (C/S module)
 Chlorine module (Cl module)
 TIC solids module (automatic or manual)
The change from C/S to Cl detection is possible without having to change the
pneumatic and electrical connections. The ceramic tube is replaced by a combustion
tube from quartz glass for this purpose.
The sample transfer to the combustion furnace is either
 automatic using the sampler FPG 48 or
 manual using a manual feed.
The analyzer can be combined with an analytical balance with an interface to the
control computer transferring the sample mass for calculating the analysis results
automatically.
The control electronics is located in a detector module (in case 2 modules are present,
the electronics are situated inside the one which was ordered with the initial system).
The control of the analyzer and the analysis of the measurements takes place via the
control and data evaluation software multiWin installed on an external PC.

3.2 Basic device

The basic device of the multi EA 4000 consists of the following main components:

 Combustion system
 Pneumatic and hose system
 Components for sample gas drying and cleaning
 Indicator and control elements, connections

3.2.1 Combustion system

The combustion furnace is a resistor-heated horizontal furnace for digestion

temperatures up to 1500 °C. A combustion tube is used as reactor. The carrier and
combustion gas is supplied via an open gas lock to the inside of the combustion tube.
Since the gas flow of the carrier and combustion gas is greater than the intake flow of
the suction pump, the excess carrier gas at the inlet of the combustion tube acts like a
"gas curtain" and prevents the intake of entering compounds to the system as well as
the loss of sample gas.

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System design HTS 1500

The combustion tube for the C/S analysis consists of a special high temperature
ceramic (HTC). This is particularly robust, corrosion-resistant and low in wear. Thanks
to the HTC technology samples can be digested without catalysts at temperatures of
up to 1500 °C. For particularly difficult matrices the combustion temperature can be
increased to 1800 °C with special additives (utilization of the exothermal effect). This
is only recommended for short time usage, due to the remarkable wearing effects on
system components.

A quartz tube is used as combustion tube for the Cl analysis. The maximal
temperature for the quartz combustion tube is 1100°C ( method settings  process
parameter)!

The combustion system is equipped with a temperature controller monitoring the

heating of the furnace, keeping the temperature at the target value and preventing
overheating.

Open gas lock Horizontal furnace (open right panel)

Fig. 1 Horizontal furnace of the basic device multi EA 4000

3.2.2 Pneumatic and Hose System

Hose system The connection between the individual components and to the detection and digistion
modules is made via a hose system. The design of the hose system in the respective
module configurations can be found in the hose diagrams in section flow schema.

Controlling the gas flows The gas flow for carrier gas and combustion gas is controlled via manually adjustable
flow meters at the front of the basic unit.

An integrated suction pump ensures the stable flow of the sample gas through the
detector. The necessary intake flow is set with the needle valve at the flow meter
"pump".

The pump and the gas flows are added automatically once the multiWin program has
been started and the actual temperature of the combustion furnace differs less than
50 °C from the target temperature. If the temperature differs more than 50 °C from the
target temperature, the pump and gas flows are automatically switched off.

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HTS1500 System design

Fig. 2 Flow meters at the basic device multi EA 4000

1 Flow meter for argon or oxygen "Ar/O2" 3 Flow meter for intake flow "pump
2 Flow meter for oxygen "O2"

3.2.3 Components for sample gas drying and cleaning

Dust trap for C/S The dust trap is attached directly to the ceramic combustion tube. Combustion dust
detection settles inside it. Larger particles in the gas flow hit against a plate positioned vertically
to the gas flow and fall down. The dust trap has to be mounted with the gas-outlet
positioned upwards. This is necessary for the correct working of the dust trap.

Fig. 3 Dust trap at the combustion furnace

Direct behind the dust trap (hose no1) in the way to the dryer (hose 2) there is an
additional inline filter to catch particles from sample gas. When changing the inline
filter, please make sure, that the inline filter is installed in the corresponding flow
direction (marking / arrow on the filter), from hose no.1 to hose no.2 (→ "Flow
schema" p. 37)

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System design HTS 1500

Fig. 4 Inline filter

Drying tube and halogen For drying the sample gas during C/S analysis the drying tube, filled with magnesium
absorber for C/S perchlorate as desiccant, has been installed in the gas path.
detection
The basic device contains a halogen absorber (U-tube) for the greatest possible
removal of interfering components in the sample gas and to protect the detector. The
U-tube is filled with special copper wool and brass wool. The filling of the halogen
absorber has to be renewed at the latest once half of the copper wool or the brass
wool is discolored.
1 Drying tube with magnesium perchlorate
2 Halogen absorber

Fig. 5 Drying tube and halogen absorber

3.2.4 Indicator and control elements, connections

The green LED at the left door of the analyzer illuminates after the analyzer has been
switched on.

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HTS1500 System design

Fig. 6 Status indicators at the basic device multi EA 4000

Behind the front doors there are the ON/OFF switch and the flow meters for the
manual control of the gas flows.

Fig. 7 Control elements behind the front doors of the multi EA 4000
1 ON/OFF switch 3 flow meter for controlling oxygen flow O2
2 Flow meter for controlling the 4 needle valve for pump flow (sample gas)
argon/oxygen flow "Ar/O2"

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System design HTS 1500

Fig. 8 Connections on the right-hand side of the multi EA 4000

1 Gas lock coupling with heat protection 3 Connection "Ar" for the connection to the
2 Connection “O2” for the connection to the combustion tube/gas lock
combustion tube/gas airlock 4 Channel for sample gas and bypass hoses during
Cl measurements

On the rear of the multi EA 4000 are the gas inlets for the oxygen and argon supply,
the connections for the attachment to the C/S or Cl module and the mains connection
cable.

1 Mains switch
2 Mains cable
3 "COM" connection to the C/S
module or Cl module
4 "out" connection – measuring
output (sample gas)
5 "pump" connection to the C/S
module or Cl module
6 "waste out"
7 Gas connection "Ar" for argon
(during Cl measurements and
pyrolysis)
8 Gas connection "O2" for oxygen
9 Service interface (debug)

Fig. 9 Connections on the rear of the multi EA 4000

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HTS1500 System design

3.3 Block schema configuration

Fig. 10 Block schema CS

Fig. 11 Block schema Cl

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System design HTS 1500

Fig. 12 Block schema CS-Cl

Fig. 13 Block schema CS-TIC auto

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HTS1500 Installation and commissioning

4 Installation and commissioning

4.1 Environmental conditions

The installation location is free of

 Ignitable gases, vapors, solvents
 Corrosive vapors
 Direct sunlight
 High dust contamination
 Strong mechanical vibrations
 Magnetic fields
 Air Drafts and strong temperature fluctuations
The installation location meets the following environmental conditions:
 Temperature range: +10 ... +35 °C (air-conditioning recommended)
 Max. humidity: 90 % at 30 °C
 Air pressure: 70 kPa to 106 kPa

4.2 Energy supply

The multi EA 4000 is operated from the single phase alternating current mains.

For the use of the basic device with the furnace module (HTS 1500) in areas with
mains voltages of 100 V/115 V/120 V/127 V, a 2-phase connection is possible using
optional accessories.

The installation of the electrical equipment of the laboratory must comply with the
standard DIN VDE 0100. After the connection point an electrical current in accordance
with the standard IEC 38 must be available.

Furnace module HTS 1500

Voltage 200 … 240 V AC (+ 10 %, -5 %)

100 V/115 V/120 V/127 V
Frequency 50/60 Hz
Fuse provided (mains side) 16 A single phase

Sampler and detector modules

Voltage (modules 100 … 240 V AC (±10 %)

and sampler)
Man. TIC solids 220 … 240 V AC (±10 %), 50/60 Hz(for 100 V AC / 115 V AC please
module enter more details below)
Frequency 50/60 Hz

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Installation and commissioning HTS 1500

Fuse provided 10 A single phase

(mains side)

4.3 Gas supply

Oxygen Quality > 2.5

Inlet pressure 200 … 400 kPa (29 … 58 psi)
Required medium approx. 150 l/h
supply
Connection Connection piece for hose with hose
diameter: OD 6 mm / ID 4 mm
only for manual TIC solids module: T-piece
for hose with hose diameter: OD 6 mm /
ID 4 mm for oxygen supply
Argon Quality > 4.6
for the use of the
Inlet pressure 200 – 400 kPa (29 – 58 psi)
Cl module and
multi EA 4000 with Required medium approx. 140 l/h
pyrolysis function supply
Connection Connection piece for hose with hose
diameter: OD 6 mm / ID 4 mm

4.4 Installation of the device

 Follow the description in chapter "Installation of furnace cartridge and heating

elements" p. 23. For the installation of the detector modules, refer to the operation
manual multi EA 4000.

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HTS1500 Preparation for service

5 Preparation for service

5.1 Service position 1 (left side panel)

Fig. 14 View left side

 Switch off the HTS 1500 and remove the power cord
 Remove the dust trap
 Loosen the 4 x screw of left side panel
 Push the panel upward
 Remove the earth cable from side panel
 Remove the left side panel

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Preparation for service HTS 1500

5.2 Service position 2 (right side panel)

Fig. 15 View right side

 Loosen the 4 x screw of right side panel

 Push the panel upward
 Remove the earth cable from side panel
 Remove hose O2 + hose Ar from side panel (inside)
 Remove the right side panel

Fig. 16 View furnace

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HTS1500 Preparation for service

5.3 Installation of furnace cartridge and heating elements

1. Bring the HTS 1500 in service position 2:

 Loosen the 4 x screw of right side panel
 Push the panel upward
 Remove the earth cable from side panel
 Remove hose O2 + hose Ar from side panel (inside)
 Remove the right side panel

2. Remove the transport locks and duct tapes inside the

housing.

3. Remove the transport lock from the furnace cartridge

(rear side) with an allen key 3 mm.

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Preparation for service HTS 1500

4. Remove the transport lock from the furnace cartridge

(front side) with an allen key 3 mm and remove the
damping material inside the gap (right side).

5. The transport lock items can be stored for a later

transport of the furnace cartridge.

6. Wear gloves for mounting of the two sets of heating

elements (each consisting of 3 single elements).

Notice:
Don’t touch the heating elements directly with your hands,
it will decrease the lifetime of the heating elements!

7. Remove the transport locks from the connecting cables.

24
HTS1500 Preparation for service

8. Insert both triple heating elements into the heating

chambers.

9. Connect all heating elements serial with the related

cables and tighten the clamps (screw M4) with a torque
spanner of 0.6 Nm.
10.Mount the thermocouple with holder on the furnace
cartridge (center of top) with two nuts M3.
11.Please be very careful, that the connecting wires are not
in contact with the holder (ground) of thermocouple!

12.Move the mounted furnace cartridge into housing of HTS

1500.

13.Mount the furnace unit on the retaining plate with the

two screws (2, 3) to the housing.
14.Connect the conductive ground to the furnace cartridge.

15.Assemble the temperature sensor (1) on the furnace

cartridge

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Preparation for service HTS 1500

16.Remove the transport lock (3) from the electrical leads

(1, 2). Connect the heating elements one by one to the
electrical leads. Pull the cable with wire braid downwards
by slightly turning it downwards. Fix the screws with a
torque spanner of 0.6 Nm.

17.Connect the thermocouple (1) and its functional

grounding (2) to the temperature sensor PCB (3)
connection.

18.Connect the protective conductor and hose no. 12 and

hose no. 15 to the related connectors on the right side
panel.
19.Mount the right side panel and fix the 4 screws.

20.Screw the gas lock and the protection plate

21.Connect the O2 hose to the gas sluice.

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HTS1500 Preparation for service

5.4 Remove the heating elements and furnace cartridge

WARNING
In the interior of the analyzer, dangerous electrical voltages and high currents occur!
Turn off the analyzer to remove the heating elements and the furnace cartridge from
the power switch on the back of the unit and unplug the power cord from the wall
outlet.
The heating elements and the furnace cartridge may only be reinstalled by the
customer service of Analytik Jena AG or by qualified personnel authorized and trained
by Analytik Jena AG. The re-commissioning of the basic device must also be carried out
by the persons mentioned.

Attention
There is a risk of burning at the furnace! Only sevice the unit in the cold operating
condition or allow the unit to cool down long enough (best overnight)!

The heating elements and the furnace cartridge made of high temperature ceramics
can be damaged by shocks during transport. The equipment parts must therefore be
removed from the basic unit and transported separately. The heating elements and
the furnace cartridge must not be removed to be moved within the laboratory.
1. Remove the dust trap from the left side panel.
2. Unscrew the gas lock. Remove the combustion tube from
the furnace.

3. Open the right side wall of the basic unit. Loosen the
four hexagon socket head screws. Do not unscrew the
screws completely.
4. Remove the protective conductor (1) and the two gas
hoses (2, 3, hose no. 12 and 15) from the inside of the
side wall. Remove the side panel.

27
Preparation for service HTS 1500

5. Disconnect the protective conductor (5) from the furnace

cartridge (4) and the L-shaped retaining plate (3).
6. Disconnect the orange connection cable of the
thermocouple (1) and the green connector for functional
grounding (2) from the inner wall of the basic unit.

7. Disconnect the electrical leads (1, 2) from the heating

elements. For this, loosen the hexagon socket screws on
the wire braid. Pull the cable with wire braid upwards by
slightly turning it upwards.

8. Loosen the two screws (2, 3), which the furnace

cartridge and retaining plate are fixed in the analyzer.
9. Unscrew the temperature sensor (1) from the furnace
unit.

10.Pull furnace cartridge and retaining plate completely out

of the analyzer and securely shut off.
11.Loosen the long wire mesh (see arrow), which
electrically connects the two heating elements.
12.Unscrew the hexagon socket screws and pull the wire
braid upwards by slightly turning it upwards.

28
HTS1500 Preparation for service

13.Carefully lift the sets of heating elements one by one

from the furnace cartridge.

14.Pack the two sets of heating elements and the wire braid
as well as the furnace cartridge in separate transport
packages.

5.5 Exchange of heating elements

 Remove the furnace unit out of the HTS 1500

Fig. 17 Disconnecting heating elements

 Remove the serial flat connecting cable between heating elements with 3 mm
Allen key.
 Detach the set of heating elements (3 pieces) upwards.
 Now you can remove both sets (3 pieces) of heating elements.
 Please be very careful while the dismounting of the single element.

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Preparation for service HTS 1500

Fig. 18 Removing heating elements

 It is only necessary to exchange the defective heating element.

 Please mount the new heating element and fix it with 0.6 Nm (torque spanner
0.6 Nm) for connecting the serial flat connecting cable.

Fig. 19 Heating elements

 Re-assembling of the new heating elements and the furnace back in housing will
be done in reverse sequence.
 Mount the flat cables to the power supply and current sensor PCB with a torque
spanner 0.6 Nm.

5.6 Exchange of thermocouple

 Switch off the HTS 1500 and unplug from mains.

 Open the furnace module and bring it in service position 2 (open right side panel).
 Remove the furnace out of the HTS 1500 (→ "Remove the heating elements and
furnace cartridge" p. 27).
 Loosen the holder of thermocouple with a nut spinner 5.5 mm and pull it out.
 Mount the new thermocouple with holder.
 Observe the temperature according instructions.

30
HTS1500 Control electronic

6 Control electronic
The gas control system contains a gas box with valves and pressure monitoring
switches at the gas inlet, a switching valve for the pyrolysis function, a suction pump
for the sample gas flow and the rotameters for the flow adjustment of 2 feed gas flows
and the sample gas flow. The suction pump and all valves operate with 24 V supply
voltage.

31
Control electronic HTS 1500

6.1 Block schema

Fig. 20 Block schema HTS 1500

32
HTS1500 Control electronic

6.2 Power supply

The HTS 1500 can be operated on mains supply 230 V AC (200 - 240 V AC; 50/60 Hz)
corresponding to the supply voltage in the application area, neutral and one phase or
2 phases of the alternating voltage are fed to the module via the specific mains
connection cable. The connection value is 16 A.
The power supply includes the mains input socket, the mains switch, the line circuit
breakers, fuse elements, the mains filter, the safety relay, the power supply unit of the
control unit and the power supply of the heating elements.
Through the power supply of the control, a 24 V DC voltage with up to 2 A is provided
to the modules of the control electronics, the gas control and the thermal
management.
The power supply of the heating elements provides the controllable voltage from 0 to
24 V with up to 125 A for the heating elements of the furnace cartridge.
The thermal management controls the housing temperature with 3 fans to a
maximum of 50 °C to ensure the correct functioning of the power supply and control
electronics. The thermal management is also active when the device is switched off by
means of the front switch.

Notice
Fans run independently from the operation of the HTS 1500!

6.2.1 Test of power supply

Fig. 21 Voltages control PCB

After switching on, all 4 LEDs for power supply must light up!

33
Control electronic HTS 1500

Voltages / signal name J105 (Pin – Pin) Expected voltage

24 V 1–5 23.5 – 24.5 V DC
5 V digital 1-3 4.9 – 5.2 V DC
24 V gesch.(switched) 1-7 23.5 – 24.5 V DC
12 V analog 2 - 12 11.8 – 12.4 V DC
10 V analog 2 - 10 9.9 – 10.1 V DC
5 V analog 2-8 4.9 – 5.1 V DC

6.2.2 Exchange of main power supply

 Switch off the furnace and unplug from mains.

 Open the furnace and bring it in service position 1 (open left side panel).
 Remove all connections of power supply and dismount the power supply from the
top side of housing.
 The re-assembly of power supply will be done in the reverse order.

6.2.3 Exchange of power supply for temperature control

 Switch off the furnace and unplug from mains.

 Open the furnace and bring it in service position 2 (open right side panel).
 Remove the furnace out of the housing.
 Remove the current sensor.
 Remove the temperature sensor.
 Remove all connections of power supply can dismount the power supply from the
rear side of housing.
 The re-assembly of power supply will be done in the reverse order.

6.3 Temperature control electronic

The control electronics, consisting of main board, current sensor and temperature
sensor, communicate with the device system, control valves and the pump of the gas
control, monitor the gas supply, regulate the selected furnace temperature and
includes a safety circuit for overtemperature protection.
The furnace temperature is controlled by measuring the temperature with a Type S
thermocouple, by monitoring the output current of the power supply of the heating
elements in accordance with the control deviation and the heating rates programmed
in the control algorithm. 6 series-connected MoSi2-U elements are used as heating
elements.
These elements are extreme cold conductors and cannot be operated with full
operating voltage in the cold state, which is why the operating current is measured by
means of a current sensor and limited by the regulation to approximately 100 A.
The maximum supply voltage of the heating elements is 24 V DC with galvanic
insolation to the grid input. This eliminates the risk of electric shock when the heating

34
HTS1500 Control electronic

elements are touched. Because of the very high capacities and currents, it is
nevertheless necessary to act with caution when working on the furnace cartridge.
The advantages of the MoSi2 elements include the possible high power density, the
very high application temperature and the property at high temperatures to form a
SiO2 protective layer, which ensures a long service life.
The heating elements used in the HTS 1500 and as spare parts are pre-glazed
(conditioned) by Analytik Jena with a special procedure to ensure this protective layer
from the beginning of the application.
In the event of a fault, individual heating elements can also be replaced. A total
exchange of all heating elements, which is indispensable for SiC, is not necessary with
this type.
Two temperature sensors on the furnace cartridge and power supply unit are
integrated in a safety circuit for software independent overtemperature protection,
which interrupts the voltage supply of the power supply unit with the safety relay in
the event of a fault.

6.3.1 Adjustment of temperature control (comparator)

The comparator for over-temperature protection (safety function) has to be adjusted.

Fig. 22 Adjustment temperature control

Adjust the potentiometer comparator 1.0 to 1.05 V, measured with a voltmeter from
the measuring point "Uset" to the measuring point "AGND".

6.3.2 Exchange of temperature control PCB

 Open the furnace and bring it in service position 1 (open left side panel)
 Loosen the four screws of PCB
 Exchange the control PCB
 Adjust the comparator(→ "Adjustment of temperature control (comparator)" p. 35)

35
Control electronic HTS 1500

6.4 Gas control system

The gas control system contains a gas box with valves and pressure monitoring
switches at the gas inlet, a switching valve for the pyrolysis function, a suction pump
for the sample gas flow and the rotameters for the flow adjustment of 2 feed gas flows
and the sample gas flow. The suction pump and all valves operate with 24 V supply
voltage.
There is a dust trap, a dust filter, a dryer tube and an optional halogen absorber in the
sample gas path for sample gas purification.

36
HTS1500 Control electronic

6.4.1 Flow schema

Fig. 23 Flow schema HTS 1500

37
Control electronic HTS 1500

6.5 Check of external communication

Fig. 24 Check of external communication

The communication at the interfaces must be checked as described below:

 A null modem cable is used to connect the COM port to an RS232 port on the PC
 A USB cable (A-B) connects the debug connection to a PC

6.5.1 Test of HTS 1500 via RS232

The communications test for the furnace module HTS 1500 (temperature controller) is
carried out using the service program (Gerätetest).

Fig. 25 Connect the service program – HTS 1500

38
HTS1500 Control electronic

Fig. 26 service program: Select the temperature controller

 The communication with the temperature controller can now be started and tested
using the "Start" function. The corresponding commands are available in the help
function (Hilfe-Funktion).

Fig. 27 Query the firmware version of the temperature controller

39
Control electronic HTS 1500

6.5.2 Testing the interface (HT furnace) with service program

 Connect the PC (service program) to the detector module on port COM.

Fig. 28 Simulation of HT 1500 interface (independent from the installed furnace type HT 1500 or HTS
1500)

 Start the device test program (Gereatetest.exe).

 Select the device under SIMULATION  HT1500:

Fig. 29 Select simulation HTS 1500

40
HTS1500 Control electronic

Fig. 30 Simulation HTS 1500

The communication between the firmware controller unit and the service program can
now be recorded or monitored (Received/Sent).

6.5.3 Testing the hardware in the furnace module HTS 1500

Socket 1 Socket 2

1 1

6 4

2(RXD) 3(TXD)

3(TXD) 2(RXD)

4 6

5(GND) 5(GND)

7 8

8 7

9 9

Fig. 31 Null modem cable (702-011.032) assignment (COM) (female 9 pin - female 9 pin)

41
Control electronic HTS 1500

6.5.4 Preparation of service PC for debug connection (USB driver installation)

For the preparation of debug interface you need to install the USB-driver, which is
available:
 from software CD multi EA 4000
 from software path in Extranet

 Connect service-PC to the USB interface “Debug” in the operating system of your
PC.
− For XP please select “not_WHQL_certified” driver
− For Windows 7/8/10/Vista please choose AJ_WHQL_certified” driver

6.5.5 Test of HTS 1500 in operation mode (multiWin) via debug connection

The standard USB/COM driver (EA/TOC-analyzer) must be installed as driver (see

chapter preparation).
 Connect the service PC with the debug interface at the HTS 1500 with a null
modem cable.
 Start "Serviceterminal".
 Select “configuration” and afterwards “display”. Select the related interface.
 For recording of the communication, capture communication as txt-file. Therefore
you have to set a suitable name and select a folder for storage resp. you can use the
preconfigured one.
 Switch on the HTS 1500.
 Switch on the other components of multi EA 4000.
 Start multiWin and initialize the multi EA 4000.

The HTS 1500 can be controlled via the COM port (RS232) via the "device test
program on service PC" ".
The debug output on the USB port can be evaluated with the "serviceterminal
program" on service PC. It ensures an observation of the firmware/temperature
controller and to capture these data for a subsequent evaluation on another PC.

8_CState=16_EState=0*CS=0*TS=0*Act=0*TOK=0*Soll=0*Ist=2.23*RV=0.00*CV
=0.0

THp=21.6*Erro_THp=0*TGi=21.6*Erro_TGi=0

Fan1: State=0 Speed=1053 Fan2: State=0 Speed=525 Fan3: State=0 Speed=659

Temp=23

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HTS1500 Control electronic

6.5.6 Commands HTS 1500 (overview about the output of service interface)

Example for a record of the device status informations:

8_CState=16_EState=0*CS=0*TS=0*Act=0*TOK=0*Soll=0*Ist=2.23*RV=0.00*CV=0.
0
THp=21.6*Erro_THp=0*TGi=21.6*Erro_TGi=0
Fan1: State=0 Speed=1053 Fan2: State=0 Speed=525 Fan3: State=0 Speed=659
Temp=23
8_CState=16_EState=0*CS=0*TS=0*Act=0*TOK=0*Soll=0*Ist=6.72*RV=0.00*CV=0.
0
THp=21.6*Erro_THp=0*TGi=21.6*Erro_TGi=0
Fan1: State=0 Speed=784 Fan2: State=0 Speed=541 Fan3: State=0 Speed=684
Temp=23
9_CState=16_EState=0*CS=0*TS=0*Act=0*TOK=0*Soll=0*Ist=11.19*RV=0.00*CV=
0.0
THp=21.6*Erro_THp=0*TGi=21.6*Erro_TGi=0
Fan1: State=0 Speed=620 Fan2: State=0 Speed=539 Fan3: State=0 Speed=740
Temp=23

Desciption of status information

CState = Current Status
Estate = Error-status
CS = status of Current Sensor
TS = status of Temperature Sensor
TOK = Temperature status
Soll = Solltemperatur
Ist = Current temperature
RV = Control parameter
CV = actual current
THp = Temperature furnace cartridge
TGi = housing temperature
Status Fan = 0 = OK
1 = blocked
2 = Speed error
Temp = Temperature fan control

6.6 Firmware

The firmware controller of multi EA 4000 (located inside one of the detection
modules) communicates with the firmware controller of HTS 1500 via RS232. The

43
Control electronic HTS 1500

related firmware of the basic unit (multi EA 4000) is depending on the technical stage
one of the following:
 T09170725 or higher (for TERN)
 P09170725 or higher (for PSoC)

6.6.1 Firmware update

The main board of HTS 1500 will be delivered ready for operation. The firmware of
temperature controller and firmware controller were programmed in the factory
before final testing.

44
HTS1500 Maintenance and care

7 Maintenance and care

7.1 Recomended service intervals during preventive maintenance

Maintenance item Action frequency

Combustion tube Observe/exchange 12 months(depending consumption)
Quartz wool(comb. tube) Exchange 12 months(depending consumption)
Dust trap Cleaning 12 months(depending
contamination)
Inlet filter Exchange 12 months(depending consumption)
Drying agent Exchange 12 months(depending consumption)
Halogen absorber filling Exchange 12 months(depending consumption)
Membrane pump Check performance 12 months
Membrane pump Exchange 36 months
O2 inlet pressure Check performance 12 months
(vacuum)
O2 gas flow value Check performance 12 months
(vacuum)
Ar inlet pressure Check performance 12 months
(vacuum)
Ar gas flow value Check 12 months
performance(vacuum)
O2 valve Cleaning 12 months
O2/ Ar-valve Cleaning 12 months
Pyrolysis valve Cleaning 12 months
Pyrolysis valve Exchange 36 months
Temperature combustion tube Measurement/adjustment 12 months
Heating elements Exchange 24 months

Fig. 32 maintenance service intervals

45
Spare parts HTS 1500

8 Spare parts

Artikelnummer Name (english)

702-891.001 furnace cartridge HTS 1500 compl.
702-891.002 pyrolysis valve mounted
702-891.003 ground cable temperature sensor
702-891.004 RS485-Bus
702-891.005 membrane pump HTS 1500 compl.
702-891.006 valve unit HTS 1500
702-891.007 fan control programmed
702-891.008 valve bus
702-891.009 buffer vessel HTS 1500
702-891.010 dust trap HTS 1500
702-891.011 gas lock HTS 1500, complete
702-891.012 EMV-lid for protection tube
702-891.013 current sensor mounted
702-891.014 TMod mounted
702-891.015 heat shield
702-891.016 temperature sensor with cable
702-891.017 TIC-reactor HTS 1500
702-891.018 fuse T2A H, 5 x 20 mm
702-891.019 installationsrelais 24 VDC 20 A
702-891.020 power supply RSP-3000-24
702-891.021 circuit breaker 16 A 1-pol.
702-891.022 switch illuminated. 6 A 1-pol
702-891.023 switch 20 A, 2-pol.
702-891.024 contact ribbon cable 4/9 330 mm PtE
702-891.025 contact ribbon cable 4/9 170 mm PtE
702-891.026 rotameter with needle valve
702-891.027 needle valve stainless steell 6 mm
702-891.028 fan 120 x 120 x 25 mm 12 V PWM
702-891.029 fan 92 x 92 x 25 mm 12 V PWM
702-891.030 fan 80 x 80 x 25 mm 12 V PWM
402-891.031 disposable in-line filter M5
702-891.032 U-tube 205 mm filled
702-891.033 power cord EU CEE//7
702-891.034 assembly heating elements
702-891.035 furnace cartridge mounted HTS 1500
702-891.036 themocouple type S HTS 1500
702-891.037 contact ribbon cable 4/9 170 mm EtE
702-891.038 contact ribbon cable 4/9 100 mm EtE

46
HTS1500 Spare parts

702-891.039 sealing plate dust trap

702-891.040 lid dust trap
702-891.041 collet for dust trap HTS 1500
702-891.042 O-Ring 34 x 5 Viton
702-891.043 O-Ring 80 x 2 Viton
702-891.044 gas lock extension for sampler
702-891.045 tube extension for gas lock
702-891.046 ferrule gas lock
702-891.047 O-Ring 55 x 1.5 Viton
702-891.048 O-Ring 34 x 3 Viton 75
702-891.049 O-Ring 45 x 1.5 Viton
702-891.050 DCU HTS 1500 programmed

47
Recommended tools for service HTS 1500

9 Recommended tools for service

order no. description link/contact

800-001-00009 Thermometer RS1313 [email protected]
10-406-496 Temperature sensor TP 63 4.5 [email protected]
800-001-00003 Flowmeter Analyt GFM17 (calibrated [email protected]
for O² ; 0….3,00l/min)
800-003-00006 Manometer 0...2.5 bar [email protected]
800-003-00008 Manometer 0...6.0 bar [email protected]
121552-62 Manometer GDH 200-13 [email protected]
702-823.146 Service program [email protected]
702-011.032 Null modem cable [email protected]
702-011.601 USB cable [email protected]
118 1861-62 Current clamp, Handheld multimeter www.conrad.biz
VC590(True RMS)
10-406-497 Torque wrench 0.3….1.2 Nm with bits [email protected]

48
HTS1500 Transportating the device

10 Transportating the device

NOTICE
The heating elements and furnace cartridge can be damaged by vibration during
transport. Therefore, these device components must be removed from the multi EA
4000 and packaged separately before a transport.
Unsuitable packaging material and residue of measuring solution and chemicals can
damage individual components of the analyzer!
Only transport the analyzer in its original packaging! Ensure that the analyzer is fully
drained and all transport locks have been fitted!

Prepare the multi EA 4000 and its modules for transport as follows:

Basic device 1. Switch off the analyzer from the mains switch at the rear of the device and allow
multi EA 4000 the device to cool down.
2. Switch off the gas supply and disconnect the mains plug from the mains outlet.
3. Disconnect all connections on the rear of the analyzer.
4. Open the doors of the analyzer. Drain the drying tube. Re-insert the drying tube.
5. Unscrew the connections at the halogen absorber and press the halogen absorber
out of its clamps. Drain the halogen absorber.
6. Pull the combustion tube out of the furnace.
7. Package the accessories carefully and in particular protect glass components
against breakage.
8. Remove the heating elements and the furnace cartridge from the multi EA 4000
and package these device components separately (→ see section "Remove the
heating elements and furnace cartridge" p. 27).

Detection modules For the preparing of the detection modules for the transport refer to the "Operating
manual multi EA 4000".

Transport conditions Note following transport conditions:

 Transport the analyzer carefully to prevent damage from impact or vibration
 Avoid major temperature fluctuations to prevent formation of condensate inside
the device and the transport container
 Use desiccant in the transport container

49