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Teledyne 6400E User's Manual

1. 286 05037 RevA Warranty Repair Questionnaire Model 6400E Model 6400E Instruction Manual 05038 Rev A Appendix C Repair Questionnaire 6400E Customer Phone Mim TELEDYNE N INSTRUMENTS Advanced Pollution Instrumentation A Teledyne Technologies Company Contact Name Fax No Site Address Model 6400E Serial No 1 Are there any failure messages Firmware Revision 2 Please complete the following table note depending on options installed not all test parameters below will be available in your instrument PARAMETER RECORDED VALUE ACCEPTABLE VALUE RANGE PPB PPM N A STABIL PPB 1 PPB WITH ZERO AIR SAMP PRESS IN HG A AMBIENT 2 IN HG A SAMPLE FLOW CM3 MIN 650 10 PMT SIGNAL WITH 20 TO 150 mV ZERO AIR PMT SIGNAL AT mV 0 5000 mV SPAN GAS CONC PPB PPM 0 20000 PPB NORM PMT AT SPAN mV 0 5000 mV GAS CONC PPB PPM 0 20000 PPB UV LAMP mV 2000 TO 4000 mV LAMP RATIO mV 30 TO 120 STR LGT PPB lt 100 PPB ZERO AIR DARK PMT mV 50 TO 200 mV DARK LAMP mV 50 TO 200 mV SLOPE 1 0 0 3 OFFSET mv lt 250 mV HVPS V 400 900 RCELL TEMP ec 50 C 1 BOX TEMP AMBIENT 5 7 C 20 CONSTANT 125 TEMP 500C 1 ETEST mV 2000 mV 500 OTEST mv 2000 mV 1000 Values
2. 9 Starting Date 10 Disabling Enabling Data Channels 11 HOLDOFF Feature 1 3 Remote iDAS Configuration 6 12 Remote Operation of the Analyzer 6 12 1 Remote Operation Using the External Digital 12 1 1 Status Outputs ise 2 1 2 Control Inputs ee 6 12 2 Remote Operation Using the External Serial I O 6 12 2 1 Terminal Operating Modes 123 6 12 2 2 Help Commands in Terminal Mode n 3s 6 12 2 3 Command Syntax 6 12 2 4 Data Types 6 12 2 5 Status Reporting 6 12 2 6 Remote Access by Modem Ms 6 12 2 7 COM Port Password Security sssessesnssnrssrsesnenarenanransne 6 12 2 8 APICOM Remote Control Program B 6 12 3 Additional Communications Documentation 129 6 12 4 Using the 6400E with a Hessen Protocol Network 130 6 12 4 1 General Overview of Hessen nennen nnne eene nn 130 6 12 4 2 Hessen COMM Port Configuration esrssesrresensnireenasanennannnnaneannenannnsnnnennenanenneneannssrssnn 130 6 12 4 3 Activating Hessen Protocol 131 6 12 4 4 Selecting a Hessen Protocol Type 131 6 12 4 5 Setting The Hessen Protocol Response Mode A 132 6 12 4 6 Hessen Protocol Gas ae 5132 6 12 4 7 Setting Hessen Protocol Status 133 6 12 4 8 Instrument ID Code 135 7 CALIBRATION PROCEDURES x 137 7 1 Calibration Preparations
3. LED COLOR FUNCTION STATUS WHEN LIT STATUS WHEN UNLIT D1 RED 2 Watchdog circuit Cycles On Off every 3 seconds under control of the CPU Sample chamber D2 YELLOW RCELL heater HEATING NOT HEATING D3 D4 YELLOW Unused N A N A D5 YELLOW IZS heater option HEATING NOT HEATING D6 YELLOW Unused N A N A Valve open to Span Gas Valve open to Zero Gas D7 GREEN Zero Span Valve path normal state Valve open to sample gas Valve open to D8 GREEN Sample Cal Valve calibration gas path inlet on rear panel normal state D9 D10 GREEN Unused N A N A Dii GREEN UV Lamp Shutter Shutter open n Shutter closed D12 14 GREEN Unused N A N A As a Safety measure special circuitry on the Relay Board watches the status of LED D1 Should this LED ever stay ON or OFF for 30 seconds indicating that the CPU or TC bus has stopped functioning the Watchdog Circuit will automatically shut of all valves as well as turn off the UV Source s and all heaters The sample pump will still be running 194 04515 Rev B Model 6400E Instruction Manual Theory Of Operation 10 4 9 MOTHERBOARD This printed circuit assembly provides a multitude of functions including A D conversion digital input output PC 104 to translation temperature sensor signal processing and is a pass through for the RS 232 and RS 485 signals 10 4 9 1 A to D Conversion Analog signals such as the voltages received from the analyzer s
4. Exits to the main Data Acquisition PREV NEXT INS DEL EDIT PRNT EXIT menu SETUP XX NAME CONC1 SET SET EDIT PRINT Press SET key until SETUP XX PARAMETERS 2 lt SET SET gt EDIT PRINT EXIT YES will delete SETUP XX EDIT PARAMS DELETE DATA NO returns to ali data in that the previous entire channel YES NO menu and retains all data Edit Data Parameter Menu 3j SETUP XX 0 1 MODE AVG PREV NEXT INS DEL EDIT EXT Use to configure the functions for this Parameter Moves the display between available Parameters Exits to the main Data Acquisition menu Inserts a new Parameter before the currently displayed Parameter Deletes the Parameter currently displayed 110 6400E Rev B Model 6400E Instruction Manual Operating Instructions To configure the parameters for a specific data parameter press FROM THE EDIT DATA PARAMETER MENU see previous section SETUP 0 PARAM CONCt MODE AVG PREV NEXT INS DEL EDIT EXIT SETUP XX PARAMETERS CONC1 SET EDIT EXIT SETUP X X PARAMETERS CONC PREV NEXT ENTR EXIT Cycle through list of available Parameters SETUP XX SAMPLE MODE AVG SET SET EDIT EXT SETUP SAMPLE MODE AVG INST AVG MIN MAX ENT Press the key for the desired mode
5. comets MENU ID COM1 Select which COM port to configure COM2 SETUP XX COM1 MODE 0 Press SET until you reach COM1 BAUD RATE SET gt EDIT Use PREV and NEXT SETUPXX COM1 BAUD RATE 19200 Berio keys to move ignores between available SET SET gt EDIT the new baud rates setting 300 SETUPXX COM1 BAUD RATE 19200 1200 4800 ENTR key 9600 PREV NEXT ENTR EXIT accepts 19200 the new 38400 setting 57600 SET c AUD RATE 315200 SETUP XX OM1 BAUD RATE 9600 NEXT ON ENTR EXIT 100 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 10 10 COM PORT TESTING The serial ports can be tested for correct connection and output in the COMM menu This test sends a string of 256 w characters to the selected COM port While the test is running the red LED on the rear panel of the analyzer should flicker To initiate the test press the following key sequence Y SETUP X COMM VARS DIAG SECONDARY SETUP MENU Test runs automatically SAMPLE RANGE 509090PPB SO2sxXXX SETUP X x COMMUNICATIONS MENU Select which COM port to BATUR EXIT test SETUPXX MODE 0 1 8 ENTR see epe ar SETUP Y X PRIMARY SETUP MENU SETUP COMI BAUD 19200 ORG S RNGE PASS CLIK MO
6. Hour in 24 hour format 00 23 9I Hour in 12 hour format 01 12 j Day of year as decimal number 001 366 Am Month as decimal number 01 12 96M Minute as decimal number 00 59 9p A M P M indicator for 12 hour clock 95S Second as decimal number 00 59 Weekday as decimal number 0 6 Sunday is 0 Year without century as decimal number 00 99 95 Y Year with century as decimal number 9595 Percent sign 272 05036 Rev C 3 Model 6400E Instruction Manual APPENDIX A 2 Setup Variables For Serial 1 0 Revision SETUP VARIABLE NUMERIC DEFAULT UNITS VALUE VALUE RANGE DESCRIPTION FACTORY_OPT BitFlag 0 0 65535 Factory option flags Add values to combine flags 1 enable dilution factor 2 zero span valves installed 4 175 installed implies zero span valves installed 8 low span valve installed 16 display units in concentration field 32 enable software controlled maintenance mode 64 enable lamp power analog output 128 enable switch controlled maintenance mode 2048 enable Internet option 6400E 6400ES 3 6400EH 6400EF 5 Low span option 5 Must power cycle instrument for these options to fully take effect 9 0503
7. esee eene netten n nnn enne n 137 1 1 Required Equipment Supplies and Expendables 137 24 2 ZeFO Alii aaxdivedsovennvacdatcancdaansepasnavsrecedceates 137 1 3 Calibration Gas Standards amp 138 1 4 Permeation Tubes sin 138 1 5 Calibration Gas 138 1 6 Data Recording Devices 138 Manual Calibration i Manual Calibration sn 141 Manual Calibration with Zero Span Valves s Manual Calibration with IZS Option Manual Calibration Checks with Izs or Zero Span Valves Manual Calibration in DUAL or AUTO Reporting Range Modes 7 9 Calibration Quality 151 8 EPA PROTOCOL CALIBRATION 8 1 Calibration Requirements 8 1 1 Calibration of Equipment 153 8 1 2 Data Recording Device 155 8 1 3 Recommended Standards for Establishing Traceability 155 8 1 4 EPA Calibration Using Permeation Tubes 5 155 8 1 5 Calibration Frequency ccccsecssennnrcansseceonnrsnerettenesnaentaneensaamannonanvanraesneneeenataseanauinnngeeseeynin 155 8 1 6 Record Keeping 156 8 1 7 Summary of Quality Assurance Checks 156 8 2 Level 1 Calibrations versus Level 2 Checks 4157 8 3 ZERO and SPAN Checks s 158 8 3 1 Zero Span Check Procedures 158 8 4 Precisions Calibration Procedures and Checks B 4 1 Precision Calibration 6400E Rev B v Model 6400E Instruction Manual 8
8. ENTR accepts the new setting and returns to the previous menu SETUP XX CAL HOLD OFF ON EXIT ignores the new setting and returns to the previous menu Toggle key to turn HOLDOFF ON or OFF ON ENTR EXIT 6400E Rev B 117 Operating Instructions Model 6400E Instruction Manual 6 11 3 REMOTE IDAS CONFIGURATION Editing channels parameters and triggering events as described in this section is can be performed via the APICOM remote control program using the graphic interface similar to the example shown in Figure 6 15 Refer to the Section 6 12 for details on remote access to the 6400E analyzer Note M100E is equivalent to M6400E lt 200 DAS Configuration and Downloaded Data TE 1 60 ATIMER 100 Records Maximum 5 NXCNCI PPM AVG Set 0 0 Records EI NOCNCI PPM AVG Set 0 0 Records 1 IN2CNCI PPM AVG Set 0 0 Records f 1 STABIL PPM AVG Sel 0 0 Records o C CALDAT ATIMER 100 Records Maximum l CI NXSLP1 AVG Set 0 0 Records I NOSLP1 AVG Set 0 0 Records i EI NXZSC1 PPM AVG Set 0 0 Records i E NOZSC1 PPM AVG Set 0 0 Records E N2CNCI PPM AVG Set 0 0 Records C STABIL PPM AVG Set 0 0 Records Data Auto 00 08 Configuration 43 Get Config Send To Inst Load Conf Seve Conlig New Config i i i i Gk Dats
9. If a current meter is not available an alternative method for calibrating the current loop outputs is to connect a 250 Q 1 resistor across the current loop output Using a voltmeter connected across the resistor follow the procedure above but adjust the output to the following values Table 6 13 Current Loop Output Calibration with Resistor VOLTAGE FOR 2 20 MA VOLTAGE FOR 4 20 MA MEASURED ACROSS MEASURED ACROSS RESISTOR RESISTOR o 0 5 V 1 0 V 100 5 0 V 5 0 V 6400E Rev 77 Operating Instructions Model 6400E Instruction Manual 6 9 4 6 AIN Calibration This is the sub menu to conduct the analog input calibration This calibration should only be necessary after major repair such as a replacement of CPU motherboard or power supplies Activate the ANALOG I O CONFIGURATION MENU see Section 6 9 1 then press STARTING FROM ANALOG O CONFIGURATION MENU DIAG ANALOG O CONFIGURATION Exit at any time to return to the main PREV NEXT ENTR EXIT DIAG menu Continue pressing SET until DIAG AIO AIN CALIBRATED NO lt SET SET gt CAL Instrument calibrates DIAG AIO CALIBRATING A D ZERO CALIBRATING A D SPAN automatically Exit to return to the DIAG AIO AIN CALIBRATED YES SET SET gt CAL EXIT CONFIGURATION 78 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 9 5 OPTIC
10. PREV NEXT JUMP EXIT 0 EXT ZERO CAL OFF Di G VO EXIT 4x s to relum lothe SAMPLE display UV LAMP SIGNAL should be 20 mV PREY NEXT JUMP PRNT EXIT 11 5 13 PMT SENSOR The photo multiplier tube detects the light emitted by the UV excited fluorescence of SO It has a gain of about 500000 to 1000000 It is not possible to test the detector outside of the instrument in the field The best way to determine if the PMT is working properly is by using the optical test OTEST which is described in Section 6 9 5 The basic method to diagnose a PMT fault is to eliminate the other components using ETEST OTEST and specific tests for other sub assemblies 11 5 14 PMT PREAMPLIFIER BOARD To check the correct operation of the preamplifier board we suggest the technician carry out the electrical and optical tests described in 6 8 5 and 6 8 6 o Ifthe ETEST fails the preamplifier board may be faulty 04515 Rev B 231 TROUBLESHOOTING amp REPAIR Model 6400E Instruction Manual 11 5 15 PMT TEMPERATURE CONTROL PCA The TEC control printed circuit assembly is located on the sensor housing assembly under the slanted shroud next to the cooling fins and directly above the cooling fan If the red LED located on the top edge of this assembly is not glowing the control circuit is not receiving power e Check the analyzers power supply the Relay boards power distribution circuitry and the
11. Toggle keys to set SETUP SEQ 1 DISABLED SETUP 4 DELTA DAYS 1 a a betws NEXT MODE EXIT 0 2 ENTR EXIT procedures 1 367 SETUP SEQ 2 DISABLED SETUPC4 DELTA DAYS 2 PREV NEAT MODE EXIT SET SET EDIT EXIT X MODE DISABLED SETUPCA DELTA dace NEXT ENTR EXIT SET SET EDIT EXIT Toggle keys to sot SETUP MODE ZERO SETUP C DELTA TIME 0000 delay time for each lleration ir F zn of tho PREV NEXT EWTR EXIT 0 0 3 ENTR EDIT HH MM 0 24 00 SETUP MODE ZERO SPAN SETUP DELTA TIEM 00 30 PREY ENTR EXIT SET SET EDIT Exit Toggle keys to set duration tor each dteratian of tho sequance Set in Decimal minutos trom 01 600 BETUP C 4 CALIBRATE OFF SET SET EDIT EXIT Toggle key SETUPC4 CALIBRATE OFF betwoen Off ond ENTR EXIT SETUPC4 CALIBRATE ON SET SET EDIT EXIT SETUP 4 SEQ 2 ZERO SPAN 2 00 30 EXIT retums 19 the SETUP PREV NEXT SET N EXIT Menu MODE Detta Days With dynamic calibration turned on the state of the internal setup variables DYN_SPAN and DYN ZERO is set to ON and the instrument will reset the slope and offset values for the SO response each time the AutoCal program runs This continuous re adjustment of calibration parameters can often mask subtle fault conditions in the analyzer It is recommended that if dynamic calibration is enabled the analyzer s test functions s
12. 0 10 IZS temperature PID derivative coefficient 05036 Rev C 3 271 APPENDIX A 2 Setup Variables For Serial 1 0 Revision Model 6400E Instruction Manual NUMERIC DEFAULT SETUP VARIABLE UNITS VALUE VALUE RANGE DESCRIPTION HVPS_SET Volts 650 550 0 2000 High voltage power supply warning Warnings limits Set point is not used 400 900 400 700 DETECTOR LIMIT mv 1000 0 5000 UV lamp and PMT detector warning Warnings limits Set point is not used 600 4995 CONC LIN ENABLE ON OFF ON ON enables concentration linearization OFF disables it SERIAL_NUMBER 00000000 Unique serial number for instrument the allowed Enclose value in double quotes character set Up when setting from the RS 232 to 100 characters interface long DISP_INTENSITY HIGH HIGH MED LOW Front panel display intensity Enclose DIM value in double quotes when setting from the RS 232 interface I2C RESET ENABLE ON OFF ON TC bus automatic reset enable CLOCK FORMAT TIME Any character in Time of day clock format flags 5 the allowed Enclose value in double quotes when setting from the RS 232 character set Up to 100 characters long interface 95a Abbreviated weekday name 95b Abbreviated month name d Day of month as decimal number 01 31
13. Ifyou are at a anti ESD work bench lay the container down on the conductive work surface In either case wait several seconds 4 Place the item in the container 5 Sealthe container If using a bag fold the end over and fastening it with anti ESD tape Never use standard plastic adhesive tape as a sealer Folding the open end over isolates the component s inside from the effects of static fields Leaving the bag open or simply stapling it shut without folding it closed prevents the bag from forming a complete protective envelope around the device 6 Once you have arrived at your destination allow any surface charges that may have built up on the bag or bin during travel to dissipate e Connect your wrist strap to ground If you are at the instrument rack hold the bag in one hand while your wrist strap is connected to a ground point If you are at a anti ESD work bench lay the container down on the conductive work surface neither case wait several seconds 7 Open the container 04515 Rev B 257 A Primer on Electro Static Discharge Model 6400E Instruction Manual 12 4 2 4 Opening Shipments from and Packing Components for Return to Teledyne Instruments Customer Service Packing materials such as bubble pack and Styrofoam pellets are extremely efficient generators of static electric charges To prevent damage from ESD Teledyne Instruments ships all electronic components and assemblies
14. Table 6 27 RS 232 Communication Parameters for Hessen Protocol Parameter Standard Hessen Data Bits 8 7 Stop Bits 1i 2 Parity None Even Duplex Full Half To change the rest of the COMM port parameters and modes see Section 6 10 8 To change the baud rate of the 6400E s COMM ports see Section 6 10 9 NOTE Make sure that the communication parameters of the host computer are also properly set Also the instrument software has a 200 ms latency before it responds to commands issued by the host computer This latency should present no problems but you should be aware of it and not issue commands to the instrument too frequently 130 6400E Rev Model 6400E Instruction Manual Operating Instructions 6 12 4 3 Activating Hessen Protocol The first step in configuring the 6400E to operate over a Hessen protocol network is to activate the Hessen mode for COMM ports and configure the communication parameters for the port s appropriately Press Repeat the entire process to SETUPXX COMTQUIETMODE OFF ENTR EXT uer set up the COM2 port TST TST CAL p SAMPLE ENTER SETUP PASS 610 Y SETUPXX COMI HESSEN PROTOCOL OFF SE CEG DAS RNGE PASS Cth MORE EXIT Toggle OFF ON keys EXIT to change activate deactivate selected mode Select which COMM SETUP MENU po
15. These latent failures are often the most costly since the failure of the equipment in which the damaged device is installed causes down time lost data lost productivity as well as possible failure and damage to other pieces of equipment or property Static Charges can t build up on a conductive surface There are two errors in this statement Conductive devices can build static charges if they are not grounded The charge will be equalized across the entire device but without access to earth ground they are still trapped and can still build to high enough levels to cause damage when they are discharged A charge can be induced onto the conductive surface and or discharge triggered in the presence of a charged field such as a large static charge clinging to the surface of a nylon jacket of someone walking up to a workbench 04515 Rev B 253 A Primer on Electro Static Discharge Model 6400E Instruction Manual As long as my analyzer is properly installed it is safe from damage caused by static discharges It is true that when properly installed the chassis ground of your analyzer is tied to earth ground and its electronic components are prevented from building static electric charges themselves This does not however prevent discharges from static fields built up on other things like you and your clothing from discharging through the instrument and damaging it 12 4 BASIC PRINCIPLES OF STATIC CONTROL It is impossible
16. Whenever a sensitive device is moved into the field of an existing electro static field a charge may be induced on the device in effect discharging the field onto the device If the device is then momentarily grounded while within the electrostatic field or removed from the region of the electrostatic field and grounded somewhere else a second discharge will occur as the charge is transferred from the device to ground 12 3 COMMON MYTHS ABOUT ESD DAMAGE I didn t feel a shock so there was no electro static discharge The human nervous system isn t able to feel a static discharge of less than 3500 volts Most devices are damaged by discharge levels much lower than that I didn t touch it so there was no electro static discharge Electro Static charges are fields whose lines of force can extend several inches or sometimes even feet away from the surface bearing the charge It still works so there was no damage Sometimes the damaged caused by electro static discharge can completely sever a circuit trace causing the device to fail immediately More likely the trace will be only partially occluded by the damage causing degraded performance of the device or worse weakening the trace This weakened circuit may seem to function fine for a short time but even the very low voltage and current levels of the device s normal operating levels will eat away at the defect over time causing the device to fail well before its designed lifetime is reached
17. cen 240 Figure 11 12 PMT UV Filter Housing Disassembled eene 241 Figure 11 13 Disassembling the Shutter Assembly 242 Figure 11 14 Shutter Assembly Exploded View 243 Figure 11 15 Location of UV Reference Detector 244 Figure 11 16 PMT Assembly Exploded View cessent 246 Figure 11 17 Pre Amplifier Board Layout 248 Figure 12 1 Triboelectric Charging 251 Figure 12 2 Basic anti ESD Work Station s sssaneseerranssananssrenerreesrennnunnennereneerennnenen 254 Figure A 1 Basic Sample Display Menu sssseeeeneen eene nennen nnne 260 Figure 2 Sample Display Menu Units with 2 5 Valve or IZS Option installed 261 Figure A 3 Primary Setup Menu Except IDAS eee 262 Figure 4 Primary Setup Menu 263 Figure A 5 Secondary Setup Menu COMM amp VARS ssssessnrersnsserennserennrnnnnnnennanaaenanaenanena 264 Figure A 6 Secondary Setup Menu COMM Menu with Ethernet Card 265 Figure A 7 Secondary Setup Menu HESSEN 266 Figure A 8 Secondary Setup Menu 267 LIST OF TABLES Table 2 1 Model 6400E Basic Unit Specifications m Table 3 1 Analog output Pin 11 Table 3
18. Figure 11 10 Hex Screw Between Lens Housing and Sample chamber 2 Remove the sample chamber from the PMT lens and filter housing by unscrewing the 4 hex screws that fasten the chamber to the housing 3 Remove the four lens cover screws Lens Cover Screws Figure 11 11 UV Lens Housing Filter Housing 4 Remove the lens filter cover 5 Carefully remove the PMT lens and set it aside on soft lint free cloth 240 04515 Rev B Model 6400E Instruction Manual TROUBLESHOOTING amp REPAIR 6 Remove the 3 piece lens filter spacer 7 Carefully remove the PMT filter and set it aside on soft lint free cloth Housing Hex Screws 4th hidden from view A O Ring A Housing Hex Screws PMT Lens PMT Filter UV Lens Filter Housing Lens Filter Spacer 8 pieces Lens Filter Cover Screws Figure 11 12 PMT UV Filter Housing Disassembled 8 Using a lint free cloth dampened with distilled water clean the lens the filter and all of the housing assembly mechanical parts 9 Dry everything with a 2nd lint free cloth 10 Reassemble the lens filter housing see Figure 11 12 11 Reattach the lens filter housing to the sample chamber 12 Reattach the sample chamber to the PMT housing 13 Reinstall the sensor module into the 6400E 14 Close the instrument 15 Turn the 6400E on and let it warm up for 60 minutes 16 Perform a leak check See Section 11 5 1 17 Cali
19. PRM EXIT SETUP XX DETAIL DATA AVAILABLE PREV NI VIEW EXIT SETUP X X PV10 PREV SETUP X X FAST DATA AVAILABLE PREV VIEW EXIT SETUP X X PV10 PREV 00 00 00 PMTDET 0000 0000 m PRM PRM gt EXIT 6400E Rev B 107 Operating Instructions Model 6400E Instruction Manual 6 11 2 2 Editing iDAS Data Channels Although IDAS configuration is most conveniently done through the APICOM remote control program see Section 6 12 2 8 the following list of key strokes shows how to edit iDAS channels using the analyzer s front panel SAMPLE RANGE 500 000 PPB 502 XXX X lt TST TST gt CAL Ei SETUP SAMPLE ENTER SETUP PASS 818 8 1 8 EN ENTR EXIT SETUP XX PRIMARY SETUP MENU EXIT will retum to the previous SAMPLE display CFG DAS RNGE PASS CLK MORE EXIT Main Data Acquisition Menu SETUP XX DATA ACQUISITION VIEW EDIT EXIT Edit Data Channel Menu 0 1 ATIMER 2 4032 Moves the display up amp SETUP X X Exits to the Main Data Acquisition down the list of Data Channels PREV NEXT INS DEL EDIT PRNT EXIT Menu Exports the configuration of all data channels to RS 232 interface inserts a new Data Channel into the list BEFORE the Channel currently being displayed gt Deletes The Data Channe currently being displayed Moves the display be
20. y Display IZS PERM TUBE TEMPERATURE Sensor Sample Flow PMT TEMPERATURE OPTIC TEST CONTROL ELECTRIC TEST CONTROL PMT OUTPUT PMT DET HIGH VOLTAGE POWER SUPPLY LEVEL Sensor 8 Reaction Cell Heater UV Reference Detector 22 17777777 125 Option PMT Permeation Temperature M sie e ed X Sensor pex fm mmm mm mmm n PMT z x IZS Valve PREAMP PCA TEC Drive Option PCA PMT TEC Figure 10 10 6400E Electronic Block Diagram The core of the analyzer is a microcomputer that controls various internal processes interprets data makes calculations and reports results using specialized firmware developed by TAI It communicates with the user as well as receives data from and issues commands to a variety of peripheral devices through a separate printed circuit assembly to which the CPU is mounted the motherboard 184 04515 Rev B Model 6400E Instruction Manual Theory Of Operation The motherboard is directly mounted to the rear panel and collects data performs signal conditioning duties and routs incoming and outgoing signals between the CPU and the analyzer s other major components Concentration data of the 6400E are generated by the photo multiplier tube PMT which produces an analog current signal corresponding to the brightness of the fluorescence reaction in the sample chamber This current signal is amplified t
21. Analyzer Operations Calibration Procedures Configuration Procedures PC 104 BUS Autonomic Systems Diagnostic Routines ANALYZER HARDWARE PC 104 BUS Figure 10 23 Basic Software Operation interface Handling Sensor Input Data Display Messages Keypad Measurement Algorithm MESS Analog Output Data RS232 amp RS485 External Digital 1 O 10 7 1 ADAPTIVE FILTER The 6400E SO analyzer software processes sample gas measurement and reference data through a built in adaptive filter built into the software Unlike other analyzers that average the sensor output signal over a fixed time period the 6400E calculates averages over a set number of samples During operation the software automatically switches between two filters of different lengths based on the conditions at hand During conditions of constant or nearly constant concentration the software computes an average of the last 240 samples This provides the calculation portion of the software with smooth stable readings If a rapid change in concentration is detected the adaptive filter switches modes and only averages the last 48 samples This allows the analyzer to respond to the rapidly changing concentration more quickly Once triggered the short filter remains engaged for a fixed time period to prevent chattering Two conditions must be simultaneously met to switch to the short filter First the instantaneous concentration must exceed the average in
22. CANNOT DYN SPAN Remote span calibration failed while the dynamic span feature was set to turned on CANNOT DYN ZERO Remote zero calibration failed while the dynamic zero feature was set to turned on CONFIG INITIALIZED Configuration was reset to factory defaults or was erased DARK CAL WARNING Dark offset above limit specified indicating that too much stray light is present in the sample chamber DATA INITIALIZED iDAS data storage was erased FRONT PANEL WARN Firmware is unable to communicate with the front panel HVPS WARNING High voltage power supply for the PMT is outside of specified limits IZS TEMP WARNING On units with IZS options installed The permeation tube temperature is outside of specified limits PMT DET WARNING PMT detector output outside of operational limits PMT TEMP WARNING RCELL TEMP WARNING REAR BOARD NOT DET PMT temperature is outside of specified limits Sample chamber temperature is outside of specified limits The CPU is unable to communicate with the motherboard RELAY BOARD WARN The firmware is unable to communicate with the relay board The flow rate of the sample gas is outside the specified limits SAMPLE FLOW WARN SAMPLE PRESS WARN Sample pressure outside of operational parameters SYSTEM RESET UV LAMP WARNING The computer was rebooted The UV lamp intensity measured by the reference dete
23. CLK Setting the Internal Time of Day 1 52 6 7 SETUP RNGE Analog Output Reporting Range Configuration 54 6 7 1 Available Analog Output Signals eee 54 6 7 2 Physical Range versus Analog ee Ponges 455 6 7 3 Reporting Range Modes 56 6 7 4 Single Range mode SNGL s raseerssenessrsrannreereneerensereserenansevnnmanannaneerarnnaneruaenynneanerasnanenans 57 6 7 5 Dual Range Mode DUAL esee eene errem h nna n hann nnt anite nhan 58 6 7 6 Auto Range Mode AUTO 4 59 6 7 7 Range Units 60 6 7 8 Dilution Ratio 61 6 8 SETUP VARS Using the 62 6 9 SETUP DIAG Using the Diagnostics Functions 64 6 9 1 Accessing the Diagnostic Features 4 65 6 9 2 Signal I O een 6 9 3 Analog Output Step Test 6 9 4 Analog I O nnns ea nnn n nhanh nh enhn a nah 6 9 4 1 Analog Output Signal Type and Range Span Selection 70 6 9 4 2 Analog Output Calibration 71 6 9 4 3 Manual Analog Output Calibration and Voltage iss 73 6 9 4 4 Analog Output Offset 5 T be 6 9 4 5 Current Loop Output Adjustment 4 76 6 9 4 6 AIN Calibration 78 6 9 5 Optic Test 4 79 6 9 6 Electrical Test 80 6 9 7 Lamp Calibration 81 6 9
24. CONC OUT 1 CHASSIS TEMP 10 PREAMP RANGE HIGH IZS TEMP 11 ST SYSTEM OK CAL CONC OUT 2 PMT TEMP 12 ST CONC VALID TEST OUTPUT 13 ST HIGH RANGE 14 STZERO CAL 15 ST SPAN CAL HVPS VOLTAGE 16 ST DIAG MODE EDIT 17 ST LAMP ALARM 18 ST DARK CAL ALARM r 19 ST FLOW ALARM 20 ST PRESS ALARM SET SET 21 SR TEMP ALARM 22 ST HVPS ALARM 24 ST SYSTEM ON2 25 RELAY WATCHDOG 26 RCELL HEATER 28 IZS HEATER 27 CAL VALVE 29 SPAN VALVE 30 H2S VALVE 31 DARK SHUTTER INTERNAL ANALOG VOLTAGE SIGNALS 52 ie Appendix A O 1V 1V 5V 10V CURR 1 Only relevant to analyzers with IZS options installed eo ee RANGE REC OFFSET AUTO CALIBRATED E e Figure A 8 Secondary Setup Menu DIAG 05036 Rev C 3 267 APPENDIX 2 Setup Variables For Serial I O Revision Model 6400E Instruction Manual APPENDIX 2 Setup Variables For Serial 1 0 Revision Table 1 6400 Setup Variables Revision NUMERIC DEFAULT SETUP VARIABLE UNITS VALUE VALUE RANGE DESCRIPTION DAS_HOLD_OFF Minutes 15 0 5 20 Duration of DAS hold off period TPC_ENABLE ON OFF OFF ON ON enables temperature and pressure compensation OFF disables it RCELL_SET oc 50 30 70 Reaction cell temperature set point Warnings 45 and warning limits 55 IZS SET oc 50 30 70 IZS temperature set point and Warnings 45 warning limits 55 DYN ZERO OFF OFF ON ON enables con
25. Cmd Any character in RS 232 interface command prompt the aliowed Displayed only if enabled with character set Up RS232 variable Enclose value to 100 characters in double quotes when setting from long the RS 232 interface TEST CHAN ID NONE None Diagnostic analog output ID Enclose value in double quotes when Fmt Reading setting from the RS 232 interface UV Reading Vacuum Pressure3 Sample Pressure Sample Flow Rcell Temp Chassis Temp IZS Temp 1 Pmt Temp HVPS Voltage LOW HIGH Range to calibrate during contact closure and Hessen calibration Enclose value tn double quotes when setting from the RS 232 interface ON enables passwords OFF disables Seconds them Stability measurement sampling period STABIL_SAMPLES Samples 2 40 Number of samples in concentration stability reading RCELL CYCLE Seconds 0 5 30 Reaction cell temperature control cycle period RCELL PROP 1 9C 0 10 Reaction cell temperature PID proportional coefficient RCELL INTEG 0 10 Reaction cell temperature PID integral coefficient RCELL_DERIV 0 10 Reaction cell temperature PID derivative coefficient IZS CYCLE Seconds 0 5 30 IZS temperature control cycle period IZS PROP 1 eC 0 10 IZS temperature PID proportional coefficient IZS_INTEG Lu 0 10 IZS temperature PID integral coefficient IZS DERIV
26. SO transformation including a relatively bright light of the same wavelength at which SO2 fluoresces as it returns to its SO ground state 330 nm In fact the intensity of the of light emitted by the UV lamp at 330nm is so bright nearly five orders of magnitude brighter than that resulting from the SO decay it would drown out the SO2 fluorescence BEFORE AFTER UV SOURCE OPTICAL FILTER BANDWIDTH LAMP OUTPUT Arbitrary Untis LAMP OUTPUT Arbitrary Unlis O2 FLUORESCENT SPECTRUM 300 400 100 200 300 400 500 WAVELENGTH nm WAVELENGTH nm Figure 10 4 Excitation Lamp UV Spectrum Before After Filtration To solve this problem the light emitted by the excitation UV lamp passes through a bandpass filter that screens out photons with wavelengths outside the spectrum required to excite SO into SO see Figure 10 4 PMT Optical Filter The PMT used in the Model 6400E reacts to a wide spectrum of light which includes much of the visible spectrum and most of the UV spectrum Even though the 214 nm light used to excite the SO is focused away from the PMT some of it scatters in the direction of the PMT as it interacts 176 04515 Rev B Model 6400E Instruction Manual Theory Of Operation with the sample gas A second optical bandpass filter placed between the sample chamber see Figure 10 2 and the PMT strips away light outside of the fluorescence spectrum of decaying SO2 see Figure 10 5 including refl
27. STATUS INPUT DEFINITION ON CONDITION A The analyzer is placed in Zero Calibration mode The mode REMOTE ZERO CAL field of the display will read ZERO CAL R B REMOTE The analyzer is placed in span calibration mode as part of SPAN CAL performing a low span midpoint calibration The mode field of the display will read LO CAL R SPARE N 7 EE The ground level from the analyzer s internal DC power Digital Ground supplies same as chassis ground U External Power i i i L input Input pin for 5 VDC required to activate pins A F Internally generated 5V DC power To activate inputs place a jumper between this pin and the U pin The 5 VDC output maximum amperage through this port is 300 mA combined with the analog output supply if used 6400E Rev B 13 Getting Started Model 6400E Instruction Manual 3 1 1 4 Connecting the Serial Ports If you wish to utilize either of the analyzer s two serial interfaces refer to Section 6 10 and 6 12 of this manual for instructions on configuration and usage 3 1 1 5 Connecting to a LAN or the Internet If your unit has a Teledyne Instruments Ethernet card Option 63 plug one end of the 7 CATS cable supplied with the option into the appropriate place on the back of the analyzer see Figure 5 6 in Section 5 5 3 and the other end into any nearby Ethernet access port 3 1 1 6 Connecting to a Multidrop Network If your unit has a Teledyne In
28. e Hexadecimal integer data are used for the same purposes as integers They consist of the two characters Ox followed by one or more hexadecimal digits 0 9 A F a f which is the C programming language convention No plus or minus sign is permitted For example Ox1 0x12 0x1234abcd are all valid hexadecimal integers 124 6400E Rev B Model 6400E Instruction Manual Operating Instructions e Floating point numbers are used to specify continuously variable values such as temperature set points time intervals warning limits voltages etc They consist of an optional plus or minus sign followed by zero or more digits an optional decimal point and zero or more digits At least one digit must appear before or after the decimal point Scientific notation is not permitted For example 1 0 1234 5678 0 1 1 are all valid floating point numbers Boolean expressions are used to specify the value of variables or signals that may assume only two values They are denoted by the keywords ON and OFF e Text strings are used to represent data that cannot be easily represented by other data types such as data channel names which may contain letters and numbers They consist of a quotation mark followed by one or more printable characters including spaces letters numbers and symbols and a final quotation mark For example a 1 123abc and are all valid text strings It is not possible to include a quot
29. gt ENTR Accepts the new setting and returns to the previous menu EXIT Ignores the new setting and returns to the previous menu Some keys only appear as needed 6400E Rev B 95 Operating Instructions Model 6400E Instruction Manual 6 10 7 MULTIDROP RS 232 SET UP The RS 232 multidrop consists of a printed circuit assembly that plugs onto the CN3 CN4 and CNS connectors of the CPU card see Figure 6 12 and the cabling to connect it to the analyzer s motherboard This PCA includes all circuitry required to enable your analyzer for multidrop operation It converts the instrument s COM1 port to multidrop configuration allowing up to eight analyzers to be connected the same I O port of the host computer Because both of the DB9 connectors on the analyzer s back panel are needed to construct the multidrop chain COM2 is no longer available for separate RS 232 or RS 485 operation however with the addition of an Ethernet Option option 63 see Sections 5 5 3 and 6 10 6 the COM2 port is available for communication over a 10BaseT LAN JP2 Cable to Ethernet Card Multidrop PCA Cable to Motherboard i Figure 6 12 Location of JP2 on RS232 Multidrop PCA option 62 Each analyzer in the multidrop chain must have One Teledyne Analytical Instruments option 62 installed 6 straight through DB9 male gt DB9 Female cable Teledyne Instruments P N WRO0000101 is require
30. 500 000 PPB SO2 XXX X CFG DAS RNGE PASS CLK MORE ee EXIT SETUPXX SECONDARY SETUP MENU COMM DAG EXIT Select which COM SETUP X X udi ok MENU port to configure mar d COMI COM2 EXIT The sum of the mode IDs of the selected SETUP X X COM1 MODE 0 modes is displayed here SET EDIT EXIT SETUP XX COM1 QUIET MODE OFF NEXT OFF Continue pressing next until SETUP XX COM1 HESSEN PROTOCOL OFF ENTR EXIT Use PREV and NEXT keys to move between available modes A mode is enabled by toggling the ON OFF key PREV NEXT OFF ENTR EXIT SETUP XX 1 HESSEN PROTOCOL ON PREV NEXT ON ENTR EXIT Continue pressing the NEXT and PREV keys to select any other modes you which to enable or disable EXIT returns to the previous menu ENTR key accepts the new settings EXIT key ignores the new settings 6400E Rev B 99 Operating Instructions Model 6400E Instruction Manual 6 10 9 COM PORT BAUD RATE To select the baud rate of one of the COM Ports press SAMPLE RANGE 500 000 PPB SO2 XXX X TST TST gt CAL SAMPLE ENTER SETUP PASS 818 ES 8 1 8 ic ENTR EXIT SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT SETUP EXIT returns SETUP XX SECONDARY SETUP MENU to the previous COMM VARS DIAG EXIT menu
31. HVPSW 6400E only 6400EH 3 Low span option NAME DESCRIPTION ATIMER Automatic timer expired EXITZR Exit zero calibration mode EXITLS 2 3 Exit low span calibration mode EXITHS Exit high span calibration mode EXITMP Exit multi point calibration mode SLPCHG Slope and offset recalculated EXITDG Exit diagnostic mode PMTDTW PMT detector warning UVLMPW UV lamp warning DRKCLW Dark calibration warning RCTMPW Reaction cell temperature warning IZTMPW IZS temperature warning PTEMPW PMT temperature warning SFLOWW Sample flow warning Sample pressure warning Vacuum pressure warning Box temperature warning High voltage power supply warning 280 05036 Rev C 3 Model 6400E Instruction Manual APPENDIX A 5 6400E iDAS Functions Revision C 3 Table 6 6400E iDAS Functions Revision NAME DESCRIPTION l UNITS PMTDET PMT detector reading mV UVDET UV lamp intensity reading mV LAMPR UV lamp ratio of calibrated intensity DRKPMT PMT electrical offset mV DARKUV UV lamp electrical offset mV SLOPE1 SO slope for range 1 SLOPE2 S0 slope for range 2 OFSET1 SO offset for range 1 mV OFSET2 50 offset for range 2 mV ZSCNC1 SO concentration for range 1 during zero span calibration just PPB before computing new slope and offset ZSCNC2 SO concentration for range 2 during zero span calibration just PPB before computing new slo
32. J23 Figure 3 9 6400 Layout Basic Unit No Valve Options 20 6400E Rev B Model 6400E Instruction Manual Getting Started 3 2 INITIAL OPERATION CAUTION Do not look at the UV lamp while the unit is operating UV light can case eye damage Always use safety glasses plastic glasses will not do If you are unfamiliar with the 6400E theory of operation we recommend that you read Chapter 10 before proceeding For information on navigating the analyzer s software menus see the menu trees described in Appendix A 1 3 2 1 STARTUP After electrical and pneumatic connections are made turn on the instrument The exhaust and PMT cooler fans should start The display should immediately display a single horizontal dash in the upper left corner of the display This will last approximately 30 seconds while the CPU loads the operating system Once the CPU has completed this activity it will begin loading the analyzer firmware and configuration data During this process string of messages will appear on the analyzer s front panel display System walts 3 seconds then automatically begins Its initialization routine No action required SELECT START OR REMOTE START CHECKING FLASH STATUS 1 System is checking the format of the instrument s flash memory chip 1f at this point FLASH FORMAT INVALID appears contact Teledyne Instruments customer service STARTING INST
33. Model 6400E Instruction Manual TROUBLESHOOTING amp REPAIR 1 Turn off the analyzer 2 Disconnect the pneumatic tubing attached to both ends of the scrubbers inner tubing e One end is connected to the sample particulate filter assembly and the other end is connected to the reaction cell assembly e Both ends are made of the 1 8 black Teflon tubing 3 Cap one end of the hydrocarbon scrubber 4 Attach the pressurized air source to the other end of the scrubber inner tubing with the leak check fixture in line Scrubber Leak Check Fixture Pump or Pressurized Air Source Figure 11 5 Hydrocarbon Scrubber Leach check Set Up 5 Use the needle valve to adjust the air input until the gauge reads 15 psia NOTE Do not exceed a pressure of more than 15psia Do not pull the vacuum through the scrubber 6 Close the shut off valve 7 Wait 5 minutes e Ifthe gauge pressure drops is gt 1 psi within 5 minutes then the hydrocarbon scrubber has an internal leak and must be replaced e Contact Teledyne Instruments Customer Service 11 5 3 2 Checking the Scrubber s Efficiency CAUTION This procedure requires the use of mothballs Mothball often contain naphthalene and or paradichlorobenzene Both of these Avoid prolonged breathing of vapors Make sure the work area is well ventilated Use gloves when handling mothballs Store mothballs in an airtight container preferably in a separate room
34. channel and allow the user to make operational decisions regarding the channel see Table 6 20 Table 6 20 iDAS Data Channel Properties PROPERTY DESCRIPTION DEFAULT SETTING RANGE The name of the data channel NONE Up to 6 letters and digits more with APICOM but only the first six are displayed on the front panel TRIGGERING The event that triggers the data channel to ATIMER Any allowed event EVENT measure and store its data parameters See APPENDIX A 5 for a list of available triggering events NUMBER AND A User configurable list of data types to be 1 Any available mm LIST OF recorded in any given channel See PMTDET concentration PARAMETERS APPENDIX A 5 for a list of available temperature pneumatic parameters or diagnostic parameter REPORT The amount of time between each channel 000 01 00 000 00 01 to PERIOD data point 366 23 59 Days Hours Minutes NUMBER OF The number of reports that will be stored in 100 1 to 1 million limited by RECORDS the data file Once the specified limit has available storage space been exceeded the oldest data are over written to make space for new data RS 232 Enables the analyzer to automatically report OFF OFF or ON REPORT channel values to the RS 232 ports CHANNEL Enables or disables the channel Provides a ON OFF or ON ENABLED convenient means to temporarily disable a L data channel CAL HOLD Orr Disables sampling of data parameters while OFF OFF
35. gt A w DAC MUX REF_GND 15 Ground reference Rear board temperature MUX analog inputs BOX_TEMP 0 Internal box temperature RCELL_TEMP 1 Reaction cell temperature IZS TEMP 2 175 temperature 3 Spare TEMP_INPUT_4 4 Diagnostic temperature input TEMP INPUT 5 5 Diagnostic temperature input 278 05036 Rev C 3 Model 6400E Instruction Manual APPENDIX A 4 6400E Signal I O Definitions Revision C 3 SIGNAL NAME BIT OR CHANNEL DESCRIPTION NUMBER TEMP_INPUT_6 6 Diagnostic temperature input 7 Spare Rear board DAC MUX analog inputs DAC CHAN 0 0 DAC channel 0 loopback DAC CHAN 1 1 DAC channel 1 loopback DAC CHAN 2 2 DAC channel 2 loopback DAC CHAN 3 _ 3 DAC channel 3 loopback Rear board analog outputs CONC_OUT_1 0 Concentration output 1 CONC_OUT_2 1 Concentration output 2 TEST_OUTPUT gt Test measurement output 3 Spare I C analog output AD5321 default 1 address 18 hex LAMP POWER 2 To Lamp power 0 5V 6400EH Low span option 05036 Rev C 3 279 APPENDIX 5 6400E iDAS Functions Revision Model 6400E Instruction Manual APPENDIX A 5 6400E iDAS Functions Revision C 3 Table A 5 6400E DAS Trigger Events Revision C 3 VPRESW BTEMPW
36. in the left most socket of the CPU board The chip is square with one corner cut off the socket is shaped accordingly 3 Remove the old chip by using a special tool or gently pry the chip out using a very fine screwdriver Make sure not to bend or destroy any of the contacts of the socket 4 Reinstall the new or additional EEPROM chip making sure the cut off edge matches that of the socket Press the chip symmetrically and straight all the way in 5 Close the rear panel and turn on power to the machine 11 6 3 SENSOR MODULE REPAIR amp CLEANING UV Lamp Power Supply Wiring Shutter Cabling Hi Exits here Gas Outlet i fitting TEC Power Cablo Heater Wiring Connector exits here fitting Thermistor lt UV Detector Wiring exits here Wiring Connector Figure 11 7 Sensor Module Wiring and Pneumatic Fittings 236 04515 Rev B Model 6400E Instruction Manual TROUBLESHOOTING amp REPAIR NOTE After any repair or service has been performed on the sensor module the 6400E should be allowed to warm up for 60 minutes Always perform a perform a leak check See Section 11 5 1 and calibrate the analyzer see Chapter 7 before placing it back in service 11 6 3 1 Removing and Reinstalling the Sensor Module Several of the procedures in this section either require the sensor module to be removed from the instrument or are easier to perform if it has been removed To remove the Senso
37. particularly if you have more than one Model 6400E analyzer on your network press _ SAMPLE RANGE 500 000 502 X SETUP XX DHCP ON T8T TST CAL SETUP SET EDIT EXIT ENTER F PASS 818 Continue pressing SET UNTIL B 4 B ENTR EXIT SETUP Xx HOSTNAME 100E SETUP xx PRIMARY SETUP MENU B ane Em CFG DAS RNGE PASS CLK MORE EXIT SEtuP HOSTNAME M 100E N SETUPxX SECONDARY SETUP MENU ALR EMT i lt CH CH INS DEL ENTR EXIT COMM vA Use these keys See Table 6 19 to edit HOSTNAME JP xX COMMUNICATIONS MENU ID EXIT SETUP XX HOSTNAME 100E FIELD1 SET SETUP X 6 SETUP X X INITIALIZATION FAILED Contact your IT Network Administrator Table 6 17 Internet Configuration Keypad Functions EDIT INITIALIZING INET 0 INITIALIZING INET 100 INITIALIZATION SUCCEEDED SETUP X X SETUPXX COMMUNICATIONS MENU iD INET COWI EXIT KEY FUNCTION CH Moves the cursor one character to the left CH Moves the cursor one character to the right INS Inserts a character before the cursor location DEL Deletes a character at the cursor location 1 Press this key to cycle through the range of numerals and characters available for insertion 0 9 A Z space O R _ L lt
38. please do so before continuing see Section 6 7 for instructions NOTE It is recommended that the LAMP CAL routine see Section 6 9 7 be performed prior to all calibration operation This will allow the instrument to account for minor changes due to aging of the UV lamp 7 1 1 REQUIRED EQUIPMENT SUPPLIES AND EXPENDABLES Calibration of the Model 6400E analyzer requires a certain amount of equipment and supplies These include but are not limited to the following Zero air source e Sulfur dioxide span gas source e Gas lines all gas line materials should be Teflon type or glass Arecording device such as a strip chart recorder and or data logger optional 7 1 2 ZERO AIR Zero air is similar in chemical composition to the Earth s atmosphere but scrubbed of all components that might affect the analyzer s readings For SO measuring devices zero air should be similar in composition to the sample gas but devoid of SO and large amounts of hydrocarbons nitrogen oxide NO and with a water vapor dew point lt 15 Devices such as the API Model 701 zero air generator that condition ambient air by drying and removal of pollutants are available We recommend this type of device for generating zero air 6400E Rev B 137 Calibration Procedures Model 6400E Instruction Manual 7 1 3 CALIBRATION GAS STANDARDS amp TRACEABILITY Span gas is specifically mixed to match the chemical composition of the gas
39. system OK 1 any alarm condition ST CONC VALID i 0 conc valid 276 05036 Rev C 3 Model 6400E Instruction Manual APPENDIX 4 6400E Signal I O Definitions Revision SIGNAL NAME BIT OR CHANNEL DESCRIPTION NUMBER 1 warnings or other conditions that affect validity of concentration ST_HIGH_RANGE 0 high auto range in use 1 low auto range ST_ZERO_CAL 0 in zero calibration 1 not in zero ST_SPAN_CAL 0 in span calibration 1 not in span ST_DIAG_MODE 0 in diagnostic mode 1 not in diagnostic mode 0 in low span calibration 1 not in low span ST_LOW_SPAN_CAL Spare 0 lamp intensity low 1 lamp intensity OK 0 dark cal warning 1 dark cal OK 0 any flow alarm 1 all flows OK 0 any pressure alarm 1 all pressures OK 0 any temperature alarm 1 all temperatures OK 0 HVPS alarm 1 HVPS OK ST_DARK_CAL_ALARM ST_FLOW_ALARM ST_PRESS_ALARM ST_TEMP_ALARM ST_HVPS_ALARM Front panel I C keyboard default address 4E hex l MAINT_MODE 5 input 0 maintenance mode 1 normal mode LANG2_SELECT 6 input 0 select second language 1 select first language English SAMPLE_LED 8 output 0 sample LED on 1 off CAL_LED 9 output 0 cal LED on 1 off FAULT_LED
40. 04069 Motherboard 04181 04180 04259 PCA 04258 Keyboard Display Interface 04420 PCA 04120 UV Detector Preamp 04693 PCA 04692 UV Lamp Driver 04468 PCA 04467 Analog Output Series Res 05039 RevA 289 Model 6400E Instruction Manual User Notes 290 04515 Rev B
41. 10 output 0 fault LED on a 1 off AUDIBLE BEEPER 14 output 0 beeper on for diagnostic testing only 1 off Relay board digital output PCF8575 default I C address 44 hex RELAY WATCHDOG 0 Alternate between 0 and 1 at least every 5 seconds 05036 Rev C 3 277 APPENDIX A 4 6400E Signal I O Definitions Revision C 3 Model 6400E Instruction Manual SIGNAL NAME BIT OR CHANNEL DESCRIPTION NUMBER i to keep relay board active RCELL_ HEATER i 0 reaction cell heater on 1 off 2 3 Spare IZS HEATER 4 0 IZS heater on LE 1 off 5 Spare CAL_VALVE 6 0 let cal gas in 1 let sample gas in SPAN VALVE 0 let span gas in 1 let zero gas in LOW SPAN VALVE amp 8 0 let low span gas in 1 let sample gas in ZERO VALVE 0 let zero gas in 1 let sample gas in DARK SHUTTER PMT SIGNAL HVPS VOLTAGE UVLAMP SIGNAL 10 E Rear board primary MUX analog inputs 0 0 close dark shutter 1 open PMT detector HV power supply output PMT temperature UV lamp intensity 4 Temperature MUX 5 6 Spare SAMPLE_PRESSURE 7 Sample pressure TEST_INPUT_8 8 Diagnostic test input REF_4096_MV 9_ 4 096 reference from MAX6241 T SAMPLE_FLOW 10 Sample flow rate VACUUM PRESSURE 10 Vacuum pressure TEST INPUT 1 1 11 Diagnostic test input Spare thermocouple input rtc
42. 2 31 pa YES SET SET gt EDIT PRNT Cycles through Selects max already active no of records cipe PARAMETER SAMPLEMODE PRECISION s channel PREV NEXT INST AVG MIN MAX see Section 6 12 2 4 Figure A 4 Cycles through avallable active parameters 1 j Only appears If 2 5 valve 125 option is installed Primary Setup Menu iDAS 05036 Rev C 3 263 APPENDIX 1 6400E Software Menu Trees Revision Model 6400E Instruction Manual SAMPLE I ENTER SETUP PASS 818 CFG RNGE PASS CLK MORE COMM VARS DIAG ecard required ID INET COM1 COM2 GTWY Ip SNET START STOP PREV NEXT JUMP EDIT PRINT DAS_HOLD_OFF TPC_ENABLE RCELL_SET IZS SET DYN ZERO DYN SPAN CONC PRECISION CLOCK_AD3 SET SET EDIT MODE BAUD RATE TEST PORT PREV NEXT PREV NEXT TEST QUIET COMPUTER 300 Go To SECURITY 1200 DIAG MENU TREE HESSEN PROTOCOL 4800 Fig A 8 MES 9600 MULTIDROP PROTOCOL 19200 ENABLE MODEM 38400 ERROR CHECKING 57760 XON XOFF HANDSHAKE ON 115200 t Only appears if 2 5 valve or IZS option is installed HARDWARE HANDSHAKE HARDWARE FIFO COMMAND PROMPT Only appears when the ENABLE INTERNET mode is OFF enabled for either COM1 or COM2 Figure A 5 Secondary Setup Menu COMM amp VARS 05036 Rev C 3 264 APPENDIX A 1 6400E Software Menu Trees Revision C 3 Model 6400E Instruction Manual SETUP
43. 232 and COM2 DB9 connectors on the instrument s back panel via a cable to the motherboard One option 62 is required for each analyzer along with one 6 straight through DB9 male gt DB9 Female cable P N WR0000101 This option can be installed in conjunction with the Ethernet option Option 63 allowing the instrument to communicate on both types of networks simultaneously For more information on using and setting up this option see Section 6 10 7 ee s CPU Card 1 as seon from inside Multidrop Figure 5 4 6400 Multidrop Card 5 5 3 ETHERNET OPTION 63 The Ethernet option allows the analyzer to be connected to any Ethernet local area network LAN running TCP IP The local area network must have routers capable of operating at 10BaseT If Internet access is available through the LAN this option also allows communication with the instrument over the public Internet 6400E Rev B 39 Optional Hardware and Software Model 6400E Instruction Manual When installed this option is electronically connected to the instrument s COM2 serial port making that port no longer available for RS 232 RS 485 communications through the COM2 connector on the rear panel The option consists of a Teledyne Instruments designed Ethernet card see Figure 5 5 which is mechanically attached to the instrument s rear panel see Figure 5 6 A 7 foot long CAT 5 network cable terminated at both ends with standard RJ 45 connectors
44. 3 NOTE Once you have completed the above set up procedures please fill out the Quality Questionnaire that was shipped with your unit and return it to Teledyne Analytical Instruments This information is vital to our efforts in continuously improving our service and our products THANK YOU 24 6400E Rev B Model 6400E Instruction Manual Getting Started 6400E Rev B 25 Getting Started Model 6400E Instruction Manual 3 3 INITIAL CALIBRATION 3 3 1 BASIC CALIBRATION PROCEDURE The following three step procedure assumes that the instrument does not have any of the available zero span Z S or IZS valve options installed Chapter 7 contains instructions for calibrating instruments with valve options Chapter 8 contains directions for performing for EPA protocol calibrations The initial calibration should be carried out with the analyzer s reporting range for SINGLE range mode with a range span of 500 PPB factory default settings for most units This will enable you to compare your results to the factory calibration STEP ONE Set verify the analog output reporting range of the 6400E SAMPLE 600 000 PPB TST TST CAL CFG DAS RNGE PASS CLK SETUP RANGE con ROL MENU MODE SET UNIT ENIT Press this button to select the concentration unlls of measure PPB PPM UGM MGM SETUP X RANGE 500 0 CONC o 0 5 0 0 ENTR EXIT SETUP XX
45. 4 Calibration Valves Options 5 4 1 Zero Span Valves Option 50 5 4 2 Internal Zero Span Gas Generator Option 51 xs 5 4 3 IZS Permeation Tubes Options 53 55 amp 57 38 5 4 4 Zero Air Scrubber Maintenance Kit Option 43 s 38 5 5 Communication 5 99339 5 5 1 RS232 Modem Cable Option 60 5 5 2 RS 232 Multidrop Option 62 ase 5 5 3 Ethernet Option 63 4 39 5 6 Additional Manuals 5 6 1 Printed Manuals Option 70 hen hhhh eran nean aha ants 4i 5 6 2 Manual on CD Part number 045150200 5 7 Extended Warranty Options 92 amp 93 5 8 Special Software Features 5 8 1 Maintenance Mode Switch 5 8 2 Second Language Switch 5 8 3 Dilution Ratio Option 6 OPERATING INSTRUCTIONS 6 1 Overview of Operating modes 6 2 Sample Mode 6400E Rev B iii Model 6400E Instruction Manual 6 2 1 Test 6 2 2 Warning Messages 6 3 Calibration Mode 6 3 1 Calibration Functions 6 3 2 SETUP PASS Calibration Password Security 6 4 Setup Mot isisisi canis eren 6 4 1 Setup Mode Password Security 6 5 SETUP CFG Viewing the Analyzer s Configuration Information 6 6 SETUP
46. 5 Dynamic Multipoint Span Calibration 8 6 Special Calibration Requirements for Dual Range c or Auto Range 8 7 References 9 INSTRUMENT MA 9 1 Maintenance Schedule 9 2 Predictive Diagnostics 9 3 Maintenance Procedures 10 THEORY OF OPERATION 10 1 Measurement Principle 10 2 The UV Light Path 10 4 Electronic Operation 8 4 2 Precision Check Aas 52 ET em wok 159 9 3 1 Changing the Sample P 9 3 2 Changing the IZS Permeation Tube 9 3 3 Changing the External Zero Air Scrubber 9 3 4 Changing Critical Flow Orifices 9 3 5 Checking for Light Leaks 10 1 1 SO Ultraviolet Fluorescence 10 2 1 UV Source Lamp 10 2 2 The Reference Detector 10 2 3 The PMT ccssccccsernenssensee 10 2 4 UV Lamp Shutter amp PMT Offset 10 2 5 Optical Filters 10 2 6 Optical 7 Measurement Interferences 2 7 1 Direct Interference 2 7 2 UV Absorption by Ozone 2 7 3 Dilution soinera earar 2 7 4 Third Body Soa aiat 2 7 5 Light Pollution neumatic Operation 1 Sample Gas Flow 2 Flow Rate Control 3 2 1 Critical Flow Orifice 10 3 3 Sample Particulate 10 3 4 Hydrocarbon Scrubber Kicker 10 3 5 Pneumatic 10 3 5 1 Sample Pressure Sensor 10 3 5 2 Sample Flow Sensor 10 4 1 CPU naansnnase
47. 502 XXX X 4 CONC EXIT ACTION Record the 50 readings presented in the upper right comer of the display ACTION Record the SO readings presented in the upper right comer of the display EXIT retums to the main SAMPLE display 146 6400E Rev B Model 6400E Instruction Manual Calibration Procedures 7 7 MANUAL CALIBRATION IN DUAL OR AUTO REPORTING RANGE MODES When the analyzer is in either Dual or Auto Range modes the user must run a separate calibration procedure for each range After pressing the CAL CALZ or CALS keys the user is prompted for the range that is to be calibrated as seen in the CALZ example below SAMPLE RANGE 500 006 PPB 502 XXX X TST TST CAL CALZ CALS SETUP SAMPLE RANGE TO CAL LOW LOW HIGH ENTR SETUP SAMPLE RANGE TO CAL HIGH WAIT 10 MINUTES LOW HIGH ENTR SETUP Or until the Analyzer enters LI reading ZERO CAL Mode stabilizes and the ZERO button See Table 5 1 for Z S RANGE 500000 SO2 XXXX is displayed f play Valve States during this operating mode TST TST ZERO CONC Continue Calibration as per Standard Procedure Once this selection is made the calibration procedure continues as previously described in Sections 7 2 through 7 6 The other range may be calibrated by starting over from the main SAMPLE display 7 7 1 CALIBRATION WITH REMOTE CONT
48. 7 1 6 DATA RECORDING DEVICES A strip chart recorder data acquisition system or digital data acquisition system should be used to record data from the 6400E s serial or analog outputs If analog readings are used the response of the recording system should be checked against a NIST traceable voltage source or meter Data recording device should be capable of bi polar operation so that negative readings can be recorded For electronic data recording the 6400E provides an internal data acquisition system iDAS which is described in detail in Section 6 11 Calibration and Calibration Check Pressing the ENTR key during the following procedure re calculates the stored values for OFFSET and SLOPE and alters the instrument s calibration If you wish to perform a calibration CHECK do not press ENTR and see Section 7 3 138 6400E Rev B Model 6400E Instruction Manual Calibration Procedures 7 2 MANUAL CALIBRATION The following section describes the basic method for manually calibrating the Model 6400E SO analyzer STEP ONE Connect the sources of zero air and span gas as shown below 0 GAS At high concentration MODEL 701 Zero Air Generator MODEL 700 Gas Dilution Calibrator with Ozone Bench Option Source of SAMPLE Gas Removed during Calibration Figure 7 1 3 way Valve VENT MODEL 701 Zero Air Generator z 50 GAS tas nign
49. 9 1 IN HG A Vacuum pressure SAMPPRESS PRES 29 9 IN HG A Sample pressure SAMPFLOW FL 700 CC M Sample flow rate PMTDET PMT 762 5 MV Raw PMT reading NORMPMTDET NORM PMT 742 9 MV PMT reading normalized for temperature pressure auto zero offset but not range UVDET UV LAMP 3457 6 UV lamp reading LAMPRATIO LAMP RATIO 100 0 UV lamp ratio of current reading divided by calibrated J reading STRAYLIGHT STR LGT 0 1 PPB Stray light offset DARKPMT DRK PMT 19 6 MV PMT dark offset LT DARKLAMP DRK LMP 42 4 MV UV lamp dark offset SLOPE Slope for current range computed during zero span calibration OFFSET OFFSET 250 0 MV Offset for current range computed during zero span calibration High voltage power supply output RCELLDUTY RCELL ON 0 00 SEC RCELLTEMP Reaction cell temperature BOXTEMP BOX TEMP 35 5 C Internal chassis temperature PMTTEMP 7 0 PMT temperature IZSDUTY d IZS ON 0 00 SEC IZS temperature control duty cycle IZSTEMP IZS TEMP 52 2C IZS temperature 502 502 261 4 PPB 502 concentration for current range TESTCHAN TEST 3721 1 MV Value output to TEST_OUTPUT analog output selected with TEST_CHAN_ID variable CLOCKTIME TIME 10 38 27 Current instrument time of day clock 1 6400EH 05036 Rev 275 APPENDIX 4 6400E Signal I O Definitions Revision Model 6400E Instruction Manual APPENDIX 4 6400E Signal I O Definitions Revision Table A 4 6
50. COM2 6400E Rev B 89 Operating Instructions Model 6400E Instruction Manual 6 10 6 ETHERNET CARD CONFIGURATION When equipped with the optional Ethernet interface the analyzer can be connected to any standard 10BaseT Ethernet network via low cost network hubs switches or routers The interface operates as a standard TCP IP device on port 3000 This allows a remote computer to connect through the internet to the analyzer using APICOM terminal emulators or other programs The firmware on board the Ethernet card automatically sets the communication modes and baud rate 115 200 kBaud for the COM2 port Once the Ethernet option is installed and activated the COM2 submenu is replaced by a new submenu INET This submenu is used to manage and configure the Ethernet interface with your LAN or Internet Server s The card has four LEDs that are visible on the rear panel of the analyzer indicating its current operating status Table 6 15 Ethernet Status Indicators LED FUNCTION LNK green ON when connection to the LAN is valid ACT yellow Flickers any activity on the LAN TxD green Flickers when the RS 232 port is transmitting data RxD yellow Flickers when the RS 232 port is receiving data 6 10 6 1 Ethernet Card COM2 Communication Modes and Baud Rate The firmware on board the Ethernet card automatically sets the communication modes for the COM2 port The baud rate is also a
51. DIAGNOSTIC SIGNAL I O FUNCTIONS The signal I O parameters found under the diagnostics DIAG menu combined with a thorough understanding of the instrument s theory of operation see Chapter 10 are useful for troubleshooting in three ways The technician can view the raw unprocessed signal level of the analyzer s critical inputs and outputs All of the components and functions that are normally under instrument control can be manually changed e Analog and digital output signals can be manually controlled This allows to systematically observe the effect of these functions on the operation of the analyzer Figure 11 2 shows an example of how to use the signal I O menu to view the raw voltage of an input signal or to control the state of an output voltage or control signal The specific parameter will vary depending on the situation Please note that the analyzer will freeze it s concentration output while in the diagnostic signal I O menu This is because manually changing 1 0 outputs can invalidate the instrument reading SAMPLE RANGE 500 600 PPB SO3zXXKk X TST TST gt CAL SAMPLE ENTER SETUP PASS 818 a 4 8 R EXIT SETUP AX PRIMARY SETUP MENU CFG DAS RHGE PASS CLK MORE ET SETUP 4 SECONDARY SETUP MENU CMA VERS DIAG EXIT DIAG SIGNAL UO PREV NEXT ENTR ExT DIAG UO 0 EXT ZERO CAL OR PREY NEXT JUMP EAT H parameter is an If parameter is an
52. Data Parameter Functions FUNCTION EFFECT _ PARAMETER Instrument specific parameter name SAMPLE MODE INST Records instantaneous reading AVG Records average reading during reporting interval MIN Records minimum instantaneous reading during reporting interval MAX Records maximum instantaneous reading during reporting interval PRECISION STORE NUM SAMPLES Decimal precision of parameter value 0 4 OFF stores only the average default ON stores the average and the number of samples in each average for a parameter This property is only useful when the AVG sample mode is used Note that the number of samples is the same for all parameters in one channel and needs to be specified only for one of the parameters in that channel Users can specify up to 50 parameters per data channel the 6400E provides about 30 parameters However the number of parameters and channels is ultimately limited by available memory 6 11 1 3 iDAS Triggering Events Triggering events define when and how the iDAS records a measurement of any given data channel Triggering events are firmware specific and are listed in Appendix A 5 The most common triggering events are e ATIMER Sampling at regular intervals specified by an automatic timer Most trending information is usually stored at such regular intervals which can be instantaneous or averaged EXITZR EXITSP SLPCHG exit zero exit span s
53. ENTR accepts the new i SETUP gt PRECISION 1 ne EXIT Ignores the new setting lt SET SET EDIT and relums to the previous EXIT SETUP PRECISION 1 1 SET Returns to previous Functions SETUP STORE NUM SAMPLES OFF lt SET EDIT EXIT SETUP XX STORE NUM SAMPLES OFF OFF ENTR EXIT een sas Tum ON or OFF P 6 11 2 5 Sample Period and Report Period The iDAS defines two principal time periods by which sample readings are taken and permanently recorded SAMPLE PERIOD Determines how often iDAS temporarily records a sample reading of the parameter in volatile memory The SAMPLE PERIOD is set to one minute by default and generally cannot be accessed from the standard iDAS front panel menu but is available via the instruments communication ports by using APICOM or the analyzer s standard serial data protocol SAMPLE PERIOD is only used when the iDAS parameter s sample mode is set for AVG MIN or MAX 6400E Rev B 111 Operating Instructions Model 6400E Instruction Manual e REPORT PERIOD Sets how often the sample readings stored in volatile memory are processed e g average minimum or maximum are calculated and the results stored permanently in the instruments Disk on Chip as well as transmitted via the analyzer s communication ports The REPORT PERIOD may be set from the front panel Ifthe INST sample mode is selected the in
54. Functions with values that are within the acceptable range but have significantly changed from the measurements recorded on the factory data sheet may also indicate a failure or a maintenance item A problem report worksheet has been provided in Appendix C to assist in recording the value of these test functions Table 11 2 contains some of the more common causes for these values to be out of range 210 04515 Rev B Model 6400E Instruction Manual TROUBLESHOOTING amp REPAIR Table 11 2 Test Functions Possible Causes for Out Of Range Values TEST FUNCTION NOMINAL VALUE S POSSIBLE CAUSE S STABIL lt 1 ppb with zero air Faults that cause high stability values are pneumatic leak iow or very unstable UV lamp output light leak faulty HVPS defective preamp board aging detectors PMT recently exposed to room light dirty contaminated reaction cell SAMPLE FL 650 cm min 10 Faults are caused due to clogged critical flow orifice pneumatic leak faulty flow sensor sample line flow restriction PMT 20 TO 150 mV with zero air High or noisy readings could be due to calibration error pneumatic leak excessive background light aging UV filter low UV lamp output PMT recently exposed to room light light leak in reaction cell reaction cell contaminated HVPS problem It takes 24 48 hours for the PMT exposed to ambient light levels to adapt to dim light NORM PMT Noisy Norm PM
55. Hardware and Software Model 6400E Instruction Manual NOTE The permeation tube is not included in the IZS Option and must be ordered separately See Section 5 4 3 below Permeation Tube Heater In order to keep the permeation rate constant the IZS enclosure is heated to a constant 50 C 10 above the maximum operating temperature of the instrument The IZS heater is controlled by a precise PID Proportional Integral Derivative temperature control loop A thermistor measures the actual temperature and reports it to the CPU for control feedback CAUTION Gas flow though the analyzer must be maintained at all time for units with a permeation tube installed Insufficient gas flow allows gas to build up to levels that will contaminate the instrument 5 4 3 IZS PERMEATION TUBES OPTIONS 53 55 amp 57 Several replacement permeation tubes are available for the IZS option They are identical in size and shape but are designed to have different effusion rates SPECIFIED FLOW OPTION EFFUSION RATE APPROXIMATE 25 CONCENTRATION RATE OPT 53 421 ng min 300 500 ppb 0 76 Ipm 55 842 ng min 600 1000ppb 0 76 Ipm 57 222 ng min 800 1200 ppb 0 56 Ipm Each tube comes with a calibration certificate traceable to a NIST standard specifying its actual effusion rate of that tube to within 5 when immersed in a gas stream moving at the specified flow rate This
56. MODE SNGL SETUP HIGH RANGE 500 0 Cone sate hawt SNGL IND AUTO ENTR EXIT 0 5 0 ENTR EXIT NOTE In AUTO range mode the LOW and HIGH ranges have separate slopes and offsets for computing SO concentration The two ranges must be independently calibrated 6400E Rev B 59 Operating Instructions Model 6400E Instruction Manual 6 7 7 RANGE UNITS The 6400E can display concentrations in parts per billion 10 mols per mol PPB parts per million 109 mols per mol PPM micrograms per cubic meter ug m UG or milligrams per cubic meter mg m MG Changing units affects all of the display analog outputs COM port and IDAS values for all reporting ranges regardless of the analyzer s range mode To change the concentration units SAMPLE RANGE 500 000 PPB 502 sXXX X TST CAL SETUP SAMPLE ENTER SETUP PASS 818 Y 8 1 8 ENTR EXIT SETUPXX PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT EXIT returns SETUP X X RANGE CONTROL MENU to the main menu gt MODE SET UNIT EXIT Select the preferred SETUP XX UNITS PPB concentration unit vs PPM PPB UGM MGM ENTER exit ENTR accepis the new unit SETUP XX CONC UNITS PPM EXIT returns to the SETUP PPM PPB UGM MGM ENTER EXIT menu NOTE Concentrations displayed in mg m and pg m use 0 C and 760 Torr as standard temperature and pressure STP Consult your local reg
57. Press EXIT to ENTR EXIT list of available parameter and to retum to the parameters activate the test DIAG menu channel 6 9 Test Parameters Available for Analog Output A4 TEST CHANNEL TEST PARAMETER RANGE NONE Test channel is turned off PMT READING 0 5000 mV B UV READING 0 5000 mV SAMPLE PRESSURE 0 40 in Hg A SAMPLE FLOW 0 1000 cm min RCELL TEMP 0 709 C CHASSIS TEMP 0 709 C IZS TEMP 0 70 C PMT TEMP 0 509 HVPS VOLTAGE 0 5000 V Once a TEST function is selected the instrument begins to report a signal the output and adds TEST to the list of test functions viewable on the display just before the TIME test function 84 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 10 SETUP COMM SETTING UP THE ANALYSER S COMMUNICATION PORTS The 6400E is equipped with two serial communication ports located on the rear panel see Figure 3 1 Both ports operate similarly and give the user the ability to communicate with issue commands to and receive data from the analyzer through an external computer system or terminal By default both ports operate on the RS 232 protocol The COM1 port can also be configured to operate in single or RS 232 multidrop mode option 62 See Section 5 5 2 and 6 10 7 The COM2 port can be configured for standard RS 232 operation half duplex RS 485 communication or for acc
58. RANGE 5V DIAG ANALOG I CONFIGURATION SET EDIT EXIT PREY NE ENTR EXIT DIAG AIO CONC OUT 1 REC OFS 0 mV DIAG AID f LIBRATED NO SET SET EDIT EXIT SET gt CAL EXIT if AutoCal Is ON go to Section 67 3 DIAG CONC OUT 1 AUTO CAL OFF SET SET EDT EXIT Press SET to select the analog output channel to be configured DISPLAYED CHANNEL CONC_OUT_1 Ai CONC OUT 2 A2 TEST OUTPUT AA DIAG CONC OUT 2 CALIBRATED NO SET CAL EXIT DIAG AIO CONC OUT 1 5V NO CAL DIAG AIO CONC OUT 1 VOLT Z 0 mV SET EDIT EXIT 0100 UP10 UP DOWN DN10 D100 ENTR EXIT These keys Increase decrease the analog output by 100 10 or 1 counts Continue adjustments until the voltage measured EXIT ignores the at the output of the analyzer and or the input of DIAG AIO CONC OUT 1 VOLT S 4500 mV NS setting the recording device matches the value In the accepts the upper right hand comer of the display to the U100 UP10 UP DOWN DN10 D100 ENTR EXIT new setting tolerance listed in Table 6 10 The concentration display will not change Only the voltage reading of your voltmeter will change DIAG AIO CONC_OUT_1 CALIBRATED YES EXIT SET CAL 74 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 9
59. RANGE 500 0 Conc a u 5 o 0 ENTR EXIT EXIT Ignores the new setting and relums to the RANGE CONTROL MENU To change the value of the reporting range span enter the number by pressing tho key under each digit unti tho expected valun appears ENTR accepls the new setting and retums to the RANGE CONTROL MENU STEP TWO Set the expected SO span gas concentration SAMPLE RANGE 90 000 PPB 502 XXX X lt TST TST CAL SETUP This sequence causes the analyzer to prompt for the expected SO span concentration CAL 502 XXX X TST TST gt ZERO CONC EXIT The SO span concentration values automalically defaull to 450 0 Conc EXIT ignores the new selling and retums to the previous display ENTR accepts the new setting and returns to the previous display To change this value to CAL 502 SPAN CONG 450 0 Conc the actual concentration of the span gas enter the number by pressing the key under each digil until the expected value appears 0 0 4 5 0 a ENTR EXIT 26 6400E Rev B Model 6400E Instruction Manual Getting Started STEP THREE Perform the zero span calibration procedure RAN 5 Di X SAMPLE RANGE 500 000 PPS S02 XXX X Set the Display to show the STABIL test function lt TST TST gt SETUP This function calculates the stability of the 502 a measurement SAMPLE STABIL X XXX P
60. Save Date i 25109 pss Basic Advonced E J ENGDAT ATIMER 100 Records Maximum EJ SMPFLW ce m AVG Set 0 0 Records Ys Basic Settings I i t D i n F 03FLOW cc m AVG Set 0 0 Records carer CIRCPRES InHg AVG Sel D 0 Records Chan MemberofRecod gt 100 C SMPPRS Ing AVG Set 0 0 Records Neon aS C BOXTMP AVG Set 0 0Recordsv New zi IIo PRU secco i 6 Enable Chicos T HoldOll gt T Bret Reports DAS Parameter Parameter 010073 Stat Date coo pec _ 1 Stat Tine ees 77707 ur epi feel bo a Saraple Period j R Precision 4 iDDO HHAME ordo EE Report Perod JDDD HH MME f samples in aversae TT Store Figure 6 15 Sample APICOM user interface for configuring the iDAS Once an iDAS configuration is edited which can be done offline and without interrupting DAS data collection it is conveniently uploaded to the instrument and can be stored on a computer for later review alteration or documentation and archival Refer to the APICOM manual for details on these procedures The APICOM user manual Teledyne Instruments part number 039450000 is included in the APICOM installation file which can be downloaded at http www teledyne api com software apicom Although Teled
61. See 2 diaphragm Replace Annually Yes instructlons Calibrate UV Perform Pitar to 2 6 9 7 amp Lamp Output LAMP CAL hardware callbratlon 11 6 3 5 PMT sensor Low level Mala hardware hardware 0 7 SLOPE or Yes 11 6 3 8 calibration callbration SLOPE gt 1 3 Clean Sample chamber chamber 11 6 3 2 amp optics windows and As necessary ves 11 6 3 3 filters Critical flow orifice amp sintered Replace As necessary Yes 9 3 4 filters 1 These Items are required to maintain full warranty all other items are strongly recommended 2 A pump rebuild kit is available from Teledyne Instruments Customer Service including all instructions and required parts see Appendix B for part numbers 164 04515 Rev B Model 6400E Instruction Manual Instrument Maintenance 9 2 PREDICTIVE DIAGNOSTICS The analyzer s test functions can be used to predict failures by looking at trends in their values see Table 9 2 and by comparing them values recorded for them at the factory and recorded on the 6400E Final Test and Validation Data Form TAI part number 04551 that was shipped with your analyzer A convenient way to record and track changes to these parameters is the internal data acquisition system iDAS Also APICOM control software can be used to download and record these data for review even from remote locations see Section 6 12 2 8 describes APICOM Table 9 2 Predictive Uses for Test Functions T
62. TEC driver circuit Bad PMT preamp board Failed PMT temperature sensor Loose wiring between PMT temperature sensor and PMT Preamp board Malfunction of analog sensor input circuitry on motherboard RCELL TEMP Sample chamber Bad reaction cell heater WARNING temperature is Bad reaction cell temperature sensor 45 C or gt 55 C Bad relay controlling the reaction cell heater Entire relay board is malfunctioning I C buss malfunction REAR BOARD Mother Board not Warning only appears on serial i o corn port s NOT DET detected on power up Front panel display will be frozen blank or will not respond Massive failure of mother board 04515 Rev B 209 TROUBLESHOOTING amp REPAIR Model 6400E Instruction Manual Table 11 1 Warning Messages Indicated Failures cont cc min WARNING MESSAGE FAULT CONDITION POSSIBLE CAUSES SAMPLE FLOW Sample flow rate is Failed sample pump WARN 500 cc min or 1000 Blocked sample inlet gas line Dirty particulate filter Leak downstream of critical flow orifice Failed flow sensor circuitry SAMPLE PRES WARN Sample Pressure is 10 in Hg or gt 35 in Hg If sample pressure is lt 10 in hg o Blocked particulate filter o Blocked sample inlet gas line o Failed pressure sensor circuitry If sample pressure is gt 35 in hg Blocked vent line on pressurized sample zero span gas supply o Bad pressure sensor circuitry This message occurs at power on If it is
63. TEST The optic test function tests the response of the PMT sensor by turning on an LED located in the cooling block of the PMT Fig 10 15 The analyzer uses the light emitted from the LED to test its photo electronic subsystem including the PMT and the current to voltage converter on the pre amplifier board To make sure that the analyzer measures only the light coming from the LED the analyzer should be supplied with zero air The optic test should produce a PMT signal of about 200021000 mV To activate the electrical test press the following key sequence SAMPLE RANGE 500 000 PPB S02 XXX X DIAG SIGNALI O lt TST TST gt CAL SAMPLE ENTER SETUP PASS 818 PREV NEXT JUMP ENTR EXIT C Press NEXT until 2j OPTIC TEST DIAG PREV NEXT ENTR EXIT SETUP XX PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE DIAG OPTIC RANGE 500 000 PPB SO2 XXXX EXIT lt TST TST gt d Press TST until E DIAG ELEC PMT 2751 MV SO2zXXX X SETUP XX SECONDARY SETUP MENU COMM VARS DIAG EXIT While the optic test is activated PMT should be 2000 mV 1000 mV lt TST TST gt EXIT NOTE This is a coarse test for functionality and not an accurate calibration tool The resulting PMT signal can vary significantly over time and also changes with low level calibration 6400E Rev B 79 Operating Instructions
64. TST TST gt ENTR CONC EXIT EXIT returns to the main SAMPLE display Check the value of the SLOPE and OFFSET test functions see Section 6 2 1 to verify that they are within the limits listed in Tabie 7 5 The Model 6400E analyzer is now ready for operation 6400E Rev B 27 Getting Started Model 6400E Instruction Manual 3 3 2 INTERFERENCES FOR SO MEASUREMENTS It should be noted that the fluorescence method for detecting SO is subject to interference from a number of sources The most common source of interference is from other gases that fluoresce in a similar fashion to SO when exposed to UV Light such as nitrogen oxide NO and poly nuclear aromatics PNA of which certain hydrocarbons such as meta xylene and naphthalene are the most pervasive The 6400E has been successfully tested for its ability to reject interference from most of these sources For a more detailed discussion of this topic see Section 10 2 7 User Notes 28 6400E Rev B Model 6400E Instruction Manual Frequently Asked Questions amp Glossary 4 FREQUENTLY ASKED QUESTIONS amp GLOSSARY 4 1 FAQ S The following list contains some of the most commonly asked questions relating to the Model 6400E SO Analyzer Q Why is the ZERO or SPAN key not displayed during calibration A The 6400E disables certain keys whenever the chosen value is out of range for that particular parameter In this case the expected span or zero va
65. Table 11 8 4 Under the DIAG gt SIGNAL 1 0 menu see Section 6 9 2 scroll through the inputs and outputs until you get to the output in question Alternately turn on and off the output noting the voltage on the voltmeter it should vary between 0 volts for ON and 5 volts for OFF 11 5 9 4 Control Inputs The control input bits can be tested by the following procedure 1 Connect a jumper from the 5 V pin on the STATUS connector to the 5 V on the CONTROL IN connector 2 Connect a second jumper from the pin on the STATUS connector to the A the CONTROL IN connector The instrument should switch from SAMPLE mode to ZERO CAL R mode 3 Connect a second jumper from the on the STATUS connector to the B pin on the CONTROL IN connector The instrument should switch from SAMPLE mode to SPAN CAL mode In each case the 6400E should return to SAMPLE mode when the jumper is removed 11 5 10 CPU There are two major types of CPU board failures a complete failure and a failure associated with the Disk On Chip DOC If either of these failures occur contact the factory For complete failures assuming that the power supplies are operating properly and the wiring is intact the CPU is faulty if on power on e watchdog LED on the motherboard is not flashing either the motherboard or the CPU is faulty There is no activity from the primary RS 232 port COM1 on the rear panel even if lt re
66. The sample chamber and the PMT assembly Figure 10 13 shows an exploded view of the sample chamber assembly Figure 10 14 shows an exploded view of the PMT Assembly 04515 Rev B 187 Theory Of Operation Model 6400E Instruction Manual 10 4 2 1 Sample Chamber The main electronic components of the sample chamber are the reference detector see Section 10 2 2 the UV Lamp see Section 10 2 1 and its electronically operated shutter see Section 10 2 4 and the sample chamber heating circuit UV Source Lamp Shutter Housing UV Source Lens amp Housing PMT Lens amp Sample Air Housing Outlet O Ring Seal Shutter Assy A Sample Air hidden from view y Inlet Sampie chamber Reference Detector Sample Chamber Sample Chamber Temperature Sensor O Ring Seal Sample Chamber Heater Light Trap Figure 10 13 6400E Sample Chamber 10 4 2 2 Sample Chamber Heating Circuit In order to reduce temperature effects the sample chamber is maintained at a constant 50 C just above the high end of the instrument s operation temperature range Two AC heaters one embedded into the top of the sample chamber the other embedded directly below the reference detector s light trap provide the heat source These heaters operate off of the instrument s main AC power and are controlled by the CPU through a power relay on the relay board A thermistor also embedded in the bottom of the s
67. VDC TO change these settings see Sections 6 9 4 1 An optional Current Loop output is available for each See Section 5 2 6400E Rev B 11 Getting Started Model 6400E Instruction Manual 3 1 1 2 Connecting the Status Outputs The analyzer s status outputs are accessed through a 12 pin connector on the analyzer s rear panel labeled STATUS They are used to interface with a device that accepts closed contact digital inputs such as programmable logic controllers PLC s STATUS 123 4 5 67 8D b x Jab 2 w 59 ss 4 a Bla 9 9 slg e 2 amp al gt oj z 2 58 Hi ti lt o 5 v gt uj o 2 gt N a 5 Ssiss o 2 o Ez 2s EZ Figure 3 3 Status Output Connector NOTE Most PLC s have internal provisions for limiting the current the input will draw When connecting to a unit that does not have this feature external resistors must be used to limit the current through the individual transistor outputs to S50mA 120 for 5V supply Table 3 2 Status Output Signals REAR PANEL STATUS LABEL DEFINITION CONDITION 1 SYSTEM OK ON if no faults are present OFF any time the HOLD OFF feature is active such as during calibration or when other faults exist possibly invalidating the current concentration 2 CONC VALID measurement example sample flow rate is outside of acceptable limits ON if concentration measurement
68. YO amp DO Any character in RS 232 COM1 modem initialization amp 10 50 2 the allowed string Sent verbatim plus carriage amp BO amp N6 amp MO character set Up return to rnodem on power up or EO Qi amp WO to 100 characters manually Enclose value in double long quotes when setting from the RS 232 interface RS232 MODE2 BitFlag 0 0 65535 RS 232 COM2 mode flags Same settings as R5232 MODE BAUD RATE2 19200 300 1200 2400 4800 9600 19200 38400 57600 115200 RS 232 COM2 baud rate Enclose value in double quotes when setting from the RS 232 interface 270 05036 Rev C 3 Model 6400E Instruction Manual APPENDIX 2 Setup Variables For Serial I O Revision C 3 REMOTE CAL MODE PASS ENABLE STABIL FREQ NUMERIC DEFAULT SETUP VARIABLE UNITS VALUE VALUE RANGE DESCRIPTION MODEM INIT2 AT YO amp DO Any character in RS 232 COM2 modem initialization amp HO amp IO SO 2 the allowed string Sent verbatim plus carriage amp BO amp N6 amp MO character set Up return to modem on power up or Q1 amp WO to 100 characters manually Enclose value in double long quotes when setting from the RS 232 interface RS232 PASS Password 940331 0 999999 RS 232 log on password MACHINE 10 ID 100 0 9999 Unique ID number for instrument COMMAND PROMPT
69. a variety of methods for identifying possible sources of failures or performance problems within the analyzer In most cases this included a list of possible causes and in some cases quick solutions or at least a pointer to the appropriate sections describing them This section describes how to determine if a certain component or subsystem is actually the cause of the problem being investigated 11 5 1 DETAILED PRESSURE LEAK CHECK Obtain a leak checker similar to TAI part number 01960 which contains a small pump shut off valve and pressure gauge to create both over pressure and vacuum Alternatively a tank of pressurized gas with the two stage regulator adjusted to lt 15 psi a shutoff valve and pressure gauge may be used CAUTION Once tube fittings have been wetted with soap solution under a pressurized system do not apply or re apply vacuum as this will cause soap solution to be sucked into the instrument contaminating inside surfaces Do not exceed 15 psi when pressurizing the system 1 Turn OFF power to the instrument and remove the instrument cover 2 Install a leak checker or a tank of gas compressed oil free air or nitrogen as described above on the sample inlet at the rear panel 3 Pressurize the instrument with the leak checker or tank gas allowing enough time to fully pressurize the instrument through the critical flow orifice Check each tube connection fittings hose clamps with soap bubble s
70. ali Figure 3 3 Status Output Connector 412 Figure 3 4 Control Input Connector S13 Figure 3 5 Internal Pneumatic Diagram of the 6400E Standard Configuration 16 viii 6400E Rev B Model 6400E Instruction Manual Figure 3 6 Figure 3 7 Figure 3 8 Figure 3 9 Figure 3 10 Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Figure 5 5 Figure 5 6 Figure 6 1 Figure 6 2 Figure 6 3 Figure 6 4 Figure 6 5 Figure 6 6 Figure 6 7 Figure 6 8 Figure 6 9 Figure 6 10 Figure 6 11 Figure 6 12 Figure 6 13 Figure 6 14 Figure 6 15 Figure 6 16 Figure 6 17 Figure 6 18 Figure 6 19 Figure 6 20 Figure 7 1 Figure 7 2 Figure 7 3 Figure 9 1 Figure 9 2 Figure 10 1 Figure 10 2 Figure 10 3 Figure 10 4 Figure 10 5 Figure 10 6 Figure 10 7 Figure 10 8 Figure 10 9 Figure 10 10 Figure 10 11 Figure 10 12 Figure 10 13 Figure 10 14 Figure 10 15 Figure 10 16 Figure 10 17 Figure 10 18 Figure 10 19 Pneumatic Connections Basic Configuration Using Gas Dilution Calibrator 17 Pneumatic Connections Basic Configuration Using Bottled Span Gas 17 Basic Pneumatic Connections for Units with Valve Options 19 6400E Layout Basic Unit No Valve Options sseesesrerarenoenenennnnennnennnnpnnnesaneee 20 Front Panel Layout eceecorsnessesecaeecceeeenennenanneeanannanensaansanaeesenene
71. all analog concentration outputs are set to the same reporting range This reporting range can be set to any value between 0 1 ppb and 20 000 ppb While the two outputs always have the same reporting range the span and scaling of their electronic signals may also be configured for different differently e g A1 0 10 V A2 0 0 1 v To select SNGLE range mode and to set the upper limit of the range press RANGE 500 000 PPB S02 XXX X S TET TST gt CAL SETUP SAMPLE ENTER SETUP PASS 818 SETUP X X RANGE MODE d 8 1 8 ENTR EXIT SNGL IND AUTO ENTR EXIT SETUP X PRIMARY SETUP MENU SETUP XX CFG DAS RNGE PASS CLK MORE EXIT MODE SET UNIT RANGE CONTROL MENU SETUP X X SETUP XX MODE SET UNIT RANGE MODE SNGL SETUP X X SETHP XX SNGL IND AUTO ENTR EXIT MODE SET UNIT RANGE CONTROL MENU RANGE 500 0 Conc ENTR EXIT RANGE CONTROL MENU EXIT x 2 returns to the main SAMPLE display 6400E Rev B 57 Operating Instructions Model 6400E Instruction Manual 6 7 5 DUAL RANGE MODE DUAL Selecting Dual Range mode allows the A1 and A2 outputs to be configured with different reporting ranges The analyzer software calls these two ranges low and high The Low range setting corresponds with the analog output labeled Ai on the rear panel of the instrument The high range setting corresponds with the A2
72. analyzer the data logger or A scale problem with the input to the data logger The analog outputs of the analyzer can be manually calibrated to compensate for either or both of these effects see Section 6 9 4 Q How do I measure the sample flow A Sample flow is measured by attaching a calibrated flow meter to the sample inlet port when the instrument is operating The sample flow should be 650 cm3 min 10 Chapter 11 includes detailed instructions on performing a check of the sample gas flow Q How often do I need to change the particulate filter A Once per week Table 9 1 contains a maintenance schedule listing the most important regular maintenance tasks 6400E Rev B 29 Frequently Asked Questions amp Glossary Model 6400E Instruction Manual Q How long does the sample pump last A The sample pump should last about one year and the pump diaphragms should to be replaced annually or when necessary Use the PRES test function displayed via the front panel to see if the diaphragm needs replacement Q Do I need a strip chart recorder or external data logger A No the 6400E is equipped with a very powerful internal data acquisition system Section 6 11 describes the setup and operation in detail 4 2 GLOSSARY ASSY acronym for Assembly cm metric abbreviation for cubic centimeter Same as the obsolete abbreviation cc DAS acronym for data acquisition system the old acronym of iDAS DIAG acron
73. and the wiring connecting them to the PMT temperature contro PCA 11 5 15 1 TEC Control Test Points Four test points are also located at the top of this assembly they are numbered left to right start with the T1 point immediately to the right of the power status LED These test points provide information regarding the functioning of the control circuit determine the current running through the control circuit measure the voltage between 1 and T2 Multiply that voltage by 10 determine the drive voltage being supplied by the control circuit to the TEC measure the voltage between T2 and T3 e If this voltage is zero the TEC circuitry is most likely open Ifthe voltage between T2 and 0 VDC and the voltage measured between T1 and T2 0 VDC there is most likely an open circuit or failed op amp on control PCA itself Ifthe voltage between T2 and 0 VDC and the voltage measured between T1 to T2 is some voltage other than 0 VDC the TEC is most likely shorted e T4is tied directly to ground To determine the absolute voltage on any one of the other test points make a measurement between that test point ant T4 11 5 16 HIGH VOLTAGE POWER SUPPLY The HVPS is located in the interior of the sensor module and is plugged into the PMT tube see Figure 10 14 It requires 2 voltage inputs The first is 15 which powers the supply The second is the programming voltage which is generated on the Preamp Board
74. being measured at about 90 of the desired full measurement range For example if the measurement range is 500 ppb the span gas should have an SO concentration of about 450 ppb Span gases should be certified to a specific accuracy to ensure accurate calibration of the analyzer Typical gas accuracy for SO gases is 1 or 2 96 SO standards should be mixed in nitrogen 7 1 4 PERMEATION TUBES Teledyne Analytical Instruments offers an IZS option operating with permeation devices The accuracy of these devices is about 5 Whereas this may be sufficient for quick daily calibration checks we strongly recommend to use certified SO span gases for accurate calibration Note Applications requiring US EPA equivalency do not allow permeation devices to be used as sources of span gas for calibration of the analyzer 7 1 5 CALIBRATION GAS All equipment used to produce calibration gases should be verified against standards of the National Institute for Standards and Technology NIST To ensure NIST traceability we recommend to acquire cylinders of working gas that are certified to be traceable to NIST Standard Reference Materials SRM These are available from a variety of commercial sources Table 7 1 NIST SRM s Available for Traceability of SO2 Calibration Gases meus NOMINAL NESTSSRM TYPE CONCENTRATION 1693a Sulfur dioxide in 50 ppm 1694a Sulfur dioxide in N2 100 ppm 1661a Sulfur dioxide in Nz 500 ppm
75. can be captured with a terminal emulation program or simply viewed by the user To enable automatic COM port reporting follow the instruction shown in section 6 11 2 2 then press the DATA ACQUISITION menu Edit Data Channel Menu SETUP XX 0 CONC ATIMER 2 4032 Exits to the main PREV NEXT INS DEL EDIT PRNT EXIT Data Acquisition menu SETUP XX SET SET EDIT PRINT EXIT Press SET key until SETUP XX 5 232 REPORT OFF SET SET EDIT PRINT ENTR accepts the new setting and retums to the previous menu EXIT ignores the new setting and retums to the previous menu SETUP X X RS 232 REPORT OFF Toggle key to tum reporting ON or OFF q ENTR EXIT 6 11 2 8 Compact Report When enabled this option avoids unnecessary line breaks on all RS 232 reports Instead of reporting each parameter in one channel on a separate line up to five parameters are reported in one line instead 6 11 2 9 Starting Date This option allows to specify a starting date for any given channel in case the user wants to start data acquisition only after a certain time and date If the Starting Date is in the past the iDAS ignores this setting 6400E Rev B 115 Operating Instructions Model 6400E Instruction Manual 6 11 2 10 Disabling Enabling Data Channels Data channels can be temporarily disabled which can reduce the read write wear on the disk o
76. each activity is completed Table 8 4 Definition of Level 1 and Level 2 Zero and Span Checks from Section 2 0 9 of Q A Handbook for Air Pollution Measurement Systems LEVEL 1 ZERO AND SPAN CALIBRATION A Level 1 zero and span calibration is a simplified two point analyzer calibration used when analyzer linearity does not need to be checked or verified Sometimes when no adjustments are made to the analyzer the Level 1 calibration may be called a zero span check in which case it must not be confused with a Level 2 zero span check Since most analyzers have a reliably linear or near linear output response with concentration they can be adequately calibrated with only two concentration standards two point concentration Furthermore one of the standards may be zero concentration which is relatively easily obtained and need not be certified Hence only one certified concentration standard is needed for the two point Level 1 zero and span calibration Although lacking the advantages of the multipoint calibration the two point zero and span calibration because of its simplicity can be and should be carried out much more frequently Also two point calibrations are easily automated Frequency checks or updating of the calibration relationship with a two point zero and span calibration improves the quality of the monitoring data by helping to keep the calibration relationship more closely matched to any change
77. excited SO in the sample chamber So k SO L 9 SO Equation 10 5 Finally the function K is affected by the temperature of the gas The warmer the gas the faster the individual molecules decay back into their ground state and the more photons of UV light are given off per unit of time In summary given that the absorption rate of SO a is constant the amount of fluorescence F isa result of The amount of exited SO created which is affected by the variable factors from equation 10 2 above concentration of SO intensity of UV light path length of the UV light x and The amount of fluorescent light created which is affected by the variable factors from equation 10 5 the amount of SO present and the rate of decay which changes based on the temperature of the gas So when and the intensity of the light Zo is known path length of excited light is short x the temperature of the gas is known and compensated for so that the rate of SO2 decay is constant K and no interfering conditions are present such as interfering gases or stray light the amount of fluorescent light emitted F is directly related to the concentration of the SO in the Sample Chamber The Model 6400E UV Fluorescence SO Analyzer is specifically designed to create these circumstances The light path is very short X A reference detector measures the intensity of the available excitation UV light an
78. factory values Note any major deviations from the factory values and take corrective action e Use the internal electronic status LED s to determine whether the electronic communication channels are operating properly Verify that the DC power supplies are operating properly by checking the voltage test points on the relay board Note that the analyzer s DC power wiring is color coded and these colors match the color of the corresponding test points on the relay board Suspect a leak first Customer service data indicate that half of all problems are eventually traced to leaks in the pneumatic system of the analyzer the source of zero air or span 04515 Rev B 207 TROUBLESHOOTING amp REPAIR Model 6400E Instruction Manual gases or the sample gas delivery system Check for gas flow problems such as clogged or blocked internal external gas lines damaged seals punctured gas lines a damaged pump diaphragm etc Follow the procedures defined in Section 11 5 for confirming that the analyzer s basic components are working power supplies CPU relay board keyboard PMT cooler etc See Figure 3 9 for general layout of components and sub assemblies in the analyzer See the wiring interconnect drawing and interconnect list see Appendix D 11 1 1 WARNING MESSAGES The most common and or serious instrument failures will result in a warning message displayed on the front panel Table A 2 in Appendix A 3 contains a list of warning
79. from outside analyzer As seen from outside analyzer GND GND DTE mode GND DCE mode Figure 6 7 Back Panel connector Pin Outs for COM1 amp COM2 in RS 232 mode 86 6400E Rev B Model 6400E Instruction Manual Operating Instructions The signals from these two connectors are routed from the motherboard via a wiring harness to two 10 pin connectors on the CPU card CN3 COM1 and CN4 COM2 CN3 amp CN4 Located on CPU card GND As seen from inside analyzer Figure 6 8 CPU connector Pin Outs for COM1 amp COM2 in RS 232 mode Teledyne Instruments offers two mating cables one of which should be applicable for your use e Part number WRO00077 a DB 9 female to DB 9 female cable 6 feet long Allows connection of COM1 with the serial port of most personal computers Also available as Option 60 see Section 5 5 1 Part number WRO00024 a DB 9 female to DB 25 male cable Allows connection to the most common styles of modems e g Hayes compatible and code activated switches Both cables are configured with straight through wiring and should require no additional adapters To assist in properly connecting the serial ports to either a computer or a modem there are activity indicators just above the COM1 port Once a cable is connected between the analyzer and a computer or modem both the red and green LEDs should be on If the lights for COM 1 are not lit use small switch on the rear pane
80. if the temperature pressure compensation TPC feature is turned on see Section 10 7 3 the output of this sensor is also used to supply pressure data for that calculation The actual pressure measurement is viewable through the analyzer s front panel display as the test function PRESS 10 3 5 2 Sample Flow Sensor A thermal mass flow sensor is used to measure the sample flow through the analyzer This sensor is also mounted on the pneumatic pressure flow sensor board upstream of the sample chamber The flow rate is monitored by the CRT which issues a warning message SAMP FLOW WARN if the flow rate is too high or too low The flow rate of the sample gas is viewable via the front panel as the SAMP FL test function 04515 Rev B 183 Theory Of Operation Model 6400E Instruction Manual 10 4 ELECTRONIC OPERATION ERO i ETHERNET p ors 1 0 OPTION Analog Outputs COMMB COMMA Female Male Control Inputs i 6 Status Outputs 1 8 Analog External Outputs 1 0 Cae oa PC 104 Fa b CPU Card Power Up i A D Circuit B Tuer E Converter Disk Oi 80 f i Pu FATU age B MOTHER STATUS Temp LED BOARD E 1 ig i 8 Flash Chip ROREM POCELE 7 PC 104 mum eet L Bus Thermistor Internal Analog Interface Digital Sensor Inputs Pneumatic Sensor SAMPLE CHAMBER TEMPERATURE PC Status
81. independently with dedicated keys CALZ and CALS To perform a manual calibration check of an analyzer with a zero span valve or IZS Option installed use the following method STEP ONE Connect the sources of Zero Air and Span Gas as shown below Source of SAMPLE Gas MODEL 700 Gas Dilution Calibrator with O generator option Filter External Zero Air Scrubber VENT Needle valve to control flow MODEL 701 Zero Air Generator Calibrated SO gas At high concentration Internal Zero Span Option 125 Option 51 Source of SAMPLE Gas Sample Exhaust M L Semn 6400E Ambient Air Zero Air Figure 7 3 Setup for Manual Calibration Check with Z S Valve or IZS Option 6400E Rev B 145 Calibration Procedures Model 6400E Instruction Manual STEP TWO Perform the Scroll to the STABIL test function Wait until STABIL falls below 0 5 ppb This may lake several minutes The value of STABIL may jump significantly Wait until STABIL falls below 0 5 ppb This may take several minutes zero span check SAMPLE RANGE 500 000 PPB 502 XXX X 4 4 lt TST TST CAL CALZ CALE SETUP SAMPLE STABIL XXX X PPB 502 XXX X TST TST gt CAL CALZ CALS SETUP ZERO CAL M LSXXX S02 XXKX TST TST gt ZERO CONC EXIT SAMPLE S PPR SO2 XkX X lt TST TST gt CAL CAL2 CALS SETUP
82. inlet port Also if the span gas is not vented at all and does not supply enough sample gas the analyzer may be evacuating the sample line Make sure to create and properly vent excess span gas e Ifthe instrument is equipped with an internal IZS valve option and the SO span value is continuously trending downward the IZS permeation tube may require replacement 11 3 7 DISCREPANCY BETWEEN ANALOG OUTPUT AND DISPLAY If the concentration reported through the analog outputs does not agree with the value reported on the front panel you may need to re calibrate the analog outputs This becomes more likely when using a low concentration or low analog output range Analog outputs running at 0 1 V full scale should always be calibrated manually See Section 6 9 4 3 for a detailed description of this procedure 218 04515 Rev B Model 6400E Instruction Manual TROUBLESHOOTING amp REPAIR 11 4 OTHER PERFORMANCE PROBLEMS Dynamic problems i e problems which only manifest themselves when the analyzer is monitoring sample gas can be the most difficult and time consuming to isolate and resolve The following section provides an itemized list of the most common dynamic problems with recommended troubleshooting checks and corrective actions 11 4 1 EXCESSIVE NOISE Excessive noise levels under normal operation usually indicate leaks in the sample supply or the analyzer itself Make sure that the sample or span gas supply is leak free and c
83. intensity of the UV light Za and not its peak intensity because the intensity of UV light is not constant in every part of the sample chamber Some of the photons are absorbed by the SO as the light travels through the sample gas Figure 10 1 UV Absorption The equation for defining the average intensity of the UV light Za is Ia 1 1 exp ax SO Equation 10 2 Where Io Intensity of the excitation UV light a The absorption coefficient of SO a constant SO Concentration of SO in the sample chamber x The distance between the UV source and the SO molecule s being affected path length The second stage of this reaction occurs after the SO reaches its excited state SO Because the system will seek the lowest available stable energy state the SO2 molecule quickly returns to its ground state Equation 10 3 by giving off the excess energy in the form of a photon Av The wavelength of this fluoresced light is also in the ultraviolet band but at a longer lower energy wavelength centered at 330nm x SO gt SO AV330nm Equation 10 3 172 04515 Rev B Model 6400E Instruction Manual Theory Of Operation The amount of detectable UV given off by the decay of the SO is affected the rate at which this reaction occurs F k SO Equation 10 4 Where F the amount of fluorescent light given off k The rate at which the SO decays into SO SO Amount of
84. is included as well Maximum communication speed is limited by the RS 232 port to 115 2 kBaud aDC Power Connector Female RIAS Connack LNK LED ACT LED TxD LED RS 232 t Ianedtr to the Motherboard Figure 5 5 6400 Ethernet Card ETHERNET OPTION 0 45 Connector Activity LED Transmit LED Receive LED Interior View Exterior View Figure 5 6 6400E Rear Panel with Ethernet Installed This option can be installed in conjunction with the RS 2323 multidrop option 62 allowing the instrument to communicate on both types of networks simultaneously For more information on using and setting up this option see Section 6 10 6 40 6400E Rev B Model 6400E Instruction Manual Optional Hardware and Software 5 6 ADDITIONAL MANUALS 5 6 1 PRINTED MANUALS OPTION 70 Additional printed copies of this manual are available from Teledyne Analytical Instruments 5 7 EXTENDED WARRANTY OPTIONS 92 amp 93 Two options are available for extending Teledyne Instruments standard warranty see Section 2 4 Both options have to be specified upon ordering the analyzer OPTION NUMBER DESCRIPTION OPT 92 Extends warranty to cover two 2 year period from the date of purchase OPT 93 Extends warranty to cover a five 5 year period from the date of purchase _ 5 8 SPECIAL SOFTWARE FEATURES 5 8 1 MAINTENANCE MODE SWITCH Teledyne Analytical Instruments analyzers
85. is to measure between 0 ppm and 500 ppb an appropriate span gas concentration would be 450 ppb SO2 Cylinders of calibrated SO gas traceable to NIST Standard Reference Material specifications also referred to as SRM s or EPA protocol calibration gases are commercially available Table 3 5 lists specific NIST SRM reference numbers for various concentrations of 502 Some applications such as EPA monitoring require a multipoint calibration procedure where span gases of different concentrations are needed We recommend using a bottle of calibrated SO gas of higher concentration in conjunction with a gas dilution calibrator such as a Teledyne Analytical Instruments Model 700 This type of calibrator precisely mixes a high concentration gas from with zero air both supplied externally to accurately produce span gas of the correct concentration Linearity profiles can be automated with this model and run unattended over night Table 3 5 NIST SRM s Available for Traceability of SO Calibration Gases 2 4 NOMINAL NISUSRM CONCENTRATION 1693a Sulfur dioxide in N2 50 ppm 1694a Sulfur dioxide in N2 100 ppm 1661a Sulfur dioxide in 500 ppm 16 6400E Rev Model 6400E Instruction Manual Getting Started 3 1 2 2 Pneumatic Connections to 6400E Basic Configuration Figures 3 5 and 3 6 show the most common configurations for gas supply and exhaust lines to the Model 6400 Analyzer Please refer to Figu
86. maintenance will be required The last 360 daily averages about 1 year are stored CALDAT Logs new slope and offset every time a zero or span calibration is performed This Data Channel also records the instrument reading just prior to performing a calibration Note this Data Channel collects data based on an event a calibration rather than a timer This Data Channel will store data from the last 200 calibrations This does not represent any specific length of time since it is dependent on how often calibrations are performed As with all Data Channels a time and date stamp is recorded for every data point logged DETAIL Samples fourteen different parameters related to the operating status of the analyzers optical sensors and PMT For each parameter value is logged once every minute e An average of the last 60 readings is calculated once every e The last 480 averages are stored 20 days This channel is useful for diagnosing problems that cause the instruments measurements to drift slowly over time FAST Almost identical to DETAIL except that for each parameter Samples are taken once per minute and reported once per minute in effect causing the instrument to record an instantaneous reading of each parameter every minute The last 360 readings for each parameter are recorded reported This channel is useful for diagnosing transients spikes and noise problems These default Data Channels can be used as they are or
87. messages along with their meaning and recommended corrective action It should be noted that if more than two or three warning messages occur at the same time it is often an indication that some fundamental analyzer sub system power supply relay board motherboard has failed rather than an indication of the specific failures referenced by the warnings In this case a combined error analysis needs to be performed The analyzer will alert the user that a warning is active by displaying the keypad labels MSG and CLR on the front panel and a text message in the top center line of the display as shown in this example SAMPLE AZERO WARNING SO2 XXX X lt TST TST gt CAL MSG CLR SETUP The analyzer will also issue a message to the serial port and cause the red FAULT LED on the front panel to blink To view or clear a warning message press WARNING made lt TST TST gt keys replaced with TEST key Pressing TEST switches to SAMPLE mode and hides waming messages until new waming s are activated SAMPLE RANGE 500 0 PPB 502 XXX X TEST CAL MSG CLR SETUP MSG indicates that one or more warming message are active but hidden Pressing MSG cycles through wamings in SAMPLE mode all warning 4 messages are hidden bul MSG button appears SAMPLE RANGE 500 0 PPB 502 XXX X lt TST TST gt CAL MSG CLR SETUP SAMPLE SYSTEM RESET 502 X XXX Press CLR to clear the cu
88. methods for rejecting interference from these gasses A special scrubber kicker mechanism removes any PNA chemicals present in the sample gas before it the reach the sample chamber The exact wavelength of light needed to excite a specific non SO fluorescing gas is removed by the source UV optical filter The light given off by Nitrogen Oxide and many of the other fluorescing gases is outside of the bandwidth passed by the PMT optical filter 10 2 7 2 UV Absorption by Ozone Because ozone absorbs UV Light over a relatively broad spectrum it could cause a measurement offset by absorbing some of the UV given off by the decaying SO in the sample chamber The Model 6400E prevents this from occurring by having a very short light path between the area where the SO fluorescence occurs and the PMT detector Because the light path is so short the amount of needed to cause a noticeable effect would be much higher than could be reasonably expected in any application for which this instrument is intended 178 04515 Rev B Model 6400E Instruction Manual Theory Of Operation 10 2 7 3 Dilution Certain gases with higher viscosities can lower the flow rate though the critical flow orifice that controls the movement of sample gas though the analyzer reducing the amount of sample gas in the sample chamber and thus the amount of SO available to react with the to the UV light While this can be a significant problem for some analyzers th
89. next 72 6400E Rev Model 6400E Instruction Manual Operating Instructions 6 9 4 3 Manual Analog Output Calibration and Voltage Adjustment For highest accuracy the voltages of the analog outputs can be manually calibrated Calibration is done through the instrument software with a voltmeter connected across the output terminals see Figure 6 5 Adjustments are made using the front panel keys by setting the zero point first and then the span point see Table 6 12 The software allows this adjustment to be made in 100 10 or 1 count increments Table 6 12 Voltage Tolerances for Analog Output Calibration genie ZERO TOLERANCE VOLI LE SPAN TOLERANCE 0 1 VDC 0 0005 90mv 0 001 1 VDC 0 001 900 mV 0 001 5 VDC 0 002 4500 mV 0 003 10 VDC 0 004 4500 mV 0 006 NOTE Outputs configured for 0 1V full scale should always be calibrated manually See Table 3 1 for pin assignments of Analog Out connector on the rear panel Recording Device ANALYZER Figure 6 5 Setup for Calibrating Analog Outputs 6400E Rev B 73 Operating Instructions Model 6400E Instruction Manual To make these adjustments the AOUT auto calibration feature must be turned off see Section 6 9 4 2 Activate the ANALOG I O CONFIGURATION MENU see Section 6 9 1 then press C Access from the DIAG menu see Section 6 9 1 Y DIAG AIO CONC OUT 1
90. of an instrument with an IZS option installed the following provisions must be followed Zero air and span gas must be supplied to the analyzer through the sample gas inlet as depicted in Figure 7 1 of Section 7 2 The calibration procedure must be initiated using the CAL key not the CALZ and CALS keys using the procedure defined in Section 7 2 Using the CAL key does not activate the zero span or sample cal valves of the IZS option thus allowing the introduction of zero air and sample gas through the sample port from more accurate external sources such as a calibrated bottle of SO or a Model 700 Dilution Calibrator SAMPLE RANGE 500 000 PPB 502 lt TST TST gt CALZ CALS SETUP Use for formal Use only for calibration informal calibration operations checkss 144 6400E Rev B Model 6400E Instruction Manual Calibration Procedures 7 6 MANUAL CALIBRATION CHECKS WITH Izs OR ZERO SPAN VALVES Zero and span checks using the zero span valve or IZS option are similar to that described in Section 7 3 except On units with an IZS option installed zero air and span gas are supplied to the analyzer through the zero gas inlet and from ambient air On units with a zero span valve option installed zero air and span gas are supplied to the analyzer through the zero gas and span gas inlets from two different sources The zero and calibration operations are initiated directly and
91. of range reading or the analyzer s inability to calculate it All pressure measurements are represented in terms of absolute pressure Absolute atmospheric pressure is 29 92 in Hg A at sea level It decreases about 1 in Hg per 300 m gain in altitude A variety of factors such as air conditioning and passing storms can cause changes in the absolute atmospheric pressure 46 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 2 2 WARNING MESSAGES The most common instrument failures will be reported as a warning on the analyzer s front panel and through the COM ports Section 11 1 1 explains how to use these messages to troubleshoot problems Section 3 2 3 shows how to view and clear warning messages Table 6 3 lists all warning messages for the current version of software Table 6 3 List of Warning Messages MESSAGE MEANING ANALOG CAL WARNING The instruments A D circuitry or one of its analog outputs is not calibrated BOX TEMP WARNING The temperature inside the 6400E chassis is outside the specified limits CANNOT DYN SPAN Remote span calibration failed while the dynamic span feature was set to turned on CANNOT DYN ZERO Remote zero calibration failed while the dynamic zero feature was set to turned on CONFIG INITIALIZED Configuration was reset to factory defaults or was erased DARK CAL WARNING Dark offset above limit specified indicating that too m
92. operating in sample mode front panel display is being updated Cal Yellow Off The instrument s calibration is not enabled Fault Red Blinking The analyzer is warming up and hence out of specification for a fault free reading various warning messages will appear MODE FIELD MESSAGE FIELD CONCENTRATION FIELD KEY DEFINITIO KEYBOARD FASTENER S02 X XXX SETUP STATUS LEI O A ON OFFS Figure 3 10 Front Panel Layout 3 2 3 WARNING MESSAGES Because internal temperatures and other conditions may be outside of specified limits during the analyzer s warm up period the software will suppress most warning conditions for 60 minutes after power up If warning messages persist after 60 minutes investigate their cause using the troubleshooting guidelines in Chapter 11 The following table includes a brief description of the various warning messages that may appear 22 6400E Rev B Model 6400E Instruction Manual Getting Started Table 3 7 Possible Warning Messages at Start Up MESSAGE MEANING ANALOG CAL WARNING The instruments internal A to D circuitry also referred to as Analog In see Table 6 6 or one of its analog outputs is not calibrated BOX TEMP WARNING The temperature inside the 6400E chassis is outside the specified limits
93. or ON instrument is in calibration mode Note that when enabled here there is also a length of the DAS HOLD OFF after calibration mode which is set in the VARS menu see Section 6 11 2 11 ENT 6400E Rev B 103 Operating Instructions Model 6400E Instruction Manual 6 11 1 2 iDAS Parameters Data parameters are types of data that may be measured and stored by the iDAS For each Teledyne Instruments analyzer model the list of available data parameters is different fully defined and not customizable Appendix A 5 lists firmware specific data parameters for the 6400E The most common parameters are concentrations of the measured gas SO temperatures of heated zones converter sample chamber box temperature pressures and flows of the pneumatic subsystem and other diagnostic measurements as well as calibration data slope and offset for each gas Most data parameters have associated measurement units such as mV ppb etc although some parameters have no units The only units that can be changed are those of the concentration readings according to the SETUP RANGE settings Note that the iDAS does not keep track of the unit of each concentration value and iDAS data files may contain concentrations in multiple units if the unit was changed during data acquisition Each data parameter has user configurable functions that define how the data are recorded see Table 6 21 Table 6 21 iDAS
94. output While the software names these two ranges low and high they do not have to be configured that way For example the low range can be set for a span of 0 150 ppb while the high range is set for 0 50 ppb In DUAL range mode the RANGE test function displayed on the front panel will be replaced by two separate functions RANGEL The range setting for the A1 output RANGE2 The range setting for the A2 output To set the ranges press following keystroke sequence SAMPLE RANGE 500 G00 PPB 502 zXXXX SETUP XX RANGE MODE DUAL TST TST CAL SETUP SNGL DUAL AUTO ENTR EXIT SAMPLE ENTER SETUP PASS 818 SETUP X RANGE CONTROL MENU 8 1 8 ENTR EXIT MODE SET UNIT SETUP XX PRIMARY SETUP MENU SETUP XX LOW RANGE 500 0 Conc CFG DAS RNGE PASS CLK MORE EXIT ENTR EXIT Toggle the Numeral Keys to set the upper limit of each SETUP X x RANGE CONTROL MENU SETUP XX HIGH RANGE 500 0 Conc range MODE SET UNIT EXIT 0 0 ENTR EXIT SETUP XX RANGE MODE SNGL SETUP X X RANGE CONTROL MENU EXIT Returns to the Main SNGL DUAL AUTO ENTR EXIT MODE SET UNIT EXIT SAMPLE Display NOTE In DUAL range mode the LOW and HIGH ranges have separate slopes and offsets for computing SO concentration The two ranges must be independently calibrated 58 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 7 6 AUTO RANGE MODE AUTO In AUTO range mode the analyzer automatically switches the r
95. that may not be the ones automatically chosen by DHCP Editing the Ethernet Interface properties is a two step process STEP 1 Turn DHCP OFF While DHCP is turned ON the ability to manually set INSTRUMENT IP GATEWAY IP and SUBNET MASK is disabled SAMPLE RANGE 500 000 PPB S02 XXX X SETUP XX COMMUNICATIONS MENU ET TST TST gt CAL SETUP tD L COMI SAMPLE ENTER SETUP PASS 818 SETUP X X DHCP ON 8 1 8 ENTR EXIT SET SET EDIT EXIT SETUP X X PRIMARY SETUP MENU DHCP ON ON ENTR m x CFG DAS RNGE PASS CLK MORE EXIT SETUP SECONDARY SETUP MENU SETUP XX DHCP ON OFF m Continue with editing of Ethernet interface ENTR accept properties see Step 2 below new settings EXIT ignores new settings COMM VARS DIAG EXIT 6400E Rev B 93 Operating Instructions Model 6400E Instruction Manual STEP 2 Configure the INSTRUMENT IP GATEWAY IP and SUBNET MASK addresses by pressing From Step 1 above Internet Configuration Keypad Functions FUNCTION Press this key to cycle through the range of numerals and available characters 0 9 amp Moves the cursor one character left or right d TUP XX DHCP OFF Deletes a character at the cursor location SET EDIT EXIT Accepts the new sen Bnd resume to the previous Ignores the new setting and retums to the previous menu
96. the front panel keyboard The procedure is in Section 7 3 and 7 6 of this manual e Automatic Zero Span Checks After the appropriate setup Z S checks can be performed automatically every night See Section 7 8 of this manual for setup and operation procedures e Zero Span checks via remote contact closure Zero Span checks can be initiated via remote contact closures on the rear panel See Section 7 7 1 of this manual e Zero Span via RS 232 port Z S checks can be controlled via the RS 232 port See Section 6 10 3 amp 6 12 and Appendix A 6 of this manual for more details 158 6400E Rev B Model 6400E Instruction Manual EPA Protocol Calibration 8 4 PRECISIONS CALIBRATION PROCEDURES AND CHECKS Calibration must be performed with a calibrator that meets all conditions specified in Subsection 2 9 2 Handbook The user should be sure that all flow meters are calibrated under the conditions of use against a reliable standard Ail volumetric flow rates should be corrected to 25 C 77 F and 760mm 29 92in Hg Make sure the calibration system can supply the range of the concentration at a sufficient flow over the whole range of concentration that will be encountered during calibration All operational adjustments to the 6400E should be completed prior to the calibration The following software features must be set into the desired state before calibration Single range selection See Section 6 7 4 of this manual If
97. the instrument will be used more than one range it should be calibrated separately on each applicable range e Automatic temperature pressure compensation should be enabled See Section 6 8 e Alternate units make sure ppb units are selected for EPA monitoring See Section 6 7 7 The analyzer should be calibrated on the same range used for monitoring If the AUTO range mode is selected the highest of the ranges will result in the most accurate calibration and should be used 8 4 1 PRECISION CALIBRATION To perform a precision calibration the instrument set up input sources of zero air and sample gas and procedures should conform to those described in Section 7 2 for analyzer s with no valve options or with an IZS valve option installed and Section 7 5 for analyzer s with Z S options installed with the following exception 8 4 2 PRECISION CHECK A periodic check is used to assess the data for precision A one point precision check must be carried out at least once every 2 weeks on each analyzer at an SO concentration between 0 08 and 0 10 ppm The analyzer must be operated in its normal sampling mode and the precision test gas must pass through all filters scrubbers conditioners and other components used during normal ambient sampling The standards from which precision check test concentrations are obtained must be traceable to NIST SRM Those standards used for calibration or auditing may be used To perform a precision check th
98. the long filter by a fixed amount Second the instantaneous concentration must exceed the average in the long filter by a portion or percentage of the average in the long filter 204 04515 Rev B Model 6400E Instruction Manual Theory Of Operation If necessary these filter lengths of these two modes may be changed to any value between 1 and 1000 samples Long sample lengths provide better signal to noise rejection but poor response times Conversely shorter filter lengths result in poor signal to noise rejection but quicker response times 10 7 2 CALIBRATION SLOPE AND OFFSET Calibration of the analyzer is performed exclusively in software During instrument calibration see Chapters 7 and 8 the user enters expected values for zero and span through the front panel keypad and commands the instrument to make readings of sample gases with know concentrations of SO The readings taken are adjusted linearized and compared to the expected values as input With this information the software computes values for instrument both slope and offset and stores these values in memory for use in calculating the SO concentration of the sample gas Instrument slope and offset values recorded during the last calibration can be viewed by pressing the following keystroke sequence SAMPLE RCELL TEMP 0 0C S02 XXX X SAMPLE RANGE 500000PPB 502 XXX X lt TST TST gt CAL SETUP lt TST TST gt CAL SAMPLE TIME
99. this feature is AT YO amp DO amp HO amp IO SO 2 amp BO amp N6 amp MO EO Q1 amp WO This string can be altered to match your modem s initialization and can be up to 100 characters long To change this setting press SAMPLE RANGE 500 000 PPB 502 XXX X TST TST gt CAL SETUP SETUP COM MODE SET EDIT SAMPLE ENTER SETUP PASS 818 8 1 8 EXIT SETUP KX COMI BAUD RATE 19200 fr lt SET SET EDIT EXT SETUP XX PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT SETUP XX COM1 MODEM INIT AT YO amp DO amp H EXIT returns SET SET EDIT EXIT to the SETJP XX SECONDARY SETUP MENU previous menu COMM VARS DIAG ALRI EXIT ENTR accepts the 4 new string and relums SETUP XX COMI MODEM INIT LA T YZ amp D 6H ta the previous menu EXIT ignores the new CE lt CH CH gt INS DEL ENTR EXIT string and retums to Selec which SETUP XX COMMUNICATIONS MENU the previous menu COM Port is M2 COMI CO tested X Press the key repeatedly to cycle through the available character set The INS key The DEL key 0 9 inserts a character deletes a character AZ The CH and CH keys move before the cursor at the cursor space 1O 8 4 amp the cursor left and right location location PP Oe 7 find TAS along the text string rtt 126 6
100. to electro static discharge Table 12 2 Sensitivity of Electronic Devices to Damage by ESD DAMAGE SUSCEPTIBILITY DEVICE VOLTAGE RANGE DAMAGE BEGINS CATASTROPHIC OCCURRING AT DAMAGE AT MOSFET 10 100 VMOS 30 1800 NMOS 60 100 GaAsFET 60 2000 EPROM 100 100 JFET 140 7000 SAW 150 500 Op AMP 190 2500 CMOS 200 3000 Schottky Diodes 300 2500 Film Resistors 300 3000 ECL 500 500 SCR 500 1000 Schottky TTL 500 2500 252 04515 Rev B Model 6400E Instruction Manual A Primer on Electro Static Discharge Potentially damaging electro static discharges can occur Any time a charged surface including the human body discharges to a device Even simple contact of a finger to the leads of an sensitive device or assembly can allow enough discharge to cause damage A similar discharge can occur from a charged conductive object such as a metallic tool or fixture When static charges accumulated on a sensitive device discharges from the device to another surface such as packaging materials work surfaces machine surfaces or other device In some cases charged device discharges can be the most destructive A typical example of this is the simple act of installing an electronic assembly into the connector or wiring harness of the equipment in which it is to function If the assembly is carrying a static charge as it is connected to ground a discharge will occur
101. trouble shooting and quality control APICOM is very helpful for initial setup data analysis maintenance and trouble shooting Figure 6 16 shows an example of APICOM being used to remotely configuration the iDAS feature Figure 6 20 shows examples of APICOM s main interface which emulates the look and functionality of the instruments actual front panel 128 6400E Rev B Model 6400E Instruction Manual Operating Instructions APIcom N ddetasEno Settings Hep Connection ij COMI Direct Cable i COM2 Connected Direct Cable i Modem Windows Modem TCP IP Download graph save Figure 6 20 APICOM Remote Control Program Interface APICOM is included free of cost with the analyzer and the latest versions can also be downloaded for free at http www teledyne api com software apicom 6 12 3 ADDITIONAL COMMUNICATIONS DOCUMENTATION Table 6 26 Serial Interface Documents Interface Tool Imam Title Part Number Available Online APICOM APICOM User Manual 039450000 YES Multi drop Les Multi drop Documentation 021790000 YES DAS Manual Detailed description of the iDAS 028370000 YES 6400E Rev B 129 Operating Instructions Model 6400E Instruction Manual 6 12 4 USING THE 6400E WITH A HESSEN PROTOCOL NETWORK 6 12 4 1 General Overview of Hessen Protocol The Hessen protocol is a multidrop protocol in which several remote instruments are connected via a
102. value to high CONFIG Configuration and Failed disk on chip INITIALIZED Calibration data reset User erased data to original Factory state DARK CAL The Dark Cal signal is Light leak in reaction cell WARNING higher than 200 mV Shutter solenoid is not functioning Failed relay board bus failure Loose connector wiring PMT preamp board bad or out of cal DATA Data Storage in iDAS Failed disk on chip INITIALIZED was erased User cleared data FRONT PANEL The CPU is unable to Warning only appears on serial 1 0 com port s WARN Communicate with the Front panel display will be frozen blank or will not respond Front Panel Display Failed keyboard Keyboard 1 buss failure Loose connector wiring 4 HVPS WARNING High voltage power High voltage power supply is bad supply output is 400 High voltage power supply is out of cal V or 900 V A D converter circuitry is bad Bosco evar IZS TEMP On units with IZS Bad IZS heater WARNING options installed The Bad IZS temperature sensor permeation tube Bad relay controlling the IZS heater temperature is Sample Entire relay board is malfunctioning chamber temperature 1 buss malfunction is Failure of thermistor interface circuitry on motherboard lt 45 C or gt 55 PMT DET PMT detector output is Failed PMT WARNING gt 4995 mV Malfunctioning PMR preamp board A D converter circuitry failure PMT TEMP PMT temperature is Bad PMT thermo electric cooler WARNING lt 2 C or gt 12 C Failed PMT
103. various sensors are converted into digital signals that the CPU can understand and manipulate by the analog to digital converter A D Under the control of the CPU this functional block selects a particular signal input and then coverts the selected voltage into a digital word The A D consists of a voltage to frequency V F converter a programmable logic device PLD three multiplexers several amplifiers and some other associated devices The V F converter produces a frequency proportional to its input voltage The PLD counts the output of the V F during a specified time period and sends the result of that count in the form of a binary number to the CPU The A D can be configured for several different input modes and ranges but in the is used in uni polar mode with a 5V full scale The converter includes a 1 over and under range This allows signals from 0 05V to 5 05V to be fully converted For calibration purposes two reference voltages are supplied to the A D converter Reference ground and 4 096 VDC During calibration the device measures these two voltages outputs their digital equivalent to the CPU The CPU uses these values to compute the converter s offset and slope and uses these factors for subsequent conversions See Section 6 9 4 6 for instructions on performing this calibration 10 4 9 2 Sensor Inputs The key analog sensor signals are coupled to the A D through the master multiplexer from two connectors on the mot
104. withstand up to 40 VDC All of the emitters of these transistors are tied together and available at D NOTE Most PLC s have internal provisions for limiting the current that the input will draw from an external device When connecting to a unit that does not have this feature an external dropping resistor must be used to limit the current through the transistor output to less than 50 mA At 50 mA the transistor will drop approximately 1 2V from its collector to emitter The status outputs are accessed through a 12 pin connector on the analyzer s rear panel labeled STATUS see Figure 6 17 The function of each pin is defined in Table 6 22 STATUS SYSTEM OK CONC VALID HIGH RANGE w ZERO CAL SPAN CAL DIAGNOSTIC MODE Connect to Internal Ground of Monitoring Figure 6 17 Status Output Connector 120 6400E Rev B Model 6400E Instruction Manual Operating Instructions Table 6 22 Status Output Pin Assignments CONNECTOR STATUS CONDITION ON CONDUCTING T System Ok ON if no faults are present 2 Conc Valid ON if concentration measurement is valid OFF when invalid 3 High Range ON if unit is in high range of any AUTO range mode 4 Zero Cal ON whenever the instrument is in ZERO calibration mode 5 Span Cal ON whenever the instrument is in SPAN calibration mode 6 Diag Mode ON whenever the instrument is in DIAGNOSTIC mode 7 8 Unused The emitters of the tr
105. 0 1 VDC 1VDC 5VDC or 10VDC Additionally A1 and A2 may be equipped with optional 0 20 mADC current loop drivers and configured for any current output within that range e g 0 20 2 20 4 20 etc The user may also adjust the signal level and scaling of the actual output voltage or current to match the input requirements of the recorder or datalogger See Section 6 9 4 3 amp 6 9 4 5 In its basic configuration the A1 and A2 channels of the 6400E output a signal that is proportional to the SO concentration of the sample gas Several operating modes are available which allow e Single range mode SNGL Mode see Section 6 7 4 Both outputs are slaved together and will represent the same concentration span e g 0 50 ppm however their electronic signal levels may be configured for different ranges e g 0 10 VDC vs 0 1 VDC See Section 6 9 4 Dual range mode DUAL mode see Section 6 7 5 The two outputs can to configured for separate and independent units of measure and measurement spans as well as separate electronic signal levels Auto range mode AUTO mode see Section 6 7 6 gives the analyzer the ability to automatically switch the A1 and A2 analog outputs between two ranges low and high dynamically as the concentration value fluctuates EXAMPLE 1 OUTPUT Output Signal 0 5 VDC representing 0 1000 ppm concentration values A2 OUTPUT Output Signal 0 10 VDC representing 0 500 ppm concentration values 54
106. 014400000 Zero Air Scrubber for IZS 1 014610000 cooler Assembly B 024180000 CD UV Filter 214 NM 024710000 Tubing 6 1 8 CLR 024720000 Tubing 6 1 8 BLK 024750000 Tubing 6 1 4 TYGON 040300100 115V Configuration Plug 041510100 PRESS FLOW SEN 041520200 Module Relay PCA amp Power Supply 0416600050 UV Lamp Power Supply 041800100 PCA PMT Preamp 6400E 042410200 Internal Pump Assy ae 045570000 UV Lamp Assy 6400E 10000001 Sintered Filter 002 024900 FLOO00003 Filter DFU 036 040180 05037 Rev A 285 APPENDIX 6400E Spare Parts List Model 6400E Instruction Manual PART NUMBER DESCRIPTION NOTES FM0000004 Flow Meter 0 1000 cc HE0000018 Heater 50W IZS HW0000020 Spring Flow Control HW0000036 TFE Thread Tape 48 FT KITO000019 Replacement Cooler Assembly M100A M200A KITO00028 Retrofit 37mm Retaining Ring Sample Filter KITO00029 Retrofit 47mm Retaining Ring Sample Filter OP0000012 UV Detector 060000001 O Ring Flow Control 080000004 O Ring Optic Cell Cell Trap OR0000006 O Ring Cell PMT OR0000007 O Ring PMT Barrel Cell ORO0000015 O Ring PMT Filter 080000016 O Ring UV Lens ORO000025 O Ring Zero Air Scrubber 0860000042 O Ring Sensor Assembly 080000046 O Ring Permeation Oven 5 0000006 Overheat SW Cell Oven VA0000033 3 Way Solenoid Valve Teflon 12V 145
107. 2 Status Output Signals v Table 3 3 Control Input Signals 13 Table 3 4 Inlet Outlet Connector 15 Table 3 5 NIST SRM s Available for Traceability of SO Calibration Gases 16 Table 3 6 Front Panel Display During System Warm Up i22 Table 3 7 Possible Warning Messages at 23 Table 5 1 Zero Span Valve Operating States s ersrnsesennssesirerennnesnnsannarevnntannnnanneonaaraess 35 Table 5 2 IZS Valve Operating States 37 Table 6 1 Analyzer Operating modes Table 6 2 Test Functions Defined Table 6 3 List of Warning Messages sesssrsrsssreesnnnreenansersnarnnntennennarrerresnesnasnseenantenaananneetat Table 6 4 Primary Setup Mode Features and Functions 50 Table 6 5 Secondary Setup Mode Features and Functions 50 Table 6 6 Variable Names VARS Revision C 3 62 Table 6 7 6400 Diagnostic DIAG Functions 64 Table 6 8 DIAG Analog I O Functions 68 Table 6 9 Analog Output Voltage Ranges 68 Table 6 10 Analog Output Current Loop e 59 x 6400E Rev B Model 6400E Instruction Manual 6400E Documentation Table 6 11 Table 6 12 Table 6 13 Table 6 14 Table 6 15 Table 6 16 Table 6 17 Table 6 18 Table 6 19 Tab
108. 217 TROUBLESHOOTING amp REPAIR Model 6400E Instruction Manual Check to make sure that there is no ambient air leaking into the zero air line Check for leaks in the pneumatic systems as described in Section 11 5 1 11 3 6 NON LINEAR RESPONSE The 6400E was factory calibrated and should be linear to within 196 of full scale Common causes for non linearity are e Leaks in the pneumatic system Leaks can add a constant of ambient air zero air or span gas to the current sample gas stream which may be changing in concentrations as the linearity test is performed Check for leaks as described in Section 11 5 The calibration device is in error Check flow rates and concentrations particularly when using low concentrations If a mass flow calibrator is used and the flow is less than 1096 of the full scale flow on either flow controller you may need to purchase lower concentration standards e The standard gases may be mislabeled as to type or concentration Labeled concentrations may be outside the certified tolerance The sample delivery system may be contaminated Check for dirt in the sample lines or sample chamber e Calibration gas source may be contaminated Dilution air contains sample or span gas Sample inlet may be contaminated with SO exhaust from this or other analyzers Verify proper venting of the analyzer s exhaust Span gas overflow is not properly vented and creates back pressure on the sample
109. 4 3 for more details regarding the electronic operation of the PMT 10 2 4 UV LAMP SHUTTER amp PMT OFFSET Inherent in the operation of both the reference detector and the PMT are a minor electronic offsets The degree of offset differs from detector to detector and from PMT to PMT and can change over time as these components age To account for these offsets the 6400E includes a shutter located between the UV Lamp and the source filter that periodically cuts off the UV light from the sample chamber This happens every 30 minutes The analyzer records the outputs of both the reference detector and the PMT during this dark period and factors them into the SO concentration calculation 04515 Rev B 175 Theory Of Operation Model 6400E Instruction Manual reference detector offset is stored as and viewable via the front panel as the test function DRK LMP e The PMT offset is stored as and viewable via the front panel as the test function DRK PMT 10 2 5 OPTICAL FILTERS The Model 6400E analyzer uses two stages of optical filters to enhance performance The first stage conditions the UV light used to excite the SO by removing frequencies of light that are not needed to produce SO The second stage protects the PMT detector from reacting to light not produced by the SO returning to its ground state UV Source Optical Filter Zinc vapor lamps output light at other wavelengths beside the 214nm required for the SO gt
110. 4 4 Analog Output Offset Adjustment Some analog signal recorders require that the zero signal is significantly different from the baseline of the recorder in order to record slightly negative readings from noise around the zero point This can be achieved in the 6400E by defining a zero offset a small voltage e g 10 of span which can be added to the signal of individual output channels by activating the ANALOG I O CONFIGURATION MENU see Section 6 9 1 then pressing C FROM ANALOG I O CONFIGURATION MENU DIAG ANALOG 1 CONFIGURATION PREV NEXT ENTR EXIT DIAG AIO AQUTS CALIBRATED NO lt SET CAL EXIT Press SET to select the analog output channel to be configured Then press EDIT to continue DIAG AIO CONC_OUT_2 5V CAL SET SET EDIT EXIT DIAG AIO CONC OUT 2 RANGE 5V SET EDIT EXIT DIAG AIO CONC OUT 2 REC OFS 0 mV Pressing ENTR accepts the new setting and retums to the previous menu Pressing EXIT ignores the new setting and returns to the previous menu EDIT EXIT SET SET Set the recorder offset in mV of DIAG AIO RECORD OFFSET 0 MV the selected channel 0 0 0 0 ENTR EXIT 6400E Rev B 75 Operating Instructions Model 6400E Instruction Manual 6 9 4 5 Current Loop Output Adjustment A current loop option is available and can be installed as a retrofit for each of the analog outputs of the analyzer see S
111. 400 Signal I O Definitions Revision SIGNAL NAME BIT OR CHANNEL DESCRIPTION NUMBER Internal inputs U7 2108 pins 9 16 bits 0 7 default I O address 322 hex 0 7 Spare Internal outputs U8 J108 pins 1 8 bits 0 7 default I O address 322 hex ELEC_TEST 1 electrical test on 0 off PREAMP RANGE HI 1 select high preamp range 0 select low range 0 0 off OPTIC TEST 1 1 optic test on 2 3 5 6 Spare I2C RESET 1 reset I C peripherals 0 normal I2C DRV RST 0 hardware reset 8584 chip 1 normal Control inputs U11 1004 pins 1 6 bits 0 5 default I O address 321 hex EXT_ZERO_CAL 0 go into zero calibration 1 0 into span calibration Sel 0 go into low span calibration 1 exit low span calibration Spare Always 1 Control inputs U14 J1006 pins 1 6 bits 0 5 default 1 O address 325 hex 0 5 Spare 6 7 Always 1 Control outputs 017 J1008 pins 1 8 bits 0 7 default 1 0 address 321 hex 0 7 Spare Control outputs U21 J1008 pins 9 12 bits 0 3 default 1 0 address 325 hex 7T 0 3 Spare Alarm outputs U21 J1009 pins 1 12 bits 4 7 default I O address 325 hex ST_SYSTEM_OK2 4 1 system OK 0 any alarm condition or in diagnostics mode d 5 7 Spare A status outputs U24 J1017 pins 1 8 bits 0 7 default I O address 323 hex ST SYSTEM OK 0 0
112. 400E Rev B Model 6400E Instruction Manual Operating Instructions To Initialize the modem press SAMPLE RANGE 500 000 PPB 502 XXX X lt TST TST gt CAL SETUP Y SETUP XX COMI SET EDIT ENT SAMPLE ENTER SETUP PASS 818 8 1 8 ENTR fe To SETUP XX COM BAUD RATE 19200 SETUPXX PRIMARY SETUP MENU SSET SET gt EDIT EAT CFG DAS RNGE PASS CLK MORE EXIT EXIT returns SETUP KX COMI M RH to the pievious SETUPXX SECONDARY SETUP MENU epee EDIT E men S DIAG EXIT SETUP XX INITIALIZE MODEM SETUPX X COMMUNICATIONS MENU Select which SET SET INIT EXIT COM Port is iD COM1 EXIT tested SETUP XX INITIALIZING MODEM SET SET INIT EXIT returns to the Communications Menu 6 12 2 7 COM Port Password Security In order to provide security for remote access of the 6400E a LOGON feature can be enabled to require a password before the instrument will accept commands This is done by turning on the SECURITY MODE see Section 6 10 8 Once the SECURITY MODE is enabled the following items apply password is required before the port will respond or pass on commands If the port is inactive for one hour it will automatically logoff which can also be achieved with the LOGOFF command Three unsuccessful attempts to log on with an incorrect password will cause subsequent logins to be disab
113. 45 bs 20 5 kg w internal pump AC Power Rating 100 V 50 60 Hz 3 254 220 240 V 50 60 Hz 2 5 A 115 V 60 Hz 3 0 A Environmental Installation category over voltage category 11 Pollution degree 2 Analog Outputs Three 3 Outputs Analog Output Ranges 100 mV 1 V 5 V 10 V 2 20 or 4 20 mA isolated current loop All Ranges with 5 Under Over Range Analog Output Resolution 1 part in 4096 of selected full scale voltage Status Outputs 8 Status outputs from opto isolators Control Inputs 6 Control Inputs 3 defined 3 spare Serial I O One 1 RS 232 One 1 RS 485 2 connecters in parallel Baud Rate 300 115200 Optional Ethernet Interface Certifications EN61326 1997 w A1 98 Class A FCC Part 15 Subpart B Section 15 107 Class A ICES 003 Class A ANSI C63 4 1992 amp AS NZS 3548 w A1 amp A2 97 Class A IEC 61010 1 90 A1 92 A2 95 1 As defined by the USEPA 2 Defined as twice the zero noise level by the USEPA 6400E Rev B Specifications Approvals and Warranty Model 6400E Instruction Manual 2 2 EPA EQUIVALENCY DESIGNATION The Model 6400E Analyzer is designated as Reference Method Number EQSA 0495 100 as per 40 CFR Part 53 when operated under the following conditions Range Any range from 50 parts per billion ppb to 10 parts per million ppm Ambient temperature range of 5 C to 40 C Line voltage range of 105 125 V
114. 4515 Rev B Model 6400E Instruction Manual Instrument Maintenance 5 Re install the PTFE O ring with the notches facing up the glass cover then screw on the hold down ring and hand tighten the assembly Inspect the visible seal between the edge of the glass window and the O ring to assure proper gas tightness 6 Re start the analyzer 9 3 2 CHANGING THE IZS PERMEATION TUBE 1 Turn off the analyzer unplug the power cord and remove the cover 2 Locate the IZS oven in the rear left of the analyzer 3 Remove the top layer of insulation if necessary 4 Unscrew the black aluminum cover of the IZS oven 3 screws using a medium Phillips head screw driver Leave the fittings and tubing connected to the cover 5 Remove the old permeation tube if necessary and replace it with the new tube Make sure that the tube is placed into the larger of two holes and that the open permeation end of the tube teflon is facing up 6 Re attach the cover with three screws and make sure that the sealing O ring is properly in place and that the three screws are tightened evenly 7 Replace the analyzer cover plug the power cord back in and turn on the analyzer 8 Carry out an IZS span check to see if the new permeation device works properly The permeation rate may need several days to stabilize WARNING Do not leave instrument turned off for more than 8 hours without removing the permeation tube Do not ship the instrument without remo
115. 6 19 Continue adjusting the both the coarse and fine switches until NORM PMT is as close to but not below the target NORM PMT signal from Step 16 20 Adjust gain adjustment potentiometer until the NORM PMT value is 10 mV of the target level from Step 16 21 Perform span and zero point calibrations see Chapter 7 to normalize the sensor response to its new PMT sensitivity 22 Review the slope and offset values and compare them to the values in Table 7 5 11 7 TECHNICAL ASSISTANCE If this manual and its trouble shooting repair sections do not solve your problems technical assistance may be obtained from Teledyne Analytical Instruments Customer Service 16830 Chestnut St City of Industry Ca Phone 626 934 1673 Email tetci_customerservice teledyne com Before you contact customer service fill out the problem report form in Appendix C USER NOTES 250 04515 Rev B Model 6400E Instruction Manual A Primer on Electro Static Discharge 12 A PRIMER ON ELECTRO STATIC DISCHARGE Teledyne Instruments considers the prevention of damage caused by the discharge of static electricity to be extremely important part of making sure that your analyzer continues to provide reliable service for a long time This section describes how static electricity occurs why it is so dangerous to electronic components and assemblies as well as how to prevent that damage from occurring 12 1 HOW STATIC CHARGES ARE CREATED Modern
116. 6 10 10 Get your terminal modem or computer to transmit data to the analyzer holding down the space bar is one way The green LED on the rear panel should flicker as the instrument is receiving data sure that the communications software is functioning properly Further help with serial communications is available in a separate manual RS 232 Manual Teledyne Instruments part number 013500000 available online at http www Teledyne ai com manuals 230 04515 Rev B Model 6400E Instruction Manual TROUBLESHOOTING amp REPAIR 11 5 12 SHUTTER SYSTEM To check the functionality of the UV light Shutter by manually activating it JUMP 01 DIAG 170 SAMPLE RANGE 552 069 PPB S02 XXX X ENTR EXIT 2 Toggle these keys until 29 is displayed 7ST gt CAL 5 SAMPLE ENTER SETUP PASS 818 8 1 8 ENTR EXIT EX wus DIAG 1 0 29DARK SHUTTER OFF io the main a Activate the SAMPLE display PREY NEXT JUMP OFF EXIT Dark Shutter SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK E EXT SETUP XX SECONDARY SETUP MENU DIAG 1 0 29DARK SHUTTER ON PREV NEXT JUMP EXIT DIAG 1 0 JUMP TO 01 33 Toggle these keys until 33 is displayed LAMP SIGNAL 3 4 MV COMM VARS DIAG ENTR EXIT DIAG SIGNALI O PREY NEXT JUMP DAG 170 33
117. 6 Rev 273 APPENDIX A 3 Warnings and Test Functions Revision C 3 Model 6400E Instruction Manual APPENDIX A 3 Warnings and Test Functions Revision C 3 Table 2 6400 Warning Messages Revision NAME MESSAGE TEXT DESCRIPTION WSYSRES SYSTEM RESET Instrument was power cycled or the CPU was reset WDATAINIT DATA INITIALIZED Data storage was erased WCONFIGINIT CONFIG INITIALIZED Configuration storage was reset to factory configuration or erased WPMT PMT DET WARNING PMT detector outside of warning limits specified by DETECTOR_LIMIT variable WUVLAMP UV LAMP WARNING UV lamp reading outside of warning limits specified by DETECTOR LIMIT variable WSAMPFLOW SAMPLE FLOW WARN Sample flow outside of warning limits specified by SAMP FLOW SET variable WSAMPPRESS SAMPLE PRESS WARN Sample pressure outside of warning limits specified by SAMP_PRESS_SET variable WVACPRESS VACUUM PRESS WARN Vacuum pressure outside of warning limits specified by VAC_PRESS_SET variable WBOXTEMP BOX TEMP WARNING Chassis temperature outside of warning limits specified by BOX_SET variable WRCELLTEMP RCELL TEMP WARNING WIZSTEMP WPMTTEMP WDARKCAL WHVPS IZS TEMP WARNING PMT TEMP WARNING DARK CAL WARNING HVPS WARNING Reaction cell temperature outside of warning limits specified by RCELL SET variable IZS temperature outside of warning limits specified by IZS S
118. 6400E Rev B Model 6400E Instruction Manual Operating Instructions The output labeled A3 is special It can be set by the user see Section 6 9 10 to output any one of the parameters accessible through the lt TST TST gt keys of the units Sample Display Output A4 is not available on the Model 6400E Analyzer 6 7 2 PHYSICAL RANGE VERSUS ANALOG OUTPUT REPORTING RANGES The entire measurement range of the 6400E is 0 20 000 ppb but many applications use only a small part of the analyzer s full measurement range This creates two performance challenges The width of the Model 6400E s physical range can create data resolution problems for most analog recording devices For example in an application where the expected concentration of SO is typically less than 500 ppb the full scale of expected values is only 0 25 of the instrument s full 20 000 ppb measurement range Unmodified the corresponding output signal would also be recorded across only 0 25 of the range of the recording device The 6400E solves this problem by allowing the user to select a scaled reporting range for the analog outputs that only includes that portion of the physical range relevant to the specific application Only the reporting range of the analog outputs is scaled the physical range of the analyzer and the readings displayed on the front panel remain unaltered Applications where low concentrations of 50 are measured require greater sensitivity and res
119. 8 Pressure Calibration 82 6 9 9 Flow Calibration 83 6 9 10 Test Channel Output 84 6 10 SETUP COMM Setting Up the Analyser s Communication 85 6 10 1 Analyzer ID 85 6 10 2 COM Port Default Settings 86 6 10 3 RS 232 Port Cable Connections 86 6 10 4 RS 485 Configuration of COM2 87 6 10 5 DTE and DCE Communication 89 6 10 6 Ethernet Card Configuration 90 6 10 6 1 Ethernet Card COM2 Communication Modes and Baud Rate 90 6 10 6 2 Configuring the Ethernet Interface Option using DHCP 6 10 6 3 Manually Configuring the Network IP Addresses 6 10 6 4 Changing the Analyzer s HOSTNAME 6 10 7 Multidrop RS 232 Set Up 6 10 8 COM Port Communication Modes 6 10 9 COM Port Baud Rate 6 10 10 COM Port Testing 6 11 Using the Data Acquisition System iDAS 6 11 1 IDAS Structure 6 11 1 1 iDAS Channels 6 11 1 2 iDAS Parameters 6 11 1 3 iDAS Triggering Events 6 11 2 Default iDAS Channels 1 D 2 1 Viewing iDAS Data and Settings 2 2 Editing IDAS Data Channels 2 3 Trigger Events 2 4 Editing iDAS Parameters 2 5 Sample Period and Report Period 6400E Rev B Model 6400E Instruction Manual 11 2 6 Number of Records E 2114 11 2 7 RS 232 Report Function 11 2 8 Compact Report 152 11 2 DA A
120. AC or 220 240 VAC at 50 or 60 Hz Sample filter Equipped with PTFE filter element in the internal filter assembly Sample flow of 650 65 cc min Vacuum pump internal capable of 14 Hg Absolute pressure 1 slpm or better Software settings Dynamic span OFF Dynamic zero OFF Dilution factor OFF AutoCal ON or OFF Dual range ON or OFF Auto range ON or OFF Temp Pressure compensation ON Under the designation the analyzer may be operated with or without the following optional equipment Rack mount with chassis slides Rack mount without slides ears only Zero span valve options Internal zero span IZS option with either 1 SO permeation tube 0 4ppm at 0 7 liter per minute certified uncertified 2 SO permeation tube 0 8 ppm at 0 7 liter per minute certified uncertified Under the designation the IZS option cannot be used as the source of calibration 4 20mA isolated analog outputs Status outputs Control inputs RS 232 output Ethernet output Zero air scrubber 4 20mA isolated output 6400E Rev B Model 6400E Instruction Manual Specifications Approvals and Warranty 2 3 CE MARK COMPLIANCE Emissions Compliance The Teledyne Analytical Instruments UV Fluorescence SO Analyzer 6400E was tested and found to be fully compliant with EN61326 1997 w A1 98 Class A FCC Part 15 Subpart B Section 15 107 Class A ICES 003 Class A ANSI C63 4 1992 amp AS NZS 3548 w A1 amp A2 97 Cla
121. ACT CLOSURES Contact closures for controlling calibration and calibration checks are located on the rear panel CONTROL IN connector Instructions for setup and use of these contacts can be found in Section 6 12 1 2 When the appropriate contacts are closed for at least 5 seconds the instrument switches into zero low span or high span mode and the internal zero span valves will be automatically switched to the appropriate configuration The remote calibration contact closures may be activated in any order It is recommended that contact closures remain closed for at least 10 minutes to establish a reliable reading the instrument will stay in the selected mode for as long as the contacts remain closed If contact closures are used in conjunction with the analyzer s AutoCal see Section 7 8 feature and the AutoCal attribute CALIBRATE is enabled the 6400E will not re calibrate the analyzer until the contact is opened At this point the new calibration values will be recorded before the instrument returns to SAMPLE mode If the AutoCal attribute CALIBRATE is disabled the instrument will return to SAMPLE mode leaving the instrument s internal calibration variables unchanged 6400E Rev B 147 Calibration Procedures Model 6400E Instruction Manual 7 8 AUTOMATIC CALIBRATION AUTOCAL The AutoCal system allows unattended periodic operation of the zero span valve options by using the analyzer s internal time of day clock AutoCal operate
122. AN PURGE AIR FROM VACUUM MANIFOLO OUTER TUBE Clean Air USED PURGE AIR TO PUMP CLEANED SAMPLE AIR AND TO EXHAUST PORT SAMPLE CHAMBER SAMPLE AIR fp FROM PARTICULATE FILTER INNER TUBE Amblent Alr Figure 10 9 6400E Hydrocarbon Scrubber Kicker In the 6400E some of the cleaned air from the inner tube is returned to be used as the purge gas in the outer tube see Figure 10 9 This means that when the analyzer is first started the concentration gradient between the inner and outer tubes is not very large and the scrubber s efficiency is relatively low When the instrument is turned on after having been off for more than 30 minutes it takes a certain amount of time for the gradient to become large enough for the scrubber to adequately remove hydrocarbons from the sample air 182 04515 Rev B Model 6400E Instruction Manual Theory Of Operation 10 3 5 PNEUMATIC SENSORS The 6400E uses two pneumatic sensors to verify gas streams These sensors are located on a printed circuit assembly called the pneumatic pressure flow sensor board 10 3 5 1 Sample Pressure Sensor An absolute pressure transducer plumbed to the input of the analyzer s sample chamber is used to measure the pressure of the sample gas before it enters the chamber This upstream used to validate the critical flow condition 2 1 pressure ratio through the instrument s critical flow orifice see Section 10 3 2 Also
123. AS channels 282 05036 Rev C 3 Model 6400E Instruction Manual APPENDIX A 6 Terminal Command Designators Revision The command syntax follows the command type separated by a space character Strings in brackets are optional designators The following key assignments also apply TERMINAL KEY ASSIGNMENTS ESC Abort line CR ENTER Execute command Ctrl C Switch to computer mode COMPUTER MODE KEY ASSIGNMENTS LF line feed Execute command Ctri T Switch to terminal mode 05036 Rev C 3 283 Model 6400E Instruction Manual APPENDIX B 6400E Spare Parts List APPENDIX B 6400E Spare Parts List NOTE Use of replacement parts other than those supplied by API may result in non compliance with European standard EN 61010 1 Table B 1 6400 Spare Parts List PART NUMBER DESCRIPTION NOTES 000940100 3 mil 60 125 000940800 Orifice 12 mil 650 cc Rx Cell 002690000 Lens UV 002 039700 002700000 Lens PMT 002 039800 T 002720000 PMT Optical Filter 002 035300 003290000 Thermistor Assembly 885 071600 003690000 Filter TFE 37 mm Qty 100 872 006400 00596000E0 Activated Charcoal 6 165 009690000 Filter TFE 47 mm Qty 100 013420000 Rotary Solenoid Assembly Shutter Solenoid see tet 013570000 Thermistor Assembly Cooler 014080100 High Voltage Power Supply
124. Appendix A 4 for a complete list of the parameters available for review under this menu NOTE Any changes of signal 1 0 settings will remain in effect only until the signal 1 0 menu is exited Exceptions are the ozone generator override and the flow sensor calibration which remain as entered when exiting To enter the signal I O test mode press SAMPLE RANGE 502 000 PPR 502 KXX K DAG SIGNAL 170 Use the NEXT amp PREV keys to move between c TST TST gt CAL SETUP PREV NEXT JUMP ENTR EXIT signal types 4 Y Use the JUMP key to SAMPLE ENTER SETUP PASS 818 DIAG 170 0 EXT ZERO CAL OFF go direclly to a B 1 8 ENTR EXIT PREV NEXT JUMP PRAT EXIT spate signal See Appendix 4 for EXIT retums a complele fist of 1o the main 1 available SIGNALS SAMPLE display DIAG 170 SETUP PRIMARY SETUP MENU EXAMPLE Enter 12 to Jump to 12 ST_CONC_VALID 4 CFS DAS RNGE PASS CLK MORE EXT 2 Exil lo retum to the Pentex 0 PIAS menu DIAG 1 0 12 ST_CONC_VALID DN SETUP SECONDARY SETUP MENU U COMM vARS DIAG EXIT PREV NEXT JUMP 2 Pressing the PRNT key will send a formatted printout to the serial port and can be captured with a computer or other output device 66 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 9 3 ANALOG OUTPUT STEP TEST This test can be used to check the accura
125. D COLOR FUNCTION STATUS INDICATED FAILURE S Failed or halted CPU faulty motherboard DL red Watchdog Circuit IC bus Continuously keyboard relay board wiring between operation ON or OFF motherboard keyboard or relay board 5 V power supply Relay 0 sample Continuously D2 yellow chamber heater ON or OFF Heater broken thermistor broken D3 ellow SPARE N A D4 ellow SPARE N A 2 Continuously i D5 yellow Relay 3 IZS heater ON or OFF Heater broken thermistor broken D6 yellow Spare N A Continuously Valve broken or stuck valve driver chip 1 07 green Zero span valve status ON or OFF broken 1 Continuously Valve broken or stuck valve driver chip D8 green Sample cal valve status ON or OFF broken D9 green SPARE N A _N A 010 green SPARE N A N A Shutter jammed or stuck faulty relay Dil green UV Lamp Shutter board problem with wiring between relay board amp shutter D12 green SPARE N A N A D13 green SPARE N A N A D14 green SPARE N A N A D15 green SPARE N A N A D16 Green SPARE N A N A 1 Only active for instruments with Z S valve or IZS options installed 214 04515 Rev B Model 6400E Instruction Manual TROUBLESHOOTING amp REPAIR 11 2 GAS FLOW PROBLEMS The standard 6400E has one main flow path With the IZS option installed there is a second flow path flow path through the IZS oven that runs whenever the IZS is on standby to purge SO from the oven chamber The IZS flow is not measured and is not available f
126. Detect Display Data Decoder Display Controller Keyboard Interrupt Status Bit Display Power Watchdog errem Parallel Data From 5 VDC Power Supply Display Write Optional Maintenance Sample LED Green Cal LED ZY Yellow 2 40 CHAR VACUUM FLUORESCENT DISPLAY i Fault LED Red Beeper FRONT PANEL Figure 10 22 Keyboard and Display Interface Block Diagram KEYBOARD 04515 Rev B 201 Theory Of Operation Model 6400E Instruction Manual The keyboard display interface electronics of the 6400E Analyzer watches the status of the eight front panel keys alerts the CPU when keys are depressed translates data from parallel to serial and back and manages communications between the keyboard the CPU and the front panel display Except for the Keyboard interrupt status bit ali communication between the CPU and the keyboard display is handle by way of the instrument s 1 buss The CPU controls the clock signal and determines when the various devices on the bus are allowed to talk or required to listen Data packets are labeled with addresses that identify for which device the information is intended Keypad Decoder Each key on the front panel communicates with a decoder IC via a separate analog line When a key is depressed the decoder chip notices the change of state of the associated signal latches and holds the state of all eight lines in effect cre
127. E OPTIONS CPU TYPE DATE FACTORY CONFIGURATION SAVED t Only appears if a applicable option feature ts installed and activated 2 Only appears whenever the currently displayed sequence is not set for DISABLED 3 Only appears when reporting range ts set to AUTO range mode TIME DATE MODE SET UNIT SNGL IND AUTO PPB PPM TIMER ENABLE Go To STARTING DATE lt SET SET gt SECONDARY SETUP MENU STARTING TIME lt SET 5 gt ERIT Fig A 5 DELTA DAYS DELTA TIME DURATION CALIBRATE cow Hrer RANGE TO CAL Figure A 3 Primary Setup Menu Except iDAS 05036 Rev C 3 262 APPENDIX A 1 6400E Software Menu Trees Revision C 3 Model 6400E Instruction Manual SAMPLE 1 ENTER SETUP PASS 818 CFG VIEW PREV NEXT CONC PNUMTC CALDAT DETAIL FAST VIEW lt PRM PRM PV10 PREV NEXT NX10 Selects data point to view Cycles through lists of parameters chosen for this IDAS channel rA REPORT PERIOD NUMBER OF RECORDS RNGE PASS EDIT PREV NEXT INS DEL EDIT PRNT YES NO CONC PNUMTC CALDAT DETAIL SET SET gt EDIT PRNT FAST Creates changes see m 22 EVENT PARAMETERS YES RS 232 REPORT MEN CHANNEL ENABLE between each CAL HOLD report PREV NEXT PREV NEXT INS DEL EDIT PRNT pb Cycles through YES NO available trigger ON ts see Section 6 11
128. E PASS GUK MORE SETUP XX HESSEN VARIATION TYPE 1 sepe SECONDARY SETUP MENU Spee cau SE XX ENTR key accepts the OMM exit new settings S DAG ALR X poru SETUP Xx HESSEN RESPONSE MODE CMD EXIT key ignores the new settings SET SET EDIT EXIT Press to change response mode SETUP XX HESSEN RESPONSE MODE CMD BCC TEXT EDIT ENTR EXIT 6 12 4 6 Hessen Protocol Gas ID The Model 6400E Analyzer is a single gas instrument that measures SQ2 As such it s default gas ID has already been set to 110 There is no need to change this setting 132 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 12 4 7 Setting Hessen Protocol Status Flags Teledyne Instruments implementation of Hessen protocols includes a set of status bits that the instrument includes in responses to inform the host computer of its condition Each bit can be assigned to one operational and warning message flag The default settings for these bit flags are Table 6 29 Default Hessen Status Bit Assignments STATUS FLAG NAME DEFAULT BIT ASSIGNMENT WARNING FLAGS SAMPLE FLOW WARNING 0001 PMT DET WARNING 0002 UV LAMP WARNING 0002 HVPS WARNING 0004 DARK CAL WARNING 0008 RCELL TEMP WARNING 0010 IZS TEMP WARNING 0020 PMT TEMP WARNING 0040 INVALID CONC 0080 CONV TEMP WARNING OPERATIONAL FLAGS In Manual Calibration Mode 0200 In Zero Calibration Mode 0400 In Span Calibration Mode 0800 UNIT
129. ELAY BOARD Figure 10 20 Interface Block Diagram 04515 Rev B 199 Theory Of Operation Model 6400E Instruction Manual 10 6 1 FRONT PANEL INTERFACE MODE FIELD MESSAGE FIELD CONCENTRATION FIELD NITIO KEY DEFINI SAMPLE RANGE 500 000 PPB 502 STATUS LEI lt TST TST gt CAL KEYBOARD seo o o E3 amp ON OFF s UV FLUORESCENCE 502 ANALYZER MODEL 6400E Figure 10 21 6400E Front Panel Layout The most commonly used method for communicating with the 6400E UV Fluorescence SO2 Analyzer is via the instrument s front panel which includes a set of three status LEDs a vacuum florescent display and a keyboard with 8 context sensitive keys 10 6 1 1 Analyzer Status LED s Three LEDS are used to inform the user of the instruments basic operating status Table 10 2 Front Panel Status LED s DEFINITION Unit is not operating in sample mode iDAS is disabled Sample Mode active Front Panel Display being updated iDAS data being stored Unit is operating in sample mode front panel display being updated iDAS hold off mode is ON IDAS disabled NAME COLOR SAMPLE Green Blinking CAL Yellow Off Auto Cal disabled On Auto Cal enabled Blinking Unit is in calibration mode FAULT Red Off SO warnings exist Blinking Warnings exist 10 6 1 2 K
130. ENTER SETUP PASS 818 CLK MORE CFG E PASS COMM VARS 0 COMM VARS MENU TREE Fig 5 SET SET DAS HOLD OFF TPC ENABLE RCELL SET 12S SET DYN ZERO DYN_SPAN CONC_PRECISION CLOCK_ADJ INSTRUMENT IP GATEWAY IP SUBNET MASK TCP PORT HOSTNAME PREV NEXT JUMP EDIT Go To DIAG MENU TREE Fig A 8 INSTRUMENT GATEWAY IP EDIT SUBNET MASK TCP PORT Only appears if a valve option is installed 2 Only appears when the Ethernet card option 63 is installed Although TCP PORT is editable regardless of the DHCP state do not change the setting for this property unless instructed to by Teledyne Instruments Customer Service personnel HOST NAME is only editable when DHCP is ON 5 INSTRUMENT IP GATEWAY IP amp SUBNET MASK are only editable when DHCP 15 OFF Figure A 6 Secondary Setup Menu COMM Menu with Ethernet Card 05036 Rev APPENDIX 1 6400E Software Menu Trees Revision Model 6400E Instruction Manual SETUP 1 ENTER SETUP PASS 818 CFG RNGE PASS CLK MORE COMM VARS DIAG ID HESN COM1 COM2 See See Fia A 5 Fig A 8 PMT DET WARNING UV LAMP WARNING DARK CAL WARNING IZS TEMP WARNING BOX TEMP WARNING PMT TEMP WARNING RCELL TEMP WARNING SAMPLE FLOW WARNING SAMPLE PRESS WARNING HVPS WARNING SYSTEN RESET REAR BOARD NOT DET RELA
131. ENTR EXIT new settings The ID can be any 4 digit number and can also be used to identify analyzers in any number of ways e g location numbers company asset number etc Toggle these keys to cycle through the available character set 0 8 SETUP X 6400E Rev B 85 Operating Instructions Model 6400E Instruction Manual 6 10 2 COM PORT DEFAULT SETTINGS As received from the factory the analyzer is set up to emulate a DCE or modem with pin 3 of the DB 9 connector designated for receiving data and pin 2 designated for sending data COM1 RS 232 fixed DB 9 male connector o Baud rate 19200 bits per second baud o Data Bits 8 data bits with 1 stop bit o Parity None COM2 RS 232 configurable DB 9 female connector o Baud rate 115000 bits per second baud o Data Bits 8 data bits with 1 stop bit o Parity None CAUTION Cables that appear to be compatible because of matching connectors may incorporate internal wiring that make the link inoperable Check cables acquired from sources other than Teledyne Instruments for pin assignments before using 6 10 3 RS 232 COM PORT CABLE CONNECTIONS In its default configuration the 6400E analyzer has two available RS 232 Com ports accessible via 2 DB 9 connectors on the back panel of the instrument The COM1 connector is a male DB 9 connector and the COM2 is a female DB9 connector Male DB 9 RS 232 Female DB 9 COM2 As seen
132. ER ZSCNCt MODE INST PRECISION 1 STORE NUM SAMPLES OFF 106 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 11 2 1 Viewing iDAS Data and Settings iDAS data and settings can be viewed on the front panel through the following keystroke sequence SAMPLE RANGE 590 000 PPB 5 8 E a PV10 PREV lt TST TST CAL VIEW KEYPAD FUNCTIONS i KEY FUNCTION SAMPLE ENTER SETUP PASS 818 lt PRM Moves to the next Parameter 8 4 8 ENTR PRM gt Moves to the previous Parameter EXIT will retum to the he NX10 Moves the view forward 10 main SAMPLE Display SETUPXX PRIMARY SETUP MENU data points channels CFG DAS RNGE PASS CLK MORE EXIT NEXT Moves to the next dala pointichannel a PREV Moves to the previous data SETUP XX DATA ACQUISITION poinchannel PV10 Moves the view back 10 data VIEW EDIT EXIT points channels Kevs onlv appear as needed SETUP XX CONC DATA AVAILABLE NEXT VIEW EXIT SETUP X X 00 00 00 CONC1 XXXX PPB PV10 PREV NEXT NX10 PRM gt EXIT SETUP X X PNUMTC DATA AVAILABLE PREV NEXT VIEW EXIT SETUP X X 00 00 00 SMPFLW 000 0 cc m PRM EXIT SETUP X X CALDAT DATA AVAILABLE PREV NEXT VIEW EXIT SETUP XX 00 00 00 SLOPE1 0 000 PRM EXIT 00 00 00 PMTDET 0000 0000 m
133. EST iDAS CONDITION BEHAVIOR FUNCTION FUNCTION EXPECTED ACTUAL INTERPRETATION Fluctuating Developing leak in pneumatic system Flow path is clogging up Slowly Check critical flow orifice amp Constant within atmospheric changes SMPPRS sample gas increasing sintered filter Replace particulate filter Slowly Developing leak in pneumatic system decreasing to vacuum developing valve failure PMT output Constant when UV within 20 of Significantly PMT cooler failure Lamp shutter check out increasing Shutter Failure closed value DRK PMT DRKPMT Constant Change in instrument response option response Decreasing SO installed from day to over time Degradation of IZS permeation tube day Standard stable for configuration constant at span concentration Concentration Decreasing Drift of instrument response UV over time Lamp output is excessively low Flow path is clogging up Slowly Check critical flow orifice amp Decreasing sintered filter Replace particulate filter Fluctuating Leak in gas flow path Fluctuating or Slowly Standard Stable and Increasing Operation near 10096 UV detector wearing out Slowly Opaque oxides building up on UV decreasing source Filter UV lamp aging Standard SAMP FL SMPFLW Operation UV detector wearing out UV source Filter developing pin holes LAMP RATIO 04515 R
134. ET variable PMT temperature outside of warning limits specified by PMT SET variable Dark offset above limit specified by DARK LIMIT variable High voltage power supply output outside of warning limits specified by HVPS SET variable WDYNZERO CANNOT DYN ZERO Contact closure zero calibration failed while DYN_ZERO was set to ON WDYNSPAN CANNOT DYN SPAN Contact closure span calibration failed while DYN_SPAN was set to ON WREARBOARD REAR BOARD NOT DET Rear board was not detected during power up WRELAYBOARD RELAY BOARD WARN Firmware is unable to communicate with the relay board WFRONTPANEL FRONT PANEL WARN Firmware is unable to communicate with the front panel WANALOGCAL ANALOG CAL WARNING The A D or at least one D A channel has not been calibrated 6400EH 274 05036 Rev C 3 Medel 6400E Instru ction Manual APPENDIX A 3 Warnings and Test Functions Revision C 3 Table A 3 6400 Test Functions Revision TEST FUNCTION bs MESSAGE TEXT DESCRIPTION RANGE RANGE 500 0 PPB 3 D A range in single or auto range modes RANGEL RANGE1 500 0 PPB 3 D A 1 range in independent range mode RANGE2 L RANGE2 500 0 PPB 3 D A 2 range in independent range mode STABILITY STABIL 0 0 PPB 3 Concentration stability standard deviation based on setting of STABIL_FREQ and STABIL_SAMPLES VACUUM 1 _vac
135. ETUP RANGE CONTROL MENU if the dilution ratio option hasbeen 4 MODE SET UNIT DIL EXIT installed EXIT ignores the new setting SETUPC3 DIL FACTOR 1 0 GAIN ENTR accepts the new setting Toggle these keys to set the dilution factor 0 0 0 4 EU ENTR EXIT This is the number by which the analyzer will multiply the SOz concentrations of the gas passing setup c3 DIL FACTOR 20 0 GAIN through the reaction cell 0 0 2 0 0 ENTR EXIT The analyzer multiplies the measured gas concentrations with this dilution factor and displays the result NOTE Once the above settings have been entered the instrument needs to be recalibrated using one of the methods discussed in Chapter 7 6400E Rev B 61 Operating Instructions Model 6400E Instruction Manual 6 8 SETUP VARS USING THE INTERNAL VARIABLES The 6400E has several user adjustable software variables which define certain operational parameters Usually these variables are automatically set by the instrument s firmware but can be manually re defined using the VARS menu Table 6 6 lists all variables that are available within the 818 password protected level Table 6 6 Variable Names VARS Revision C 3 ALLOWED DESCRIPTION VALUES Ivo VARIABLE Changes the internal data acquisition system iDAS hold off time which is the duration when data are not stored in he iDAS becaus
136. GRESS WHEN INSTRUMENT IS POWERED OFF If the instrument is powered off in the middle of a REPORT PERIOD the samples accumulated so far during that period are lost Once the instrument is turned back on the iDAS restarts taking samples and temporarily them in volatile memory as part of the REPORT PERIOD currently active at the time of restart At the end of this REPORT PERIOD only the sample readings taken since the instrument was turned back on will be included in any AVG MIN or MAX calculation Also the STORE NUM SAMPLES feature will report the number of sample readings taken since the instrument was restarted 112 6400E Rev B Model 6400E Instruction Manual Operating Instructions To define the REPORT PERIOD follow the instruction shown in section 6 11 2 2 then press Use the PREV and NEXT keys to scroll to the data channel to be edited From the DATA ACQUISITION Edit Data Channel Menu SETUP XX 0 ATIMER 2 4032 R Exits to the main Data Acquisition INS DEL EDIT PRNT EXIT menu NAME CONC PREV NEXT SETUP XX SET SET EDIT PRINT ExIT Set the number of days between reports 66 Press keys to set hours between reports in the format HH MM max 23 59 This is a 24 hour clock PM hours are 13 thru 23 midnight is 00 00 Example 2 15 PM 14 15 E Press SET key until you reach REPORT PERIOD SETUP XX
137. HH MM SS HVPS 553 VOLTS SAMPLE XXX X SAMPLE PMT TEMP 0 0C aig SAMPLE OFFSET XX X MV 502 XXX X TST TST CAL SETUP SAMPLE BOX TEMP 0 0C S02 XXX X lt TST TST gt CAL Z lt TST TST gt CAL SETUP SAMPLE SLOPE XXX 502 XXX X 10 7 3 TEMPERATURE AND PRESSURE COMPENSATION TPC FEATURE As explained in the theory of operations see Chapter 10 changes in temperature can significantly effect the amount of fluoresced UV light generated in the instruments sample chamber To negate this effect the Model 6400E maintains the sample gas at a stable raised temperature Pressure changes can also have a noticeable if more subtle effect on the SO concentration calculation To account for this the Model 6400E software includes a feature which allows the instrument to compensation of the SO calculations based on changes in ambient pressure 04515 Rev B 205 Theory Of Operation Model 6400E Instruction Manual When the TPC feature is enabled the analyzer s SO concentration divided by a factor call PRESSCO which is based on the difference between the ambient pressure of the sample gas normalized to standard atmospheric pressure Equation 10 5 As ambient pressure increases the compensated SO concentration is decreased SAMPLE PRESSURE HG A x SAMP PRESS SLOPE PRESSCO 29 92 HG A Equation 10 5 SAMPLE PRESSURE The ambient pressure of the sample ga
138. IAG I O 6 9 2 DIAG AOUT 6 9 3 DIAG OPTIC 6 9 5 DIAG ELEC DIAG LAMP 6 9 7 DIAG PCAL 6 9 8 DIAG FCAL 6 9 9 DIAG TCHN 6 9 10 64 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 9 1 ACCESSING THE DIAGNOSTIC FEATURES To access the DIAG functions press the following keys SAMPLE S00000PPR SO2 XXXX DIAG ANALOG I O CONFIGURATION TST TST gt CAL SETUP PREV NEXT ENTR EXIT SAM i AG SAMPLE ENTER SETUP PASS 818 DIAG OPTIC TEST to the main SAMPLE 8 1 8 ENTR EXIT PREV NEXT ENTR EXIT display EXIT retums SETUPXX PRIMARY SETUP MENU DIAG ELECTRICAL TEST to the PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT PREV NEXT ENTR EXIT From this point SETUF XX SECONDARY SETUP MENU DIAG LAMP CALIBRATION forward EXIT retums to the T J SECONDARY COMM VARS DIAG EXIT PREV NEXT ENTR EXIT SETUP MENU LL SIGNAL 170 DIAG PRESSURE CALIBRATION ENTR EXIT PREV NEXT ENTR DIAG ANALOG OUTPUT DIAG FLOW CALIBRATION PREV ENTR PREV NEXT ENTR PREV TEST CHAN OUTPUT ENTR EXIT 6400E Rev B 65 Operating Instructions Model 6400E Instruction Manual 6 9 2 SIGNAL I O The signal 1 0 diagnostic mode allows to review and change the digital and analog input output functions of the analyzer See
139. IAG Menu see Section 6 9 2 By activating the instrument s AutoCal feature see Section 7 8 Remotely by using the external digital control inputs see Section 6 12 1 2 and Section 7 7 1 or Remotely through the RS 232 485 serial I O ports see Appendix A 6 for the appropriate commands External Zero Air Scrubber The 17 option includes an external zero air scrubber assembly that removes all SO the zero air source The scrubber is filled with activated charcoal Span Gas Source Span gas is created when zero air passes over a permeation tube containing liquid SO2 under high pressure which slowly permeates through a PTFE membrane into the surrounding air The speed at which the SO permeates the membrane is called the effusion rate The concentration of the span gas is determined by three factors Size of the membrane The larger the area of the membrane the more permeation occurs Temperature of the SO Increasing the temperature of the increases the pressure inside the tube and therefore increases the effusion rate Flow rate of the zero air If the previous two variables are constant the permeation rate of the into the zero air stream will be constant Therefore a lower flow rate of zero air produces higher concentrations of SO The 6400E usually has a constant flow rate and a constant permeation rate hence variations in concentration can be achieved by changing the IZS temperature 6400E Rev B 37 Optional
140. INSTRUCTION MANUAL MODEL 6400E UV FLUORESCENCE SO ANALYZER TELEDYNE ANALYTICAL INSTRUMENTS 16830 Chestnut Street PO Box 1580 City of Industry Ca 91748 Phone 626 934 1500 Phone 626 961 9221 Fax 626 961 2538 one m i 07090 ee 7060 GPS r4 E APPLICATION OF COUNCIL DIRECTIVE STANDARDS TO WHICH CONFORMITY IS DECLARED MANUFACTURER S NAME MANUFACTURER S ADDRESS TYPE OF EQUIPMENT MODEL NUMBER 89 336 EEC AND 73 23 EEC DECLARATION OF CONFORMITY 89 336 EEC EN61326 1997 w A1 98 Class A EN 61010 1 2001 2nd Edition TELEDYNE ANALYTICAL INSTRUMENTS 16830 Chestnut Street 502 Analyzer 6400E and 6400 I THE UNDERSIGNED HEREBY DECLARE THAT THE EQUIPMENT SPECIFIED ABOVE CONFORMS TO THE ABOVE STANDARD S PER 73 123 EEC City of Industry CA 91748 1020 U S A Su US SIGNATURE FULL NAME Stephen Broy POSITION Director of Engineering d n A c DATE S ZO City of Industry California PLACE Model 6400E Instruction Manual Copyright 2004 Teledyne Analytical Instruments 6 July 2004 ii 6400E Rev B Model 6400E Instruction Manual SAFETY MESSAGES Your safety and the safety of others is very important We have provided many important safety messages in this manual Please read these messages carefully A safety message alert
141. Instruction Manual 6 10 8 COM PORT COMMUNICATION MODES Each of the analyzer s serial ports can be configured to operate in a number of different modes which are listed in the following table Each COM port needs to be configured independently Table 6 18 COMM Port Communication modes DESCRIPTION QUIET Quiet mode suppresses any feedback from the analyzer iDAS reports and 1 warning messages to the remote device and is typically used when the port is communicating with a computer program such as APICOM Such feedback is still available but a command must be issued to receive them COMPUTER 2 Computer mode inhibits echoing of typed characters and is used when the port is communicating with a computer program such as APICOM SECURITY 4 When enabled the serial port requires a password before it will respond The only command that is active is the help screen CR HESSEN The Hessen communications protocol is used in some European countries PROTOCOL 16 Teledyne Instruments part number 02252 contains more information on this protocol E 7 1 When turned on this mode switches the COMM port settings from 2048 No parity 8 data bits 1 stop bit to Even parity 7 data bits 1 stop bit RS 485 1024 Configures the COM2 Port for RS 485 communication RS 485 mode has precedence over multidrop mode if both are enabled MULTIDROP 32 Multidrop protocol allows a multi instrument configuration on a single PR
142. JUMP T EXIT SETUP XX 4 DYN ZERO ON PREV NEXT JUMP EDIT PRN T SETUPXX DYN ZERO ON ON ENTR EXIT 4 SETUP Kx 5 DYN SPAN ON Toggle this keys to change setting PREV NEXT JUMP EDIT PRHT EXIT SETUP XX DYN SPAN ON ON ENTR EXIT Toggle this keys to change setting SETUP Xx 6 CONC_PRECUISION 3 SETUP X K ISION 3 PREY NEXT EDIT PRNT EXIT SERM CONC PRECIN AUTO 1 2 3 4 ENTR EXIT f Toggle these keys to change setting SETUP XX CLOCK_ADJ 0 SaciDay SETUP XK CLOCK ADJ 0 SeciDay PREV JUMP EDIT PRHT EXIT REV NEXT J ANT a ENTR EXIT D 0o I Toggle tese keys to change selling 6400E Rev B 63 Operating Instructions Model 6400E Instruction Manual 6 9 SETUP DIAG USING THE DIAGNOSTICS FUNCTIONS A series of diagnostic tools is grouped together under the SETUP MORE DIAG menu As these parameters are dependent on firmware revision see Menu Tree A 5 in Appendix A The individual parameters however are explained in more detail in the following section indicated in Table 6 7 These tools can be used in a variety of troubleshooting and diagnostic procedures and are referred to in many places of the maintenance and trouble shooting sections Table 6 7 6400 Diagnostic DIAG Functions FRONT PANEL MODE SECTION INDICATOR DIAGNOSTIC FUNCTION AND MEANING SIGNAL 1 0 Allows observation of all digital and anal
143. L REVISION ee SAMPLE 6400E SO2 ANALYZER Press EXIT at CPU TYPE any time to DATE FACTORY CONFIGURATION NEXT PREV EXIT return to SAVED SETUP menu 7 Only appears relevant oplion of Feature is active 6400E Rev B 51 Operating Instructions Model 6400E Instruction Manual 6 6 SETUP CLK SETTING THE INTERNAL TIME OF DAY CLOCK The 6400E has a built in clock for the AutoCal timer Time TEST function and time stamps on COM port messages and iDAS data entries To set the time of day press SAMPLE RANGE 500 000 PPB S02 XXX X lt TST TST gt CAL ETUP SAMPLE ENTER SETUP PASS 818 ENTR EXIT SETUP XX PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE SETUPXX Enter Current TIME OF DAY CLOCK Time of Day Enter Current Date of Year TIME DATE SETUP X X SETUP XX DATE 01 JAN 02 TIME 12 00 0 1 JAN ENTR EXIT 2 00 ENTR EXIT SETUP X X3 TIME 12 00 SETUP X X DATE 01 JAN 02 12 00 ENTR EXIT 01 JAN 02 ENTR EXIT rr SETUP XX TIME OF DAY CLOCK Y TIME DATE EXIT SETUP XX PRIMARY SETUP MENU EXIT retums to the main SAMPLE display CFG DAS RNGE PASS CLK MORE 52 6400E Rev B Model 6400E Instruction Manual Operating Instructions In order to compensate for CPU clocks which run fast or slow there is a v
144. L value is below 0 5 ppb 14 15 Use a span gas equal to 80 of the reporting range Example for a reporting range of 500 ppb use a span gas of 400 ppb scroll to the OFFSET function and record the value Scroll to the NORM PMT value NOTE Do not overload the PMT by accidentally setting both adjustment switches to their maximum setting This can cause permanent damage to the PMT 16 Determine the target NORM PMT value according to the following formulas Ifthe reporting range is set for lt 2 000 ppb the instrument will be using the 2 000 ppb physical range Target NORM PMT 2 x span gas concentration OFFSET Ifthe reporting range is set for gt 2 001 ppb the instrument will be using the 20 000 ppb physical range Target NORM PMT 0 2 x span gas concentration OFFSET EXAMPLE If the OFFSET is 33 mV the Reporting Range is 500 ppb the span gas should be 400 ppb and the calculation would be Target NORM PMT Target NORM PMT 2 x 400 33 mV 833 mV 04515 Rev B 249 TROUBLESHOOTING amp REPAIR Model 6400E Instruction Manual 17 Set the HVPS coarse adjustment switch to the lowest setting that will give you more than the target NORM PMT signal from Step 16 The coarse adjustment typically increments the NORM PMT signal in 100 300 mV steps 18 Adjust the HVPS fine adjustment such that the NORM PMT value is at or just above the target NORM PMT signal from Step 1
145. LES OFF PARAMETER REFGND MODE AVG PRECISION 4 STORE SRMPLES OFF Connected 00 01 32 Auto detect CRAP E SCROLL CARS oo Cspture Pant echo Figure 6 16 iDAS Configuration Through a Terminal Emulation Program Both procedures are best started by downloading the default iDAS configuration getting familiar with its command structure and syntax conventions and then altering a copy of the original file offline before uploading the new configuration CAUTION Whereas the editing adding and deleting of iDAS channels and parameters of one channel through the front panel keyboard can be done without affecting the other channels uploading an iDAS configuration script to the analyzer through its communication ports will erase all data parameters and channels by replacing them with the new iDAS configuration Backup of data and the original iDAS configuration is advised before attempting any iDAS changes 6400E Rev B 119 Operating Instructions Model 6400E Instruction Manual 6 12 REMOTE OPERATION OF THE ANALYZER 6 12 1 REMOTE OPERATION USING THE EXTERNAL DIGITAL I O 6 12 1 1 Status Outputs The status outputs report analyzer conditions via optically isolated NPN transistors which sink up to 50 mA of DC current These outputs can be used interface with devices that accept logic level digital inputs such as programmable logic controllers PLC s Each Status bit is an open collector output that can
146. Mark Compliance 2 4 Warranty 3 GETTING STARTED nnannsasnessovonnnranrasasnaveroveeesasevossasaesansastoeovesveeusasnoensasarennusoseosronnsonenan gt 3 1 Unpacking and Initial Setup nig 3 1 1 Electrical Connections 10 3 1 1 1 Connecting the Analog Outputs dl 3 1 1 2 Connecting the Status Outputs 12 3 1 1 3 Connecting the Control Inputs 13 3 1 1 4 Connecting the Serial Ports 14 3 1 1 5 Connecting to a LAN or the Internet 14 3 1 1 6 Connecting to a Multidrop Network 14 3 1 2 Pneumatic Connections 15 3 1 2 1 Calibration Gases 16 3 1 2 2 Pneumatic Connections to 6400E Basic Cont auradan 417 3 1 2 3 Connections with Internal Valve Options Installed 19 3 2 Initial Operation 21 3 2 1 Startup 2 3 2 2 Warm Up e 22 3 2 3 Warning Messages uA 3 2 4 Functional Check es 24 3 3 Initial Calibration seve 26 3 3 1 Basic Calibration Procedure 26 3 3 2 Interferences for SO Measurements 28 4 FREQUENTLY ASKED QUESTIONS amp GLOSSARY awed 4 1 FAQ s sse e 29 4 2 Glossary 30 5 OPTIONAL HARDWARE AND SOFTWARE 5 1 Rack Mount Kits Options 20a 20b amp 21 5 2 Current Loop Analog Outputs Option 41 5 2 1 Converting Current Loop Analog Outputs to Standard Voltage Outputs 5 3 Particulate Filter Kit Option 42A 5
147. Maximum dark offset allowed SO2 SPAN1 Conc 400 4000 0 1 50000 Target SO concentration during span d calibration of range 1 S02 SLOPE1 PPB mV 1 0 25 4 SO slope for range 1 PPM mV 1500 1500 400 4000 0 1 50000 0 25 4 1500 1500 SO offset for range 1 Target SO concentration during span calibration of range 2 SO slope for range 2 SO offset for range 2 RANGE MODE SNGL SNGL DUAL Range control mode Enclose value in double quotes when setting from 2 AUTO AUTO2 the RS 232 interface PHYS_RANGE1 PPM 2 500 0 1 2500 Low pre amp range E 3 3 5 10000 n PHYS RANGE2 PPM 22 5500 0 1 2500 High pre amp range 5 10000 CONC_RANGE1 Conc 500 5000 0 1 50000 D A concentration range 1 CONC RANGE2 Conc 500 5000 0 1 50000 D A concentration range 2 ZERO CONC THRESH 10 10 0 10 0 Percentage of CONC RANGE1 or CONC RANGE to treat as zero concentration If this is negative then concentration will peg at threshold when below this threshold SAMP_FLOW_SET cc m 700 250 0 1200 Sample flow set point for flow EXE ee calculation and warning limits Warnings 350 1200 175 325 9 SAMP FLOW SLOPE 1 0 5 1 5 Sample flow slope correction factor adjusted flow measured flow x slope VAC_SAMP_RATIO 0 53 0 1 2 Maximum vacuum pressure sample pressure ratio for valid
148. Model 6400E Instruction Manual 6 9 6 ELECTRICAL TEST The electrical test function creates a current which substitutes the PMT signal and feeds it into the preamplifier board This signal is generated by circuitry on the pre amplifier board itself and tests the filtering and amplification functions of that assembly along with the A D converter on the motherboard It does not test the PMT itself The electrical test should produce a PMT signal of about 2000 1000 mV To activate the electrical test press the following keys SAMPLE RANGE 5000PPB 2 DIAG SIGNAL 1 0 PREY NEXT JUMP ENTR EXIT SAMPLE ENTER SETUP PASS 818 Press NEXT until q ENTR EXIT TST TST gt CAL SETUP DIAG ELECTRICAL TEST SETUP XX PRIMARY SETUP MENU PREV NEXT ENTR EXIT SFG DAS RNGE PASS CLK MORE DIAG ELEC RANGE 500 0 PPB S02 zXXX X TST TST gt EXIT 6 Press TST until While the electrical test is i activated PMT should equal DIAG ELEC 1732 MV SO2zX XXX 2000 mV 1000 mV SETUP XX SECONDARY SETUP MENU COMM VARS DIAG lt TST TST gt EXIT 80 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 9 7 LAMP CALIBRATION An important factor in accurately determining SO concentration is the amount of UV light available to transform the SO into SO see Section 10 1 1 The model 6400E compensates for variations in the intensity of the a
149. N 4 STORE NUM SAMPLES OFF PARAMETER HVPS MODE AVG PRECISION 4 STORE NUM SAMPLES OFF PARAMETER REFGND MODE AVG PRECISION 4 STORE NUM SAMPLES OFF PARAMETER REF4096 MODE AVG PRECISION 4 STORE NUM SAMPLES OFF LIST OF CHANNELS NAME DETAIL EVENT ATIMER REPORT PERIOD 000 01 00 NO OF RECORDS 480 5 232 REPORT OFF CHANNEL ENABLED ON CAL HOLD OFF OFF CONC EVENT ARMER REPORT PERIOD 000 00 05 NO OF RECORDS 4032 RS 232 REPORT ON CHANNEL ENABLED ON CAL HOLD OFF ON NAME PNUMTC EVENT ATIMER REPORT PERIOD 01 00 00 NO OF RECORDS 360 RS 232 REPORT OFF CHANNEL ENABLED ON CAL HOLD OFF OFF NAME CALDAT EVENT SLPCHG NO OF RECORDS 200 95 222 REPORT OFF CHANNEL ENABLED ON CAL HOLD OFF OFF Same parameters amp seltings as DETAIL Figure 6 14 Default iDAS Channels Setup NAME FAST EVENT ATIMER REPORT PERIOD 00 00 01 NO OF RECORDS 360 RS 232 REPORT OFF CHANNEL ENABLED ON CAL HOLD OFF OFF PARAMETER CONCT MODE AVG PRECISION 1 STORE NUM SAMPLES OFF PARAMETER STABIL MODE AVG PRECISION 2 STORE NUM SAMPLES OFF PARAMETER SMPFLW MODE AVG PRECISION 1 STORE NUM SAMPLES OFF PARAMETER SMPPRS MODE AVG PRECISION 4 STORE NUM SAMPLES OFF PARAMETER SLOPE1 MODE INST PRECISION S STORE NUM SAMPLES OFF PARAMETER OFSETt MODE INST PRECISION 4 STORE NUM SAMPLES OFF PARAMET
150. ON Never disconnect electronic circuit boards wiring harnesses or electronic subassemblies while the unit is under power 4 Inspect the interior of the instrument to make sure all circuit boards and other components are in good shape and properly seated 5 Check the connectors of the various internal wiring harnesses and pneumatic hoses to make sure they are firmly and properly seated 6 Verify that all of the optional hardware ordered with the unit has been installed These are checked on the paperwork Form 04551 accompanying the analyzer 6400E Rev B 9 Getting Started Model 6400E Instruction Manual VENTILATION CLEARANCE Whether the analyzer is set up on a bench or installed into an instrument rack be sure to leave sufficient ventilation clearance AREA MINIMUM REQUIRED CLEARANCE Back of the instrument 10 cm 4 inches Sides of the instrument 2 5 cm 1 inch Above and below the instrument 2 5 cm 1 inch e Various rack mount kits are available for this analyzer See Chapter 5 of this manual for more information 3 1 1 ELECTRICAL CONNECTIONS CAUTION Check the voltage and frequency label on the rear panel of the instrument See Figure 3 1 for compatibility with the local power before plugging the 6400E into line power Do not plug in the power cord if the voltage or frequency is incorrect CAUTION Power connection must have functioning ground conn
151. OTOCOL communications channel Multidrop requires the use of instrument IDs ENABLE 64 Enables to send a modem initialization string at power up Asserts certain MODEM lines in the RS 232 port to enable the modem to communicate ERROR 128 Fixes certain types of parity errors at certain Hessen protocol installations CHECKING XON XOFF 256 Disables XON XOFF data flow control also known as software handshaking HANDSHAKE HARDWARE Enables CTS RTS style hardwired transmission handshaking This style of HANDSHAKE 8 data transmission handshaking is commonly used with modems or terminal emulation protocols as well as by Teledyne Instrument s APICOM software HARDWARE 512 Improves data transfer rate when on of the COMM ports FIFO COMMAND 4096 Enables a command prompt when in terminal mode PROMPT Modes are listed in the order in which they appear in the SETUP gt MORE gt COMM gt COM 1 OR 2 gt MODE menu The default sting for this feature is ON Do not disable unless instructed to by Teledyne Instruments Customer Service personnel 98 6400E Rev B Model 6400E Instruction Manual Operating Instructions Press the following keys to select a communication mode for a one of the COMM Ports such as the following example where HESSEN PROTOCOL mode is enabled SAMPLE lt TST TST CAL SAMPLE ENTER SETUP PASS 818 B 1 p EXIT SETUP XX PRIMARY SETUP MENU RANGE
152. PB SO2 XXXX TST TST CAL SETUP ACTION Allow zero gas to enter the sample port at the rear of the instrument STABIL X XXX PPB Wait until STABIL fatis below 0 5 ppb This may take several minutes M P CAL S02 X lt TST TST gt SETUP PN m M P CAL STABIL X XXX PPB SO2 XXX X lt TST TST gt ZERO CONC EXIT Press ENTR to changes the OFFSET amp SLOPE values for the SO measurements Press EXIT to feave the calibration unchanged and return to the previous menu M P CAL STABIL X XXX PPB 502 XXX X lt TST TST gt ENTR CONC EXIT ACTION Allow span gas to enter the sample port at the rear of the instrument The value of STABIL may jump significantly Wait until it falls back below 05 ppb The SPAN key now M P CAL STABIL X XXX PPB 502 XXX X This may take several appears during the minutes transition from zero to span TST TST gt SPAN CONC You may see both keys 34 If either the ZERO or Press ENTR to change the EXIT SPAN buttons fail to M P CAL RANGE 5000PPB SO2 XXXX OFFSET amp SLOPE values for the appear see Section 11 50 measurements for troubleshooting tips v aD TST TST gt ENTR SPAN CONC EXIT Press EXIT to leave the calibration unchanged and return to the previous menu RANGE 500 0 PPB M P CAL 502 XXX X lt
153. PMT only detects light given off by decaying 50 the pathway of the excitation UV and field of view of the PMT are perpendicular to each other and the inside surfaces of the sample chamber are coated with a layer of black Teflon that absorbs stray light UV Source Optical Fiiter Window Seal E 214 nm Reference 4 x Lamp Detector Filicred Fluorescent UV Excitation Ll Optical Filter T 330 nm Floorescent Ur Only Focused Fluorescent ur Figure 10 2 UV Light Path 10 2 1 UV SOURCE LAMP The source of excitation UV light for the Model 6400E is a low pressure zinc vapor lamp An AC voltage heats up and vaporizes zinc contained in the lamp element creating a light producing plasma arc Zinc vapor lamps are preferred over the more common mercury vapor lamps for this 174 04515 Rev B Model 6400E Instruction Manual Theory Of Operation application because they produce very strong emission levels at the wavelength required to convert SO to SO 213 9 nm see Figure 10 4 The lamp used in the Model 6400E is constructed with a vacuum jacket surrounding a double bore lamp element see Figure 10 3 The vacuum jacket isolates the plasma arc from most external temperature fluctuations The jacket also contains the thermal energy created by the lamps operation thereby helping the lamp heat up to and maintain proper vaporization temperature Light is emitted through a 20 mm x 5 mm portal Vacuum Jacket Light Outp
154. PRES also viewable via the front panel To cause the analyzer to measure and record a value for PRES press SAMPLE RANGE 500 0 PPB 502 zXXX X SIGNAL I O x TST TST CAL UP SAMPLE ENTER SETUP PASS B18 Repeat Pressing NEXT until ENTR EXIT Exit at any lime to retum to main the DIAG PRESSURE CALIBRATION SETUP menu PREV NEXT ENTR EXIT SETUP PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE DIAG FCAL ACTUAL PRES 27 20 IN HG A SETUP SECONDARY SETUP MENU 2 7 2 0 ENTR EXIT COMM VARS DIAG The value displayed is the ENTR accepts the current output of the UV new value source reference detector EXIT ignores the new value 82 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 9 9 FLOW CALIBRATION The flow calibration allows the user to adjust the values of the sample flow rates as they are displayed on the front panel and reported through COM ports to match the actual flow rate measured at the sample inlet This does not change the hardware measurement of the flow sensors only the software calculated values To carry out this adjustment connect an external sufficiently accurate flow meter to the sample inlet see Chapter 11 for more details Once the flow meter is attached and is measuring actual gas flow press SAMPLE RANGE 500 0 PPB 02 XXX X DIAG SIGNAL 1 0 lt TST TST CAL SETUP NEXT ENTR EXIT SAMPLE ENTE
155. PUTS The analyzer comes equipped with four Analog Outputs A1 A2 A3 and a fourth that is a spare A1 and A2 Outputs The first two A1 and A2 are normally set up to operate in parallel so that the same data can be sent to two different recording devices While the names imply that one should be used for sending data to a chart recorder and the other for interfacing with a datalogger either can be used for both applications Both of these channels output a signal that is proportional to the SO concentration of the sample gas The A1 and A2 outputs can be slaved together or set up to operated independently A variety of scaling factors are available See Section 6 7 for information on setting the range type and Section 6 9 4 for adjusting the electronic scaling factors of these output channels Test Output The third analog output labeled A3 is special It can be set by the user see Section 6 9 10 to carry the signal level of any one of the parameters accessible through the TEST menu of the unit s software 196 04515 Rev B Model 6400E Instruction Manual Theory Of Operation In its standard configuration the Analyzer comes with all four of these channels set up to output a DC voltage However 4 20mA current loop drivers can be purchased for the first two of these outputs 1 and A2 see Section 5 2 Output Loop back All three of the functioning analog outputs are connected back to the A D converter through a Loop back circuit T
156. Pin Out nennen nnne nnne nnne nennen nennen 228 Example of HVPS Power Supply Outputs 233 Example of HVPS Power Supply Outputs 244 Static Generation Voltages for Typical Activities Sensitivity of Electronic Devices to Damage by ESD 6400E Setup Variables Revision 6400E Warning Messages Revision 6400E Test Functions Revision C 3 6400E Signal 1 0 Definitions Revision C 3 6400E DAS Trigger Events Revision C 3 5 6400E iDAS Functions Revision C 3 281 Terminal Command Designators Revision C 3 6400E Spare Parts List ud List of Included Electronic Schematics seen enemies 289 6400E Rev B xi Model 6400E Instruction Manual 6400E Documentation 1 6400E DOCUMENTATION Thank you for purchasing the Model 6400E UV Fluorescence SO Analyzer The documentation for this instrument is available in several different formats e Printed format part number 045150100 Additional documentation for the Model 6400E UV Fluorescence SO Analyzer is available from Teledyne Instruments website at http www teledyne api com manuals e APICOM software manual part number 03945 Multi drop manual part number 01842 DAS Manual part number 02837 1 1 USING THIS MANUAL This manual has the following data structures 1 0 Table of Contents Outlines the contents of the manual in the order the information is presented
157. R SETUP PASS 818 Exit at Repeat Pressing NEXT until any time to return to main ENTR EXIT the SETUP menu FLOW CALIBRATION DIAG SETUP XX PRIMARY SETUP MENU ENTR EXIT PREV NEXT CFG DAS RNGE PASS CLK MORE DIAG FCAL ACTUAL FLOW 607 CC M SETUP XX SECONDARY SETUP MENU COMM VARS DIAG ENTR accepts the new value EXIT ignores the new value The value displayed is the current output of the UV source reference detector 6400E Rev B 83 Operating Instructions Model 6400E Instruction Manual 6 9 10 TEST CHANNEL OUTPUT When activated output channel A4 can be used to report one of the test functions viewable from the SAMPLE mode display To activate the A4 channel and select a test function follow this key sequence 502 XXX X RANGE 500 0 PPB SETUP lt TST TST gt CAL Table 6 14 Continue to press NEXT until v C SAMPLE ENTER SETUP PASS 818 DAS TEST CHAN OUTPUT 8 1 8 ENTR EXIT any ma PREV NEXT ENTR EXIT lo retum SETUP XX PRIMARY SETUP MENU DIAG TEHN TEST CHANNEL NONE CFG DAS RNGE PASS CLK MORE EXIT NEXT ENTR EXIT DIAG TCHN TEST CHANNEL PMT DETECTOR SETUP SECONDARY SETUP MENU PREV NEXT ENTR COMM VARS DIAG DAG SIGNAL 1 0 Press PREV or NEXT Press ENTR to to move through the seleci the displayed
158. RATION USING PERMEATION TUBES TAI does not recommend the use of permeation tubes as a source of span gas for EPA protocol calibration operations 8 1 5 CALIBRATION FREQUENCY To ensure accurate measurements of the SO concentrations calibrate the analyzer at the time of installation and re calibrate it No later than three months after the most recent calibration or performance audit which indicated analyzer calibration to be acceptable An interruption of more than a few days in analyzer operation repairs which might affect its calibration Physical relocation of the analyzer other indication including excessive zero or span drift of possible significant inaccuracy of the analyzer Following any of the activities listed above the zero and span should be checked to determine if a calibration is necessary If the analyzer zero and span drifts exceed locally established calibration 6400E Rev B 155 EPA Protocol Calibration Model 6400E Instruction Manual units or the calibration limits in Section 2 0 9 Subsection 9 1 3 Q A Handbook a calibration should be performed 8 1 6 RECORD KEEPING Record keeping is a critical part of all quality assurance programs Standard forms similar to those that appear in this manual should be developed for individual programs Three things to consider in the development of record forms are e Does the form serve a necessary function Is the docu
159. RE EXIT L SET SET gt EDIT EXIT ey SETUP x X COM1 TEST PORT TRANSMITTING TO COM1 EXIT returns to COMM menu a 6400E Rev 101 Operating Instructions Model 6400E Instruction Manual 6 11 USING THE DATA ACQUISITION SYSTEM IDAS The 6400E analyzer contains a flexible and powerful internal data acquisition system iDAS that enables the analyzer to store concentration and calibration data as well as a host of diagnostic parameters The iDAS of the 6400E can store up to about one million data points which can depending on individual configurations cover days weeks or months of valuable measurements The data are stored in non volatile memory and are retained even when the instrument is powered off Data are stored in plain text format for easy retrieval and use in common data analysis programs such as spreadsheet type programs The iDAS is designed to be flexible users have full control over the type length and reporting time of the data The iDAS permits users to access stored data through the instrument s front panel or its communication ports Using APICOM data can even be retrieved automatically to a remote computer for further processing The principal use of the iDAS is logging data for trend analysis and predictive diagnostics which can assist in identifying possible problems before they affect the functionality of the analyzer The secondary use is for data analysis docu
160. REPORT PERIOD 000 00 05 SET SET gt EDIT PRINT SETUP XX REPORT PERIODD DAYS 0 ENTR EXIT SETUP XX REPORT PERIODD TIME 01 01 ENTR accepts the new string and retums to the previous menu EXIT ignores the new string and 0 0 0 5 ENTR EXIT lif at any time an illegal entry is selected g days gt 366 the ENTR key will disappear from the display retums to the previous menu 2 6400 113 Operating Instructions Model 6400E Instruction Manual 6 11 2 6 Number of Records The number of data records in the 6400E is limited to about a cumulative one million data points in all channels one megabyte of space on the disk on chip However the actual number of records is also limited by the total number of parameters and channels and other settings in the iDAS configuration Every additional data channel parameter number of samples setting etc will reduce the maximum amount of data points somewhat In general however the maximum data capacity is divided amongst all channels max 20 and parameters max 50 per channel The iDAS will check the amount of available data space and prevent the user from specifying too many records at any given point If for example the iDAS memory space can accommodate 375 more data records the ENTR key will disappear when trying to specify more than that number of records This check for memory space may also make an up
161. RUMENT CODE 24 STARTING INSTRUMENT W FLASH 2 The instrument Is loading configuration and calibration data from the flash chip M6400 50 ANALYZER The Instrument is gt loading the analyzer BOOT PROGRESS 50 ___ _ _ firmware The revision level of the firmware installed in your BOOT PROGRESS 000000K 80 __ analyzer Is briefly displayed 502 SETUP fully booted Press CLR to clear initial warning messages see Sectlon 3 2 3 SOFTWARE REVISION X X SAMPLE SYSTEM RES TEST CAL The analyzer should automatically switch to SAMPLE mode after completing the boot up sequence and start monitoring SO gas 6400E Rev B 21 Getting Started Model 6400E Instruction Manual 3 2 2 WARM UP The 6400E requires about 60 minutes warm up time before reliable SO measurements can be taken During that time various portions of the instrument s front panel will behave as follows See Figure 3 10 for locations Table 3 6 Front Panel Display During System Warm Up NAME COLOR BEHAVIOR SIGNIFICANCE Concentration N A Displays current N A Field compensated SO Concentration Mode Field N A Displays blinking Instrument is in sample mode but is still in the SAMPLE process of warming up STATUS LED S Sample Green Blinking iDAS holdoff feature see Table 6 8 is active the first 15 minutes after startup ON Unit is
162. S OF MEASURE FLAGS 2000 PPB 4000 PPM 6000E SPARE UNUSED BITS 100 8000 UNASSIGNED FLAGS Box Temp Warning Sample Press Warning System Reset Rear Board Not Detected Relay Board Warning Front Panel Warning Analog Cal Warning Cannot Dyn Zero Cannot Dyn Span Instrurnent Off NOTES It is possible to assign more than one flag to the same Hessen status bit This allows the grouping of similar flags such as all temperature warnings under the same status bit Be careful not to assign conflicting flags to the same bit as each status bit will be triggered if any of the assigned flags is active 6400E Rev B 133 Operating Instructions Model 6400E Instruction Manual To assign or reset the status flag bit assignments press SAMPLE RANGE 500 000 PPB 502 XXX X lt TST TST gt CAL ETUP SAMPLE ENTER SETUP PASS 818 8 1 8 ENTR EXIT SETUP X X PRIMARY SETUP MENU GFG DAS RNGE PASS CLK MORE EXIT SETUP XX SECONDARY SETUP MENU COMM VARS DIAG ALRM SETUPXX COMMUNICATIONS MENU ID HESN Repeat pressing SET unti HESSEN STATUS FLAGS COM COM2 SETUP X SET SET EDIT SETUP X PMT DET WARNING 0002 PREV NEXT EDIT PRINT EXIT Repeat pressing NEXT or PREV until the desired
163. SAMPLE display NOTE If the ZERO or SPAN keys are not displayed during zero or span calibration the measured concentration value is too different from the expected value and the analyzer does not allow to zero or span the instrument Consult Section 11 3 for more information on calibration problems 140 6400E Rev B Model 6400E Instruction Manual Calibration Procedures 7 3 MANUAL CALIBRATION CHECKS Informal calibration checks which only evaluate but do not alter the analyzer s response curve are recommended as a regular maintenance item and in order to monitor the analyzer s performance To carry out a calibration check rather than a full calibration follow these steps STEP ONE Connect the sources of zero air and span gas as shown in Figure 7 1 STEP TWO Perform the zero span calibration check procedure ACTION Supply the instrument with zero gas Y SAMPLE RANGE 500 000 PPB 902 2XXXX 4 lt TST TST CAL SETUP SAMPLE STABIL XXX X PPB SO2 XXX X lt TST TST gt CAL SETUP Scroll the display to the STABIL test function Wait until STABIL is below 0 5 ppb This may take several minutes ACTION Record the SO2 concentration reading SAMPLE STABILE XXX X PPE 502 lt TST TST CAL SETUP capo The value of ACTION STABIL may jump Supply span gas to the instrument significantly Wait until it fa
164. SEMBLY The pressure flow sensor circuit board located behind the sensor assembly can be checked with a voltmeter using the following procedure which assumes that the wiring is intact and that the motherboard and the power supplies are operating properly e Measure the voltage across TP1 and TP2 it should be 10 0 0 25 V If not the board may be faulty e Measure the voltage across capacitor C2 it should be 5 0 0 25 V If not the board may be faulty 11 5 17 1 Sample Pressure Measure the voltage across test points TP1 and TP4 With the sample pump disconnected or turned off this voltage should be 4500 250 mV With the pump running it should be about 0 2 V less as the sample pressure drops by about 1 in Hg A from ambient pressure If this voltage is significantly different the pressure transducer S2 or the board may be faulty A leak in the sample system to vacuum may also cause this voltage to be between about 0 6 and 4 5 Make sure that the front panel reading of the sample pressure is at about 1 in Hg A less than ambient pressure 04515 Rev B 233 TROUBLESHOOTING amp REPAIR Model 6400E Instruction Manual 11 5 18 IZS OPTION The zero span valves and IZS options need to be enabled in the software contact the factory on how to do this See Figure 5 2 and 5 3 for a flow diagram with zero span valve or IZS option e Check for the physical presence of the valves or the 125 option e Check that a working perm tube i
165. SETUP XX INST IP 000 000 000 000 Some keys only appear as needed Nd SET SET EDIT EXIT Cursor location is indicated by brackets SETUP X X INST IP 0 00 000 000 CH CH DEL 0 ENTR EXIT SET SET EDIT ETIP X X GATEWAY IP 000 000 000 000 EXIT lt SET SET gt EDIT SETUP TCP PORT 3000 J X X SUBNET MASK 255 255 255 0 SETUP XX GATEWAY IP 0 00 000 000 CH CH DEL 7 ENTR EXIT SETUP SUBNET MASK 2 55 255 255 0 ENTR EXIT CH CH DEL 7 Pressing EXIT from any of the above display menus causes tha Ethernet p y Le The PORT number needs to remain at 3000 Do not change this setting unless instructed to by Teledyne Instruments Customer Service personnel option to reinitialize its Internal interface TUP X S INITIALIZING INET 0 firmware aan 7 INITIALIZING INET 100 SETUP XX INITIALIZATION SUCCEEDED SETUP XX INITIALIZATION I SETUP XX COMMUNICATIONS MENU Contact your IT Network Administrator ID COMI EXIT 94 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 10 6 4 Changing the Analyzer s HOSTNAME The HOSTNAME is the name by which the analyzer appears on your network The default name for all Teledyne Instruments Model 6400E analyzers is 100E To change this name
166. T should last for the lifetime of the analyzer However in some cases the high voltage power supply HVPS or the thermo electric cooler TEC may fail To replace the PMT the HVPS or the TEC PMT Housing End Plate This is the entry to the PMT Exchange PMT Output Connei PMT Power Supply High voltage Power Supply amp Aux Signal HVPS Connector O Test LED di E Cold Block Connector to PMT Pre Amp PCA 12V Power Connector Insulation Gasket ight from Reaction PMT Temperature Chamber shines Sensor through hole In side of Cold Block Thermo Electri Cooler TEC PMT Heat Exchange Fins TEC Driver Cooling Fan Housing Figure 11 16 PMT Assembly Exploded View 1 Remove the sensor module as described in Section 11 6 3 5 2 Remove the entire sensor module assembly from the 3 Remove the reaction cell assembly 4 Remove the two connectors on the PMT housing end plate facing towards the front panel 5 Remove the end plate itself 4 screws with plastic washers R 6 Remove the two desiccant bags inside the PMT housing 7 Along with the plate slide out the OPTIC TEST LED and the thermistor that measures the PMT temperature Both may be coated with a white thermal conducting paste Do not contaminate the inside of the housing or the PMT tube with this grease 246 04515 Rev B Model 6400E Instruction Manual TROUBLESHOOTING amp REPAIR 8 Unscr
167. T value assuming unchanging SO concentration of sample gas Calibration error HVPS problem PMT problem UV LAMP SIGNAL LAMP RATIO fe el STR LGT 3500 mV 200mv 30 TO 120 40 100 ppb DRK PMT 50 200 mV High dark PMT reading could be due to light leak shutter not closing NUR doli isa ae a E ae This is the instantaneous reading of the UV lamp intensity Low UV lamp intensity could be due to aging UV lamp UV lamp position out of alignment faulty lamp transformer aging or faulty UV detector UV detector needs adjusting dirty optical components Intensity lower than 600 mV will cause UV LAMP WARNING Most likely cause is a UV lamp in need of replacement The current output of the UV reference detector divided by the reading stored in the CPU s memory from the last time a UV Lamp calibration was performed Out of range lamp ratio could be due to malfunctioning UV lamp UV lamp position out of alignment faulty lamp transformer aging or faulty UV detector dirty optical components pin holes or scratches in the UV optical filters light leaks High stray light could be caused by aging UV filter contaminated reaction cell light leak pneumatic leak completely high pmt temperature high electronic offset High dark UV detector could be caused by light leak shutter not closing DRK LMP 50 200 mV completely high electronic offset 400
168. TUP XX 0 CONC1 ATIMER 2 4032 R 3 Exits to the Main Data Acquisition menu PREV NEXT INS DEL EDIT PRNT EXIT lt a SETUP XX 1 SET SET EDIT PRINT EXIT SETUP XX SET SET EDIT PRINT EXIT 3 SETUP XX ENTR accepts the new string and returns to the previous menu EXIT ignores the new string and returns to the previous menu lt PREV NEXT gt ENTR EXIT Press each key repeatedly to cycle through the list of available trigger events 6400E Rev B 109 Operating Instructions Model 6400E Instruction Manual 6 11 2 4 Editing iDAS Parameters Data channels can be edited individually from the front panel without affecting other data channels However when editing a data channel such as during adding deleting or editing parameters all data for that particular channel will be lost because the iDAS can store only data of one format number of parameter columns etc for any given channel In addition an iDAS configuration can only be uploaded remotely as an entire set of channels Hence remote update of the iDAS will always delete all current channels and stored data To modify add or delete a parameter follow the instruction shown in section 6 11 2 2 then press From the DATA ACQUISITION menu Edit Data Channel Menu SETUPXX 0 1 ATIMER 2 4032 R
169. This is a good overview of the topics covered in the manual There is also a list of tables a list of figures and a list of appendices In the electronic version of the manual clicking on any of these table entries automatically views that section 6400E Rev B 1 6400E Documentation Model 6400E Instruction Manual 2 0 Specifications and Warranty This section contains a list of the analyzer s performance specifications a description of the conditions and configuration under which EPA equivalency was approved and TAI s warranty statement 3 0 Getting Started A concise set of instructions for setting up installing and running your analyzer for the first time 4 0 FAQ Answers to the most frequently asked questions about operating the analyzer 5 0 Optional Hardware amp Software A description of optional equipment to add functionality to your analyzer 6 0 Operation Instructions This section includes step by step instructions for operating the analyzer and using its various features and functions 7 0 Calibration Procedures General information and step by step instructions for calibrating your analyzer 8 0 EPA Protocol Calibration Specific information regarding calibration requirements for analyzers used in EPA regulated monitoring applications 9 0 Instrument Maintenance Description of certain preventative maintenance procedures that should be regularly performed on you instrument to keep it in good operating conditio
170. This power supply is unlike a traditional PMT HVPS It is like having 10 independent power supplies one to each pin of the PMT The test procedure below allows you to test each supply 1 Check the HVPS test function via the front panel Turn off the instrument and record the reading level Adjustment of the HVPS output level is covered in the hardware calibration procedure in Section 11 6 3 8 2 Turn off the instrument 3 Remove the cover and disconnect the 2 connectors at the front of the PMT housing 4 Remove the end plate from the PMT housing 5 Remove the HVPS PMT assembly from the cold block inside the sensor Un plug the PMT 232 04515 Rev B Model 6400E Instruction Manual TROUBLESHOOTING amp REPAIR 6 Re connect the 7 pin connector to the Sensor end cap and power up the instrument 7 Check the voltages between the pairs of pins listed in Table 11 9 The result for each pair should be equal and approximately 10 of the reading level recorded in Step 1 Table 11 9 Example of HVPS Power Supply Outputs If HVPS reading 700 VDC PIN PAIR NOMINAL READING 122 70 VDC 223 70 VDC 324 70 VDC 425 70 VDC 526 70 VDC 627 70 VDC 728 70 VDC 8 Turn off the instrument power and re connect the PMT tube then re assemble the sensor If any faults are found in the test the HVPS must be replaced There are no user serviceable parts inside the HVPS 11 5 17 PNEUMATIC SENSOR AS
171. To select an output signal type DC Voltage or current and level for one output channel activate the ANALOG I O CONFIGURATION MENU see Section 6 9 1 then press d Access from DIAG Menu see Section 6 9 1 2 DIAG ANALOG 17 CONFIGURATION PREV NEXT ENTR EXIT DIAG AIO AOUTS CALIBRATED NO SET SET CAL EXIT Press SET gt to select the analog output channel to be configured Press EDIT to continue DIAG AIO CONC_OUT_2 5V CAL SET SET EDIT EXIT DIAG AIO CONC_OUT_2 RANGE 5V EDIT EXIT DIAG AIOQUTPUT RANGE These keys set the signal level and type of the selected channel Pressing ENTR records the new setting and retums to the previous menu Pressing EXIT ignores the new setting and retums to the previous menu DIAG AIOOUTPUT RANGE 10V 8v 30 CURR ENTR EXIT 70 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 9 4 2 Analog Output Calibration Mode The analog outputs can be calibrated automatically or manually In its default mode the instrument is configured for automatic calibration of all channels Manual calibration should be used for the 0 1V range or in cases where the outputs must be closely matched to the characteristics of the recording device Outputs configured for automatic calibration can be calibrated as a group or individually Calibration of the analog o
172. V to 900 V Incorrect HVPS reading could be caused by HVPS broken preamp board circuit HVPS problems 50 C 19C Incorrect temperature reading could be caused by malfunctioning heater relay RCELL TEMP board communication bus relay burnt out ambient Incorrect temperature reading could be caused by Environment out of BOX TEMP 50C empberature operating range broken thermistor runaway heater 79C 29C Incorrect temperature reading could be caused by TEC cooling circuit broken PMT TEMP constant High chassis temperature 12V power supply IZS TEMP 50 C 19C Malfunctioning heater relay board communication 1 C bus relay burnt out OPTION ambient Incorrect sample gas pressure could be due to pneumatic leak malfunctioning PRESS 2 IN HG A valve malfunctioning pump clogged flow orifices sample inlet overpressure faulty pressure sensor SLOPE 1 0 0 3 Slope out of range could be due to poor calibration quality span gas concentration incorrect leaks UV Lamp output decay lt 250 mV High offset could be due to incorrect span gas concentration contaminated zero OFFSET air leak low level calibration off light leak aging UV filter contaminated reaction cell pneumatic leak TIME OF Current time Incorrect Time could be caused by Internal clock drifting move across time DAY zones daylight savings time 04515 Rev B 211 TROUBLESHOOTING amp REPAIR Model 6400E Instruction Manual 11 1 3 USING THE
173. Y BOARD FRONT PANEL ANALOG CAL WARNING CANNOT DYN ZERO CANNOT DYN SPAN INVALID CONC lt SET SET EDIT VARIATION RESPONSE MODE GAS LIST STATUS FLAGS PREV NEXT INS DEL EDIT PRNT Select from list of available gases see Section 6 12 4 6 ZERO CAL SPAN MANUAL MODE GAS TYPE Set Hessen ID number for PPB GAS ID selected gas type PPM 502 110 REPORTED REPORTED see Section 6 12 4 6 See Table 6 27 for Flag Assignments MGM Only appears if a valve is installed Only appears when the HESSEN mode is enabled for either COM1 or COM2 Figure A 7 Secondary Setup Menu HESSEN Submenu 05036 Rev C 3 266 APPENDIX A 1 6400E Software Menu Trees Revision C 3 Model 6400E Instruction Manual ENTER SETUP PASS 818 CFG RNGE PASS MORE DIAG COMM VARS eo PREV NEXT SIGNAL ANALOG ANALOG I O OPTIC ELECTRICAL LAMP PRESSURE FLOW TEST 1 O OUTPUT CONFIGURATION TEST TEST CALIBRATION CALIBRATION CALIBRATION CHANNEL 1 ena ENTR ENTR ENTR ENTR ENTR l I 1 Start step Test Starts Test Starts Test Starts Test Starts Test Starts Test EXT ZERO CAL 1 EXTSPAN CAL 2 MAINT MODE 3 LANG2 SELECT NONE PMT READING 2 SAMPLE LED SET SET UV READING LE PRESSURE 6 FAULT CED SAM AMPLE FLOW 2 AUDIBLE BERAR AOUTS CALIBRATED RCELL TEMP 9 OPTICTEST
174. _1 Sets the basic electronic configuration of the A1 analog output SO2 There are three options RANGE Selects the signal type voltage or current loop and full scale level of the output e REC OFS Allows to set a voltage offset not available when RANGE is set to Current loop CURR AUTO CAL Performs the same calibration as AOUT CALIBRATED but on this one channel only NOTE Any change to RANGE or REC OFS requires recalibration of this output CONC OUT 2 Same as for CONC OUT 1 but for analog channel 2 SO CONC OUT 3 Spare TEST OUTPUT Same as for CONC OUT 1 but for analog channel 4 TEST ions CALIBRATED Shows the calibration status YES NO and initiates a calibration of the analog to digital converter circuit on the motherboard To configure the analyzer s four analog outputs set the electronic signal type of each channel and calibrate the outputs This consists of Selecting an output type voltage or current if an optional current output driver has been installed and the signal level that matches the input requirements of the recording device attached to the channel see Sections 6 9 4 1 Calibrating the output channel This can be done automatically or manually for each channel see Sections 6 9 4 2 amp 6 9 4 3 Adding a bipolar recorder offset to the signal if required see Section 6 9 4 4 In its standard configuration the analyzer s outputs can be set for the fo
175. abeled D1 on the relay board in conjunction with the performance of the front panel display Assuming that the DC power supplies are operating properly and the wiring from the motherboard to the keyboard as well as from the keyboard to the relay board is intact the I C bus is operating properly if Dion the relay board is flashing or e Diis not flashing but pressing a key on the front panel results in a change to the display If the display is locked up or if the analyzer is not booting up at all the I C bus may be the cause Contact customer service if you suspect a problem with the bus 11 5 7 KEYBOARD DISPLAY INTERFACE The front panel keyboard the display and the keyboard display circuit board can be verified by observing the operation of the display when power is applied to the instrument and when a key is pressed on the front panel Assuming that there are no wiring problems and that the DC power supplies are operating properly The vacuum fluorescent display is working properly if on power up a character is visible on the upper left hand corner of the display e If the analyzer starts operation with a normal display but pressing a key on the front panel does not change the display then there are three possible problems e One or more of the keys is bad The interrupt signal between the keyboard circuit and the motherboard is broken due to a cabling problem or e The keyboard circuit is bad You can verif
176. al SAMPLE TEST CAL CALZ CALS n t CLR SETUP AUTO range lt TST TST gt LOW HIGH LOW HIGH LOW HIGH mode eee a PRES ZERO SPAN CONC ZERO SPAN CONC ENTER SETUP PASS 818 SAMP FL PMT NORM PMT UV LAMP LAMP RATIO Primary Setup Menu STR LGT DRK PMT DRK LAMP SLOPE CFG DAS RANG PASS CLK MORE OFFSET Only appear if reporting range is set for HVPS RCELL TEMP BOX TEMP Secondary Setup Menu PMT TEMP t Only appears when warning messages are activated IZS TEMP see Section 6 2 2 TEST Press this key to cycle through list of active warn ng TIME TEST FUNCTIONS messages COMM VARS DIAG Viewable by user while 3 Press th s key to clear erase the warning message nstrument is in SAMPLE Mode currently displayed see Section 6 2 1 Only appears if the IZS valve option is installed 5 Only appears if the TEST analog output channel is activated Figure A 2 Sample Display Menu Units with Z S Valve or IZS Option installed 05036 Rev C 3 261 APPENDIX 1 6400E Software Menu Trees Revision Model 6400E Instruction Manual CFG PREV NEXT SETUP 1 ENTER SETUP PASS 818 RNGE PASS MORE ON CLK Go To iDAS MENU TREE PREV NEXT Fig 8 OFF MODEL NAME SERIAL NUMBER SOFTWARE REVISION LIBRARY REVISION iCHIP SOFTWARE REVISION HESSEN PROTOCOL REVISION ACTIVE SPECIAL SOFTWAR
177. al gas supply and vacuum systems are the most common source of unstable and non repeatable concentration readings e Check for leaks in the pneumatic systems as described in Section 11 5 1 Consider pneumatic components in the gas delivery system outside the 6400E such as a change in zero air source ambient air leaking into zero air line or a worn out zero air scrubber or a change in the span gas concentration due to zero air or ambient air leaking into the span gas line e Once the instrument passes a leak check do a flow check see Section 11 5 2 to make sure that the instrument is supplied with adequate sample gas Confirm the UV lamp sample pressure and sample temperature readings are correct and steady Verify that the sample filter element is clean and does not need to be replaced 11 3 4 INABILITY TO SPAN NO SPAN KEY In general the 6400E will not display certain keyboard choices whenever the actual value of a parameter is outside of the expected range for that parameter If the calibration menu does not show a SPAN key when carrying out a span calibration the actual concentration must be outside of the range of the expected span gas concentration which can have several reasons e Verify that the expected concentration is set properly to the actual span gas concentration in the CONC sub menu e Confirm that the SO span gas source is accurate e If you are using bottle calibration gas and have recently changed bottl
178. alyzer into a power supply that is too high a voltage or frequency can damage the UV lamp the pump and the AC Plugging the analyzer into a power supply that is too low a voltage or frequency will cause these components to not operate properly If an incorrect power configuration is suspected check the serial number label located on the instrument s rear panel see figure 3 1 to make sure that the instrument was configured for the same voltage and frequency being supplied If the information included on the label matches the line voltage but you still suspect an AC power configuration problem check the power configuration jumpers located on the relay board see figure 11 6 If the Jumper block is WHITE the instrument is configured for 115 VAC at 60 Hz e If the Jumper block is BLUE the instrument is configured for 220 240 VAC at 50 Hz 224 04515 Rev B Model 6400E Instruction Manual TROUBLESHOOTING amp REPAIR J2 Power Configuration Jumper Figure 11 6 Location of Relay Board Power Configuration Jumper 11 5 5 DC POWER SUPPLY If you have determined that the analyzer s AC main power is working but the unit is still not operating properly there may be a problem with one of the instrument s switching power supplies which convert AC power to 5 and 15 V PS1 as well as 12 V DC power PS2 The supplies can either have DC output at all or a noisy output fluctuating To assist trac
179. alyzer s SO measurement To clean the sample chamber 1 Remove the sensor module as described in Section 11 6 3 1 2 Remove the sample chamber mounting bracket by unscrewing the four bracket screws 238 04515 Rev B Model 6400E Instruction Manual TROUBLESHOOTING amp REPAIR Sample Chamber Bracket Standoffs 4th standoff hidden from view Sample Chamber Bracket Screws Sample Chamber Bracket Standoffs Figure 11 9 Sample Chamber Mounting Bracket 3 Unscrew the 4 hexagonal standoffs 4 Gently remove the chamber cover 5 Using a lint free cloth dampened with distilled water wipe the inside surface of the chamber and the chamber cover 6 Dry the chamber surfaces with a 2nd lint free cloth 7 Re assemble the chamber and re install the sensor module 04515 Rev B 239 TROUBLESHOOTING amp REPAIR Model 6400E Instruction Manual 11 6 3 3 Cleaning the PMT Lens amp PMT filter NOTE The sample chamber should only be opened or cleaned on instructions from the Teledyne Instruments customer service department Be careful not to leave thumbprints on the interior of the sample chamber The various oils that make up fingerprints fluoresce brightly under UV light and will significantly affect the accuracy of the analyzer s SO measurement To clean the PMT Lens and filter 1 Remove the sensor module as described in Section 11 6 3 1 Hex Screws Bottom two hidden from view
180. ample chamber reports the cell s temperature to the CPU through the thermistor interface circuitry of the motherboard 188 04515 Rev B Model 6400E Instruction Manual Theory Of Operation 10 4 3 PHOTO MULTIPLIER TUBE PMT The 6400E uses a photo multiplier tube PMT to detect the amount of fluorescence created by the SO and reaction in the sample chamber PMT Housing End Plate This is the entry to the PMT Exchange PMT Output Connector PMT Preamp PCA PMT Power Supply amp Aux Signal High voltage Power Supply HVPS Connector O Jest LED PMT Cold Block es gt k Connector to PMT EN Pre Amp PCA Insulation Gasket 12V Power Connector PMT Temperature from Reset 2 Sensor through hole in side of Cold Block 7 Thermo Electric Cooler TEC PMT Heat Exchange Fins TEC Driver PCA Cooling Fan Housing Figure 10 14 PMT Housing Assembly A typical PMT is a vacuum tube containing a variety of specially designed electrodes Photons from the reaction are filtered by an optical high pass filter enter the PMT and strike a negatively charged photo cathode causing it to emit electrons A high voltage potential across these focusing electrodes directs the electrons toward an array of high voltage dynodes The dynodes in this electron multiplier array are designed so that each stage multiplies the number of emitted electrons by emitting multiple new electrons The g
181. anel CPU Status LED Figure 11 3 CPU Status Indicator 11 1 4 2 CPU Status Indicator The CPU board has two red LEDs LED1 is the upper most LED and is a 5V power indicator so it should always be on However both CPU LEDs only indicate if the CPU is powered up properly and generally working The lower LED will sometimes be stable and sometimes will blink It can continue to blink even if the CPU or firmware are locked up and is not an effective indicator for debugging system problems 04515 Rev B 213 TROUBLESHOOTING amp REPAIR Model 6400E Instruction Manual 11 1 4 3 Relay Board Status LEDs The most important status LED on the relay board is the red I C Bus watch dog LED labeled D1 or W D which indicates the health of the communications bus This LED is located in the upper left hand corner of the relay board when looking at the electronic components If D1 is blinking then the other LED s can be used in conjunction with the DIAG menu 1 0 functions to test hardware functionality by switching devices on and off and watching the corresponding LED go on or off The LED only indicates that the logic signal for an output has been activated If the output driver i e the relay or valve driver IC is defective then the LED will light up but the attached peripheral device will not turn on Table 11 3 Relay Board Status LEDs FAULT LE
182. ansistors on pins 1 8 are bussed D Emitter Bus together For most applications this pin should be connected to the circuit ground of the receiving device 5 VDC source 30 mA maximum combined rating with De Power Contro Inputs Digital Ground ee from the analyzer s internal 5 15 VDC power 6 12 1 2 Control Inputs Control inputs allow the user to remotely initiate ZERO and SPAN calibration modes are provided through a 10 pin connector labeled CONTROL IN on the analyzer s rear panel These are opto isolated digital inputs that are activated when a 5 VDC signal from the U pin is connected to the respective input pin Table 6 23 Control Input Pin Assignments INPUT STATUS CONDITION WHEN ENABLED Zero calibration mode is activated The mode field of the display will read ZERO CAL R Span calibration mode is activated The mode field of the display will read SPAN CAL R Unused Unused Unused Unused A External Zero Cal External Span Cal Digital Ground Provided to ground an external device e g recorder c 1 1 w DC Power For Input for 5 VDC required to activate inputs A F This voltage Input Pull Ups can be taken from an external source or from the pin Internal 5v Internal source of 5V which can be used to activate inputs Supply when connected to pin U 6400E Rev B 121 Operating Instructions Model 6400E Inst
183. ant levels Pushing an epoxy printed circuit board across a workbench using a plastic handled screwdriver or even the constant jostling of Styrofoam pellets during shipment can also build hefty static charges 04515 Rev B 251 A Primer on Electro Static Discharge Model 6400E Instruction Manual Table 12 1 MEANS OF GENERATION Walking across nylon carpet Walking across vinyl tile 65 90 RH Static Generation Voltages for Typical Activities 10 25 RH 12 000V Worker at bench 6 000V Poly bag picked up from bench 20 000V LL Moving around in a chair padded with urethane foam 18 000V 12 2 HOW ELECTRO STATIC CHARGES CAUSE DAMAGE Damage to components occurs when these static charges come in contact with an electronic device Current flows as the charge moves along the conductive circuitry of the device and the typically very high voltage levels of the charge overheat the delicate traces of the integrated circuits melting them or even vaporizing parts of them When examined by microscope the damage caused by electro static discharge looks a lot like tiny bomb craters littered across the landscape of the component s circuitry A quick comparison of the values in Table 12 1 with the those shown in the Table 12 2 listing device susceptibility levels shows why Semiconductor Reliability News estimates that approximately 60 of device failures are the result of damage due
184. apter 5 the display controller turns on an LED located on the back of the keyboard interface PCA whenever the instrument is placed in maintenance mode Display Power Watchdog The Model 6400E s display can begin to show garbled information or lock up if the DC voltage supplied to it falls too low even momentarily To alleviate this a brown out watchdog circuit 202 04515 Rev B Model 6400E Instruction Manual Theory Of Operation monitors the level of the power supply and in the event that the voltage level fails below a certain level resets the display by turning it off then back on Link To The Relay While the CPU s I C communication with the relay board is also routed through the keyboard display interface information passed to and from the relay board via this channel is not recognized by acted upon or affected by the circuitry of the keyboard display interface 04515 Rev B 203 Theory Of Operation Model 6400E Instruction Manual 10 7 SOFTWARE OPERATION The 6400E SO analyzer is at its heart a high performance 386 based microcomputer running MS DOS Inside the DOS shell special software developed by TAI interprets user commands vie the various interfaces performs procedures and tasks stores data in the CPU s various memory devices and calculates the concentration of the sample gas DOS Shell API FIRMWARE Memory Handling IDAS Records Calibration Data System Status Data
185. are equipped with a switch that places the instrument in maintenance mode When present the switch is accessed by opening the hinged front panel and is located on the rearward facing side of the display keyboard driver PCA on the left side near the particulate filter When in maintenance mode the instrument ignores all commands received via the COMM ports that alter the operation state of the instrument This includes all calibration commands diagnostic menu commands and the reset instrument command The instrument continues to measure concentration and send data when requested This feature is of particular use for instruments connected to multidrop or Hessen protocol networks 5 8 2 SECOND LANGUAGE SWITCH Teledyne Analytical Instruments analyzers are equipped with a switch that activates an alternate set of display messages in a language other than the instrument s default language This switch is accessed by opening the hinged front panel and is located on the rearward facing side of the display keyboard driver PCA on the right side 6400E Rev B 41 Optional Hardware and Software Model 6400E Instruction Manual To activate this feature the instrument must also have a specially programmed Disk on Chip containing the second language Contact Teledyne Instruments Customer Service personnel for more information 5 8 3 DILUTION RATIO OPTION The dilution ration feature is a software option that is designed for applications where
186. are in the Signal 1 0 REF 4096 MV mv 4096mv 2mv and Must be Stable REF mv 0 0 5 and Must be Stable If option is installed TELEDYNE API CUSTOMER SERVICE Page 1 of 2 Email api customerservice teledyne com PHONE 858 657 9800 TOLL FREE 800 324 5190 FAX 858 657 9816 Model 6400E Instruction Warranty Repair Be one Manual Questionnaire INSTRUMENTS Advanced Pollution Instrumentation Model 6400E festi 05038 Rev A 3 What is the sample flow amp sample pressure w sample inlet on rear of machine capped SAMPLE FLOW cc SAMPLE PRESS IN HG A 4 What are the failure symptoms 5 If possible please include a portion of a strip chart pertaining to the problem Circle pertinent data Thank you for providing this information Your assistance enables Teledyne Instruments to respond faster to the problem that you are encountering OTHER NOTES TELEDYNE API CUSTOMER SERVICE Page 2 of 2 Email api customerservice teledyne com PHONE 858 657 9800 TOLL FREE 800 324 5190 FAX 858 657 9816 Model 6400E Instruction Manual APPENDIX D ELECTRONIC SCHEMATICS APPENDIX D ELECTRONIC SCHEMATICS Table D 1 List of Included Electronic Schematics DOCUMENT DOCUMENT TITLE 04002 PCA 04003 Pressure Flow Sensor Board 03956 PCA 03955 Relay Driver 04070 PCA
187. ariable to speed up or slow down the clock by a fixed amount every day To change this variable press SAMPLE RANGE 500 000 PPB S02 XXX X SETUPXX 1 DAS HOLD OFF 150 Minutes TST TST gt CAL SETUP PREV NEXT JUMP EDIT PRNT EXIT SAMPLE ENTER ate PASS 818 Continue to press NEXT until 8 1 8 p EXIT SETUP XX PRIMARY SETUP MENU SETUP XX 8 CLOCK ADJ 0 Sec Day CFG DAS RNGE PASS CLK MORE EXIT PREV JUMP PRNT EXIT T SETUP X X CLOCK_ADJ 0 Sec Day SETUP XX SECONDARY SETUP MENU ENTR EXIT COMM VARS DIAG EXIT Enter sign and number of seconds per day the clock gains or loses SETUP XX 8 CLOCK_ADJ 0 Sec Day 0 MEASURE_MODE H2S EDIT PRNT EXIT NEXT JUMP EDIT PRNT EXIT PREV NEXT JUMP 3x EXIT returns to the main SAMPLE display 6400E Rev B 53 Operating Instructions Model 6400E Instruction Manual 6 7 SETUP RNGE ANALOG OUTPUT REPORTING RANGE CONFIGURATION 6 7 1 AVAILABLE ANALOG OUTPUT SIGNALS The analyzer has three active analog output signals accessible through a connector on the rear panel ANALOG OUT SO concentration outputs Test Channel Not Used LOW range when HIGH range when DUAL mode is selected DUAL mode is selected Figure 6 4 Analog Output Connector Key All three outputs can be configured either at the factory or by the user for full scale outputs of
188. arry out a detailed leak check as described earlier in this chapter Another possibility of excessive signal noise may be the preamplifier board the high voltage power supply and or the PMT detector itself Contact the factory on trouble shooting these components 11 4 2 SLOW RESPONSE If the analyzer starts responding too slowly to any changes in sample zero or span gas check for the following Dirty or plugged sample filter or sample lines Sample inlet line is too long Dirty or plugged critical flow orifices Check flows pressures and if necessary change orifices see Section 9 3 6 Wrong materials in contact with sample use Teflon materials only Sample vent line is located too far from the instrument sample inlet and causes long mixing and purge times Locate sample inlet overflow vent as close as possible to the analyzer s sample inlet port Dirty sample chamber Insufficient time allowed for purging of lines upstream of the analyzer e Insufficient time allowed for SO calibration gas source to become stable 11 4 3 THE ANALYZER DOESN T APPEAR ON THE LAN OR INTERNET Most problems related to internet communications via the Ethernet card option will be due to problems external to the analyzer e g bad network wiring or connections failed routers malfunctioning servers etc However there are several symptoms that indicate the problem may be with the Ethernet card itself 04515 Re
189. ating an 8 bit data word alerts the key depress detect circuit a flip flop IC translates the 8 bit word into serial data and sends this to the I C interface chip Key Depress Detect Circuit This circuit flips the state of one of the inputs to the interface chip causing it to send an interrupt signal to the CPU T C Interface Chip This IC performs several functions e Using a dedicated digital status bit it sends an interrupt signal alerting the CPU that new data from the keyboard is ready to send Upon acknowledgement by the CPU that it has received the new keyboard data the rc interface chip resets the key depress detect flip flop In response to commands from the CPU it turns the front panel status LEDs on and off and activates the beeper e Informs the CPU when the optional maintenance and second language switches have been opened or closed see Chapter 5 for information on these options Display Data Decoder This decoder translates the serial data sent by the CPU in TTY format into a bitmapped image which is sent over a parallel data bus to the display Display Controller This circuit manages the interactions between the display data decoder and the display itself It generates a clock pulse that keeps the two devices synchronized It can also in response to commands from the CPU turn off and or reset the display Additionally for analyzers with the optional maintenance switch is installed See Ch
190. ation mark character within a text string Some commands allow you to access variables messages and other items such as iDAS data channels by name When using these commands you must type the entire name of the item you cannot abbreviate any names 6 12 2 5 Status Reporting Reporting of status messages as an audit trail is one of the three principal uses for the RS 232 interface the other two being the command line interface for controlling the instrument and the download of data in electronic format You can effectively disable the reporting feature by setting the interface to quiet mode see Section 6 10 8 Table 6 18 Status reports include iDAS data when reporting is enabled warning messages calibration and diagnostic status messages Refer to Appendix A 3 for a list of the possible messages and this section for information on controlling the instrument through the RS 232 interface General Message Format All messages from the instrument including those in response to a command line request are in the format X DDD HH MM Id MESSAGE lt CRLF gt Where X is a command type designator a single character indicating the message type as shown in the Table 6 25 DDD HH MM is the time stamp the date and time when the message was issued It consists of the Day of year DDD as a number from 1 to 366 the hour of the day HH as a number from 00 to 23 and the minute MM as a number from 00 to 59 ID is the ana
191. being left out of the assembly 6 Carefully replace the analyzer cover 7 If tubing was changed carry out a leak check see Section 11 5 1 USER NOTES 04515 Rev B 169 Model 6400E Instruction Manual Theory Of Operation 10 THEORY OF OPERATION The 6400E UV Fluorescence SO Analyzer is a microprocessor controlled analyzer that determines the concentration of sulfur dioxide SO in a sample gas drawn through the instrument It requires that sample and calibration gases be supplied at ambient atmospheric pressure in order to establish a constant gas flow through the sample chamber where the sample gas is exposed to ultraviolet light causing the SO become excited SO2 As these SO molecules decay into S0 they fluoresce The instrument measures the amount of fluorescence to determine the amount of SO present in the sample gas Calibration of the instrument is performed in software and usually does not require physical adjustments to the instrument During calibration the microprocessor measures the sensor output signal when gases with known amounts of SO at various concentrations are supplied and stores these measurements in memory The microprocessor uses these calibration values along with other performance parameters such as the PMT dark offset UV lamp ratio and the amount of stray light present and measurements of the temperature and pressure of the sample gas to compute the final SO concentration This concentrat
192. being piped into the chamber by the tubing walls optical filters discussed in section 10 2 5 remove UV with wavelengths extraneous to the excitation and decay of SO2 SO2 Most importantly during instrument calibration the difference between the value of the most recently recorded PMT offset see Section 10 2 4 and the PMT output while measuring zero gas calibration gas devoid of 50 is recorded as the test function OFFSET This OFFSET value is used during the calculation of the SO concentration Since this offset is assumed to be due to stray light present in the sample chamber is also multiplied by the SLOPE and recorded as the function STR LGT Both OFFSET amp STR LGT are viewable via the front panel see Section 6 2 1 04515 Rev B 179 Theory Of Operation Model 6400E Instruction Manual 10 3 PNEUMATIC OPERATION Caution It is important that the sample airflow system is leak tight and not pressurized over ambient pressure Regular leak checks should be performed on the analyzer as described in the maintenance schedule Table 9 1 Procedures for correctly performing leak checks can be found in Section 11 5 1 Relative Pressure versus Absolute Pressure In this manual vacuum readings are given in inches of mercury absolute pressure in Hg A i e indicate an absolute pressure referenced against zero a perfect vacuum 10 3 1 SAMPLE GAS FLOW The Flow of gas through the 6400E UV Fluor
193. brate the analyzer see Chapter 7 04515 Rev B 241 TROUBLESHOOTING amp REPAIR Model 6400E Instruction Manual 11 6 3 4 Replacing the UV filter lens NOTE Be careful not to leave thumbprints on the interior of the sample chamber The various oils that make up fingerprints fluoresce brightly under UV light and will significantly affect the accuracy of the analyzer s SO measurement 1 Turn off the instrument s power and remove the power cord from the instrument 2 Unplug J4 connector from the motherboard to allow tool access e Alternatively remove the sensor module as described in Section 11 6 3 1 3 Remove 4 screws from the shutter cover see figure 11 13 and remove the cover 4 Remove 4 screws from the UV filter retainer Reaction UV Filter Retainer amp Lens Housing Fliter Retainer Screws Shutter Housing ue Shutter Cover _ Screws Figure 11 13 Disassembling the Shutter Assembly 5 Carefully remove the UV filter 6 Install the UV filter e Handle carefully and never touch the filter s surface UV filter s wider ring side should be facing out 7 Install UV filter retainer and tighten screws 8 Install the shutter cover and minifit connector Tighten 4 shutter cover screws 9 Reinstall the sensor module and Plug J4 connector into the motherboard 242 04515 Rev B Model 6400E Instruction Manual TROUBLESHOOTING amp REPAIR 11 6 3 5 Adjusting the UV Lamp Peaking t
194. bration modes SAMPLE RANGE 500 0 PPB S02 XXX X lt TST TST gt CAL CALZ CALS SETUP SAMPLE ENTER SETUP PASS 0 Prompts password number ENTR EXIT ENTER SETUP PASS 0 Press individual 1 ENTR EXIT keys to set 101 4 M P CAL RANGE 500 d PPB 502 XXX X lt TSI TST ZERO CONC EXIT Continue calibration process 6400E Rev 49 Operating Instructions Model 6400E Instruction Manual 6 4 SETUP MODE The SETUP mode contains a variety of choices that are used to configure the analyzer s hardware and software features perform diagnostic procedures gather information on the instruments performance and configure or access data from the internal data acquisition system iDAS For a visual representation of the software menu trees refer to Appendix A 1 The areas access under the Setup mode are Table 6 4 Primary Setup Mode Features and Functions KEYPAD MANUAL MODE OR FEATURE LABEL DESCRIPTION SECTION Lists key hardware and software configuration Analyzer Configuration CFG information 6 5 Used to set up an operate the AutoCal feature Auto Cal Feature ACAL Only appears if the analyzer has one of the internal 7 8 valve options installed Internal Data Acquisition iDAS DAS Used to set up the iDAS system and view recorded data 6 11 Analog Output Reporting Used to configure the output signals generated by the RNGE 6 7 Range Confi
195. cal Instruments should be properly packed for handling and returned freight prepaid to the nearest designated Service Center After the repair the equipment will be returned freight prepaid User Notes 8 6400E Rev B Model 6400E Instruction Manual Getting Started 3 GETTING STARTED 3 1 UNPACKING AND INITIAL SETUP CAUTION To avoid personal injury always use two persons to lift and carry the Model 6400E 1 Inspect the received packages for external shipping damage If damaged please advise the shipper first then TAI 2 Included with your analyzer is a printed record Form number 04551 of the final performance characterization performed on your instrument at the factory This record is an important quality assurance and calibration record for this instrument It should be placed in the quality records file for this instrument 3 Carefully remove the top cover of the analyzer and check for internal shipping damage Remove the set screw located in the top center of the rear panel e Remove the screws fastening the top cover to the unit four per side Lift the cover straight up NOTE Printed circuit assemblies PCAs are sensitive to electro static discharges too small to be felt by the human nervous system Failure to use ESD protection when working with electronic assemblies will void the instrument warranty See Chapter 12 for more information on preventing ESD damage CAUTI
196. calibration is performed at a tube temperature of 50 C 5 4 4 ZERO AIR SCRUBBER MAINTENANCE KIT OPTION 43 This kit includes the following items needed to refurbish the zero air scrubber included with the IZS valve options TAI PART NO DESCRIPTION 00596000E0 Activated charcoal 0000001 Sintered filter for span gas inlet fitting FLO000003 Replacement particulate filter OR0000001 O Ring aty 2 38 6400E Rev B Model 6400E Instruction Manual Optional Hardware and Software 5 5 COMMUNICATION OPTIONS 5 5 1 RS232 MODEM CABLE OPTION 60 This option consists of a cable to connect the analyzer s COM1 port to a computer code activated switch or any other communications device that is equipped with a DB 9 male connector The cable is terminated with two DB 9 female connectors one of which fits the analyzer s COM1 port Some older computers or code activated switches with a DB 25 serial connector will need a different cable or an appropriate adapter 5 5 2 RS 232 MULTIDROP OPTION 62 The multidrop option is used with any of the RS 232 serial ports to enable communications of up to eight analyzers with the host computer over a chain of RS 232 cables via the instruments COM1 Port It is subject to the distance limitations of the RS 232 standard The option consists of a small printed circuit assembly which is plugs into to the analyzer s CPU card see Figure 5 4 and is connected to the RS
197. cancantratiom Setup for Manual Calibration without Z S valve or IZS Option Source of SAMPLE Gas Removed during Calibration Sample Exhaust MODEL 6400E Zero Alr STEP TWO Set the expected SO span gas concentrations In this example the instrument is set for single SNGL range mode with a reporting range span of 500 ppb The SO span concentration values automatically default to 450 0 Conc To change this value to the actual concentration of the span gas enter the number by pressing the key under each digit until the expected value appears The span gas concentration should always be 90 of the selected reporling range EXAMPLE Reporting range 800 ppb Span gas conc 720 ppb SAMPLE RANGE 500 000 PPB 502 XXX X TST IST CAL SETUP This sequence causes the analyzer to prompt for the expected SO span concentration CAL RANGE 500 90 PPS 502 XXX X TST TST gt ZERO CONC EXIT EXIT ignores the new selling SO2SPAN CONC 450 0 Conc and retums to the previous 0 0 4 o ENTR EXIT display ENTR accepts the new setting and returns to the previous display 6400E Rev B 139 Calibration Procedures Model 6400E Instruction Manual STEP THREE Perform the zero span calibration SAMPLE RANGE 500 0 PPE SOZ2zXXXX Set the Display to show the 502 STB test function lt TST TST gt CAL SETUP This
198. cation of UV Reference Detector Potentiometer 5 Finger tighten the thumbscrew NOTE DO NOT over tighten the thumbscrew 244 04515 Rev B Model 6400E Instruction Manual TROUBLESHOOTING amp REPAIR 11 6 3 6 Replacing the UV Lamp 1 2 Turn off the analyzer Disconnect the UV lamp from its power supply e You can find the power supply connector by following the two white UV Lamp power supply wires from the lamp to the power supply Loosen but do not remove the two UV lamp bracket screws and the large brass thumbscrew located on the shutter housing see Figure 11 14 so that the lamp can be moved NOTE DO NOT grasp the UV lamp by its cap when changing its position see Figure 11 14 Always grasp the main body of the lamp B on nu Remove the UV Lamp by pulling it straight up Insert the new UV lamp into the bracket Tighten the two UV lamp bracket screws but leave the brass thumb screw un tightened Connect the new UV lamp to the power supply Turn the instrument on and perform the UV adjustment procedure as defined in section 11 6 3 5 9 Finger tighten the thumbscrew NOTE DO NOT over tighten the thumbscrew 10 Perform a lamp calibration procedure see Section 6 9 7 and a zero point and span point calibration see Chapter 7 04515 Rev B 245 TROUBLESHOOTING amp REPAIR Model 6400E Instruction Manual 11 6 3 7 Replacing the PMT HVPS or TEC The PM
199. common communications channel to a host computer The remote instruments are regarded as slaves of the host computer The remote instruments are unaware that they are connected to a multidrop bus and never initiate Hessen protocol messages They only respond to commands from the host computer and only when they receive a command containing their own unique ID number The Hessen protocol is designed to accomplish two things to obtain the status of remote instruments including the concentrations of all the gases measured and to place remote instruments into zero or span calibration or measure mode Teledyne Analytical Instruments implementation supports both of these principal features The Hessen protocol is not well defined therefore while TAI s application is completely compatible with the protocol itself it may be different from implementations by other companies The following subsections describe the basics for setting up your instrument to operate over a Hessen Protocol network For more detailed information as well as a list of host computer commands and examples of command and response message syntax download the Manual Addendum for Hessen Protocol from the Teledyne Instruments web site http www teledyne api com manuals index asp 6 12 4 2 Hessen COMM Port Configuration Hessen protocol requires the communication parameters of the 6400E s COMM ports to be set differently than the standard configuration as shown in the table below
200. configure the analyzer s Ethernet properties See your network administrator To view the above properties press DHCP ON SAMPLE RANGE 500 000 PPB 502 XXX X SETUP X X SETUP SET EDIT ENTER SETUP PASS 818 SETUP XX INST IP 0 0 0 0 SAMPLE 8 1 8 ENTR EXIT GATEWAY IP 0 0 0 0 SETUP X X SETUPXX PRIMARY SETUP MENU EDIT Key Disabled CFG DAS RNGE PASS CLIK MORE EXIT SET SET EXIT F SETUP SUBNET MASK 0 0 0 0 SETUP SECONDARY SETUP MENU lt SET SET gt EXIT SETUP X X EXIT SET SET EDIT EXIT From this point on EXIT retums to COMMUNICATIONS MENU SETUP XX HOSTNAME M100E SET EDIT EXIT Don not alter unless directed to by Teladyne Instruments Customer Service personnel 92 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 10 6 3 Manually Configuring the Network IP Addresses There are several circumstances when you may need to manually configure the interface settings of the analyzer s Ethernet card The INET sub menu may also be used to edit the Ethernet card s configuration properties Your LAN is not running a DHCP software package The DHCP software is unable to initialize the analyzer s interface You wish to program the interface with a specific set of IP addresses
201. confirmed that power has not been interrupted Failed 5 VDC power Fatal error caused software to restart Loose connector wiring The computer has rebooted SYSTEM RESET UV LAMP The UV lamp intensity UV lamp is bad WARNING is 600mV or 4995 Reference detector is bad or out of adjustment mV Mother board analog sensor input circuitry has failed Fogged or damaged lenses filters In UV light path A D converter circuitry failure Light leak in reaction cell Shutter solenoid stuck closed 1 Normally 29 92 In Hg at sea level decreasing at 1 in Hg per 1000 ft of altitude with no flow pump disconnected 11 1 2 FAULT DIAGNOSIS WITH TEST FUNCTIONS Besides being useful as predictive diagnostic tools the TEST functions viewable from the front panel can be used to isolate and identify many operational problems when combined with a thorough understanding of the analyzer s theory of operation see Chapter 10 We recommend use of the APICOM remote control program to download graph and archive TEST data for analysis and long term monitoring of diagnostic data The acceptable ranges for these test functions are listed in Table A 3 in Appendix A 3 The actual values for these test functions on checkout at the factory were also listed in the Final Test and Validation Data Sheet which was shipped with the instrument Values outside the acceptable ranges indicate a failure of one or more of the analyzer s subsystems
202. cord the data from the Mode 6400E RS 232 port or analog outputs If analog readings are being used the response of that system should be checked against a NIST referenced voltage source or meter Data recording device should be capable of bi polar operation so that negative readings can be recorded 8 1 3 RECOMMENDED STANDARDS FOR ESTABLISHING TRACEABILITY To assure data of desired quality two considerations are essential 1 the measurement process must be in statistical control at the time of the measurement and 2 the systematic errors when combined with the random variation in the measurement process must result in a suitably small uncertainty Evidence of good quality data includes documentation of the quality control checks and the independent audits of the measurement process by recording data on specific forms or on a quality control chart and by using materials instruments and measurement procedures that can be traced to appropriate standards of reference To establish traceability data must be obtained routinely by repeat measurements of standard reference samples primary secondary and or working standards More specifically working calibration standards must be traceable to standards of higher accuracy such as those listed in Table 7 1 Cylinders of working gas traceable to NIST SRM s called EPA Protocol Calibration Gas are also commercially available from sources such as Scott Specialty Gases etc 8 1 4 EPA CALIB
203. ctive Safety Glasses when working with the UV Lamp Assembly 04515 Rev B 243 TROUBLESHOOTING amp REPAIR Model 6400E Instruction Manual 1 Set the analyzer display to show the signal I O function UVLAMP SIGNAL see Section 11 1 3 UVLAMP_SIGNAL is function 33 2 Slightly loosen the large brass thumbscrew located on the shutter housing see Figure 11 14 so that the lamp can be moved 3 While watching the UVLAMP SIGNAL reading slowly rotate the lamp or move it back and forth vertically until the UVLAMP SIGNAL reading is at its maximum NOTE DO NOT grasp the UV lamp by its cap when changing its position see Figure 11 14 Always grasp the main body of the lamp 4 Compare the UVLAMP SIGNAL reading to the information in Table 11 10 and follow the instructions there Table 11 10 Example of HVPS Power Supply Outputs UVLAMP SIGNAL ACTION TO BE TAKEN 3500mVX200mV No Action Required Adjust the UV reference detector potentiometer see Figure 11 15 gt 4900mvV at any time until UVLAMP SIGNAL reads approximately 3600mV before continuing to adjust the lamp position Adjust the UV reference detector potentiometer see Figure 11 15 until UVLAMP SIGNAL reads as close to 3500mV as possible 600mV Replace the lamp 3700mV or lt 3300mV uv Detector Adjustment boc Reference Detector PCA Pot Figure 11 15 Lo
204. ctor reading too low or too high NOTE See TABLE 11 1 for a more detailed lists of possible causes of the above warning messages To view and clear warning messages TEST deactivates waming messages NOTE If the waming message persists after several attempts to clear it ihe message may indicate a reg problem and not an artifact of the warm up period SAMPLE HVPS WARNING 502 000 EST CAL MSG CLR SETUP SAMPLE RANGE 500 000PPB 502 000 MSG eclivales warning messages TST TST gt CAL MSG CLR SETUP IST TST Keys replacat uh TEST key SAMPLE SYSTEM RESET 502 000 Prose CUR iD dear ine CURT A message TEST CAL MSG CLR If more than one waming is active the next message will take its place Once the lasi warning has been cleared the analyzer retums to SAMPLE mode MS Make sure warning messages are due to real problems 6400E Rev B 23 Getting Started Model 6400E Instruction Manual 3 2 4 FUNCTIONAL CHECK 1 After the analyzer s components have warmed up for at least 60 minutes verify that the software properly supports any hardware options that were installed Check to make sure that the analyzer is functioning within allowable operating parameters Appendix C includes a list of test functions viewable from the analyzer s front panel as well as their expected values These functions are also useful tools for dia
205. cy 42323 11 5 4 AC Power Configuration 4224 11 5 5 DC Power Supply 11 5 6 1 Bus 11 5 7 Keyboard aud Interface 11 5 8 Relay Board 11 5 9 Motherboard 11 5 9 1 A D functions 11 5 9 2 Analog Output Voltages 11 5 9 3 Status Outputs 11 5 9 4 Control Inputs 11 5 10 CPU esses 11 5 11 RS 232 Communication 11 5 11 1 General RS 232 Troubleshooting 11 5 11 2 Modem or Terminal dua iu MUTO 11 5 12 Shutter System 11 5 13 Sensor 11 5 14 PMT Preamplifier Board 6400E Rev B vii Model 6400E Instruction Manual 11 5 15 PMT Temperature Control PCA 11 5 15 1 TEC Control Test Points 11 5 16 High Voltage Power Supply 11 5 17 Pneumatic Sensor Assembly 11 5 17 1 Sample Pressure 11 5 18 IZS Option 11 5 19 Box Temperature 11 5 20 PMT Temperature 11 6 Repair Procedures 11 6 1 Disk on Chip Replacement 11 6 2 Flash Chip Replacement or Upgrade 11 6 3 Sensor Module Repair amp Cleaning 11 6 3 1 Removing and Reinstalling the Sensor Module 11 6 3 2 Cleaning the Sample 238 11 6 3 3 Cleaning the PMT Lens amp PMT filter 11 6 3 4 Replacing the UV filter lens 11 6 3 5 Adjusting the UV Lamp Peaking the Lamp 11 6 3 6 Replacing the UV 11 6 3 7 Replacing the PMT HVPS or TEC 11 6 3 8 PMT Hardware Calibration FACTORY CAL 11 7 Technica
206. cy and proper operation of the analog outputs The test forces all four analog output channels to produce signals ranging from 0 to 100 of the full scale range in 20 increments This test is useful to verify the operation of the data logging recording devices attached to the analyzer To begin the Analog Output Step Test press SECONDARY SETUP MENU SETUP COMM VARS DIAG SAMPLE RANGE 500 000 PPB S02 XXX X DIAG SIGNAL 1 0 TST VST CAL SETUP NEXT ENTR EXIT SAMPLE ENTER SETUP PASS 818 DIAG ANALOG OUTPUT 8 1 8 ENTR EXIT PREV NEXT ENTR EXIT SETUP XX PRIMARY SETUP MENU DIAG AOUT ANALOG OUTPUT CFG DAS RNGE PASS CLK MORE EXIT DIAG AOUT ANALOG OUTPUT Pressing the key under 0 while performing the test will pause the test at that level Brackets will appear around the value example 20 Pressing the same key again will resume the test Performs analog output step test 0 100 Exit Exit retums to the DIAG menu 6400E Rev B 67 Operating Instructions Model 6400E Instruction Manual 6 9 4 ANALOG I O CONFIGURATION Table 6 8 lists the analog I O functions that are available in the 6400E Table 6 8 DIAG Analog I O Functions SUB MENU FUNCTION AOUTS Shows the status of the analog output calibration YES NO and initiates a CALIBRATED calibration of all analog output channels CONC_OUT
207. d check for traceability See Section 2 9 2 Q A Handbook Obtain air from another source or regenerate Revise forms as appropriate Locate problem and Correct or return to supplier System must be checked out against known standards Activity Matrix for Calibration Procedure EQUIPMENT amp SUPPLIES ACCEPTANCE LIMITS FREQUENCY AND ACTION IF METHOD OF REQUIREMENTS ARE MEASUREMENT NOT MET Calibration gases NIST traceable Assayed against an NIST SRM semi annually Sec 2 0 7 Q A Handbook nem Working gas standard is unstable and or measurement method is out of control take corrective action such as obtaining new calibration gas Dilution gas Zero air free of contaminants See Section 2 9 2 Q A Manual Return to supplier or take appropriate action with generation system Use calibration procedure in Subsec Multi point calibration 2 2 Q A Handbook also Federal Register Perform at least once every quarter or anytime a level span check indicates a discrepancy or after maintenance which may affect the calibration Subsec 2 5 Manual Repeat the calibration 154 6400E Rev B Model 6400E Instruction Manual EPA Protocol Calibration 8 1 2 DATA RECORDING DEVICE Either a strip chart recorder data acquisition system digital data acquisition system should be used to re
208. d for each analyzer To set up the network for each analyzer 4 Turn the analyzer on and change its ID code see Section 6 10 1 to a unique 4 digit number 5 Remove the top cover see Section 3 1 of the analyzer and locate JP2 on the multidrop PCA see Figure 6 12 6 Make sure that the jumpers are in place connection pins 9 lt gt 10 and 11 lt gt 12 96 6400E Rev B Model 6400E Instruction Manual Operating Instructions 7 If the analyzer is to be the last instrument on the chain make sure a jumper is in place connecting pins 21 22 8 If you are adding an analyzer to the end of an already existing chain don t forget to remove JP2 pins 21 22 on the multidrop PCA on the analyzer that was previous the last instrument in the chain 9 Close the instrument 10 Using straight through DB9 male gt DB9 Female cables interconnect the host and the analyzers as shown in Figure 6 13 NOTE Teledyne Analytical Instruments recommends setting up the first link between the Host and the first analyzer and testing it before setting up the rest of the chain Host KEY Female DB9 RS 232 port ug Male DB9 Last Analyzer COM2 Analyzer com2 Analyzer com2 Analyzer com2 Make Sure Jumper between JP2 pins 21 lt gt 22 is installed Figure 6 13 RS232 Multidrop PCA Host Analyzer Interconnect Diagram 6400E Rev B 97 Operating Instructions Model 6400E
209. d is used to remove effects of lamp temperature of the sample gas is measured and controlled via heaters attached to the sample chamber so that the rate of decay K is constant e A special hydrocarbon scrubber removes the most common interfering gases from the sample gas And finally the design of the sample chamber reduces the effects of stray light via its optical geometry and spectral filtering The net result is that any variation in UV fluorescence can be directly attributed to changes in the concentration of SO in the sample gas 04515 Rev B 173 Theory Of Operation Model 6400E Instruction Manual 10 2 THE UV LIGHT PATH The optical design of the Model 6400E s sample chamber optimizes the fluorescent reaction between SO and UV Light see Figure 10 2 and assure that only UV light resulting from the decay of SO into SO is sensed by the instruments fluorescence detector UV radiation is generated by a lamp specifically designed to produce a maximum amount of light of the wavelength needed to excite SO into SO2 330 nm and a special reference detector circuit constantly measures lamp intensity see Equation 10 2 A Photo Multiplier Tube PMT detects the UV given off by the SO decay 214 nm and outputs an analog signal Several focusing lenses and optical filters make sure that both detectors are exposed to an optimum amount of only the right wavelengths of UV To further assure that the
210. del 6400E Software Menu Trees Model 6400E Setup Variables Available Via Serial I O Model 6400E Warnings and Test Measurements Via Serial 1 0 Model 6400E Signal I O Definitions Model 6400E iDAS Functions Model 6400E Terminal Command Designators 04515 Rev B 259 APPENDIX A 1 6400E Software Menu Trees Revision C 3 Model 6400E Instruction Manual APPENDIX 1 6400E Software Menu Trees Revision SAMPLE TEST CAL mMsG CLR SETUP Only appear if ENTER SETUP PASS 818 reporting range lt TST TST gt Is set for LOW HIGH AUTO range Primary Setup Menu mode CFG DAS RANG PASS CLK MORE ZERO SPAN CONC RANGE STABIL PRES SAMP FL PMT NORM PMT UV LAMP LAMP RATIO STR LGT DARK PMT DARK LMP SLOPE OFFSET HVPS RCELL TEMP I Secondary Setup Menu COMM VARS DIAG Only appears when warning messages are activated see Section 6 2 2 Press this key to cycle through list of active warning messages TEST FUNCTIONS Viewable by user while BOX TEMP PMT TEMP IZS TEMP TEST TIME instrument is in SAMPLE Mode see Section 6 2 1 Figure A 1 Press this key to clear erase the warning message currently displayed Oniy appears if the IZS valve option is installed 5 Only appears if the TEST analog output channel s activated Basic Sample Display Menu 05036 Rev C 3 260 APPENDIX A 1 6400E Software Menu Trees Revision Model 6400E Instruction Manu
211. ding straps mats and containers Failure to use ESD protection when working with electronic assemblies will void the instrument warranty See Chapter 12 for more information on preventing ESD damage 11 6 1 DISK ON CHIP REPLACEMENT Replacing the Disk on Chip DOC will cause all of the instrument configuration parameters to be lost unless the replacement chip carries the exact same firmware version If the analyzer is equipped with at least one EEPROM flash chip the configuration settings are stored in a backup file on the EEPROM It is recommended to document all analyzer parameters that may have been changed such as calibration range auto cal analog output serial port and other settings before replacing the chip 1 Turn off power to the instrument fold down the rear panel by loosening the mounting screws 2 When looking at the electronic circuits from the back of the analyzer locate the Disk on Chip in the right most socket of the CPU board The chip should carry a label with firmware revision date and initials of the programmer 3 Remove the IC with a dedicated IC removal tool or by gently prying it up from the socket Do not bend the connector pins 4 Install the new Disk on Chip making sure the notch at the end of the chip matches the notch in the socket It may be necessary to straighten the pins somewhat to fit them into the socket Press the chip all the way in 5 Close the rear panel and turn on p
212. e analyzer s AUTOCAL feature LO CALR Unit is performing LOW SPAN midpoint calibration initiated remotely through the the CAL key SAMPLE Sampling normally flashing text indicates adaptive filter is on SAMPLE A Indicates that unit is in SAMPLE mode and AUTOCAL feature is activated SETUP SETUP mode is being used to configure the analyzer The gas measurement will continue during this process SPAN CAL A Unit is performing SPAN calibration initiated automatically by the analyzer s AUTOCAL feature Unit is performing SPAN calibration initiated manually by the user Unit is performing SPAN calibration initiated remotely through the COM ports or digital control inputs Unit is performing ZERO calibration procedure initiated automatically by the AUTOCAL feature ZERO CAL M Unit is performing ZERO calibration procedure initiated manually by the user Unit is performing ZERO calibration procedure initiated remotely through the COM ZERO CAL R ports or digital control inputs Only Appears on units with Z S valve or IZS options The revision of the analyzer firmware is displayed following the word SETUP e g SETUP C 4 COM ports or digital control inputs M P CAL This is the basic calibration mode of the instrument and is activated by pressing SPAN CAL M SPAN CAL ZERO CAL A Finally the various CAL modes allow calibration of the analyzer Becaus
213. e Teledyne Instruments conforms to the standard pin assignments in the implementation of RS 232 Problems with RS 232 connections usually center around 4 general areas e Incorrect cabling and connectors This is the most common problem See Figure 6 8 for connector and pin out information and Section 6 10 3 e The communications baud rate and protocol parameters are incorrectly configured e See Section 6 10 9 on how to set the baud rate e The COM port communications mode is set incorrectly see Section 6 10 8 Ifa modem is used additional configuration and wiring rules must be observed See Section 6 12 2 6 e Incorrect setting of the DTE DCE Switch is set correctly See Section 6 10 5 11 5 11 2 Modem or Terminal Operation These are the general steps for troubleshooting problems with a modem connected to a Teledyne Instruments analyzer e Check cables for proper connection to the modem terminal or computer e Check the correct position of the DTE DCE as described in Section 6 10 5 e Check the correct setup command see Section 6 12 2 6 e Verify that the Ready to Send RTS signal is at logic high The 6400E sets pin 7 RTS to greater than 3 volts to enable modem transmission sure the baud rate word length and stop bit settings between modem and analyzer match see Section 6 12 2 6 and Section 6 10 e Use the RS 232 test function to send w characters to the modem terminal or computer See Section
214. e Handbook for Air Pollution Measurement Systems Volume II Ambient Air Specific Methods EPA 600 4 77 027a 1977 3 Catalog of NBS Standard Reference Materials NBS Special Publication 260 1975 76 Edition U S Department of Commerce NBS Washington D C June 1975 Tel 301 975 6776 for ordering the catalog 4 Quality Assurance Handbook for Air Pollution Measurement Systems Volume I Principles EPA 600 9 76 005 March 1976 User Notes 6400E Rev B 161 Model 6400E Instruction Manual Instrument Maintenance 9 INSTRUMENT MAINTENANCE Predictive diagnostic functions including data acquisition failure warnings and alarms built into the analyzer allow the user to determine when repairs are necessary without performing unnecessary preventative maintenance procedures There is however a minimal number of simple procedures that when performed regularly will ensure that the analyzer continues to operate accurately and reliably over its lifetime Maintenance repair and troubleshooting procedures are covered in Chapters 9 and 11 of this manual NOTE A span and zero calibration check must be performed following some of the maintenance procedures listed below Refer to Chapter 7 CAUTION Risk of electrical shock Disconnect power before performing any operations that require entry into the interior of the analyzer NOTE The operations outlined in this chapter must be performed by qualifi
215. e design of the Model 6400E is very tolerant of variations in sample gas flow rate and therefore does not suffer from this type of interference 10 2 7 4 Third Body Quenching While the decay of SO to SO happens quickly it is not instantaneous Because it is not instantaneous it is possible for the extra energy possessed by the excited electron of the SO molecule to be given off as kinetic energy during a collision with another molecule This in effect heats the other molecule slightly and allows the excited electron to move into a lower energy orbit without emitting a photon The most significant interferents in this regard are nitrogen oxide NO carbon dioxide CO2 water vapor H20 and molecular oxygen 02 In ambient applications the quenching effect of these gasses is negligible For stack applications where the concentrations of some or all of these may be very high specific steps MUST be taken to remove them from the sample gas before it enters the analyzer 10 2 7 5 Light Pollution Because 6400E measures light as a means of calculating the amount of SO present obviously stray light can be a significant interfering factor The Model 6400E removes this interference source in several ways The sample chamber is designed to be completely light tight to light from sources other than the excitation UV source lamp pneumatic tubing leading into the sample chamber is completely opaque in order to prevent light from
216. e inlet port Ideally the pressure of the sample gas should be equal to ambient atmospheric pressure NOTE Maximum pressure of any gas at the sample inlet should not exceed 1 5 in Hg above ambient pressure and ideally should equal ambient atmospheric pressure In applications where the sample gas is received from a pressurized manifold a vent must be provided to equalize the sample gas with ambient atmospheric pressure before it enters the analyzer The vented gas needs to be routed outside the immediate area or shelter surrounding the instrument 3 Attach zero air and span gas supply lines as appropriate see Figures 3 6 3 7 amp 3 8 For this type of analyzer zero air and span gas are defined in Section 3 1 2 1 NOTE US EPA requirements state that zero air and span gases be supplied at twice the instrument s specified gas flow rate Therefore for the 6400E zero and span gasses should be supply to their respective inlets in excess of 1300 cc min 650 cc min x 2 Supply and vent lines should be of sufficient length and diameter to prevent back diffusion and pressure effects 4 Once the appropriate pneumatic connections have been made check all pneumatic fittings for leaks using a procedure similar to that defined in Section 11 5 1 18 6400E Rev B Model 6400E Instruction Manual Getting Started 3 1 2 3 Connections with Internal Valve Options Installed If your analyzer is equiped with
217. e instrument set up sources of zero air and sample gas and procedures should conform to those described in Section 7 3 for analyzer s with no valve options or with an IZS valve option installed and Section 7 6 for analyzer s with Z S options installed with the following exception Connect the analyzer to a precision gas that has an SO concentration between 0 08 and 0 10 ppm If a precision check is made in conjunction with a zero span check it must be made prior to any zero or span adjustments Record this value Information from the check procedure is used to assess the precision of the monitoring data see 40 CFR 58 for procedures for calculating and reporting precision 6400E Rev B 159 EPA Protocol Calibration Model 6400E Instruction Manual 8 5 DYNAMIC MULTIPOINT SPAN CALIBRATION Dynamic calibration involves introducing gas samples of known concentrations to an instrument in order to record the instruments performance at a predetermined sensitivity and to derive a calibration relationship A minimum of three reference points and one zero point uniformly spaced covering 0 to 90 percent of the operating range are recommended to define this relationship The analyzer s recorded response is compared with the known concentration to derive the calibration relationship To perform a precision check the instrument set up sources of zero air and sample gas should conform to those described in Section 7 2 Follow the procedures d
218. e of its importance this mode is described separately in Chapter 7 6 2 SAMPLE MODE This is the analyzer s standard operating mode In this mode the instrument is analyzing SO and calculating concentrations 6 2 1 TEST FUNCTIONS A series of test functions is available at the front panel while the analyzer is in SAMPLE mode These parameters provide information about the present operating status of the instrument and are useful during troubleshooting see Section 11 1 2 They can also be recorded in one of the iDAS channels see Section 6 11 for data analysis To view the test functions press one of the TST TST gt keys repeatedly in either direction 44 6400E Rev B Model 6400E Instruction Manual Operating Instructions Table 6 2 Test Functions Defined DISPLAY PARAMETER UNITS DESCRIPTION RANGE RANGE PPB PPM The Full Scale limit at which the reporting range of the UGM amp analyzer s ANALOG OUTPUTS are currently set RANGEL MGM THIS IS NOT the Physical Range of the instrument See Section RANGE2 6 7 for more information If DUAL or AUTO Range modes have been selected two RANGE functions will appear one for each range STABIL STABILITY mV Standard deviation of SO Concentration readings Data points are recorded every ten seconds The calculation uses the last 25 data points PRES SAMPLE in Hg A The current pressur
219. e of the sample gas as it enters the sample PRESSURE 9 chamber measured between the SO and Auto Zero valves cm min The flow rate of the sample gas through the sample chamber SAMP FL SAMPLE FLOW This value is not measured but calculated from the sample cc m pressure PMT PMT Signal mV The raw output voltage of the NORM NORMALIZED mV The output voltage of the PMT after normalization for offset and PMT PMT Signal temperature pressure compensation if activated Source UV UV LAMP Lamp Intensity mV The output voltage of the UV reference detector The current output of the UV reference detector divided by the reading stored in the CPU s memory from the last time a UV P Lamp calibration was performed F The offset due to stray light recorded by the CPU during the last STR LGT Stray Light ppb zero point calibration performed The PMT output reading recorded the last time the UV source DRK PMT Dark PMT mv lamp shutter was closed ETE E i 1 DRK LMP Dark UV mV The UV reference detector output reading recorded the last time Source Lamp the UV source lamp shutter was closed SLOPE SO The sensitivity of the instrument as calculated during the last measurement calibration activity The slope parameter is used to set the span Slope calibration point of the analyzer OFFSET SO The overall offset of the instrument as calculated during the last measurement calibration activity The offset parameter is used to set the
220. e the software considers the data to be DAS HOLD OFF questionable That is the case during warm up or just after he instrument returns from one of its calibration modes to ISAMPLE mode DAS HOLD OFF can be disabled entirely in leach iDAS channel Enables or disables the temperature and pressure be between 0 5 and 20 minutes Default 15 min 1 TPC_ENABLE compensation TPC feature see Section 10 7 3 ON OFF Sets the sample chamber temperature Increasing or decreasing this temperature will increase or decrease the 309 C 709 C RCELL SET rate at which SO2 decays into SO see Section 10 1 1 Do not adjust this setting unless under the direction of TAI Default 509 C customer service personnel Sets the IZS option temperature Increasing or decreasing this temperature will increase or decrease the permeation rate of the IZS source see Section 5 4 2 309 C 709 C 3 IZS_SET Default 50 C Dynamic zero automatically adjusts offset and slope of the SO response when performing a zero point calibration during an AutoCal see Chapter 7 Dynamic span automatically adjusts slope and slope of the SO response when performing a zero point calibration during an AutoCal see Chapter 7 Note that the DYN ZERO and DYN SPAN features are not allowed for applications requiring EPA equivalency Allows the user to set the number of significant digits to the right of the dec
221. eam directly onto the reference detector This allows the reference detector to accurately measure the effective intensity of the excitation UV by Eliminating the effect of flickering inherent in the plasma arc that generates the light Making sure that all of the light emitted by the source lamp passed though the 214 nm filter and not absorbed by the SO reaches the reference detector Conversely this also makes sure that the volume of sample gas affected by the excitation beam is similar to the volume of fluorescing SO being measured by the PMT eliminating a possible source of measurement offset 10 2 7 MEASUREMENT INTERFERENCES It should be noted that the fluorescence method for detecting SO is subject to interference from a number of sources The 6400E has been successfully tested for its ability to reject interference from most of these sources 10 2 7 1 Direct Interference The most common source of interference is from other gases that fluoresce in a similar fashion to SO when exposed to UV Light The most significant of these is a class of hydrocarbons called poly nuclear aromatics PNA of which xylene and naphthalene are two prominent examples Nitrogen oxide fluoresces in the a spectral range near to SO For critical applications where high levels of NO are expected an optional optical filter is available that improves the rejection of NO contact customer service for more information The Model 6400E Analyzer has several
222. ecled SOz span The SO span concentration 2 concentration values automatically defauit 16 4500 Conc M PCAL 50000 502 XXX X To change this value to the actual concentration of the 18T TST gt ZERO CONC EXIT span gas enter the number by pressing the key under each digit until the expected value appears EXIT ignores the new setting The span gas concentration M P CAL 502 SPAN CONC 450 0 Conc and retums to the previous should always be 90 of the display selected reporting range 0 0 4 5 n ENTR EXIT ENTR accepts the new selling and returns to the previous display EXAMPLE Reporting range 7 800 ppb Span gas conc 720 ppb 142 6400E Rev B Model 6400E Instruction Manual Calibration Procedures Step Three Perform the calibration or calibration check according to the following flow chart Analyzer enters ZERO CAL mode Analyzer enters SPAN CAL Mode if either the ZERO or SPAN button fails to appear see Chapter 11 for troubleshooting tips SAMPLE RANGE 500 000 PPB S02 XXX X lt TST TST gt CAL C SETUP Scroll the display to the OUT XXX STABIL test function This SAMPLE STABIL X PPB SUE ERE A function calculates the stability of tha SO measurements TST TST gt CAL CALZ CALS SETUP ACTION Allow zero gas to enter the sample port at the rear of the instrument Wa
223. ected UV form the source lamp and other stray light PMT OPTICAL FILTER BANDWIDTH 108 eas a ae 104 8 995 9 bat 10 i25 1 SEE ee eee nee 10 LAMP OUTPUT Arbitrary Unis 10 ee eee ear JE LUORESCENT SPECTRUM 100 200 300 400 500 WAVELENGTH nm Figure 10 5 PMT Optical Filter Bandwidth 10 2 6 OPTICAL LENSES Two optical lenses are used to focus and optimize the path of light through the sample chamber If source UV is unfocused PMT When source UV is focused PMT receives fluorescence from area and Reference Detector view outside Reference Detector view similar volume of 0 Reference Detector When source UV is focused Reference Detector most of the emitted light UV Source 214 If source UV is unfocused Lens Filt ilter Reference Detector only sees a small portion of emitted light 330 nm Filter PMT Lens Figure 10 6 Effects of Focusing Source UV in Sample Chamber 04515 Rev B 177 Theory Of Operation Model 6400E Instruction Manual A lens located between PMT and the sample chamber collects as much of the fluoresced UV created there as possible and focuses it on the most sensitive part of the PMT s photo cathode Another lens located between the excitation UV source lamp and the sample chamber collimates the light emitted by the lamp into a steady circular beam and focuses that b
224. ection Do not defeat the ground wire on power plug Turn off analyzer power before disconnecting or connecting electrical subassemblies Do not operate with cover off SAMPLE e txHAUST nre TX STATUS e ett Dow apcaceius Mea ie ox Py ad e ZERO AR an Croire ee rere Figure 3 1 Rear Panel Layout 6400E Rev B 10 Model 6400E Instruction Manual Getting Started 3 1 1 1 Connecting the Analog Outputs Attach a strip chart recorder and or data logger to the appropriate contacts of the analog output connecter on the rear panel of the analyzer ANALOG OUT Figure 3 2 Analog Output Connector The A1 and A2 channels output a signal that is proportional to the SO concentration of the sample gas The output labeled A3 is special It can be set by the user see Section 6 9 10 to output any one of the parameters accessible through the TST TST gt keys of the units sample display Pin outs for the Analog Output connector at the rear panel of the instrument are Table 3 1 Analog output Pin Outs ANALOG OUTPUT VOLTAGE OUTPUT CURRENT LOOP OPTION Ground I Out V Out T Out Ground I Out V Out I Out Ground T Out Not Available Not Available Not Available Not Available The default analog output voltage setting of the 6400E UV Fluorescence SO Analyzer is 0 5
225. ections 5 2 This option converts the DC voltage analog output to a current signal with 0 20 mA output current The outputs can be scaled to any set of limits within that 0 20 mA range However most current loop applications call for either 2 20 mA or 4 20 mA range All current loop outputs have a 5 over range Ranges with the lower limit set to more than 1 mA e g 2 20 or 4 20 mA also have a 596 under range To switch an analog output from voltage to current loop after installing the current output printed circuit assembly follow the instructions in Section 6 9 4 1 and select CURR from the list of options on the Output Range menu Adjusting the signal zero and span values of the current loop output is done by raising or lowering the voltage of the respective analog output This proportionally raises or lowers the current produced by the current loop option Similar to the voltage calibration the software allows this current adjustment to be made in 100 10 or 1 count increments Since the exact current increment per voltage count varies from output to output and from instrument to instrument you will need to measure the change in the current with a current meter placed in series with the output circuit see Figure 6 6 Soo Table 3 3 cr cc coonector on the Recording Analyzer Devien Figure 6 6 Setup for Calibrating Current Outputs NOTE Do not exceed 60 V between curre
226. ed maintenance personnel only NOTE The front panel of the analyzer is hinged at the bottom and may be opened to gain access to various components mounted on the panel itself or located near the front of the instrument such as the particulate filter Two fasteners located in the upper right and left corners of the panel lock it shut see Figure 3 10 6400E Rev B 163 Instrument Maintenance Model 6400E Instruction Manual 9 1 MAINTENANCE SCHEDULE Table 9 1 is the recommended maintenance schedule for the 6400E Please note that in certain environments with high levels of dust humidity or pollutant levels some maintenance procedures may need to be performed more often than shown Table 9 1 6400 Preventive Maintenance Schedule ITEM ACTION FREQUENCY CAL MANUAL DATE PERFORMED CHECK SECTION Change Particulate filter particle filter Weekly No 9 3 1 Verify test Review and 9 2 functions evaluate Weekly No Appendix C Evaluate Zero span check offset and Weekly slope Zero and p eri span Every 3 months calibration External zero air scrubber Prange Every 3 months No optional perform flow check Check Flow Every 6 Months No L Internal IZS Permeation Tube Replace Annually YES Perform Annually or after pneumatic leak Ve eee repairs Involving Yes 11 5 1 check 9 pneumatics
227. either the zero span valve option Option 50 or the internal zero span option Option 51 the pneumatic connections should be made as follows Zero Span Valves Option 50 Source of MODEL 700 SAMPLE Gas Gas Dilution Callbrator with Oy generator option VENT if input is pressurized Sample Exhaust MODEL sd 6400E Externa Zero Air Scrubber MODEL 701 Zero Air Zero Air Generator Calibrated Sq Filter At high concent Needle valve to contro flow Internal Zero Span Option IZS Option 51 Source of SAMPLE Gas Ambient Air Figure 3 8 Basic Pneumatic Connections for Units with Valve Options Caution Gas flow must be maintained at all times for units with IZS Options installed The IZS option includes a permeation tube which emits SO Insufficient gas flow can build up SO to levels that will damage the instrument Remove the permeation device when taking the analyzer out of operation 6400E Rev B 19 Getting Started Model 6400E Instruction Manual UV Source Lap Front itm Particulate Filter ON OFF Hydrocarbon Scrubber SWITCH Kicker Hidden from view PMT Housing Pump Assy PMT Preamp PCA Sensor Housing PMT Cooling System Relay Board PS2 12 VDC PSL 5 VDC 15VDC Reference Detector PC 104 Card 19 Power f D Receptacle Vacuum E i Rear Panel Manifold Analog Output Connectors Board 319 321
228. electronic devices such as the types used in the various electronic assemblies of your analyzer are very small require very little power and operate very quickly Unfortunately the same characteristics that allow them to do these things also makes them very susceptible to damage from the discharge of static electricity Controlling electrostatic discharge begins with understanding how electro static charges occur in the first place Static electricity is the result of something called triboelectric charging which happens whenever the atoms of the surface layers of two materials rub against each other As the atoms of the two surfaces move together and separate some electrons from one surface are retained by the other Materials Materials Makes Separate Contact iz Protons 3 Protons 3 Protons 3 Protons 3 ELECTRONS 3 ELECTRONS 3 ELECTRONS 2 n 2 4 CHARGE 0 Nev CHARGE 0 NET CHARGE eR NET CHARGES m Figure 12 1 Triboelectric Charging If one of the surfaces is a poor conductor or even a good conductor that is not grounded the resulting positive or negative charge can not bleed off and becomes trapped in piace or static The most common example of triboelectric charging happens when someone wearing leather or rubber soled shoes walks across a nylon carpet or linoleum tiled floor With each step electrons change places and the resulting electro static charge builds up quickly reaching signific
229. en 0 and 20 mA Information on calibrating or adjusting these outputs can be found in Section 6 9 4 5 d 323 ge Output Shunts installed u P Installed on J21 Analog Output A2 esse eet na Figure 5 1 Current Loop Option Installed on the Motherboard 6400E Rev B 33 Optional Hardware and Software Model 6400E Instruction Manual 5 2 1 CONVERTING CURRENT LOOP ANALOG OUTPUTS TO STANDARD VOLTAGE OUTPUTS NOTE Servicing or handling of circuit components requires electrostatic discharge protection i e ESD grounding straps mats and containers Failure to use ESD protection when working with electronic assemblies will void the instrument warranty See Chapter 12 for more information on preventing ESD damage To convert an output configured for current loop operation to the standard 0 to 5 VDC output operation 1 Turn off power to the analyzer 2 If a recording device was connected to the output being modified disconnect it 3 Remove the top cover Remove the set screw located in the top center of the rear panel Remove the screws fastening the top cover to the unit four per side e Lift the cover straight up 4 Disconnect the current loop option PCA from the appropriate connector on the motherboard see Figure 3 9 5 Place a shunt between the leftmost two pins of the connector see Figure 5 1 spare shunts P N CN0000132 were shipped with the instrument attac
230. eporting range between two user defined ranges low and high The unit will switch from low range to high range when either the SO concentration exceeds 98 of the low range span The unit will return from high range back to low range once both the SO concentration falls below 75 of the low range span In AUTO Range mode the instrument reports the same data in the same range on both the A1 and A2 outputs and automatically switches both outputs between ranges as described above Also the RANGE test function displayed on the front panel will be replaced by two separate functions RANGE1 The LOW range setting for all analog outputs RANGE2 The HIGH range setting for all analog outputs The high low range status is also reported through the external digital status bits see Section 6 12 1 1 To set individual ranges press the following keystroke sequence SAMPLE RANGE 500 000 PPB S02 XXX X TST TST CAL pee SETUPXX RANGE MODE AUTO SNGL IND AUTO ENTR EXIT SAMPLE ENTER SETUP PASS 818 ENTR RANGE CONTROL MENU EXIT x 2 retums to the main MODE SET UNIT SAMPLE display SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT SETUP X X LOW RANGE 500 0 Conc SETUP XX RANGE CONTROL MENU Toggle the numeral 0 5 0 0 ENTR EXIT keys to set the LOW and HIGH MODE SET UNIT EXIT range value i ENTR accepts the naw setting EXIT SETUP X X RANGE
231. es lt TST TST gt keys replaced with SAMPLE RANGE 500 000 PPM 502 X lt TST TST gt CAL MSG CLR SETUP SAMPLE HVPS WARNING SO2 XXX X Press CLR to clear the current message if more than one warning is active the next message will take its place Once the last warning has been cleared the analyzer retums to TEST CAL MSG CLR SETUP SAMPLE mode Figure 6 3 Make sure warning messages are not due to real problems Viewing and Clearing 6400E WARNING Messages 6400E Rev B 47 Operating Instructions Model 6400E Instruction Manual 6 3 CALIBRATION MODE 6 3 1 CALIBRATION FUNCTIONS Pressing the CAL key switches the 6400E into calibration mode In this mode the user can calibrate the instrument with the use of calibrated zero or span gases If the instrument includes either the zero span valve option or IZS option the display will also include CALZ and CALS keys Pressing either of these keys also puts the instrument into multipoint calibration mode The CALZ key is used to initiate a calibration of the zero point e The CALS key is used to calibrate the span point of the analyzer It is recommended that this span calibration is performed at 90 of full scale of the analyzer s currently selected reporting range Because of their critical importance and complexity calibration operations are described in detail in other sections of the manual Chapter 7 detail
232. es bottle to bottle variation may be the cause Check for leaks in the pneumatic systems as described in Section 11 5 1 Leaks can dilute the span gas and hence the concentration that the analyzer measures may fall short of the expected concentration defined in the CONC sub menu Ifthe physical low level calibration has drifted changed PMT response or was accidentally altered by the user a low level calibration may be necessary to get the analyzer back into its proper range of expected values One possible indicator of this scenario is a slope or offset value that is outside of its allowed range 0 7 1 3 for slope 20 to 150 for offsets See Section 11 6 3 8 on how to carry out a low level hardware calibration 11 3 5 INABILITY TO ZERO NO ZERO KEY In general the 6400E will not display certain keyboard choices whenever the actual value of a parameter is outside of the expected range for that parameter If the calibration menu does not show a ZERO key when carrying out a zero calibration the actual gas concentration must be significantly different from the actual zero point as per last calibration which can have several reasons e Confirm that there is a good source of zero air If the IZS option is installed compare the zero reading from the IZS zero air source to an external zero air source using SO free air Check any zero air scrubber for performance It may need to be replaced see Section 9 3 3 04515 Rev B
233. escence SO2 Analyzer is created by a small internal pump that pulls air though the instrument EXHAUST GAS INSTRUMENT CHASSIS 1 1 0 1 1 I I HYDROCARBON SCRUBBER KICKER SAMPLE SAMPLE GAS veria CHAMBER INLET cal E 4 37 A SAMPLE FILTER se EU a a oam a ae ee ee oam MP a CRITICAL ZERO AIR INLET EXHAUST TO OUTER 1 FLOW LAYER OF KICKER I ORIFICE SPAN GAS INLET 1 ROW SENSOR SAMPLE PRESSURE f 1 i SENSOR H I FLOW PRESSURE 1 SENSOR PCA b m ene me ee nn mee ee tee eee em ee eee ee ee ee 1 Figure 10 7 6400 Gas Flow and Location of Critical Flow Orifice 180 04515 Rev B Model 6400E Instruction Manual Theory Of Operation 10 3 2 FLOW RATE CONTROL The Model 6400E uses a special flow control assembly located in the exhaust vacuum manifold see Figure 10 7 to maintain a constant flow rate of the sample gas through the instrument This assembly consists of A critical flow orifice Two o rings Located just before and after the critical flow orifice the o rings seal the gap between the walls of assembly housing and the critical flow orifice spring Applies mechanical force needed to form the seal between the o rings the critical flow orifice and the assembly housing 10 3 2 1 Critical Flow Orifice The most important component of this flow co
234. escribed in section 7 2 for calibrating the zero points For each mid point SAMPLE RANGE 500 000 PPB 502 zXXX X Sel the Display to show the STABIL test function This function calculates the stability of the SO measurement TST TST gt CAL SETUP sy SAMPLE STABIL X XXX PPB 502 XXX X SETUP lt TST TST CAL ACTION Allow calibration gas diluted to proper concentration for Midpoint N to enter the sample port STABILZX XX SAMPLE TST TST gt CAL CALZ CALS SETUP Wait until STABIL falls below 0 5 ppb This may take several minules Record the 502 reading as displayed on the instrument s front panel SPAN CALM RANGE 500 0 PPB 50 TST TST ZERO SPAN ACTION Allow Calibration Gas diluted to proper concentration for Midpoint N 1 to enter the sample port 160 6400E Rev Model 6400E Instruction Manual EPA Protocol Calibration 8 6 SPECIAL CALIBRATION REQUIREMENTS FOR DUAL RANGE OR AUTO RANGE If Dual Range or Auto Range is selected then it should be calibrated for both Rangel and Range2 separately For zero and span point calibration follow the procedure described in Section 7 2 Repeat the procedure for both the HIGH and LOW Ranges 8 7 REFERENCES 1 Environmental Protection Agency Title 40 Code of Federal Regulations Part 50 Appendix A Section 10 3 2 Quality Assuranc
235. ess via an LAN by installing the Teledyne Instruments Ethernet interface card option 63 see Section 5 5 3 and 6 10 6 A code activated switch CAS can also be used on either port to connect typically between 2 and 16 send receive instruments host computer s printers dataloggers analyzers monitors calibrators etc into one communications hub Contact Teledyne Analytical Instruments sales for more information on CAS systems 6 10 1 ANALYZER ID Each type of Teledyne Analytical Instruments analyzer is configured with a default ID code The default ID code for all 6400E analyzers is 100 The ID number is only important if more than one analyzer is connected to the same communications channel such as when several analyzers are on the same Ethernet LAN see Section 6 10 6 in a RS 232 multidrop chain see Section 6 10 7 or operating over a RS 485 network see Section 6 10 4 If two analyzers of the same model type are used on one channel the ID codes of one or both of the instruments needs to be changed so that they are unique to the instruments To edit the instrument s ID code press SAMPLE RANGE 500 000 PP amp S02 XXX X lt TST TST CAL ESRB SAMPLE ENTER SETUP PASS B18 8 1 B ENTR EXIT SETUP X amp PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE XX COMMUNICATIONS MENU ID HESM CORI 2 s ENTR key accepts the MACHINE 1D 100 10 new settings EXIT key ignores the
236. essure Compensation Feature 10 7 4 Internal Data Acquisition System iDAS 11 TROUBLESHOOTING amp REPAIR 11 1 General Troubleshooting 11 1 1 Warning Messages 11 1 2 Fault Diagnosis with Test Functions 11 1 3 Using the Diagnostic Signal 1 0 Functions 11 1 4 Status LEDS eren rne nnne 11 1 4 1 Motherboard Status Indicator Watchdog 213 11 1 4 2 CPU Status Indicator 213 11 1 4 3 Relay Board Status LEDs esee 214 11 2 Gas Flow Problems E 11 2 1 Zero or Low Sample Flow 5 11 2 2 High 215 11 3 Calibration 216 11 3 1 Negative Concentrations 11 3 2 No 11 3 3 Unstable Zero and Span 4217 11 3 4 Inability to Span No SPAN Key vas 4217 11 3 5 Inability to Zero No ZERO Key 217 11 3 6 Non Linear Response 218 1 3 7 Discrepancy Between Analog Output and Display 218 1 4 Other Performance Problems 219 11 4 1 Excessive noise 11 4 2 Slow Response 11 4 3 The Analyzer Doesn t Appear on the Internet 1 5 Subsystem Checkout 2221 11 5 1 Detailed Pressure Leak Check 4221 11 5 2 Performing a Sample Flow Checl 222 11 5 3 Hydrocarbon Scrubber Kicker 222 11 5 3 1 Checking the Scrubber for Leaks 4222 11 5 3 2 Checking the Scrubber s Efficien
237. ev B 165 Instrument Maintenance Model 6400E Instruction Manual 9 3 MAINTENANCE PROCEDURES The following procedures need to be performed regularly as part of the standard maintenance of the Model 6400E 9 3 1 CHANGING THE SAMPLE PARTICULATE FILTER The particulate filter should be inspected often for signs of plugging or excess dirt It should be replaced according to the service interval in Table 9 1 even without obvious signs of dirt Filters with 1 and 5 pore size can clog up while retaining a clean look We recommend handling the filter and the wetted surfaces of the filter housing with gloves and tweezers Do not touch any part of the housing filter element PTFE retaining ring glass cover and the O ring with bare hands To change the filter according to the service interval in Table 9 1 1 Turn OFF the analyzer to prevent drawing debris into the sample line 2 Open the 6400E s hinged front panel and unscrew the knurled retaining ring of the filter assembly 01628 Retaining Ring 01629 Window 024310100 O Ring PTFE Notches UP PTFE Membrane Filter Element FL 19 ium FL6 5 OR 58 Viton O Ring 03588 Bracket 03522 Body FT 8 Connector Fitting FT 8 Connector Fitting Figure 9 1 Sample Particulate Filter Assembly 3 Carefully remove the retaining ring glass window PTFE O ring and filter element 4 Replace the filter element carefully centering it in the bottom of the holder 166 0
238. ew the PMT assembly It is held to the cold block by two plastic screws e Because the threads of the plastic screws are easily damaged it is highly recommended to use new screws when reassembling the unit 9 Carefully take out the assembly consisting of the HVPS the gasket and the PMT 10 Change the PMT or the HVPS or both clean the PMT glass tube with a clean anti static wipe and DO NOT TOUCH it after cleaning 11 1f the cold block or TEC is to be changed disconnect the TEC driver board from the preamplifier board e Remove the cooler fan duct 4 screws on its side including the driver board e Disconnect the driver board from the TEC and set the sub assembly aside Remove the end plate with the cooling fins 4 screws and slide out the PMT cold block assembly which contains the TEC e Unscrew the TEC from the cooling fins and the cold block and replace it with a new unit 12 Re assemble the TEC subassembly in reverse order CAUTION The thermo electric cooler needs to be mounted flat to the heat sink If there is any significant gap the TEC might burn out Make sure to apply heat sink paste before mounting it and tighten the screws evenly and cross wise Make sure to use thermal grease between TEC and cooling fins as well as between TEC and cold block Align the side opening in the cold block with the hole in the PMT housing where the sample Chamber attaches e Evenly tighten the long mounting screws fo
239. exmask Display test s T ID LIST ALL name hexmask NAMES HEX Print test s to screen name Print single test CLEAR ALL name hexmask Disable test s SET ALL name hexmask Display warning s W 10 LIST ALL name hexmask NAMES HEX Print warning s name Clear single warning CLEAR ALL name hexmask Clear warning s ZERO LOWSPAN SPAN 1 2 Enter calibration mode ASEQ number Execute automatic sequence C ID COMPUTE ZERO SPAN Compute new slope offset EXIT Exit calibration mode ex ABORT Abort calibration sequence LIST Print all 1 0 signals name value Examine or set I O signal LIST NAMES Print names of all diagnostic tests ENTER name Execute diagnostic test Exit diagnostic test RESET DATA CONFIG exitcode Reset instrument D ID PRINT name SCRIPT Print iDAS configuration RECORDS name Print number of iDAS records REPORT name RECORDS number FROM start date TO end date VERBOSE COMPACT HEX Print Print iDAS records DAS records date format MM DD YYYY or YY HH MM SS CANCEL Halt printing iDAS records LIST Print setup variables name value warn low warn high Modify variable v name value Modify enumerated variable CONFIG Print instrument configuration MAINT ON OFF Enter exit maintenance mode MODE Print current instrument mode iren data channel definitions Upload iDAS configuration CHANNELBEGIN propertylist CHANNELEND Upload single iDAS channel CHANNELDELETE name Delete iD
240. eyboard A row of eight keys just below the vacuum florescent display see Figure 10 21 is the main method by which the user interacts with the analyzer As the software is operated labels appear on the bottom row of the display directly above each active key defining the function of that key 200 04515 Rev B Model 6400E Instruction Manual Theory Of Operation as it is relevant for the operation being performed Pressing a key causes the associated instruction to be performed by the analyzer Note that the keys do not auto repeat In circumstances where the same key must be activated for two consecutive operations it must be released and re pressed 10 6 1 3 Display The main display of the analyzer is a vacuum florescent display with two lines of 40 text characters each Information is organized in the following manner see Figure 10 21 Mode Field Displays the name of the analyzer s current operating mode Message Field Displays a variety of informational messages such as warning messages operation data and response messages during interactive tasks Concentration Field Displays the actual concentration of the sample gas currently being measured by the analyzer Keypad Definition Field Displays the definitions for the row of keys just below the display These definitions dynamic context sensitive and software driven 10 6 1 4 Keyboard Display Interface Electronics I C to from CPU Key Press
241. f serial communications port TCP IP acronym for transfer control protocol internet protocol the standard communications protocol for Ethernet devices VARS acronym for variables the variables settings of the analyzer USER NOTES 6400E Rev B 31 Model 6400E Instruction Manual Optional Hardware and Software 5 OPTIONAL HARDWARE AND SOFTWARE This section includes a descriptions of the hardware and software options available for the Model 6400E UV Fluorescence SO Analyzer For assistance with ordering these options please contact the sales department of Teledyne Advanced Pollution Instruments at TEL 626 961 2358 TEL 626 934 1651 FAX 626 934 1531 WEBSITE http www teledyne ai com 5 1 RACK MOUNT KITS OPTIONS 20A 20B amp 21 There are several options for mounting the analyzer in standard 19 racks Option Number E Description OPT 20A Rack mount brackets with 26 in chassis slides OPT 20B Rack mount brackets with 24 in chassis slides L OPT 21 Rack mount brackets only 5 2 CURRENT LOOP ANALOG OUTPUTS OPTION 41 This option adds isolated voltage to current conversion circuitry to the analyzer s analog outputs This option may be ordered separately for any of the analog outputs it can be installed at the factory or added later Call Teledyne Analytical Instruments sales for pricing and availability The current loop option can be configured for any output range betwe
242. from the analyzer 04515 Rev B 223 TROUBLESHOOTING amp REPAIR Model 6400E Instruction Manual To check the ability of the scrubber to efficiently remove hydrocarbons from the sample air 1 Disconnect the sample gas supply line from the sample inlet at the back of the analyzer 2 With the instrument operating watch the SO concentration reading on the analyzers front panel display Wait until the reading stabilizes probably somewhere near 0 ppb 3 Place a mothball near the sample inlet 4 Watch the SO concentration reading for 30 40 seconds e If the scrubber is working properly the reading should remain stabile If the reading rises significantly more than 2 3 ppb the hydrocarbon scrubber must be replaced Contact Teledyne Instruments Customer Service 11 5 4 AC POWER CONFIGURATION The 6400E digital electronic systems will operate with any of the specified power regimes As long as instrument is connected to 100 120 VAC or 220 240 VAC at either 50 or 60 Hz it will turn on and after about 30 seconds show a front panel display Internally the status LEDs located on the Motherboard and CPU should turn on as soon as the power is supplied On the other hand the analyzer s various non digital components such as the pump the UV lamp and the AC powered heaters require that the relay board be properly configured for the type of power being supplied to the instrument CAUTION Plugging the an
243. function calculates the stability of the SOz measurement SAMPLE RANGE 500 0 PPB 502 XKK X lt TST TST gt CAL SETUP Y ACTION Allow zero gas to enter the sample port at the rear of the instrument r Wait until SO2 STB falls below 0 5 ppb This may take several minutes 502 5 PPB Q2 CAL TST TST gt SETUP M P CAL SO2 STB X XXX PPB x TST TST gt ZERO CONC EXIT Press ENTR to changes the OFFSET amp SLOPE values for the SO measurements Press EXIT to leave the calibration unchanged and retum to the previous menu CAL S02 STB X XXX PPB TST IST EWR CONG ACTION Allow span gas to enter the sample port at the rear of the instrument The value of 502 STB may Jump significantly Wait until it falls back below 0 5 ppb This may take several minutes M P CAL 502 STB X XXX PPB 502 The SPAN key now appears lt TST TST gt SPAN CONC EXIT during the transition from zero to span You may see both keys Press ENTR to change the MP CAL RANGE 5000 SO XXXX OFFSET amp SLOPE values for the 50 measurements lt STs Press EXIT to leave the calibration gt AN TST TST ENTR SPAN CONE N unchanged and return to the previous menu CAL RANGE 500 0 PPS EXIT retums to the main TST TST gt ENTR CONC EXIT 1 9
244. gh Voltage Supply KEY AC POWER DC POWER h Pressure Sensor Gas Flow Sensor R 5 P i 1 1 Sample Cal i UV Source UV Source UV Source IZS Option H Sample 1 forZ Sand Lamp Lamp Lamp 1 Permeation 4 Chamber 125 1 Shutter Power Shutter Tube 1 Heaters b oven ct Supply Heater 1 Figure 10 19 Power Distribution Block Diagram 198 04515 Rev B Model 6400E Instruction Manual Theory Of Operation 10 6 COMMUNICATIONS INTERFACE The analyzer has several ways to communicate the outside world see Figure 10 20 Users can input data and receive information directly through the front panel keypad and display Direct two way communication with the CPU is also available by way of the analyzer s RS232 amp RS485 1 0 ports see Section 6 10 and 6 12 Alternatively an Ethernet communication option can be substituted for one of the COMM ports The analyzer can also send status information and data via the eight digital status output lines see Section 6 12 1 1 and the three analog outputs see Section 6 7 located on the rear panel as well as receive commands by way of the six digital control inputs also located on the rear pane see Section 6 12 1 2 COMM A mele RS 232 ONLY COMM B RS 232 or RS 485 gt Female CPU 1 ETHERNET lt OPTION ar ud m ICBUS DISPLAY R
245. gnosing performance problems with your analyzer see Section 11 1 2 The enclosed Final Test and Validation Data sheet part number 04551 lists these values before the instrument left the factory To view the current values of these parameters press the following key sequence on the analyzer s front panel Remember until the unit has completed its warm up these parameters may not have stabilized SAMPLE RANGE 500 0 PPB S02 XXX X lt TST TST gt CAL SETUP RANGE STABIL PRES SAMP FL PMT NORM PMT UV LAMP LAMP RATIO STR LGT Refer to DARK PMT Section DARK LAMP 6 2 1 for SLOPE definitions OFFSET of these HVPS test RCELL TEMP functions BOX TEMP PMT TEMP IZS TEMP TEST TIME Toggle lt TST TST gt keys to scroll through list of functions 1 Only appears if IZS option is installed Only appears if analog output A3 is actively reporting a test function If your analyzer has an Ethernet card Option 63 installed and your network is running a dynamic host configuration protocol DHCP software package the Ethernet option will automatically configure its interface with your LAN However it is a good idea to check these settings to make sure that the DHCP has successfully downloaded the appropriate network settings from your network server See Section 6 10 6 2 If your network is not running DHCP you will have to configure the analyzer s interface manually See Section 6 10 6
246. guration instruments Analog outputs t Eb d PASS Turns the calibration password feature ON OFF 6 3 2 Internal Clock Configuration Used to Set or adjust the instrument s internal clock 6 6 See Table 6 5 This button accesses the instruments secondary setup Advanced SETUP features MORE men Table 6 5 Secondary Setup Mode Features and Functions KEYPAD MANUAL MODE OR FEATURE LABEL DESCRIPTION SECTION TT Used to set up and operate the analyzer s various Peral COMM external 1 0 channels including RS 232 RS 485 ore modem communication and or Ethernet access System Status Variables VARS Used to view various variables related to the 6 8 instruments current operational status Used to access a variety of functions that are used to configure test or diagnose problems with a variety of 6 9 the analyzer s basic systems System Diagnostic Features DIAG NOTE Any changes made to a variable during one of the following procedures is not acknowledged by the instrument until the ENTR Key is pressed If the EXIT key is pressed before the ENTR key the analyzer will beep alerting the user that the newly entered value has not been accepted 50 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 4 1 Setup MODE PASSWORD SECURITY Whenever the Model 6400E s SETUP mode is activated the instrument will prompt the user to enter a secu
247. hange rotoco type P We RET OFF ENTR EXIT 6400E Rev B 131 Operating Instructions Model 6400E Instruction Manual NOTE While Hessen Protocol Mode can be activated independently for COM1 and COM2 The TYPE selection affects both Ports 6 12 4 5 Setting The Hessen Protocol Response Mode The Teledyne Instruments implementation of Hessen Protocol allows the user to choose one of several different modes of response for the analyzer Table 6 28 6400E Hessen Protocol Response Modes MODE ID MODE DESCRIPTION CMD This is the Default Setting Reponses from the instrument are encoded as the traditional command format Style and format of responses depend on exact coding of the initiating command BCC Responses from the instrument are always delimited with lt STX gt at the beginning of the response lt ETX gt at the end of the response followed by a 2 digit Block Check Code checksum regardless of the command encoding TEXT Responses from the instrument are always delimited with lt CR gt at the beginning and the end of the string regardless of the command encoding To Select a Hessen response mode press SAMPLE RANGE 500 000 PPB S02 XXX X TST CAL SETUP SAMPLE ENTER SETUP PASS 818 8 1 8 ENTR EXIT SETUP X X COMMUNICATIONS MENU 10 HESN COM1 EXIT SETUP XX PRIMARY SETUP MENU CRG DAS RNG
248. haracter All Commands follow the syntax X ID COMMAND lt CR gt Where X is the command type one letter that defines the type of command Allowed designators are listed in Table 6 25 and Appendix A 6 ID is the analyzer identification number see Section 6 10 1 Example the Command 200 followed by a carriage return would print the list of available commands for the revision of software currently installed in the instrument assigned ID Number 200 COMMAND is the command designator This string is the name of the command being issued LIST ABORT NAME EXIT etc Some commands may have additional arguments that define how the command is to be executed Press CR or refer to Appendix A 6 for a list of available command designators CR is a carriage return All commands must be terminated by a carriage return usually achieved by pressing the ENTER key on a computer Table 6 25 Command Types COMMAND TYPE Calibration Diagnostic Logon Test measurement COMMAND Variable Warning Si lt jaic o 6 12 2 4 Data Types Data types consist of integers hexadecimal integers floating point numbers Boolean expressions and text strings Integer data are used to indicate integral quantities such as number of records a filter length etc They consist of an optional plus or minus sign followed by one or more digits For example 1 12 123 are all valid integers
249. hat keep the sample chamber at a steady temperature and when installed the zero span and internal zero span valve sets and heaters 04515 Rev B 185 Theory Of Operation Model 6400E Instruction Manual 10 4 1 CPU The CPU is a low power 5 VDC 0 8A max high performance 386 based microcomputer running the DR DOS operating system Its operation and assembly conform to the PC 104 specification version 2 3 for embedded PC and PC AT applications It has 2 MB of DRAM memory on board and operates at 40 MHz clock rate over an internal 32 bit data and address bus Chip to chip data handling is performed by two 4 channel direct memory access DMA devices over data busses of either 8 bit or 16 bit bandwidth The CPU supports both RS 232 and RS 485 serial protocols Figure 10 11 shows the CPU RS 485 COM1 amp COM2 Disk on chip RS 232 485 Configuration jumper ic 5 T1907 M61 Or 3 XBS12261000F Figure 10 11 6400E CPU Board The CPU includes two types of non volatile data storage one disk on chip and one or two flash chips 10 4 1 1 Disk On Chip While technically an EEPROM the disk on chip DOC appears to the CPU as behaves as and performs the same function in the system as an 8 mb disk drive It is used to store the computer s operating system the TAI firmware and most of the operational data generated by the analyzer s internal data acquisition system iDAS Sections 10 7 4 and 6 11 186 04515 Rev B M
250. he nominal flow should not occur in the 6400E unless a pressurized sample zero or span gas is supplied to the inlet ports Be sure to vent excess pressure and flow just before the analyzer inlet ports When supplying sample zero or span gas at ambient pressure a high flow would indicate that one or more of the critical flow orifices are physically broken very unlikely case allowing more than nominal flow or were replaced with an orifice of wrong specifications If the flows are more than 15 higher than normal we recommend that the technician find and correct the cause of the flow problem 04515 Rev B 215 TROUBLESHOOTING amp REPAIR Model 6400E Instruction Manual 11 3 CALIBRATION PROBLEMS 11 3 1 NEGATIVE CONCENTRATIONS Negative concentration values can be caused for several things A slight negative signal is normal when the analyzer is operating under zero gas and the signal is drifting around the zero calibration point This is caused by the analyzer s zero noise and may cause reported concentrations to be negative for a few seconds at a time down to 5 ppb but should alternate with similarly high positive values Mis calibration is the most likely explanation for negative concentration values If the zero air contained some SO gas contaminated zero air or a worn out zero air scrubber and the analyzer was calibrated to that concentration as zero the analyzer may report negative values when measuring air tha
251. he Lamp There are three ways in which ambient conditions can effect the UV Lamp output and therefore the accuracy of the SO concentration measurement These are Line Voltage Change UV lamp energy is directly proportional to the line voltage This can be avoided by installing adequate AC Line conditioning equipment such as a UPS surge suppressor Lamp Aging Over a period of months the UV energy will show a downward trend usually 30 in the first 90 days and then a slower rate until the end of useful life of the lamp Periodically running the UV lamp calibration routine see Section 6 9 7 will compensate for this until the lamp output becomes too low to function at all Lamp Positioning The UV output level of the lamp is not even across the entire length of the lamp Some portions of the lamp shine slightly more brightly than others At the factory the position of the UV lamp is adjusted to optimize the amount of UV light shining through the UV filter lens and into the reaction cell Changes to the physical alignment of the lamp can affect the analyzers ability to accurately measure SO Reaction DO NOT Shutter Housing use Lamp Cap to adjust Lamp position UV Lamp Power Supply Wires Adjust Lamp BOW Position by grasping lamp body ONLY UV Filter Retainer amp Lens Housing Shutter Assy UV Lamp Bracket Mounting Screws Figure 11 14 Shutter Assembly Exploded View CAUTION ALWAYS wear UV Prote
252. hed to JP1 on the back of the instruments keyboard and display PCA 6 Reattach the top case to the analyzer 7 The analyzer is now ready to have a voltage sensing recording device attached to that output 5 3 PARTICULATE FILTER KIT OPTION 42 This option includes a one year supply of 50 replacement particulate filters 47mm in diameter 1 micrometer pore size 34 6400E Rev B Model 6400E Instruction Manual Optional Hardware and Software 5 4 CALIBRATION VALVES OPTIONS 5 4 1 ZERO SPAN VALVES OPTION 50 The Model 6400E SO analyzer can be equipped with a zero span valve option for controlling the flow of calibration gases generated from external sources This option contains two sets of Teflon solenoid valves located inside the analyzer that allow the user to switch either zero span or sample gas to the instrument s sensor Figure 5 2 shows the internal pneumatic connections for a Model 6400E with the zero span valve option installed INSTRUMENT CHASSIS EXHAUST GAS OUTLET KICKER EXHAUST TO PUMP I HYDROCARBON I SAMPLE SAMPLE GAS e CHAMBER INLET i PRESSURE i SENSOR FLOW PRESSURE SENSOR i SAMPLE i Figure 5 2 Pneumatic Diagram of the 6400E With Z S Option Installed Table 5 1 describes the state of each valve during the analyzer s various operational modes Table 5 1 2 Valve Operating State
253. herboard 100K terminating resistors on each of the inputs prevent cross talk from appearing on the sensor signals PMT DETECTOR OUTPUT This signal output by the PMT preamp PCA is used in the computation of the SO SO and SO concentrations displayed at the top right hand corner of the front panel display and output through the instruments analog outputs and COMM ports PMT HIGH VOLTAGE POWER SUPPLY LEVEL This input is based on the drive voltage output by the PMT pram board to the PMT s high voltage power supply HVPS It is digitized and sent to the CPU where it is used to calculate the voltage setting of the HVPS and stored in the instruments memory as the test function HVPS HVPS is viewable as a test function see Section 6 2 1 through the analyzer s front panel PMT TEMPERATURE This signal is the output of the thermistor attached to the PMT cold block amplified by the PMT temperature feedback circuit on the PMT preamp board It is digitized and sent to the CPU where it is used to calculate the current temperature of the PMT 04515 Rev B 195 Theory Of Operation Model 6400E Instruction Manual This measurement is stored in the analyzer Memory as the test function PMT TEMP and is viewable as a test function see Section 6 2 1 through the analyzer s front panel SAMPLE GAS PRESSURE SENSOR This sensor measures the gas pressure at the exit of the sample chamber SAMPLE FLOW SENSOR This sensor measure the flow rate of the sam
254. his permits the voltage outputs to be calibrated by the CPU without need for any additional tools or fixtures see Section 6 9 4 2 10 4 11 EXTERNAL DIGITAL I O This External Digital I O performs two functions STATUS OUTPUTS Logic Level voltages are output through an optically isolated 8 pin connector located on the rear panel of the analyzer These outputs convey good bad and on off information about certain analyzer conditions They can be used to interface with certain types of programmable devices see Section 6 12 1 1 CONTROL INPUTS By applying 5VDC power supplied from an external source such as a PLC or Datalogger see Section 6 12 1 2 Zero and Span calibrations can be initiated by contact closures on the rear panel 10 4 12 I C DATA BUS IC is a two wire clocked bi directional digital serial I O bus that is used widely in commercial and consumer electronic systems A transceiver on the Motherboard converts data and control signals from the PC 104 bus to C The data is then fed to the Keyboard Display Interface see Section 10 6 1 4 and finally onto the Relay Board An data bus is used to communicate data and commands between the CPU the Keyboard Display Interface and the various switches and relays on the Relay Board 10 4 13 POWER UP CIRCUIT This circuit monitors the 5V power supply during start up and sets the Analog outputs External Digital 1 O ports and I C circuitry to specific values until the CPU b
255. imal point display of concentration and stability values Adjusts the speed of the analyzer s clock Choose the 7 CLOCK_ADJ foo if the clock is too slow choose the sign if the clock is fast DYN ZERO ON OFF 5 DYN SPAN ON OFF AUTO 1 2 3 4 Default AUTO 60 to 60 s day 6 CONC_PRECISION 62 6400E Rev Model 6400E Instruction Manual Operating Instructions To access and navigate the VARS menu use the following key sequence SAMPLE RANGE 500 000 PPS 502 XXX FST TST CAL SETUP SAMPLE ENTER SETUP PASS 818 8 1 8 ENTR SETUP X X PRIMARY SETUP MENU CFG DAS RNGE PASS CLK MORE EXIT SETUP SECONDARY SETUP MENU VARS DIAG EXIT SS SETUP XX ENTER VARS PASS 818 EXIT ignores the new setting ENTR accepts the new selling 8 128 ENTR EXIT SETUP 0 kao 0 snutes NEXT JUMP SETUP X X DAS_HOLD_OFF 15 0 Minutes EDIT EXIT 4 5 0 ENTR EXIT Toggle this keys to change selling TPC ENABLE ON 1 TPC ENABLE ON PREV NEXT JUMP EDIT PRNT EXIT SETUP X X ON ENTR EXIT Toggle this keys to change setling SETUP X X 26 52 0 Deg PREV N SUMP EDIT EXIT DO NOT change theses set points unless specifically instructed to by T API Customer Service SETUP X X V NEXT
256. in properly sealed ant ESD containers Static charges will build up on the outer surface of the anti ESD container during shipping as the packing materials vibrate and rub against each other To prevent these static charges from damaging the components or assemblies being shipped make sure that you e Always unpack shipments from Teledyne Instruments Customer Service by Opening the outer shipping box away from the anti ESD work area Carry the still sealed ant ESD bag tube or bin to the anti ESD work area Follow steps 6 and 7 of Section 12 4 2 3 above when opening the anti ESD container at the work station Reserve the anti ESD container or bag to use when packing electronic components or assemblies to be returned to Teledyne Instruments Always pack electronic components and assemblies to be sent to Teledyne Instruments Customer Service in anti ESD bins tubes or bags Do not use pink poly bags If you do not already have an adequate supply of anti ESD bags or containers available Teledyne Instruments Customer Service department will supply them see Section 11 7 for contact information Always follow steps 1 through 5 of Section 12 4 1 3 User Notes 258 04515 Rev B Model 6400E Instruction Manual APPENDIX A Version Specific Software Documentation APPENDIX A Version Specific Software Documentation APPENDIX 1 APPENDIX A 2 APPENDIX A 3 APPENDIX A 4 APPENDIX A 5 APPENDIX A 6 Mo
257. ined in this chapter must be performed by qualified maintenance personnel only CAUTION Risk of electrical shock Some operations need to be carried out with the analyzer open and running Exercise caution to avoid electrical shocks and electrostatic or mechanical damage to the analyzer Do not drop tools into the analyzer or leave those after your procedures Do not shorten or touch electric connections with metallic tools while operating inside the analyzer Use common sense when operating inside a running analyzer NOTE The front panel of the analyzer is hinged at the bottom and may be opened to gain access to various components mounted on the panel itself or located near the front of the instrument such as the particulate filter A locking screw located at the top center of the panel and two fasteners located in the upper right and left corners of the panel lock it shut see Figure 3 10 11 1 GENERAL TROUBLESHOOTING The analyzer has been designed so that problems can be rapidly detected evaluated and repaired During operation the analyzer continuously performs diagnostic tests and provides the ability to evaluate its key operating parameters without disturbing monitoring operations A systematic approach to troubleshooting will generally consist of the following five steps Note any warning messages and take corrective action as necessary e Examine the values of all TEST functions and compare them to
258. ing DC Power Supply problems the wiring used to connect the various printed circuit assemblies and DC powered components and the associated test points on the relay board follow a standard color coding scheme as defined in Table 11 4 Table 11 4 DC Power Test Point and Wiring Color Code NAME TEST POINT COLOR DEFINITION DGND 1 Black Digital ground 5V 2 Red AGND 3 Green Analog ground 15V 4 Blue 15V 5 Yellow 12V 6 EE Purple 12R 7 Orange 12 V return ground line A voltmeter should be used to verify that the DC voltages are correct as listed in Table 11 5 An oscilloscope in AC mode and with band limiting turned on can be used to evaluate if the supplies are excessively noisy gt 100 mV peak to peak Table 11 5 DC Power Supply Acceptable Levels CHECK RELAY BOARD TEST POINTS POWER VOLTAG FROM TEST E pedis TO TEST POINT MINV MAXV NAME NAME 04515 Rev B 225 TROUBLESHOOTING amp REPAIR Model 6400E Instruction Manual PS1 5 DGND 1 5 2 4 80 T5 25 PS1 15 AGND 3 15 4 13 5 16 0 PS1 i5 AGND 3 15V 5 14 0 16 0 51 AGND AGND 3 DGND i 0 05 30 05 PS1 Chassis DGND 1 Chassis N A 0 05 0 05 PS2 12 12V Ret 6 12V 7 11 8 12 5 PS2 DGND 12V Ret 6 DGND 1 0 05 0 05 11 5 6 BUS Operation of the bus can be verified by observing the behavior of the LED l
259. ink that is cooled by moving air see Figure 10 16 A Thermocouple embedded into the cold block generates an analog voltage corresponding to the current temperature of the PMT The PMT Preamp PCA conditions and amplifies this signal then passes it on to the TEC Control PCA 10 4 4 2 TEC Control Board The TEC control printed circuit assembly is located ion the sensor housing assembly under the slanted shroud next to the cooling fins and directly above the cooling fan Using the amplified PMT temperature signal from the PMT preamplifier board see Section 10 4 5 it sets the drive voltage for the thermoelectric cooler The warmer the PMT gets the more current is passed through the TEC causing it to pump more heat to the heat sink A red LED located on the top edge of this circuit board indicates that the control circuit is receiving power Four test points are also located at the top of this assembly For the definitions and acceptable signal levels of these test points see Chapter 11 04515 Rev B 191 Theory Of Operation Model 6400E Instruction Manual 10 4 5 PMT PREAMPLIFIER The PMT preamplifier board amplifies the PMT signal into a useable analog voltage PMT that can be processed by the motherboard into a digital signal to be used by the CPU to calculate the SO concentration of the gas in the sample chamber The output signal of the PMT is controlled by two different adjustments First the voltage across the electron multi
260. inted in capital bold letters such as SETUP or ENTR represent messages as they appear on the analyzer s front panel display NOTE The flowcharts in this manual contain typical representations of the analyzer s display during the various operations being described These representations are not intended to be exact and may differ slightly from the actual display of your instrument User Notes 6400E Rev B 3 Model 6400E Instruction Manual Specifications Approvals and Warranty 2 SPECIFICATIONS APPROVALS AND WARRANTY 2 1 SPECIFICATIONS Table 2 1 Model 6400E Basic Unit Specifications Min Max Range Physical Analog Output In 1ppb increments from SOppb to 20 O00ppb dual ranges or auto ranging Measurement Units ppb ppm ug m3 mg m3 user selectable Zero Noise 0 2 ppb RMS Span Noise 0 2 ppb RMS Lower Detectable Limit 0 4 ppb RMS Zero Drift 24 hours 0 5 ppb Zero Drift 7 days 1ppb Span Drift 7 Days 0 596 FS Linearity 1 of full scale Precision Temperature Coefficient Temperature Range Humidity Range Voltage Coefficient 0 05 per V Lag Time 20 sec Rise Fall Time 95 in 100 sec Sample Flow Rate 0 5 of reading1 lt 0 1 per C 650cc min 10 5 400C 0 95 RH non condensing Dimensions H x W x D 7 x 17 x 23 5 178 mm x 432 mm x 597 mm Weight Analyzer Basic Configuration
261. inue DIAG CONC_OUT_2 5V CAL SET SET gt EDIT EXIT DIAG AIO CONC OUT 2 RANGE 5V DIAG AIO SET ET SET CONC OUT 2 CALIBRATED NO CAL EXIT DIAG AIO CONC OUT 2 REC OFS 0 mV DIAG EQ EXIT SET SET CONC OUT 2 AUTO CAL ON DIAG DIAG AIO SET SET SET gt EDIT AUTO CALIBRATING CONC_OUT_2 CONC OUT_2 CALIBRATED YES L To select manual output calibration for a particular channel press Access from DIAG Menu see Section 8 9 1 DIAG ANALOG 17 O CONFIGURATION DIAG AIO CONC_OUT_2 REC OFS 0 mV Exil to return to the main E EXT 7 sample display NEXT ENTR EXIT SET SET EDIT DIAS xov AOUTS CALIBRATED NO DIAGAIO CONC OUT 2 AUTO CAL ON SEL SEIS CAU EXIT SET SET EDIT EXIT Press SET to select the analog output channel to Y be configured Then press EDIT to continue m DIAG AIO AQUT AUTO CAL ON DIAG AIO CONC OUT 2 5V CAL ON ENTR EXIT lt SET SET EDIT EXIT Toggles the ENTR accepts the new setting auto cal mode and retums lo the previous menu ON OFF for EXIT ignores the new setting and this analog returns to the previous manu output channel EXIT only Now the analog output channels should either be automatically calibrated or they should be set to manual calibration which is described
262. ion value and the original information from which it was calculated are stored in the unit s internal data acquisition system and reported to the user through a vacuum fluorescent display or as electronic data via several communication ports This concentration value and the original information from which it was calculated are stored in the unit s internal data acquisition system iDAS Section 6 11 and reported to the user through a vacuum fluorescent display or several communication ports 10 1 MEASUREMENT PRINCIPLE 10 1 1 SO ULTRAVIOLET FLUORESCENCE The physical principle upon which the 6400E s measurement method is based is the fluorescence that occurs when sulfur dioxide SO2 is excited by ultraviolet light with wavelengths in the range of 190 nm 230 nm This reaction is a two step process The first stage Equation 10 1 occurs when SO molecules are struck by photons of the appropriate ultraviolet wavelength In the case of the Model 6400E a band pass filter between the source of the UV light and the affected gas limits the wavelength of the light to approximately 214 nm The SO molecules absorbs some of energy from the UV light causing one of the electrons of each of the affected molecules to move to a higher energy orbital state SO diu S02 Equation 10 1 04515 Rev B 171 Theory Of Operation Model 6400E Instruction Manual The amount SO converted to excited SO in the sample chamber is dependent on the average
263. is valid 3 HIGH RANGE ON if unit is in high range of the AUTO Range Mode 4 T ZERO CAL ON whenever the instrument s ZERO point is being calibrated 5 SPAN CAL ON whenever the instrument s SPAN point is being calibrated 6 DIAG MODE ON whenever the instrument is in DIAGNOSTIC mode 7 8 SPARE D EMITTER BUS The emitters of the transistors on pins 1 8 are bussed together SPARE DC POWER 5 VDC 300 mA source combined rating with Control Output if used V IN ground level from the analyzer s internal DC power supplies 12 6400E Rev B Model 6400E Instruction Manual Getting Started 3 1 1 3 Connecting the Control Inputs If you wish to use the analyzer to remotely activate the zero and span calibration modes several digital control inputs are provided through a 10 pin connector labeled CONTROL IN on the analyzer s rear panel There are two methods for energizing the control inputs The internal 5V available from the pin labeled is the most convenient method However if full isolation is required an external 5 VDC power supply should be used CONTROL IN CONTROL IN EEE ECE ARN RE AQ Ew pos SPAN CAL ZERO CAL SPAN CAL ZERO CAL 5 VDC Power Supply Local Power Connections External Power Connections Figure 3 4 Control Input Connector Table 3 3 Control Input Signals
264. isabled whereas diagnostic should be collected LED STATE Off Blinking Sampling normally The iDAS can be disabled only by disabling or deleting its individual data channels 102 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 11 1 IDAS STRUCTURE The iDAS is designed around the feature of a record A record is a single data point of one parameter stored in one or more data channels and generated by one of several triggering event The entire iDAS configuration is stored in a script which can be edited from the front panel or downloaded edited and uploaded to the instrument in form of a string of plain text lines through the communication ports iDAS data are defined by the PARAMETER type and are stored through different triggering EVENTS in data CHANNELS which relate triggering events to data parameters and define certain operational functions related to the recording and reporting of the data 6 11 1 1 iDAS Channels The key to the flexibility of the iDAS is its ability to store a large number of combinations of triggering events and data parameters in the form of data channels Users may create up to 20 data channels and each channel can contain one or more parameters For each channel one triggering event is selected and up to 50 data parameters which can be the same or different between channels Each data channel has several properties that define the structure of the
265. it untii STABIL falls below 0 05 ppb This may take several minutes ABIL ZERO CALM 502 XXX X TST TST gt ZERO CONC ZERO CAL 502 XXX X EXIT returns the unit to SAMPLE mode wilhout TST YST ER CORE EG changing the calibration values ZERO GAL 502 XXX X CAL h XXX 157 TST CAL CALZ CALS SETUP The value of STABIL may jump significantly Wait until it falls below 0 5 ppb This may take several minutes SPAN CAL M X amp SOS XXXX EXIT retums to the SAMPLE mode wilhout TST TST ENTR CONC EXT changing the calibration values Pressing ENTR changes the calibration of the insert AN CAL 502 XXX X EXIT retums to the main SAMPLE display 27ST IST SPAN CONC EXIT 6400E Rev B 143 Calibration Procedures Model 6400E Instruction Manual 7 5 MANUAL CALIBRATION WITH IZS OPTION Under the best conditions the accuracy off the SO effusion rate of the 125 option s permeation tube is about 5 This can be subject to significant amounts of drift as the tube ages and the amount of SO contained in the tube is depleted Whereas this may be sufficient for informal calibration checks it is not adequate for formal calibrations and is not approved for use by the US EPA as a calibration source Therefore for formal calibrations
266. itting and connect all tubing 11 Power up the analyzer and allow it to warm up for 60 minutes 12 Perform a leak check See Section 11 5 1 9 3 5 CHECKING FOR LIGHT LEAKS When re assembled after maintenance of repair or when operated improperly the 6400E can develop small leaks around the PMT which let stray light from the analyzer surrounding into the PMT housing To find such light leaks follow the below procedures CAUTION This procedure can only be carried out with the analyzer running and its cover removed This procedure should only be carried out by qualified personnel 1 Scroll the TEST functions to PMT 2 Supply zero gas to the analyzer 3 With the instrument still running carefully remove the analyzer cover Take extra care not to touch any of the inside wiring with the metal cover or your body Do not drop screws or tools into a running analyzer 4 Shine a powerful flashlight or portable incandescent light at the inlet and outlet fitting and at all of the joints of the sample chamber as well as around the PMT housing The PMT value should not respond to the light the PMT signal should remain steady within its usually noise 5 If there is a PMT response to the external light symmetrically tighten the sample chamber mounting screws or replace the 1 4 vacuum tubing with new black PTFE tubing this tubing will fade with time and become transparent Often light leaks are also caused by O rings
267. k settings at nominal values needed 2 6400E in SAMPLE mode Analyzer operational Zero and span within Level 1 zero span every 2 Find source of error and check tolerance limits as weeks Level 2 between repair Level 1 checks at frequency desired analyzer by user After corrective action re calibrate analyzer Precision check Assess precision as described in Sec 2 0 8 and Subsec 3 4 3 Ibid Every 2 weeks Subsec 3 4 3 Ibid Calc report precision Sec 2 0 8 Ibid 156 6400E Rev B Model 6400E Instruction Manual EPA Protocol Calibration 8 2 LEVEL 1 CALIBRATIONS VERSUS LEVEL 2 CHECKS Essential to quality assurance are scheduled checks for verifying the operational status of the monitoring system The operator should visit the site at least once each week It is recommended Level 1 zero and span check conducted on the analyzer every two weeks Level 2 zero and span checks should be conducted at a frequency desired by the user Definitions of these terms are given in Table 8 4 In addition an independent precision check between 0 08 and 0 10 ppm must be carried out at least once every two weeks Table 8 3 summarizes the quality assurance activities for routine operations A discussion of each activity appears in the following sections To provide for documentation and accountability of activities a checklist should be compiled and then filled out by the field operator as
268. l Assistance eser 12 A PRIMER ON ELECTRO STATIC DISCHARGE 12 1 How Static Charges are 12 2 How Electro Static Charges Cause Damage 12 3 Common Myths About ESD Damage 12 4 Basic Principles of Static Control iiy 12 4 1 General Rules 12 4 2 Basic anti ESD Procedures for Analyzer Repair and Maintenance 12 4 2 1 Working at the Instrument Rack 12 4 2 2 Working at a Anti ESD Work Bench 12 4 2 3 Transferring Components from Rack To Bench and Back 12 4 2 4 Opening Shipments from and Packing Components for Return to Teledyne Instruments CUSTOMER ERATAN IVES PERSAR PaRa A REEF KESAREA AAA 258 LIST OF APPENDICES APPENDIX A VERSION SPECIFIC SOFTWARE DOCUMENTATION APPENDIX A 1 6400E Software Menu Trees Revision C 3 APPENDIX 2 Setup Variables For Serial 1 0 Revision APPENDIX A 3 Warnings and Test Functions Revision C 3 APPENDIX A 4 6400E Signal 1 0 Definitions Revision C 3 APPENDIX A 5 6400E iDAS Functions Revision C 3 APPENDIX A 6 Terminal Command Designators Revision C 3 APPENDIX B 6400E SPARE PARTS LIST APPENDIX C REPAIR QUESTIONNAIRE 6400E APPENDIX D ELECTRONIC SCHEMATICS LIST OF FIGURES Figure 3 1 Rear Panel Layout serseseseeeeeeeeonannnnnnenennrerensnnenrsnreneeerrennnansrranenee 10 Figure 3 2 Analog Output Connector
269. l to switch it between DTE and DCE modes see Section 6 10 5 If both LEDs are still not illuminated check the cable for proper wiring The two LEDs located over COM2 are currently deactivated If you have problems getting COM2 to activate it may be necessary to install a null modem cable contact customer service for information 6 10 4 RS 485 CONFIGURATION OF COM2 As delivered from the factory COM2 is configured for RS 232 communications This port can be re configured for operation as a non isolated half duplex RS 485 port capable of supporting up to 32 instruments with a maximum distance between the host and the furthest instrument being 4000 feet If you require full duplex or isolated operation please contact Teledyne Instruments Customer Service reconfigure COM2 as an RS 285 port set switch 6 of SW1 to the ON position see Figure 6 9 The RS 485 port can be configured with or without a 150 Q termination resistor To include the resistor install jumper at position JP3 on the CPU board see Figure 6 9 To configure COM2 as an un terminated RS 485 port leave JP3 open 6400E Rev B 87 Operating Instructions Model 6400E Instruction Manual CN4 JP3 COM2 RS 232 CN3 COM1 RS 232 CN5 COM2 RS 485 Figure 6 9 CPU card Locations of RS 232 486 Switches Connectors and Jumpers 88 6400E Rev B Model 6400E Instruction Manual Operating Instructions When COM2 is configured for RS 485 opera
270. le 6 20 Table 6 21 Table 6 22 Table 6 23 Table 6 24 Table 6 25 Table 6 26 Table 6 27 Table 6 28 Table 6 29 Table 7 1 Table 7 2 Table 7 3 Table 7 4 Table 7 5 Table 8 1 Table 8 2 Table 8 3 Table 8 4 Table 9 1 Table 9 2 Table 10 1 Table 10 2 Table 11 1 Table 11 2 Table 11 3 Table 11 4 Table 11 5 Table 11 6 Table 11 7 Table 11 8 Table 11 9 Table 11 10 Table 12 1 Table 12 2 Table A 1 Table A 2 Table A 3 Table A 4 Table A 5 Table A 6 Table A 7 Table B 1 Table D 1 Analog Output Pin E 69 Voltage Tolerances for Analog Output Calibration Current Loop Output Calibration with Resistor Test Parameters Available for Analog Output 4 84 Ethernet Status nennen 90 LAN Internet Configuration Properties Internet Configuration Keypad Functions COMM Port Communication modes 98 Front Panel LED Status Indicators for 102 iDAS Data Channel 103 iDAS Data Parameter Functions 104 Status Output Pin Assignments eese enne nne nnn hehehe nenne nennen 121 Control Input Pin Assignments rhet 121 Terminal Mode Software Commands 123 Command T
271. le the timer STARTING DATE Sept 4 2002 Start after Sept 4 2002 STARTING TIME 01 00 First Span starts at 01 00 DELTA DAYS 2 Do Sequence 2 every other day 6400E Rev B 149 Calibration Procedures Model 6400E Instruction Manual To program the sample sequence shown above OFG ACAL DAS RNSE PASS CLK MORE EXIT SAMPLE SOL XxKx X SETUP STARTING TIME 14 15 TST SETUP SET SET EDIT EKT j SETUPXX PRIMARY SETUP MENU SETUPS DELTA DAYS 1 SET SET EDIT EXIT SETUP SEQ2 ZERO SPAN 1 00 00 PREY NEXT MODE SET Default value is ON SETUP x TIMER ENABLE ON EDIT STARTING DATE 01 JAN 02 SETUP X SET SET EDIT Toggle keys to sel day month amp SETUP X STARTING DATE U1 JAN U2 zeae 4 SEP 0 3 ENTR EXT Format DD MON YY SETUP STARTING DATE 04 SEP 03 SET SET EDIT SETUP C4 STARTING DATE 04 SEP 03 SET SET EDIT STARTING TIME 00 00 Toggle keys to sot time Formal HH MM This is a 24 hr clock PM hours are 13 24 Example 2 15 PM 14 15 EDIT SETUP C STARTING 60 03 41 55 5 SETUP Z4 DURATION 15 0 MINUTES SET SET EDIT SETUPC 4 DURATION 15 OMINUTES
272. led for 1 hour even if the correct password is used If not logged on the only active command is the request for the help screen The following messages will be returned at logon o LOGON SUCCESSFUL Correct password given o LOGON FAILED Password not given or incorrect o LOGOFF SUCCESSFUL Connection terminated successfully 6400E Rev B 127 Operating Instructions Model 6400E Instruction Manual To log on to the 6400E analyzer with SECURITY MODE feature enabled type LOGON 940331 940331 is the default password To change the default password use the variable RS232_PASS issued as follows V RS232_PASS NNNNNN Where N is any numeral between 0 and 9 6 12 2 8 APICOM Remote Control Program APICOM is an easy to use yet powerful interface program that allows to access and control any of Teledyne Instruments main line of ambient and stack gas instruments from a remote connection through direct cable modem or Ethernet Running APICOM a user can Establish a link from a remote location to the 6400E through direct cable connection via RS 232 modem or Ethernet View the instrument s front panel and remotely access all functions that could be accessed when standing in front of the instrument Remotely edit system parameters and set points Download view graph and save data for predictive diagnostics or data analysis Retrieve view edit save and upload iDAS configurations Check on system parameters for
273. lis below 0 5 ppb This may take several minutes ACTION Record tha SO concentration reading SAMPLE SiABILEXXX 502 lt IST TST gt CAL SETUP The SPAN key appears during the transition from zero to span You may see both keys 6400E Rev B 141 Calibration Procedures Model 6400E Instruction Manual 7 4 MANUAL CALIBRATION WITH ZERO SPAN VALVES Zero and Span calibrations using the Zero Span Valve option are similar to that described in Section 7 2 except that Zero air and span gas is supplied to the analyzer through the zero gas and span gas inlets rather than through the sample inlet zero and cal operations are initiated directly and independently with dedicated keys CALZ amp CALS STEP ONE Connect the sources of zero air and span gas to the respective ports on the rear panel see Figure 3 1 as shown below Source of SAMPLE Gas MODEL 700 Gas Dilution Calibrator with generator option Sample Exhaust MO DEL Soan 6400E External Zero Air Scrubber MODEL 701 Eero AIE Zero Air Generator Calibrated Sq Needle valve to control flow Figure 7 2 Setup for Manual Calibration with Z S Valve Option Installed Step Two Set the expected SO Span gas value SAMPLE RANGE 500 000 PPB 02 XXX X lt 5 TST gt CAL SETUP This sequence causes the analyzer to prompt for the exp
274. llowing DC voltages Each range is usable from 5 to 5 of the nominal range Table 6 9 Analog Output Voltage Ranges RANGE MINIMUM OUTPUT MAXIMUM OUTPUT 0 0 1 V 5 mV 105 mV 0 1V 0 05 V 41 05 V 05v 0 25 V 45 25 V oiov 0 5V 410 5 V The default offset for all ranges is 0 VDC 68 6400E Rev B Model 6400E Instruction Manual Operating Instructions The following DC current output limits apply to the current loop modules Table 6 10 Analog Output Current Loop Range MINIMUM OUTPUT MAXIMUM OUTPUT RANGE 0 20 mA 0 mA These are the physical limits of the current loop modules typical applications use 2 20 or 4 20 mA for the lower and upper limits Please specify desired range when ordering this option 20 mA The default offset for all ranges is 0 mA Pin assignments for the output connector at the rear panel of the instrument are shown in Table 6 11 ANALOG OUT A1 A2 A3 A4 Table 6 11 Analog Output Pin Assignments ANALOG VOLTAGE CURRENT OUTPUT SIGNAL SIGNAL V Out 1 Out Ground I Out V Out I Out Ground I Out Not Used Not Used V Out not available Ground not available See Figure 3 1 for a the location of the analog output connector on the instruments rear panel 6400E Rev B 69 Operating Instructions Model 6400E Instruction Manual 6 9 4 1 Analog Output Signal Type and Range Span Selection
275. load of an iDAS configuration with APICOM or a Terminal program fail if the combined number of records would be exceeded In this case it is suggested to either try from the front panel what the maximum number of records can be or use trial and error in designing the iDAS script or calculate the number of records using the DAS or APICOM manuals To set the number of records for one channel from the front panel press SETUP DAS EDIT ENTR and the following key sequence From the DATA ACQUISITION menu see Section 6 12 2 2 Edit Data Channel Menu SETUP XX 0 ATIMER 2 900 Exits to the main Data Acquisition menu PREV NEXT INS DEL EDIT PRNT EXIT SETUP XX NAME CONC SET SET EDIT PRINT EXIT C Press SET key until SETUP XX NUMBER OF RECORDS 000 SET SET EDIT PRINT EXIT SETUP XX EDIT RECOPRDS DELET DATA NO retums to the YES will delete all data previous menu in this channel ee MO gt E ENTR accepts the new setting and returns to the previous menu Toggle keys to set number of records 1 999899 SETUP XX REPORT PERIODD DAYS 0 EXIT ignores the new setting and retums the previous 4 2 0 0 ENTR r j enu 114 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 11 2 7 RS 232 Report Function The 6400E iDAS can automatically report data to the communications ports where they
276. lope and offset values be checked frequently to assure high quality and accurate data from the instrument 150 6400E Rev B Model 6400E Instruction Manual Calibration Procedures 7 9 CALIBRATION QUALITY After completing one of the calibration procedures described above it is important to evaluate the analyzer s calibration SLOPE and OFFSET parameters These values describe the linear response curve of the analyzer The values for these terms both individually and relative to each other indicate the quality of the calibration To perform this quality evaluation you will need to record the values of both test functions see Section 6 2 1 or Appendix A 3 all of which are automatically stored in the iDAS channel CALDAT for data analysis documentation and archival Make sure that these parameters are within the limits listed in the following Table Table 7 5 Calibration Data Quality Evaluation FUNCTION MINIMUM VALUE OPTIMUM VALUE MAXIMUM VALUE SLOPE 0 700 1 000 1 300 OFFS 50 0 mV n a 250 0 mV These values should not be significantly different from the values recorded on the TAI Final Test and Validation Data sheet that was shipped with your instrument If they are refer to the troubleshooting Chapter 11 6400E Rev B 151 Model 6400E Instruction Manual EPA Protocol Calibration 8 EPA PROTOCOL CALIBRATION 8 1 CALIBRATION REQUIREMENTS If the 6400E is to be used for EPA SLAMS
277. lope change Sampling at the end of irregularly occurring calibrations or when the response slope changes These triggering events create instantaneous data points e g for the new slope and offset concentration response values at the end of a calibration Zero and 104 6400E Rev B Model 6400E Instruction Manual Operating Instructions slope values are valuable to monitor response drift and to document when the instrument was calibrated e WARNINGS Some data may be useful when stored if one of several warning messages appears This is helpful for trouble shooting by monitoring when a particular warning occurred 6 11 2 DEFAULT IDAS CHANNELS A set of default Data Channels has been included in the analyzer s software for logging SO concentration and certain predictive diagnostic data These default channels include but are not limited to CONC Samples SO concentration at one minute intervals and stores an average every five minutes with a time and date stamp Readings during calibration and calibration hold off are not included in the data By default the last 4032 hourly averages are stored PNUMTC Collects sample flow and sample pressure data at five minute intervals and stores an average once a day with a time and date stamp This data is useful for monitoring the condition of the pump and critical flow orifice sample flow and the sample filter clogging indicated by a drop in sample pressure over time to predict when
278. lue is too different from the actually measured value and the instrument does not allow to span or zero to that point Chapter 11 describes this in detail Q Why does the ENTR key sometimes disappear on the front panel display A Sometimes the ENTR key will disappear if you select a setting that is invalid or out of the allowable range for that parameter such as trying to set the 24 hour clock to 25 00 00 or a range to more than 20 000 ppb Once you adjust the setting to an allowable value the ENTR key will re appear Q Can I automate the calibration of my analyzer A Any analyzer with zero span valve or IZS option can be automatically calibrated using the instrument s AutoCal feature However the accuracy of the IZS option s permeation tube is 5 While this may be acceptable for basic calibration checks the IZS option is not permitted as a calibration source in applications following US EPA protocols To achieve highest accuracy it is recommended to use cylinders of calibrated span gases in combination with a zero air source TAloffers a zero air generator Model 701 and a gas dilution calibrator Model 700 for this purpose Q What do I do if the concentration on the instrument s front panel display does not match the value recorded or displayed on my data logger even if both instrument s are properly calibrated A This most commonly occurs for one or both of the following reasons difference in circuit ground between the
279. lyzer ID a number with 1 to 4 digits MESSAGE is the message content that may contain warning messages test measurements iDAS reports variable values etc CRLF is a carriage return line feed pair which terminates the message 6400E Rev B 125 Operating Instructions Model 6400E Instruction Manual The uniform nature of the output messages makes it easy for a host computer to parse them into an easy structure Keep in mind that the front panel display does not give any information on the time a message was issued hence it is useful to log such messages for trouble shooting and reference purposes Terminal emulation programs such as HyperTerminal can capture these messages to text files for later review 6 12 2 6 Remote Access by Modem The 6400E can be connected to a modem for remote access This requires a cable between the analyzer s COM port and the modem typically a DB 9F to DB 25M cable available from Teledyne Instruments with part number WR0000024 Once the cable has been connected check to make sure the DTE DCE is in the correct position Also make sure the 6400E COM port is set for a baud rate that is compatible with the modem which needs to operate with an 8 bit word length with one stop bit The first step is to turn on the MODEM ENABLE communication mode Mode 64 Section 6 10 8 Once this is completed the appropriate setup command line for your modem can be entered into the analyzer The default setting for
280. mentation and archival in electronic format To support the iDAS functionality Teledyne Instruments offers APICOM a program that provides a visual interface for remote or local setup configuration and data retrieval of the iDAS see Section 6 11 The APICOM manual which is included with the program contains a more detailed description of the iDAS structure and configuration which is briefly described in this section The 6400E is configured with a basic iDAS configuration which is enabled by default New data channels are also enabled by default but each channel may be turned off for later or occasional use Note that iDAS operation is suspended while its configuration is edited through the front panel To prevent such data loss it is recommended to use the APICOM graphical user interface for iDAS changes The green SAMPLE LED on the instrument front panel which indicates the analyzer status also indicates certain aspects of the iDAS status Table 6 19 Front Panel LED Status Indicators for iDAS IDAS STATUS System is in calibration mode Data logging can be enabled or disabled for this mode Calibration data are typically stored at the end of calibration periods concentration data are typically not sampled diagnostic data should be collected Instrument is in hold off mode a short period after the system exits calibrations IDAS channels can be enabled or disabled for this period Concentration data are typically d
281. mentation complete Will the forms be filed in such a manner that they can easily be retrieved when needed 8 1 7 SUMMARY OF QUALITY ASSURANCE CHECKS The following items should be checked on a regularly scheduled basis to assure high quality data from the 6400E See Table 8 3 for a summary of activities Also the QA Handbook should be checked for specific procedures Table 8 3 Activity Matrix for Quality Assurance Checks ACTION IF CHARACTERISTIC ACCEPTANCE LIMITS FREQUENCY AND METHOD REQUIREMENTS ARE OF MEASUREMENT IREMENT Shelter temperature Sample introduction Mean temperature between 22 C and 28 C 72 and 82 F daily fluctuations not greater than 2 C No moisture foreign Check thermograph chart weekly for variations greater than 2 C 4 F Weekly visual inspection Mark strip chart for the affected time period Repair or adjust temperature control Clean repair or replace Legible ink traces Correct chart speed and range Correct time system material leaks as needed obstructions sample line connected to manifold Recorder Adequate ink amp paper Weekly visual inspection Replenish ink and paper supply Adjust time to agree with clock note on chart Analyzer operational TEST measurements Weekly visual inspection Adjust or repair as described in Subsec 9 1 3 of Sec 2 0 9 Q A Handboo
282. message flag is displayed See Table 6 29 For xxample x SETUP X SYSTEM RESET 0000 PREV NEXT EDIT PRNT EXIT The lt CH and CH gt keys move the cursor left and right along the bit string SETUP X SYSTEM RESET 0 000 ENTR key accepts the new settings EXIT key ignores the new settings CH CH 0 ENTR EXI Press the key repeatedly to cycle through the available character set 0 9 Note Values of A F can also be set but are meaningless 134 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 12 4 8 Instrument ID Code Each instrument on a Hessen Protocol network must have a unique ID code The 6400E is programmed with a default ID code of 100 To change this code see Section 6 10 1 User Notes 6400E Rev B 135 Model 6400E Instruction Manual Calibration Procedures 7 CALIBRATION PROCEDURES This chapter describes the calibration procedures for the 6400E All of the methods described in this section can be initiated and controlled through the COM ports NOTE If you are using the 6400E for US EPA controlled monitoring see Chapter 8 for information on the EPA calibration protocol 7 1 CALIBRATION PREPARATIONS The calibration procedures in this section assume that the analog range and units of measure range mode and reporting range have already been selected for the analyzer If this has not been done
283. monitoring it must be calibrated in accordance with the instructions in this section In order to insure that high quality accurate measurements are obtained at all times the 6400E must be calibrated prior to use A quality assurance program centered on this aspect and including attention to the built in warning features of the 6400E periodic inspection regular zero span checks and routine maintenance is paramount to achieving this The US EPA strongly recommends obtaining a copy of the Quality Assurance Handbook for Air Pollution Measurement Systems Volume II Part I abbreviated Q A Handbook Volume IT Special attention should be paid to Section 2 9 of the EPA handbook which deals with fluorescence based SO analyzers and upon which most of this section is based Specific regulations regarding the use and operation of ambient sulfur dioxide analyzers can be found in 40 CFR 50 and 40 CFR 58 8 1 1 CALIBRATION OF EQUIPMENT In general calibration is the process of adjusting the gain and offset of the 6400E against some recognized standard The reliability and usefulness of all data derived from any analyzer depends primarily upon its state of calibration In this section the term dynamic calibration is used to express a multipoint check against known standards and involves introducing gas samples of known concentration into the instrument in order to adjust the instrument to a predetermined sensitivity and to produce a calibration relation
284. mple gas inlet and the output of the zero span subsystem functionally very similar to the valves included in the zero span valve option Figure 5 3 shows the internal pneumatic connections for a Model 6400E with the IZS option installed Table 5 2 describes the operational state of the valves associated with the IZS option during the analyzer s various operating modes 1 1 LIE PUMP HYDROCARBON bo y SCRUBBER i KICKER se SAMPLE SAMPLE GAS INLET CHAMBER Me oF EXHAUST TO OUTER LAYER OF KICKER 125 Permeation EE zm 2 22 KE uo Na FLOW SENSOR 50 Source SAMPLE i PRESSURE j SENSOR CRITICAL i FLOWIPRESSURE SENSOR ZERO AIR INLET SPAN GAS INLET Figure 5 3 Pneumatic Diagram of the 6400E with IZS Options Installed 36 6400E Rev B Model 6400E Instruction Manual Optional Hardware and Software Table 5 2 IZS Valve Operating States MODE VALVE CONDITION VALVE PORT CONNECTIONS FIG 5 2 Sample Cal Open to SAMPLE inlet 322 SAMPLE Zero Span Open to ZERO AIR inlet 322 Sample Cal Open to zero span valve 122 ZERO CAL Zero Span Open to ZERO AIR inlet 322 Sample Cal Open to zero span valve 1252 SPAN CAL Zero Span Open to SPAN GAS inlet 122 The state of the IZS valves can also be controlled Manually from the analyzer s front panel by using the SIGNAL I O controls located under the D
285. n chip The ALL 01 channel of the 6400E for example is disabled by default To disable a data channel follow the instruction shown in section 6 11 2 2 then press From the DATA ACQUISITION em Edit Data Channel Menu Exits to the main SETUP XX 0 ATIMER 2 4032 PREV NEXT INS DEL EDIT PRNT EXIT Data Acquisition SETUP XX SET SET EDIT PRINT Press SET key until SETUP XX CHANNEL ENABLE ON SET SET EDIT PRINT ENTR accepts the new setting and returns to the previous menu EXIT i 1 SETUPXX CHANNEL ENABLE ON ignores ine new sel ng and returns to the previous Toggle key to turn menu OFF ENTR EXIT channel ON or OFF 116 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 11 2 11 HOLDOFF Feature The iDAS HOLDOFF feature allows to prevent data collection during calibrations and during the DAS_HOLDOFF period enabled and specified in the VARS see Section 6 8 To enable or disable the HOLDOFF follow the instruction shown in Section 6 11 2 2 then press From the DATA ACQUISITION menu Edit Data Channel Menu SETUP XX 0 ATIMER 2 4032 R Exits to the main PREV NEXT INS DEL EDIT PRNT EXIT Data Acquisition menu NAME CONC SETUP XX lt SET SET EDIT PRINT Press SET key until CAL HOLD OFF ON SETUP SET EDIT PRINT EXIT
286. n This section also includes information on using the iDAS to record diagnostic functions useful in predicting possible component failures before they happen 10 0 Theory of Operation An in depth look at the various principals by which your analyzer operates as well as a description of how the various electronic mechanical and pneumatic components of the instrument work and interact with each other A close reading of this section is invaluable for understanding the instrument s operation 11 0 Troubleshooting Section This section includes pointers and instructions for diagnosing problems with the instrument such as excessive noise or drift as well as instructions on performing repairs of the instrument s major subsystems 2 6400E Rev B Model 6400E Instruction Manual 6400E Documentation 11 0 Electro static Discharge Primer This section describes how static electricity occurs why it is a significant concern and how to avoid it and avoid allowing ESD to affect the reliable and accurate operation of your analyzer Appendices For easier access and better updating some information has been separated out of the manual and placed in a series of appendices at the end of this manual These include software menu trees warning messages definitions of iDAS amp serial I O variables spare parts list repair questionnaire interconnect listing and drawings and electronic schematics NOTE Throughout this manual words pr
287. nd in Appendix A 6 6 12 2 2 Help Commands in Terminal Mode Table 6 24 Terminal Mode Software Commands FUNCTION Switches the analyzer to terminal mode echo edit If mode flags 1 amp 2 are OFF the interface can be used in interactive mode with a terminal emulation program COMMAND Control T Control C Switches the analyzer to computer mode no echo no edit CR A carriage return is required after each command line is typed into the carriage return terminal computer The command will not be sent to the analyzer to be executed until this is done On personal computers this is achieved by pressing the ENTER key BS Erases one character to the left of the cursor location backspace ESC Erases the entire command line escape 1D CR Tes command prints a complete list of available commands along with the definitions of their functionality to the display device of the terminal or computer being used The ID number of the analyzer is only necessary if multiple analyzers are on the same communications line such as the multi drop setup Control C Pauses the listing of commands Control P i Restarts the listing of commands 6400E Rev B 123 Operating Instructions Model 6400E Instruction Manual 6 12 2 3 Command Syntax Commands are not case sensitive and all arguments within one command i e ID numbers keywords data values etc must be separated with a space c
288. ng pneumatic paths most likely critical flow orifices or sintered filters To perform a sample flow check 1 Disconnect the sample inlet tubing from the rear panel SAMPLE port shown in Figure 3 1 2 Attach the outlet port of a flow meter to the sample inlet port on the rear panel Ensure that the inlet to the flow meter is at atmospheric pressure 3 The sample flow measured with the external flow meter should be 650 cm3 min 1096 4 Low flows indicate blockage somewhere in the pneumatic pathway See troubleshooting chapter 11 for more information on how to fix this 11 5 3 HYDROCARBON SCRUBBER Kicker There are two possible types of problems that can occur with the scrubber pneumatic leaks and contamination that ruins the inner tube s ability to absorb hydrocarbons 11 5 3 1 Checking the Scrubber for Leaks Leaks in the outer tubing of the scrubber can be found using the procedure described in section 11 5 1 Use the following method to determine if a leak exists in the inner tubing of the scrubber e This procedure requires a pressurized source of air chemical composition is unimportant cap able of supplying up to 15 psia an a leak checking fixture such as the one illustrated in Figure 11 4 oS SSS ea Vacuum Pressure I 1 Gauge Needle Valve l 1 TO SCRUBBER FROM PUMP or I PRESSURIZED AIR SOURCE l Manual Shut Off I Valve l Figure 11 4 Simple Leak Check Fixture 222 04515 Rev B
289. nt loop outputs and instrument ground 76 6400E Rev B Model 6400E Instruction Manual Operating Instructions To adjust the zero and span values of the current outputs activate the ANALOG I O CONFIGURATION MENU see Section 6 9 1 then press C FROM ANALOG CONFIGURATION MENU DIAG AIG CONC OUT 2 CALIBRATED NO DIAG ANALOG 1 O CONFIGURATION CCAD EXIT PREV NEXT ENTR EXIT DIAG AIO CONC OUT 2 ZERO 0 mV Increase or decrease the current DIAS AIN A G FREQUENCY 50 HZ Ui00 UP10 UP DOWN DN10 0100 ENTR EXIT output by 100 10 or 1 counts The resulting change in output voltage Is SET EDIT EXIT displayed in the upper line i d Continue adjustments until the correct current is measured with the current DIAG AIN CALIBRATED NO DIAGAIO CONC_OUT_2 ZERO r mv meter EBIT gu U100 UP10 UP DOWN DH10 0100 ENTR EXIT AQUT CALIBRATED HO DIAG OUT 2 SPAN 10000 mV ENTR retums to the previous Ui00 UPIO UP DOWN ON10 D100 ENTR EXIT menu Press SET to select the analog output channel 1o be configured Then press EDIT to continue EXAMPLE DIAG AIO CONC_OUT_2 ZERO 9731 mV EXIT ignores the new setting CONC OUT CURR NO CAL Ut00 UPIO UP DOWN DNIO 01 0 ENTR EXIT accepts the new EDIT EXIT CONC_OUT_2 CALIBRATED YES DIAG AIO CONC OUT 2 RANGE CURR EDIT EXIT CAL EXIT
290. ntrol assembly is the critical flow orifice Critical flow orifices are a remarkably simple way to regulate stable gas flow rates They operate without moving parts by taking advantage of the laws of fluid dynamics By restricting the flow of gas though the orifice a pressure differential is created This pressure differential combined with the action of the analyzer s pump draws the gas through the orifice As the pressure on the downstream side of the orifice the pump side continues to drop the speed that the gas flows though the orifice continues to rise Once the ratio of upstream pressure to downstream pressure is greater than 2 1 the velocity of the gas through the orifice reaches the speed of sound As long as that ratio stays at least 2 1 the gas flow rate is unaffected by any fluctuations surges or changes in downstream pressure because such variations only travel at the speed of sound themselves and are therefore cancelled out by the sonic shockwave at the downstream exit of the critical flow orifice CRITICAL FLOW ORIFICE AREA OF AREA OF HIGH LOW PRESSURE PRESSURE A NISI Lee 3 ri 1 Shockwave O RINGS SPRING FILTER Figure 10 8 Flow Control Assembly amp Critical Flow Orifice The actual flow rate of gas through the orifice volume of gas per unit of time depends on the size and shape of the aperture in the orifice The larger the hole the more gas molecules moving 04515 Rev B 181 Theo
291. o a DC voltage signal front panel test parameter PMT by a PMT preamplifier printed circuit assembly located on top of the sensor housing PMT is converted to digital data by a bi polar analog to digital converter located on the motherboard In addition to the PMT signal a variety of sensors report the physical and operational status of the analyzer s major components again through the signal processing capabilities of the motherboard These status reports are used as data for the SO concentration calculation e g pressure and temperature reading used by the temperature pressure compensation feature and as trigger events for certain warning messages and control commands issued by the CPU They are stored in the CPU s memory and in most cases can be viewed through the front panel display The CPU communicates with the user and the outside world in a variety of ways e Through the analyzer s keyboard and vacuum fluorescent display over a clocked digital serial I O bus using the I C protocol pronounced I squared C RS 232 amp RS485 serial 1 0 channels e Various analog voltage and current outputs and e Several digital I O channels Finally the CPU issues commands also over the bus to a series of relays and switches located on a separate printed circuit assembly the relay board located in the rear of the chassis on its own mounting bracket to control the function of key electromechanical devices such as heaters t
292. o ground before doing anything else e Use wrist strap terminated with an alligator clip and attach it to a bare metal portion of the instrument chassis This will safely connect you to the same ground level to which the instrument and all of its components are connected Pause for a second or two to allow any static charges to bleed away Open the casing of the analyzer and begin work Up to this point the closed metal casing of your analyzer has isolated the components and assemblies inside from any conducted or induces static charges If you must remove a component from the instrument do not lay it down on a non ESD preventative surface where static charges may lie in wait Only disconnect your wrist strap after you have finished work and closed the case of the analyzer 12 4 2 2 Working at a Anti ESD Work Bench When working on an instrument of an electronic assembly while it is resting on a anti ESD work bench 1 Plug you anti ESD wrist strap into the grounded receptacle of the work station before touching any items on the work station and while standing at least a foot or so away This will allow any charges you are carrying to bleed away through the ground connection of the work station and prevent discharges due to field effects and induction from occurring Pause for a second or two to allow any static charges to bleed away Only open any anti ESD storage bins or bags containing sensitive devices or assemblies after yo
293. odel 6400E Instruction Manual Theory Of Operation 10 4 1 2 Flash Chip This non volatile memory includes 64 kb of space The 6400E CPU board can accommodate up to two EEPROM flash chips The 6400E standard configuration is one chip with 64 kb of storage capacity which is used to store a backup of the analyzer configuration as created during final checkout at the factory Separating these data onto a less frequently accessed chip significantly decreases the chance of those key data to get corrupted In the unlikely event that the flash chip should fail the analyzer will continue to operate with just the DOC However all configuration information will be lost requiring the unit to be recalibrated 10 4 2 SENSOR MODULE Electronically the 6400E sensor module is a group of components that create the UV light that initiates the fluorescence reaction between SO and O3 sense the intensity of that fluorescence and generate various electronic signals needed by the analyzer to determine the SO concentration of the sample gas see Section 10 1 and sense and control key environmental conditions such as the temperature of the sample gas and the PMT Y UV Lamp PMT Preamp PCA SAMPLE CHAMBER Reaction Cell Lamp Shutter Housing Sample Gas Outlet Sample Gas Inlet K Z Reference Detector PMT Cooling System PMT HOUSING Figure 10 12 6400E Sensor Module These components are divided into two significant subassemblies
294. og Output Voltages To verify that the analog outputs are working properly connect a voitmeter to the output in question and perform an analog output step test as described in Section 6 9 3 For each of the steps taking into account any offset that may have been programmed into the channel see Section 6 9 4 4 the output should be within 1 of the nominal value listed in the Table 11 7 except for the 0 step which should be within 2 3 mV If one or more of the steps is outside of this range a failure of one or both D A converters and their associated circuitry on the motherboard is likely Table 11 7 Analog Output Test Function Nominal Values FULL SCALE OUTPUT VOLTAGE 100MV iv 5 10V STEP NOMINAL OUTPUT VOLTAGE 1 0 0 mV 20 mV 1 11 5 9 3 Status Outputs The procedure below can be used to test the Status outputs i Connect a cable jumper between the pin and the V pin on the status output connector 2 Connect a 1000 Q resistor between the 5 V and the pin for the status output that is being tested Table 11 8 Status Outputs Check Pin Out PIN left to right STATUS 1 System Conc Valid High Range Zero Cal Span Cal Diag Mode Spare Spare COIN 228 04515 Rev B Model 6400E Instruction Manual TROUBLESHOOTING amp REPAIR 3 Connect a voltmeter between the pin and the pin of the output being tested see
295. og signals in the instrument Allows certain digital signals such as valves and heaters to be toggled ON and OFF ANALOG I O When entered the analyzer performs an analog output step test This can be used to calibrate a chart recorder or to test the analog output accuracy ANALOG 1 0 CONFIGURATION Analog input output parameters are available for viewing and configuration DIAG AIO 6 9 4 OPTIC TEST When activated the analyzer performs an optic test which turns on an LED located inside the sensor module near the PMT Fig 10 15 This diagnostic tests the response of the PMT without having to supply span gas ELECTRICAL TEST When activated the analyzer performs an electric test which generates a current intended to simulate the PMT output to verify the signal handling and conditioning of the PMT preamp board LAMP CALIBRATION The analyzer records the current voltage output of the UV source reference detector This value is used by the CPU to calculate the lamp ration used in determining the SO concentration PRESSURE CALIBRATION The analyzer records the current output of the sample gas pressure sensor This value is used by the CPU to compensate the SO concentration when the TPC feature is enabled FLOW CALIBRATION This function is used to calibrate the gas flow output signals of sample gas and ozone supply These settings are retained when exiting DIAG TEST CHAN OUTPUT Configures the A4 analog output channel D
296. olution looking for fine bubbles e Once the fittings have been wetted with soap solution do not re apply vacuum as it will draw soap solution into the instrument and contaminate it Do not exceed 15 psi pressure 4 If the instrument has the zero and span valve option the normally closed ports on each valve should also be separately checked Connect the leak checker to the normally closed ports and check with soap bubble solution 5 If the analyzer is equipped with an IZS Option Connect the leak checker to the Dry Air inlet and check with soap bubble solution 6 Once the leak has been located and repaired the leak down rate of the indicated pressure should be less than 1 in Hg A 0 4 psi in 5 minutes after the pressure is turned off 7 Clean soap solution from all surfaces re connect the sample and exhaust lines and replace the instrument cover Restart the analyzer 04515 Rev B 221 TROUBLESHOOTING amp REPAIR Model 6400E Instruction Manual 11 5 2 PERFORMING A SAMPLE FLOW CHECK CAUTION Use a separate calibrated flow meter capable of measuring flows between 0 and 1000 cm min to measure the gas flow rate though the analyzer Do not use the built in flow measurement viewable from the front panel of the instrument Sample flow checks are useful for monitoring the actual flow of the instrument to monitor drift of the internal flow measurement A decreasing actual sample flow may point to slowly cloggi
297. olution than typically necessary for measurements of higher concentrations The 6400E solves this issue by using two hardware physical ranges that cover the instruments entire 0 and 20 000 ppb measurement range a 0 to 2 000 ppb physical range for increased sensitivity and resolution when measuring very low SO concentrations and a to 20 000 ppb physical range for measuring higher SO concentrations The analyzer s software automatically selects which physical range is in effect based on the analog output reporting range selected by the user e If the high end of the selected reporting range is lt 2 000 ppb The low physical range is selected e If the high end of the selected reporting range is gt 2 001 ppb The high physical range is selected Once properly calibrated the analyzer s front panel will accurately report concentrations along the entire span of its 0 and 20 000 ppb physical range regardless of which reporting range has been selected for the analog outputs and which physical range is being used by the instruments software 6400E Rev B 55 Operating Instructions Model 6400E Instruction Manual 6 7 3 REPORTING RANGE MODES The 6400E provides three analog output range modes to choose from e Single range SNGL mode sets a single maximum range for the analog output If single range is selected see Section 6 7 4 both outputs are slaved together and will represent the same measurement span e g 0 50 ppm howeve
298. oots and the instrument software can establish control 04515 Rev B 197 Theory Of Operation Model 6400E Instruction Manual 10 5 POWER SUPPLY CIRCUIT BREAKER The analyzer operates on 100 VAC 115 VAC or 230 VAC power at either 50Hz or 60Hz Individual units are set up at the factory to accept any combination of these five attributes As illustrated in Figure 10 19 below power enters the analyzer through a standard IEC 320 power receptacle located on the rear panel of the instrument From there it is routed through the ON OFF switch located in the lower right corner of the front panel AC line power is converted stepped down and converted to DC power by two DC power supplies One supplies 12 VDC for various valves and valve options while a second supply provides 5 VDC and 15 VDC for logic and analog circuitry as well as the TEC cooler All AC and DC Voltages are distributed through the Relay Board A 6 75 ampere circuit breaker is built into the ON OFF switch In case of a wiring fault or incorrect supply power the circuit breaker will automatically turn off the analyzer CAUTION Should the power circuit breaker trip correct the condition causing this situation before turning the analyzer back on ON OFF POWER ENTRANCE Preamp PS 1 5 VDC 15 VDC Chassis Cooling Fan PMT Cooling Fan Display Keypad CPU Mother Board Temperature Sensors PMT Hi
299. or calibrated external thermometer temperature sensor to verify the accuracy of the box temperature 11 5 20 PMT TEMPERATURE PMT temperature should be low and constant It is more important that this temperature is maintained constant than it is to maintain it low The PMT cooler uses a Peltier thermo electric element powered by 12 VDC from the switching power supply PS2 The temperature is controlled by a proportional temperature controller located on the preamplifier board Voltages applied to the cooler element vary from 0 1 to 12 VDC The temperature set point hard wired into the preamplifier board will vary by about 1 C due to component tolerances The actual temperature will be maintained to within 0 1 C around that set point On power up of the analyzer the front panel enables the user to watch that temperature drop from about ambient temperature down to its set point of 6 8 C e Ifthe temperature fails to drop after 20 minutes there is a problem in the cooler circuit Ifthe control circuit on the preamplifier board is faulty a temperature of 1 C is reported 234 04515 Rev B Model 6400E Instruction Manual TROUBLESHOOTING amp REPAIR 11 6 REPAIR PROCEDURES This section contains some procedures that may need to be performed when a major component of the analyzer requires repair or replacement NOTE Servicing of circuit components requires electrostatic discharge protection i e ESD groun
300. ou adjust the setting to an allowable value the ENTR key will re appear 6 1 OVERVIEW OF OPERATING MODES The 6400E software has a variety of operating modes Most commonly the analyzer will be operating in SAMPLE mode In this mode a continuous read out of the SO concentration is displayed on the front panel and output as an analog voltage from rear panel terminals calibrations can be performed and TEST functions and WARNING messages can be examined The second most important operating mode is SETUP mode This mode is used for performing certain configuration operations such as for the iDAS system the reporting ranges or the serial RS 232 RS 485 Ethernet communication channels The SET UP mode is also used for performing various diagnostic tests during troubleshooting Mode Field SAMPLE A RANGE 500 0 PPB SO2 400 0 TST TST gt CAL SETUP ooo oo GO amp Figure 6 1 Front Panel Display The mode field of the front panel display indicates to the user which operating mode the unit is currently running 6400E Rev B 43 Operating Instructions Model 6400E Instruction Manual Besides SAMPLE and SETUP other modes the analyzer can be operated in are Table 6 1 Analyzer Operating modes MODE L EXPLANATION DIAG of the analyzer s diagnostic modes is active see Section 6 9 LO CALA Unit is performing LOW SPAN midpoint calibration initiated automatically by th
301. ouble shooting or a thorough understanding of the analyzer performance are required INSTRUMENT CHASSIS EXHAUST GAS OUTLET KICKER EXHAUST TO PUMP HYDROCARBON SCRUBBER KICKER SAMPLE CHAMBER SAMPLE FILYER ZERO AIR INLET EXHAUST TO OUTER LAYER OF KICKER 2 ISPAN GAS INLET FLOW SENSOR SAMPLE PRESSURE SENSOR i 1 1 1 FLOW PRESSURE 6400E Rev 15 Getting Started Model 6400E Instruction Manual Figure 3 5 Internal Pneumatic Diagram of the 6400E Standard Configuration 3 1 2 1 Calibration Gases ZERO AIR A gas that is similar in chemical composition to the earth s atmosphere but without the gas being measured by the analyzer in this case 502 If your analyzer is equipped with an IZS or external zero air scrubber option it is capable of creating zero air For analyzers without an IZS or external zero air scrubber option a zero air generator such as the Teledyne Instruments Model 701 can be used SPAN GAS A gas specifically mixed to match the chemical composition of the type of gas being measured at near full scale of the desired measurement range In this case SO2 measurements made with the Teledyne Analytical Instruments Model 6400E UV Fluorescence SO2 Analyzer it is recommended that you use a span gas with a SO2 concentration equal to 9096 of the measurement range for your application EXAMPLE If the application
302. output input signal signal or control DIAG UO 20 TEMP TH hy DIAG HO 18 9 DT qute PANT EXIT PREY NEXT IAP EXIT Toggles parameter ON OFF PREY NEXT OFF PRHT EXT DIAG HO 18 ELL HEATER OFF Exit retums to DIAG display amp ali values retum io software control Figure 11 2 Example of Signal I O Function 212 04515 Rev B Model 6400E Instruction Manual TROUBLESHOOTING amp REPAIR 11 1 4 STATUS LEDS Several color coded light emitting diodes LEDs are located inside the instrument to determine if the analyzer s CPU communications bus and relay board are functioning properly 11 1 4 1 Motherboard Status Indicator Watchdog DS5 a red LED on the upper portion of the motherboard just to the right of the CPU board flashes when the CPU is running the main program After power up DS5 should flash on and off about once per second If characters are written to the front panel display but DS5 does not flash then the program files have become corrupted Contact Teledyne Instruments customers service department If 30 60 seconds after a restart DS5 is not flashing and no characters have been written to the front panel display the firmware may be corrupted or the CPU may be defective If DS5 is permanently off or permanently on the CPU board is likely locked up and the analyzer should not respond either with locked up or dark front p
303. ower to the machine Generally all of the setup information will need to be re entered unless the firmware revision has not changed and the analyzer is equipped and properly configured with an EEPROM chip Whenever changing the version of installed software the memory must be reset Failure to ensure that memory is reset can cause the analyzer to malfunction and invalidate measurements Note especially that the A D converter must be re calibrated and all information collected in step 1 above must be re entered before the instrument will function correctly 04515 Rev B 235 TROUBLESHOOTING amp REPAIR Model 6400E Instruction Manual 11 6 2 FLASH CHIP REPLACEMENT OR UPGRADE The 6400E CPU board can accommodate up to two EEPROM flash chips The standard configuration is one chip with 64 kb of storage capacity which is used to store a backup of the analyzer configuration as created during final checkout at the factory Replacing this chip will erase that backup configuration which will be replaced with a new copy when restarting the analyzer However if the firmware and or the DOC is changed at the same time all analyzer configuration settings and iDAS data will be lost In this case refer to the previous section on how to back up your settings 1 Turn off power to the instrument fold down the rear panel by loosening the mounting screws 2 When looking at the electronic circuits from the back of the analyzer locate the EEPROM chip
304. pe and offset zu CONC1 SO concentration for range 1 PPB d CONC2 50 concentration for range 2 PPB STABIL SO concentration stability STRLGT Stray light reading RCTEMP Reaction cell temperature IZS temperature PMT temperature Sample flow cc m SMPFLW Sample pressure VACUUM Vacuum pressure BOXTMP Internal box temperature HVPS High voltage power supply output Volts 2 TESTS Diagnostic test input TEST_INPUT_8 mV _ TEST11 Diagnostic test input TEST_INPUT_11 mV TEMP4 Diagnostic temperature input TEMP_INPUT_4 5 Diagnostic temperature input TEMP_INPUT_5 C L TEMP6 Diagnostic temperature input TEMP_INPUT_6 C REFGND Ground reference REF_GND mV RF4096 ere mV reference REF_4096_MV mV 6400E only 6400EH 05036 Rev C 3 281 APPENDIX A 6 Terminal Command Designators Revision 6400E Instruction Manual APPENDIX A 6 Terminal Command Designators Revision C 3 Table A 7 Terminal Command Designators Revision C 3 COMMAND ADDITIONAL COMMAND SYNTAX DESCRIPTION 1D Display help screen and this list of commands LOGON ID password Establish connection to instrument LOGOFF 1D Terminate connection to instrument SET ALL name h
305. ple gas as it exits the sample chamber 10 4 9 3 Thermistor Interface This circuit provides excitation termination and signal selection for several negative coefficient thermistor temperature sensors located inside the analyzer They are SAMPLE CHAMBER TEMPERATURE SENSOR The source of this signal is a thermistor imbedded in the of the sample chamber block It measures the temperature of the sample gas in the chamber This data are used by the CPU to control sample chamber the heating circuit and as part of the SO calculations when the instrument s Temperature Pressure Compensation feature is enabled This measurement is stored in the analyzer Memory as the Test Function RCEL TEMP and is viewable as a test function see Section 6 2 1 through the analyzer s front panel IZS OPTION PERMEATION TUBE TEMPERATURE SENSOR This thermistor attached to the permeation tube in the IZS option reports the current temperature of that tube to the CPU as part of control loop that keeps the tube at a constant temperature BOX TEMPERATURE SENSOR A thermistor is attached to the motherboard It measures the analyzer s inside temperature This information is stored by the CPU and can be viewed by the user for troubleshooting purposes through the front panel display This measurement is stored in the analyzer Memory as the test function BOX TEMP and is viewable as a test function see Section 6 2 1 through the analyzer s front panel 10 4 10 ANALOG OUT
306. plier array of the PMT is adjusted with a set of two hexadecimal switches Adjusting this voltage directly affects the HVPS voltage and hence the signal from the PMT Secondly the gain of the amplified signal can further be adjusted through a potentiometer These adjustments should only be performed when encountering problems with the software calibration that cannot be rectified otherwise See Section 11 6 3 8 for this hardware calibration O Test Generator PMT Fine Galn Set Rotary Switch Test Control From CPU 1 1 1 1 1 1 Amp to Voltage Converter Amplifier E Test Control From CPU Low Pass Noise Filter Temperature Feedback Circuit Figure 10 17 PMT Preamp Block Diagram The PMT temperature control loop maintains the PMT temperature around 7 C and can be viewed as test function PMT TEMP on the front panel see Section 6 2 1 The electrical test ETEST circuit generates a constant electronic signal intended to simulate the output of the PMT after conversion from current to voltage By bypassing the detector s actual signal it is possible to test most of the signal handling and conditioning circuitry on the PMT preamplifier board See section 6 9 6 for instructions on performing this test The optical test OTEST feature causes an LED inside the PMT cold block to create a light signal that can be measured with the PMT If zero air is supplied
307. r Module ay 2 Turn off the instrument power Open the top cover of the instrument Remove the set screw located the top center of the rear panel e Remove the screws fastening the top cover to the unit four per side Lift the cover straight up Disconnect the sensor module pneumatic lines see Figure 11 7 e Gas inlet line 1 8 black Teflon line with stainless steel fitting e Gas outlet line 1 4 black Teflon line with brass fitting Disconnect all electrical wiring to the Sensor Module e UV lamp power supply wiring Shutter cabling e Reaction cell thermistor wiring yellow Reaction cell heater wiring red UV detector wiring e TEC power cable PMT wiring connectors J5 amp J6 on the PMT preamplifier PCA Remove the three sensor module mounting screws 04515 Rev B 237 TROUBLESHOOTING amp REPAIR Model 6400E Instruction Manual Mounting Screw Mounting Screw Figure 11 8 Sensor Module Mounting Screws Follow the above steps in reverse order to reinstall the sensor module 11 6 3 2 Cleaning the Sample chamber NOTE The sample chamber should only be opened or cleaned on instructions from the Teledyne Instruments customer service department Be careful not to leave thumbprints on the interior of the sample chamber The various oils that make up fingerprints fluoresce brightly under UV light and will significantly affect the accuracy of the an
308. r good thermal conductivity 13 Re insert the TEC subassembly Make sure that the O ring is placed properly and the assembly is tightened evenly 14 Re insert the PMT HVPS subassembly Don t forget the gasket between HVPS and PMT Use new plastic screws to mount the PMT assembly on the PMT cold block 15 Insert the LED and thermistor into the cold bloc 16 Insert new two desiccant bags 17 Carefully replace the end plate sure that the O ring is properly in place Improperly placed O rings will cause leaks which in turn cause moisture to condense on the inside of the cooler causing the HVPS to short out 04515 Rev B 247 TROUBLESHOOTING amp REPAIR Model 6400E Instruction Manual 18 Reconnect the cables and the reaction cell sure to tighten these screws evenly 19 Replace the sensor assembly into the chassis and fasten with four screws and washers 20 Perform a leak check the system 21 Power up the analyzer and verify the basic operation of the analyzer using the ETEST and OTEST features see Section 6 9 5 amp 6 9 6 or by measuring calibrated zero and span gases 22 Allow the instrument to warm up for 60 minutes 23 Perform a PMT Hardware calibration see Section 11 6 3 8 24 Perform a zero point and span calibration See Chapter 7 11 6 3 8 PMT Hardware Calibration FACTORY CAL The sensor module hardware calibration adjusts the slope of the PMT output when the Instruments
309. r their electronic signal levels may be configured for different ranges e g 0 10 VDC vs 0 1 VDC See Section 6 9 4 1 Dual range DUAL allows the A1 and A2 outputs to be configured with different measurement spans see Section 6 7 5 e Auto range AUTO mode gives the analyzer to ability to output data via a low range and high range When this mode is selected see Section 6 7 6 the 6400E will automatically switch between the two ranges dynamically as the concentration value fluctuates Also in this mode the RANGE Test function displayed on the front panel during SAMPLE mode will be replaced by two separate functions range1 amp range2 Range status is also output via the External Digital I O Status Bits see Section 6 12 1 1 To select the Analog Output Range Type press SAMPLE RANGE 500 000 PPB 502 XXX X TST TST gt CAL SETUP SAMPLE ENTER SETUP PASS 818 8 1 8 ENTR EXIT SETUP XX RANGE CONTROL MENU SETUP X X MODE SET UNIT EXIT CFG D amp S RNGE PASS CLK MORE EXIT SETUP XX RANGE MODE SNGL EXIT Retums to the Main SNGL DUAL AUTO ENTR EXIT SAMPLE Display range modes may be active at am GoTo GoTo Go To aoe od Section Section Section 674 675 676 Only one of the 56 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 7 4 SINGLE RANGE MODE SNGL The default range mode for the analyzer is single range in which
310. rately on each applicable range Calibration documentation should be maintained with each analyzer and also in a central backup file 6400E Rev B 153 EPA Protocol Calibration Model 6400E Instruction Manual Table 8 1 Activity Matrix for Calibration Equipment amp Supplies chart width of 150 mm 6 in is recommended FREQUENCY AND ACTION IF EQUIPMENT amp ACCEPTANCE LIMITS METHOD OF REQUIREMENTS ARE MEASUREMENT NOT MET Recorder Compatible with output Check upon receipt Return equipment to signal of analyzer min supplier Sample line and Constructed of PTFE or Check upon receipt Return equipment to 2 3 2 Q A Handbook manifold glass supplier Calibration Meets guidelines of See Section 2 3 9 Q A Return equipment equipment reference 1 and Section Handbook supplies to supplier or take corrective action Traceable to NIST SRM meets limits in traceability protocol for Working standard SO cylinder gas or SO permeation tube accuracy and stability see Section 2 0 7 Q A Handbook Zero air Clean dry ambient air free of contaminants that cause detectable response with the SO analyzer Record form Must not be the same as used for calibration Audit equipment Table 8 2 Develop standard forms Analyzed against NIST SRM see protocol in Section 2 0 7 Q A Handbook Obtain new working standard an
311. re 3 1 for the locations of pneumatic connections on the rear panel and Table 3 4 for nomenclature NOTE Sample and calibration gases should only come into contact with PTFE Teflon or glass or materials They should not come in contact with FEP or stainless steel materials MODEL 701 Zero Air Generator Source of MODEL 700 SAMPLE Gas VENT Removed Gas Dilution during ifl sample gas is supp alibrator Calibration with Ozone Bench Optlon allbrated S0 GAS At high concentration gt Figure 3 6 Pneumatic Connections Basic Configuration Using Gas Dilution Calibrator MODEL 701 Zero Air Generator Source of SAMPLE Gas VENT Removed 9 m 3 way Valve during if sample gas is supp Calibration 5 Needle valve to flow LN alibrated SO GAS At high concentration Sample E ec M ODEL 2d 6400E Zero Air 2 gt Figure 3 7 Pneumatic Connections Basic Configuration Using Bottled Span Gas 6400E Rev B 17 Getting Started Model 6400E Instruction Manual 1 Attach the 1 4 exhaust line to the exhaust port of the analyzer CAUTION The exhaust from the analyzer needs to be vented outside the shelter or immediate area surrounding the instrument and conform to all safety requirements using a maximum of 10 meters of 1 4 PTFE tubing 2 Attach the sample line to the sampl
312. reanpedeatanenesnonnneoraen 190 PMT Cooling System 191 PMT Preamp Block Diagram 192 Relay Board Status LED Locations ssseeannnnsnnrreerennnereerernnssnansnnnnanererennaennnannnnnn 194 Power Distribution Block nenne nene nnne nnne nne 198 6400E Rev B Model 6400E Instruction Manual Figure 10 20 Interface Block Diagramm ccsseccescsnntseeesscensnnenenaaneseeneneaenaneeansagaarennenannanenen ens 199 Figure 10 21 6400E Front Panel Layout eee 200 Figure 10 22 Keyboard and Display Interface Block Diagram 201 Figure 10 23 Basic Software 204 Figure 11 1 Viewing and Clearing warning messages 208 Figure 11 2 Example of Signal I O Function 212 Figure 11 3 CPU Status Indicator 213 Figure 11 4 Simple Leak Check Fixture 222 Figure 11 5 Hydrocarbon Scrubber Leach check Set Up 223 Figure 11 6 Location of Relay Board Power Configuration Jumper 225 Figure 11 7 Sensor Module Wiring and Pneumatic Fittings 236 Figure 11 8 Sensor Module Mounting Screws 238 Figure 11 9 Sample Chamber Mounting Bracket cccsseccsseeseecsseeees 239 Figure 11 10 Hex Screw Between Lens Housing and Sample chamber 240 Figure 11 11 UV Lens Housing Filter Housing
313. reatly increased number of electrons emitted from one end of electron multiplier are collected by a positively charged anode at the other end which creates a useable current signal This current signal is amplified by the preamplifier board and then reported to the motherboard 04515 Rev B 189 Theory Of Operation Model 6400E Instruction Manual Dynode Focusing Electrode Electron Muhiplier Figure 10 15 Basic PMT Design A significant performance characteristic of the PMT is the voltage potential across the electron multiplier The higher the voltage the greater is the number of electrons emitted from each dynode of the electron multiplier making the PMT more sensitive and responsive to small variations in light intensity but also more noisy dark noise The gain voltage of the PMT used in the 6400E is usually set between 450 V and 800 V This parameter is viewable through the front panel as test function HVPS see Section 6 2 1 For information on when and how to set this voltage see Section 11 6 3 8 The PMT is housed inside the PMT module assembly see Figure 10 12 amp 10 14 This assembly also includes the high voltage power supply required to drive the PMT an LED used by the instrument s optical test function a thermistor that measures the temperature of the PMT and various components of the PMT cooling system including the thermo electric cooler TEC 190 04515 Rev B Model 6400E Instruction Manual Theor
314. rity password The default password is 818 This allows access to all of the instruments basic functions and operating modes as well as some of its more powerful diagnostic tools and variables The analyzer will automatically insert 818 into the password prompt field Simply press ENTR to proceed Other password levels exist allowing access to special diagnostic tools and variables used only for specific and rarely needed troubleshooting and adjustment procedures They may be made available as needed by Teledyne Instruments Customer Service department 6 5 SETUP CFG VIEWING THE ANALYZER S CONFIGURATION INFORMATION Pressing the CFG key displays the instrument configuration information This display lists the analyzer model serial number firmware revision software library revision CPU type and other information Use this information to identify the software and hardware when contacting customer service Special instrument or software features or installed options may also be listed here SAMPLE RANGE 500 000 PPB S02 XXX X lt TST TST gt CAL SETUP SAMPLE ENTER SETUP PASS 818 Press NEXT of PREV to move back 8 1 8 ENTR EXIT and forth through the following list of Configuration Information MODEL NAME SAMPL RY 5 SEERIAL NUMER MPLE PRIMA ETUP MENU Press EXIT at any time to E ART REVISION CFG DAS RNGE PASS CLK MORE EXIT return to the SAMPLE display p 7 iCHIP SOFTWARE REVISION HESSEN PROTOCO
315. rom the front panel The full flow diagrams of the standard configuration see Figure 3 5 and with options installed see Figure 5 2 and 5 3 help in trouble shooting flow problems In general flow problems can be divided into three categories Flow is too high Flow is greater than zero but is too low and or unstable Flow is zero no flow When troubleshooting flow problems it is essential to confirm the actual flow rate without relying on the analyzer s flow display The use of an independent external flow meter to perform a flow check as described in Section 11 5 2 is essential 11 2 1 ZERO OR LOW SAMPLE FLOW If the pump is operating but the unit reports a XXXX gas flow do the following three steps e Check for actual sample flow e Check pressures Carry out a leak check To check the actual sample flow disconnect the sample tube from the sample inlet on the rear panel of the instrument Make sure that the unit is in basic SAMPLE mode Place a finger over the inlet and see if it gets sucked in by the vacuum or more properly use a flow meter to measure the actual flow If there is proper flow of around 650 cm3 min contact customer service If there is no flow or low flow continue with the next step Check that the sample pressure is at or around 28 or abouti in Hg A below ambient atmospheric pressure 11 2 2 HIGH FLOW Flows that are significantly higher than the allowed operating range typically 10 11 of t
316. rrent if waming messages re appear TST TST gt CAL MSG CLR SETUP waming message the cause needs to be found Do if more than one waming is aclive the message wili take fis place Once the last waming has been cleared the analyzer returns to SAMPLE Mode not repeatedly clear warnings without corrective action Figure 11 1 Viewing and Clearing warning messages 208 04515 Rev B Model 6400E Instruction Manual TROUBLESHOOTING amp REPAIR Table 11 1 Warning Messages Indicated Failures WARNING MESSAGE FAULT CONDITION POSSIBLE CAUSES ANALOG CAL The instruments A D A parameter for one of the analog outputs even one not currently WARNING circuitry or one of its being used has been changed and the analog output analog outputs is not calibration routine was not re run calibrated A D circuitry failure on motherboard Other motherboard electronic failure BOX TEMP Box Temp is lt 5 Cor NOTE Box temperature typically runs 7 c warmer than ambient WARNING gt 48 C temperature Poor blocked ventilation to the analyzer Stopped exhaust fan Ambient temperature outside of specified range CANNOT DYN Dynamic Span Measured concentration value is too high or low SPAN operation failed Concentration slope value to high or too low CANNOT DYN Dynamic Zero Measured concentration value is too high ZERO operation failed Concentration offset
317. rt of the analyzer s system cannot provide information about the portions of the system not checked and therefore cannot be used as a verification of the overall analyzer calibration 6400E Rev B 157 EPA Protocol Calibration Model 6400E Instruction Manual 8 3 ZERO AND SPAN CHECKS A system of Level 1 and Level 2 zero span checks see Table 8 4 is recommended These checks must be conducted in accordance with the specific guidance given in Subsection 9 1 of Section 2 0 9 Handbook It is recommended Level 1 zero and span checks conducted every two weeks Level 2 checks should be conducted in between the Level 1 checks at a frequency desired by the user Span concentrations for both levels should be between 70 and 90 of the measurement range Zero and span data are to be used to e Provide data to allow analyzer adjustment for zero and span drift e Provide a decision point on when to calibrate the analyzer e Provide a decision point on invalidation of monitoring data Items 1 and 2 are described in detail in Subsection 9 1 3 of Section 2 0 9 Q A Handbook Item 3 is described in Subsection 9 1 4 of the same section Refer to the Troubleshooting Chapter 11 of this manual if the instrument is not within the allowed variations 8 3 1 ZERO SPAN CHECK PROCEDURES The Zero and Span calibration can be checked a variety of different ways They include e Manual Zero Span Check Zero and Span can be checked from
318. rt to configure ID COMI CONG EXIT COM1 E7 1 MODE OFF PREY NEXT OFF The sum of the mode 1Ds of the selected modes is displayed here COM1 MODE 0 7 1 MODE ON ENTR key accepts the new settings ENTR EXIT EXIT key ignores the new settings 6 12 4 4 Selecting a Hessen Protocol Type Currently there are two version of Hessen Protocol in use The original implementation referred to as TYPE 1 and a more recently released version TYPE 2 that has more flexibility when operating with instruments that can measure more than one type of gas For more specific information about the difference between TYPE Land TYPE 2 download the Manual Addendum for Hessen Protocol from the Teledyne Instruments web site http www teledyne AI com manuals To select a Hessen Protocol Type press SAMPLE RANGE 600 000 PPB 502 XXX X TST TST CAL SETUP SETUP X X COMMUNICATIONS MENU SAMPLE ENTER SETUP PASS 818 20 HESN B 4 8 ENTR EXIT i SETUP X HESSEN VARIATION TYPE 4 SETUP X X PRIMARY SETUP MENU SET EDIT EXIT CFG DAS RNGE PASS CLK MORE EXIT 2A ux ENTR key accepts the i new settings SETUP X HESSEN VARIATION TYPE 1 EXIT key ignores the SETUP xx SECONDARY SETUP MENU new settings TYE1 TYPE2 EXIT COMM SETUP HESSEN VARIATION TYPE 2 Press to c
319. rticular function Table 11 6 Relay Board Control Devices FUNCTION ValveO Valve3 Valve4 Valve7 All heaters CONTROL DEVICE SOCKETED 11 5 9 MOTHERBOARD 11 5 9 1 A D functions A basic check of the analog to digital A D converter operation on the motherboard is to use the Signal I O function under the DIAG menu Check the following two A D reference voltages and input signals that can be easily measured with a voltmeter Using the Signal 1 0 function see Section 6 9 2 and Appendix D view the value of REF 4096 MV and REF GND e The nominal value for REF 4096 MV is 4096 mV 10 mV The nominal value for REF GND is 0 mV 3 mV respectively of their nominal values 4096 and 0 and are If these signals are stable to within 0 5 mV the basic A D converter is functioning properly e If these values fluctuate largely or are off by more than specified above one or more of the analog circuits may be overloaded or the motherboard may be faulty Choose one parameter in the Signal 1 0 function such as SAMPLE PRESSURE see previous section on how to measure it Compare its actual voltage with the voltage 04515 Rev B 227 TROUBLESHOOTING amp REPAIR Model 6400E Instruction Manual displayed through the SIGNAL I O function If the wiring is intact but there is a difference of more than 10 mV between the measured and displayed voltage the motherboard may be faulty 11 5 9 2 Anal
320. ruction Manual There are two methods to activate control inputs The internal 5V available from the pin is the most convenient method see Figure 6 18 However to ensure that these inputs are truly isolated a separate external 5 VDC power supply should be used see Figure 6 19 Figure 6 18 LI ZERO SPAN Control Inputs with local 5 V power supply ZERO SPAN 5 VDC Power Supply Figure 6 19 Control Inputs with external 5 V power supply 122 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 12 2 REMOTE OPERATION USING THE EXTERNAL SERIAL I O 6 12 2 1 Terminal Operating Modes The Model 6400E can be remotely configured calibrated or queried for stored data through the serial ports As terminals and computers use different communication schemes the analyzer supports two communicate modes specifically designed to interface with these two types of devices Computer mode is used when the analyzer is connected to a computer with a dedicated interface program such as APICOM More information regarding APICOM can be found in later in this section or on the Teledyne Instruments website at http www teledyne api com software apicom Interactive mode is used with a terminal emulation programs such as HyperTerminal or a dumb computer terminal The commands that are used to operate the analyzer in this mode are listed in Table 6 24 a
321. ry Of Operation Model 6400E Instruction Manual at the speed of sound pass through the orifice Because the flow rate of gas through the orifice is only related to the minimum 2 1 pressure differential and not absolute pressure the flow rate of the gas is also unaffected by degradations in pump efficiency due to age The critical flow orifice used in the Model 6400E is designed to provide a flow rate of 650 cm min 10 3 3 SAMPLE PARTICULATE FILTER To remove particles in the sample gas the analyzer is equipped with a Teflon membrane filter of 47 mm diameter also referred to as the sample filter with a 1 pore size The filter is accessible through the front panel which folds down and should be changed according to the suggested maintenance schedule in Table 9 1 10 3 4 HYDROCARBON SCRUBBER Kicker It is very important to make sure the air supplied sample chamber is clear of hydrocarbons To accomplish this task the 6400E uses a single tube permeation scrubber The scrubber consists of single tube of a specialized plastic that absorbs hydrocarbons very well This tube is located within outer flexible plastic tube shell As gas flows through the inner tube hydrocarbons are absorbed into the membrane walls and transported through the membrane wall and into the hydrocarbon free purge gas flowing through the outer tube This process is driven by the hydrocarbon concentration gradient between the inner and outer of the tubes CLE
322. s VALVE PORT MODE VALVE CONDITION CONNECTION FIG 5 2 Sample Cal Open to SAMPLE inlet 322 SAMPLE Zero Span Open to ZERO AIR inlet 322 Sample Cal Open to zero span inlet 122 ZERO CAL Zero Span Open to ZERO AIR inlet 322 Sample Cal Open to zero span inlet 122 SPAN CAL Zero Span Open to SPAN GAS inlet 122 6400E Rev B 35 Optional Hardware and Software Model 6400E Instruction Manual The state of the zero span valves can also be controlled e Manually from the analyzer s front panel by using the SIGNAL 1 0 controls located under the DIAG Menu see Section 6 9 2 activating the instrument s AutoCal feature see Section 7 8 e Remotely by using the external digital control inputs see Section 6 12 1 2 and Section 7 7 1 or e Remotely through the RS 232 485 serial 1 0 ports see Appendix A 6 for the appropriate commands Sources of zero and span gas flow must be capable of supplying at least 600 cm min Both supply lines should be vented outside of the analyzer s enclosure In order to prevent back diffusion and pressure effects these vent lines should be between 2 and 10 meters in length 5 4 2 INTERNAL ZERO SPAN GAS GENERATOR OPTION 51 The 6400E can be equipped with an internal zero air and span gas generator IZS This option includes a heated enclosure for a permeation tube an external scrubber for producing zero air and a set of valves for switching between the sa
323. s drifts in the analyzer response LEVEL 2 ZERO AND SPAN CHECK A Level 2 zero and span check is an unofficial check of an analyzer s response It may include dynamic checks made with uncertified test concentrations artificial stimulation of the analyzer s detector electronic or other types of checks of a portion of the analyzer etc Level 2 zero and span checks are not to be used as a basis for analyzer zero or span adjustments calibration updates or adjustment of ambient data They are intended as quick convenient checks to be used between zero and span calibrations to check for possible analyzer malfunction or calibration drift Whenever a Level 2 zero or span check indicates a possible calibration problem a Level 1 zero and span or multipoint calibration should be carried out before any corrective action is taken If a Level 2 zero and span check is to be used in the quality control program a reference response for the check should be obtained immediately following a zero and span or multipoint calibration while the analyzer s calibration is accurately known Subsequent Level 2 check responses should then be compared to the most recent reference response to determine if a change in response has occurred For automatic Level 2 zero and span checks the first scheduled check following the calibration should be used for the reference response It should be kept in mind that any Level 2 check that involves only pa
324. s Output nnne nnn nennen nnn nnne nene 120 Control Inputs with local 5 V power supply 122 Control Inputs with external 5 V power supply 122 APICOM Remote Control Program 129 Setup for Manual Calibration without Z S valve or IZS Option 139 Setup for Manual Calibration with Z S Valve Option Installed 142 Setup for Manual Calibration Check with Z S Valve or 175 Option 145 Sample Particulate Filter Assembly 166 Critical Flow Orifice Assembly 168 UV Absorption UV Light Path Source UV Lamp 6 6 Excitation Lamp UV Spectrum Before After Filtration PMT Optical Filter Bandwidth Effects of Focusing Source UV in Sample Chamber 177 6400 Gas Flow and Location of Critical Flow 180 Flow Control Assembly amp Critical Flow Orifice 181 6400E Hydrocarbon Scrubber Kicker 182 6400E Electronic Block nennen 184 6400 CPU Board cccccnnscsccecescnsaneveneansnsonnaesseneesnseesenennansenseaeenah 186 6400E Sensor Module 6400E Sample Chamber PMT Housing Assembly n ans nneserserssresesnenessessnreerorernenneennanennnnnrentrenanenannnaaaneaen 189 Basic Design eressnsnsasrnresceenenrneessenansereerensnennnrnnnnennsnara
325. s as measured by the instrument s sample pressure sensor in Hg A SAMP PRESS SLOPE Sample pressure slope correction factor The default setting for Section 6 8 describes the method for enabling disabling the TPC feature 10 7 4 INTERNAL DATA ACQUISITION SYSTEM IDAS The iDAS is designed to implement predictive diagnostics that stores trending data for users to anticipate when an instrument will require service Large amounts of data can be stored in non volatile memory and retrieved in plain text format for further processing with common data analysis programs The iDAS has a consistent user interface in all Teledyne Analytical instruments New data parameters and triggering events can be added to the instrument as needed Depending on the sampling frequency and the number of data parameters the iDAS can store several months of data which are retained even when the instrument is powered off or a new firmware is installed The iDAS permits users to access the data through the instrument s front panel or the remote interface The latter can automatically download stored data for further processing For information on using the iDAS refer to Sections 6 11 User Notes 206 04515 Rev B Model 6400E Instruction Manual TROUBLESHOOTING amp REPAIR 11 TROUBLESHOOTING amp REPAIR This section contains a variety of methods for identifying and solving performance problems with the analyzer Caution The operations outl
326. s basic calibration and calibration check operations Chapter 8 describes how to perform an APE protocol calibration For more information concerning the zero span zero span shutoff and IZS valve options see Section 5 4 48 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 3 2 SETUP PASS CALIBRATION PASSWORD SECURITY The 6400E calibration functions may be password protected for to prevent inadvertent adjustments When the calibration password has been enabled using the PASS menu item found under the Setup Menu see below the system will prompt the user for a password anytime CAL CALZ CALS activated The default status of the calibration password is OFF To enable the calibration password press SAMPLE RANGE 500 0 PPB 502 XXX X TST TST gt CAL SAMPLE ENTER SETUP PASS 818 8 1 8 E EXIT SETUP XX PRIMARY SETUP MENU CFG DAS RNGE a CLK MORE ExT SETUP CAL PASSWORD ENABLE OFF ENTR accepts displayed password value EXIT retums to SAMPLE display CAL PASSWORD default state is Toggles password status OFF ENTR EXIT 3 ETUP PASSWORD ENABLE ON ENTR EXIT ENTR accepts he change EXIT ignores the change SETUP XX PASSWORD ENABLE ON ON ENTR EXIT If the calibration password 100 is enabled the following keypad sequence will be required to enter one of the cali
327. s by executing user defined sequences to initiate the various calibration modes of the analyzer and to open and close valves appropriately It is possible to program and run up to three separate sequences SEQ1 SEQ2 and SEQ3 Each sequence can operate in one of three modes or be disabled Table 7 2 AutoCal Modes MODE ACTION DISABLED Disables the sequence ZERO Causes the sequence to perform a zero calibration or check ZERO SPAN Causes the sequence to perform a zero and span concentration calibration or check SPAN Causes the sequence to perform a span concentration calibration or check Each mode has seven parameters that control operational details of the sequence Table 7 3 AutoCal Attribute Setup Parameters ATTRIBUTE NAME ACTION Timer Enabled Turns on the Sequence timer Starting Date Sequence will operate on Starting Date Starting Time Sequence will operate at Starting Time Delta Days Number of days to skip between each sequence Delta Time Incremental delay on each Delta Day that the sequence starts Duration Duration of the sequence in minutes Enable to do dynamic zero span calibration disable to do a cal Calibrate check only This must be set to OFF for units used in US EPA applications and with IZS option installed The programmed STARTING TIME must be a minimum of 5 minutes later than the real time clock See Section 6 6 for setting real time clock 2 Avoid setting t
328. s installed in the IZS oven assembly e Check front panel for correct software configuration When the instrument is in SAMPLE mode the front panel display should show CALS and CALZ buttons in the second line of the display The presence of the buttons indicates that the option has been enabled in software In addition the IZS option is enabled if the TEST functions show a parameter named IZS TEMP The IZS option is heated with a proportional heater circuit and the temperature is maintained at 50 C 1 Check the IZS TEMP function via front panel display see Section 6 2 1 and the IZS TEMP signal voltage using the SIGNAL I O function under the DIAG Menu see Section 6 9 2 e 50 the temperature signal from the IZS thermistor should be around 2500 mV 11 5 19 BOX TEMPERATURE The box temperature sensor thermistor is mounted on the motherboard at the bottom right corner of the CPU board when looking at it from the front It cannot be disconnected to check its resistance Box temperature will vary with but will always read about 5 C higher than ambient room temperature because of the internal heating zones sample chamber and other devices To check the box temperature functionality we recommend to check the BOX TEMP signal voltage using the SIGNAL 1 0 function under the DIAG Menu see Section 6 9 2 e At about 30 C 5 above typical room temperature the signal should be around 1500 mV We recommend to use a certified
329. s it DIL_FACTOR 1 0 1 1000 Dilution factor if dilution enabled with FACTORY OPT variable USER UNITS PPB PPM PPB PPM Concentration units for user interface Enclose value in double quotes when setting from the RS 232 interface LAMP_CAL mv 3500 1000 5000 Last calibrated UV lamp reading 268 05036 Rev C 3 Model 6400E Instruction Manual APPENDIX 2 Setup Variables For Serial I O Revision C 3 SO2 OFFSETI SO2 SPAN2 Conc S02 SLOPE2 PPB mV PPM mv SO2 OFFSET2 mV 0 NUMERIC DEFAULT SETUP VARIABLE UNITS VALUE VALUE RANGE L DESCRIPTION LAMP 0 9 0 5 1 5 UV lamp compensation attenuation factor TEMPCO GAIN 0 0 2 Temperature coefficient attenuation factor for pressure readings SLOPE CONST 8 6 25 0 1 10 Constant to make visible slope close to 1 DARK ENABLE 4 ON OFF OFF ON ON enables PMT UV dark calibration OFF disables it DARK FREQ Minutes 30 720 0 1 1440 Dark calibration period DARK DWELL Seconds 10 1 60 Dwell time after closing dark shutter or turning off lamp or selecting E preamp range DARK POST DWELL Seconds 10 30 1 180 Dwell time after opening dark shutter or turning on lamp DARK SAMPLES Samples 5 1 10 Number of dark samples to average DARK FSIZE Samples 2 1 100 Dark offset moving average filter size DARK_LIMIT mv 200 400 0 1000
330. s 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 GENERAL SAFETY HAZARD Refer to the instructions for details on the specific hazard CAUTION Hot Surface Warning CAUTION Electrical Shock Hazard TECHNICIAN SYMBOL All operations marked with this symbol are to be performed by qualified maintenance personnel only 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 ensue with possible hazardous consequences NOTE Technical Assistance regarding the use and maintenance of the Model 6400E UV Fluorescence SO Analyzer or any other Teledyne Instruments product can be obtained by Contacting Teledyne Analytical Instruments Customer Service Department at 626 934 1673 6400E Rev B i Model 6400E Instruction Manual TABLE OF CONTENTS 1 6400E DOCUMENTATION ccccccsccenscessnnscecnennnenceneeessnsneaseraesunneeeeee ana resa ea ah eh hanh enin 1 1 1 Using This Manual serene 2 SPECIFICATIONS APPROVALS AND WARRANTY eene 2 1 Specifications 2 2 EPA Equivalency Designation 2 3 CE
331. sample flow calculation 05036 Rev C 3 269 APPENDIX 2 Setup Variables For Serial I O Revision Model 6400E Instruction Manual BAUD_RATE T NUMERIC DEFAULT SETUP VARIABLE UNITS VALUE VALUE RANGE DESCRIPTION SAMP_PRESS_SET Hg 29 92 0 100 Sample pressure set point for pressure MITTERE a T RED compensation and warning limits Warnings 15 35 SAMP PRESS SLOPE 1 0 5 1 5 Sample pressure slope correction factor adjusted pressure measured pressure x slope VAC PRESS SET Hg 6 0 100 Vacuum pressure set point for 3 10 nicae compensation and warning BOX SET oc 30 5 60 Box temperature warning limits Set Warnings 8 50 point is not used PMT SET oc 7 0 40 PMT temperature set point and _ Warnings warning limits RS232_MODE BitFlag 0 0 65535 RS 232 COM1 mode flags Add values 300 1200 2400 4800 9600 19200 38400 57600 to combine flags 1 quiet mode 2 computer mode 4 enable security 16 enable Hessen protocol 32 enable multi drop 64 enable modem 128 ignore RS 232 line errors 256 disable XON XOFF support 512 disable hardware FIFOs 1024 enable RS 485 mode goan even parity 7 data bits 1 stop 4096 enable command prompt RS 232 COM1 baud rate Enclose value in double quotes when setting from the RS 232 interface 115200 MODEM_INIT AT
332. sasansassannrnasarsreaasaneaanannsyraanransenasreeraesareensneraysaanaannanenareeseraaaaaranasasaana 10 4 1 1 Disk On Chip 10 4 1 2 Flash Chip 10 4 2 Sensor Module 10 4 2 1 Sample Chamber 10 4 2 2 Sample Chamber Heating Circuit 10 4 3 Photo Multiplier Tube PMT 10 4 4 PMT Cooling System 10 4 4 1 Thermoelectric Cooler TEC 10 4 4 2 TEC Control Board 10 4 5 PMT Preamplifier 10 4 6 Pneumatic Sensor Board 10 4 7 Relay Board 10 4 7 1 Heater Contro 10 4 7 2 Valve Control 10 4 8 Status LEDs amp Watch Dog Circuitry 10 4 9 Motherboard 10 4 9 1 A to D ConversiOn nnn nene natus nnne nennen 10 4 9 2 Sensor Inputs ssesssrersssssssesereersnearnannnrenreenaaenanaansnnenansnassenssarraasansanarannnavanarnennanan 10 4 9 3 Thermistor Interface 10 4 10 Analog Outputs 10 4 11 External Digital 1 0 6400E Rev B Model 6400E Instruction Manual 10 4 12 C Data Bus i E 197 10 4 13 Power up Circuit 10 5 Power Supply Circuit Breaker 10 6 Communications Interface 10 6 1 Front Panel Interface 10 6 1 1 Analyzer Status LED s 10 6 1 2 Keyboard 10 6 1 3 Display 10 6 1 4 Keyboard Display Interface Electronics 10 7 Software Operation 10 7 1 Adaptive Filter 10 7 2 Calibration Slope and Offset 10 7 3 Temperature and Pr
333. se the instrument is mounted in a rack If necessary squeeze the clips for a tighter grip on the cartridge 9 3 4 CHANGING CRITICAL FLOW ORIFICES A critical flow orifice located on the exhaust manifold maintains the proper flow rate of gas through the 6400E analyzer Refer to section 10 3 2 1 for a detailed description of its functionality and location Despite the fact this these device is protected by sintered stainless steel filters it can on occasion clog particularly if the instrument is operated without a sample filter or in an environment with very fine sub micron particle size dust 1 Turn off power to the instrument and vacuum pump 2 Locate the exhaust manifold see Figure 3 9 3 Disconnect the pneumatic line 4 Unscrew the NPT fitting D Gas Line fitting Ut CJ 1 C34 Sintered Filter O Ring 5 4 Critica Flow Orifice 4 0 89 Figure 9 2 Critical Flow Orifice Assembly 5 Take out the components of the assembly a spring a sintered filter two O rings and the orifice 168 04515 Rev B Model 6400E Instruction Manual Instrument Maintenance You may need to use a scribe or pressure from the vacuum port to get the parts out of the manifold Discard the two O rings and the sintered filter Replace the critical flow orifice Let the part dry Re assemble the parts as shown Figure 9 2 using new filter and o rings 10 Reinstall the NPT f
334. semanennenaanennea 22 Current Loop Option Installed on the Motherboard Pneumatic Diagram of the 6400E With Z S Option Installed Pneumatic Diagram of the 6400E with IZS Options Installed 6400E Multidrop Card nennen nnne 39 6400E Ethernet 6400E Rear Panel with Ethernet Installed Front Panel Display 43 Viewing 6400E TEST Functions 46 Viewing and Clearing 6400E WARNING Messages 47 Analog Output Connector 254 Setup for Calibrating Analog Outputs cdd Setup for Calibrating Current Outputs isse 076 Back Panel connector Pin Outs for COM1 amp COM2 in RS 232 mode 86 CPU connector Pin Outs for COM1 amp COM2 in RS 232 mode 487 CPU card Locations of RS 232 486 Switches Connectors and Jumpers 88 Back Panel connector Pin Outs for 2 RS 485 mode 89 CPU connector Pin Outs for 2 in RS 485 mode a BO Location of 2 2 on RS232 Multidrop PCA option 62 96 RS232 Multidrop PCA Host Analyzer Interconnect Diagram 97 Default iDAS Channels 106 Sample APICOM user interface for configuring the iDAS 118 iDAS Configuration Through a Terminal Emulation Program eene 119 Statu
335. ship This relationship is derived from the instrumental response to successive samples of different known concentrations As a minimum three reference points and a zero point are recommended to define this relationship The true values of the calibration gas must be traceable to NIST SRM s See Table 7 1 All monitoring instrument systems are subject to some drift and variation in internal parameters and cannot be expected to maintain accurate calibration over long periods of time Therefore it is necessary to dynamically check the calibration relationship on a predetermined schedule Zero and span checks must be used to document that the data remains within control limits These checks are also used in data reduction and validation Table 8 1 summarizes the initial quality assurance activities for calibrating equipment Table 8 2 is a matrix for the actual dynamic calibration procedure Calibrations should be carried out at the field monitoring site The Analyzer should be in operation for at least several hours preferably overnight before calibration so that it is fully warmed up and its operation has stabilized During the calibration the 6400E should be in the CAL mode and therefore sample the test atmosphere through all components used during normal ambient sampling and through as much of the ambient air inlet system as is practicable If the Instrument will be used on more than one range i e DUAL or AUTO ranges it should be calibrated sepa
336. slope and offset values are outside of the acceptable range and all other more obvious causes for this problem have been eliminated Connector to TEC control toard Coarse Adjustment HVPS Fine Adjustment Gain Adjustment Conligutetion Plug onnector to Signals conneaor to Power OTEST Adjustment ETEST Adjustment Connector to end Figure 11 17 Pre Amplifier Board Layout 1 Set the instrument reporting range type to SNGL see Section 6 7 4 2 Perform a zero point calibration using zero air see Chapter 7 3 Let the instrument stabilize by allowing it to run for one hour 4 Adjust the UV Lamp See Section 11 6 3 1 5 Perform a LAMP CALIBRATION procedure see Section 6 9 7 6 Locate the Preamp board see Figure 3 9 248 04515 Rev B Model 6400E Instruction Manual TROUBLESHOOTING amp REPAIR 7 10 11 12 13 Locate the Following Components On the Preamp board see Figure 11 17 HVPS coarse adjustment switch Range 0 9 then A F e HVPS fine adjustment switch Range 0 9 then A F Gain adjustment potentiometer Full scale is 10 to 12 turns Set the HVPS coarse adjustment to its minimum setting 0 Set the HVPS fine adjustment switch to its maximum setting F Turn the gain adjustment potentiometer clockwise to its maximum setting Set the front panel display to show STABIL see Section 6 2 1 Feed span gas into the analyzer Wait until the STABI
337. ss A Tested on 21 February 2003 08 March 2003 at CKC Laboratories Inc Report Number CE03 021A Safety Compliance The Teledyne Analytical Instruments UV Fluorescence SO Analyzer 6400E was tested and found to be fully compliant with IEC 61010 1 90 A1 92 A2 95 Issued by CKC Laboratories on 4 April 2003 Report Number WO 80146 2 4 WARRANTY Warranty Policy Prior to shipment Teledyne Analytical Instruments equipment is thoroughly inspected and tested Should equipment failure occur Teledyne Analytical Instruments assures its customers that prompt service and support will be available Coverage After the warranty period and throughout the equipment lifetime Teledyne Analytical Instruments stands ready to provide on site or in plant service at reasonable rates similar to those of other manufacturers in the industry All maintenance and the first level of field troubleshooting is to be performed by the customer Non TELEDYNE ANALYTICAL INSTRUMENTS Manufactured Equipment Equipment provided but not manufactured by Teledyne Analytical Instruments is warranted and will be repaired to the extent and according to the current terms and conditions of the respective equipment manufacturers warranty General Teledyne Analytical Instruments warrants each product manufactured by Teledyne Analytical Instruments to be free from defects in material and workmanship under normal use and service for a period of one year from the da
338. strument stores and reports an instantaneous reading of the selected parameter at the end of the chosen REPORT PERIOD In AVG MIN or MAX sample modes the settings for the SAMPLE PERIOD and the REPORT PERIOD determine the number of data points used each time the average minimum or maximum is calculated stored and reported to the COMM ports The actual sample readings are not stored past the end of the of the chosen REPORT PERIOD Also the SAMPLE PERIOD and REPORT PERIOD intervals are synchronized to the beginning and end of the appropriate interval of the instruments internal clock If SAMPLE PERIOD were set for one minute the first reading would occur at the beginning of the next full minute according to the instrument s internal clock e Ifthe REPORT PERIOD were set for of one hour the first report activity would occur at the beginning of the next full hour according to the instrument s internal clock EXAMPLE Given the above settings if iDAS were activated at 7 57 35 the first sample would occur at 7 58 and the first report would be calculated at 8 00 consisting of data points for 7 58 7 59 and 8 00 During the next hour from 8 01 to 9 00 the instrument will take a sample reading every minute and include 60 sample readings When the STORE NUM SAMPLES feature is turned on the instrument will also store how many sample readings were used for the AVG MIN or MAX calculation but not the readings themselves REPORT PERIODS IN PRO
339. struments RS 232 multidrop card Option 62 see Section 6 10 7 for instructions on setting it up CAUTION To prevent dust from getting into the analyzer it was shipped with small plugs inserted into each of the pneumatic fittings on the rear panel Make sure that all dust plugs are removed before attaching exhaust and supply gas lines 14 6400E Rev Model 6400E Instruction Manual Getting Started 3 1 2 PNEUMATIC CONNECTIONS NOTE To prevent dust from getting into the analyzer it was shipped with small plugs inserted into each of the pneumatic fittings on the rear panel Make sure that all dust plugs are removed before attaching exhaust and supply gas lines Table 3 4 Inlet Outlet Connector Nomenclature REAR PANEL LABEL FUNCTION Sample Connects the sample gas to the analyzer When operating the analyzer without zero span option this is also the inlet for any calibration gases Exhaust Connect an exhaust gas line to this port vented outside the shelter or immediate area surrounding the instrument Zero Air On Units with zero span valve or IZS option installed this port connects the zero air gas or the zero air cartridge to the analyzer Figure 3 5 shows the internal pneumatic flow of the 6400E in its Standard configuration For information on instruments in which one of the various zero span valve options see Figures 5 2 and 5 3 Refer to these diagrams whenever tr
340. t 100 120 VAC line power and in series for units configured for 220 230 VAC One configuration plug on the relay board determines the power configuration for the entire analyzer On units with IZS options installed an additional set of AC heaters is attached to the IZS permeation tube Some special 6400E models may have other non standard heating zones installed such as a dilution manifold 10 4 7 2 Valve Control The relay board also hosts two valve driver chips each of which can drive up four valves In its basic configuration the Model 6400E requires no special valves to operate However on units with either the zero span valve or the IZS option installed The valves are Manifold valves may also be present in certain special versions of the analyzer 04515 Rev B 193 Theory Of Operation Model 6400E Instruction Manual 10 4 8 STATUS LEDS amp WATCH DOG CIRCUITRY IZS Option Permeation Tube Heater ero Span and IZS Options Zero Span Valve ero Span and IZS Options Sample CAL Valve Sample Chamber Heater 12 Watchdog LED Figure 10 18 Relay Board Status LED Locations Thirteen LEDs are located on the analyzer s relay board to indicate the status of the analyzer s heating zones and valves as well as a general operating watchdog indicator Table 10 1 shows the states of these LEDs and their respective functionality Table 10 1 Relay Board Status LED s
341. t contains little or no S02 The same problem occurs if the analyzer was zero calibrated using ambient air or span gas If the response offset test function for SO OFFSET are greater than 150 mV a failed PMT or high voltage supply or sample chamber contamination could be the cause 11 3 2 NO RESPONSE If the instrument shows no response display value is near zero even though sample gas is supplied properly and the instrument seems to perform correctly Confirm response by supplying SO span gas of about 8096 of the range value to the analyzer Check the sample flow rate for proper value Check for disconnected cables to the sensor module Carry out an electrical test with the ELECTRICAL TEST procedure in the diagnostics menu see Section 6 9 6 If this test produces a concentration reading the analyzer s electronic signal path is working Carry out an optical test using the OPTIC TEST procedure in the diagnostics menu see Section 6 9 5 If this test results in a concentration signal then the PMT sensor and the electronic signal path are operating properly If the 6400E passes both ETEST and OTEST the instrument is capable of detecting light and processing the signal to produce a reading Therefore the problem must be in the pneumatics optics or the UV lamp lamp driver 216 04515 Rev B Model 6400E Instruction Manual TROUBLESHOOTING amp REPAIR 11 3 3 UNSTABLE ZERO AND SPAN Leaks in the 6400E or in the extern
342. t defines that identifies the LAN the device is EDIT k connected to SUBNET Configured putari All addressable devices and MASK by DHCP when DHCP Computers on a LAN must have is ON the same subnet mask Any transmissions sent devices with different assumed to be outside of the LAN and are routed through gateway computer onto the Internet This number defines the terminal control port by which the instrument is addressed by terminal emulation software such as Internet or Teledyne Instruments APICOM The name by which your analyzer will appear when addressed from other computers on the LAN or via the Internet While the default setting for all Teledyne Instruments 6400E analyzers is 6400E the host name may be changed to fit customer needs TCP PORT 3000 Editable HOST NAME 6400E Editable 1 Do not change the setting for this property unless instructed to by Teledyne Instruments Customer Service personnel 6400E Rev B 91 Operating Instructions Model 6400E Instruction Manual NOTE It is a good idea to check these settings the first time you power up your analyzer after it has been physically connected to the LAN Internet to make sure that the DHCP has successfully downloaded the appropriate information from you network server s If the gateway IP instrument IP and the subnet mask are all zeroes e g 0 0 0 0 the DCHP was not successful You may have to manually
343. t gt is pressed Note that the RS 232 port has programmable baud rates from 200 to 115200 baud Since the CPU board remembers the programmed baud rate even when power is off this means that there is no default baud rate for the port when the instrument boots up the rate will be whatever it was last programmed to be In some cases configuration memory might be corrupted and the baud rate could be a random unrelated value For these reasons it is best to test all possible baud rates when performing this test See the RS 2323 Communication section below for more details regarding port configuration In some rare circumstances this failure may be caused by a bad IC on the motherboard specifically U57 the large 44 pin device on the lower right hand side of the board If this is true removing U57 from its socket will allow the instrument to start up but the measurements will be invalid e ifthe analyzer stops during initialization the vacuum fluorescent display shows some text it is likely that the DOC the firmware or the configuration and data files have been corrupted 04515 Rev B 229 TROUBLESHOOTING amp REPAIR Model 6400E Instruction Manual 11 5 11 RS 232 COMMUNICATION 11 5 11 1 General RS 232 Troubleshooting Teledyne Instruments analyzers use the RS 232 protocol as the standard serial communications protocol RS 232 is a versatile standard which has been used for many years but at times is difficult to configur
344. tact closure dynamic zero OFF disables it DYN SPAN OFF OFF ON ON enables contact closure dynamic L span OFF disables it CONC PRECISION 1 AUTO 0 1 2 3 4 Number of digits to display to the right of the decimal point for concentrations on the display Enclose value in double quotes when setting from the RS 232 interface CLOCK_ADJ Sec Day o 60 60 Time of day clock speed adjustment LANGUAGE SELECT ENGL ENGL SECD EXTN Selects the language to use for the user interface Enclose value in double quotes when setting from the RS 232 interface MAINT_TIMEOUT 0 1 100 Time until automatically switching out of software controlled maintenance mode CONV_TIME 33 MS 33 MS 66 MS Conversion time for PMT and UV detector channels Enclose value in S E m ue ms double quotes when setting from the RS 232 interface 1 1 SEC 2 SEC DWELL_TIME Seconds 1 0 2 0 1 10 Dwell time before taking each sample FILT SIZE Samples 240 303 54 1 480 Moving average filter size FILT ASIZE Samples 20 6 1 100 Moving average filter size in adaptive mode FILT_DELTA PPM 0 02 10 0 001 0 1 Absolute change to trigger adaptive 1 100 filter FILT_PCT 5 10 1 100 Percent change to trigger adaptive filter FILT_DELAY Seconds 180 0 300 Delay before leaving adaptive filter mode FILT_ADAPT m ON OFF OFF ON ON enables adaptive filter OFF disable
345. te of delivery All replacement parts and repairs are warranted for 90 days after the purchase 6400E Rev B 7 Specifications Approvals and Warranty Model 6400E Instruction Manual If a product fails to conform to its specifications within the warranty period Teledyne Analytical Instruments shall correct such defect by in Teledyne analytical Instruments discretion repairing or replacing such defective product or refunding the purchase price of such product The warranties set forth in this section shall be of no force or effect with respect to any product i that has been altered or subjected to misuse negligence or accident or ii that has been used in any manner other than in accordance with the instruction provided by Teledyne Analytical Instruments or iii not properly maintained THE WARRANTIES SET FORTH IN THIS SECTION AND THE REMEDIES THEREFORE ARE EXCLUSIVE AND IN LIEU OF ANY IMPLIED WARRANTIES OF MERCHANTABILITY FITNESS FOR PARTICULAR PURPOSE OR OTHER WARRANTY OF QUALITY WHETHER EXPRESSED OR IMPLIED THE REMEDIES SET FORTH IN THIS SECTION ARE THE EXCLUSIVE REMEDIES FOR BREACH OF ANY WARRANTY CONTAINED HEREIN Teledyne Analytical Instruments SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF OR RELATED TO THIS AGREEMENT OF Teledyne Analytical Instruments PERFORMANCE HEREUNDER WHETHER FOR BREACH OF WARRANTY OR OTHERWISE Terms and Conditions All units or components returned to Teledyne Analyti
346. the sample gas is diluted before being analyzed by the Model 6400E Typically this occurs in continuous emission monitoring CEM applications where the quality of gas in a smoke stack is being tested and the sampling method used to remove the gas from the stack dilutes the gas Once the degree of dilution is known this feature allows the user to add an appropriate scaling factor to the analyzer s SO concentration calculation so that the measurement range and concentration values displayed on the instrument s front panel display and reported via the analog and serial outputs reflect the undiluted values Contact Teledyne Analytical Instruments Customer Service personnel for information on activating this feature Instructions for using the dilution ratio option can be found in Section 6 7 8 User Notes 42 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 OPERATING INSTRUCTIONS To assist in navigating the analyzer s software a series of menu trees can be found in Appendix A of this manual NOTE The flow charts appearing in this section contain typical representations of the analyzer s display during the various operations being described These representations may differ slightly from the actual display of your instrument The ENTR key may disappear if you select a setting that is invalid or out of the allowable range for that parameter such as trying to set the 24 hour clock to 25 00 00 Once y
347. they can be customized to fit a specific application They can also be deleted to make room for custom user programmed Data Channels This can be done via the instruments front panel or downloaded via the analyzer s COM ports using a program such as APICOM see Section 6 12 2 8 or other terminal emulation program 6400E Rev B 105 Operating Instructions Model 6400E Instruction Manual Sending an iDAS configuration to the analyzer through its COM ports will replace the existing configuration and will delete all stored data Back up any existing data and the iDAS configuration before uploading new settings The Channel Properties Triggering Events and Data Parameters Functions for these default channels are PARAMETER PMTDET MODE AVG PRECISION 4 STORE NUM SAMPLES OFF PARAMETER UVDET MODE AVG PRECISION 4 STORE NUM SAMPLES OFF PARAMETER LAMPR MODE AVG PRECISION 4 STORE NUM SAMPLES OFF PARAMETER DRKPMT MODE AVG PRECISION 4 STORE NUM SAMPLES OFF PARAMETER DARKUV MODE AVG PRECISION 4 STORE NUM SAMPLES OFF PARAMETER CONCI MODE AVG PRECISION 3 STORE NUM SAMPLES OFF PARAMETER STABIL MODE AVG PRECISION 4 STORE NUM SAMPLES OFF PARAMETER STRLGT MODE AVG PRECISION 4 STORE NUM SAMPLES OFF PARAMETER RCTEMP MODE AVG PRECISION 2 STORE NUM SAMPLES OFF PARAMETER SMPPRS MODE AVG PRECISION 4 STORE NUM SAMPLES OFF PARAMETER BOXTEMP MODE AVG PRECISIO
348. tion the port uses the same female DB 9 connector on the back of the instrument as when Com2 is configured for RS 232 operation however the pin assignments are different Female DB 9 COM2 As seen from outside analyzer RX TX RX TX GND 29090 88 485 Figure 6 10 Back Panel connector Pin Outs for COM2 in RS 485 mode The signal from this connector is routed from the motherboard via a wiring harness to a 6 pin connector on the CPU card CN5 CN5 Located on CPU card GND As seen from inside analyzer Figure 6 11 CPU connector Pin Outs for COM2 in RS 485 mode 6 10 5 DTE AND DCE COMMUNICATION RS 232 was developed for allowing communications between data terminal equipment DTE and data communication equipment DCE Basic terminals always fall into the DTE category whereas modems are always considered DCE devices The difference between the two is the pin assignment of the Data Receive and Data Transmit functions DTE devices receive data on pin 2 and transmit data on pin 3 e DCE devices receive data on pin 3 and transmit data on pin 2 To allow the analyzer to be used with terminals DTE modems DCE and computers which can be either a switch mounted below the serial ports on the rear panel allows the user to set the configuration of COM1 for one of these two modes This switch exchanges the receive and transmit lines on COM1 emulating a cross over or null modem cable The switch has no effect on
349. to stop the creation of instantaneous static electric charges It is not however difficult to prevent those charges from building to dangerous levels or prevent damage due to electro static discharge from occurring 12 4 1 GENERAL RULES Only handle or work on all electronic assemblies at a properly set up ESD station Setting up an ESD safe work station need not be complicated A protective mat properly tied to ground and a wrist strap are all that is needed to create a basic anti ESD workstation see figure 12 2 Protective Mat Wrist Strap Ground Point Figure 12 2 Basic anti ESD Work Station 254 04515 Rev B Model 6400E Instruction Manual A Primer on Electro Static Discharge For technicians that work in the field special lightweight and portable anti ESD kits are available from most suppliers of ESD protection gear These include everything needed to create a temporary anti ESD work area anywhere Always wear an Anti ESD wrist strap when working on the electronic assemblies of your analyzer An anti ESD wrist strap keeps the person wearing it at or near the same potential as other grounded objects in the work area and allows static charges to dissipate before they can build to dangerous levels Anti ESD wrist straps terminated with alligator clips are available for use in work areas where there is no available grounded plug Also anti ESD wrist straps include a current limiting resistor
350. to the analyzer the entire measurement capability of the sensor module can be tested including the PMT and the current to 192 04515 Rev B Model 6400E Instruction Manual Theory Of Operation voltage conversion circuit on the PMT preamplifier board See section 6 9 5 for instructions on performing this test 10 4 6 PNEUMATIC SENSOR BOARD The flow and pressure sensors of the 6400E are located on a printed circuit assembly just behind the PMT sensor Refer to Section 11 5 17 on how to test this assembly The signals of this board are supplied to the motherboard for further signal processing All sensors are linearized in the firmware and can be span calibrated from the front panel See section 6 7 5 for instructions on performing this test 10 4 7 RELAY BOARD The relay board is the central switching unit of the analyzer It contains power relays status LEDs for all heated zones and valves as well as valve drivers thermocouple amplifiers power distribution connectors and the two switching power supplies of the analyzer The relay board communicates with the motherboard over the I C bus and is the main board for trouble shooting power problems of any kind 10 4 7 1 Heater Control The 6400E uses a variety of heaters for its individual components All heaters are AC powered and can be configured for 100 120 VAC or 220 230VAC at 50 60 Hz The two sample chamber heaters are electronically connected in parallel for analyzers a
351. to the circuits of your ESD sensitive device Also the liquid impregnating the plastic is eventually used up after which the bag is as useless for preventing damage from ESD as any ordinary plastic bag Anti Static bags made of plastic impregnated with metal usually silvery in color provide all of the charge equalizing abilities of the pink poly bags but also when properly sealed create a Faraday cage that completely isolates the contents from discharges and the inductive transfer of static charges Storage bins made of plastic impregnated with carbon usually black in color are also excellent at dissipating static charges and isolating their contents from field effects and discharges Never use ordinary plastic adhesive tape near an ESD sensitive device or to close an anti ESD bag The act of pulling a piece of standard plastic adhesive tape such as Scotch tape from its roll will generate a static charge of several thousand or even tens of thousands of volts on the tape itself and an associated field effect that can discharge through or be induced upon items up to a foot away 04515 Rev B 255 A Primer on Electro Static Discharge Model 6400E Instruction Manual 12 4 2 BASIC ANTI ESD PROCEDURES FOR ANALYZER REPAIR AND MAINTENANCE 12 4 2 1 Working at the Instrument Rack When working on the analyzer while it is in the instrument rack and plugged into a properly grounded power supply 1 Attach you anti ESD wrist strap t
352. tween the PROPERTIES for this data channel SETUP XX NAME CONC1 Exits returns to the previous Menu SET SET EDIT PRNT EXIT Reports the configuration of current E Allows to edit the channel name see next key sequence data channels to the RS 232 ports When editing the data channels the top line of the display indicates some of the configuration parameters For example the display line 0 CONC ATIMER 4 800 represents to the following configuration Channel No 0 NAME CONC TRIGGER EVENT ATIMER PARAMETERS Four parameters are included in this channel EVENT This channel is set up to record 800 data points 108 6400E Rev B Model 6400E Instruction Manual Operating Instructions To edit the name of a data channel follow the above key sequence and then press 1 FROM THE PREVIOUS KEY SEQUENCE bb SETUP XX 1 lt SET SET EDIT PRINT EXIT SETUP XX ENTR accepts the new string and retums to the previous c N c 1 ENTR EXIT menu EXIT ignores the new string and retums to the previous menu Press each key repeatedly to cycle through the avallable character set 0 9 A Z space amp _ lt gt 6 11 2 3 Trigger Events To edit the list of data parameters associated with a specific data channel press From the DATA ACQUISITION menu see Section 6 11 2 2 Edit Data Channel Menu SE
353. u have plugged your wrist strap into the work station e Lay the bag or bin on the workbench surface Before opening the container wait several seconds for any static charges on the outside surface of the container to be bled away by the work station s grounded protective mat 256 04515 Rev B Model 6400E Instruction Manual A Primer on Electro Static Discharge 4 Do not pick up tools that may be carrying static charges while also touching or holding an ESD Sensitive Device Only lay tools or ESD sensitive devices and assemblies on the conductive surface of your workstation Never lay them down on a non ESD preventative surfaces 5 Place any static sensitive devices or assemblies in anti static storage bags or bins and close the bag or bin before unplugging your wrist strap 6 Disconnecting your wrist strap is always the last action taken before leaving the work bench 12 4 2 3 Transferring Components from Rack To Bench and Back When transferring a sensitive device from an installed Teledyne Instruments analyzer to a Anti ESD workbench or back 1 Follow the instructions listed above for working at the instrument rack and work station 2 Never carry the component or assembly without placing it in a anti ESD bag or bin 3 Before using the bag or container allow any surface charges on it to dissipate If you are at the instrument rack hold the bag in one hand while your wrist strap is connected to a ground point
354. uch stray light is _ present in the sample chamber DATA INITIALIZED IDAS data storage was erased PMT DET WARNING PMT TEMP WARNING RCELL TEMP WARNING REAR BOARD NOT DET RELAY BOARD WARN SYSTEM RESET FRONT PANEL WARN Firmware is unable to communicate with the front panel HVPS WARNING High voltage power supply for the PMT is outside of specified limits IZS TEMP WARNING On units with IZS options installed The permeation tube temperature is SAMPLE FLOW WARN The flow rate of the sample gas is outside the specified limits SAMPLE PRESS WARN Sample pressure outside of operational parameters UV LAMP WARNING outside of specified limits PMT detector output outside of operational limits PMT temperature is outside of specified limits Sample chamber temperature is outside of specified limits The CPU is unable to communicate with the motherboard The firmware is unable to communicate with the relay board The computer was rebooted The UV lamp intensity measured by the reference detector reading too low or too high To view and clear warning messages TEST deactivates warning messages NOTE if the warning message persists after several attempts to clear the message may Indicate a real problem and not an artifact ofthe warm up period os TEST SAMPLE RANGE 509 000 PPB 02 XXX X CAL MSG CLR SETUP MSG activates warning messag
355. ulations for the STP used by your agency Here are the conversion factors from volumetric to mass units used in the 6400E SO ppb x 1 34 ug m ppm x 1 34 mg m 60 6400E Rev B Model 6400E Instruction Manual Operating Instructions 6 7 8 DILUTION RATIO The dilution ratio is a software option that allows the user to compensate for any dilution of the sample gas before it enters the sample inlet Using the dilution ratio option is a 4 step process 1 Select reporting range units Follow the procedure in Section 6 7 7 2 Select the range Use the procedures in Section 6 7 4 6 7 6 Make sure that the SPAN value entered is the maximum expected concentration of the undiluted calibration gas and that the span gas is either supplied through the same dilution inlet system as the sample gas or has an appropriately lower actual concentration For example with a dilution set to 100 a 1 ppm gas can be used to calibrate a 100 ppm sample gas if the span gas is not routed through the dilution system On the other hand if a 100 ppm span gas is used it needs to pass through the same dilution steps as the sample gas 3 Setthe dilution factor as a gain e g a value of 20 means 20 parts diluent and 1 part of sample gas SAMPLE RANGE 500 000 PPB 502 XXX X lt TST TST gt CAL SETUP SAMPLE ENTER 5 818 8 1 8 ENTR EXIT SETUP C3 PRIMARY SETUP MENU CFG DAS E PASS CLK MORE EXIT DIL only appears S
356. usually around one meg ohm that protects you should you accidentally short yourself to the instrument s power supply Simply touching a grounded piece of metal is insufficient While this may temporarily bleed off static charges present at the time once you stop touching the grounded metal new static charges will immediately begin to re build In some conditions a charge large enough to damage a component can rebuild in just a few seconds Always store sensitive components and assemblies in anti ESD storage bags or bins Even when you are not working on them store all devices and assemblies in a closed anti Static bag or bin This will prevent induced charges from building up on the device or assembly and nearby static fields from discharging through the it Use metallic anti ESD bags for storing and shipping ESD sensitive components and assemblies rather than pink poly bags The famous pink poly bags are made of a plastic that is impregnated with a liquid similar to liquid laundry detergent which very slowly sweats onto the surface of the plastic creating a slightly conductive layer over the surface of the bag While this layer may equalizes any charges that occur across the whole bag it does not prevent the build up of static charges If laying on a conductive grounded surface these bags will allow charges to bleed away but the very charges that build up on the surface of the bag itself can be transferred through the bag by induction on
357. ut Portal Zinc Vapor Plasma Arc Figure 10 3 Source UV Lamp Construction 10 2 2 THE REFERENCE DETECTOR A vacuum diode UV detector that converts UV light to a DC current is used to measure the intensity of the excitation UV source lamp It s location directly across from the source lamp at the back of a narrow tube shaped light trap placers it directly in the path of the excitation UV light A window transparent to UV light provides an air proof seal that prevents ambient gas from contaminating the sample chamber The shape of the light trap and the fact that the detector is blind to wavelengths other than UV no extra optical filtering is needed 10 2 3 THE PMT The amount of fluoresced UV produced in the sample chamber is much less than the intensity of excitation UV source lamp see Figure 10 4 Therefore a much more sensitive device is needed to detect this light with enough resolution to be meaningful The Model 6400E uses a Photo Multiplier Tube or PMT for this purpose A PMT is typically a vacuum tube containing a variety of specially designed electrodes Photons enter the PMT and strike a negatively charged photo cathode causing it to emit electrons These electrons are accelerated by a high voltage applied across a series of special electrodes called dynodes that multiply the amount of electrons until a useable current signal is generated This current increases or decreases with the amount of detected light see Section 10
358. utomatically set at 115 200 kBaud 6 10 6 2 Configuring the Ethernet Interface Option using DHCP The Ethernet option for you 6400E uses Dynamic Host Configuration Protocol DHCP to automatically configure its interface with your LAN This requires your network servers also be running DHCP The analyzer will do this the first time you turn the instrument on after it has been physically connected to your network Once the instrument is connected and turned on it will appear as an active device on your network without any extra set up steps or lengthy procedures Should you need to the following Ethernet configuration properties are viewable via the analyzer s front panel 90 6400E Rev B Model 6400E Instruction Manual Operating Instructions Table 6 16 LAN Internet Configuration Properties PROPERTY DEFAULT STATE DESCRIPTION SHOP This displays whether the DHCP is i turned ON or OFF STATUS On Editable or EDIT key This string of four packets of 1 to INSTRUMENT Configured disabled 3 numbers each e g IP ADDRESS by DHCP when DHCP 192 168 76 55 is the address of Lol is ON the analyzer itself A string of numbers very similar EDIT key GATEWAY IP Configured disabled 0 the Instrument IP address e g ADDRESS by DHCP when DHCP 92 168 76 1 that is the address is ON of the computer used by your LAN to access the Internet Also a string of four packets of 1 to 3 numbers each e g 255 255 252 0 tha
359. utputs needs to be carried out on first startup of the analyzer performed in the factory as part of the configuration process or whenever re calibration is required To calibrate the outputs as a group activate the ANALOG I O CONFIGURATION MENU see Section 6 9 1 then press Access from DIAG Menu see Section 6 9 1 DIAG ANALOG 1 O CONFIGURATION Exit at any tima an to retum to the NEXT ENTR Exit main DIAG menu DIAG AQUTS CALIBRATED NO E If AutoCal has been SET SET gt CAL tumed off for any channel the message for that channel will be similar to DIAG AUTO CALIBRATING OUT 1 es AUTO CALIBRATING CONC OUT 2 2 NOT AUTO CAL AUTO CALIBRATING TEST_OUTPUT CONC_OUT_1 If any of the channels have not been calibrated this message will read NO Exit to retum to the DIAG AIO CALIBRATED YES configuration menu SET SET CAL To automatically calibrate an single analog channel press 6400E Rev B 71 Operating Instructions Model 6400E Instruction Manual C Access from DIAG Menu see Section 9 1 DIAG ANALOG 170 CONFIGURATION EXIT to Retum EV EXT to the main PREY NEXT ENTR EXIT Sample Display DIAG AIO AQUTS CALIBRATED NO Y BETS GAL Ex Press SET gt to select the Analog Output channel to be configured Then Press EDIT to cont
360. v 219 TROUBLESHOOTING amp REPAIR Model 6400E Instruction Manual If none of the Ethernet s cards four status LED s located on the analyzer s rear panel is lit it is possible that the card is not receiving power or is suffering from a massive failure Under the Setup CFG menu see Section 6 5 the firmware revision of the iChip processor on the Ethernet card should be listed It will appear something like SAMPLE iChip Rev IL702P16 1 3 NEXT PREV EXIT If 2 as the revision number something is preventing the iChip from being initialized On initial start up after iChip driver is enabled the analyzer s COMM port driver tests the iChip to determine the baud rate at which it is set to function This test occurs when the instrument is approximately 75 though its boot up procedure and takes about 90 seconds to complete This test should only occur on the initial start up of the analyzer after the Ethernet card is installed and activated usually at the factory A 90 second pause at this point in its boot process every time it is turned on could indicate that a problem exists with the iChip itself the Ethernet card or the analyzer s Disk on Chip memory that is preventing it from holding the proper baud rate setting for the COM2 port in memory 220 04515 Rev B Model 6400E Instruction Manual TROUBLESHOOTING amp REPAIR 11 5 SUBSYSTEM CHECKOUT The preceding sections of this manual discussed
361. vailable UV light by adjusting the SO concentration calculation using a ratio LAMP RATIO that results from dividing the current UV lamp UV LAMP intensity by a value stored in the CPU s memory LAMP CAL Both LAMP Ration and UV Lamp are test functions viewable from the instruments front panel To cause the analyzer to measure and record a value for LAMP CAL press SAMPLE RANGE 800 0 PPB SOZ XXX X DIAG SIGNAL 170 TST TST gt CAL SETUP NEXT ENTR EXIT 4 SAMPLE ENTER SETUP PASS 818 Y Repeat Pressing NEXT until Exit at any time to return ENTR EXIT DIAG LAMP CALIBRATION SETUP XX PRIMARY SETUP MENU PREV NEXT ENTR EXIT CPG DAS RMGE PASS CLK MORE DIAG FCAL LAMP CAL VALUE 4262 4 mV 4 2 6 2 4 ENTR EXI SETUP SECONDARY SETUP MENU VARS DIAG The value displayed 15 the current output of the UV source reference detector ENTR accepts the new value EXIT ignores the new value 6400E Rev B 81 Operating Instructions Model 6400E Instruction Manual 6 9 8 PRESSURE CALIBRATION A sensor at the exit of the sample chamber continuously measures the pressure of the sample gas This data is used to compensate the final SO concentration calculation for changes in atmospheric pressure when the instrument s TPC feature is turned on see Section 10 7 3 and is stored in the CPU s memory as the test function
362. ving the permeation tube The tube continues to emit gas even at room temperature and will contaminate the entire instrument 9 3 3 CHANGING THE EXTERNAL ZERO AIR SCRUBBER The chemicals in the external scrubber need to be replaced periodically according to Table 9 1 or as needed This procedure can be carried out while the instrument is running Make sure that the analyzer is not in either the ZERO or SPAN calibration modes 1 Locate the scrubber on the outside rear panel 2 Remove the old scrubber by disconnecting the 1 4 plastic tubing from the particle filter using 9 16 and 1 2 wrenches 3 Remove the particle filter from the cartridge using 9 16 wrenches 4 Unscrew the top of the scrubber canister and discard charcoal contents Make sure to abide to local laws about discarding these chemicals The rebuild kit listed in Appendix B comes with a Material and Safety Data Sheet which contains more information on these chemicals 04515 Rev B 167 Instrument Maintenance Model 6400E Instruction Manual 5 Refill the scrubber with charcoal at the bottom 6 Tighten the cap on the scrubber hand tight only 7 Replace the DFU filter if required with a new unit and discard the old 8 Replace the scrubber assembly into its clips on the rear panel 9 Reconnect the plastic tubing to the fitting of the particle filter 10 Adjust the scrubber cartridge such that it does not protrude above or below the analyzer in ca
363. wo or more sequences at the same time of the day Any new sequence which is initiated whether from a timer the COM ports or the contact closure inputs will override any sequence which is in progress NOTE If at any time an illegal entry is selected Example Delta Days gt 367 the ENTR key will disappear from the display WARNING The CALIBRATE attribute must always be set to OFF for analyzers used in US EPA controlled applications that have IZS option installed 148 6400E Rev B Model 6400E Instruction Manual Calibration Procedures Calibration of instruments used in US EPA related applications should only be performed using external sources of zero air and span gas with an accuracy traceable to EPA or NIST standards and supplied through the analyzer s sample port see Section 7 2 The following example sets Sequence2 to carry out a zero span calibration every other day starting at 01 00 on September 4 2002 lasting 15 minutes This sequence will start 0 5 hours later each day Table 7 4 Example Auto Cal Sequence MODE AND DELTA TIME 00 30 Do Sequence 2 0 5 h later each day DURATION Operate Span valve for 15 min CALIBRATE ON The instrument will re set the slope and offset values for the SO channel at the end of the AutoCal sequence ATTRIBUTE VALUE COMMENT SEQUENCE 2 Define Sequence 2 MODE ZERO SPAN Select Zero and Span Mode TIMER ENABLE ON Enab
364. y Of Operation 10 4 4 PMT COOLING SYSTEM The performance of the analyzer s PMT is significantly affected by temperature Variations in PMT temperature are directly reflected in the signal output of the PMT Also the signal to noise ratio of the PMT output is radically influenced by temperature as well The warmer The PMT is the noisier its signal becomes until the noise renders the concentration signal useless To alleviate this problem a special cooling system exists that maintains the PMT temperature at a stable low level Preamp PCA sends buffered and amplified thermistor signal to TEC PCA TEC PCA sets appropriate drive voltage for cooler TEC Control PMT Preamp PCA Thermistor outputs temp of cold block to preamp PCA Heat form PMT is absorbed by the cold block and transferred to the heat sink via the TEC then bled off into the coo air stream E 2 4 ex Cooling Fan Figure 10 16 PMT Cooling System 10 4 4 1 Thermoelectric Cooler TEC The core of the 6400E PMT cooling system is a solid state heat pump called a thermoelectric cooler TEC Thermoelectric coolers transfer heat from a one s de of a special set of semiconductor junctions to the other when a DC current is applied The heat is pumped at a rate proportional to the amount of current applied In the Model 6400E the TEC is physically attached to a cold block that absorbs heat directly from the PMT and a heat s
365. y this failure by logging on to the instrument using APICOM or a terminal program If the analyzer responds to remote commands and the display changes accordingly the display wiring or the I C bus may be faulty 226 04515 Rev B Model 6400E Instruction Manual TROUBLESHOOTING amp REPAIR 11 5 8 RELAY BOARD The relay board circuit can most easily be checked by observing the condition of its status LEDs as described in Section 11 1 4 and the associated output when toggled on and off through the SIGNAL 1 0 function in the DIAG menu see Section 6 9 2 Ifthe front panel display responds to key presses and D1 on the relay board is not flashing then either the connection between the motherboard and the relay board is bad or the relay board itself is bad If Di on the relay board is flashing but toggling an output in the Signal I O function menu does not toggle the output s status LED the there is a circuit problem or possibly a blown driver chip on the relay board If Di on the Relay board is flashing and the status indicator for the output in question heater valve etc toggles properly using the Signal I O function but the output device does not turn on off then the associated device valve or heater or its control device valve driver heater relay is malfunctioning Several of the control devices are in sockets and can easily be replaced The table below lists the control device associated with a pa
366. ym for diagnostics the diagnostic settings of the analyzer DHCP acronym for dynamic host configuration protocol A protocol used by LAN or Internet servers to automatically set up the interface protocols between themselves and any other addressable device connected to the network DOC Disk On Chip the analyzer s central storage area for analyzer firmware configuration settings and data This is a solid state device without mechanically moving parts that acts as a computer hard disk drive under 2 DOS with disk label C DOC chips come with 2 mb in the E series analyzer standard configuration but are available in larger sizes DOS Disk Operating System The E series analyzers use DR DOS EEPROM also referred to as a FLASH chip FLASH flash memory is non volatile solid state memory GFC Acronym for Gas Filter Correlation PC bus a clocked bi directional serial bus for communication between individual analyzer components iDAS acronym for internal data acquisition system IP acronym for internet protocol LAN acronym for oca area network LED acronym for light emitting diode PCA acronym for printed circuit assembly the gt PCB with electronic components ready to use 30 6400E Rev B Model 6400E Instruction Manual Frequently Asked Questions amp Glossary PCB acronym for printed circuit board the bare board without electronic components RS 232 a type of serial communications port RS 485 a type o
367. yne Analytical Instruments recommends the use of APICOM the iDAS can also be accessed and configured through a terminal emulation program such as HyperTerminal see Figure 6 16 However all configuration commands must be created following a strict syntax or be pasted in from of a text file which was edited offline and then uploaded through a specific transfer procedure 118 6400E Rev B Model 6400E Instruction Manual Operating Instructions 36 200 at CAS Hyperterminal File Edt View Cal Transfer Help Dll ala aoee SETUP PROPERTIES FOR ENGDAT NAHE ENGDAT ATIMER EVENT REPORT PERIOD 9000 80 02 NUMBER OF RECORDS 00 N c RS 232 REPORT ON CHANNEL ENABLED ON CAL HOLD OFF OFF PARAMETERS 14 PARAHETER RCTEMP MODE AVG PRECISION 4 STORE SRMPLES OFF PARAMETER CNVTMP MODE RVG PRECISION 4 STORE SRMPLES 0FF PRRRMETER PMTTMP MODE AVG PRECISION 4 STORE SRMPLES OFF PARAMETER BOXTHP MODE AVG PRECISION 4 STORE SRMPLES OFF PRRRMETER O3FLOW MODE RVG PRECISION 4 STORE SRMPLES OFF PARAMETER SMPFLW MODE QVG PRECISION 4 STORE SRMPLES OFF PARAHETER SHPPRS MODE AVG PRECISION 4 STORE SRMPLES OFF PARAMETER RCPRES MODE AVG PRECISION 4 STORE SRMPLES OFF PARAMETER AZERO HODE AVG PRECISION 4 STORE SRMPLES OFF PARAMETER HVPS MODE AVG PRECISION 4 STORE SRMPLES OFF PRRRMETER PMTDET MODE RVG PRECISION 4 STORE_SAXPLES OFF PARAMETER RF4096 MODE RVG PRECISION 4 STORE SRMP
368. ypes 124 Serial Interface Documents RS 232 Communication Parameters for Hessen Protocol 6400E Hessen Protocol Response Modes Default Hessen Status Bit NIST SRM s Available for Traceability of SO2 Calibration Gases dad dB AutoCal Modes eese eene enn hne enne ha tana seen nee 148 AutoCal Attribute Setup Parameters 148 Example Auto Cal Sequence 149 Calibration Data Quality Evaluation 151 Activity Matrix for Calibration Equipment amp Supplies 154 Activity Matrix for Calibration 154 Activity Matrix for Quality Assurance Checks 156 Definition of Level 1 and Level 2 Zero and Span Checks 5157 6400E Preventive Maintenance 164 Predictive Uses for Test Functions 4105 Relay Board Status LED s Front Panel Status LED s Warning Messages Indicated Failures Test Functions Possible Causes for Out Of Range Values E Relay Board Status nennen nennen nnne nnn hern nnn nenne eene nnns 214 DC Power Test Point and Wiring Color 225 DC Power Supply Acceptable Levels Relay Board Control Analog Output Test Function Nominal Values 228 Status Outputs Check
369. zero Offset ER point of the analyzer response HVPS HVPS V The PMT high voltage power supply RCELL SAMPLE CHAMBER C The current temperature of the sample chamber TEMP TEMP BOX TEMP BOX The ambient temperature of the inside of the analyzer case TEMPERATURE i PMT TEMPERATURE C The current temperature of the PMT IZS TEMP 125 ec The current temperature of the internal zero span option Only TEMPERATURE appears when IZS option is enabled TEST TEST SIGNAL mv Signal of a user defined test function on output channel A4 TIME CLOCK TIME hh mm ss The current day time for iDAS records and calibration events 6400E Rev B 45 Operating Instructions Model 6400E Instruction Manual To view the TEST Functions press the following Key sequence SAMPLE RANGE 500 0 PPB SO2 XXX X TST TST gt CAL SETUP Toggle lt TST TST gt keys to scroll through list of functions RANGE STABIL PRES SAMP FL PMT NORM PMT UV LAMP LAMP RATIO STR LGT Refer to DARK PMT Section DARK LAMP 6 2 1 for SLOPE definitions OFFSET of these HVPS test RCELL TEMP functions BOX TEMP PMT TEMP IZS TEMP TEST TIME Only appears if IZS option is installed Only appears if analog output A3 is actively reporting a test function Figure 6 2 Viewing 6400E TEST Functions NOTE A value of XXXX displayed for any of the TEST functions indicates an out

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