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PSI 300
Particle Size Analyzers
Maintenance Manual
Maintenance Manual
Code 10000004258e Revision A Page 2 (21)
Contents
1. MAINTENANCE OF THE PSI 300 .................................................................................................................3
1.1 Feeler gauge and zero level tuning....................................................................................................4
General...........................................................................................................................................4
Checking of the feeler gauge tuning ..............................................................................................5
Re-tuning with the feeler gauges ...................................................................................................7
DRC module replacement..............................................................................................................9
1.2 Measurement head (PSTS) maintenance..........................................................................................9
Replacement of the protective rubber............................................................................................9
1.3 Sample tank level switch operation..................................................................................................11
1.4 Replacing the PLC battery ...............................................................................................................12
1.5 Replacing panel Compact flash card ...............................................................................................13
1.6 Replacing panel battery....................................................................................................................14
1.7 Replacing panel................................................................................................................................15
Restoring project from CF card ....................................................................................................16
Panel settings...............................................................................................................................16
Restore project from Proficy Machine Edition..............................................................................17
Backup project to CF card............................................................................................................17
1.8 Replacing I/O module.......................................................................................................................17
1.9 Replacing CPU.................................................................................................................................18
1.10 Downloading PLC configuration.....................................................................................................19
2. Troubleshooting .........................................................................................................................................20
Panel ............................................................................................................................................20
READER COMMENTS
Maintenance Manual
Code 10000004258e Revision A Page 3 (21)
DAILY:
Check and clean the sample screens, replace if worn out.
WEEKLY:
Check the smudge filter in the water supply line. Filter will be cleaned when
using manual water service hose.
Keep the PSI system "neat". Wash measuring head if covered with slurry
splashes. Panel display can clean necessary. Before cleaning display set
display to service state by pushing Clean display touch. After that, wipe the
display with a damp cloth. Return to display mode with Clean display
touch.
Wash calibration and daily sample cutters when changing sample bucket. .
YEARLY:
Replace the protective rubber in measuring head (see chapter 1.2).
Replace Air Silencer and Air Filter of PSI 300 pneumatics module.
OCCASIONAL MAINTENANCE:
Checking the feeler gauge tuning (see chapter 1.1)
Retuning with the feeler gauges (see chapter 1.1)
Replace of PLC battery (see chapter 1.4)
Replace panel compact flash card (see chapter 1.5)
Replace panel backup battery (see chapter 1.6)
Maintenance Manual
Code 10000004258e Revision A Page 4 (21)
General
PSI 300 has been set at the factory so that physical size of the measured
particle is shown in micrometers in status display.
Status display shows the current value of the probe in “raw measurement” field
when PSI is measuring. The zero level is reduced from the measurement value,
so when there is no slurry, raw measurement value should be 0 um.
When the Zero level is increasing, probably something is stuck in between the
measurement elements and they need to be cleaned. When the Zero level is
decreasing the measurement elements are wearing.
Normally there is no need for re-tuning the PSTS. This is for the reason that the
instrument does an automatic Zero check measurement and then Zero Level is
re-calculated. Anyhow the tuning is good to check occasionally and especially it
is recommended right after the installation, just before the slurry calibration is
committed. If the tuning is not correct during slurry calibration but is corrected in
association of later service it may cause re-calibration task of the unit.
For proper results 50µm thick plastic film gauges are recommended. The
difference between the thickness of a feeler and corresponding reading in
display must be less than +/- 5%.
If the error is more than +/- 5%, feeler gauge re-tuning must be done.
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Code 10000004258e Revision A Page 7 (21)
When feeler gauge tuning was properly pre-done no new slurry calibration is
required after a component replacement or even a replacement of the whole
measurement head.
Tuning is done with Fine Adjust potentiometers "Gain" and "Offset" located on
the front of DRC module - Figure 5.
4000 µm
Offset
Input signal
Gain
1000 µm
Turn the Standby switch to position 0, flush the measurement head and
measurement channel with the water.
Turn the Mains switch to OFF and open the PSTS cover.
5 Loose the screws holding the sensor and motor assembly in the base
plate. Lift and take away the sensor, motor assembly.
Maintenance of the sensor can be done in the instrument workshop.
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Code 10000004258e Revision A Page 10 (21)
7 Prop up the rod with the "special tool" attached onto the PSTS housing and
remove the upper measurement element with is holder.
9 Clean the sensor and check that the rod bearings are not damaged.
Replace the bearings if needed.
11 Check the condition of the upper and lower measurement element and
change if needed. Once again prop up the rod with the "special tool" and
tighten the upper measurement element onto the rod.
Install the sensor back onto the PSTS base plate, connect the cables and
close the PSTS cover.
1 2 3 4 5 6 7 8 9 10
8
7
11
The level switch requires no configuration or tuning. Wiring of the level switch at
the PCS- cabinet defines the operation mode to PNP open collector action.
You may simulate the operation of the tuning fork (i.e. is detecting process
sample level) by firmly pressing the forks against each other. When the level is
detected the output changes and the state of concerned PLC input(s) changes
accordingly. Next to the wiring connector the level switch has a physical LED
indicating the status of the output.
Slurry supply hose may change to feed position if PSI 300 is not set to standby.
There is no alarm or any kind of notification if the compact flash card wears out.
It is important that the compact flash card is replaced before it wears out.
All saved data will disappear when the storage CF card is replaced. This
means that datalogs and calibration logs are removed. Parameters are set
to default.
Not all CF cards work with the panel. It is important that the new CF card is
approved by Outokumpu technology.
Panel settings
Restoring project does not restore network settings or other windows CE
settings. These settings need to be changed separately.
Go to control panel (start->settings: control panel). Tap “network and dial-
up connections”.
The port for DCS connection is LAN1. Type customer specified IP address,
subnet mask and default gateway.
The port LAN2 is PSI 300 maintenance port. Use following IP address
configuration:
– IP: 10.9.8.7
– Subnet mask: 255.255.255.0
Close network and dial-up connections
Tap “system” from control panel
– set the storage memory to 5000KB from memory tab.
Tap Date/time from control panel
– Correct the date and time settings
Tap Regional settings
– Correct regional settings
– Important: The date format displayed in navigation bar is the same as
short date format in regional settings.
Tap Display from control panel.
– uncheck “auto turn off backlight while on external power” from Backlight
tab
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Code 10000004258e Revision A Page 17 (21)
Also for possible CPU module break down, it is good to first try downloading the
configuration before stating that the CPU module is broken.
2. Troubleshooting
Panel
Warning popup: Retentive Directory Warning
Explanation:
The panel has 512 kB battery backed up memory for data retention. Every
time a project is downloaded to panel a retentive value folder and files are
created. There are different folders for different named project. The panel
does not remove old project folders. PSI 300 project must always have
same name, so that the folder is always same and this warning does not
appear.
Solution:
Warning popup:
“\PCFlash\Storage\fxviewruntime\project\webroot\customdocuments\DATABASE.LOG:
The system cannot find the path specified”
Explanation:
This error message will appear if new storage CF card is used at the first
time. It means that it cannot find the path specified.
Solution:
The program will create the current path and error message is not
displayed again.
If the problem reappears, check that the CF card is mounted correctly. Also
use windows explorer to check that the panel finds the card (PCFlash
storage). Otherwise, replace the CF card.
Warning popup: “Cannot open corrupted logging file! Logging file overwritten”
Explanation:
Sometimes the logging file might corrupt on shutdown. This may indicate
that the CF card is faulty.
Solution:
The panel will remove the old logging file and create a new one.
Explanation:
Panel cannot find CF card for some reason or the CF card is broken or
unformatted.
Solution:
Format the CF card. Notice: formatting CF card with the panel will take
hours. It is recommended that a PC is used to format it.
Explanation:
This message is displayed when the CF card includes backup of a PSI 300
project. Normally this should not be displayed, because the backup CF
card is different than the storage CF card. Storage CF card does not
include PSI 300 software backup.
Solution:
Click “no” if you are not restoring the project because of panel. Also make
sure that the storage CF card is in instead of backup CF card.
TELEFAX MESSAGE DATE: Page 1
READER COMMENTS
The design team of Outotec is committed to ensure the quality and usefulness of this manual
and the PSI 300 analyzer system. Your comments, recommendations and suggestions will
help make our continuous effort more effective.
Please take few moments to write your comments either directly on the form provided or on a
photocopy of it.
Outotec, Analyzers
Fax to: FAX: INT + 358 205 292998
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