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AIRNET II

PARTICLE COUNTER
Service Manual
Author: Jerry Swinford

www.pmeasuring.com

September 23, 2009

Airnet is a registered trademark of Particle Measuring Systems, Inc.


Molex is a registered trademark of Molex Corporation
All trademarks appearing in this manual are the property of their respective owners.

DO NOT REPRODUCE OR DISTRIBUTE


CONFIDENTIAL INFORMATION
FOR INTERNAL PMS USE ONLY
This confidential document contains proprietary information, which is protected by
copyright. All rights are reserved. No part of this document may be reproduced,
distributed, or transmitted in any form without the prior written consent of Particle
Measuring Systems. The information contained in this document is subject to change
without notice.
2009 by Particle Measuring Systems, Inc.
All Rights Reserved

September 23, 2009


Page ii

Table of Contents
1

PURPOSE ................................................................................................................... 1

INTRODUCTION ...................................................................................................... 2

RELATED DOCUMENTS........................................................................................ 3

AIRNET II FEATURES ............................................................................................ 4

4.1

Connector Panel................................................................................................................................ 4

4.2

Status & Activity LEDs .................................................................................................................... 5

4.3

Flow Pressure Sensors ...................................................................................................................... 5

SYSTEM COMPONENTS ........................................................................................ 6

5.1
Processor Board (1000013669) ........................................................................................................ 7
5.1.1
Connector Pinouts....................................................................................................................... 7
5.1.1.1 CO12....................................................................................................................................... 7
5.1.1.2 CO3 Detector Board ............................................................................................................... 8
5.1.1.3 CO10 4-20mA Board.............................................................................................................. 8
5.1.1.4 CO11 Pulses ........................................................................................................................... 8
5.1.1.5 CO6 RS-232 ........................................................................................................................... 9
5.1.1.6 CO8 Ethernet .......................................................................................................................... 9
5.1.1.7 CO7 BDM .............................................................................................................................. 9
5.1.1.8 CO9 Power & Thresholds....................................................................................................... 9
5.1.2
Power Supplies ......................................................................................................................... 10
5.1.2.1 Power over Ethernet (PoE) ................................................................................................... 10
5.2

Detector Board (1000013676) ........................................................................................................ 10

5.3

Laser Board (1000013943) ............................................................................................................. 11

5.4

4-20 mA Board (1000013684) ........................................................................................................ 11

5.5

Cabling ............................................................................................................................................ 12

DISASSEMBLY ....................................................................................................... 13

ASSEMBLY .............................................................................................................. 15

TEST POINTS .......................................................................................................... 16

8.1

Processor Board .............................................................................................................................. 16


September 23, 2009

Page iii

8.2

Laser Board..................................................................................................................................... 16

8.3

Detector Board ................................................................................................................................ 16

8.4

4-20mA Board ................................................................................................................................. 17

COMPONENT REPLACEMENT PROCEDURES ............................................. 18

9.1

Processor Board (1000013669) ...................................................................................................... 18

9.2

Detector Board (1000013676) ........................................................................................................ 18

9.3

Laser Board (1000013943) ............................................................................................................. 18

9.4

4-20 mA Board (1000013684) ........................................................................................................ 18

10

TROUBLE SHOOTING ...................................................................................... 19

10.1 Power ............................................................................................................................................... 19


10.1.1 +5V ........................................................................................................................................... 19
10.1.2 +3.3V ........................................................................................................................................ 19
10.1.3 +1.8V ........................................................................................................................................ 19
10.1.4 +12V ......................................................................................................................................... 19
10.1.5 -12V .......................................................................................................................................... 19
10.2

Ethernet ........................................................................................................................................... 19

10.3

Laser ................................................................................................................................................ 19

11

SERIAL COMMANDS ........................................................................................ 20

12

APPENDIX ............................................................................................................ 21

12.1

Processor Board .............................................................................................................................. 21


12.1.1.1
Processor........................................................................................................................... 21
12.1.1.2
FLASH ............................................................................................................................. 21
12.1.1.3
SDRAM ............................................................................................................................ 21
12.1.1.4
EEPROM .......................................................................................................................... 21
12.1.1.5
Ethernet Controller ........................................................................................................... 21
12.1.1.6
Serial Ports........................................................................................................................ 21
12.1.1.7
4 20mA Outputs (Optional) ........................................................................................... 21
12.1.1.8
BDM Port ......................................................................................................................... 21

12.2 Power over Ethernet (PoE) ............................................................................................................ 21


12.2.1 Power Up Sequence .................................................................................................................. 22
12.3

Additional Equipment .................................................................................................................... 22

September 23, 2009


Page iv

1 Purpose
The purpose of this document is to give a high level description of how the Airnet II Particle Counter operates and to
provide troubleshooting and service information. This manual does not cover the Airnet II calibration.

September 23, 2009


Page 1

2 Introduction
The Airnet II is an aerosol particle counter. It operates from either an external DC power supply or from Power over
Ethernet (PoE). The instrument has an RS-232 interface, Ethernet interface, and three 4-20 mA output channels.

September 23, 2009


Page 2

3 Related Documents
L:\Engineering\Release\Firmware\AirNet_II\PMS_Documentation\AirNetII_Command_Summary.doc

September 23, 2009


Page 3

4 Airnet II Features
4.1 Connector Panel
The connector panel on the Airnet II comes in two versions, one with the cutout for the optional 4-20mA board and one without.

With 4-20mA option

Without 4-20mA option

With 4-20mA option

Without 4-20mA option

September 23, 2009


Page 4

4.2 Status & Activity LEDs


The Airnet II has two LEDs, one for status and one for activity indication. They are both located on the Processor board. The top case has one light pipe for each LED.
The activity LED is green and the status LED is bi-color (Red/Green/Both).

4.3 Flow Pressure Sensors


The pressure sensors are located on the Detector board. The differential pressure sensor and the bench pressure sensor have tubes connected to the. The atmospheric
pressure sensor does not have a tube attached.

September 23, 2009


Page 5

5 System Components

-48V

+3.3V +3.3V

Spare Digital Input


D/A

SBM1040
20R-JMDSS-G-1-TF

43045-0611

4-20 mA Output
Connector

D/A

20PS-JMDSS-G-1-TF

CDBHD1100

4-20 mA Board
D/A

Raw DC
320uF

Si3440
Ethernet
Connector

H2019NL

6339191-4

0V

Power Over
Ethernet
Controller

SPI Data
SPI Clock

-48V

100k

0.1

LTC4267-3

4-20 mA_Latch
BA5516

Spare_Latch

60.4k

Optional 4-20 mA Board


0V

CDBHD1100

PS2911

+24V
Power Input
Threshold Output
Connector
39-30-0060

2200pF
250 VAC

Line Filter

Surge
Protection

0V

CDBHD1100

BNX022-01L

Threshold 1
Threshold 2

Laser Board

+5V

XHP-5

B5B-XH-A(LF)(SN)

XHP-4

Laser
Module

B4B-XH-A(LF)(SN)

POR
+5V

-12V

+5V

+1.8V

LTC1728ES5-5

+1.8V

+3.3V

+3.3V

+5V
+3.3V

+12V

Triple
DC/DC
Converter

-12V

DC/DC
Converter
LT3873

LT3507

+1.8V

Option Configuration Bit 0


Option Configuration Bit 1
Laser On

+3.3V
+3.3V

Status

25 MHz Osc
CWX813-25.0M

MII Interface

Detector Board
Op Amp

+12V

5V Reference

+5V

Pulses

Baseline Restore

Diff Press
Sensor

Activity
LED

ADC
Reference

-12V

HSMF-C165

Status
LED

Flow
Pressure Sensor A/D

HSMF-C165

+3.3V

AD124S051CIMM

10 MHz Osc

+3.3V

CWX813-10.0M

Power PC
+12V

EEPROM
32 kbits

I 2C
+3.3V

+5V
BNCH Press
Sensor

+12V

Particle Threshold 2
Baseline Restore Threshold

ATM Press
Sensor

24AA32A-ISNG

4.096V
Reference

-12V

Particle Threshold 1

+5V

3V Reference

+12V

MAX15006

20R-JMDSS-G-1-TF

Op Amp

BCM5221

Reset

+5V

20PS-JMDSS-G-1-TF

Detector

Transimpedance
Amp

Ethernet
I/F

FLASH
32 Mbits
x2

SPI Clock
Thresh_Latch

Particle Threshold 1 & 2


Baseline Restore Threshold

4-20 mA_Latch

LTC2604CGN

Address

Spare_Latch

Data

PC28F256M29EWH

32
32

+3.3V

Spare Digital Input


SPI Data
Control

SDRAM
128 Mbits

CH1 Clock

XHP-2

S2B-XH-A

MT48LC4M32B2B5-6

Drawn By: Jerry Swinford


Date Drawn: September 22, 2009

BDM
Connector

+3.3V

BNC
31221RFX

Front Panel

CH2 Clock

Pulses

Main Board

RS-232
Connector
FRJAE-666

RS-232
Transceiver

TSM-105-01-L-DV

MPC875CVR80

ISL4221EIRZ

September 23, 2009


Page 6

The Airnet II electronics is made up of a Processor board, Detector board, Laser board, and an optional 4-20 mA board.
The DC power supplies are on the Processor board. The Detector board and the optional 4-20 mA board are connected to
the processor board by board-to-board connectors. The Laser board is connected to the Processor board by a cable.

5.1 Processor Board (1000013669)

Processor Board (1000013669)


The Processor board interfaces to and controls the rest of the system components. The major components of the Processor
board are:
FLASH memory for System firmware
SDRAM for System memory
EEPROM memory for System configuration
D/A to set thresholds and baseline restore
Serial interfaces (RS-232 & SPI)
Ethernet Interface
Power supplies (PoE and system power)

5.1.1 Connector Pinouts


There are eight connectors on the Processor board.
Ref Des
CO3
CO6
CO7
CO8
CO9
CO10
CO11
CO12

Description
Detector Board, Board-to-board Connector
RS-232 Connector
Background Debug (BDM) Connector
Ethernet Connector
Power Input and Threshold Voltage Output Connector
4-20mA Board, Board-to-board Connector
Pulse Output Cable Connector
Laser Board Cable Connector

Mfr
JST
Amphenol
Samtec
AMP
Molex
JST
JST
JST

P/N
20R-JMDSS-G-1-TF(LF)(SN)
FRJAE-666
TSM-105-01-L-DV
6339191-4
39-30-0060
20R-JMDSS-G-1-TF(LF)(SN)
B2B-XH-AM(LF)(SN)
B5B-XH-AM(LF)(SN)

5.1.1.1 CO12
Pin Number
1
2
3
4
5

Description
+5V
-12V
Ground
Laser Status
#Laser_On
September 23, 2009

Page 7

5.1.1.2 CO3 Detector Board


Pin Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Description
+5V
Differential Pressure
+5V
Bench Pressure
Ground
Ground
+12V
Baseline Restore
+12V
Ground
Ground
Ground
-12V
Atmospheric Pressure
-12V
Ground
Ground
Ground
Ground
Pulses

5.1.1.3 CO10 4-20mA Board


Pin Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

Description
#Busy
V_Bus
Ground
V_Bus
Spare_Latch
#HRESET
Ground
Ground
Optional Board Configuration Bit 0
4-20mA_Latch
Ground
Ground
Optional Board Configuration Bit 0
4-20_SPICK
Ground
SPIMOSI
Spare_SPICK
SPIMISO
Ground
Spare Input (PE23)

5.1.1.4 CO11 Pulses


Pin Number
1
2

Description
Pulses (Center)
Ground (Ring)

September 23, 2009


Page 8

5.1.1.5 CO6 RS-232


Pin Number
1
2
3
4
5
6

Description
Shorted to pins 4 & 5 with a capacitor to ground
TxD
RxD
Shorted to pins 1 & 5 with a capacitor to ground
Shorted to pins 1 & 4 with a capacitor to ground
Ground

5.1.1.6 CO8 Ethernet


Pin Number
1
2
3
4
5
6
7
8
9
10
11
12

Description
Tx+ (PoE)
Tx- (PoE)
Rx+ (PoE)
Shorted to pin 5 (PoE)
Shorted to pin 4 (PoE)
Rx- (PoE)
Shorted to pin 8 (PoE)
Shorted to pin 7 (PoE)
Yellow LED Cathode
Yellow LED Anode
Green LED Cathode
Green LED Anode

5.1.1.7 CO7 BDM


Pin Number
1
2
3
4
5
6
7
8
9
10

Description
VFLS0
#SRESET
Ground
DSCK
Ground
VFLS1
#HRESET
DSDI
Pulled up to +3.3V
DSDO

5.1.1.8 CO9 Power & Thresholds


Pin Number
1
2
3
4
5
6

Description
+24VDC In
Channel 1 Threshold
Channel 2 Threshold
0VDC
Ground
Ground

September 23, 2009


Page 9

5.1.2 Power Supplies


The Airnet II power supplies are on the processor board. The instrument can be powered from an external +24VDC supply
or via Power over Ethernet (PoE). The DC voltages that are produced are: +5V, +3.3V, +1.8V, and 12V. The PoE
standard does not dictate the polarity of the DC voltage supplied over the Ethernet cable. Therefore, the PoE supply has
bridge rectifiers on the input. A bridge rectifier was also added to the +24V input so that the instrument will not be
damaged if the +24V power is wired backwards.

5.1.2.1 Power over Ethernet (PoE)


The PoE supply produces +12VDC. This is connected through a diode to the V_Bus (a.k.a. Raw_DC) that is used to
produce all of the system voltages. The external +24VDC is also connected to V_Bus through a diode. When the +24VDC
is being used to power the instrument, the PoE circuit will be disabled. If a Power Sourcing Equipment (PSE) device such
as a PoE Ethernet switch is connected it will go through the PoE negotiation sequence and be denied. I believe it may
continue to try this negotiation sequence forever. So, if PoE is available it is not recommended to power the instrument
with the external +24VDC. The Airnet II is a Class 0 PD.
There is more detailed information about PoE in general in the Appendix.

5.2 Detector Board (1000013676)


The Detector board does the particle detection and sends particle pulses to the Processor board. The Detector board also has
pressure sensors that are used for monitoring the flow. The outputs of these sensors are sent to the Processor board where
they are measured with an A/D converter.

September 23, 2009


Page 10

Detector Board (1000013676) and Board-to-Board Connector

5.3 Laser Board (1000013943)


The Laser board drives the solid state laser. The Laser board is connected to the Processor board by the LEM cable
(1000013724).

Laser Board (1000013943) and Cable (1000013724)

5.4 4-20 mA Board (1000013684)


The 4-20 mA board is optional. It connects to the Processor board via a board-to-board connector. It has three channels,
two particle channels and one for status.

4-20 mA Board (1000013684)

September 23, 2009


Page 11

The 4-20mA board is mounted in the Airnet II with two socket head cap screws. The length of these screws is critical. If
one of the screws is too long it will break the differential pressure sensor on the Detector board.

5.5 Cabling
There are two cables in the Airnet II. One cable connects the Processor board to the Laser board. The other cable connects
to the Processor board to a BNC connector on the rear of the Airnet II.
PMS P/N
1000013724
1000013725

Description
Processor board to Laser board cable (LEM)
Processor board to Pulse BNC cable (Pulse)

Pulse Cable (1000013725)

September 23, 2009


Page 12

6 Disassembly
The bottom of the case is held on by the four feet.
1.

Remove the four feet by unscrewing the socket head cap


screws with a hex wrench.

Socket head cap screws in feet


2.

With the bottom removed, the cover can be removed by


removing the four socket head cap screws in the four
corners.

Socket head cap screws


3.

Lift off the top of the case.

September 23, 2009


Page 13

4.

Remove the Processor board by removing the four socket


head cap screws in the four corners.

Remove Processor Board


5.

Remove the tubing from the pressure sensor on the Detector


board. Remove the two socket head caps screws. Remove
the Detector board.
The pressure sensors can be damaged easily. Therefore, the
tubing should only be removed if it is necessary.

Remove Detector Board


6.

The 4-20mA board is removed by removing the two socket


head cap screws.

Remove 4-20mA Board

September 23, 2009


Page 14

7 Assembly
Assembling the Airnet II has a few critical steps.
1.

The length of the socket head cap screws used to mount the
4-20mA board is critical. If the screw protrudes too far
through the mounting bracket it will damage the differential
pressure sensor on the Detector board.

Socket head cap screw length

Socket head cap screw length


2.

Socket head cap screw length

Care must be taken when mounting the Processor board. If


the board-to-board connectors are not properly aligned when
the Processor board is pressed down, the connector on the
Detector board and/or the 4-20mA board will be damaged.

Board-to-board connectors

September 23, 2009


Page 15

8 Test Points
8.1 Processor Board
TP
7
8
9
10
11
12, 14
13
15
17
18
19
20

Signal Name
Baseline Restore Threshold
CH1_THRESH
CH2_THRESH
+1.8VDC
+3.3V
GND
D
L_STATUS
CH2CLK
CH1CLK
ADC IN4
DAC4_OUT

Description
Baseline restore voltage for Detector board
Particle channel 1 threshold voltage
Particle channel 2 threshold voltage
+1.8V power for processor chip
+3.3V power
System ground
Ground for PoE circuit. Connected to system ground through C146
Status output from Laser board
Channel 2 particle pulses going to counter
Channel 1 particle pulses going to counter
Spare input to A/D converter
Spare output from D/A converter

8.2 Laser Board


There are no test points on the analog board.

8.3 Detector Board


There are four test points on the analog board.
TP
1
2
3
4

Signal Name
Photodiode Anode
Photodiode Cathode
+12VDC
-12VDC

Description
Photodiode Anode
Photodiode Cathode
+12VDC
-12VDC

September 23, 2009


Page 16

8.4 4-20mA Board


There are eleven test points on the 4-20mA board.
TP
1
2
3
4
5
6
7
8
9
10
11

Signal Name
GND
GND
V_OUT_C
V_OUT_B
V_OUT_A
#HRESET
4-20mA_Latch
4-20_SPICK
SPIMOSI
V_Bus
V_OUT_D

Description
Ground
Ground
D/A output for 4-20mA channel 3 (0 to +5VDC)
D/A output for 4-20mA channel 2 (0 to +5VDC)
D/A output for 4-20mA channel 1 (0 to +5VDC)
System reset
SPI latch to D/A
SPI clock
SPI serial data
Raw power from Processor board
Spare D/A output (0 to +5VDC)

September 23, 2009


Page 17

9 Component Replacement Procedures


9.1 Processor Board (1000013669)
The Processor board contains the D/A that sets the thresholds and the baseline restore voltage. It contains the A/D that
measures the pressure sensors. Both of these devices have precision voltage references. The value of these references may
be different on the new Processor board. This may affect the flow setting and the calibration. If the Processor board is
replaced, run setup and calibration.

9.2 Detector Board (1000013676)


If the Detector board is replaced, run flow and calibration.

9.3 Laser Board (1000013943)


If the Laser board is replaced, run calibration.

9.4 4-20 mA Board (1000013684)


If the 4-20mA board is replaced, nothing else is required.

September 23, 2009


Page 18

10 Trouble Shooting
10.1 Power
The Airnet II can be powered from either an external +24VDC supply or from a PoE switch. It is possible that the Airnet II
can function from the +24VDC input and not from the PoE input. This would indicate that the PoE circuit is faulty but the
rest of the supplies are OK. There is a Power LED (D21) on the Processor board. If it is not illuminated then the +3.3V
supply is faulty. If it is illuminated it does not guarantee that the rest of the supplies are OK. All of the voltages must be
verified with a meter.

10.1.1 +5V
The +5V can be verified by measuring pin 1 on CO12 (Laser cable connector).

10.1.2 +3.3V
The +3.3V is OK if D21 is illuminated or measuring TP11.

10.1.3 +1.8V
The +1.8V can be verified by measuring TP10.

10.1.4 +12V
The +12V can be verified by measuring pin 8 on U43.

10.1.5 -12V
The -12V can be verified by measuring pin 2 on CO12 (Laser cable connector).

10.2 Ethernet
The Ethernet circuit and connector are on the Processor board. If it is determined that the Ethernet problem is a hardware
problem then the Processor board must be replaced.

10.3 Laser
The firmware will turn the laser off if the air flow is not correct. This can be checked by measuring the #Laser_On signal.
This is a low true signal, which means that if the firmware is telling the laser to be on, #Laser_On will measure about 0V.
This signal is on CO12 pin 5.

September 23, 2009


Page 19

11 Serial Commands
The serial commands are described in the AirNetII PMS/OPC command summary document.

September 23, 2009


Page 20

12 Appendix
12.1 Processor Board
The major components of the Processor board are described below.

12.1.1.1

Processor

The processor is a Freescale MPC875.

12.1.1.2

FLASH

The system firmware is stored in the FLASH. The FLASH is two PC28F256M29EW parts. These are 16-bit wide 256 Mbit
parts. This is 64 Mbytes of FLASH. The address space of the FLASH is from 0xF0000000 to 0xF3FFFFFF.

12.1.1.3

SDRAM

The SDRAM system memory is one Micron MT48LC4M32B2B5-6 part. This a 32-bit wide 128 Mb part. This is 16
Mbytes of SDRAM. The address space of the SDRAM is 0x00000000 to 0x00FFFFFF.

12.1.1.4

EEPROM

The EEPROM is used to store system parameters. There are 32 kbits. The EEPROM is accessed via the SPI bus.

12.1.1.5

Ethernet Controller

The Ethernet Controller is accessed via the Media Independent Interface (MII). D34 on the Processor board is a bi-color
LED. The Green portion of the LED indicates the speed of the link (10/100) and the Red portion of the LED indicates
whether the link is half duplex or full duplex.

12.1.1.6

Serial Ports

There is one RS-232 serial port and the SPI serial interface.

12.1.1.6.1

SPI Interface

The SPI interface is used within the instrument. The processor controls the EEPROM, the optional 4-20mA output D/A, the
threshold D/A, and the pressure sensor A/D via the SPI interface.

12.1.1.6.2

RS-232

The RJ-11 connector on the Processor board is for the RS-232 port.

12.1.1.7

4 20mA Outputs (Optional)

If the Airnet II has 4-20mA outputs, the optional 4-20mA board is installed.

12.1.1.8

BDM Port

The Background Debug Port (BDM) is used to view and / or modify the internal memory, registers, and peripherals on any
of the processor buses.

12.2 Power over Ethernet (PoE)


IEEE802.3af is the standard that defines PoE. There are two basic components to PoE, the Powered Device (PD) and the
Power Sourcing Equipment (PSE). The standard requires the use of CAT 3 cable at a minimum. The cable has four twisted
pairs. The PSE provides 44-57VDC over two of the four pairs, either the two spare pairs or the two data pairs. Since the
standard does not specify which pairs are to be used, the PD must accept power from either set of wire pairs.

September 23, 2009


Page 21

12.2.1 Power Up Sequence


To ensure that power is not applied to an Ethernet device that is not a PD, the standard requires the PSE to look for a 25k
resistance (signature resistance) on the wire pairs that will be powered. Therefore, the PD must provide this resistance as
part of the power up sequence. The standard also specifies five classes of power levels.
Class
0
1
2
3
4

Usage
Default
Optional
Optional
Optional
Reserved

Maximum Power Levels at Input of PD (Watt)


0.44 12.94
0.44 3.84
3.84 6.49
6.49 12.95

The PD has a power classification resistor that is detected by the PSE. This allows the PSE to determine how many devices
it can power. If the total available power is 100W and each of the PDs are class 3, the PSE can power seven. If the PDs are
class 1 then the PSE can power twenty six.

12.3 Additional Equipment


In addition to the standard accessories, there are some items that may be useful.
Mfr.
SL Power
PMS
PMS
PMS
PMS
SL Power
Dell

P/N
LS15RB2401J04
1000014175
1000014176
1000014177
1000014178
PW183RB
PowerConnect 3524P

Description
Input: PoE Output: 11.4W, +24VDC (for powering old Airnet in PoE installation)
Adapter cable for powering Airnet II from Airnet power supply
Adapter cable for connecting Airnet II 4-20mA outputs to old Airnet installation
Adapter cable for powering old Airnet from Airnet II power supply
Adapter cable for connecting old Airnet 4-20mA outputs to Airnet II installation
Desktop style universal 30 Watt IEEE802.3af compliant PoE power supply
24 port PoE Ethernet switch, 370W for the 24 PoE ports

September 23, 2009


Page 22