. ystem Operation The GCM-A's main purpose is to detect overheating in air cooled generators. This section describes system operation. GCM-A Initialization With system power on, press the RESET push-button on the backside of the DISPLAY PANEL. The GCM-A DISPLAY PANEL will respond with ; (a) all discrete LED's lit; (b) all pixels of the LCD display on. Once communication has been established with the rest of the system; (a) all discrete LED's, except AC POWER, LOCAL, SYSTEM TROUBLE , AMBIENT FLOW TROUBLE and GENERATOR FLOW TROUBLE, will turn off; (b) all segments of the AMBIENT and GENERATOR displays will turn off; and (c) the display will echo the results of cold-start initialization. • GCM-A Ver 2.2E-7 • CHECKSUM OK • POWER OK • "STARTING "." (will flash for two seconds) • VACUUM=X.x • AMB FLO=14.0 LPM • GEN FLO=14.0 LPM • LED=N .NmA(99%) • WATER OK • END DIAGNOSTICS • WAIT...10 (10 second delay) • NORMAL OPERATION will flash for two seconds; the GCM-A will begin normal operation and the display will read "GCM-A by E/One". See Normal for more information. GA0519POI REV B GCM-A Software V ersion 2.2E beyond ninety nine. Press the ENTER key to save your changes and return to the SETUP MENU . Press the FN key to discard the changes and return to the SETUP MENU . Setting the Generator Gain The generator gain determines the sensitivity of the submicron particle detector. The higher the generator gain setting, the more sensitive the detector. The factory default value for the generator gain is 1.0. The generator gain can be changed by selecting GEN GAIN from the SETUP MENU . When GEN GAIN is selected, the generator gain will be displayed on the LCD display. Press the UP ARROW key to increase it. Press the DOWN ARROW key to decrease it. It cannot be decreased below 1.0 or increased beyond 9.9. Press the ENTER key to save your changes and return to the SETUP MENU . Press the FN key to discard the changes and return to the SETUP MENU. Setting the Generator Warning Level The generator waming level determines what electrical output from the cloud chamber detector will trigger a WARNING indication. The generator warning level is expressed as a percentage of full scale. A WARNING indication is given when the output of the cloud chamber detector exceeds the value of generator warning level. The factory default value for the generator warning level is 50 percent. The generator warning level can be changed by selecting GEN WARN from the SETUP MENU . When GEN WARN is selected , the generator warning level will be displayed on the LCD display. Press the UP ARROW key to increase it. Press the DOWN ARROW key to decrease it. It cannot be decreased below thirty or increased beyond the generator alarm level. Press the ENTER key to save your changes and return to the SETUP MENU . Press the FN key to discard the changes and return to the SETUP MENU. Setting the Generator Alarm Level The generator alarm level determines what electrical output from the cloud chamber detector will trigger an ALARM indication. The generator alarm level is expressed as a percentage of full scale. An ALARM indication is given when the output of the cloud chamber detector exceeds the value of generator alarm level. The factory default value for the generator alarm level is 80 percent. The generator alarm level can be changed selecting GEN ALARM from the SETUP MENU. When GEN ALARM is selected, the generator alarm level will be displayed on the LCD display. ~ss the UP ARROW key to increase it. Press the DOWN ARROW key to decrease it. It cannot be decreased below the generator warning level or increased beyond ninety nine . Press the ENTER key to save your changes and return to the SETUP MENU . Press the FN key to discard the changes and return to the SETUP MENU . Setting the Differential Warning Level The differential warning level determines what electrical output from the cloud chamber detector will trigger a WARNING indication . The differential warning level is expressed GA0519POI REV B 10 GCM-A Software Version 2.2:: as a percentage of full scale. A WARNING indication is given when the generator output level exceeds the ambient output level by a value greater than the differential warning level. The factory default value for the differential warning level is 30 percent. The differential warning level can be changed by selecting DIF WARN from the SETUP MENU. When DIF WARN is selected , the differential warning level will be displayed on the LCD display. Press the UP ARROW key to increase it. Press the DOWN ARROW key to decrease it. It cannot be decreased below thirty or increased beyond the differential alarm level. Press the ENTER key to save your changes and return to the SET~ MENU. Press the FN key to discard the changes and return to the SETUP MENU . Setting the Differential Alarm Level The differential alarm level determines what electrical output from the cloud chamber detector will trigger an ALARM indication. The differential alarm level is expressed as a percentage of full scale . An ALARM indication is given when the generator output level exceeds the ambient output level by a value greater than the differential alarm level. The factory default value for the differential alarm level is 50 percent. The differential alarm level can be changed by selecting DIF ALARM from the SETUP MENU. When DIF ALARM is selected, the differential alarm level will be displayed on the LCD display. Press the UP ARROW key to increase it. Press the DOWN ARROW key to decrease it. It cannot be decreased below the differential warning level or increased beyond ninety nine. Press the ENTER key to save your changes and return to the SETUP MENU. Press the FN key to discard the changes and return to the SETUP MENU. About the Faults Log The Faults log traps these error conditions: I/O Fault, COMM Fault, AMB Flow Fault, GEN Flow Fault, Vacuum Fault, Photocell Fault Release Fault, Water Fault and Power Fault. • An I/O Fault is logged when a communication error is detected in the communication channel that connects the processor with the relay outputs . • A COMM Fault is logged when a communication error is detected in the communication channel that connects the processor to the Display or I/O board . • An AMB FLOW FAULT is logged when flow rate through the ambient air intake falls below 7 LPM or climbs above 21 LPM . • A GEN FLOW FAULT is logged when flow rate through the generator air intake falls below 7 LPM or climbs above 21 LPM . • A VACUUM FAULT is logged when the maximum vacuum level is less than 3.7 psi. • A PHOTOCELL FAULT is logged when the LED current deviates from its normal range. The normal range of LED current is from 4 mA to 20 mA. • A RELEASE FAULT is logged when the minimum vacuum level is greater than 0.7 psi. GA05I9POI REV B 11 GCM-A Software Version 2.2E • A Water FAULT is logged when the GCM-A uses an unusual amount of water. An unusual amount is defined as filling for more than 15 continuous seconds or going without water for more than 48 hours. • A Power Fault is logged when the measured voltage of one or more of the power supplies is out of specification. About the Power Log The Power log records the minimum and maximum voltage of each power supply. The voltage is sampled once every two seconds. When SHOW POWER LOG is selected. the GCM-A will display the minimum and maximum for each power supply in the format <nominal value>=<minimum value> . <maximum value> . An example for the 12-volt power supply is +12V=11.8.12.1. Use _ UP ARROW key or DOWN ARROW key to scroll through the five power supply voltag e:; Press the FN key to return to the LOG MENU . About the Event Log The Event log records the date and time of Significant operational events. The events are stored in a circular queue holding the last two hundred events. The oldest event is overwritten each time a new event is recorded . The list of possible events is containec Table 4 (Events). The most recent event is displayed when SHOW EVENT LOG is selected . Press the ENTER key to display the date and time of the event. Press the DOWN ARROW key display the previous event. Press the UP ARROW key to display the next event. (The display will wrap around to the oldest event if the UP ARROW key is pressed while displaying the most recent event). Remote Access Settings for remote operation can be reached by selecting the ADVANCED option 0 SETUP MENU . There are ten options available in the ADVANCED SETUP menu. The options are: • SET PASSWORD: Select this item to change the remote access password. • MODBUS ADAPTER: Select this item to change the E/One network address for the MODBUS adapter. • MOD BUS ADDRESS: Select this item to change the MODBUS address of the MOD8 US adapter. • MODBUS INTERFACE: Select this item to setup the electrical interface of the MODBUS adapter. • SET ADDRESS: Select this item to change the instrument remote access address. • SET BAUD RATE: Select this item to change the I/O board serial port communica:; speed . • SET DATE/TIME: Select this item to set the date and time. GA0519POI REV B 12 GCM-A Software Version :'_ • LOCK FILE SYSTEM: Select this item to lock the file system in preparation for changing the data recording media. • FORMAT ALL FILES: Select this item to initialize the file system to the factory defaults. • RESET I/O: Select this item to reset the I/O board . When SET PASSWORD is selected, "0000" will be displayed on the LCD display. (The current password is not displayed). Enter a four digit password by pressing the UP ARROW key to increase the lowest digit and the DOWN ARROW to shift the numQ..er to the left. (for example press the UP ARROW once, the DOWN ARROW once , the UP ARROW twice, the DOWN ARROW once , and the UP ARROW three times to enter the password 123). Press the ENTER key to save the password and return to the Advanced Menu. Press the FN key to leave the original password unchanged and return to the Advanced Menu. When MODBUS ADAPTER is selected, the current EIOne network address will be displayed on the LCD display. The address should be set to LOCAL to utilize the RS485 port integrated into the I/O board . Press the UP ARROW to increase the address; press the DOWN ARROW to decrease it. Press the ENTER key to save your changes and return to the Advanced Menu. Press the FN key to discard changes and return to the Advanced Menu. When MODBUS ADDRESS is selected, the current MODBUS address will be displayed on the LCD display. Press the UP ARROW to increase the address; press the DOWN ARROW to decrease it. Press the ENTER key to save your changes and return to the Advanced Menu. Press the FN key to discard changes and return to the Advanced Menu. The MODBUS address is retrieved from the adapter card over the EIOne internal network so a ..WAIT ..... prompt may briefly appear. If the prompt does not disappear within a few seconds the adapter is not responding . Verify that the MODBUS ADAPTER address is set to LOCAL to utilize the RS485 port integrated into the I/O board. When MODBUS INTERFACE is selected , the current electrical interface configuration for the adapter card will be displayed . The possible configurations are; RS232 , RS485 two-wire and RS485 four-wire. The integrated RS485 port only supports RS485 2-wire; and it will be the only setting available when MODBUS ADAPTER is set to LOCAL. Use the UP ARROW or DOWN ARROW to change the selection. Press the ENTER key to save your changes and return to the Advanced Menu. Press the FN key to discard changes and return to the Advanced Menu. When SET ADDRESS is selected, the current address will be displayed on the LCD display. Press the UP ARROW to increase the address; press the DOWN ARROW to decrease it. Press the ENTER key to save your changes and return to the Advanced Menu. Press the FN key to discard changes and return to the Advanced Menu. When SET BAUD RATE is selected , the baud rate will be displayed on the LCD display. Three baud rates are available: 2400, 9600 and 38,400 baud. Press the UP ARROW to increase baud rate; press the DOWN ARROW to decrease it. Press the ENTER key to save your changes and return to the Advanced Menu. Press the FN key to discard changes and return to the Advanced Menu. GA0519POI REV B 13 GCM-A Software Version 2.2E The following three selections affect the onboard file system. The onboard file system used to save historical data. The fault log , the event log and trending data is stored in the file system . The three selections allow the file system to be stopped , started and initialized. When SET DATE/TIME is selected , the date will be displayed on the LCD display. The date and time has six sellable fields : the year, month , day, hour, minute and second. The selected field will flash . Press the ENTER key to advance to the next field. Press the FN key to return to the previous field. Press the UP ARROW to increment the field ; press the DOWN ARROW to decrement it. Press the ENTER key with the second field flashill£ to save your changes and return to the Advanced Menu . Press the FN key with the year field flashing to discard your changes and return to the Advanced Menu. When LOCK FILE SYSTEM is selected , the current state of the file system lock will be displayed on the LCD display. Press the UP ARROW to turn the lock on ; press the DOWN ARROW to turn it off. Press the ENTER key to save your changes and return to the Advanced Menu. Press the FN key to discard changes and return to the Advanced Menu . When FORMAT ALL FILES is selected , the file system definition will be reset to the factory defaults. The file system must be locked before selecting this option or the formwill be cancelled. Once complete the format cannot be undone. The file system must be unlocked or the GCM-A restarted after the format is complete . GA0519POI REV B 14 GCM-A Software Version - = MODBUS • IMPLEMENTATION: The GCM-A operates as a MODBUS Slave Device. It uses the RTU (Remote Terminal Unit) transmission mode with even parity. The physical connection is an isolated RS485 2-Wire interface operating at 9600 BAUD. The GCM-A supports the Read Holding Registers (code Ox03) and Read Input REl!listers (code Ox04) commands. Both commands access the same registers . • REGISTER LOCATIONS: The register locations for the GCM-A are described in Table 1 (MODBUS Register Addresses) The register set for the GCM-A is always available starting at offset 16. They are also available at an alternate starting location. The alternate location is calculated by multiplying 512 times the value stored in SET ADDRESS . For example if the SET ADDRESS value is 80 the address of the first register will be 512 X 80 + 16 or 40976. (See SET ADDRESS under REMOTE COMMUNICATION for information on changing the SET ADDRESS value). Table 1 (MODBUS Register Addresses) NUMBER 1038 16 19 20 21 22 GCM-A DESCRIPTION INTERF ACE TYPE MODBUS ADDRESS XX RS485-2 WlRE ONLY Default value is 3FIO hex, RS485-2Wire modbus address 16 RELAY OUTPUTS BIT 0 NAME= FLOW TROUBLE RELAY BIT I NAME=DIFFERENTIAL ALARM RELAY BIT 2 NAME=GENERATOR ALARM RELAY BIT 3 NAME=AMBIENT ALARM RELAY BIT 4 NAME-WARNING RELAY BIT 5 NAME=NO TROUBLE RELAY AMBIENT FLOW IN LPM X 10 GENERATOR FLOW IN LPM X 10 AMBIENT OUTPUT LEVEL IN PERCENT X 10 GENERA TOR OUTPUT LEVEL IN PERCENT X 10 GA0519POI REV B 15 GCM-A Software Version 2.2E Modes of Operation Startup The GCM-A initializes all relays to the de-energized position. The GCM-A executes a "power on self-test" (POST) to verify its proper operation . It verifies its software by checksum testing the contents of its read-only memory (ROM). It tests its power supplies , vacuum pump and cloud chamber solenoids. It sets the LED current and fills the humidifier with water. It checks the flow through the generator and ambient sampling system. The POST will take about 30 seconds to complete if no errors are encountered . At the conclusion of the POST the GCM-A display panel will flash NORMAL OPERATION for two seconds before beg inning normal operation. If the FN key is pressed while it is still flashing , normal operation will be canceled and the GCM-A will enter alternating operating mode instead. Startup Problems The GCM-A verifies its software by checksum testing the contents of its read-only memory (ROM). If it finds a problem it will stop the POST process and flash BAD CHECKSUM on the LCD. The FN key may be pressed to allow the GCM-A to continue the POST process. However, proper operation cannot be guaranteed if this error is present. The GCM-A will annunciate any problems it finds with the power supplies, 1/0 board , vacuum levels, LEDl photocell , water usage or flow rates . The presence of one or more of these faults will not stop the POST process. However, they should be corrected as soon as possible because they indicate a hardware problem. +5 VOLTS=N .N a flashing 5-volt power supply voltage indicates that the 5-volt power supply is out of specification . +12 VOLTS=N .N a flashing 12-volt power supply voltage indicates that the 12-volt po _ supply is out of specification. +15 VOLTS=N.N a flashing 15-volt power supply voltage indicates that the 15-volt po .",supply is out of specification. The GCM-A will annunciate any problems it finds with the submicron particle detector. The GCM-A will pause on each error and wait for the operator to acknowledge the erroby pressing the FN key. " BAD RELEASE indicates that the solenoid valves could not reduce the vacuum in the cloud chamber below 0.7 psi. BAD VACUUM indicates that the vacuum pump could not provide at least 3.7 psi of vacuum to the cloud chamber. AMB FLO=N.N LPM a flashing airflow indicates that the ambient airflow indicated is 'eso: than 7 LPM or greater than 21 LPM. This error indicates that the airflow needs to be adjusted according to the procedure "Adjusting the Ambient Airflow." GA0519POl REV B 16 GCM-A Software Version - GEN FLO=N.N LPM a flashing airflow indicates that the generator airflow indicated is less than 7 LPM or greater than 21 LPM. This error indicates that the airflow needs to be adjusted according to the procedure "Adjusting the Generator Airflow. " CONTINUE FILLING? Indicates that the humidifier is using an unusually large quantity of water. It may indicate that the water level sensor has failed . Press ENTER to continue filling . Alternating Operation When the GCM-A is in alternating operation mode it will monitor the flow rate and' particulate level but it will not generate any alarms or warnings. The SYSTEM TROUBLE LED and the MANUAL LED will be illuminated whenever the GCM-A is in this mode of operation. The GCM-A will display the ambient particulate level on the bar graph labeled ambient and the generator particulate level on the bar graph labeled generator. The particulate level of the generator and ambient air are also available through two four to twenty rnilliamp (4-20 mAl outputs. The difference between the generator and ambient level is also available on a third four to twenty milliamp output. The particulate level is updated every fifteen seconds. The GCM-A alternates between the two particulate sampling systems so that a new ambient level and a new generator level are available every thirty seconds. Generator Only Operation When the GCM-A is in generator only operating mode it will monitor the flow rate and particulate level of the generator sampling system but it will not generate any alarms or warnings. The ambient particle level will not be monitored. The SYSTEM TROUBLE LED and the MANUAL LED will be illuminated whenever the GCM-A is in this mode of operation. The GCM-A will display the generator particulate level on the bar graph labeled generator. The bar graph labeled ambient will read zero. The particulate level of the generator air is also available through a four to twenty milliamp (4-20 mAl output. The outputs for the ambient particulate level and the difference level will read 4 rnilliamps. The particulate level of the generator air is updated every fifteen seconds. Ambient Only Operation When the GCM-A is in ambient only operating mode it will monitor the flow rate and particulate level of the ambient sampling system but it will not generate any alarms or warnings. The generator particle level will not be monitored. The SYSTEM TROUBLE LED and the MANUAL LED will be illuminated whenever the GCM-A is in this mode of operation. The GCM-A will display the ambient particulate level on the bar graph labeled ambient. The bar graph labeled generator will read zero. The particulate level of the ambient air is GA0519POI REV B 17 GCM-A Software Version 2.2E also available through a four to twenty milliamp (4-20 mAl output. The outputs for the generator particulate level and the difference level will read 4 milliamps. The particulate level of the ambient air is updated every fifteen seconds. Normal Operation When the GCM-A is in normal operation it will monitor the sampling system flow rate anc particulate level of the generator and ambient air. It will indicate warning(s) or alarm(s) . the particulate level is above the warning or alarm levels. The GCM-A will display the ambient particulate level on the bar graph labeled ambient and the generator particulate level on the bar graph labeled generator. The particulate level of the generator and ambient air are also available through two four to twenty milliamp (4-20 mAl outputs. The difference between the generator and ambient level is also available on a third four to twenty milliamp output. The particulate level is updated every fifteen seconds. The GCM-A alternates between the two particulate sampling systems so that a new ambient level and a new generator level are available every thirty seconds. GA0519POI REV B 18 GCM-A Software Version - = Generator Condition Monitor Dis The display located on the front panel not only provides the user with a keypad interface to assist in the setup and operation of the Generator Condition Monitor, but also various LED 's and bar graph displays to relay visually the current state of operatio n the GCM-A. Detailed descriptions of these visual indicators are found below. Display Layout m LOCAL . REM OTE . • e DIFFEREN TIAL 100% ---1 • AC POWER , MAN U AL ALAR" WARNIN G GENERATOR - [. 50% WARNIN G AMBI ENT - [. ALARM WARNII\o G 0% AMBIE' T AL ARM GE'ERA TOR GCM - A moo"" -f SYS TEM CENER A TOR FLOW A ~I, 8IEN T FLOW Control Keys The following keys allow the user to interact with the GCM-A. RESET Clear an alarm Fn Activate the menu or exit a menu item without saving changes. Select a menu item or confirm a choice. ENTER GA05 19PO I REV B 19 GCM-A Software Version 2.2E GCM-A Menu Displays The following sections provide definitions and user information regarding the various menus that are accessible via the GCM-A's LCD display. It is strongly recommended that users familiarize themselves with this section . Additional questions can be forwarded to Environment One Corporation. Navigating the LCD Display Four keys are used to control menu operation: FN, ENTER, UP ARROW and DOWN ARROW. • The FN key activates and exits the menu. • The ENTER key selects an item from the menu. • The UP ARROW and DOWN ARROW keys change the selection displayed. LCD Menu Display - Two Modes of Operation The menu has two modes of operation, scrolling and non-scrolling. • In scrolling mode, the selection shown on the LCD changes automatically every two seconds. • In non-scrolling mode, the UP ARROW and DOWN ARROW keys must be used to change the selection. Scrolling is the default mode. Users can change modes by reviewing the SETUP MENU section in the following pages. Menu Profile Five menus are available: Function, Log, Setup, Test and View. The Function menu is the top-level menu ; all other menus are accessed through this menu. " GA0519POI REV B 2 GCM-A Software Version 2.2E Up Arrow Down Arrow Navigation key or used with so me menu options to increase the value of a constant. Navigation key or used with some menu options to decrease the value of a constant. 1 Bar graph Displays The following analog signals are displayed on the display panel. AMBIENT GENERATOR Bar graph indicating the ambient output level. Range: 0 to I 00%. Bar graph indicating the generator output level. Range: 0 to 100%. Discrete Indicators The following discrete signals are displayed on the display panel. LOCAL Lit when the local display has the focu s REMOTE Lit when the remote display has the focus AC POWER Lit whenever the display panel is powered and functionin!! orooerlv Lit when the GCM-A is in a manual mode of ooeration Lit when a differential alarm occurs. can only be cleared bv nressinQ reset. Lit when the differential output level is above its resnective waminQ level Lit when a generator alarm occurs, can only be cleared bv nressinQ reset. Lit when the generator output level is above its r . ve waminQ level. Lit when an ambient alarm occurs. can only be cleared hv nressinQ reset Lit when the ambient output level is above its resnective waminQ level. Lit when the GCM-A detects an abnormal condition. Lit when the airflow through the generator samnlinQ svstem is out of snecification. Lit when the airflow through the ambient sampli : svstem is out of snecification. MAN UAL DIFFERENTIAL ALARM DIFFERENTIAL WARNING GENERA TOR ALARM GENERATOR WARNING AMBIENT ALARM AMBIENT WARNING SYSTEM T.ROUBLE GENE~~OR FLOW TROUBL AMBIENT FLOW TROUBLE GA0519POI REV B 20 GCM-A Software Versio - I Troubleshooting Guide Table 2 (Customer Contacts) - -- Contact Ref' Status AMBIENT ALARM General Purpose Energized when an ambient alarm occurs, can only be cleared by pressing reset. I GENERATOR ALARM General Purpose Energized when a generator alarm occurs, can only be cleared by pressing reset. ':3 DIFFERENTIAL ALARM General Purpose Energized when a differential alarm occurs, can only be cleared by pressing reset. 5 FLOW TROUBLE General Purpose Energized whenever the airflow through the ambient or generator sampling system is out of specification. 7,8 SYSTEM TROUBLE General Purpose De-energized when the GCM-A detects an abnormal condition. 7,8,9, 10, 11&12 COMMON WARNING General Purpose Energized whenever the ambient, generator or differential output level is above its respective warning level. 2,4& 6 , Applicable line in Table 3 (GCM-A Status) GA0519POI REV B 21 GCM-A Software Version 2.2E Table 3 (GCM-A Status) Condition I Ambient Alarm 2 Ambient Warning 3 Generator Alarm 4 Generator Warning 5 Differential Alarm 6 Differential Warning 7 Generator Flow Trouble 8 Ambient Flow Trouble 9 Power Supply Problem 10 110 Error II Detector Problem 12 Disabled '" GA0519POl REV B Typical Cause The concentration of submicron particles in the ambient gas stream is above the alarm level. The ambient output level is above its warning level. The concentration of submicron particles in the generator gas stream is above the alarm level. The ambient output level is above its warning level. The difference between the generator output level and the ambient output level is above its alarm level. The difference between the generator output level and the ambient output level is above its warning level. The flow rate through the generator sampling system was less than 7 or greater than 21 LPM The flow rate through the Ambient sampling system was less than 7 or greater than 21 LPM One or more power supplies are not within tolerance. The GCM-A is detecting a communication error while trying to talk to the VO board or the display. Vacuum pump or solenoid failure. Operating mode set to disabled in SETUP MENU 22 Indicators Effected Ambient Alarm Relay Ambient Alarm LED Common Warning Relay Ambient Warning LED Generator Alarm Relay Generator Alarm LED Common Warning Relay Generator Warning LED Differential Alarm Relay Differential Alarm LED Common Warning Relay Differential Warning LED Flow Trouble Relay Generator Flow Tbl LED Flow Trouble Relay Ambient Flow Tbl LED System System System System Trouble Trouble Trouble Trouble Relay LED Relay LED System System System System Trouble Trouble Trouble Trouble Relay LED Relay LED GCM-A Software Version Table 4 (Events) EVENT GCM-ARESET VOTSTPBLM ADCCALPBLM DC POWER PBLM DESCRIPTION The GCM-A started operating. Caused by power being applied or the reset on the back of the display being pressed. The GCM-A could not detect that the proper VO board was attached. The 12 bit analog to digital converter failed calibratioll. VACUUM FAULT One or more of the DC power supplies was out of calibration. The GCM-A issued a vacuum fault RELEASE FAULT The GCM-A issued a release fault PHOTOCELL FAULT The GCM-A issued an LED/photocell fault DIF ALARM The GCM-A issued a differential alarm. GEN ALARM The GCM-A issued a generator alarm. AMBALARM The GCM-A issued an ambient alarm. ALARM RESET The alarm reset key was pressed. NORMAL OPERATION ALTERNATING Started operation in normal mode. Started operating in alternating mode. GENERA TOR ONLY Started operating in generator monitoring only mode. AMBIENT ONLY Started operating in ambient monitoring only mode. AMBLOWFLOW The ambient flow was below 7 LPM. AMB HIGH FLOW The ambient flow was above 21 LPM. GEN LOW FLOW The generator flow was below 7 LPM. GEN HIGH FLOW The generator flow was above 21 LPM. FLOW OK The high or low flow fault cleared GA0519POI REV B 23 GCM-A Software Version 2.2E - Revision History REV DESCRIPTION Initial Date - RELEASED PER ECN 09-11641 R. Williams Feb 26, 2009 A B REVISED PER ECN 09-11937 REVISED PER ECN 12-18373 R. Williams R. Williams April 20, 2009 May 21, 2012 Checked By Eng Appv'l Edward Li Issued By Brendyn Rojas ..- -- --- -____- l Vdt- ::"",-~ =-..;.':"~..:.:;- _ _ ..._u _"""--.... ...l:1000''''', --.............., .. _ ... IMM ... ~'!'OU<)(.H,..'.(41XT Design Notes Software version 2.2E is a form fit and function replacement for software version 2.20. It is upwardly compatible and provides the following enhancements: • Added water dwell to adjust the water fill rate. Software version 2.20 is a form fit and function replacement for software version 2.2C. It is upwardly compatible and provides the following enhancements: • Added water level and water peak to adjust the water level in the humidifier. Software version 2.2C is a form fit and function replacement for software version 2.2B. i is upwardly compatible and provides the following enhancements: • Added support for MOOBUS communication. Software version 2.2B is a form fit and function replacement for software version 2.2A is upwardly compatible and provides the following enhancements: • Wider software flow control adjustment range. Software version 2.2A is derived from software version 1.7F. It is the initial release software for the redesigned GCM-A. 0 " I I I , , GA0519PO I REV B 24 GCM-A Software Ve --- ! -41 Ienu Navigation Tutorial Activating the Menu 1. Press FN to start the menu. The LCD should display the prompt <FUNCTION MENU>. 2. Press FN again to turn it off. Navigating the Menu in Scrolling Mode (Default) , 1. Press FN to start the menu. The LCD should display the prompt <FUNCTION MENU>. After two seconds the prompt should change to GO TO LOG MENU . 2. Wait until the prompt GO TO LOG MENU appears and press the ENTER key. 3. The LCD should display the prompt <LOG MENU>. 4. Wait until the prompt SHOW PROGRAM 10 appears and press the ENTER key. The display should show GCM-A VER 2.2E-7. 5. Press the FN key. The prompt will be restored to SHOW PROGRAM 10. 6. Press FN again. The prompt will be restored to GO TO LOG MENU. 7. Press FN a third time. The LCD will display "GCM-A by E/One" as the menu is deactivated. Disabling Scrolling Mode 1. Press FN to start the menu. 2. Wait until the prompt GO TO SETUP MENU appears and press ENTER. 3. Wait until the prompt SET SCROLL OFF appears and press ENTER. 4. The prompt will flash SET SCROLL OFF. 5. Press FN to return to the beginning of the menu. Navigating the Menu in Non-Scrolling Mode 1. The LCD should display the prompt <FUNCTION MENU>. Press the DOWN ARROW key until the prompt GO TO LOG MENU appears and press the ENTER key. 2. The LCD should display the prompt <LOG MENU>. Press the DOWN ARROW key until the prompt SHOW PROGRAM 10 appears and press the ENTER key. The display should show GCM-A VER 2.2E-7. 3. Press the FN key. The prompt will be restored to SHOW PROGRAM 10. 4. Press FN again. The prompt will be restored to GO TO LOG MENU . 5. Press FN a third time. The LCD will display "GCM-A by E/One." GA0519POI REV B 3 GCM-A Software Version 2.2E Function (FN) Menu • GO TO LOG MENU Select this item to enter the LOG MENU. The log menu contains selections to view and clear the fault and power logs. The log menu also includes a selection to view the software version number. • GO TO SETUP MENU Select this item to enter the Setup Menu . The Setup Menu includes selections for calibration and configuration. Items that can be configured include the warning and alarm levels, the operating mode and the menu scroll rate. The setup menu also includes a selection to calibrate the ambient and generator sample flow sensors. • GO TO TEST MENU Select this item to enter the Test Menu. The Test Menu contains selections to test the power supplies , keypad , relays , solenoids , and the 4 to 20 mA outputs. • GO TO VIEW MENU Select this item to enter the View Menu. The View Menu conta selections to view the water usage, LED current, particle levels, vacuum, sample flo internal registers and ADC registers. ~ Log Menu • SHOW FAULTS LOG Select this item to view the faults log. See About the Fault Log for more information. • CLEAR FAULTS LOG Select this item to clear the faults log. When selected, the CLEAR FAULTS LOG prompt will flash for two seconds before clearing the faults 10£ If the FN key is pressed while it is still flashing , clearing of the log will be canceled . =: About the Fault Log for more information. • SHOW POWER LOG Select this item to view the power log. See About the Power L ; for more information. • CLEAR POWER LOG Select this item to clear the power log. When selected, the CLEAR POWER LOG prompt will flash for two seconds before clearing the power _ If the FN key is pressed while it is still flashing, clearing of the log will be canceled . ~ =: About the Power Log for more information. • SHOW EVENT LOG Select this item to view the events log. See About the Event La-; for more information. • SHOW PROGRAM 10 Select this item to display the program identification and re . level in the format GCM-A Rev. X.X. This manual was written for software version 2.25 Press the UP arrow key to access additional version information. The next prompt gives the 1/0 board version in the format 110 VERSION XXX. The last prom gives the controller board part number in the format PROC=XXXXXXGXX. This manual was written for controller board PI N GA0516G01 . Press the FN key to retu ~ the LOG MENU. Setup Menu • AMB GAIN Select this item to change the ambient gain. See Setting the Ambient GE: for more information. GA0519POl REV B 4 GCM-A Software Version _ • GEN GAIN Select this item to change the generator gain. See Setting the Generator Gain for more information. • AMB FLOW ADJ Select this item to change the ambient flow limits. See Adjusting the Ambient Airflow for more information. • GEN FLOW ADJ Select this item to change the generator flow limits. See Adjusting the Generator Airflow for more information. • AMB WARN Select this item to change the ambient warning level. See Setting the Ambient Warning Level for more information. , • GEN WARN Select this item to change the generator warning level. See Setting the Generator Warning Level for more information. • DIF WARN Select this item to change the difference warn ing level. See Setting the Difference Warning Level for more information. • AMB ALARM Select this item to change the ambient alarm level. See Setting the Ambient Alarm Level for more information. • GEN ALARM Select this item to change the generator alarm level. See Setting the Generator Alarm Level for more information. • DIF ALARM Select this item to change the difference alarm level. See Setting the Difference Alarm Level for more information. • SET WATER LEVEL Select this item to adjust the water level in the humidifier. A larger number will increase the depth of water in the humidifier. This setting works together with the water peak setting to control the water level in the humidifier. The factory default value is 2500. A lower value may be required if the GCM-A is located in an area with a high ambient temperature. • SET WATER PEAK Select this item to adjust the water level in the humidifier. A larger number will decrease the depth of water in the humidifier. This setting works together with the water level setting to control the water level in the humidifier. The factory default value is 100. • SET WATER DWELL Select this item to increase the water flow rate into the humidifier during a fill cycle. A larger number will lengthen the water flow cycle . The factory default value is 0.1 sec. • ADVANCED Select this item to setup the GCM-A for remote access. See Remote Access for more information. • MONITORING MODE This item is to be used for troubleshooting. When selected , the GCM-A will display its operation mode. The GCM-A can operate in one of four modes: Normal Operation, Alternating Operation, Ambient Only and Generator Only. Use the arrow keys to scroll through the choices and press the ENTER key to select one. See Normal Operation, Alternating Operation, Ambient Only Operation or Generator Only Operation for more information. • SET SCROLL OFF This item is displayed when the scrolling is turned on. Select this item to turn off scrolling. When scrolling is inactive, the displayed menu items will not change until a menu key (UP ARROW, DOWN ARROW, FN or ENTER) is pressed . GA0519PO I REV B 5 GCM-A Software Version 2.2E • SET SCROLL ON This item is displayed when the scrolling is turned off. Select this item to turn on scrolling. When scrolling is active, the displayed menu items will change once every two seconds. Test Menu • CONTACT TEST Select this item to start an interactive test of the relay contacts. The GCM-A will place all relays and solenoids except one in a de-energized condition . The LCD will display the name of the single relay or solenoid that is still energized. Use the arrow keys to change which relay is energized. Press the FN or ENTER keys to terminate the test. • KEYPAD TEST Select this item to start an interactive test of the keypad . The LCD will display the prompt PRESS ANY KEY at the start of the test. Test the keypad by pressing , one at a time , all of the keys on the keypad , reserving the FN key for last. The LCD will echo the name of each key as it is pressed . The test will terminate when the FN key is pressed. • OUTPUT TEST Select this item to start an interactive test of the 4 to 20 mA outputs. The GCM-A will set the 4 to 20 mA outputs to 4 mA and display CURRENT=4 mA on the LCD display at the start of the test. Use the arrow keys to increase or decrease the current in 1 mA steps. Press FN to terminate the test. • POWER TEST Select this item to test the power supplies. When Power Test is selected, the GCM-A will display the voltage for each power supply in the format <nominal value>=<present value>. An example of the 12-volt power supply is +12 VOLTS=12 .1. The GCM-A will scroll through all four power supply voltages. The voltages are displayed for two seconds each. • SYSTEM TEST Select this item to test the submicron particle detection subsystem . The submicron particle detection subsystem consists of the inlet manifold , the ambien and generator airflow meters, the cloud chamber detector, the vacuum pump and the water level sensors. The GCM-A will annunciate any problems it detects. View Menu • VIEW WATER USAGE Select this item to display the GCM-A's water meter. The watemeter indicates the number of times the GCM-A has added water to the humidifier. The water meter is cleared by restarting the GCM-A. • VIEW LED Select this item to display the current through the cloud chamber LED in milliamperes. • VIEW LEVEL Select this item to display the output of the cloud chamber and the zone being sampled at a once/second update rate. • VIEW VACUUM Select this item to display the vacuum level. Two numbers are displayed : the peak vacuum present during the expansion process and the minimum vacuum present during the fill/flush process. • VIEW FLOW Select this item to display the ambient or generator airflow in liters per minute. Press the up or down arrow keys to toggle between the ambient airflow and the generator airflow. GA0519POI REV B 6 GCM-A Software Version 2. = • VIEW 12BIT ADC Select this item to display the voltage at each of the four inputs to the 12-bit AID converter. Use the UP ARROW or DOWN ARROW to scroll through all four channels. Press the FN key to return to the View Menu . • VIEW REGISTER Select this item to display the values in the internal registers. Use the UP ARROW to view the next register or the DOWN ARROW to view the previous one. Press the FN key to return to the View Menu . , GA0519POl REV B 7 GCM-A Software Version 2.2E Procedures Adjusting the Ambient Airflow Allow the flow meters to stabilize by letting the GCM-A warm up for at least 15 minutes prior to making this adjustment. IMPORTANTllt is important to note that the GCM-A system addresses flow monitoring in two ways : the first is by using an external instrument (DP Gauge) to validate flow through the zone manifold; the second method is by way of internal air flow sensors located within the inlet manifold of the GCM-A. For the purposes of system design parameters and validation , the DP Gauge is designated as the authoritative source of information regarding flow across the zone manifold . The GCM-A's internal flow sensor is calibrated with the DP Gauge. Locate the zone manifold that supplies ambient air to the GCM-A. Connect a differentia pressure gauge to the taps on the zone manifold. Loosen or tighten the Allen head flow adjustment screw until the differential Pressure gauge reads 6 millimeters of water (tum the screw clockwise to decrease the flow and reduce the differential pressure). Calibrate the GCM-A's internal air flow sensor with the differential pressure at 6 millimeters of water. The AMB FLOW ADJ selection on the SETUP menu is used to calibrate it. Select SETUP from the main menu then AMB FLOW ADJ from the SETUP menu. The GCM-A will display the ambient airflow in liters per minute. Press the ENTER key to recalibrate the sensor. The GCM-A will respond by flashing SETTING LIMITS for two seconds while it recalibrates the sensor to read 14 LPM. (The sensor may need a second recalibration if the initial value was close to zero or above 25 LPM.) Disconnect the differential pressure gauge and replace the sealing caps on the zone manifold taps. Adjusting the Generator Airflow Allow the flow meters to stabilize by letting the GCM-A warm up for at least 15 minutes prior to making this adjustment. IMPORTANT! It is important to note that the GCM-A system addresses flow monitorif1£ in two ways: the first is by using an external instrument (DP Gauge) to validate flow through the zone manifold; the second method is by way of internal air flow sensors located within the inlet manifold of the GCM-A. For the purposes of system design param~ers and validation , the DP Gauge is designated as the authoritative source of information regarding flow across the zone manifold. The GCM-A's internal flow sens is calibrated with the DP Gauge. Locate the zone manifold that supplies generator air to the GCM-A. Connect a differential pressure gauge to the taps on the zone manifold. Loosen or tighten the AI ehead flow adjustment screw until the differential Pressure gauge reads 6 millimeters 0' water (turn the screw clockwise to decrease the flow and reduce the differential pressure). GA0519POI REV B 8 GCM-A Software Version -.:: Calibrate the GCM-A's internal air flow sensor with the differential pressure at 6 millimeters of water. The GEN FLOW ADJ selection on the SETUP menu is used to calibrate it. Select SETUP from the main menu then GEN FLOW ADJ from the SETUP menu. The GCM-A will display the generator airflow in liters per minute. Press the ENTER key to recalibrate the sensor. The GCM-A will respond by flashing SETIING LIMITS for two seconds while it recalibrates the sensor to read 14 LPM. (The sensor may need a second recalibration if the initial value was close to zero or above 25 LPM.) Disconnect the differential pressure gauge and replace the sealing caps on manifold taps . th~ zone Setting the Ambient Gain The ambient gain determines the sensitivity of the submicron particle detector. The higher the ambient gain setting , the more sensitive the detector. The factory default value for the ambient gain is 1.0. The ambient gain can be changed by selecting AMB GAIN from the SETUP MENU . When AMB GAIN is selected , the ambient gain will be displayed on the LCD display. Press the UP ARROW key to increase it. Press the DOWN ARROW key to decrease it. It cannot be decreased below 1.0 or increased beyond 9.9. Press the ENTER key to save your changes and return to the SETUP MENU. Press the FN key to discard the changes and return to the SETUP MENU . Setting the Ambient Warning Level The ambient warning level determines what electrical output from the cloud chamber detector will trigger a WARNING indication . The ambient warn ing level is expressed as a percentage of full scale. A WARN ING indication is given when the output of the cloud chamber detector exceeds the value of ambient warning level. The factory default value for the ambient warning level is 50 percent. The ambient warning level can be changed by selecting AMB WARN from the SETUP MENU . When AMB WARN is selected , the ambient warning level will be displayed on the LCD display. Press the UP ARROW key to increase it. Press the DOWN ARROW key to decrease it. It cannot be decreased below thirty or increased beyond the ambient alarm level. Press the ENTER key to save your changes and return to the SETUP MENU. Press the FN key to discard the changes and return to the SETUP MENU . Setting the Ambient Alarm Level The ambient alarm level determines what electrical output from the cloud chamber detector will trigger an ALARM indication. The ambient alarm level is expressed as a percentage of full scale. An ALARM indication is given when the output of the cloud chamber detector exceeds the value of ambient alarm level. The factory default value for the ambient alarm level is 80 percent. The ambient alarm level can be changed by selecting AMB ALARM from the SETUP MENU. When AMB ALARM is selected, the ambient alarm level will be displayed on the LCD display. Press the UP ARROW key to increase it. Press the DOWN ARROW key to decrease it. It cannot be decreased below the ambient warning level or increased GA051 9PO I REV B 9 GCM-A Software Version 2.2E
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