Teledyne Scuba Diving Equipment HEATED THC User's Manual
Contents
1. Password Incorrect Change Password Enter New Password ETS EA he Reenter New Password A A AIN W Teledyne Analytical Instruments 36 Operation Password Mismatch Password Changed LOGOUT Restrict Access ENTER YES ESCAPE NO MODEL 4030 THC Monitor V1 0 SELF TEST Begin Self Test ENTER YES ESCAPE NO Running Diagnostic 5V Test 15V Test DAC A Test DAC B Test Diagnostic Result 5V GOOD 15V GOOD DAC A GOOD DAC B GOOD Teledyne Analytical Instruments 37 Operation SPAN THC Span Yes SMP Span No THC Sp 8 00 ppm SMP Sp 0 00 ppm Span Begin Begin Span ENTER YES ESCAPE NO ALARMS l DEFEATED L 1 HIGH L 1 NON FAILSAF L 1 NON LATCHING L 1 20 00 ppm L 1 SOURCE THC 2 DEFEATED L 2 HIGH L 2 NON FAILSAF L 2 NON LATCHING L 2 50 00 ppm L 2 SOURCE THC EJ CJ Dop p p p p hae RANG EJ Range Select Auto AutoRange Src THC Man Rng R1 RI 0 10 00ppm R2 0 100 00ppm R3 0 1000 00ppm W Teledyne Analytical Instruments 38 Operation ANALOG OUT ADJUST CH1 mA Offset CH1 mA Gain CH1 Select CH2 Select THC WAVE CHANGE STREAM CHANGE STREAM NOT AVAILABL2. CJ TIMING THC I P 100 00 THC TIME 05m00s THC I Begin 00m05s THC I End 00m05s AIR I Begin 00m05s AIR I End 00m05s THC Base 1 O00m03s THC Base 2 O00m03s SMP I P 100 00 SMP TIME 05m00s SMP I Begin 00m05s SMP I End 00m30s SMP Base 1 00m03s SMP Base 2 00m03s W Teledyne Analytical Instruments 39 as ET amp STANDBY Switch to Sleep Mode ENTER YES ESCAPE NO notification if logged out Access Restricted Re enter Password 4 4 5 Setting up an AUTO CAL AUTOCAL is not available for standard configurations of the 4040 4 4 6 Adjusting the GAIN The output of the FID is conditioned by an amplification circuit with 3 user adjustable settings 0 xl 1 x10 2 x100 The resulting signal is converted to a number Numbers outside the range 262144 to 262143 are unreliable and lead to inaccurate measurements If the number is outside this range during analysis the message GAIN TOO HIGH is shown on the 2 line of the display and the analyzer is not updated to a new calculated value The Gain Too High message may be removed by pressing the ESCAPE key The gain has been set at the factory such that the analyzer will work reliably within the prescribed range of operation The user may change the gain when a different level of sample is to be analyzed W Teledyne Analytical Instruments 40 Operation To setup the GAIN
3. 1 From the Analysis Screen press an arrow key to enter the Setup Mode The VFD will display the first 2 lines of functions available gt GAIN ADJUST PASSWORD lt A Y gt If the arrow is not adjacent to the GAIN ADJUST menu item use the A V keys to move the arrow to the proper position lt Enter gt Press lt Enter gt to activate the function and move you to the next screen gt GAIN 1 Note for instruction on how to please refer to the section 4 4 3 Navigation and Data Entry In the example the number to the right of the word GAIN is 1 this reflects a gain of x10 4 4 6 Password Protection Before a unique password is assigned the system assigns TAI by default If the password is the default it will be displayed automatically The operator just presses lt Enter gt from the any of the MAIN MENU items to be allowed access to that item s sub menu If the password has previously been changed from the default then the initial display will be A A A and the correct letters must be input If user has LOGGED OUT then only the following SUB MENU procedures may be executed 14 PASSWORD 15 LOGOUT which only repeats the logout 16 MODEL W Teledyne Analytical Instruments 41 Operation Note however that the instrument can still be used for analysis without entering the password To defeat security the password must be entered Note If you use password security it is strongly
4. ae ET amp Gain plus the Offset value plus a value that is proportionate to the number indicated to the right of GAIN If these 2 values are modified and entered and accepted then the analog output will be affected in like manner in ANALYSIS MODE That is it will be scaled by the gain value then summed with the offset value The analog output for each channel may be set to source THC SMP AVG WAVE or R ID In the case of THC SMP AVG the output will reflect the percent of range for the respective selection In the case of WAVE the output will track the FID output In the case of R ID the output will reflect the selected range LOW 1 5 of full scale MID 1 2 of full scale HIGH 4 5 of full scale 4 4 15 Standby This function allows you to place the instrument in STANDBY CAUTION STANDY SHUTS DOWN POWER TO THE DISPLAYS ONLY INTERNAL CIRCUITS ARE STILL ENERGIZED AND ELECTRICAL SHOCK HAZARD STILL EXISTS To place the instrument in STANDBY status lt A Y gt From the MAIN MENU scroll to the STANDBY function using the UP DOWN keys lt Enter gt Pressing lt Enter gt places the instrument in STANDBY To exit STANDBY scroll again to the STANDBY function and press lt Enter gt again 4 5 Advanced User Functions The Model 4030 provides additional functions for tailoring the instrument to your specific application These functions include 20 Timing 4 5 1 Timing Timing controls the parameters
5. Equipment will be required to operate the analyzer The recommended composition of these gases is specified in the Application Data section of the Appendix The gases should be supplied from cylinders that are equipped with the type of regulator specified in the aforementioned sections CAUTION UNDER NO CIRCUMSTANCES SHOULD YOU EMPLOY A REGULATOR THAT IS NOT EQUIPPED N WITH A METALLIC DIAPHRAGM ANYWHERE IN THE SYSTEM The regulators should be inspected prior to installation to be sure that they are oil free Failure to comply with these directives will result in a constant drift in analyzer output as organic compounds will outgas into the plumbing system at a rate that is related to the ambient temperature Use 316 stainless steel dual stage stainless steel diaphragm regulators only in fuel sample and blanket air lines shutoff valves should be used downstream from each regulator Place the supply cylinders as close to the analyzer as possible and interconnect them to the analyzer with new tubing Be sure that all plumbing connections are free of leaks Note Use only stainless steel tubing throughout the system Consult the assembly piping outline drawings and any Addenda included with this manual to determine if special conditions apply W Teledyne Analytical Instruments 25 Installation CAUTION THE GASES USED MUST BE OF THE HIGHEST QUALITY ULTRA ZERO GRADES AS SHOWN BELOW FAILURE TO DO SO WILL RESULT IN CONTAMINAT
6. Series 4030 CAUTION THE ANALYZER SHOULD ONLY BE USED FOR THE PURPOSE AND IN THE MANNER DESCRIBED IN THIS MANUAL IF YOU USE THE ANALYZER IN A MANNER OTHER THAN THAT FOR WHICH IT WAS INTENDED UNPREDICTABLE BEHAVIOR COULD RESULT POSSIBLY ACCOMPANIED WITH HAZARDOUS CONSEQUENCES This manual provides information designed to guide you through the installation calibration and operation of your new analyzer Please read this manual and keep it available Occasionally some instruments are customized for a particular application or features and or options added per customer requests Please check the front of this manual for any additional information in the form of an Addendum which discusses specific information procedures cautions and warnings that may be specific to your instrument Manuals do get misplaced Additional manuals can be obtained from Teledyne at the address given in the Appendix Some of our manuals are available in electronic form via the internet Please visit our website at www teledyne ai com Teledyne Analytical Instruments ii Series 4030 Additional Safety Information DANGER COMBUSTIBLE GAS USAGE WARNING This is a general purpose instrument designed for usage in a non hazardous area It is the customer s responsibility to ensure safety especially when combustible gases are being analyzed since the potential of gas leaks always exist The customer should ensure that
7. The main features of the analyzer include 1 Easy to use front panel interface that includes a red 5 digit LED display and a vacuum fluorescent display VFD driven by microprocessor electronics W Teledyne Analytical Instruments 7 Introduction 2 High resolution accurate readings of concentration 3 Versatile analysis with three user definable analysis ranges 4 Microprocessor based electronics 8 bit CMOS microprocessor with 32 KB RAM and 128 KB ROM 5 Auto ranging allows analyzer to automatically select the proper preset range for a given measurement Manual override allows the user to lock onto a specific range of interest 6 Two adjustable concentration alarms and a system failure alarm 7 Extensive self diagnostic testing at startup and on demand 8 RS 232 serial digital port for use with a computer or other digital communication device 9 Analog outputs for selectable concentration analog input waveform and range identification 0 1 VDC standard and isolated 4 20 mA dc 10 Superior Accuracy 1 2 Principle of Operation The sample is brought to a heated SAMPLE CHAMBER 50 120 C per application and into a sample loop and a 10 port 2 position Position A amp B switching valve The carrier gas typically nitrogen pushes the sample alternatively from each sample loop into the FID to detect the hydrocarbons 1 3 Analyzer Description The standard analyzer is housed in a sheet steel equipment case
8. a fixed volume of sample which is collected in Sample Loop is pushed into the FID detector Series 4030 uses a Flame Ionization Detector to sense hydrocarbons The FID was selected based on the positive performance and extensive experience in the use of this detector in other Teledyne analyzers namely Model 402R and Model 4020 The FID has proven itself to be a rugged stable long life sensor giving years of trouble free operation in various applications Typically Model 4030 is calibrated using a known mixture of methane in air and thus the THC is shown as equivalent ppm methane concentration A separate SAMPLE SELECTOR MODULE Unit optional may be provided with a heated chamber 120 C Typical and a manual 3 way valve This allows the User to connect Sample gas and the Span gas to the back of the Sample Selector Unit and manually select the gas to Model 4030 for analysis The User must ensure that the Sample gas is kept above the dew point to avoid condensation from the Sample point to its entry into Model 4030 4 Teledyne Analytical Instruments 9 Introduction The Series 4030 Analyzer is composed of three subsystems Sample System 2 Detector Cell 3 Electronic Signal Processing Display and Control 2 2 Sample System The Analyzer contains two 2 separate isothermal chambers controlled by individual PID temperature controllers viewed just behind the Front Panel The three chambers SAMPLE and FID are describe
9. flush mounted in a 19 rack The front interface panel is mounted on a door which when opened allows convenient access to the Analyzer electronics The entire front panel can slide out of the chassis to provide greater access to the electronics and to the sample system Gas pressure and flow controls are mounted on the front panel adjacent to the LED and VFD displays and user interface At the rear of the instrument are ports for the introduction of air carrier fuel span and sample gas A single 50 pin user interface cable connector contains input output and alarm signals available to the user An RS 232 port is also available at the rear panel for connection to a remote computer or other digital communication device The Analyzer is set up for either 120 VAC 60 Hz or 230 50 60Hz operations depending Teledyne Analytical Instruments 8 Introduction on the customer s requirements The appropriate power cord for your unit has been shipped with this instrument 1 4 Applications Monitoring the ambient air for Total Hydrocarbons in chemical and petrochemical plants Fugitive emission monitoring Process emission gases in the chemical industry 2 1 Introduction Using a built in pump the heated Sample from the Sample Selector Unit is brought to the heated SAMPLE CHAMBER of Model 4030 housing filter cartridge switching valve and sample loops Using nitrogen carrier gas and the microprocessor actuated switching valve
10. Observe the fuel pressure gauge on the analyzer control panel The gauge indication will decay as the fuel in the line is exhausted When the gauge reading reaches the vicinity zero the flame will be extinguish as the fuel solenoid shuts off the fuel supply The analyzer will automatically try to re ignite After 5 attempts it will display flame failure check air fuel and the flame failure LED will be on 3 Open the cylinder supply valve and re ignite the flame by pushing the UP and DOWN buttons simultaneously 4 3 2 Ignition and or Flame Guard Circuit Failure If the flame ignition or guard circuits do not operate as described in the above two sections set the instrument fuel regulator to the recommended pressure 4 3 3 Sample Pump A built in Sample Pump is provided to draw Sample Gas from the Sample line The gas flow rate should be maintained at about 1000 to 1200 cc minute using the Front Panel FLOW CONTROL valve clockwise increases flow 4 4 Analyzer Operation Although the Model 4030 has been programmed for your application at the factory it can be further configured at the operator level Teledyne Analytical Instruments 29 Operation Depending on the specifics of the application this might include all or a set of the following procedures 1 Setting system parameters 1 Establish a security password if desired requiring operator to log in 2 Establish and start an automatic calibration cycle not availa
11. Range 1 Contact 39 Range 2 Contact 40 41 42 Alarm 2 NC Contact 43 Alarm 2 NO Contact 44 Alarm 2 C Contact 45 Alarm 1 NC Contact 46 Alarm 1 NO Contact 47 48 Exhaust Solenoid Return 49 50 Sample Solenoid Return 3 3 4 RS 232 Port The digital signal output is a standard RS 232 serial communications port used to connect the analyzer to a computer terminal or other digital device It requires a standard 9 pin D connector Input The input functions using RS 232 that have been implemented to date are described in Table 3 5 Table 3 5 Commands via RS 232 Input Command AS lt enter gt AL lt enter gt RL lt enter gt RM lt enter gt RH lt enter gt RA lt enter gt Description immediately starts an auto span immediately revert to Analyze THC Phase Change to Manual Range LOW Change to Manual Range MEDIUM Change to Manual Range HIGH Change to Manual Range AUTO Teledyne Analytical Instruments 24 Installation Implementation The RS 232 protocol allows some flexibility in its implementation Table 3 6 lists certain RS 232 values that are required by the Model 4030 implementation Table 3 6 Required RS 232 Options Parameter Setting Baud 2400 Byte 8 bits Parity none Stop Bits 1 Message Interval Sent at the end of each cycle 3 3 5 Supporting Gases Normally four supporting gases of different composition see Section 4 1
12. Sample Loop kept inside a heated SAMPLE CHAMBER and maintained at a constant temperature in the range of 50 to 120 C as per application With a 2 position 10 port switching valve and Carrier Gas the sample collected inside the Sample Loop is pushed inside the Flame Ionization Detector FID and analyzed for the THC The sample integrity as it enters the Analyzer is maintained by ensuring that condensation does not take place inside the SAMPLE CHAMER This is ensured by maintaining a high temperature 50 80 C typical inside the SAMPLE CHAMBER Also the sample is diluted with the Carrier Gas to ensure that once the mixed sample reached FID no further condensation takes place A separate SAMPLE SELECTOR MODULE unit optional may be provided for use in conjunction with the Model 4030 This allows the User to bring the heated Sample gas Max 120 C and the Span gas to the Sample Selector Unit and manually select either Sample or Span for entry into the Model 4030 The User is responsible for making all gas connections from the Sample point to the Sample Selector Unit and also between Sample Selector Unit and Model 4030 The User must also ensure that gases are heated above the dew point Max temp allowed 120 C and are cleaned to better than 2 micron filter 1 1 Main Features of the Analyzer The Analyzer is sophisticated yet simple to use A dual display on the front panel prompts and informs the operator during all phases of operation
13. The carrier gas containing sample and fuel are combined within a tee fitting located in the isothermal chamber The mixed gas is emitted from a burner within the sensor assembly Blanket air is introduced into the sensor or cell by means of a separate fitting that is located in the base section of the assembly The upper half of the assembly houses the anode igniter collector and flame guard thermistor 2 3 Detection Cell The upper section of the stainless steel flame ionization cell houses the cylindrical collector electrode the high voltage 260 VDC anode igniter coil and the sensing thermistor of the flame guard circuit see cell cross section Figure 2 1 WARNING DANGEROUS HIGH VOLTAGE EXISTS AT THE ANODE IGNITER COIL 260 VDC DO NOT ATTEMPT TO DISCONNECT THE IGNITER COIL CABLE OR DISASSEMBLE ANY OF THE FLAME IONIZATION CELL COMPONENTS WITHOUT TURNING OFF THE POWER AND DISCONNECTING THE POWER CORD The collector is interconnected with the electrometer amplifier PC board by a coaxial cable Although the cable and fittings are intended for coaxial service the cable is actually being used as a shielded single conductor connection Teledyne Analytical Instruments 11 Introduction The anode igniter as its name implies serves two functions When relay K2 at PCB part number B74671 is energized the coil becomes an electrical heating element that glows red hot and ignites the hydrogen fuel When relay K2 at B74671 i
14. access the offset function lt A Y gt From the MAIN MENU scroll to the ANALOG ADJUST function using the UP DOWN keys lt Enter gt Pressing lt Enter gt activates the function and takes you to the next screen ANALOG OUT ADJUST H1 Offset 0 H1 Gain 0 H1 Select THC H2 Select R ID C OQ COQ A lt Enter gt Use the lt Enter gt key to move over to the Offsetfield lt A Y gt Use the UP DOWN keys to change each digits value lt Enter gt Use the lt Enter gt key to save the value lt Escape gt Use the lt Escape gt key to revert to the original value Use the same procedure to set the gain of the instrument After the last digit is entered the final lt Enter gt press will accept the gain value The values entered do not have explicit units of current or voltage Adjustment should be gauged using a voltmeter or current meter attached to the analog output When the ANALOG ADJUST menu is entered the following is displayed gt CH1 mA Offset 0 CH1 mA Gain 0 When the arrow is on the Offset or when the user presses lt Enter gt to modify the offset the analog output is 4mA plus a value that is proportionate to the number indicated to the right of Offset That number may be modified 500 to 500 When the arrow is on the Gain or when the user presses lt Enter gt to modify the gain the output is 20mA scaled by the value to the right of Teledyne Analytical Instruments 51
15. advised to keep a copy of the password in a separate safe location If the password is lost and security is enabled the analyzer must be cold booted Cold booting invalidates parameters necessary for correct operation so they must be re entered ENTERING A PASSWORD To install a new password or change a previously installed password you must key in and ENTER the old password first If the default password is in effect it will be displayed as the default gausses for each letter pressing lt Enter gt for each letter of the password will enter the default password for you To enter a password lt any key gt From the ANALYSIS SCREEN Enter MAIN MENU setup by pressing an ARROW KEY lt A Y gt Use the UP or DOWN key to scroll to PASSWORD AUTOCAL gt PASSWORD lt Enter gt Press lt Enter gt to activate the password function Either the default TAI password or AAA place holders for an existing password will appear on screen ENTER PASSWORD SCREEN Enter a Password T A L lt A Y gt Use the A W keys to change the letters to the proper password lt Enter gt Press lt Enter gt to advance to the next letter W Teledyne Analytical Instruments 42 zs EStiOn lt Enter gt The last lt Enter gt enters the password lt Escape gt Steps back to the previously entered letter or if on the first letter returns to the MAIN MENU If the correct password has been entered the 404
16. and defeat the alarm until the pertinent phase is re completed TRIGGER POINT This is the threshold at which an active alarm can enter into alarm condition If an alarm is HIGH ACTIVE and set at 20 00 ppb then when the analysis concentration is at or above 20 00 ppb an alarm condition is initiated or maintained SOURCE The alarm can react to measurement levels of THC SMP or AVG the average of the previous 2 CAUTION IT IS NOT GOOD PRACTICE TO SILENCE AN EXISTING ALARM BY SETTING THE ALARM ATTRIBUTE TO DEFEAT THE ALARM WILL NOT AUTOMATICALLY RETURN TO ACTIVE STATUS IT MUST BE RESET BY THE OPERATOR BY PRESSING THE ESCAPE BUTTON IF IT IS NOT RESET YOUR PROCESS WILL BE RUNNING WITHOUT SAFEGUARDS THIS INSTRUMENT IS DESIGNED TO PROVIDE 4 4 12 The Range Function gt Range Select Man Autorange Src THC Man Rng RI RI 0 10 0 ppm R2 0 100 0 ppm R3 0 1000 0 ppm Teledyne Analytical Instruments 49 s s LTStiOn The value of the upper limit of the currently selected range AUTO or MANUAL affects the voltage and current of the analog outputs on the rear of the analyzer as well as contact closures indicating which range is current The Analog outputs on the rear of the analyzer represent the proportion of the analysis concentration to the currently selected range limit MANUAL AUTO RANGE SELECT In Manual Range select the Range indicated on the second line Man Rng is
17. is flashing The ENTER key is then used to accept the value and move you to the next field to continue programming 4 4 3 3 ESCAPE The ESCAPE key is used in several context sensitive ways 4 When showing the THC analysis mode the ESCAPE key temporarily clears any present alarms However if the alarm condition is still present the alarm will re occur when re detected Also pressing the ESCAPE key clears the messages generated by incorrect gain settings i e bad span gain too high When the selected option is a function on the MAIN MENU or any SUB MENU screen the menu name appears with a flashing arrow next to it the ESCAPE key is used to return to the parent menu finally returning to the ANALYSIS SCREEN the function 9 Ifthe selected option is a modifiable item value is flashing The ESCAPE key is used to escape to the parent menu without Teledyne Analytical Instruments 33 zs s s eStion saving the value The value will revert to the original before modification if anv 4 4 4 Menu Structure The 4030 screen setup consists of several classes of screens and items No item occupies more than 1 line It is important to read and understand the NAVIGATION AND DATA ENTRY section to fully understand the menu structure The ANALYSIS SCREEN displays the following LINE 1 Analysis value of THC Alarms if present dashes if not AL 2 means alarm 2 has been triggered AL 1 means a
18. of the valve and data acquisition It is specific to the setup of the instrument and must be determined at the factory or TAI trained personnel W Teledyne Analytical Instruments 52 Appendix Recommended Spare Parts List Qty P N B74671 B74677 B30927 C75825A A46128 B 13207 C62371A B74674A C65507A B74677A L79 F77 L156 L154 A33748 V825 CP2408 ph p bd dt dt ed ed ed ed ed ed ed dt ed ed pd pd Description PC board Flame guard amp anode power supply PC board Electrometer amplifier PC board Temperature control Micro processor PC board Coaxial cable Sensor Assy Display PCB Assy Interface to Motherboard PCB Assy Backpanel Power Supply PCB Assy Electrometer PCB Assy Lamp neon Fuse 6 25A 3 AG Lens red LED red Thermistor assembly Ten way valve PID temperature controller A minimum charge of US 20 00 is applicable to spare parts orders IMPORTANT Orders for replacement parts should include the part number and the model and serial number of the system for which the parts are intended Teledyne Analytical Instruments 53 Appendix Send orders to TELEDYNE INSTRUMENTS Analytical Instruments 16830 Chestnut Street City of Industry CA 91749 1580 Telephone 626 934 1500 Fax 626 961 2538 Web www teledyne ai com or your local representative Email ask_tai teledyne com Drawing List D77214 Model 4030 Outline diagram D77215 Wiring diagram Rev 2
19. the principles of operating of this equipment are well understood by the user Misuse of this product in any manner tampering with its components or unauthorized substitution of any component may adversely affect the safety of this instrument Since the use of this instrument is beyond the control of Teledyne no responsibility by Teledyne its affiliates and agents for damage or injury from misuse or neglect of this equipment is implied or assumed WARNING HYDROGEN GAS IS USED IN THIS INSTRUMENT AS A FUEL HYDROGEN IS EXTREMELY FLAMMABLE EXTREME CARE MUST BE USED WHEN WORKING AROUND GAS MIXTURES CONTAINING FLAMMABLE GASES A Successful leak check was performed at TI Al on the sample system of this instrument prior to calibration testing and shipping Ensure that there are no leaks in the fuel supply lines before applying power to the system Always purge the entire system before performing any maintenance and always leak check the system after removing any tubing or fittings on the sample W Teledyne Analytical Instruments lii Series 4030 WARNING A system See the procedures for purging and leak checking this instrument on the following pages If toxic gases or other hazardous materials are introduced into the sample system the same precautions regarding leak checking and purging apply to the sample lines and sample supply or delivery lines ELECTRICAL SHOCK HAZARD WITH THE EXCEPTION OF OPENING THE DOOR AND
20. 0 now allows access to all the SUBMENU items The 4040 next presents the CHANGE PASSWORD screen CHANGE PASSWORD SCREEN gt Change Password lt Escape gt Press lt Escape gt to return to the MAIN MENU you are now logged in and have access to ALL SUBMENU items lt Enter gt Press lt Enter gt to change the password ENTER NEW PASSWORD SCREEN Enter a new Password L T A JL lt A Y gt Use the A W keys to change the letters to the new password lt Enter gt Press lt Enter gt to advance to the next letter lt Enter gt The last lt Enter gt moves to the REPEAT PASSWORD ENTRY screen lt Escape gt Steps back to the previously entered letter or if on the first letter returns to the CHANGE PASSWORD menu REPEAT PASSWORD ENTRY SCREEN Teledyne Analytical Instruments 43 zs s LStion Reenter a new Password A A KAS Note that the new password has been replaced by A as placeholder characters This is to ensure that the wrong password is not mistakenly entered lt A Y gt Use the A W keys to reenter the letters of the new password lt Enter gt Press lt Enter gt to advance to the next letter lt Enter gt If the repeated password matches the previously entered new password the new password is set the 4060 resumes the ANALYSIS SCREEN after displaying a brief message Password Changed lt Escape gt Steps back to the previously entered le
21. 1 and consists of an electrometer amplifier and an operational amplifier This circuit is a very high gain current to voltage converter circuit having an input impedance measuring in the billions of ohms It is static sensitive and highly susceptible to contamination Special care must be taken in handling this PC board 2 3 2 Anode Power Supply The high voltage anode power supply components are mounted on the anode power supply printed circuit board High voltage regulation is achieved through the use of series connected zener diodes The simplicity of this circuit s design can be attributed to the extremely low current demand of the anode circuit The positive output voltage is Teledyne Analytical Instruments 13 Introduction nominally 125 volts Output tolerance is 10 volts from the specified 125 volts 2 3 3 Flame Guard Circuit A thermistor controlled transistorized switching circuit is employed to operate a relay in the event of a flameout condition A panel indicator light and fuel shut off solenoid valve are operated by the relay to alarm personnel that a flameout condition has occurred The fuel shut off solenoid valve stops the hydrogen flow 2 3 4 Flame Ignition Circuit The flame ignition circuit includes the anode igniter electrode in the detector cell a transformer and processor controlled relay The circuit is automatically energized when the FID cools due to lack of flame If automatic ignition fails
22. ADJUSTING THE PRESSURE REGULATORS FLOW CONTROLLER OR OBSERVING THE PRESSURE GAUGES AND THE FLOWMETER ONLY AUTHORIZED AND SUITABLY TRAINED PERSONNEL SHOULD PERFORM WORK INSIDE OF THE INSTRUMENT COMPONENTS WITHIN THE COVER ON THE INSIDE OF THE DOOR INSIDE THE ISOTHERMAL CHAMBER SAMPLE SYSTEM AND ON THE ELECTROMETER AMPLIFIER PC BOARD CONTAIN DANGEROUSLY HIGH VOLTAGE SUFFICIENT TO CAUSE SERIOUS INJURY OR DEATH There are the following three types of inaccessible shock hazards within the Analyzer 1 Line voltages and line related voltages such as 115 VAC which exists within the 230 VAC versions as well These voltages stop when the Analyzer is turned off and the mains line cord is removed from the instrument 2 The sensor anode supply voltage approximately 250 VDC This voltage exists on the Flame Guard anode power supply PCB the motherboard and the anode igniter terminals on the sensor THIS VOLTAGE WILL REMAIN HAZARDOUS FOR MANY MINUTES AFTER THE ANALYZER HAS BEEN TURNED OFF 3 External hazardous voltages which may be connected to the Analyzer alarm relay connections W Teledyne Analytical Instruments iv Series 4030 Procedure for Removal of Internal Inaccessible Shock Hazards CAUTION A SERVICING OR MAINTENANCE OF THE ANALYZER SHOULD ONLY BE DONE BY SUITABLE TRAINED PERSONNEL TO AVOID THESE INACCESSIBLE HAZARDOUS VOLTAGES WHEN SERVICING THE SERIES 4060 PERFORM EACH OF THE FOLLOWING STEPS IN T
23. D Contact Range 3 ID Contact Range 3 ID Contact Not Used Not Used W Teledyne Analytical Instruments 22 Installation 3 3 3 7 NETWORK I O A serial digital input output for local network protocol At this printing this port is not yet functional It is to be used in future options to the instrument Pins 13 and 29 3 3 3 8 Pin Out Table The following table summarizes all the outputs inputs available in the 50 pin D Sub connector on the back panel of the Analyzer Table 3 4 Pin out of 50 pins D Sub Connector Pin Description Output 4 20 ma Channel 2 ID Output 4 20 ma Range ID Output 4 20 ma Channel 1 Output 4 20 ma Output Output 0 1 v Channel 1 Output 0 1 v Channel 2 BJOINj OJNIJIBGJOQ OJo D Q _ A O1 op Span Solenoid Return Span Solenoid Hot 18 Range 3 Contact 19 Range 3 Contact 20 Alarm 3 C Contact 21 Range 1 Contact 22 Range 2 Contact 23 Output 0 1 v Channel 2 24 Output 0 1 v Channel 1 25 26 27 28 Alarm 1 C Contact 29 N W Teledyne Analytical Instruments 23 30 Installation 31 32 Exhaust Solenoid Hot 33 Sample Solenoid Hot 34 Range 4 Contact not used 35 Range 4 Contact not used 36 Alarm 3 NC Contact 37 Alarm 3 NO Contact 38
24. ENU STRUCTURE section to fully understand navigation and data entry 4 4 3 1 ARROW KEYS Pressing the ARROW KEYS select menus and modifies values 1 Inthe ANALYSIS SCREEN the ARROW KEYS cause entry into the MAIN MENU 6 When the selected option is a function on the MAIN MENU or any SUB MENU screen the ARROW KEYS move to the next lower or upper menu 7 Ifthe selected option isa MODIFIABLE ITEM value is flashing The ARROW KEYS increment or decrement numeric values or toggle ON OFF YES NO or ENABLE DISABLE type values 4 4 3 2 ENTER The ENTER key is used in several context sensitive ways 2 When showing the THC analysis mode the ENTER key toggles the LINE 2 display LINE 2 display mode 1 data Current analysis mode Teledyne Analytical Instruments 32 Operation Dynamic real time FID input level Time spent in mode Range Activity indicator LINE 2 display mode 2 data Current analysis mode Analysis TOTAL AREA from most recent pass of current mode Time spent in mode Range Activity Indicator 3 When the selected option is a function on the MAIN MENU or any SUB MENU screen the function name appears with an arrow next to it In some cases the item in the menu is the parent of another SUB MENU in other cases the item in the menu is the parent of a MODIFIABLE ITEM 8 Ifthe selected option isa MODIFIABLE ITEM the ARROW KEYS are used to modify the value of the item A modifiable item
25. HE ORDER GIVEN BEFORE SERVICING BEGINS Switch off the power to the Analyzer and remove the main line power cord from the Analyzer Remove all external voltages from the connections to the alarm contacts Wait one minute Discharge the anode supply voltage a Connect one end of an insulated to 1000 VDC or more clip lead to Analyzer chassis ground the standoff for the upper right corner of the mother PCB Put one end of a 500V rated 1000 ohm resistor in the other end of the clip lead Check the voltage between chassis ground the standoff for the upper right corner of the mother PCB and the top side of R2 at PCB number B74671 It should be between SVDC and 5VDC If is in that range the inaccessible hazardous voltage removal procedure is completed if not repeat steps 4 a and 4 b If it is absolutely necessary to work inside the instrument with power on use the ONE HAND RULE Work with one hand only Keep the other hand free without contacting any other object This reduces the possibility of a ground path through the body in case of accidental contact with hazardous voltages WARNING THIS INSTRUMENT IS DESIGNED TO BE OPERATED IN A NONHAZARDOUS AREA THE ANALYZER USES HYDROGEN GAS AND OR OTHER COMBUSTIBLE GASES IN ITS OPERATION THIS EQUIPMENT IF NOT USED AND MAINTAINED PROPERLY CAN BE AN EXPLOSION HAZARD THE ANALYZER Teledyne Analytical Instruments v Series 4030 CAUTION A DEPEND
26. ING ON THE APPLICATION MAY ALSO USE TOXIC GASES IT IS THEREFORE THE CUSTOMER S RESPONSIBILITY TO ENSURE THAT PROPER TRAINING AND UNDERSTANDING OF THE PRINCIPLES OF OPERATION OF THIS EQUIPMENT ARE UNDERSTOOD BY THE USER SINCE THE USE OF THIS INSTRUMENT IS BEYOND THE CONTROL OF TELEDYNE NO RESPONSIBILITY BY TELEDYNE ITS AFFILIATES AND AGENTS FOR DAMAGE OR INJURY RESULTING FROM MISUSE OR NEGLECT OF THIS INSTRUMENT IS IMPLIED OR ASSUMED MISUSE OF THIS PRODUCT IN ANY MANNER TAMPERING WITH ITS COMPONENTS OR UNAUTHORIZED SUBSTITUTION OF ANY COMPONENT MAY ADVERSELY AFFECT THE SAFETY OF THIS INSTRUMENT WHEN OPERATING THIS INSTRUMENT THE DOORS MUST BE CLOSED AND ALL COVERS SECURELY FASTENED THE GAUGES MUST BE IN PROPER WORKING ORDER DO NOT OVERPRESSURIZE THE SYSTEM READ THIS MANUAL BEFORE OPERATING THE INSTRUMENT AND ADHERE TO ALL WARNINGS INCLUDED IN THIS MANUAL W Teledyne Analytical Instruments vi Introduction Introduction A mem Teledyne Analytical Instruments Series 4030 Total Hydrocarbon THC Analyzer is designed to measure the quantity of hydrocarbons present in a heated sample gas such as gaseous mixtures or ambient air in various industrial applications The Analyzer is a microprocessor controlled digital instrument based on Teledyne s highly successful Model 402R series Total Hydrocarbon Analyzer coupled with carrier gas a switching valve and a sample draw pump optional This allows for the sample into the
27. ION AND FAILURE TO DETECT LOW CONCENTRATIONS OF HYDROCARBONS AIR USE ULTRA ZERO GRADE AIR WITH THC LESS THAN 0 1 PPM DO NOT USE OIL PUMPED AIR UNDER ANY CIRCUMSTANCES FUEL USE ULTRA HIGH PURITY UHP GRADE HYDROGEN WITH THC LESS THAN 0 5 PPM CARRIER GAS USE ULTRA HIGH PURITY GRADE NITROGEN GAS WITH THC LESS THAN 0 1 PPM 3 3 5 2 EFFLUENT All the gases introduced into the detection cell vent from one fitting at the rear of the analyzer TAI recommends that the cell be permitted to vent directly to the atmosphere wherever possible If a vent line is required the installation must include a drop out pot to collect the water that is formed by the burning of the hydrogen fuel The vent line must be constructed so that water and dirt cannot collect in it 3 3 5 3 SAMPLE BYPASS VENT The sample bypassed by the back pressure regulation system vents from a separate port at the rear of the analyzer If a vent line is required it must be installed so that water and dirt cannot accumulate in it 3 3 5 4 FUEL AND AIR CONNECTIONS The fuel used to provide combustion should be Hydrogen gas zero quality with certified THC of less than 0 5 ppm and a pressure of 30 psig The compressed air ultra zero gas quality with THC less than 0 1 ppm should be used at a controlled pressure of 30 psig Connect the fuel and air sources to the instrument according to the gas connection diagram included at the back of this manual Teledyne Anal
28. Series 4030 INSTRUCTION OPERATING AND MAINTENANCE MANUAL FOR SERIES 4080 HEATED THC TN FLOW L CONTROL FLAME OUT O FUEL CARRIER SAMPLE FLOW FUEL CARRIER RIES N B S x 4030 SERI TOTAL HYDROCARBON HEATED ANALYZER SPAN SAMPLE TEMP GAUGE SPAN GAS BYPASS FLOW R TELEDYNE ANALYTICAL INSTRUMENTS DANGER Toxic and or flammable gases or liquids may be present in this monitoring system Personal protective equipment may be required when servicing this instrument Hazardous voltages exist on certain components internally which may persist for a time even after the power is turned off and disconnected Only authorized personnel should conduct maintenance and or servicing Before conducting any maintenance or servicing consult with authorized supervisor manager P N M77216 ECO XX XXXX DATE 12 13 05 W Teledyne Analytical Instruments Series 4030 Copyright 2004 Teledyne Analytical Instruments All Rights Reserved No part of this manual may be reproduced transmitted transcribed stored in a retrieval system or translated into any other language or computer language in whole or in part in any form or by any means whether it be electronic mechanical magnetic optical manual or otherwise without the prior written consent of Teledyne Analytical Instruments 16830 Chestnut Street City of Industry CA 91749 1580 Warranty This equip
29. Teledyne Analytical Instruments 54
30. YES in the initial menu for the respective phase 4 4 11 The Alarms Function The Model 4030 is equipped with two alarms and a system failure alarm relay Each alarm relay has a set of form C contacts rated for 3 amperes resistive load at 250 VAC See Figure in Chapter 3 Installation and or the Interconnection Diagram included at the back of this manual for relay terminal connections The alarm relay contacts are accessible to the user from the 50 pin Equipment Interface connector The system failure alarm has a fixed configuration described in Chapter 3 Installation The concentration alarms can be configured from the ALARM function screen as follows gt AL 1 DEFEATED AL 1 HIGH AL 1 NON FAILSAFE AL 1 NON LATCHING Teledyne Analytical Instruments 47 Operation AL 1 20 00 ppb AL 1 SOURCE THC AL 2 ACTIVE AL 2 LOW AL 2 FAILSAFE AL 2 LATCHING AL 2 50 00 ppb AL 2 SOURCE SMP Note For the purpose of example Alarm 2 has been set differently than Alarm 1 Note An alarm in alarm condition is signaling that action must be taken such as correcting the alarm or the analysis concentration If an active not defeated alarm has been set to HIGH at 20 0 ppb and the analysis concentration is above that level then the alarm condition is occurring DEFEATED If an alarm is defeated its relay is de energized regardless of failsafe condition A defeated alarm does not rea
31. ble 3 Choose auto ranging or select a fixed range of analysis 4 Set alarm set points and modes of alarm operation 5 Calibrate analog output select analog output source 2 Routine operation 1 Calibrate the instrument Procedures for accessing and or changing parameters as well as analyzer operation are detailed in the sections to follow In general the sequence of menus available on screen follows a logical course for setup and operation It is not required however to follow this sequential path The user could for instance go directly to set an analysis range and then program an offset to the current output for matching a range on the user s recording device The only exception to this is when the instrument is powered up It will go through a warm up period followed by a diagnostic self test routine Teledyne Analytical Instruments 30 zs s LStiOn 4 4 1 Default Parameters The versatilitv of this analvzer usuallv results in significant changes being made to parameters over the course of time to better suit a particular application Occasionally processes change requiring alteration to alarms ranges etc At some time it may be beneficial to reset the analyzer to the default conditions as it was when shipped from the factory Below is a listing of the default parameters used in configuring your instrument Range A pplication Range Alarms Auto Span Timing THC Span Password Analog Outp
32. ct to a transition over its trip point in either direction HIGH If an alarm is set as HIGH it will not create a new alarm condition see latching if the analysis concentration is below the trip point if the analysis concentration is above the trip point then an alarm condition will be created or maintained FAILSAFE A non defeated alarm that is in FAILSAFE mode energizes an alarm relay in a non alarm condition and de energizes an alarm relay in an alarm condition Note Failsafe condition of an alarm is in software This is not related to relays that have both normally open and normally closed terminals LATCHING The latching property configures the alarm such that the user must manually relieve the alarm condition even though the concentration no longer violates the trip point of the alarm So if an alarm is NON LATCHING and the analysis concentration temporarily drifts above the trip point of a HIGH alarm the alarm condition occurs Teledyne Analytical Instruments 48 Operation only during the time the concentration is above the trip point If that alarm were LATCHING the alarm condition would persist even though the concentration is no longer above the trip point until the user released it RELEASING A LATCHED ALARM When alarm conditions are present the main analysis screen will have one of the following messages AL1 AL 2 AL12 Pressing ESCAPE in the main analysis screen will release a latched alarm
33. d below The Analyzer consists of aSAMPLE CHAMBER containing the 10 port switching valve and 2 sample loops A sample filter with replaceable filter cartridge is also included inside the Sample Chamber The Analyzer also consists of an FID chamber containing the Flame pressure regulators pressure gauges and flow restrictors 2 2 1 Input Porting The Analyzer is equipped with ports for the introduction of air fuel carrier gas and sample gas It is imperative that these gases are supplied at constant pressures using two stage stainless steel diaphragm gas regulators The recommended pressure range is 30 to 60 psig Teledyne Analytical Instruments 10 Introduction 2 2 2 Gas Flow Control System The Piping diagram is in the rear of this manual A 10 port switching valve is used to control and direct gas flows to the FID detector The fixed volume sample loop ensures the same volume of sample injection in the Analyzer every cycle 2 2 3 Fuel and Blanket Air Systems Stable flow is achieved by maintaining a constant pressure across restrictors upstream from the cell Each system incorporates an adjustable pressure regulator pressure gauge and restrictor A flame out light is included to indicate when the flame fails A fuel shut off solenoid valve mounted on the line that supplies fuel stops the fuel flow in case of flame failure This valve is located in line with the fuel port 2 2 4 Flame lonization Detection Cell
34. dard power supply requires 110 VAC 50 60 Hz or 220 VAC 50 60 Hz optional power 3 3 3 2 FUSE INSTALLATION The fuse block at the right of the power cord receptacle accepts US or European size fuses A jumper replaces the fuse in whichever fuse receptacle is not used 3 3 3 3 50 PIN EQUIPMENT INTERFACE CONNECTOR Figure 3 2 shows the pin layout of the Equipment Interface connector The arrangement is shown as seen when the viewer faces the rear panel of the analyzer The pin numbers for each input output function are given where each function is described in the paragraphs below UT ee eee Figure 3 2 Equipment Interface Connector Pin Arrangement 3 3 3 4 ANALOG OUTPUT There are four DC output signal pins two pins per output For polarity see Table 3 1 The outputs are 0 1 VDC 0 1 VDC 4 20mA DC and 4 20mA DC The Ist and 3 outputs 0 1 VDC and 4 20mA DC operate analogously as do the 2 and 4 outputs 0 1 VDC and 4 20mA DC Teledyne Analytical Instruments 19 Installation Both the first and third set of outputs as well as the second and fourth set of outputs may be set to any of the following functions THC Total hydrocarbon as measured in the first phase of detection The output is the percentage of the selected range SMP An alternate measurement that occurs during the second phase of detection The output represents the percentage of the selected range WAVE Analogous to th
35. e continuous output of the FID RID Indicates the selected range Low Range is at 1 5 of maximum output Mid Range is at 1 2 of maximum output High Range is 4 5 of maximum output Table 3 1 Analog Output Connections Pin D ON Nn A Q 24 Function Channel 2 4 20 mA floating Channel 2 4 20 mA floating Channel 1 4 20 mA floating Channel 1 4 20 mA floating Channel 2 0 1 VDC Channel 2 0 1 VDC Channel 1 0 1 VDC Channel 1 negative ground Teledyne Analytical Instruments 20 Installation 3 3 3 5 ALARM RELAYS The nine alarm circuit connector pins connect to the internal alarm relay contacts Each set of three pins provides one set of Form C relay contacts Each relay has both normally open and normally closed contact connections The contact connections are shown in Table 3 4 They are capable of switching up to 3 amperes at 250 VAC into a resistive load The connectors are Threshold Alarm 1 Can be configured as high actuates when concentration is above threshold or low actuates when concentration is below threshold Can be configured as failsafe or non failsafe Configured as latching or non latching Can be configured out defeated Threshold Alarm 2 Can be configured as high actuates when concentration is above threshold or low actuates when concentration is below threshold System Alarm Actuates when power is removed from analyzer It is triggered if 4030 fai
36. e enclosure Refer to the system analyzer outline drawings for dimensions Note To completely slide the Model 4030 Analyzer out of the enclosure pull Analyzer out until it stops and then push down on the release levers found almost at the end of the sliders both sides at the same time W Teledyne Analytical Instruments 15 Installation Regardless of configuration the analyzer system must be installed on a level surface with sufficient space allocated on either side for personnel and test equipment access Subject to the foregoing the Analyzer system should be placed as close to the sample point as is possible All pertinent dimensions connecting points and piping details can be found in the drawings section as part of the outline input output and piping diagrams These drawings are specific to the instrument or system to which the manual applies 3 3 User Connections All user connections are made on the rear panel Consult the input output and outline diagrams in the drawing section of the manual Not all the features displayed may be present in your system Refer to any Addenda for additional information that may apply to your instrument 3 3 1 Electrical Power Connections The standard analyzer requires a supply of 100 125VAC single phase power Power connections are made at the rear panel of the unit Refer to the input output diagram for more information The electrical power service must include a high quality grou
37. em Self Diagnostic Test The Model 4030 has a built in self diagnostic testing routine Preprogramming signals are sent through the power supply output board preamp board and sensor circuit The return signal is analyzed and at the end of the test the status of each function is displayed on the screen either as OK or BAD If any of the functions fail the System Alarm is tripped Note The self diagnostics are run automatically by the analyzer whenever the instrument is turned on but the test can also be run by the operator at will Note The self diagnostics will interrupt analysis temporarily To initiate a self test lt A V gt From the MAIN MENU scroll to the SELF TEST function lt Enter gt Activate the SELF TEST function by pressing lt Enter gt This brings up the SELF TEST initialization screen BeginSelf Test ENTER Yes ESCAPE NO W Teledyne Analytical Instruments 45 zs EStiOn lt Enter or Escape gt Start the diagnostic testing routine by pressing lt Enter gt or cancel out by pressing lt Escape gt If you pressed lt Enter gt the self test routine will begin and after a few moments the results will appear onscreen The module is functioning properly if it is followed by OK otherwise it is followed by BAD In this case please contact TAI Customer Service for an explanation of the problem To return the analyzer to the MAIN MENU press lt Enter gt after the results screen If you
38. five times there will be a message that reports this and the flame can be manually ignited by pressing simultaneously the Up and Down key W Teledyne Analytical Instruments 14 Installation Installation of the Series 4030 Analyzer includes 1 Unpacking Mounting 2 3 Gas connections 4 Electrical connections 5 Testing the system 3 1 Unpacking the Analyzer Although the Analyzer is shipped with all the materials you need to install and prepare the system for operation Carefully unpack the Analyzer and inspect it for damage Immediately report any damage or shortages to the shipping agent 3 2 Mounting the Analyzer The Series 4030 and the Sample Selector Unit are general purpose units and as such are designed with non sealed enclosures They must be installed in an area where the ambient temperature is not permitted to drop below 40 F nor rise above 100 F In areas outside these temperatures auxiliary heating cooling must be supplied The 4030 enclosure is oil and dust resistant and although it is designed to resist moisture it should NOT be considered completely watertight Mounting to walls or racks must be made securely Avoid locations that are subject to extreme vibration and sway Sufficient space must be provided around the analyzers to accommodate the necessary electrical conduit and plumbing connections The front panel must be allowed to be pulled out for possible service access to all components of th
39. ge reads the recommended pressure of 3 5 psig Note Adjust fuel settings only when the red LED flame failure light is off IN FLOW KL CONTROL FLAME OUT O 75 TELEDYNE ANALYTICAL INSTRUMENTS FUEL CARRIER f j SAMPLE PR A FLOW FUEL CARRIER 4030 SERIES S N a TOTAL HVDROCARBON HEATED ANALVZER 4 TELEDYNE ANALYTICAL INSTRUMENTS C Figure 4 1 Front Panel View of Regulator and Gages 4 3 Flame Ignition Observe that after warm up count down timer reaches zero timer to preheat the sensor the amber heater lamp is blinking indicating that Teledyne Analytical Instruments 28 zs EStiOn the temperature controller is maintaining the temperature set point and the red flame failure lamp is on See Figure 4 1 The Series 4030 will automaticallv attempt a flame ignition sequence following the warm up period which has been preset at the factorv If the ignition process fails the instrument will attempt to ignite the flame 4 more times If it continues to fail after the fifth attempt a flame failure message will appear on the display If this occurs refer to Section 4 3 1 4 3 1 Verification of the Flame Guard Circuit The operation of the flame guard circuit has been checked at the factory but should be re verified during start up Use the following procedure after ignition of the flame has been achieved 1 Turn off the fuel at the supply cylinder 2
40. larm 1 has been triggered AL 12 means both alarms have been triggered If in Span calibration Alarm display is replaced with the message SPAN LINE 2 display mode 1 Current analysis mode Dynamic real time FID input level Time spent in mode Range Activity indicator LINE 2 display mode 2 Current analysis mode Analysis TOTAL AREA from most recent pass of current mode identified by the units vS volt Seconds the alternate mode TOTAL AREA is shown while the ESCAPE key is held down Time spent in mode Range Activity Indicator 10 The MAIN MENU and SUB MENU screens have a flashing arrow on the left side indicating which item is being pointed to Teledyne Analytical Instruments 34 Operation 11 MODIFIABLE ITEM screens have a flashing value somewhere in the line 4 4 4 1 MAIN MENUS The MAIN MENU consists of 13 functions you can use to customize and check the operation of the analyzer They are listed here with brief descriptions 1 10 11 13 AUTO CAL Used to define and or start an automatic calibration sequence AUTOCAL is not available for standard configurations of the 4030 GAIN Used to change the amplification of the incoming signal This is factory set and should not change PASSWORD Used to establish password protection or change the existing password LOGOUT Logging out prevents unauthorized tampering with the analyzer settings MODEL Displa
41. ls to ignite after five times The System Alarm may be reset by selecting the STANDBY function in the menu to send to sleep mode then press the ENTER or ESCAPE key to restart the analyzer However if the condition that caused the 4030 to fail ignition is not remedied the 4030 will likely fail to ignite again and the System Alarm will be re triggered Further detail on flame ignition failure can be found in Chapter 4 Section 4 3 1 Teledyne Analytical Instruments 21 Installation Table 3 2 Alarm Relay Contact Pins Pin 45 28 46 42 44 43 36 20 37 Contact Threshold Alarm 1 normally closed contact Threshold Alarm 1 moving contact Threshold Alarm 1 normally open contact Threshold Alarm 2 normally closed contact Threshold Alarm 2 moving contact Threshold Alarm 2 normally open contact System Alarm normally closed contact System Alarm moving contact System Alarm normally open contact 3 3 3 6 RANGE ID RELAYS There are three dedicated Range ID relay contacts They are assigned to relays in ascending order Low range is assigned to Range 1 ID Medium range is assigned to Range 2 ID and High range is assigned to Range 3 ID Table 3 6 lists the pin connections Contacts are normally open and they close when 4040 switches to that particular range Table 3 3 Range ID Relay Connections Pin 21 38 22 39 19 18 34 35 Function Range 1 ID Contact Range 1 ID Contact Range 2 ID Contact Range 2 I
42. maintained as the current range of operation In Auto Range select the software determines the smallest range whose limit is larger than the analysis concentration AUTO RANGE SOURCE The automatic selection of range can be set to select according to the THC SMP or AVG concentration RANGE LIMITS Ranges may be set as low as 2 0 ppb and as high as 9999 99 ppm Range 3 can only be set at a value greater than Range 2 Range 2 can only be set at a value greater than Range 1 4 4 13 Changing Stream CHANGE STREAM is not available for standard configurations of the 4030 Affects the relay on the rear panel that controls which gas is allowed to flow to the column and detector When the instrument has electronically controlled calibration valves the gas stream can be switched here You can set the incoming gas source to span sample or zero gas which is nothing more than a 3 source of gas without entering the calibration mode in order to check instrument response During a span calibration the span stream is activated After a span calibration the stream reverts to whatever was set before the span This value is not remembered if the power in cycled on the unit the analyzer will default to the analyze stream W Teledyne Analytical Instruments 50 zs EStiOn 4 4 14 Analog output Adjustment The software in this instrument provides a wav to enter to manage the analog output of the analvzer FOR ANALOG CHANNEL 1 ONLY To
43. ment is sold subject to the mutual agreement that it is warranted by us free from defects of material and of construction and that our liability shall be limited to replacing or repairing at our factory without charge except for transportation or at customer plant at our option any material or construction in which defects become apparent within one year from the date of shipment except in cases where quotations or acknowledgements provide for a shorter period Components manufactured by others bear the warranty of their manufacturer This warranty does not cover defects caused by wear accident misuse neglect or repairs other than those performed by Teledyne or an authorized service center We assume no liability for direct or indirect damages of any kind and the purchaser by the acceptance of the equipment will assume all liability for any damage which may result from its use or misuse We reserve the right to employ any suitable material in the manufacture of our apparatus and to make any alterations in the dimensions shape or weight of any parts in so far as such alterations do not adversely affect our warranty Important Notice This instrument provides measurement readings to its user and serves as a tool by which valuable data can be gathered The information provided by the instrument may assist the user in eliminating potential hazards caused by his process however it is essential that all personnel involved in the use of the ins
44. nd wire A high quality round wire is a wire that has zero potential difference when measured to the power line neutral If you have the 220 VAC option you will require 220 or 240 VAC 50 60 Hz power Check the analyzer input output diagram power schematic outline and wiring diagrams for incoming power specifications and connecting points CAUTION PRIMARY POWER TO THE SYSTEM SHOULD NOT 1 BE SUPPLIED UNTIL ALL CUSTOMERS WIRING IS INSPECTED PROPERLV BV START UP PERSONNEL 3 3 2 Gas Connections The analvzer gas connection diagram identifies the various gas connection points as to function and location Figure 3 1 shows the gas connection points for Model 4030 and SAMPLE SELECTOR MODULE optional W Teledyne Analytical Instruments 16 Installation FROM SAMPLE SELECTOR MODULE 4030 ANALYZER REAR VIEW Na x e GC ce TO 4030 ANALYZER VENT HEATED TRACE LINE USER PROVIDED SAMPLE IN HEATED TRACE LINE SPAN GAS IN USER PROVIDED Figure 3 1 Gas Connections Gas connections to the instrument are made at the 1 8 or 1 4 stainless steel tube fittings provided on the rear panel Note that the Purge and Sensor Vent fittings are 1 4 while all other gas connections are 1 8 If the Sample line is heat traced to avoid condensation the User must ensure that a clean 2 micron or better filter and heated sample maintained at a constant temperature not exceeding 120 C is delive
45. ortant We have provided many important safety messages in this manual Please read these messages carefully A safety message alerts you to potential hazards that could hurt you or others Each safety message is associated with a safety alert symbol These symbols are found in the manual and inside the instrument The definition of these symbols is described below gt e PE Symbol e GENERAL WARNING CAUTION Refer to the instructions for details on the specific danger These cautions warn of specific procedures which if not followed could cause bodily Injury and or damage the instrument CAUTION HoT SURFACE WARNING This warning is specific to heated components within the instrument Failure to heed the warning could result in serious burns to skin and underlying tissue WARNING ELECTRICAL SHOCK HAZARD Dangerous voltages appear within this instrument This warning is specific to an electrical hazard existing at or nearby the component or procedure under discussion Failure to heed this warning could result in injury and or death from electrocution Technician Symbol All operations marked with this symbol are to be performed by qualified maintenance personnel only NOTE Additional information and comments regarding a specific component or procedure are highlighted in the form of a note STAND BY This symbol indicates that the instrument is on Stand by but circuits are active Teledyne Analytical Instruments i
46. pressed lt Escape gt you will be returned to the Analyze Mode 4 4 10 Span The SPAN function is used to calibrate the analyzer The analyzer is calibrated using span gas as described in Section 4 1 This section assumes that this gas has been properly connected and the line checked for leaks To initiate a pan calibration lt A V gt lt Enter gt From the MAIN MENU scroll down to the SPAN function Press lt Enter gt to activate the SPAN function gt THC SMP THC SMP Span YES Span NO Sp 8 00 ppm Sp 0 00 ppm Span Begin Teledyne Analytical Instruments 46 Operation The first line determines whether a span calculation will be performed for THC The second line determines whether a span calculation will be preformed for SMP The third line allows the user to modify the span target value for THC calibration The fourth line allows the user to modify the span target value for SMP The last line commences the span after the following query Begin Span ENTER YES ESCAPE NO Pressing lt Enter gt enters the SPAN mode in the SMP phase first The first pass in the SMP phase only purges the sample gas from the column no span calculation is performed this time around Then the THC is span calibrated followed by the second pass of the SMP mode where the span calculation is performed The 4030 goes through all of these phases but span values are only adjusted if the user selected
47. red to the Sample Selector Module and the connection between the Sample Selector Module and the Model 4030 is similarly heat traced The Sample Selector Unit contains provisions to accept tubing diameter in the range of 1 25 to 1 50 inches typically the O D of the heat traced lines It is recommended that all gas tubing leading to the connections on the back of the analyzer be of the coiled type This will facilitate sliding the unit out of the case without disconnecting the gas supply to the analyzer Teledyne Analytical Instruments 17 Installation Before tubing is connected to the system it must be decontaminated to rid it of hydrocarbon deposits Using a small torch heat each length of tubing while passing nitrogen through it until it glows red Begin at the nitrogen source end and proceed down the length of the tube chasing the red glow and hydrocarbon deposits down to the open end of the tube Cap tubing while not in use with suitable non contaminating caps All sample calibration and supporting gas lines which deliver gas to the analyzer must be decontaminated before connection vent lines do not When connecting the various gas lines to the system be absolutely certain that no dead ends are left that is no unused branch lines should be left capped off where pockets might form of material that is not representative of the current contents of the line or which might keep contaminants from being p
48. s de energized the coil is connected to the 260 volt DC terminal of the anode flame guard power supply PC board In this configuration the necessary potential difference is established between the coil anode and collector to promote ionization of the burned hydrocarbons The coil functions as the high voltage anode in all three range positions of the selector switch The thermistor acts as the sensor in the flame guard circuit Its ambient temperature resistance is in the 100 K ohms region When the flame is ignited its resistance is reduced by a factor of 100 The thermistor is coupled to a semiconductor control circuit on the anode flame guard power supply PC board which will be described in a following section The cell electrodes of both the anode igniter and flame guard thermistor are connected to the electronics chassis by means of a plug in cable Teledyne Analytical Instruments 12 Introduction Figure 2 1 Flame Ionization Cell The electrode section of the cell may be removed for inspection by turning off the power disconnecting the electrode lead plug and removing the screws which retain the electrode assembly in the sensor body 2 3 1 Electrometer Amplifier The collector cable is coupled directly to a coaxial fitting located on the electrometer amplifier PC board The PC board is located on the side panel next to but outside of the isothermal chamber See Figure 2
49. trument or its interface be properly trained in the process being measured as well as all instrumentation related to it The safety of personnel is ultimately the responsibility of those who control process conditions While this instrument may be able to provide early warning of imminent danger it has no control over process conditions and it can be misused In particular any alarm or control systems installed must be tested and understood both as to how they operate and as to how they can be defeated Any safeguards required such as locks labels or redundancy must be provided by the user or specifically requested of Teledyne at the time the order is placed Therefore the purchaser must be aware of the hazardous process conditions The purchaser is responsible for the training of personnel for providing hazard warning methods and instrumentation per the appropriate standards and for ensuring that hazard warning devices and instrumentation are maintained and operated properly Teledyne Analytical Instruments the manufacturer of this instrument cannot accept responsibility for conditions beyond its knowledge and control No statement expressed or implied by this document or any information disseminated by the manufacturer or its agents is to be construed as a warranty of adequate safety control under the user s process conditions W Teledyne Analytical Instruments Series 4030 Your safety and the safety of others are very imp
50. tter or if on the first letter returns to the CHANGE PASSWORD menu Note If you log off the system using the LOGOUT function in the MAIN MENU you will now be required to reenter the password to gain access to most menus 4 4 7 Logging Out The LOGOUT function provides a convenient means of leaving the analyzer in a password protected mode without having to shut the instrument off By entering LOGOUT you effectively log off the instrument leaving the system parameters protected until the password is reentered The system will continue analysis however To log out lt AV gt From the MAIN MENU scroll to field of LOGOUT function lt Enter gt Press lt Enter gt to logout The screen will display the message Restrict Access ENTER Yes ESCAPE NO Teledyne Analytical Instruments 44 zs EStiOn Pressing lt Enter gt will logout the current user and protect the system from unauthorized changes to parameters If user has LOGGED OUT then only the following SUB MENU procedures may be executed 17 PASSWORD 18 LOGOUT which only repeats the logout 19 MODEL Note however that the instrument can still be used for analysis without entering the password To defeat security the password must be entered 4 4 8 The Model Screen The MODEL screen displays the model and software version information It is accessed via the MAIN MENU by scrolling A W to MODEL and pressing lt Enter gt 4 4 9 Syst
51. urged out of the system CAUTION THE GASES USED MUST BE OF THE HIGHEST QUALITY ULTRA ZERO GRADES AS SHOWN BELOW FAILURE TO DO SO WILL RESULT IN CONTAMINATION AND FAILURE TO DETECT LOW CONCENTRATIONS OF HYDROCARBONS AIR USE ULTRA ZERO GRADE WATER PUMPED AIR WITH THC LESS THAN 0 1 PPM FUEL USE ULTRA HIGH PURITY UHP GRADE HYDROGEN GAS 100 WITH THC LESS THAN 0 5 PPM CARRIER GAS USE ULTRA HIGH PURITY GRADE NITROGEN GAS WITH THC LESS THAN 0 1 PPM 3 3 3 Electrical Connections Figure 3 1 shows the Series 4030 rear panel There are connections for power digital communications and both digital and analog concentration output For safe connections no uninsulated wiring should be able to come in contact with fingers tools or clothing during normal operation CAUTION USE SHIELDED CABLES ALSO USE PLUGS THAT PROVIDE EXCELLENT EMI RFI PROTECTION THE PLUG CASE MUST BE CONNECTED TO THE CABLE SHIELD AND IT MUST BE TIGHTLY FASTENED TO Teledyne Analytical Instruments 18 Installation THE ANALYZER WITH ITS FASTENING SCREWS ULTIMATELY IT IS THE INSTALLER WHO ENSURES THAT THE CONNECTIONS PROVIDE ADEQUATE EMI RFI SIELDING 3 3 3 1 PRIMARY INPUT POWER The power cord receptacle and fuse block are located in the same assembly Insert the power cord into the power cord receptacle CAUTION POWERIS APPLIED TO THE INSTRUMENT S CIRCUITRY AS LONG AS THE INSTRUMENT IS AN CONNECTED TO THE POWER SOURCE The stan
52. uts Refer to the data sheet on the first page of this manual Auto Enabled AL1 20ppm AL2 50ppm HI NON FAILSAFE NON LATCHING THC levels Not available 8 ppm methane in air TAI Ch1 THC levels Ch2 Range ID 4 4 2 Style Conventions The following typeface conventions are used when referring to screen names key presses and screen readout Screens Key presses Arial 12 pt type in capital letters Example ANALYZE or MAIN screen or menu lt key gt The particular keystroke to enter is placed between lt and gt Example lt enter gt or lt escape gt or lt A gt UP key or lt Y gt DOWN key Only when the keystroke is to be entered will it be placed between the brackets If discussing a 4 Teledyne Analytical Instruments 31 s LTStiOn particular kev it will be tvped as text using all caps Example this is the ENTER kev Screen Modes Times New Roman 12 pt italic Example Analvsis Mode or Setup Mode Screen Readout Arial Narrow 12 pt bold Example AUTOCAL or Zeroin 12 days 4 4 3 Navigation and Data Entry Note All menus time out after 15 fifteen seconds elapse with no button presses the analyzer returns to the ANALYSIS SCREEN if parameters have been altered but not saved with the ENTER key the alterations are lost Navigation and Data Entry is possible using 2 ARROW KEYS the ENTER key and the ESCAPE key It is important to read and understand the M
53. ys Manufacturer Model and Software version of the instrument SELF TEST The instrument performs a self diagnostic routine to check the integrity of the power supply and output boards SPAN Set up and or start a span calibration ALARMS Used to set the alarm set points and determine whether each alarm will be active or defeated HI or LO acting and failsafe or not RANGE Used to set up three analysis ranges that can be switched automatically With auto ranging or used as individual fixed ranges ANALOG OUT ADJUST Adjust the analog output with offset and scaling for Channel 1 only CHANGE STREAM Not available 12 TIMING Low level application specific timing parameters Factory set Do not change these STANDBY Removes power to outputs and displays but maintains power to internal circuitry Any function can be selected at anytime Just scroll through the MAIN MENU with the DOWN UP keys to the appropriate function and Teledyne Analytical Instruments 35 ae ET amp ENTER it The analyzer will immediately start that function unless password restrictions have been assigned Password assignment is explained in Section 4 4 10 4 4 4 2 EXPANDED MENUS An exhaustive list of menu messages is provided as follows AUTOCAL AUTO SPAN NOT AVAILABLE AUTOCAL is not available for standard configurations of the 4030 PASSWORD Enter Password ITA TAS LE GAIN ADJUST GAIN 0
54. ytical Instruments 26 Operation Operation gt 4 1 Placing the System in Operation 1 Plug the power in the AC power inlet in the back of the Analyzer and the Sample Selector Unit 2 Allow at least 2 hours warm up heat up sensor amp sample system after making the air adjustment described below Warm up time is set by the software at the factory but may be overridden by pressing the lt ENTER gt key DO NOT attempt to ignite the flame during warm up countdown Condensation will occur 4 2 Activating the Support Gases 4 2 1 Air 1 Set the air tank regulator to 30 psig 2 Adjust the Analyzer Air regulator until the air pressure gauge reads the recommended air pressure of 9 psig After the air is flowing through the sensor and warm up time has been completed activate the following gases 4 2 2 Carrier Gas Set the Carrier gas tank regulator to 50 psig and adjust the Analyzer Sample regulator until its sample pressure gauge reads the recommended sample pressure of 9 5 psig 4 2 3 Span Gas The Span gas containing certified mixture of methane in air recommended range 6 to 8 ppm methane in zero grade air may be connected to the Span Manifold or the 14inch connection on the back of the Sample Selector Module Teledyne Analytical Instruments 27 Operation 4 2 4 Fuel 1 Open the main valve on the tank and set the fuel tank pressure regulator to 30 psig 3 Adjust the Fuel regulator until its pressure gau
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