Weathering

Instrumentation Products

Ci3000+
Ci4000
Ci5000
Weather-Ometer ®®

Instrument
Service Guide
Doc. No. 07-7030-00
Revision 0
November 10, 1999
 Table Of Contents
1.0 INTRODUCTION 11
2.0 WARNINGS AND PRECAUTIONS 12
3.0 REQUIRED TOOLS AND NIST TRACEABILITY 13
3.1 Required Tools 13
3.2 NIST Traceability 13
4.0 DATA PANEL SERVICE AND SETUP PAGES 14
4.1 Accessing the Service Pages 14
4.2 Service Page Functions 14
4.2.1 PID Loop Parameters – Page 91 14
4.2.2 Manual Calibration – Page 92 14
4.2.3 Manual Checkout: Discretes – Page 93 15
4.2.4 Manual Checkout: Analogs – Page 94 15
4.3 Data Panel Control Pages 15
4.4 Data Panel Error Messages 17
5.0 TROUBLESHOOTING PROCEDURES - QUICK GUIDE 19
5.1 Power-up Malfunctions 20
5.1.1 Description 20
5.1.2 Troubleshooting Guide 23
5.1.3 Troubleshooting Flow Chart 24
5.1.4 Troubleshooting Procedure 25
5.1.5 Power Component Configuration 26
5.2 Xenon Lamp and Irradiance Malfunctions 29
5.2.1 Description 29
5.2.2 Troubleshooting Guide 34
5.2.3 Troubleshooting Flow Chart – Lamp Ignition Failure 35
5.2.4 Troubleshooting Flow Chart – Irradiance High or Low 36
5.2.5 Troubleshooting Flow Chart – 2-Sun Irradiance Considerations 37
5.2.6 Troubleshooting Procedure – Lamp Ignition Failure (Ignitor) 38
5.2.7 Troubleshooting Procedure – Irradiance High or Low (Watt. Regulator) 39
5.2.8 Troubleshooting Procedure – 2-Sun Irradiance Considerations 42
5.3 Humidification Malfunctions 44
5.3.1 Description 44
5.3.2 Troubleshooting Guide 45
5.3.3 Troubleshooting Flow Chart – Humidification Failure 46
5.3.4 Troubleshooting Flow Charts – RH Control and Sensing Errors 47
5.3.5 Troubleshooting Procedure – Humidification Failure 48
5.3.6 Troubleshooting Procedure – RH Control and Sensing Errors 50
5.3.6.1 RH Reading is 0% or 100% 51

Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 2
 Table Of Contents
List of Figures
Figure 5.1–1 Booster Transformer T1 21
Figure 5.1–2 Main Reactor L1 21
Figure 5.1–3 Auxiliary Reactor L2 21
Figure 5.1–4 Isolation Transformer T2 22
Figure 5.1–5 Chamber Safety Thermostat S4 25
Figure 5.1–6 Ci3000+ Power Component Configuration Guide 26
Figure 5.1–7 Ci4000 Power Component Configuration Guide 27
Figure 5.1–8 Ci5000 Power Component Configuration Guide 28
Figure 5.2–1 Ci3000+ Xenon Lamp Circuit 30
Figure 5.2–2 Ci4000 Xenon Lamp Circuit 31
Figure 5.2–3 Ci5000 Xenon Lamp Circuit 32
Figure 5.2–4 Xenon Lamp Assembly Guide 33
Figure 5.2–5 Ci3000+ Xenon Lamp Ignitor 38
Figure 5.2–6 Ci4000 Xenon Lamp Ignitor 38
Figure 5.2–7 Ci5000 Xenon Lamp Ignitor 38
Figure 5.2–8 Chamber Overtemperature Thermostat 38
Figure 5.2–9 Xenon Lamp Wattage Regulator 40
Figure 5.2–10 Wattage Regulator Power LED 40
Figure 5.2–11 Wattage Regulator Output LED 41
Figure 5.2–12 One and Two Sun Circuit Block Diagram 42
Figure 5.3–1 Humidification System Plumbing Diagram 44
Figure 5.3–2 Air Pressure Regulator Bowl Drain Valve 48
Figure 5.3–3 Humidification Nozzle (rear panel) 48
Figure 5.3–4 Humidification Nozzle Detail 48
Figure 5.3–5 Humidifier Water Line Filter 48
Figure 5.3–6 Humidification Block Diagram 49
Figure 5.3–7 Humidification Solenoid Valve Locations 49
Figure 5.3–8 Humidification Water Control Relay Q1 50
Figure 5.3–9 Humidity PC Board Jumpers 50
Figure 5.3–10 APC1 Filter PC Board 51
Figure 5.4–1 Chamber Safety Thermostat S4 52
Figure 5.4–2 Chamber Overtemperature Alarm 52
Figure 5.4–3 Chamber Temperature Transmitter 55
Figure 5.4–4 Air Heater Control Relay Q2 56
Figure 5.5–1 Xenon Lamp Cooling System Electrical Block Diagram 59
Figure 5.5–2 CS-6 Lamp Cooling System Plumbing Diagram (Ci3000+) 60
Figure 5.5–3 CS-6 Lamp Cooling System Plumbing Diagram (Ci4000/Ci5000) 61
Figure 5.5–4 CS-6 Lamp Cooling System 62
Figure 5.5–5 Testing the Flow Switch 67
Figure 5.5–6 CS-6 Pump Shaft Coupling 67
Figure 5.6–1 Lenze 8200 Blower Controller 69
Figure 5.6–2 Blower System Electrical Block Diagram 69
Figure 5.6–3 Blower Wheel Mounting 73
Figure 5.6–4 Lenze Display and Input Select Jumper 75
Figure 5.7–1 Black Sensor Transmitter & Collector Ring (Ci4000/Ci5000) 78
Figure 5.7–2 Black Sensor Transmitter & Collector Ring (Ci3000+) 78
Figure 5.7–3 Temperature Control Systems Electrical Block Diagrams 79
Figure 5.7–4 Blower Controller and Chamber Temp. Transmitter (Ci4/Ci5) 80

Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 7
 Table Of Contents
List of Figures (cont.)

Figure 8.3–6 CS-6 Circulator Pump and Motor 184

Figure 8.3–7 Circulator Pump/Motor Coupling 184
Figure 8.3–8 CS-6 Pump/Motor Details 184
Figure 8.3–9 Ci3000+ and Ci4000 Rack Motors 185
Figure 8.3–10 Ci5000 Rack Motor & Controller 185
Figure 8.3–11 Rack Drive Gear Alignment 185
Figure 8.3–12 Ci4000 Rack Motor Wiring Diagram 186
Figure 8.4–1 Rack & Specimen Spray Solenoid Valves 186
Figure 8.4–2 CS-6 and Humidification Solenoid Valves 186
Figure 8.5–1 Rack Speed Controller (Ci5000) 187
Figure 8.5–2 Water Resistivity Monitor 187
Figure 8.5–3 Transmitter Locations 187
Figure 8.5–4 Chamber Overtemperature Alarm 188
Figure 8.5–5 Lamp Water Temperature Controller 189
Figure 8.5–6 Blower Motor Controller 190
Figure 8.5–7 Lenze Display and Input Select Jumper 190
Figure 8.5–8 AFE Data Panel Mark I (early Ci4000) 193
Figure 8.5–9 AFE Data Panel Mark II 193
Figure 8.5–10 Typical PLC Module (side view) 194
Figure 8.5–11 PLC0 Fuse 195
Figure 8.6–1 Ci4000 Xenon Lamp Ignitor 196
Figure 8.6–2 Ci5000 Xenon Lamp Ignitor 196
Figure 8.6–3 Ci4000 Ignitor Terminal 196
Figure 8.6–4 Ci4000 Ignitor Sealing Washers 196
Figure 8.7–1 Xenon Lamp Wattage Regulator 197
Figure 8.7–2 Wattage Regulator Trimpots 197
Figure 8.8–1 CS-6 Reservoir Tank 198
Figure 8.8–2 Level Switch Float Orientation (Dry) 198
Figure 8.9–1 Ci4000 Air Heater 198
Figure 8.9–2 Ci4000 Rack Hub 198
Figure 8.9–3 Ci5000 Rack Hub 198
Figure 8.9–4 Air Heater Terminals 200
Figure 8.10–1 Collector Ring 200
Figure 8.11–1 Rack Bearings 201
Figure 8.11–2 Rack Driveshaft Components 201
Figure 8.11–3 Ci5000 Rack Hub 201
Figure 8.12–1 Chart Recorder Terminals 202
Figure 8.12–1 Chart Recorder Electrical Diagram 202

List of Tables

Table 5.6 – 1 Lenze 8200 Blower Motor Controller Setup Codes 77

Table 5.13–1 PLC6 Indicator Light Legend 124
Table 8.5–1 Lenze 8200 Blower Motor Controller Setup Codes 192

Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 10
 1.0 INTRODUCTION
This manual provides instructions for the trouble-
shooting, calibration, maintenance and repair or
replacement of all applicable systems and com-
ponents of the Ci3000 + , Ci4000 and Ci5000
Weather-Ometers. These procedures should be
performed only by a qualified service technician.
Specifications may be subject to change without
notification.
Observe Precautions
Before conducting any procedures, read the warn-
ings and precautions in Section 2.0. Doing so will
help ensure your safety and minimize the poten-
tial for damage to the instrument. Beforehand,
always read the procedure that you will be con-
ducting to become familiar with the steps involved,
tools required and safety precautions.
Topics Covered
This manual covers the following topics:
n Troubleshooting
Power-up Malfunctions
Xenon Lamp & Power Circuit Malfunctions
Humidification Malfunctions
Chamber Overtemperature Malfunctions
CS-6 Lamp Cooling System Malfunctions
Blower System Malfunctions
Temperature Control Malfunctions
Specimen Rack Drive Malfunctions
Water Spray Malfunctions
Water Resistivity Monitor Malfunctions
Optional Chart Recorder Malfunctions
Data Panel Malfunctions
PLC (Programmable Logic Controller)
Malfunctions
Optional Data Acquisition System Malfunctions
Reference Material Test Malfunctions (SRM)
n Calibration
Black Sensor (BPT and BST)
Chamber (dry bulb) Sensor
Relative Humidity
Lamp Wattage
Lamp Irradiance
Air valve (Damper)
Rack Speed Control
Resistivity Monitor
Lamp & Rack Alignment
Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0
n Maintenance
Lamp Water Fitting Gasket
Lamp Outer Filter Cleaning
Light Rod End Cleaning
Lamp Burner Socket Inspection
Test Chamber Cleaning
Demineralizer Cartridge Replacement
Flow Switch Filter Screen Cleaning
Lamp Water Reservoir Cleaning
Light Monitor Filter Replacement
Inlet Air Filter Cleaning
Humidifier Water Filter Cleaning
Humidifier - Inspection, Cleaning & Adjustment
Air Regulator Oil Trap Cleaning
Lamp, Rack & Light Rod Alignment
n Component Replacement
Relay Replacement
Sensor Replacement
Electric Motor Replacement
Solenoid Valve Replacement
Controller and Transmitter Replacement
Ignitor Replacement
Wattage Regulator Replacement
CS-6 Cooling Coil & Level Switches
Air Heater Replacement
Collector Ring Replacement
Rack Bearing Replacement
Chart Recorder Replacement
Data Panel and Software Downloading
n Appendix
A – PLC and Data Panel Software Configuration
B – Optional Yokogawa Chart Recorder Manual
C – Component Parts Lists
The Troubleshooting section is designed not only
to help you pinpoint and verify malfunctions, but
to provide a basic explanation of operating
principles of the various instrument subsystems.
Electrical block diagrams, while simplified, include
accurate component wiring designations.
Additional Questions
If you have questions or encounter problems that
are not addressed in this manual, please contact
Atlas Service at (773) 327-4520, or send a fax to
(773) 327-5787, Chicago, Illinois U.S.A.
11
 5.0 TROUBLESHOOTING PROCEDURES
5.2 Xenon Lamp and Irradiance Lamp malfunctions can result from numerous
Control Malfunctions causes. Ignition of the lamp can be prevented by
a damaged or disconnected lamp, a CS-6
malfunction, such as low or lost water flow, or by
5.2.1 Description
the malfunction of a lamp circuit component. Low
lamp irradiance output is often the result of burner
Irradiance is provided by the xenon lamp system
or lamp filter aging, or expired interference filters
which is comprised of the xenon lamp and power
in the light monitor. This section focuses on
supply components that include the booster
troubleshooting of the lamp assembly, lamp circuit
transformer T1, igniter L3, main reactor L1,
components and the light monitor. For CS-6
auxiliary reactor L2 and wattage regulator AR1.
troubleshooting, refer to Section 5.5.
The Ci3000+ has a 4500 watt xenon lamp capable
of operating from 1700 to 4500 watts. The 6500
watt xenon lamp in the Ci4000 is capable of
operating within the range of 2500 to 7400 watts.
The 12,000 watt lamp in the Ci5000 operates within
the range of 4000 to 14000 watts.

The xenon lamp receives its high-voltage ignition

pulse from the igniter, which drops out of the circuit
after the lamp is operating steadily. The instrument
is designed to provide three ignition attempts
before an ignition failure message is displayed on
Data Panel MAIN page 1.

At minimum wattage, the lamp receives its power

from the main reactor only. At higher wattage levels,
the auxiliary reactor and wattage regulator (in
series with the main reactor) contribute additional
power and provide precision wattage control.

Irradiance control is provided by the light monitor

which continuously monitors lamp output and
provides a voltage signal to the PLC. The PLC then
increases or decreases lamp wattage to maintain
a stable irradiance level. Lamp wattage is
continuously monitored by the wattage transducer
A1 which provides a voltage signal to the PLC.

Lamp cooling is provided by the CS-6 lamp cooling

system which pumps filtered D.I. water through the
xenon lamp. Heat is extracted from the cooling
water by a tap water coil in the CS-6 reservoir tank.
In locations where tap water is expensive or its
temperature is too high, an optional LiquiAir unit
or a refrigeration unit may be present to provide
cooling of the lamp water.
65000W Xenon Lamp

Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 29
 Ci3000+

5.2.1 Description (cont.)

5.2 Xenon Lamp and Irradiance Control Malfunctions

5.0 TROUBLESHOOTING PROCEDURES

1 2 3 4 K1-4 C1-2 CB2-1 1 2 CB2-2
Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0

XENON XENON 4 IGNITION WATTAGE 10

WATTAGE 4
CIRCUIT LAMP IGNITOR TRANS-
CIRCUIT TRANS- 6
BREAKER RELAY BREAKER DUCER IGNITION
5 L3a DUCER PULSE
CB1 K1 CB2 RELAY
RELAY 3
XENON K9 K9
9 RELAY 5
K3
LAMP 2 1
APC1
XE C1-2 A1-2 F1 PLC5-10
2 TP1 FUSE A1-4 32 31
IGNITION INTERNAL (+)
3 BLEEDER
CAPACITOR RESISTOR .062A

RESISTOR

500 OHM
250V PLC5 2
C1 20K OHM
20W ANALOG INPUT
Figure 5.2 – 1 Ci3000+ Xenon Lamp Circuit

40 mfd

TRANSDUCER 2
3 2 5
1 A1b MODULE
X1 X3 (15V) X2 (30V)
WATTAGE IGNITOR

A1a (COIL)
WATTAGE C1-1
BOOSTER TRANSDUCER L3b
IGNITION
4 TP2 A1-5 34 33
TRANSFORMER PULSE A1-1 PLC5-8
RELAY APC1
T1 K3 3
1

7 1
6
L1-2
1

L1-2 WATTAGE
L1-2 TRANSDUCER 1
RELAY PLC6-7 1 (+)

FRONT PCB
WATTAGE

REAR PCB
L1-2 K9 PLC6
MAIN ANALOG OUTPUT REGULATOR
REACTOR MODULE
AR1
PLC6-19 2
L1 L1-1 2 3

2 4 IGNITION
XENON XENON AUX. 1 3
CIRCUIT LAMP CIRCUIT
AMPLIFIER
BREAKER RELAY REACTOR RELAY
BREAKER
CB1 K1 L2 CB2
K5
3 4
3 4 5 6 L1-1

RELAY COIL SWITCHING SOURCE

AND PLC INDICATOR LIGHTS
RELAY PLC TERMINAL LED#
K1 PLC3-2 A1
K3 PLC3-3 A2
K5 PLC3-7 A5
K9 PLC3-17 B5
NOTE: WHEN PLC LED IS ON PLC CONTACT
IS CLOSED TO PROVIDE VOLTAGE TO RELAY.
30
 5.2.1 Description (cont.)

5.2 Xenon Lamp and Irradiance Control Malfunctions

Ci4000

5.0 TROUBLESHOOTING PROCEDURES

Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0

1 2 3 4 1 2 CB2-2
XENON XENON IGNITION WATTAGE 10
CIRCUIT LAMP WATTAGE CIRCUIT
4 TRANS-
BREAKER RELAY TRANS- BREAKER
4 DUCER
CB1 K1 DUCER CB2 RELAY 9
IGNITOR C1-2 RELAY
3 K9
2 3 K9
BOOSTER L3a 2 IGNITION 6
5 3 PULSE
TRANSFORMER IGNITION
BLEEDER A1-2 F1
APC1
PLC5-10
RELAY
RESISTOR TP1 A1-4 32 31 K3 5
T1 CAPACITOR 56K OHM
FUSE
INTERNAL (+)
1 XENON C1 1
Figure 5.2 – 2 Ci4000 Xenon Lamp Circuit

.062A

RESISTOR
2

500 OHM
C1-1 250V PLC5
LAMP ANALOG INPUT RESISTOR
XE A1b MODULE R4
C2-2 C3-2 IGNITION 4 WATTAGE 1.8K OHM
1 PULSE TRANSDUCER
TP2 2W
RELAY A1-1
A1-5 34 33
K3 3 WATTAGE PLC5-8
APC1 2
TRANSDUCER
56Κ Ω

56Κ Ω

C2 C3 RELAY IGNITOR
K9 L3b 1
TB2-2 TB2-2
TB2-2
6 7
C2-1 C3-1 WATTAGE
VOLTAGE 7
BOOST 3 TRANSDUCER WATTAGE
1 (+) PLC6-7

FRONT PCB
REAR PCB
BOOST PLC6
CAPACITORS CAP. RELAY A1a (COIL) REGULATOR ANALOG OUTPUT
(40 MFD)
4 K4 MODULE
L1-2 AR1 2 PLC6-19
L1-2 2 3
2 2
AUX. 1 3 4
XENON XENON MAIN IGNITION
CIRCUIT AMPLIFIER CIRCUIT
BREAKER
LAMP REACTOR REACTOR RELAY BREAKER
RELAY
CB1 K1 L1 1 L2 K5 CB2
3 4
6 L1-1 L1-1
3 4 5

RELAY COIL SWITCHING SOURCE

AND PLC INDICATOR LIGHTS

RELAY PLC TERMINAL LED#

K1 PLC3-2 A1
K3 PLC3-3 A2
K5 PLC3-7 A5
K9 PLC3-17 B5
NOTE: WHEN PLC LED IS ON PLC CONTACT
31

IS CLOSED TO PROVIDE VOLTAGE TO RELAY.

 5.2.1 Description (cont.)

5.2 Xenon Lamp and Irradiance Control Malfunctions

Ci5000

5.0 TROUBLESHOOTING PROCEDURES

1 2 3 4 K1-4 CB2-1 1 2 CB2-2

XENON XENON IGNITION

Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0

11 WATTAGE
CIRCUIT LAMP 3 CIRCUIT 9
BREAKER RELAY IGNITOR TRANS- BREAKER
WATTAGE
IGNITION 6
TRANS-

TRANSFORMER T4
CB1 K1 5 L3 7 R DUCER WATTAGE CB2 PULSE
DUCER

HIGH VOLTAGE
2
RELAY 4 TRANS- RELAY
XENON K9 DUCER 10
RELAY
K3
7
K9
2 3 LAMP A1b

BOOSTER XE 1
TP 1
APC1
10 PLC5-10
TRANSFORMER 8 W 1 2 A1-4 32 31
3 (+) 6

RESISTOR
T1

500 OHM
12
FUSE PLC5 w/b

460V
230V

TRANSFORMER T4
STEP DOWN 63 mA ANALOG INPUT 5

HIGH VOLTAGE
1
IGNITION
2
TRANSFORMER 1SLO-BLO MODULE IGNITOR
Figure 5.2 – 3 Ci5000 Xenon Lamp Circuit

BLEEDER brn
T3 3
CAPACITOR RESISTOR 2 4 A1-5 34 33 L3
C1 56K OHM PLC5-8 w/b 4
APC1
(80 MFD) TP 2
1
blk
2
IGNITION 4
CAP. RELAY 1
K3
3 7 6
TB6-1 TB6-1
K15 7
1-SUN
WATTAGE 1 (+) PLC6-7
WATTAGE

FRONT PCB
REAR PCB
LOW 3 TRANSDUCER PLC6
MAIN 4 3 RELAY
K4 REGULATOR ANALOG OUTPUT
REACTOR HI 2-SUN K9 MODULE
4 AR1 2
L1 LOW COM 60Hz 2 3
PLC6-19

2 4
XENON XENON AUX. 1 3 IGNITION
CIRCUIT LAMP WATTAGE REACTOR AMPLIFIER CIRCUIT
BREAKER RELAY BREAKER
CB1 K1
TRANSDUCER L2
RELAY
CB2
K5
1 A1a (COIL) 2
3 4
3 4 T1-1 6 7 L1-1

RELAY COIL SWITCHING SOURCE

AND PLC INDICATOR LIGHTS

RELAY PLC TERMINAL LED#

K1 PLC3-2 A1
K3 PLC3-3 A2
K5 PLC3-7 A5
K9 PLC3-17 B5
32

NOTE: WHEN PLC LED IS ON PLC CONTACT

IS CLOSED TO PROVIDE VOLTAGE TO RELAY.
 5.2 Xenon Lamp and Irradiance Control Malfunctions (cont.)

5.0 TROUBLESHOOTING PROCEDURES

Burner Tip Must Not Be
Visible Beside Socket

Burner Lamp Electrode

Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0

Socket Correct Incorrect

End View of Lamp
Inner
Union Ring
Filter
Union Ring

Lower
Burner
Washer Filter
Housing Socket
Union Ring

Union Ring
Union Ring
Union Ring
Spring

Alignment
Pin
Outer Outer
Filter Filter

Xenon Union Ring

Burner
Alignment Union Ring
Pin
Washer
Union Ring Union Ring Union Ring
Mounting Ring
Upper Sealing
Filter Washer
Housing Pin

Burner
Lamp
Base Water
Union Ring Fitting

Install the two Connect the upper Hold the lamp Check that the spring Turn the lamp upside Check that the burner tip Check that there is a
sealing washers filter housing to the sideways, and inside the lower filter down. Check that the is inside the socket as sealing washer inside the
onto the outer outer filter. Be sure slowly slide the housing tube is in place. sealing washer is in shown. Gently hand lamp water fitting.
filter ends if none to match the inner filter into the Connect the lower filter place on the burner tighten the union ring. Connect the lamp and
are in place. alignment pin and outer filter. Do NOT housing to the outer filter. base. Slide the rotate it until the
hole. Gently hand drop the inner filter Gently hand tighten the burner up into the Clean the outer filter with alignment pin falls into
tighten. in place or damage union ring. burner socket. Look an optical cleaner or a 1:1 place. Gently hand
may occur. down through the mixture of alcohol and tighten the mounting ring.
lower filter housing to acetone. Hold the lamp by
ensure that the the upper or lower filter
burner tip is inside housing only.
the burner socket.
33

Figure 5.2–4 Xenon Lamp Assembly Guide

 5.0 TROUBLESHOOTING PROCEDURES
5.2 Xenon Lamp and Irradiance Control Malfunctions (cont.)
5.2.2 Troubleshooting Guide
MALFUNCTION PROBABLE CAUSE
Lamp fails to ignite Chamber door open or switch failure
Xenon lamp/ignition breakers off
Lamp assembled/installed incorrectly
Lamp ignitor lead off or loose
Light rod dirty or damaged
Light monitor malfunction
Lamp burner socket damaged
Low lamp starting voltage
CS-6 cooling water flow low
Ignitor malfunction
Relay failure in lamp circuit
PLC malfunction
Lamp output is high/low Burner is near end of life
Lamp filters expired
Burner tip/socket damaged
Incorrect irradiance calibration
Interference filters expired
Light rod is misaligned
Wattage regulator malfunction
Lamp will not operate 1-Sun or 2-Sun relay failure
above 1-Sun level
(Ci5000 only)
Lamp operating at Burner is near end of life
excessive wattage Lamp filters expired
Burner tip/socket damaged
Incorrect irradiance calibration
Interference filters expired
Light rod is misaligned
Wattage regulator malfunction
No wattage display Blown fuse F1 on A1 transducer
A1 wattage transducer board failure
Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0
CORRECTIVE ACTION
Close door or check switch.
Turn on circuit-breakers.
Check lamp.
Check lead connections.
Inspect/clean light rod.
Check filters & photodiodes.
Inspect/replace (Sec. 7.2.4).
Check/adjust taps on T1 and L1.
Check CS-6 (see Section 5.5)
Conduct procedure in 5.2.6.
Conduct procedure in 5.2.6.
Conduct procedure in 5.2.6.
Replace xenon burner.
Replace lamp filters.
Inspect/replace socket or burner.
Recalibrate (Section 6.9).
Check/replace filters (Sec. 7.2.9).
Align light rod (Secs. 7.2.14 & .15)
Conduct procedure in 5.2.7.
Perform procedure 5.2.8.
Replace xenon burner.
Replace lamp filters.
Inspect/replace socket or burner.
Recalibrate (Section 6.9).
Check/replace filters (Sec. 7.2.9).
Align per Section 7.2.14 or 7.2.15.
Conduct procedure in 5.2.7.
Check fuse.
Check board output w/ lamp on.
34
 5.0 TROUBLESHOOTING PROCEDURES
5.2 Xenon Lamp and Irradiance Control Malfunctions (cont.)
5.2.3 Troubleshooting Flow Chart - Lamp Ignition Failure
1) Confirm Xenon and
Ignition circuit-breakers
are on.
2) Check lamp for age,
damage, proper installa-
tion and ignitor lead con-
nections.
3) Check for messages
on Data Panel MAIN
page 1.
4) Initiate standard test
no. 1.
Ignition pulse
is not audible
5) Check for line voltage
to ignitor during pulse.
No voltage
present
6) Check for continuity
between relay terminals
K3-5 & K3-6 (Ci3 & Ci4)
or K3-6 & K3-7 (Ci5)*.
No
Continuity
7) Check for 24Vac at
relay K3 coil during pulse.
No voltage
present
8) Check for continuity at
terminals PLC3-1 and
PLC3-3 during pulse.
Continuity
9) Check for 24Vac at
TB3-7 & TB3-9 (Ci4) or
TB3-5 & TB3-8 (Ci5).
Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0
“Lamp Water Temperature High”
“Lamp Water Flow is Low”
Check CS-6 cooling system
(Section 5.5).
“Chamber Temperature is High”
Messages Reset chamber safety thermo-
displayed stat S4 in electronics drawer.
Previous lamp is malfunc-
Ignition pulse Install calibrated lamp Lamp
tioning. Inspect for dam-
is audible and attempt ignition. ignites
age. Check burner socket.
Measure line voltage and
Lamp does check transformer taps.
not ignite Set T1 lamp voltage boost
Voltage is On Ci3000+ and Ci4000, to next higher selection
present replace ignitor. On (see Section 5.1.5).
Ci5000 check 1&2-Sun
relays K15 and K4. Also check light rod clean-
liness/integrity and light
monitor filters and photo-
diodes (Sec. 7.2.9).
Check voltage at breaker
Continuity CB2. If no voltage, replace
breaker.
Voltage is Coil has failed. Replace
present relay K3.
If LED A2 on PLC3 module
No is on during pulse, replace
continuity PLC3 module. If the LED
is off, download software
program to PLC (see
Appendix A & Sec. 5.13.5).
*Ci3 denote Ci3000+
Check breaker CB5 and T2 Replace failed breaker or Ci4 denotes Ci4000
No voltage Ci5 denotes Ci5000
output at T2-X3 & T2-X4. transformer T2.
35
 5.0 TROUBLESHOOTING PROCEDURES
5.2 Xenon Lamp and Irradiance Control Malfunctions (cont.)

5.2.4 Troubleshooting Flow Chart - Irradiance High or Low

1) Perform Wattage Cali-
bration and Irradiance
Calibration procedures.

2) Initiate standard test

no. 1.

3) Confirm light monitor

output at PLC5-11 & -13 Check light monitor filters
No output
(or at PLC5-12 & -14 for & photocells (Sec. 7.2.9).
2nd light sensor).

4) Initiate custom watt-

age-controlled test at
minimum lamp wattage.
R4 is open-circuited or
Continuity
5) Observe upper green wattage regulator failed.
Check for continuity at
Power LED on wattage LED is off
relay K9 (K9-9 & K9-10).
regulator. No Check for 24Vac across
continuity relay K9 coil terminals.
6) Check drive current
signal to wattage regu- Current is Potential PLC6 module Voltage No voltage
lator terminal AR1-1. zero or well failure. Confirm below. present present
Should be approx. 4mA. above 4mA

7) Initiate custom mid-
range wattage test at:
Ci3-3000W, Ci4 – 5000W
Ci5 – 8000W
8) Observe lower green
Output LED on wattage
regulator.
Replace
relay K9.
If B5 LED on PLC3 is
on, replace PLC3. If
LED is off, download
LED dim or software to PLC. If
off & drive Replace the wattage operation not restored,
current well regulator. replace PLC3. See
above 4mA Section 5.13.5.

Drive Run mid-range wattage Run standard test no.

current is Replace PLC6 Analog test again. Drive signal Drive
1 and confirm stable
still 4mA, Output module (see should be approximately current in
irradiance within test
zero or Section 5.13.8 first). 9 to 11mA. range
tolerance.
unstable

Drive current
still zero or
out of range.

Replace the CPU

module of the PLC (see Drive Reinstall old PLC6
Sec. 5.13.3). Run mid- current in module & confirm
range wattage test range operation by running
again and check drive standard test no. 1.
signal current.

Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 36
 5.0 TROUBLESHOOTING PROCEDURES
5.2 Xenon Lamp and Irradiance Control Malfunctions (cont.)

5.2.5 Troubleshooting Flow Chart - 2-Sun Irradiance Considerations (Ci5000 only)

1) Create and initiate a

custom 2-Sun test.

Relay K14 or A14 rack

2) Check for rack speed Rack at
speed controller is
of 10 RPM. 1 RPM
malfunctioning.

3) Check for continuity

between K14 relay termi- Continuity Check for 0 volts between
nals K14-3 and K14-4. ground and relay K15
terminal K15-3. If voltage
present, K15 or K14 is
No stuck closed. Replace bad
continuity relay.

No voltage
4) Check for 24Vac at
K14 coil terminals K14-1
and K14-2.
If A8 LED on PLC3 is
on, replace PLC3. If
LED is off, download
software to PLC. If
operation not restored,
replace PLC3. See
Section 5.13.5.
Voltage
Replace relay K14.
present

Voltage
5) With K14 operating Relay K4 is o.k.
present
properly, check for volt-
age between ground and
K4 relay terminal K4-3. No voltage Check for 24Vac at K4
present coil terminals K4-1 and
K4-2. If no voltage is
present, replace K4. If
voltage is present, re-
place PLC3 Logic Output
module (see Sec. 5.13.5
first).

Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 37
 5.0 TROUBLESHOOTING PROCEDURES
5.2 Xenon Lamp and Irradiance
Control Malfunctions (cont.)
5.2.6 Troubleshooting Procedure –
Lamp Ignition Failure (Ignitor)
Ignitor LS-8
Light
Monitor
Figure 5.2 – 5 Ci3000 + Lamp Ignitor & LS-8
Figure 5.2 – 6 Ci4000 Xenon Lamp Ignitor
Figure 5.2 – 7 Ci5000 Xenon Lamp Ignitor
1) Ensure that the xenon lamp is properly installed
and that the ignitor lead is firmly secured to the
lamp electrode. Also ensure that the lamp lead
connection to the ignitor terminal is secure and
free of corrosion.
Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0
2) Confirm that the Xenon Lamp and Ignition
circuit-breakers are turned on.
3) Check for messages on the Data Panel MAIN
page 1 Messages display.
A) Check the CS-6 lamp cooling system
(Sec. 5.5) if one of these messages appears:
Lamp Water Temperature High
Lamp Water Flow is Low
B) If the message “Chamber Temperature is
High” is displayed, reset the chamber safety
thermostat (S4) inside the electronics drawer.
Press the red reset button on the thermostat.
S4
Figure 5.2 – 8 Chamber Overtemperature Thermostat
4) Initiate standard test no. 1 to attempt lamp
ignition.
5) If the ignition start pulse is audible (up to 4
attempts), but the lamp will not ignite, the problem
is either the lamp itself or low lamp-circuit voltage.
A) Install the calibrated reference lamp and
initiate the test. If the lamp lights, then the
previously installed xenon lamp is
malfunctioning. Examine it for damage,
burner tip and socket damage or corrosion.
Check the burner age as recorded on the
Xenon Burner Warranty Log card. The lamp
may be at the end of its life (1200 hours or
more).
B) If the calibration lamp will not ignite,
measure line voltage to the instrument and
38
 5.0 TROUBLESHOOTING PROCEDURES
5.2 Xenon Lamp and Irradiance
Control Malfunctions (cont.)
5.2.6 Troubleshooting Procedure –
Lamp Ignition Failure (Ignitor) (cont.)
check the transformer tap connections as
described in Section 5.1.1. Set the T1 booster
transformer lead T1-3 to the next higher lamp
boost voltage terminal. Re-attempt lamp
ignition. If the lamp still does not ignite,
continue below.
Also check the light rod for cleanliness and
damage. Confirm the LS-8 light sensor
interference filters have not expired and that
the photodiodes are functional (Sec. 7.2.9).
CAUTION: SHOCK HAZARD.
Conduct step 6 below with
meter leads clipped onto the
specified terminals. DO NOT hold probes
onto the terminals during lamp ignition or
electric shock and injury may result.
Note: In the steps below you must shut the
instrument off with the front panel power
switch after each attempt at igniting the lamp.
This will reset the lamp starting circuit.
6) Check voltage to the ignitor: Connect a voltmeter
(with clip leads) to terminals L3-1 and L3-2. Attempt
lamp ignition while watching the meter. The meter
should indicate line voltage (230V or 480V) during
the ignition pulse.
A) If line voltage is present during the ignition
pulse, the ignitor has failed. Replace it (see
Section 8.6).
B) If no voltage is present, continue below.
7) Check relay K3 operation: During an ignition
attempt, check for continuity between the terminals
of Ignition Pulse Relay K3. There should be
continuity for 1 second during each ignition pulse
between terminals:
Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0
Ci3/4000 - Terminals K3-5 and K3-6
Ci5000 - Terminals K3-6 and K3-7
A) If there is continuity across the K3 contacts
during the ignition pulse, then there is a
problem with the line voltage supply to the
relay. Check wiring to the relay and voltage
at the CB2 Ignition circuit-breaker terminals
CB2-2 and CB3-4. There should be line
voltage between each terminal and ground.
If not, replace the circuit-breaker.
B) If the relay does not activate, its coil is
bad or the PLC is not sending it an activation
signal or the 24Vac supply to the PLC is bad.
B1) Check for 24Vac on the relay coil during
the ignition pulse. If 24Vac is present, the coil
is bad. Replace the relay (see Section 8.1).
B2) During the ignition pulse, check for
continuity between terminals PLC3-1 and
PLC3-3. If there is no continuity, and the A2
LED on PLC3 is on, replace the module (see
Section 5.13.5 first). If A2 is off, download
the PLC software program to the PLC.
B3) Check for continuous 24Vac across:
Ci3/4000 – TB3-7 and TB3-9
Ci5000 – TB3-5 and TB3-8
This is the 24Vac supply to the 24Vac control
circuit. If 24Vac is not present, check circuit-
breaker CB5 and the 24Vac output of the
isolation transformer T2 at terminals
T2-X3 and T2-X4. Replace the failed breaker
or transformer.
5.2.7 Troubleshooting Procedure – Irradiance
Low or High (Wattage Regulator)
To maintain an accurate and stable irradiance level
during a test, the PLC receives a signal from the
light monitor (at PLC5-11/-13 or PLC2-12/-14),
compares it to the irradiance setpoint reference,
and then alters its output (at PLC6-7/-19) to
increase or decrease wattage regulator output.
39
 5.0 TROUBLESHOOTING PROCEDURES
5.2 Xenon Lamp and Irradiance
Control Malfunctions (cont.)
5.2.7 Troubleshooting Procedure – Irradiance
Low or High (Wattage Regulator) (cont.)
This drive signal is applied to terminals AR1-1 and
AR1-2 of the wattage regulator AR1.
Figure 5.2 – 9 Xenon Lamp Wattage Regulator
Troubleshooting consists of first confirming light
monitor operation and its output signal to the PLC.
Then the instrument is operated at constant
wattage and the PLC output signal to the wattage
regulator is checked. If a stable drive signal is
present, but lamp operation is erratic or out of
wattage tolerance, it is likely that the wattage
regulator is malfunctioning.
1) Perform the Wattage Calibration (Sec. 6.8) and
then the Irradiance Calibration (Sec. 6.9) to
eliminate calibration as a contributive factor.
2) Initiate standard test no. 1 SAE J-1885. Set it
up so the lamp will operate for 30 minutes.
3) With the lamp operating, confirm that the voltage
signal from the light monitor is present at the PLC
Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0
terminals PLC5-11 and PLC5-13 (or at terminals
PLC5-12 and PLC5-14 if the optional sensor is
installed and is controlling irradiance).
A) If no voltage is present, there is a problem
with the light sensor wiring, interference filter
or the photocell. Check each of these before
continuing (See Section 7.2.9).
B) If the signal is present, the light monitor is
functioning properly.
4) Shut off all power to the instrument at the wall-
mounted disconnect switch.
5) Disconnect the AR1-1 lead from the wattage
regulator and connect an ammeter in series with
Power
LED
Figure 5.2 – 10 Wattage Regulator Power LED
the lead and terminal AR1-1. This will allow
measurement of the 4-20mA drive signal from the
PLC to the wattage regulator.
6) Apply power to the instrument. Initiate a custom
test using wattage control rather than irradiance
control. Set the wattage level to minimum for the
lamp type in use (1700 watts for Ci3000+, 2500
watts for Ci4000, 4000 watts for Ci5000). Set the
test duration to 30 minutes.
7) Observe the LED indicator lights on the wattage
regulator. With power on and the xenon lamp
operating, the upper green lamp should be on
indicating that the regulator is receiving power.
40
 5.0 TROUBLESHOOTING PROCEDURES
5.2 Xenon Lamp and Irradiance
Control Malfunctions (cont.)
5.2.7 Troubleshooting Procedure – Irradiance
Low or High (Wattage Regulator) (cont.)
A) If the LED is off, check for continuity across
terminals K9-9 and K9-10 of relay K9. If there
is continuity, then resistor R4 (Ci4 only) is
open-circuited or the wattage regulator has
failed. Replace the regulator per Section 8.7.
Soft
Start
LED
Output
LED
Figure 5.2 – 11 Wattage Regulator Output LED
B) Check for 24Vac volts across the K9 relay
coil terminals K9-1 and K9-2.
B1) If voltage is present, and there is no
continuity between terminals K9-9 and
K9-10, replace relay K9 per Section 8.1.
B2) If voltage is not present, and the B5
LED on PLC3 is on, replace the PLC3
module (see Section 5.13.5). If B5 is off,
download the software program to the
PLC. If this fails to restore operation,
replace PLC3.
8) Observe the ammeter on the AR1-1 terminal. It
should display a reading of approximately 4mA.
A) If the ammeter reading is zero, or well
above 4mA, there is potentially a problem
Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0
with the PLC Analog Output PLC6 module.
(This will be checked in a later step.)
9) Stop the wattage test and alter it to the mid-
range operating wattage level shown below.
Ci3000+ – 3000 watts
Ci4000 – 5000 watts
Ci5000 – 8000 watts
10) Initiate the new test to ignite the lamp.
11) Observe the green LED indicator light on the
lower circuit board of the wattage regulator. This
is the output indicator and becomes brighter as
output increases. It should be on brightly.
A) If the LED is very dim or off, and the
ammeter reading is well above 4mA, there
is a problem with the wattage regulator
output. Replace the regulator (Section 8.7).
B) If the ammeter reading is zero, still at 4mA
or is unstable, there is a problem with the
PLC Analog Output PLC6 module or the PLC
CPU (PID settings, corrupt PLC software or
CPU failure).
B1) Replace the PLC6 module (see Sec.
5.13.8 first). Run the mid-range wattage
test again. Check the level and stability
of the ammeter reading. It should be very
stable and approximately 5 to 10 mA.
B2) If replacement of the PLC6 module
does not correct the problem, download
the custom programs from the PLC to a
laptop computer and replace the CPU
module of the PLC (see Sections 5.13 and
Appendix A). Upload the custom pro-
grams and the correct PLC operating
software. Run the mid-range wattage test
again and observe the ammeter reading
for stability. If this corrects the problem,
reinstall the old PLC6 module and confirm
operation.
41
 5.0 TROUBLESHOOTING PROCEDURES
5.2 Xenon Lamp and Irradiance 1) Program a custom, 2-sun irradiance test with
Control Malfunctions (cont.) the parameters shown below.

Test List (Data Panel page 6)

5.2.8 Troubleshooting Procedure – 2-Sun Select an unused Custom test. Press F6, the test
Irradiance Considerations number and Enter three times. Press F2.

If the xenon lamp in the Ci5000 fails to operate at Test Criteria (Data Panel page 7)
higher (2-Sun) irradiance levels, there may be a Total Segments 1
malfunction of the 1-Sun or 2-Sun relays, or the Duration Units Time
components driving them (Fig. 5.2–9). Additionally, Black Sensor BPT
if the error message “Test Irrad. Not Match with Black Temp. Active Yes
Filters” appears on the screen at the start of a test, Radiation@filter 340 nm
it indicates that the irradiance level chosen is in Chamber Temp. Active No
the 2-Sun range and you must recalibrate the lamp
for this irradiance level. Segment (Data Panel page 8)
Segment Number 1
2-Sun irradiance levels are defined as follows: Light or Dark Light
Time or Irradiance 30 min.
0.70 W/m2 or higher @ 340 nm filter Irradiance 1.50 W/m2
1.40 W/m2 or higher @ 420 nm filter Black Temp. 80 °C
Chamber (DB) Temp. 60 °C
75.0 W/m2 or higher @ 300-400 nm filter
Relative Humidity 0%
At 1-Sun irradiance levels, the rack rotates at 1 Segment (cont.) (Data Panel page 9)
RPM. At 2-Sun levels it rotates at 10 RPM. Relay Set sprays to off.
K14 switches the input to the rack speed controller.
Conduct the procedure below to determine the Test List (Data Panel page 6)
cause of 2-Sun operation failure. Press F8. Press F5, the custom test number and
Enter three times to load the new custom test.
L3
PLC3 IGNITOR
LOGIC
OUTPUT L3-12 Run/Stop Segment (Data Panel page 3)
MODULE
K3-3 L2-2
Test Duration 0 hours 30 min
A8 TB6-1
A14 PLC3-10
24Vac
RACK TB3-5 TB3-9
TB6-1 2) Press F4 on RUN/STOP page 3 to start the test.
MOTOR TB3-6 K14-1 K14-2
3
SPEED TB3-7
COIL
CONTROL K14-9
N.C. K14 N.C.
K14-11 K15-1 C K15 CAUTION: SHOCK HAZARD
O ONE
RACK
SPEED I SUN
In the procedures below, you
K14-4 K14-3 K15-2
A14-S3 RELAY L RELAY must check for voltages at live
A14-S2 TB3-11 4 electrical terminals. Avoid
A14-S1
R2
10K
contact with component terminals and
wear insulated gloves to prevent electrical
3 shock.
L1 LOW K4-1 PLC3-5
MAIN K4 C A4
O
REACTOR
HI
TWO
SUN I
PLC3 3) When the Ci5000 is running a test at
LOW COM K4-2 LOGIC
RELAY L
OUTPUT 2-Sun irradiance level, the rack should be rotating
MODULE
TB2-2
4
TB3-8
at 10 RPM. Check rack speed. If it is rotating at 1
24Vac RPM, relay K14 or the rack speed control A14 is
Figure 5.2 – 12 One and Two Sun Circuit Block Diagram malfunctioning (see Section 5.8).

Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 42
 5.0 TROUBLESHOOTING PROCEDURES
5.2 Xenon Lamp and Irradiance
Control Malfunctions (cont.)

5.2.8 Troubleshooting Procedure – 2-Sun

Irradiance Considerations (cont.)

In 2-Sun mode, PLC3 de-energizes (closes) the

2-Sun relay K4. It also energizes relay K14 causing
the 1-Sun relay relay K15 to open. K14 also causes
closure of contacts A14-S2 and A14-S3 of the A14
rack speed control board to provide 10 RPM rack
rotation (see Fig. 5.2–9).

3) Check for continuity between terminals K14-3

and K14-4.

A) If there is continuity, relay K14 is likely

operating properly. Check for voltage
between ground and terminal K15-3 of relay
K15. It should be 0 volts. If voltage is present,
K15 is stuck closed or contacts K14-9 and
K14-11 of relay K14 are stuck closed.
Replace the malfunctioning relay (Sec. 8.1).

B) If there is no continuity, check for 24Vac

at the K14 coil terminals K14-1 and K14-2. If
voltage is present, replace K14. If no voltage
is present, and the A8 indicator light on PLC3
is off, download the software program to the
PLC. If indicator light A8 is on, replace the
PLC3 Logic Output module (see Section
5.13.5 first).

4) With relay K14 operating properly, check for

voltage between ground and terminal K4-3 of relay
K4.

A) If voltage is present, K4 is o.k.

B) If voltage is not present, check for 24Vac

at the K4 coil terminals K4-1 and K4-2. If
voltage is present, the PLC3 Logic Output
module is malfunctioning. Replace it (see
Section 5.13.5 first). If voltage is not present,
relay K4 is stuck open. Replace K4 (Sec.
8.1).

Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 43
 8.0 REPAIR & REPLACEMENT PROCEDURES
8.2 Sensor Replacement (cont.) Light Rod Optional Channel 2
Connector Interference Filter
(300-400nm shown)
8.2.7 Light Monitor Photodiodes
Capsule Channel 2
Cover O-Ring Capsule &
Photodiode
The LS-8 Light Monitor, used on the Ci5000, A13
Enhanced Ci4000and Ci3000+, includes one or
two capsules that contain an interference filter and
a photodiode. Light from the xenon lamp is
transmitted to the photodiode via the quartz light
rod. The photodiode produces a microampere (µA)
output proportional to the light intensity it receives Beam Splitter (not present
passing through the interference filter. on single bandwidth units)

Older Ci4000 instruments have either a single light Channel 1

Interference Filter
sensor in a sheetmetal enclosure or an optional (340/420nm shown)
dual band sensor in a machined aluminum
housing.
Channel 1
In all three light monitors, the types of photodiodes Capsule &
used are the same, but their mountings differ. Photodiode
A10

Note: The photodiode used with a 340 or Ci3000+, Ci5000 & Enhanced Ci4000 Light Sensor
420nm narrow-band interference filter is
different than the one used with a 300-
400nm wide-band filter. Do not mix them.
A13 Photodiode Filter Light Path
Sensor Cell #2 Housing
Photodiode Part Numbers O-ring
340nm 420 nm 300-400 nm
Older
Ci4000 09-3515-00 09-3515-00 09-3493-00

Ci3+, Ci5
& Ci4000 09-3529-00* 09-3530-00* 09-3531-00*
Enhanced
Housing
*LS-8 capsule assembly including photodiode Cover Interference Filter
(Note orientation
of arrow)
Leads for
code
jumpering Interference Filter Housing and
Filter Beam Splitter
Interference Filter
(Note orientation
of arrow)
A10 Photodiode
Sensor Cell #1

O-Ring Older Ci4000 Dual Bandwidth Light Sensor

Photodiode

Figure 8.2 – 7 LS-8 Light Sensor Capsule Assembly Figure 8.2 – 8 Dual Bandwidth Light Sensors

Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 180
 8.0 REPAIR & REPLACEMENT PROCEDURES
8.2 Sensor Replacement (cont.) 8.2.8 Chamber Overtemperature Thermostat

8.2.7 Light Monitor Photodiodes (cont.) This thermostat is accessed from inside the
electronics drawer (but may be easier to replace
by removing the right-side access panel).

Chamber Wall
Sensor
Housing Reset

Interference
Filter (Note
orientation of
arrow)
Figure 8.2 – 10 Chamber Overtemp. Thermostat S4
A10 Photodiode
Sensor Cell
Guidelines
Filter Housing
Cap 1) The face of the thermostat must be in contact
Sensor with the exterior wall of the test chamber. Apply a
Housing Cover small amount of silicon thermal grease to the face
DO NOT remove of the thermostat when mounting a new one.
screws in this location (Thermal grease is commonly used in the
electronics industry when mounting transistors to
Figure 8.2 – 9 Older Ci4000 Single Bandwidth heat sinks to improve thermal transfer.)
Light Sensor
2) Apply sealant to the mounting screws. The
Guidelines screws extend into the test chamber and could
allow leakage without sealant in place.
1) The photodiode is fragile. Handle it with care
and avoid touching its front window. If you do, clean
it with alcohol or optical cleaner and a soft cloth. 8.2.9 Chamber Overtemperature Sensor
This applies to the interference filters as well. (Older Ci4000 only)

2) Always ensure that the direction arrow on the
340 or 420nm filter is pointing toward the
photodiode (direction of light travel) when
assembling the light sensor. The 300-400nm filter
may be installed either way.
On some of the early Ci4000 instruments, a
Chamber Overtemperature alarm was included
beside the Lamp Cooling Water Controller in the
top section. It has an RTD temperature sensor
mounted in the test chamber.

3) DO NOT attempt to install a photodiode normally Replace the three-wire

used with the 340/420nm filter in place of the one sensor by disconnecting it
used with the 300-400nm filter, or vice versa. The AL1
0000 RESET from the back of the alarm.
spectral response of each is different and will result AL2
Remove the old sensor
in erroneous readings. from the test chamber
Eurotherm 92
Chamber Overtemperature
taking note of its insertion
Figure 8.2–11 Chamber depth in its mounting. Install
Overtemperature Alarm the new sensor.

Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 181
 INDEX
Symbols BP Transmitters & Collector Rings 78
Burner Socket
2-Sun Irradiance Levels 90 Maintenance 158
2-Sun Irradiance Test 42
6-Channel Chart Recorder 109 C
A Calibration 134
Black Sensor Check 137
Access Panel Black Sensor Circuit 138
Removal 134 Calibration Schedule 136
Air Filter Chamber Sensor Check 141
Cleaning 165 Chamber Sensor Circuit 143
Air Heater Ci5000 Rack Speed 154
Element Resistance Values 89 Component Locations 134
Element Terminals 88 Damper Calibration 153
Power Ratings 81 Irradiance Calibration 151
Air Heater Control Relay Q2 56 Procedures 134
Air Regulator Relative Humidity 146, 147
Oil Trap Cleaning 165 Water Resistivity Monitor 156
Air Valve (Damper) Wattage Calibration 148
Troubleshooting 88 Chamber Dry Bulb (DB)
Alignment Error Message 18. See also Sensors: Temperature:
Lamp/Rack/Light Rod 168 Error Message
APC1 Filter PC Board 51 Sensor Check 141
Atlas Fax Number 11 Temp. Sensor Locations 142
Auxiliary Reactor L2 21 Transmitter Location 141
Transmitter Terminals 141
B Chart Recorder 109
Bearings Channel Assignments 109
Specimen Rack 201 Electrical Diagram 112
Black Panel Sensor Error Messages - Fatal 112
Circuit Calibration 138 LIST Printout 109
Sensor Check Procedure 137 Malfunction Troubleshooting 109
Transmitters/Collector Ring 78 mR1000 Manual 205
Black Standard Panel Recorder Replacement 202
Circuit Calibration 138 Chart Recorder Block Diagram 112
Error Messages 18. See also Sensor: Temperature: Control Panel. See Data Panel: Error Messages
Error Message CS-6 Lamp Cooling System
Sensor Check Procedure 137 Demineralizer Cartridge Replacement 160
Blower Electrical Diagram 59
Error Message 17 Flow Switch Filter Cleaning 160
Blower Controller 69 Flow Switch Testing 67
Blower Controller Code List 77 Malfunction Troubleshooting 59
Blower System Plumbing Diagram 60
Blower Wheel Mounting 73 Pump/Motor Coupling 67
Chamber Overtemp. 17 Reservoir Cleaning 162
Controller Code Listing 77 Reservoir Diagram 62
Controller Error Messages 70 CS-6 Pump Shaft Coupling 67
Controller Indicator Lights 70
Controller Keypad Functions 75
D
Controller Programming 76 Damper
Electrical Diagram 69 Calibration 153
Malfunction Troubleshooting 69 Chamber overtemp. 17
Motor Controller Input Jumper 75
Blower Wheel Mounting 73

Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 231
 INDEX
Safety Thermostat 23
Photo of 25
Tools Required 13
Transformer, Reactor Config. 20
Configuration Guides 26
Transformer T1 21

W
Water Control Relay Q1 50
Water Resistivity Monitor 104
Calibration 156
Malfunction Troubleshooting 104
Sensor Cleaning 108
Water Spray Systems 99
Electrical Diagrams 103
Malfunction Troubleshooting 99
Plumbing (Ci3+) 100
Plumbing (Ci4, Ci5) 99
Water Solenoid Valves 100
Wattage
Setting Minimum 40
Wattage Calibration 148
Wattage Powermeter
Connections, calibration 148
Wattage Regulators 40

X
Xenon Lamp
1 & 2-Sun Relays 42
Alignment (Ci3+) 171
Alignment (Ci4, Ci5) 168
Assembly Guide 33
Burner Socket 158
Circuit Drawings 30
CS-6 Cooling System 59
Error Messages 17
Ignitors (photos) 38
Malfunction Troubleshooting 29
Min. Wattage Setting 40
Operating Ranges 29
Outer Filter Cleaning 158
Water Flow Switch 67
Wattage Regulators (photos) 40

Ci3000+ / Ci4000 / Ci5000 Weather-Ometer® Service Guide Doc. No. 07-7030-00 Rev. 0 234