10000004417ea Maintenance of Courier 6 CCA Cooling System Ara 120417

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Courier 6 10000004417e A , Edit Revision
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2502)
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TW 5.4.2002
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Maintenance of Courier 6 CCA cooling system KEA 20.4.2002

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Product Code
Courier 6 10000004417e (prev. code 710 2502)
Title Author
TW
Maintenance of Courier 6 CCA cooling system

Language validated by Revision validated Date
Checked by Revision checked Date

K.Anttila 0.1p02 20.4.2002
Approved by Revision to be published Date

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THIS IS THE LAST MANAGEMENT LINE. DO NOT REMOVE IT! Pages total 29, management pages 3.
Code 10000004417e (prev. code 710 2502) Revision A Page 1 (25)
Product Code Revision

Courier 6 10000004417e A
(prev. code 710
2502)
Title Author Date
TW 5.4.2002
Checked by Date
KEA 20.4.2002
Approved by Date
JKK 21.4.2002
Contents
1. About this document .............................................................................................................................. 3
2. Safety precautions .................................................................................................................................. 4
3. Overview.................................................................................................................................................. 5
3.1 Modules ........................................................................................................................................ 5
Chiller ....................................................................................................................................... 6
Pump container ......................................................................................................................... 6
Temperature Control Module ..................................................................................................... 7
Air module................................................................................................................................. 7
CBS .......................................................................................................................................... 8
RAS .......................................................................................................................................... 8
XTA .......................................................................................................................................... 8
3.2 Cooling circulation ......................................................................................................................... 9
Cooling circulation in LCS ......................................................................................................... 9
Cooling circulation in RCS ....................................................................................................... 10
Cooling circulation in TCS ....................................................................................................... 11
4. Maintenance .......................................................................................................................................... 13
4.1 Tools ........................................................................................................................................... 13
4.2 Basic maintenance ...................................................................................................................... 13
Check list for LCS ................................................................................................................... 13
Check list for RCS ................................................................................................................... 13
Check list for TCS ................................................................................................................... 14
4.3 Additional maintenance ............................................................................................................... 14
4.4 Task descriptions ........................................................................................................................ 15
Checking water pressure ......................................................................................................... 15
Checking air pressure ............................................................................................................. 15
Checking water circulation....................................................................................................... 15
Checking chiller fault codes ..................................................................................................... 16
Checking connecting hoses and cables ................................................................................... 16
Switching CCA power off/on .................................................................................................... 16
Cleaning CCA inside ............................................................................................................... 16
Cleaning chiller condenser ...................................................................................................... 17
Changing water ....................................................................................................................... 17
Cleaning mud filter .................................................................................................................. 18
Changing air filters .................................................................................................................. 18
5. Troubleshooting.................................................................................................................................... 19
5.1 Chiller alarms .............................................................................................................................. 19
5.2 System alarms ............................................................................................................................ 19
Appendix 1: Recommended set values ................................................................................................... 21
Appendix 2: Cooling water requirements ................................................................................................ 25
READER COMMENTS
1. About this document

This document describes the Courier 6 cooling system and provides instructions
for maintaining the Cooling Cabinet Assembly (CCA). It is aimed for Outotec
support personnel, especially the technicians that perform maintenance tasks
on the Courier 6 analyzers on-site. The document also contains all the warnings
and safety precautions necessary when performing these tasks.
Note, Tip, and Warning signs used in this document:
This sign stands for information especially worth noticing.
This sign stands for information including extra advice.
a This sign stands for information of extreme importance.

2. Safety precautions
a Before any maintenance work on the chiller, always switch the CCA power
off inside the Probe Control Set (PCS) cabinet. Make sure that the water
circulation stops.
a Before any maintenance work on the air dryer, always make sure that the
air pressure is set to zero.
For filling the pump container water tank, use only bottled drinking water
(pH 7 - 8). For further requirements, refer to Appendix 2.
3. Overview
The Courier 6 cooling system has two functions: to cool the X-ray tube and to
stabilize the enviromental temperature of the measurement components.
There are three CCA variations available:

Local Cooling Set (LCS)the chiller is installed inside the CCA
Remote Cooling Set (RCS)the chiller is installed outside the CCA
Tap Water Cooling Set (TCS)no chiller is involved; cooling is arranged by
using the local water distribution system
3.1 Modules
3 5
4
1
2
1
Figure 1. Cooling system components in CCA (LCS).

1 = chiller, 2 = pump container, 3 = TCM,
4 = air module, 5 = CBS
The Courier 6 cooling system consists of the following modules:

chiller
in LCS, located in CCA
in RCS, located in a separate container
not in TCS
pump container, located in CCA
Temperature Control Module (TCM), located in CCA
air module, located in CCA
Connection Box Set (CBS), located in CCA
Radiator Set (RAS), located in the Probe Set (PRS)
X-ray Tube Assembly (XTA), located in PRS
Chiller
The chiller module consists of a Rittal water chiller and an adapter plate. The
chiller is an on/off type unit. In other words, the compressor and condenser fans
stop when the temperature of the circulating water reaches the set minimum,
and start when it reaches the set maximum. The temperature difference
between these has to be at least 5 C.
In the TCS variant, the chiller is substituted with a circulating pump, heat
exhanger and mud filter.
Pump container
Figure 2. Pump container (frame walls removed).

1 = filling cap, 2 = filter insert, 3 = submersible pump
The container module consists of a container frame and lid, and a submersible
pump. The container is a two-piece design. The water compartments are,
however, connected via small-area holes. Two compartments are necessary
because the system requires two separately controllable water temperatures.
There is a filter insert in the container lid to prevent any dirt from getting in the
system when pouring new water to the container.
The submersible pump is a centrifugal pump the motor of which has been cast
in epoxy.
Temperature Control Module
1 3
4
Figure 3. Temperature Control Module.

1 = XTA temperature control, 2 = RAS temperature controller,
3 = XTA pressure gauge, 4 = RAS pressure gauge
TCM is a module that contains all XTA cycle and RAS cycle temperature control
elements. Also the flow controls are located there.
Air module
Instrument air is lead through an air module to provide the Automatic Window
Changer (AWC) with pure, dry air. The air module consist of the Air Filter Set
(AFS) and the Air Dryer Set (ADS).
1 2
Figure 4. AFS.
1 = sound absorber, 2 = filter, 3 = pressure gauge
1 2
4
Figure 5. ADS.
1 = micro filter, 2 = sub micro filter, 3 = air dryer, 4 = air regulator set
(ARS)
CBS
Figure 6. Cooling system fuse in CBS
The CBS module contains all CCA connection strips for connection to PCS. In
LCS and RCS, a fuse that controls the chiller and other cooling system power is
located in CBS.
RAS
The RAS module consists of a heat exhanger cell and fans. The role of this
module is to circulate and stabilize the air around the measurement
components. It also acts as a water condenser, since the warm air meets the
coldest surfaces there.
XTA
The XTA module contains an X-ray source, high voltage connection, radiation
shields.
3.2 Cooling circulation

The following sections present the cooling circulation in all CCA variants.
Cooling circulation in LCS
8
4
9 5 1
2
7
Figure 7. LCS cooling circulation.

1 = non-return valve, 2 = RAS pressure gauge,
3 = RAS temperature controller valve
4 = RAS radiator + fans, 5 = XTA temperature controller valve,
6 = water container + submersible pump + filter insert,
7 = XTA pressure gauge, 8 = XTA cooling duct, 9 = flow switch
Heat exhange in chiller
The fans in the chiller condenser take air from the analyzer environment. This
air cools down the condenser lamina heated by the condesing coolant.
Next, the condensed and pressurized (by a compressor) coolant vaporizes in

the evaporizer. For that, it takes heat from the water circulating around the
evaporizer. The water cools down and flows into the RAS circuit.
Heat exhange in RAS
In the RAS module, the fans recycle air through the RAS radiator inside of
which the cooled water circulates. A TC valve controls the water flow into the
radiator so that the recycled air temperature is the set value 0.5 C.
Heat exhange in XTA and pump container
In the XTA circuit, the submersible pump recycles water that transfers heat from
the X-ray source to the lower water compartment of the pump container. When
the water temperature in the XTA circuit reaches the set maximum, a TC valve
opens letting in colder water from the RAS circuit. The small-area holes
between the two container compartments allow the warm water to flow into the
upper compartment and to the chiller.
Cooling circulation in RCS
Heat exhange takes place in the RCS solution excactly the same way as in the
LCS solution.
8 4
3
9 5
1
2
7
1
11
6 10
12
Figure 8. RCS cooling circulation.

3 = RAS temperature controller valve,
4 = RAS radiator + fans, 5 = XTA temperature controller valve,
7 = XTA pressure gauge, 8 = XTA cooling duct, 9 = flow switch,
10 = circulating pump, 11 = relief valve, 12 = pump pressure gauge
Cooling circulation in TCS
In the TCS solution, the chiller is replaced with a tapwater cooled heat
exhanger. For other parts, the heat exhange process is similar to the LCS and
RCS solutions.
8
4
9 1
5
2
7
11 12 13 14
1
10
15
Figure 9. TCS cooling circulation.

3 = RAS temperature controller valve, 4 = RAS radiator + fans,
5 = XTA temperature controller valve,
7 = XTA pressure gauge, 8 = XTA cooling duct, 9 = flow switch,
10 = circulating pump, 11 = magnet valve, 12 = pressure switch,
13 = mud filter, 14 = manual valve, 15 = tap water flow valve
Heat exhange in tap water cooled heat exhanger
Tap water taken from the local water distribution system flows through a mud
filter to a plate heat exhanger. The closed circuit water coming from the pump
container cools down there before flowing into the RAS cooling circuit (see
Figure 9 above). The heated tap water is lead to sewer.
4. Maintenance
4.1 Tools
In addition to the basic tools, you need an air blow gun (6/4 mm) or a vacuum
cleaner.
4.2 Basic maintenance

All CCA types require basic maintenance every six months. The tasks vary
slightly depending on the CCA variant installed.
Follow the order presented in the checklists below. For more detailed task
descriptions, see the section 4.4.
Check list for LCS
Every six months:

1. Check the water pressures
2. Check the water circulation
3. Check the air pressures
4. Check the chiller fault codes
5. Switch the CCA power off
6. Change the water
7. Clean the filter insert in the pump container
8. Clean the inside of the CCA
9. Clean the chiller condenser
10. Check the air module tubings
11. Switch the CCA power on
12. Verify the water pressures
13. Verify the air pressures
Check list for RCS
Every six months:

4. Check the chiller fault codes
5. Check the hoses and cables between the chiller and CCA
8. Change the water
11. Clean the chiller condenser
Check list for TCS
Every six months:

5. Change the water
9. Clean the mud filter
4.3 Additional maintenance

In addition to the basic maintenance, perform the following tasks if the device
contains the optional AWC and air dryer.
Every 12 months:
change the AFS air filter
change the ADS micro and sub micro filters
Every four years:

change the air dryer
4.4 Task descriptions
Checking water pressure
1 2
Figure 10. Water pressure gauges. 1 = XTA gauge, 2 = RAS gauge
Read the pressure gauges before doing any other maintenance work. Write
the readings down.
Read the gauges also after completing all other maintenance work. They
should show the same readings as before.
For 50 Hz supply current, a typical water pressure in the XTA circuit is 0.4
bar and in the RAS circuit 0.7 bar. For 60 Hz supply current, the values are
slightly higher, about 0.5 bar and 0.9 bar, respectively.
Checking air pressure

The general instrument air pressure should be 6 bar.
The AWC air pressure (#3 in Figure 4 on page 7) should be 4 bar.
If the AWC pressure is not in the set value:
check the sound absorber and clean it if necessary
change the AFS filter
Checking water circulation

Visually inspect all cooling water hoses and connections. Make sure there
are no leakages or buckling in the hoses.
Check the operation of the flow switch:
Squeeze a hose to stop the circulation. Release the hose.
On the PCS display, the event message screen should now show the
event X-tube cwf/sensor. For more information on using the PCS
display, refer to the Operating manual.
Checking chiller fault codes

With the CCA power on, look at the chiller display. The display should show
only the temperature. If the number changes, the numbers 1-8 indicate a
failure.
For code explanations and instructions on correcting the faults, refer to
Installation and Operating Instructions for Recooling Systems SK 3318.500
- SK 3319.500 by Rittal (SK 3318.500-3319.500.pdf).
Checking connecting hoses and cables
In the RCS, check the hoses and cables between the chiller and CCA. Make
sure there are no leakages or buckling in the hoses.
Switching CCA power off/on
To switch the CCA power off:

1. Make sure the analyzer is in maintenance mode. For instructions, refer to
the Courier 6SL Maintenance of measurement cell document.
2. Inside the PCS cabinet, switch the CCA power (F5) off. Make sure the
water circulation stops.
To switch the power on, set F5 on.
Cleaning CCA inside

Use a vacuum cleaner, or
Use pressurized air. Connect your air blow gun into the air outlet available
in CCA (shown in Figure 11 below).
If you use pressurized air, always blow outwards.
Figure 11. Air outlet in CCA

To clean the inside of the CCA:

1. Pull the chiller out from the cabinet.
2. Vacuum or blow the inside of the cabinet clean.
3. When pushing the chiller back into the cabinet, make sure there is no
buckling or folding in the hoses.
If there is a lot of dust inside the cabinet, consider installing filters in the
air intakes.
Cleaning chiller condenser

Use a vacuum cleaner, or
Use pressurized air. Connect your air blow gun to the air outlet available in
CCA (shown in Figure 11 above).
If you use pressurized air, always blow outwards.
To clean the chiller condenser:

1. Remove the air inlet grille. You have to detach the chiller display connector.
2. Vacuum or blow the lamina of the condenser clean.
For instructions on more intensive cleaning, refer to Installation and Operating

Instructions for Recooling Systems SK 3318.500 - SK 3319.500 by Rittal (SK
3318.500-3319.500.pdf).
a Do not wash the chiller condenser lamina with water.
Changing water
To change the water:

1. Open a manual valve in the bottom of the pump container and let the
closed circuit water drain out.
2. Open the filling cap and lift the filter insert out. Flush the sieve.
3. Put the filter insert back and pour bottled drinking water in the container
until the surface is visible and level with the mark in the filter insert stick.
The water amount needed is approximately 16 l. For information on water
requirements, see Appendix 2.
If the sieve is slimy, consider adding biocide in the water. Refer to local
water treatment instructions.
Cleaning mud filter
In TCS, to clean the mud filter:

1. Close the manual valve (in the tap water line before the mud filter). See
Figure 9 on page 12. Make sure the magnet valve is closed.
2. To drain the filter, open the filter emptying valve.
3. Open the filter shield and lift the insert out for flushing.
4. Reinstall the insert and the shield.
5. Close the emptying valve and open the manual valve. Make sure the
magnet valve is open.
Changing air filters
To change a filter:
1. Pressing the latch, pull the filter cover down.
2. Unscrew the filter holder. The used filter falls off.
3. Put the new filter in its place, secure with the holder and push the cover
back in its place.
a Protect the new filters against dust, dirt and grease.

5. Troubleshooting
5.1 Chiller alarms

For information on the chiller fault numbers, refer to the Installation and
Operating Instructions for Recooling Systems SK 3318.500 - SK 3319.500 by
Rittal (SK 3318.500-3319.500.pdf).
5.2 System alarms

Below are listed all cooling system related events and alarms that are shown on
the PCS display.
X-tube temp / sensor high (2/1/24)
This event indicates that the X-ray tube temperature is too high at the moment.
X-tube temperature high (2/1/3)
This alarm indicates that the X-ray tube temperature is or has been too high.
When this alarm is on, the high voltage cannot be switched on. To reset this
alarm, use the Safety and Interlock Unit (SIU) reset switch located inside the
PRS.
X-tube cwf / sensor (2/1/55)
This event indicates that there is no cooling water flow the XTA circuit at the
moment.
X-tube c water flow (2/1/62)
This alarm indicates that there is or has been no cooling water flow in the XTA
circuit. When this alarm is on, the high voltage cannot be switched on. To reset
this alarm, use the SIU reset switch located inside the PRS.
Chiller ready / sensor (2/1/57)
This event indicates that the chiller is not ready at the moment.
Chiller ready (2/1/61)
This alarm indicates that the chiller is or has been not ready. When this alarm is
on, the high voltage cannot be switched on. Reset this alarm on the PCS
display. For instructions, refer to the Operating manual.
Ext cwp / sensor (2/1/63)
This event indicates that the cooling water pressure is not at the set level at the
moment.
Ext c water pressure (2/1/64)
This alarm indicates that the cooling water pressure has not been on set level
continuously for a set time. When this alarm is on, the high voltage cannot be
switched on. Reset this alarm on the PCS display. For instructions, refer to the
Operating manual.
Probe interior temp warning (2/1/50)
This alarm indicates that the temperature inside the PRS exceeds the set
warning limit. This alarm will reset, when the temperature drops below the
warming limit or when it exceeds the alarm limit.
Probe interior temp alarm (2/1/49)
This alarm indicates that the temperature inside the PRS exceeds the set alarm
limit. When this alarm is on, the high voltage cannot be switched on. To reset
this alarm, use the SIU reset switch located inside the PRS.
Appendix 1: Recommended set values

Set values for Rittal chiller SK 3318.500
For instructions on how to change the values, refer to Installation and Operating
Instructions for Recooling Systems SK 3318.500 - SK 3319.500 by Rittal (SK
3318.500-3319.500.pdf).
Table 1. Settings for Rittal chiller
Setting Value
Medium temperature 20
Filter mat monitor 99 (off)
Temperature unit 0 ( C)
Adjustable min. 15
Adjustable max. 25
Tolerance for fault code '1' 5
Mode of the PLC interface 0 (normal)
Set values for Rittal chiller SK 3318.509

Table 2 Settings for Rittal Chiller type SK 3318.509
No. Setting Value

1 Target temperature for fixed set point control 15.0
2 Switching hysteresis; Fixed set point control 5.0
3 Difference to room temperature 5.0
4 Min. target value 10.0
5 Max. target value 28.0
6 Switching hysteresis; Combined control 2.0
7 Tolerance for error message F.01 15.0
8 Heating control (Medium) OFF
Set values for Rittal chiller SK 3318.xxx

Table 3 Settings for Rittal Chiller type SK 3318.609
No. Setting Value

1 Set temperature with fixed set point control 17.5
2 Switching hysteresis, fixed set point control 5.0
3 Difference from room temperature 5.0
4 Minimum set point 10.0
5 Maximum set point 28.0
6 Switching hysteresis, combined control 2.0
7 Tolerance for error message F.01 15,0
8 Heating control (Medium) OFF
All other parameters are in factory default values. Do not change.
Set values for Brkert temperature controller Type MA8652-2
For instructions on how to change the values, refer to Operating Instructions for
Compact Temperature Controller Type 8652-2 by Brkert (8625-2.pdf).
Table 4. Settings for Brkert TC MA8652-2
Setting Value
Temperature unit C
Internal set point 20 30
Amplification factor KP 7
Reset time TN 70
Inverted control YES
Zero-point switch off YES
Valve opening % Custom
Set values for Burgert temperature controller Type MA8611
For instructions on how to change the values, refer to Operating Instructions for
Process controller and ration controller eController Type 8611
(MA8611_00805625_Standard_EN.pdf). Settings are done on two levels
manual operating state (table 5) and configuration level (table 6).
Table 5. Setting for Burgert Type MA8611, manual operating state
Setting Value 1 Value 2

SET 25 (20-30)
Any other parameters are left onto factory default values

Table 6. Settings for Burgert Type MA8611, configuration level
Setting Value 1 Value 2

MODE CODE 0001 (Factory default)
T factory default
SCV 0450
2835
PT factory default
UNIT factory default
DPT 0,1 (factory default)
SETP INT factory default
AOUT (Pass, no use)
CALI (Pass, no use)
FILT 08 factory default
PARA KP1 20.00
TN 70.0
DEAD 0.5 (factory default)
INV YES
STRT 000 (factory default)
BACK
B_IN (Pass, no use)
B_01 (Pass, no use)
B_02 (Pass, no use)
VALV Factory set (d not change)
CODE Factory set (do not change)
DISPL LOFF No (factory default)
PVAL (factory default)
FACT (Pass, do not execute)
U_01 (Pass, factory set)
B_01 (Pass, factory set)
END Switch to Process Operating
level, Automatic Operating
State)
Set values for Danfoss temperature controller and XTA cooling water switch
The XTA circuit water temperature should be set to 30 degrees as the

temperature switch of the XTA circulation water temperature is set to 35
degrees with differential gap of 3 degrees.
Appendix 2: Cooling water requirements

a Do not use distilled water.
Use bottled drinking water. It is not recommended to use untreated tap

water.
Table 7. Cooling water requirements

value
pH 7 8,5
Carbonate hardness 3 - 8 dH
3
Free carbon dioxide 8 - 15 mg/dm
3
Combined carbon dioxide 8 - 15 mg/dm
3
Aggressive carbon dioxide 0 mg/dm
2-
Sulphide (S ) Zero
3
Oxygen (O 2) <10 mg/dm
- 3
Chloride ions (Cl ) <50 mg/dm
3
Sulphate ions (SO4 )
2- <250 mg/dm
3
-
Nitrates + nitrites (NO 3 + NO2 )
- <10 mg/dm
3
Chemical Oxygen Demand (COD) <7 mg/dm
3
Ammonia (NH 3) <5 mg/dm
3
Iron (Fe) <0.2 mg/dm
3
Manganese (Mn) <0.2 mg/dm
Conductivity 200 - 2200 S /cm
3
Evaporation residue <500 mg/dm
3
Potassium permanganate (KMnO4) <20 mg/dm
consumption
3
Suspended matter <3 mg/dm
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 COURIER 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.
Your assistance is greatly appreciated.

Thank you for choosing the COURIER analyzer system.
Outotec, Analyzers
Fax to: FAX: INT + 358 205 292998
or mail to: P.O. Box 84, FI-02201 Espoo, Finland
or e-mail to: analyzers@outotec.com
Attn: Manager, Analyzer Sales Support
From:
Analyzer Serial Number:
Manual:

Code 10000004417e (prev. code 710 2502) Revision A
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Management page i (3)

a Document macros must be run in normal view (View - Normal).

2. Fill in all the details in the table below.

Product Code Revision

Maintenance of Courier 6 CCA cooling system KEA 20.4.2002

Do not edit the headers or the document covers manually!

5. Fill in the document record table below.

Revision, Description of revision and additional comments, info and

DO NOT REMOVE THE FOLLOWING STANDARD IMAGES!

Note standard image

Tip standard image

a Warning standard image

Check and approval details

Maintenance of Courier 6 CCA cooling system

Checked by Revision checked Date

Approved by Revision to be published Date

Archived by Revision archived Date

Product Code Revision

2. Safety precautions .................................................................................................................................. 4

Changing air filters .................................................................................................................. 18

Appendix 1: Recommended set values ................................................................................................... 21

Appendix 2: Cooling water requirements ................................................................................................ 25

1. About this document

Note, Tip, and Warning signs used in this document:

This sign stands for information especially worth noticing.

This sign stands for information including extra advice.

a This sign stands for information of extreme importance.

There are three CCA variations available:

Figure 1. Cooling system components in CCA (LCS).

The Courier 6 cooling system consists of the following modules:

Figure 2. Pump container (frame walls removed).

Temperature Control Module

Figure 3. Temperature Control Module.

Figure 6. Cooling system fuse in CBS

3.2 Cooling circulation

Cooling circulation in LCS

Figure 7. LCS cooling circulation.

Heat exhange in chiller

Next, the condensed and pressurized (by a compressor) coolant vaporizes in

Heat exhange in RAS

Heat exhange in XTA and pump container

Cooling circulation in RCS

Figure 8. RCS cooling circulation.

Cooling circulation in TCS

Figure 9. TCS cooling circulation.

Heat exhange in tap water cooled heat exhanger

4.2 Basic maintenance

Check list for LCS

Every six months:

Check list for RCS

Every six months:

Check list for TCS

Every six months:

4.3 Additional maintenance

Every four years:

4.4 Task descriptions

Checking water pressure

Figure 10. Water pressure gauges. 1 = XTA gauge, 2 = RAS gauge

Checking air pressure

Checking water circulation

Checking chiller fault codes

Checking connecting hoses and cables

Switching CCA power off/on

To switch the CCA power off: