Professional Documents
Culture Documents
Installation, Operation
and Service Manual
M4000
12/27/2012 Rev K
2001, MEECO, Inc. All rights reserved. No part of this publication may be reproduced, transmitted,
transcribed, stored in a retrieval system, or translated into any language in any form by any means
without the written permission of MEECO, Inc.
AquaVolt is a trademark of MEECO, Inc.
LabVIEW executable. LabVIEW 1994, National Instruments Corporation. All rights reserved.
United States Patent Nos. 4,901,221; 4,914,568; 5,291,587 and 5,301,366. Other patents pending.
SmartHeap memory manager 1991-1994, Arthur D. Applegate. All rights reserved.
For service and support, please contact MEECO, Inc., 250 Titus Ave., Warrington, PA 18976-2426,
PHONE: (215) 343-6600 or
(800) 641-6478, FAX: (215) 343-4194
Thank You
Dear Customer,
We commend you on your selection of the MEECO AquaVolt moisture analyzer. We
appreciate the time, effort and money you devoted to selecting equipment best suited to
your needs. We want to assure you that you made the appropriate choice. We respect
the fact that, by purchasing our equipment, you show your faith in our technology and
our organization. Therefore, we pledge to repay you with exceptional quality, service
and support.
Founded in 1948, MEECO provides instrumentation of the highest quality and finest
precision for some of industrys toughest analytical and measurement tasks. As the field
of moisture analysis grew and changed during the past few decades, MEECO led in
product innovation. Thus, our second pledge to our customers is to continue to keep
pace with market needs now and long into the future.
As always, we are working hard to make our documentation clear and complete. Please
let us know if you discover omissions, unclear explanations or inaccuracies. Your
feedback will help us make necessary improvements to both the manual and the
instrument.
We welcome calls and faxes regarding any questions and/or comments to:
VP Marketing
MEECO, Inc.
250 Titus Avenue
Warrington, PA 18976
Phone: (215) 343-6600
Toll Free: (800) 641-6478
FAX: (215) 343-4194
Finally, thank you for choosing a MEECO AquaVolt moisture analyzer. Please
remember that we value your opinion as much as your patronage. We welcome your
comments, questions and suggestions about our equipment.
Sincerely,
The MEECO Staff
MEECO Warranty
MEECO, Inc. (MEECO) warrants that newly manufactured instruments will be (A) free
from defects in materials and workmanship for a period of one year from the date of
delivery, except for the Aquavolt+ and the Tracer-2 instruments for which the period
shall be two years from the date of invoice, and (B) free from any lawful lien, security
interest or encumbrance from any person claiming by, through or under MEECO,
provided the full purchase price is paid in a timely fashion. MEECO warrants that any
cell which it has cleaned and resensitized (C&R) will be free from defects in materials
and workmanship for a period of 90 days from the date of completion of the C&R
service. The warranties regarding defects in materials and workmanship do not apply to
(i) defects, malfunction or damages arising out of or relating to improper installation,
improper use, improper storage, negligence, misuse, abuse, mishandling, accident or
failure to follow operating or maintenance instructions, or (ii) instruments and parts
repaired, altered, modified, contaminated or serviced by anyone except a MEECO
authorized service technician. If a newly manufactured instrument does not meet the
warranties specified in clause (A) above and the purchaser notifies MEECO promptly,
MEECOs sole responsibility will be to repair or replace such instrument or to correct
any defect in materials or workmanship that developed under proper and normal use
within one year (two years in the case of Aquavolt+ and Tracer-2 instruments) from the
date of invoice of such instrument. All warranties, expressed or implied in law, are
subject to the requirement that repairs of the instruments are made or attempted solely
by MEECO or under MEECOs supervision, and if repairs are made or attempted to be
made by any other person, all warranties, express or implied, shall terminate. Parts
considered consumable or expendable, including without limitation, batteries, fuses, and
filter elements, are excluded from the warranties set forth herein.
THE WARRANTIES CONTAINED IN THIS SECTION ARE EXCLUSIVE AND IN LIEU
OF ALL OTHER WARRANTIES AND NO OTHER WARRANTIES WHATSOEVER,
EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF PERFORMANCE,
MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE AND NO
INFRINGEMENT, APPLY TO THE INSTRUMENTS, AND NO WARRANTY SHALL BE
IMPLIED OR ARISE FROM ANY COURSE OF DEALING OR USAGE OF TRADE. NO
EXPRESS WARRANTY OR GUARANTY, EXCEPT AS MENTIONED ABOVE, GIVEN
BY ANY PERSON, WITH RESPECT TO THE INSTRUMENTS, SHALL BIND MEECO
AND ALL ORAL OR WRITTEN REPRESENTATIONS MADE OR IMPLIED IN ANY
MANUAL, LITERATURE, ADVERTISING BROCHURE OR OTHER MATERIALS ARE
EXPRESSLY SUPERSEDED.
THE PARTIES AGREE THAT THE PURCHASERS SOLE AND EXCLUSIVE REMEDY
AGAINST MEECO SHALL BE FOR THE CORRECTION OF ANY DEFECTS IN
MATERIALS OR WORKMANSHIP AS DESCRIBED IN THE FIRST PARAGRAPH
ABOVE. The purchaser expressly agrees that no other remedy shall be available and
that MEECO shall not be liable for delays, deprivation of use, or any other damages,
direct, indirect, exemplary, moral, incidental, consequential or punitive, which may result
to the purchaser because the instrument does not operate to the purchasers
satisfaction. IN NO EVENT SHALL MEECO BE LIABLE TO THE PURCHASER OR
ANY THIRD PARTY BASED UPON BREACH OF WARRANTY, BREACH OF
CONTRACT, NEGLIGENCE, STRICT TORT LIABILITY OR OTHERWISE, FOR ANY
INDIRECT, SPECIAL, INCIDENTAL, CONSEQUENTIAL, EXEMPLARY, MORAL OR
ii
During the warranty period, MEECOs obligation shall be limited to the repair or
replacement of materials or the correction of any workmanship shown to its satisfaction
to be defective. Please contact MEECOs Customer Service Coordinator for a Return
Authorization Number (RA#). All units and/or cells returned without an RA# may
experience service delays. Please return units and/or cells DDP Warrington, PA, USA,
to:
MEECO Service Department
Attention: RA# _____________
250 Titus Avenue
Warrington, PA 18976
Phone (215) 343-6600
Facsimile: (215) 343-4194
Toll Free: (800) 641-6478
service@meeco.com
NOTE: Prior to sending instruments to MEECO, instruments must be purged, properly
shut down, and properly capped. Please refer to the manual for procedures. Failure to
do so may void the warranty contained herein. Instruments or cells returned are subject
to review, and contaminated instruments may be returned to the purchaser at its cost
without service.
iii
Product Registration
Please fill out the information requested below to register your analyzer and return to MEECO at the
address noted on the next page.
Model/Type:_________________________ Serial Number _____________________________
Company: ____________________________________________________________________
Dept.: ________________________________________________________________________
User Name: ___________________________________________________________________
Users Title: ___________________________________________________________________
Address: _____________________________________________________________________
City: _______________________________ State: ________________ Zip Code: _________
Country: ____________________________
Phone: _____________________________ Fax:_____________________________________
Purchase Date: ________________________________________________________________
Type of Application:_____________________________________________________________
Yes
No
Yes
No
Why did you purchase a MEECO Analyzer? (Please mark all that apply)
Reliability
Versatility
Accuracy
Durability
Speed of Readings
Price
Other ____________________________________________________________
Yes
No
iv
How did you hear about MEECO? (Please mark all that apply)
Accessories/Options
Extended Warranty
vi
vii
Table of Contents
Thank You ________________________________________________________________________ i
Product Registration ______________________________________________________________ iv
Extended Warranty Agreement _____________________________________________________ vi
Table of Figures __________________________________________________________________ x
AquaVolt SPECIFICATIONS _____________________________________________________ xi
Serial Number Identification _______________________________________________________ xii
Warning! Labels _________________________________________________________________ xiii
Unit Hook-up_____________________________________________________________________ 7
Internal Pressure Regulator Adjustment ______________________________________________ 9
Basic Menu Operation ____________________________________________________________ 10
Status Display __________________________________________________________________________10
Adjusting Parameters ____________________________________________________________________11
Cell Protection___________________________________________________________________ 13
Cell Protection Below Lower Detection Limit _________________________________________________13
Cell Protection Above Maximum Range _____________________________________________________13
2 Shutdown _________________________________________________________________ 15
Shutdown _______________________________________________________________________ 15
3 Maintenance ______________________________________________________________ 17
Cell Change Procedure ___________________________________________________________ 17
Removal and Installation of the Electrolytic Cell _______________________________________________18
Battery Replacement Procedure ____________________________________________________________19
viii
System Protocol__________________________________________________________________ 29
Floating Point Operations _________________________________________________________________29
Flowchart for floating point operations_______________________________________________________30
Integer Operations _______________________________________________________________________31
Flowchart for write integers _______________________________________________________________32
Error Handling _________________________________________________________________________33
Appendix 1 _________________________________________________________________ 35
The AquaVolt Concept __________________________________________________________ 35
Electrolytic Cell Principle _________________________________________________________ 36
Cell Construction _______________________________________________________________________36
Faradays Law __________________________________________________________________________38
Appendix 2 _________________________________________________________________ 43
Construction of a Sampling Manifold________________________________________________ 43
Appendix 3 _________________________________________________________________ 45
Calibration Factors When Nitrogen is Not the Calibration Gas __________________________ 45
Appendix 4 _________________________________________________________________ 49
Approvals ______________________________________________________________________ 49
ix
Table of Figures
Figure 1 Front Panel .................................................................................................................3
Figure 2 Rear Panel ..................................................................................................................4
Figure 3 Internal View ..............................................................................................................5
Figure 4 Side View ....................................................................................................................6
Figure 5 Removing Electrolytic Cell....................................................................................... 18
Figure 6 Flowchart for Read (Floating Point Variables) ....................................................... 29
Figure 7 Flowchart for Write (Floating Point Variables) ...................................................... 30
Figure 8 Flowchart for Read (Integer Operations)................................................................ 31
Figure 9 Flowchart for Write (Integer Operation) ................................................................ 32
Figure 10 Element Cross Section ............................................................................................ 36
Figure 11 Cell Body................................................................................................................. 37
Figure 12 Cell Coating ............................................................................................................ 37
Figure 13 Delta Flow ............................................................................................................... 40
Figure 14 General Arrangement of Electrolytic Cell ............................................................. 41
Figure 15 Sample Manifold ....................................................................................................44
AquaVolt SPECIFICATIONS
Ranges: 1-1000 ppm inerts, oxygen, hydrogen
Sensor: Meeco AP Style Cell
Lower Detection Limit: 1 ppm
Accuracy: +/- 5% of reading or 0.4 ppm, whichever is greater
Unit of Measure: Field selectable choices: ppmV, ppmV, ppmW, dewpoint in C or F
Power: 100 - 240 VAC, 50/60 Hz 2.5 AMP Replaceable fuse in Power Entry module
Output Signal: (Field Configurable Isolated 0-5 VDC or Isolated Current Output 4-20mA, 0-20mA, or 0-24
mA) RS - 232 Communications Standard
Alarms: Standard
One (1) Cell Alarm Fixed
Two (2) User Adjustable Moisture Level Alarms
Inlet Pressure: 10-3000 psig (0.7 - 204 Bar)
Ambient Temperature: 0 C to 60 C, Max. 80% RH non condensing
Flow Rate: ~ 1.1 slpm combined sample and bypass
Gas Connection: 1/8" Compression tube fitting
Weight: 25 lbs. (11.34 kg )
Dimension: See Section 1 Figure 2 and Figure 4
xi
XXXXX- 41 -0
|_____| |_| |
|
| |
Unit Serial # | Hardware Revision #
Model #
Please have this number available when you contact MEECO with any questions regarding service.
The software version will be displayed on the initial menu when the unit is powered up.
xii
Warning! Labels
NOTE: Before operating the AquaVolt, please be sure to read all warning
notes which are shown throughout the manual. We have listed all of the
warning notes on this page for your convenience. Read this instruction manual
completely before operating your AquaVolt. Failure to do so may cause
damage to your unit.
Do not remove the cap fittings on the rear of the AquaVolt until you are ready to start up
the unit. Leaving the AquaVolt open or uncapped for more than a few minutes causes the
electrolytic cell to get very wet, resulting in a long initial drydown period, or damage to the
electrolytic cell.
Never access any internal components of the AquaVolt without first turning off the main
power switch on the front panel and unplugging the unit from the AC Power Source!
Be sure to read the Unpacking Instructions and Getting Started guidelines before proceeding
any further. Failure to do so can result in extremely long drydown times for your instrument.
Maintain the instrument on a dry gas purge when it is idle, with at least 100 sccm flow from
the sample outlet on the back of the unit.
When purging your MEECO system, be sure that your purge gas is within the operating
range of the unit. Otherwise, please use a MEECO SMA (Standard Moisture Addition) to
avoid cell dry-out and sluggish performance.
NEVER service the AquaVolt without first disconnecting AC power; this may result in
electrical shock.
xiii
xiv
Section 1
1
Installation
& Startup
NOTE: The AquaVolt should only be used in a manner specified by the manufacturer, and therefore, requires operators to read this manual in its entirety.
Unpacking Instructions
Remove the AquaVolt from the carton and packing material.
Retain the carton and packing material for future use.
The AquaVolt is shipped ready for use.* At the factory, we dried the analyzer to a low ppm level. To
keep the system clean and dry during shipment, we capped all inlet and outlet fittings.
IMPORTANT: Do not remove the cap fittings on the rear of the AquaVolt until
you are ready to startup the unit. Leaving the AquaVolt open or uncapped for
more than a few minutes causes the electrolytic cell to get very wet, resulting
in a long initial drydown period, or damage to the electrolytic cell.
* If inlet pressure is above 600 psig, see internal pressure regulator adjustment section.
Section 1
A 67.5V battery connected to the electrolytic cell keeps it dry during shipment. The battery connects
internally to the electrolytic cell. When AC power is connected to the analyzer, the battery automatically
disconnects from the cell. The battery resides in the holder in standby mode until a power outage or
disconnection occurs. At this time, the battery then powers the cell.
Getting Started
The following guidelines will help make the installation of the AquaVolt go smoothly.
Choose a suitable location for the AquaVolt. The AquaVolt should be mounted in a 19" rack.
We recommend that, in addition to the front panel mounts, you support the unit with side rails or
bottom braces to evenly distribute the unit's weight. In either case, make sure that it is level
during operation to permit accurate operation of the mass flow controller.
Prepare your sample line properly by purging it before attempting to hook up the AquaVolt. This
prevents prolonged exposure of the analyzer to ambient moisture levels. To construct your
sampling system in a way to allow switching the AquaVolt between two separate samples
without disconnecting the unit, please refer to MEECOs recommended guidelines for the
construction of a sampling manifold located in
Use only clean, high quality stainless steel tubing for the sample line connection. Eliminate
excess components and dead legs in the sample line. When components are necessary, use only
high-quality components with metal seals.
Be certain an appropriately rated power cord is connected at the rear of the unit, and to use an
easily accessible socket outlet no more than 3 meters from the AquaVolt.
The AquaVolt is capable of handling inlet pressures up to 3000 psig (204 Bar). Avoid
redundant regulators and other components in the sample line, which act as moisture traps.
WARNING: Avoid back pressure into the sample and bypass outlets.
Section 1
Component Identification
Front Panel
Figure 1
Front Panel
(A) Alphanumeric Vacuum-fluorescent display, 2 characters high x 20 characters wide;
Display
displays moisture reading, units of measure, setup selections and alarm
status.
(B) Power Switch Main Power on/off function
(C) Menu Key Use to access the various setup menus or to enter a selected option on
the alphanumeric display
(D) Arrow Keys
Left and right arrow keys are used to display menu parameters for review
or editing. The up and down arrow keys enable the operator to adjust the
value of the parameter displayed.
Section 1
Rear Panel
Figure 2
Rear Panel
(A) Sample Inlet
(B) Alarms
For removal and replacement of electrolytic cell; also for access to internal
pressure regulator for pressure adjustment
Section 1
Internal View
Figure 3
Internal View
Electrolytic Cell
Senses moisture
(B)
(C)
(D)
(E)
Power Supply
(F)
Main Board
(G)
67.5V Battery
for N2)
Section 1
Side View
Figure 4
Side View
Section 1
Unit Hook-up
WARNING: Be sure to read the Unpacking Instructions and Getting Started
guidelines on the previous pages before proceeding any further. Failure to do
so can result in long drydown times or damage to your instrument.
After a few moments, the display will change to the standard "status display" as shown below.
Section 1
If the AquaVolt is turned off without going through the shutdown sequence or in the case of a power
failure, the system will return to the mode it was in prior to the loss of power and all user programmable
settings will be saved. This feature is especially useful when quickly moving the system from one location
to another. For initial hook-up, however, the moisture values, mode and other information displayed at
this time are not meaningful. A detailed description of the displayed data is provided in Section 1, "Basic
Operation," and should be reviewed after initial hook-up.
4. Uncap the Sample Inlet (Fig. 2, Item A) , and quickly connect a closed gas source of between
10-3000 psig (.7-204 Bar) to the sample inlet. See internal pressure regulator adjustment section
if inlet pressure exceeds 600 psig.
5. Uncap the Bypass Outlet (Fig. 2, Item C)
6. Enable the gas source to allow a gas flow from the source, through the Bypass Outlet, to purge
the source line. This process should continue for 5 minutes.
7. When the instrument moisture reading is on scale and decreasing in value, uncap the Sample
Outlet (Fig. 2, Item D).
8. Select the proper gas type under the Measure mode menu selection.
The AquaVolt is now ready for operation.
Section 1
Section 1
Status Display
S Service
M Measure
1 - User Set
2 - User Set
C - Cell Alarm
F - Flow Alarm
10
Section 1
Adjusting Parameters
Normally the Status Display will be shown on the vacuum fluorescent display. Pressing the 'M' key while
the Status Display is shown will change the display to parameter adjustment mode. Once in the
parameter adjustment mode, the keys have the following functions:
Up
Down
Left
Right
M/Enter Information
Access the parameter list when viewing the Status Display; save
the changes made to the currently displayed parameter and go to
the next parameter when viewing parameters.
When changing a parameter's value, the previously saved value will be preceded by an asterisk. This is
only to show the previously selected value.
If twenty seconds pass without any key being pressed, the display will revert back to the Status Display
and any changes to the currently displayed parameter will be lost. To regain access to the parameter list,
press the 'M' key.
The following table displays the parameters, along with their ranges, in the order in which they are
accessed.
Display Text
Operating Mode:
Range of Value
Measure, Service
Shutdown
Moisture Units
Communications ID#:
0 to 15
11
Definition or Usage
Measure Mode measures
moisture under default
parameters, whereas Service
Mode parameters may be
altered.
Section 1
Display Text
Recorder Output
MODE:
Recorder Scale:
Range of Value
0-5 Vdc, 4-20 mA,
0-20 mA, 0-24 mA
1 - any value up to the upper limit
of the unit.( 2 ppm increments)
1 or 2 (ENABLED or DISABLED)
Cell Alarm:
Always Enabled
ENABLED, DISABLED
(Default 5%)
Flow Alarm
Deviation:
3 to 25 (% of scale deviation)
Software Revision:
Uptime:
Definition or Usage
The selection of recorder output
signal.
The range of values to provide
full scale output of the recorder
output.
The effect of the derived
moisture level on the alarm
output relay. Alarms will always
be displayed in the Status
Display regardless of this setting.
The value at which point the
derived moisture level is
considered to be an alarm.
Alarm will trigger when the
reading is below the lower
detection limit.
The effect of flow deviation on
the alarm output relay. Alarms
will always be displayed in the
Status Display regardless of this
setting.
The amount of deviation from set
point at which to be considered a
flow alarm.
Software version and release
date of the installed software.
Duration that the unit has been
powered up.
Pressing the LEFT arrow key when viewing the "Operating Mode:" parameter or the RIGHT arrow key
when viewing the software revision will return you to the STATUS display.
Pressing the left arrow key when viewing the "Operating Mode" parameter or the right arrow key when
viewing the software revision will return you to the status display.
If you wish to just review the settings, use the RIGHT arrow key to step through the list. This will prevent
accidentally changing a parameter.
12
Section 1
Cell Protection
Cell Protection Below Lower Detection Limit
The AquaVolt is equipped with a cell protection feature which will aid in preventing a cell from drying
out. If the cell reading drops to 200ppb, power to the cell is removed. After 5 minutes, power is reapplied
and the cell level checked. If the measurement is now greater than 200ppb, the unit will return to normal
operation. If the measurement is still below 200ppb the testing process will continue an additional 5
minutes. During this wait period, the display will flash "Cell Protection" and the time remaining in cell
protection mode.
13
Section 1
14
Section 2
2
Shutdown
Shutdown
MEECO recommends that you maintain the AquaVolt on a dry gas purge (dry gas not less than 1 ppm)
with AC power applied when not in use. This way the instrument will be in good condition when you go to
use it again.
Since the complete shutdown procedure includes removing the AquaVolt from the sample and capping
the instrument, generally a small amount of moisture will enter the unit. This will cause you to wait through
an initial drydown period again upon the next startup. Therefore, maintaining the instrument on a slight
purge is better than taking the instrument completely off line.
IMPORTANT: Maintain the instrument on a dry gas purge when it is idle, with at least
100 sccm flow.
Of course, if you need to move the AquaVolt, disconnection from the sample is unavoidable. Please
follow the shutdown procedure step by step to limit the analyzers exposure to moisture.
To shut down the AquaVolt, follow the instructions on the display to perform the following steps:
1. Cap the Sample Outlet (Figure 2, Item D).
2. Cap the Bypass Outlet (Figure 2, Item C).
WARNING: Do not perform the next step until the sample inlet pressure is
reduced to a safe level. Also, do not leave the instrument capped and
connected to a pressurized sample line for extended periods. Regulator
leakage can allow the internal instrument pressure to rise to the level of the
inlet pressure which could damage the unit.
3. Disconnect the Sample Inlet (Figure 2, Item A) and cap with a 1/8" compression plug fitting. You
should also plug the sampling system.
4. Turn off the power by pressing the Power Switch on the front panel (Figure 1, Item B).
If you remove power to the unit, the cell will automatically switch to the 67.5 V DC battery located inside
of the unit.
Since the 67.5 V battery can run down, only use it when you ship or transport the unit. Otherwise, keep
the AquaVolt connected to an AC source and powered on.
NOTE: The AquaVolt will automatically switch on/off the 67.5 V battery
when connected or disconnected from AC source.
15
Section 3
16
Section 3
3
Maintenance
WARNING: When purging your MEECO system, be sure that your purge gas is within
the operating range of the unit. Otherwise, please use a MEECO SMA (Standard
Moisture Addition) to avoid cell dry-out and sluggish performance.
17
Section 3
Figure 5
Removing Electrolytic Cell
3. Carefully disconnect the cell leads by unplugging the connector (Figure 5, Item A).
4. Loosen the cell nuts (Fig. 5, Item B) at the top and bottom of the cell with a 7/8" wrench.
5. Remove the cell retaining strap (Fig. 5, Item C)
6. Remove the cell along with the PTFE gaskets from the top and bottom fittings.
7. Install new PTFE gaskets in the top and bottom fittings.
8. Remove the red plastic end caps from the new cell.
9. Install the new cell in the holder and install the cell retaining strap.
10. Connect the new cell leads to the connector.
11. Tighten the cell top and bottom nuts about 1/8 turn beyond finger tight.
12. Install the red end caps on the cell which was removed.
13. Return the old cell to MEECO for servicing.
18
Section 3
1. Power off and then disconnect the AC power cord from the AquaVolt
2. Remove the AquaVolt module from the chassis by removing rear screws (Fig. 2, Item K) and
then sliding module out of the chassis (the sample line may need to be disconnected from the
inlet for this step).
3. Remove the 15 top cover screws (1/16" hex head) then remove the cover from the AquaVolt.
4. Remove the battery electrical connection clip from the battery terminals.
5. Remove the two nuts and washers that fasten the battery bracket to the AquaVolt chassis.
6. Lift the battery to clear the two threaded studs, and then move it forward to allow removal of the
battery.
7. Remove and replace the 67.5 Vdc NEDA 200 battery (MEECO P/N L0027 Replacement Battery).
8. Reverse the above steps to reassemble your AquaVolt and return it to service.
9. It is not necessary to change the battery if the unit is powered.Software Upgrade Installation
19
Section 3
Flash Reprogramming
To reprogram the flash memory of the AquaVolt, the following procedure should be followed.
1. Obtain the latest software for theAquaVolt from MEECO Inc.
2. Turn power to the AquaVolt off.
3. Connect a 1 to 1 nine pin cable from the serial port of a computer to the serial connection on the
rear of the AquaVolt.
4. Run a terminal program on the computer such as Hyperterminal with communications settings*
of:
9600 bits per second
No parity
8 data bits
1 stop bit
Be sure flow control is set to none.
5. Power the AquaVolt on.
6. Once the AquaVolt is powered on there is a 10 second opportunity to type CTRL Z, which will
bring up the bootloader program. If you miss the opportunity, recycle the power and repeat.
7. A menu of choices will appear on the display.
a) Menu of choices
S = Save your current firmware
U = Update your firmware
X = Exit program mode
8. It is recommended that you save your present configuration first before trying to update.
9. To save your present firmware, press the S key.
10. Use the transfer option of the communications program to receive a file using xmodem.
11. Enter a file name and a folder to store your existing software.
12. When the file is finished being saved you will see a transfer complete and the previous menu
choices repeated.
13. To upload the new firmware press U to update the AquaVolt. After pressing U the operator is
given the choice of continuing or aborting. Press C to continue.
14. Use the transfer option of the communications program to send a file using xmodem.
15. Choose the file with the new firmware for the AquaVolt.
16. At the end of the transmission a menu will appear. Press X to reset the AquaVolt with the
new code.
20
Section 3
Changing Fuses
There are two 2.5 Amp IEC fuses mounted in a removable fuse holder on the rear of the AquaVolt (see
Figure 2, Item G). If the AquaVolt has no power indications with the power switch on and AC power
connected, there may be a problem with the fuses. To remove and replace these fuses:
1. Switch the AquaVolt power off and disconnect the AC power cord from the AC source.
2. Remove the fuse holder cap of the power entry module.
3. Remove the fuses from the fuse holder and examine for an open fuse. If necessary, use an
ohmmeter to check for continuity across each fuse.
4. If the fuse is open, replace with a fast-acting, 250V/2.5A IEC fuse (MEECO P/N L3380).
5. Replace the AC power cord at the rear of the unit. Power the unit back on and check for normal
operation.
This completes the Fuse Replacement procedure.
21
Section 3
Description
FUSE, 2.5 AMP
Battery
15 Volt Power Supply
PCB Assembly
APR Cell (Inert Gas Only)
APO Cell (Oxygen and Inert Gas)
APRH Cell (Hydrogen and Inert Gas)
22
QTY
2
1
1
1
1
1
1
Section 4
4
General
Information
Female - DB-9
1.
2.
3.
4.
5.
6.
7.
8.
9.
Not used
TX signal
RX signal
Not used
Signal ground
Not used
Not used
Not used
Not used
23
Section 4
I/O Connector
Male - DB-9
1.
2.
3.
4.
5.
6.
7.
8.
9.
Normally Closed
Common
Normally Open
Female - DB-9
5. com - Low Level Alarm
4. nc - Low Level Alarm
9. no - Low Level Alarm
1. com - Level Alarm1
2. nc - Level Alarm 1
6. no - Level Alarm1
8. com - Level Alarm 2
3. nc - Level Alarm 2
7. no - Level Alarm 2
24
Section 5
5
Serial
Communication
General Information
The Serial Communication feature allows you to monitor the instrument from a host computer via an RS232 connection. You can read integer and floating point data to and from memory locations inside the
AquaVolt. Access to these memory locations allows complete monitoring of the instrument.
25
Section 5
Communications Protocol
The communication protocol functions in the following sequence. The host initiates an exchange of data
by sending a command byte to a network of instruments. This command byte consists of a one bit field
that distinguishes command bytes from data bytes, a three-bit field that contains the commands op-code,
and a four bit field that contains the address of the receiving instrument. The addressed instrument
responds by echoing the command byte back to the host. The host sends a data byte containing a seven
bit operand address referring to a lookup table of internal AquaVolt variables. A list of these variables
and their addresses is provided in the AquaVolt Variable Reference portion of this section. The
instrument acknowledges receipt of this operand byte by echoing it back to the host. If the command was
a request for an integer or floating point number, the AquaVolt sends a series of data bytes to the host,
each being echoed back to the AquaVolt for verification. If the command was a write integer or write
floating point command, the host sends a series of data bytes to the AquaVolt, each being echoed back
to the host for verification. Refer to the flowcharts in the following text for the choreography of this
exchange.
Communication Parameters
The AquaVolt uses the following communication parameters:
Baud Rate:
Data Bits:
Start Bits:
Stop Bits:
Parity:
9600 Baud
8
1
1
None
26
Section 5
Message Structure
Command Byte:
XXX = command field
0 = Read integer
1 = Read floating point
2 = Write integer
3 = Write floating point
4 = Reversed
5 = Reversed
6 = Reversed
7 = Error acknowledge
0-15 = AquaVolt address (Each AquaVolt
should be assigned its own unique address)
Data Byte:
XXXXXXX = data or operand
Systems Commands
Write Integer
Read Integer
Retrieves a 32 bit single precision floating point number from the specified
AquaVolt memory location.
Error Acknowledge
Issued by an AquaVolt to alert the host that the echo character received
by an AquaVolt did not match the character that was sent by that
AquaVolt during a read integer or read floating point operation.
27
Section 5
Variable Format
Since data bytes can only carry seven bits of usable data, integer and floating point variables are
represented in the following fashion:
Floating Points:
Byte 1:
Byte 2:
Byte 3:
Byte 4:
Byte 5:
s = sign bit
Ex = expoment
Mx = manitissa
Integers:
Byte 1:
Byte 2:
Byte 3:
Dx= integer data
28
Section 5
System Protocol
Floating Point Operations
The following flowcharts indicated the order of operations the host computer must perform for proper
transfer of floating point data to and from theAquaVolt.
Flowchart for read floating point variables:
Loop Counter
=0
No
Recei ve echo
before ti meout
Process Error
Yes
Send operand
byte to Aquavol t
No
Recei ve echo
before ti m eout?
Process Error
Yes
Process Error
No
Yes
Echo data byte
Recei ve error
character ?
Yes
Process Error
No
Loop counter
=5
No
Yes
.
Figure 6
Flowchart for Read (Floating Point Variables)
29
Section 5
No
Recei ve echo
before ti m eout
Process Error
Yes
Send operand
byte to Aquavol t
No
Recei ve echo
before ti m eout?
Process Error
Yes
No
Recei ve echo
before ti m eout ?
Process Error
Yes
Increm ent l oop counter
Loop counter
=5
No
Yes
Figure 7
Flowchart for Write (Floating Point Variables)
30
Section 5
Integer Operations
The Following flowcharts indicated the core of operations the host computer must perform for proper
transfer of integer data to and from the Aquavolt.
Flowchart for read integer operations:
Loop Counter
=0
Send command
byte to Aquavolt
No
Receive echo
before timeout
Process Error
Yes
Send operand
byte to Aquavolt
No
Receive echo
before timeout?
Process Error
Yes
Process Error
No
Yes
Echo data byte
Receive error
character ?
Ye s
Process Error
No
Loop counter
=3
No
Yes
Figure 8
Flowchart for Read (Integer Operations)
31
Section 5
Counter
= 0
Send
command
byte to Aquavolt
Receive echo
bef ore timeout
No
Process
Error
Y es
Send operand
byte to Aquavolt
Receive echo
bef ore
timeout?
No
Process
Error
Process
Error
Yes
Send data
byte
Receive echo
bef ore timeout ?
No
Yes
Increment
loop
counter
Loop counter
= 3
No
Yes
Transf er
Complete
Figure 9
Flowchart for Write (Integer Operation)
32
Section 5
Error Handling
When an error acknowledge (see item on command bytes in preceding section on Message Structure) is
received by the host, the current data exchange is terminated and the data is lost. The exchange must be
reiterated by the host from the beginning with the retransmission of the command byte. In addition, the
host computer is responsible for establishing the proper time-out periods referred to in the decision boxes
of the preceding flowcharts. This time-out period should be in the neighborhood of 50 milliseconds or
greater for effective error trapping.
ASCI Mode (Software Rev. 2.13 and above)
The AquaVolt may be queried with an ASCII terminal when configured for RS-232 operation. Simply
send the following formatted command to the AquaVolt Do not sent the '<' and '>' characters.
<type><index#><CR>
Where:
Type is "i" or "I" for integer values and "f" or "F" for floating point values.
Index # is the index of the variable being queried.
CR is the carriage return character.
No special setup is required to operate in ASCII mode. The AquaVolt will automatically recognize an
ASCII query or a binary query and return a message in the appropriate format.
Type
F0
Moisture value in ppb with gas correction assuming 100 sccm flow rate.
F1
F5
F8
R/W
Integer variables:
I0
Software revision
I3
R/W
I4
2 = Measure mode
3 = Service mode
R/W
I7
Gas Type
4 = Shutdown mode
R/W
R/W
2 = Disable
R/W
2 = Disable
R/W
2 = Disable
R/W
33
Section 5
34
Appendix 1
Appendix
1
Much of the success of the AquaVolt derives from a time proven electrolytic cell design (see Figure 15).
35
Appendix 1
Cell Construction
The electrolytic cell consists of a hollow glass tube about four inches long, with an outside diameter of
about 1/8"(2.5 mm) of an inch and about 1/16" (1mm) of an inch inside diameter. Two metal electrode
wires run parallel in a double spiral along the inside of the tube. These wires are partially imbedded in the
glass, fixing their position. This assembly, called the element, is shown in Figure 10.
Figure 10
Element Cross Section
The element is then assembled into a protective metal body, before being plumbed into the moisture
analyzer. Within the body, as shown in Figure 11, a seal surrounds the element so that gas can only flow
through the element. The electrode wires extend from the bottom end of the element and pass through
insulated feedthrough to the outside of the body to separate terminals. A voltage can then be applied to
the terminals. At this point, they register no current since the electrodes never contact each other.
36
Appendix 1
Figure 11
Cell Body
Next, the inside of the element is covered with a thin coating of phosphorous pentoxide (P2O5) as shown
in Figure 12. One of the most hygroscopic materials known, P2O5, is often used in driers or as a
desiccant.
Figure 12
Cell Coating
37
Appendix 1
Faradays Law
In operation, the sample gas enters the element and the P2O5 absorbs 100% of the water molecules
present in the gas flow. A voltage, applied across the electrode terminals, electrolyzes moisture in the
film. Once equilibrium is reached, the rate at which water molecules enter the cell will exactly match the
rate that molecules are electrolyzed. Each electrolyzed water molecule displaces two electrons from the
anode to the cathode. The electrolysis current (Amps) gives the electrical charge (Coulombs) displaced
per second.
Consequently, since the elementary charge of an electron is known, you can determine the rate that
water molecules enter the cell by current measurement. When the rate of water molecules entering the
cell is known, the moisture reading is expressed in parts-per-million (ppm) by comparing the rate of water
molecules to the rate of total gas molecules entering the cell. The rate of total gas molecules entering can
be determined by controlling the flow rate through the cell. The relationship between measured current
and moisture concentration in the electrolytic cell is governed by these absolute principles of Faradays
Law without any need for calibration versus a moisture standard.
You can derive the relationship numerically as follows:
In this example, assume a standard 100 cc/minute flow of gas through the element. Standard
means at standard temperature and pressure, which are 25 C (298.16 K) and 1.0 atm (14.7
psi). Also assume a moisture concentration of 1 ppm.
Calculate first, the total number of moles of gas that flow through the element per minute by using
the Ideal Gas Law.
PV = nRT
where,
P = Pressure [atmosphere]
V = Volume [liter]
T = Temperature [Kelvin]
R = 0.08205 [atmosphere liter Kelvin-1 mole-1]
n = number of moles of gas [mole]
Therefore, since.
n=
P x V
( R x T )
n=
1.0 x 0.1
(0.08205 x 298.16)
-3
n=
4.0851 x 10 moles
Per definition, a mole of gas contains 6.022 x 1023 molecules of gas. Therefore, the total number of
molecules of gas that flow through the element per minute is:
-3
23
21
molecules
Since the gas contains 1 ppm of moisture (one out of a million molecules is a water molecule), the
number of water molecules that enter the element per minute is:
2.46 x 1021 molecules = 2.46 x 1015 water molecules
1 x 106
38
Appendix 1
As mentioned earlier, to electrolyze one water molecule, two electrons have to be transported from one
electrode to the other. Also, an electron represents one elementary charge or 1.6022 x 10-19
Coulombs(C). Therefore the total amount of charge due to electrolysis flowing through the electrodes per
minute is:
15
2.46 x 10
-19
x 2 electrons x 1.6022 x 10
-4
C = 7.85 x 10 C
Current is measured in units of amperes (Amps). One ampere (A) is defined as one Coulomb per second.
Since you know the total charge per minute (in Coulombs), you can determine the charge flowing per
second, which is:
-4
-6
7.85 x 10 C = 13.138 x 10 C
60
This corresponds to a current of 13.138 microAmpere.
Thus, by principle of Faradays Law (and as derived here), a gas containing 1 ppm of moisture flowing
through the element at 100 cc per minute, standard conditions, results in an electrolysis current of 13.138
microAmpere.
Then again, for the theoretical to hold true in practice, certain conditions must hold true. These are:
a) Accurate flow rate through the element.
b) Accurate current measurement.
c) All moisture passing through the element is absorbed by the P2O5.
MEECOs test procedures are documented in a test record, detailed later in this manual, that you receive
with the unit. With regard to a) and b) listed above, MEECO uses NIST traceable test equipment to insure
the accuracy of the flow and current measurements in the AquaVolt. Assumption c) requires additional
discussion.
39
Appendix 1
Fi
Figure 13
Delta Flow
Now suppose, as in Figure 13, that you are in the part of the curve where it starts to flatten. In this case,
the reading at 100 cc/minute is too low while the 50 cc/minute reading is not affected. You will not find the
100 cc/minute reading to be twice the 50 cc/minute reading as it should. Had the test been conducted at a
lower concentration within the operating range, the 100 cc/minute reading would be twice the 50
cc/minute reading due to being on the linear scope of response.
Note 1:
When performing the Delta Flow at very low concentrations, the flow-independent
background has an impact on the result. This effect should not be interpreted in terms of
flattening of the response curve.
Note 2:
There is a proportionality of the electrolysis current with the flow rate of the sample gas
through the element. Increasing to higher and higher flow rates will eventually result in
diffusion limited behavior. At some point, the residence time of a moisture molecule in the
element becomes too short to guarantee that it is going to be absorbed with a 100%
probability. The chosen flow rate of 100 cc/minute is a very safe value for cells of the
geometry that MEECO produces. Attempts to interpret results at higher flow rates should be
regarded in the context of this effect.
Note 3:
The onset of the effect discussed in Note 2 causes all Delta Flow tests, in practice, to fall
short of 100%, when the 50 cc/minute moisture measurement, doubled, is compared to the
100 cc/minute measurement.
Note 4:
40
Appendix 1
Figure 14
General Arrangement of Electrolytic Cell
41
Appendix 1
42
Appendix 2
Appendix
2
Use high-quality, stainless steel tubing for all parts of the manifold between the sample inlets and
up to the inlet connection of the AquaVolt. Avoid using NPT threaded components as they do not
provide the necessary leak integrity.
Use only high-quality, low dead volume shut-off valves for valves #1 and #2. These may be 1/4
turn valves.
The branches for the purge vents should be 2" from either side of the tee to prevent back
diffusion. This is dimension A in the diagram
The flow meters and needle valves need not be of high quality as long as they are located at least
2" from the sample line (dimension B in the diagram). Their only purpose is to control a small,
continuous purge of about 100 sccm.
43
Appendix 2
To introduce Sample #1, simply open valve 1, keeping valve 2 closed. Both purge vents should be open,
allowing a slight, continuous bleed from both vents. The purge through the vent closest to valve 2 insures
that no moisture trapped in the dead space between valve 2 and the tee can contaminate the sample.
Similarly, to introduce Sample #2, simply close valve 1 and quickly open valve 2. In this configuration, it is
also desirable that the pressures of Sample #1 and Sample #2 be the same in order to prevent pressure
spikes that might force moisture from the dead spaces past the purge branches to the analyzer.
Figure 15
Sample Manifold
44
Appendix 3
Appendix
3
45
Appendix 3
Conversion Factors (Nitrogen Base)
GAS NAME
Acetylene
Air
Allene
Ammonia
Argon
Arsine
Boron Trichloride
Boron Trifluoride
Bromine Pentafluoride
Bromine Trifluoride
Bromotrifluoroethylene
Bromotrifluoromethane f-13B1
1,3-Butadiene
Butane
1-Butene
CIS-2-Butene
Trans-2-Butene
Carbon Dioxide
Carbon Disulfide
Carbon Monoxide
Carbon Tetrachloride
Carbon Tetrafluoride f-14
Carbonyl Fluoride
Carbonyl Sulfide
Chlorine
Chlorine Dioxide
Chlorine Trifluoride
2-Chlorobutane
Chlorodifluoromethane f-22
Chloroform (Trichloromethane)
Chloropentafluoroethane f-115
Chlorotrifluoroethylene
Chlorotrifluoromethane f-13
Cyanogen
Cyanogen Chloride
Cyclobutane
Cyclopropane
Deuterium
Diborane
Diboromodifluoromethane f-12B2
1,2-Dibromotetrafluoroethane f-114B2
Dichlorodifluoromethane f-12
Dichlorofluoromethane f-21
Dichlorosilane
1,2-Dichloroethane
1,2-Dichlorotetrafluoroethane f-114
2,2 Dichloro
1,1-Difluoro-1-Chloroethane
1,1-Difluoroethane
1,1-Difluoroethylene
Diethylsilane
Difluoromethane f-32
Dimethylamine
Dimethylether
2,2-Dimethylpropane
Disilane
Ethane
Ethanol
Ethylacetylene
Ethyl Chloride
Ethylene
Ethylene Oxide
Fluorine
Fluoroform f-23
FORMULA
C2H2
Mixture
C3 H4
NH3
Ar
AsH3
BCl3
BF3
BrF5
BrF3
C2BrF3
CBrF3
C4 H6
C4 H1 0
C4 H8
C4 H8
C4 H8
CO2
CS2
CO
CCl4
CF4
COF2
COS
Cl2
ClO2
ClF3
C4H9Cl
CHClF2
CHCl3
C2ClF5
C2ClF3
CClF3
(CN)2
ClCN
C4 H8
C3 H6
D2
B2H6
CBr2F2
C2Br2F4
CCl2F2
CHCl2F
SiH2Cl2
C2H4Cl2
C2Cl2F4
C2HC12F3
C2H3ClF2
CH3CHF2
CH2CF2
C4H12Si
CF2H2
(CH3)2NH
(CH3)2O
C(CH3)4
Si2H6
C2 H6
C2 H6 O
C4 H6
C2H5Cl
C2 H4
C2 H4 O
F2
CHF3
46
SENSOR FACTOR
0.615
0.998
0.478
0.786
1.395
0.754
0.443
0.579
0.287
0.439
0.326
0.412
0.354
0.257
0.294
0.32
0.291
0.773
0.638
0.995
0.344
0.44
0.567
0.68
0.876
0.693
0.433
0.234
0.505
0.442
0.243
0.337
0.43
0.498
0.618
0.387
0.505
0.995
0.448
0.363
0.215
0.39
0.456
0.442
0.382
0.231
0.259
0.341
0.415
0.458
0.183
0.627
0.37
0.392
0.247
0.332
0.49
0.394
0.365
0.408
0.619
0.589
0.924
0.529
Appendix 3
Conversion Factors (Nitrogen Base)cont.
GAS NAME
Germane
Germanium Tetrachloride
Halothane (R-123B1)
Helium
Hexafluoroacetone
Hexaflorobenzine
Hexafluoroethane f-116
Hexafuoropropylene (HFP)
Hexamethyldisilane (HMDS)
Hexane
Hydrogen
Hydrogen Bromide
Hydrogen Chloride
Hydrogen Cyanide
Hydrogen Fluoride
Hydrogen Iodide
Hydrogen Selenide
Hydrogen Sulfide
Iodine Pentafluoride
Isobutane
Isobutene
Isopentane
Krypton
Methane
Methylacetylene
Methyl Bromide
3-Methyl-1-butene
Methyl Chloride
Methyl Fluoride
Methyl Mercaptan
Methyl Silane
Methyl Trichlorosilane (MTS)
Methyl Vinyl Ether
Monoethanolamine
Monoethylamine
Monomethylamine
Neon
Nickel Carbonyl
Nitric Oxide
Nitrogen
Nitrogen Dioxide
Nitrogen Trifluoride
Nitrogen Trioxide
Nitrosyl Chloride
Nitrous Oxide
Octofluorocyclobutane
Oxygen
Oxygen Difluoride
Ozone
Pentafluorethane f-125
Pentane (n-Pentane)
Perchloryl Fluoride
Perfluorobutane
Perfluoro-2-Butene
Perfluoromethyl-vinylether
Perfluoropropane
Pentane (n-Pentane)
Phosgene
Phosphine
Phosphorous Pentafluoride
Phosphorous Trifluoride
Propane (same as CH3CH2CH3)
Propylene (Propene)
FORMULA
GeH4
GeCl4
C2HBrClF3
He
F3CCOCF3
C6F6
C2F6
C3F6
(CH2)6Si2
C6H14
H2
HBr
HCl
HCN
HF
HI
H2Se
H2 S
IF
C4 H1 0
C4 H8
C5H12
Kr
CH4
C3 H4
CH3Br
C5 H1 0
CH3Cl
CH3F
CH4S
CH6Si
CH3Cl3Si
C3 H6 O
C2H7NO
C2HH5NH2
CH3NH2
Ne
Ni(CO)4
NO
N2
NO2
NF3
N2 O 3
NOCl
N2 O
C4F8
O2
OF2
O3
C2HF5
C5H12
ClO3F
C4F10
C4F8
PMVE
C3F8
C5H12
COCl2
PH3
PF5
PF3
C 3 H8
C3 H6
47
SENSOR FACTOR
0.649
0.268
0.257
1.386
0.219
0.632
0.255
0.249
0.139
0.204
1.008
0.987
0.983
0.744
0.998
0.953
0.837
0.85
0.283
0.26
0.289
0.211
1.382
0.763
0.473
0.646
0.252
0.687
0.761
0.588
0.393
0.267
0.377
0.305
0.359
0.565
1.398
0.212
0.995
1
0.758
0.501
0.443
0.644
0.752
0.169
0.988
0.672
0.738
0.287
0.212
0.448
0.738
0.268
0.296
0.179
0.212
0.504
0.783
0.346
0.495
0.343
0.401
Appendix 3
Conversion Factors (Nitrogen Base)cont.
GAS NAME
Rhenium Hexafluoride
Silane
Silicon Tetrachloride
Silicon Tetrafluoride
Sulfur Dioxide
Sulfur Hexafluoride
Sulfur Tetrafluoride
Sulfur Trioxide
Sulfuryl Fluoride
Tetrachloromethane
Tetrafluoroethylene (TFE)
Tetrafluorohydrazine
Trichlorofluoromethane f-11
Trichlorosilane
Trimethyloxyborane (TMB)
1,1,2-Trichloro-1,1,2-Triflouroet f-113
Trimethylamine
Tungsten Hexafluoride
Uranimum Hexafluoride
Vinyl Bromide
Vinyl Chloride
Vinyl Fluoride
Water Vapor
Xenon
FORMULA
ReF6
SiH4
SiCl4
SiF4
SO2
SF6
SF4
SO3
SO2F2
CCl4
C2F4
N2F4
CCl3F
SiHC3
B(OCH3)3
C2Cl3F3
(CH3)3N
WF6
UF6
C2H3Br
C2H3Cl
C2H3F
H2O
Xe
48
SENSOR FACTOR
0.23
0.625
0.31
0.395
0.728
0.27
0.353
0.535
0.423
0.344
0.361
0.367
0.374
0.329
0.3
0.231
0.316
0.227
0.22
0.524
0.542
0.576
0.861
1.383
Appendix 4
Appendix
4
Approvals
CE Certification of AquaVolt
MEECO Inc.
250 Titus Ave.
Warrington PA 18976
U.S.A.
Reference: CE Certification of AauaVolt.
Report # NY2249-01
The MEECO Inc. AquaVolt bearing the CE mark has been successfully tested to the regulations
of the Electro Magnetic Compatibility directive (EMC directive 89/336/EEC).
Special attention is required however when selecting the power and signal cables to be used with
CE marked equipment.
A cable, which is overall completely screened with a 100% shield, should be used. The shield
should be terminated to an earth ground. Use of a ferrite clamp (238 ohms @ 100 Mhz) on the voltage
output cable is required to meet the directive.
For pin configuration, please refer to the instruction manual.
49