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Teledyne Carbon Monoxide Analyzer 300 User's Manual

1. 79 9 4 Output voltage range changes din 80 9 5 Flow readout adjustment ea 81 94 DC 81 81 10 0 MAROUBLESHOO TN Erica nn 83 TOT OVEN LEW fiaa halaq ira ili aid 83 10 2 Troubleshooting fundamental analyzer operation 84 10 3 Troubleshooting using warning messages 85 10 4 Troubleshooting using test function values 87 10 5 Troubleshooting dynamic problems i 88 10 6 Troubleshooting individual sub assemblies and components 90 10 7 Warranty repair questionnaire iii 99 11 0 ROUTINE MAINTENANCE C E RR hc ro 101 11 1 Model 300 maintenance schedule iii ae 101 11 2 Replacement of sample filter I 101 11 3 Leak checking ire oen e a ne ei 102 LT AMC amen the prom lla 103 120 SPABEBARTSEISTS asian Say S u 105 12 1 SPARE PARTS FOR CE MARK UNITS eese 105 12 2 SPARE PARTS FOR NON CE MARK UNITS eere 107 APPENDIX A LIST OF AVAILABLE MODEL 300 OPTIONS 109 APPENDIX B TIPS ON CONNECTING THE TELEDYNE API ANALYZER 111 APPENDIX ELECTRICAL SCHEMATIC INDEX
2. 115 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page iv TABLES TABLE LT STATUS OUTPUTS an aaa ie asispa 11 TABLE 1 1 FINAL TEST AND CALIBRATION VALUES 19 TABLE 2 1 PASSWORD LEVELS rin 24 TABLE 2 2 SYSTEM MODES a 26 TABLE 23 TEST MEASUREMENTS i latet ttt o 26 TABLE 24 WARNING MESSAGES ssi eit ne 21 TABLED STATUS LEDS ES an ale 29 TABLE 3 1 CALIBRATION CONTROLS kauen 36 TABLE 4 1 SETUP FUNCTIONS 2 22 N 51 TABLE 54 DIAGNOSTIC TESIS ts o 54 TABLE S a 57 TABLE 7 1 RS 232 MESS AGB TYPES esse 61 TABLE 7 2 WARNING MESSAGE CLEAR COMMANDS 64 TABLE 755 STATUS REPORTS aaa ae ae ee 64 TABL E 74 CONTROL COMMANDS see ee 65 TABLE 7 5 DIAGNOSTIC EOMMANDS ae 66 TABLE L6 DIAGNOSTIC REPORTS re cbe 66 TABLE 7 7 TEST MEASUREMENT REQUEST COMMANLDS 67 TABLE 7 9 RS 232 VARIABLE NAMES u 69 TABLE 9 1 V F BOARD SWITCH SETTINGS 80 TABLE 10 1 WARNING MESSAGES 86 TABLE 102 TEST FUNCTION VALUES u 88 TABLE 10 3 V F BOARD JUMPERS FACTORY SETTINGS 94 TABLE 10 4 V F BOARD JUMPERS RANGES FOR ANALOG OUTPUT 95 TABLE 11 1
3. ns in ner 40 A A Setting the dale yq o 40 4 5 Adjustine the CLOCK SPCC un 40 4 6 Setting the CO concentration range enne eene nne 41 4 7 Setting the analog output offset i 41 4 5 Selling the RS 232 Daud tale sense aa 42 4 9 Setting the analyzer LD Sa rn seele 42 4 10 Disabling the calibration passWord 42 4 11 Data acquisition system DAS iuis treten Irt ee na 42 4 12 Software c nfi guration aid 50 4 13 Summary of setup functions nn ea 50 50 DIRGNOS TGs En ee ea 53 Test measurement u a eisen eu 33 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page iii 2 2 Dae AO en tes eN 53 6 0 HANDLING WARNINGS 59 7 0 RS 232 COMMUNICATION Sula A a et DAR 61 E 62 T2 W AI tdi 63 7 3 Status COMO usina aaa H 64 YE DU ucc TERT 65 T3 Test measurements y da ie 67 7 6 Viewing and modifying variables enne 68 SO CALIBRATION Seren 71 8 1 REQUIRED EQUIPMENT AND GAS STANDARDS 71 8 2 MUEFEPOINT CALIBRA TON nes re 13 SS Z EROS PAN CHECKIN G asien 76 9 0 ADUUSTMENTS re ad 77 9 1 Power supply board adjustnen a a ar a a dd 77 9 2 A D D A Calibration procedure sea a ri 79 9 3 Dark current signal adjust
4. Enter the number of records desired and press ENTR Only when you press ENTR is the data file actually deleted If you press EXIT the property will not be modified and data file will not be deleted RS 232 REPORT This property controls printing of reports on the RS 232 channel If set to ON then every time a new report is stored it s also printed on the RS 232 channel If this property is set to OFF the reports are still stored in the data file but not printed on the RS 232 channel PARAMETERS This property shows the number of parameters being sampled Each data channel can sample up to 10 parameters each with a separate sampling mode This parameter also specifies the mode of data collection When sampling a reading such as a concentration at periodic intervals it is desirable to use the AVG mode to generate an average of the readings during the interval But when sampling the concentration when P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 46 exiting calibration it is desirable to take a single instantaneous reading using the INST mode The table below summarizes the available sampling modes Sampling Modes Mode Description INST Records instantaneous reading AVG Records average reading during reporting interval Records minimum reading during reporting interval Records maximum reading during reporting interval Each parameter in this list can refer to a different or the same
5. TEST CHAN OUTPUT Output SETUP MORE DIAG Generate RS 232 TABLE 4 1 P N 02163G1 Teledyne Model 300 CO Analyzer Instruction Manual Page 51 5 0 DIAGNOSTICS The Teledyne API carbon monoxide analyzer contains two levels of diagnostics test measurements which can be viewed at all times except when in setup by pressing TEST and lower level diagnostic operations which can only be performed by pressing SETUP DIAG 5 1 Test measurements As stated test measurements can be viewed at any time except when in setup To view a different test measurement simply press the TEST button Table 2 3 lists the test measurements which are available Viewing these test measurements does not interfere with the operation of the Model 300 or the carbon monoxide reading in any way so they may be viewed freely NOTE IF THE VALUE OF ANY TEST FUNCTION IS DISPLAYED AS THIS INDICATES THAT THE READING IS OFF SCALE OR OTHERWISE NON VALID Additionally the values of most TEST functions can output as an analog voltage at the instrument s rear panel see Figure 1 2 The TEST function to be output is selected by pressing SETUP MORE DIAG Press NEXT until TEST CHANNEL OUTPUT appears Press ENTR Select test channel function and press ENTR Table 5 1 below lists the Test functions available for analog output In addition to outputting a value to the analog output channel these tests activate a new test measurement which dis
6. 5A CB ER IN AC PD REAR PANEL FIGURE 1 5 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 16 SYNC DEMOD V F BOARD CPU BOARD B e V R U dl OPTICAL BENCH E 1 m POWER SUPPLY MODULE FILTER WHEE MODEL 300 ASSEMBLY LAYOUT FIGURE 1 6 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 17 1 7 Operation verification The Model 300 Analyzer is now ready for operation 1 2 10 11 12 Read Sections 1 3 and all of Section 4 of the manual to understand the Analyzer operation Turn on the power by pressing the on off switch on the front panel see Figure 2 1 The display should turn on and green sample status LED should be energized The green LED should blink indicating the instrument has entered the HOLD OFF mode Sample mode can be entered immediately by pressing the EXIT button on the front panel The red fault light will also be on until the flows temperatures and voltages are within operating limits Clear the fault messages After a 60 minute warm up review the TEST function values in the front panel display by pushing the left most keyboard button labeled TEST Not every TEST function is a diagnostic of corre
7. 7 Adjust source for maximum signal strength Typically source has no effect on wave shape Not to exceed 27V peak to peak 8 Adjust input mirror as needed to create a wave shape with distinct flattening of the peaks and symmetrical Knees at the peaks A smaller waveform with nice symmetry is preferable to a larger one which is asymmetrical 9 With zero air in verify an MR RATIO of 1 18 to 1 22 is desired If the analyzer shows a significantly different value slightly adjust the input mirror 10 Adjust R7 for a CO MEAS reading of 4200 200 mV P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 98 10 7 Warranty repair questionnaire Organization Contact Phone Address Model 300 Serial Number Are there any warning messages YES O NO If YES please list Please record the following values TEST VALUES CALIBRATION VALUES RANGE PPM PPB CO MEAS ZERO mV CO REF ZERO mV CO SPAN SETTING PPM PPB MR RATIO ZERO CO SLOPE CO MEAS SPAN mV CO OFFSET CO REF SPAN mV MR RATIO SPAN SAMPLE PRESS IN HG A SAMPLE FLOW SCC MIN SETUP VALUES SAMPLE TEMP C BENCH TEMP C ELECTRIC TEST PPM WHEEL TEMP C BOX TEMP C DARK MEAS mV DC POWER SUPPLY mV DARK REF mV TIME HH MM SS Has the unit been leak checked YES O NO LI What are failure symptoms If possible please include a portion of a strip chart pertaining to the problem Ci
8. C V BOXTMP Box temperature o ee DCPS DC power supply composite voltage Example Sample the CO concentration Range 1 once per minute default and issue a report once per 5 minutes and print the report on the RS 232 channel 1 Press SETUP DAS EDIT ENTR INS to create a new data channel and begin editing its properties 2 Edit the NAME property and give it any name you want but do not set the blank name all dashes or duplicate names because they won t be accessible from the RS 232 interface 3 For each of the remaining properties press the SET gt to view the current setting and then press EDIT to change the property if necessary The table below lists the proper settings for all of the properties for this example P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 48 NAME COSMIN timer is expired PARAMETERS SO Range 1 concentration REPORT PERIOD 000 00 05 1 e 5 minutes Average of 5 minutes reported every 5 minutes NUMBER OF 4032 i e two weeks Stores 4032 of Report RECORDS Period 5 minutes average RS 232 REPORT RS 232 is enabled CHANNEL ON Data channel is enabled ENABLED CAL HOLD OFF Hold off is enabled Sample measurement period of filtered CO concentration is 1 minute by default 4 11 3 RS 232 reporting Automatic RS 232 reporting can be independently enabled and disabled for each Data Channel For all default data channels RS 232
9. CAUTION Connect the exhaust fitting on the rear panel See Fig 1 4 to a suitable vent outside the analyzer area P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 13 ANALYZER BASIC EXHAUST PUMP Lage IR SOURCE GAS FILTER WHEEL CA Ux SAMPLE IN FILTER mu WHITE CELL TEMP FLOW SAMPLE CELL SENSOR METER gt BAND PASS FILTERE gt PRESSURE SENSOR DETECTOR MIXER PRE AMP V to F x TO DISPLAY D to A CPU and 1 0 ANALYZER WITH IZS OPTION PN EXHAUST PUMP De Lam IR SOURCE GAS FILTER Wi 2 FILTER TT WHITE CELL EMP FLOW SAMPLE CELL SENSOR METER J SAMPLE IN VALVE BA ASS FILTER er ND PASS FILTER ED PRESSURE M PpSe SENSOR N Z N DETECTOR ERD V MIXER PRE AMP VENT 7 N SPAN lt IN V to TO DISPLAY SPAN GAS IN vave D to A CPU and 170 Dee P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 14 REAR PANEL PNEUMATIC CONNECTIONS FIGURE 1 4 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 15 ZERO SPAN STATUS OUT TEST RS 232 DAS EC R N 5 5 US EXHA ENT AIR
10. b should be within 1 of chart and m should be 1 96 to 2 04 The correlation coefficient r should be 0 998 or higher The Analyzer is now calibrated All CO concentration data should be obtained by reading the Analyzer output in volts or percentage of chart and converting to ppm from the appropriate equation or curve If poor correlation exists check for 1 Flow calculation errors Concentration calculation errors Leaks in manifold Dirt in the manifold Proper manifold venting Zero air system BD P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 75 If none of these help see the TROUBLESHOOTING SECTION 10 0 Record all the Analyzer setup data from the display Range DCPS Box Temp Wheel Temp Bench Temp Sample Temp Sample Flow Pressure MR ratio Measure reference ratio CO Reference CO Measure These data can be useful in future troubleshooting 8 3 ZERO SPAN CHECKING It is recommended that the Model 300 be checked daily for zero and span drift The EPA requires that the Analyzer be zero and span checked at least once every two weeks With the Automatic Zero Span Check and Remote Zero Span Check features of the Model 300 daily zero and span checks are easy For Automatic Zero Span Check and Remote Zero Span Check to be effective it is necessary that the Analyzer have the Zero Span valve option This option includes the two three way stainless steel valves and requires user supplied sou
11. 1s within calibration limits This command adjusts slope and offset values Initiated only If automatic calibration sequence setup is programmed and enabled TABLE 7 4 NOTE THE COMMANDS IN TABLE 7 4 CAN ONLY BE ENTERED VIA THE RS 232 PORT WHEN THE ANALYZER IS IN THE SAMPLE MODE When a control command is issued the CPU will respond by issuing a status report For example if the host computer issues the command C CALZ lt CRLF gt to do a zero check the CPU will send the status report C DDD HH MM START ZERO CALIBRATION lt CRLF gt to the RS 232 output 7 4 Diagnostics The diagnostics mode can be entered from the RS 232 port as well as from the front panel The diagnostics commands available are listed below P N 02163G1 Teledyne Model 300 CO Analyzer Instruction Manual Page 65 NOTE THE DIAGNOSTICS MODE MAY ONLY BE ENTERED VIA THE RS 232 PORT WHEN THE ANALYZER IS IN SAMPLE MODE DIAGNOSTIC COMMANDS D EXIT Exit diagnostics mode Prints all Signal I O values See Table 5 2 for Signal Definitions D name value Examines or sets I O signal See Table 5 2 for a list of signals Must issue D ENTER SIG before using this command D RESET Reset analyzer same as power on D RESET RAM Resets analyzer and erases RAM Erases all DAS data Keeps setup variables and calibration D RESET EEPROM Resets analyzer and erases RAM and EEPROM Erases all DAS data Resets all setup variables to factory
12. CALSEXIT Exitspancheek A NA re CALZERO ENTR Adj CO conc zero value CAL SPAN ENTR Adj CO conc to span va CALEXT_ dl ae i e i SETUP ACAL SEQI Setupauto cal SEQI Disabled SETUP ACAL SEQ2 SEQ2 Disabled SETUP ACAL SEQ3 Setupauto cal SEQ3 Disabled TABLE 3 1 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 36 3 6 Remote zero span check or adjustment contact closure In addition to adjustment via the front panel buttons the Analyzer can be adjusted by means of two contact closures called EXT_ZERO_CAL and EXT_SPAN_CAL See Figure 1 2 for the location of the terminals for connection of the contacts on the rear panel The CPU monitors these two contact closures every 1 second and looks for a positive transition i e 0 1 on either signal If a positive transition occurs on EXT ZERO CAL the CPU will perform a zero check If a positive transition occurs on EXT_SPAN_CAL the CPU will perform a span check When a negative transition i e 1 0 is detected the CPU will go into hold off Also if a positive transition occurs on either signal while the M300 is in zero span check or hold off it will immediately switch to the specified mode For example if the analyzer is in zero check and a positive transition is detected on EXT_SPAN_CAL then the instrument will immediately go into span check To perform a z
13. MODE ZERO TIMER ENABLED ON STARTING DATE 12 20 93 STARTING TIME 22 30 DELTA DAYS 1 DELTA TIME 00 00 DURATION 15 CALIBRATE OFF Example 2 to perform a 15 min zero span check once per day retarding 15 minutes everyday starting at 11 30 pm 12 20 93 Sl Ox Du IES MODE ZERO SPAN TIMER ENABLED ON STARTING DATE 12 20 93 STARTING TIME 23 30 DELTA DAYS 0 DELTA TIME 23 45 DURATION 15 CALIBRATE OFF Example 3 to perform span check once per week starting at 11 30 pm 12 20 93 1 2 3 MODE SPAN TIMER ENABLED ON STARTING DATE 12 20 93 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 35 STARTING TIME 23 30 DELTA DAYS 7 DELTA TIME 00 00 DURATION 15 CALIBRATE OFF TA AE Example 4 to perform zero check once per day at 10 30 pm and a span check once per week starting at 11 30 pm 12 20 93 1 Select any one of SEQx and program as example 1 2 Select any other SEQx and program as example 3 Avoid setting two or more sequences at the same time of the day 3 5 Summary of front panel check and calibration controls The calibration controls are summarized below in terms of the button sequences used to access them CALIBRATION CONTROLS CALZ Beginzerochek CALZZERO ENTR Adjust CO conc to zero CALZEXIT Exitzerocheck Cass Beginspnchek CALS SPAN ENTR Adj CO conc to span va
14. Remote checking via the RS 232 interface supports zero span and zero followed by span check and is identical to remote check via the contact closure inputs This RS 232 control feature is provided mainly so that a host computer at another location can control the Analyzer See Section 7 0 for detailed information on using the RS 232 interface to do a remote Z S check 3 8 Power on hold off Whenever the Model 300 is powered on it will go through a HOLD OFF sequence see Section 3 10 below like it does after a zero span check 3 9 Hold off Every type of check or adjustment zero span manual remote etc is followed by a hold off period of from 1 to 20 minutes during which time the internal data acquisition system DAS does not accumulate CO readings into the DAS average To set the hold off time press SETUP MORE VARS and press NEXT until the variable HOLDOFF_TIME is displayed To change the setting enter a number from 1 to 20 and then press ENTR to store the new value or EXIT to leave the hold off time unchanged P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 38 4 0 SETUP MODE This section describes the setup variables which are used to configure the Analyzer 4 1 Setup mode operation ALL the setup variables are stored in the Analyzer s EEPROM and are retained during power off and even when new software revisions are installed NOTE IFA VARIABLE IS MODIFIED BUT ENTR IS NOT PRESSED THE VARI
15. as described in the preceding sections have been isolated andresolved P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 88 If all the checks described in the preceding sections have been successfully performed the following will provide an itemization of the most common dynamic problems with recommended troubleshooting checks and corrective actions 10 5 1 Noisy or unstable readings at zero 1 Check for leaks in the pneumatic system as described in Section 11 2 2 Confirm that the Zero gas is free of Carbon Monoxide 3 Check for a dirty particulate filter and replace as necessary as described in Section 11 1 4 Check for dirty Sample Cell and or pneumatic lines Clean as necessary as described in Section 11 3 10 5 2 Noisy unstable or non linear span readings 1 Check for leaks in the pneumatic systems as described in Section 11 2 Check for a dirty particulate filter and replace as necessary as described in Section 11 1 3 Check for dirty pneumatic system components and clean or replace as necessary as described in Section 11 3 4 Check for proper adjustment of DAC and ADC electronics by performing the adjustment procedure in Section 9 2 5 Confirm the Sample Temperature Sample Pressure and Sample Flow readings are correct Check and adjust as required 10 5 3 Slow response to changes in concentration 1 Check for dirty pneumatic components and clean or replace as necessary as described in
16. default Resets calibration values TABLE 7 5 These commands may be used whether the diagnostics have been entered from the keyboard SETUP DIAG or the RS 232 D ENTER lt CRLF gt However when the diagnostics are entered via the keyboard no feedback is sent to the RS 232 channel This prevents the RS 232 output from getting unnecessarily cluttered with diagnostic data Whenever the diagnostic mode is entered or exited a report is issued to the RS 232 output The table below summarizes the diagnostic reports DIAGNOSTIC REPORTS C DDD HH MM III ENTER DIAGNOSTIC MODE C DDD HH MM EXIT DIAGNOSTIC MODE TABLE 7 6 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 66 7 5 Test measurements All the test measurements which can be displayed by pressing the TEST button are also available to the host computer via the RS 232 interface The host computer should issue a request for a test measurement and then the CPU will send the current value of the test measurement to the RS 232 output The format of the test measurement message is T DDD HH MM TEST MEASUREMENT lt CRLF gt For example the format of the DC Power Supply output in millivolts would be T 194 11 29 0000 DCPS 2500 MV lt CRLF gt To request a test measurement the host must issue a command of the form T MEASUREMENT lt CRLF gt For a summary of all test functions issue the command T LIST The table below lists the comm
17. Analyzer Instruction Manual Page 94 V F BOARD SWITCH SETTINGS RANGES FOR ANALOG OUTPUT User Set Switches Switch 100 mV 1V 5V 10 V Full Scale Full Scale Full Scale Full Scale S1 Recorder Output S2 DAS Output S3 Test Output 54 Spare TABLE 10 4 3 If Voltages and Jumper settings are correct the V F card is faulty and should be replaced 10 6 4 Checking the DC power supply board A schematic and physical diagram of the DC Power Supply Board are shown on Drawings 015 and 016 in Appendix C The overall performance of the DC Power Supply Board can be checked by observing the value of the DCPS test functions If this value a composite of five regulator value recorded in Table 1 1 of this manual under Test Values the outputs of the individual regulators should be checked by measuring for the following voltages 1 Remove Plugs J8 J6 and J13 from the front of the Power Supply Module Verify that the following voltages are present 24VDC between J8 pins 2 and 4 24VDC between J6 pins 12 and 13 25V AC between J13 pins 4 and 5 15V AC between J13 pins 3 and 2 38V AC between J13 pins 6 and 7 If any of these voltages is not present the Power Supply Module is defective and should be replaced 2 Confirm that the following voltages are present on the V F Board 5V between V F TP 4 and V F TP 5 15V between V F TP 1 and V F TP 3 15V between V F TP 2 and V F TP 3 12V between Mother Board Pad J13
18. CO Analyzer Instruction Manual Page 107 00960 02 00960 03 00960 04 00969 00969 01 00982 00987 01037 01070 01077 01079 01080 01581 01595 01934 03 CB004 CH024 FA004 FLOO1 001 HE002 HW020 HW036 HW037 OP009 OROO1 ORO18 ORO21 OR030 OR034 OR039 PU010 PU020 PU022 SW006 TU001 TU002 TU009 VA002 VA004 M300 47 MM FILTER EXPENDABLES KIT KNF PUMP MODEL MPU5247 N79 M300 37 MM FILTER EXPENDABLES KIT KNF PUMP MODEL NOSATI M300 47 MM FILTER EXPENDABLES KIT KNF PUMP MODEL FNOSATI FILTER TFE 47 MM QTY 100 FILTER TFE 47 MM QTY 25 ASSY SYNCHRONOUS MOTOR OPTO INTERRUPTER ASSEMBLY CO CO CONVERTER ASSEMBLY INSTRUCTION MANUAL FOR M300 FIELD MIRROR INPUT MIRROR OUTPUT MIRROR SOURCE ASSEMBLY WITH ADAPTOR OBJECTIVE MIRROR ASSY SAMPLE THERMISTOR FUSE 3 AG 3 AMP 250V CATALYST CO CO CONVERTER 1 OZ FAN SINTERED FILTER 002 024900 HEATER CO CO CONVERTER 12W HEATER 50W IZS SPRING FLOW CONTROL TFE THREAD TAPE 48 FT TIE CABLE WINDOW SAPPHIRE O RING FLOW CONTROL O RING SAMPLE FILTER O RING SCRUBBER O RING 2 141 V O RING INPUT OUTPUT MIRROR DETECTOR O RING WINDOW PUMP DIAPHRAM KNF MODEL MPU527N79 PUMP 115V 50 60 Hz PUMP REBUILD KIT KNF MODEL NOSATI OVERHEAT SW CELL TUBING 6 1 8 CLR TUBING 6 1 8 BLK TUBING 6 1 4 TYGON SOLENOID SS 3 WAY 24V SOLENOID SS 2 WAY 24V P N 02163G1 Teledyne API Model 300 CO Analyzer
19. CPU in that their functions change depending on the mode of the Analyzer or the operations being performed The legend above a button identifies its current function If there is no legend above a button it has no function and will be ignored if pressed P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 27 ILLUSTRATION OF NORMAL DISPLAY FIGURE 2 2 If TEST is pushed the upper center display cycles through the menu of test parameters e g Sample flow see Table 2 3 If CALZ is pushed the sequence of operations for setting the Analyzer zero is initiated see Section 3 1 If CALS is pushed the sequence of operations for setting SPAN is initiated see Section 3 1 CAL is used to initiate span setting using sample gas such as during a formal calibration Pushing MSG will cause a message to appear on the upper center display Pushing CLR will erase a message provided the condition causing the message has ceased Pushing SETUP changes the function of the push buttons and is used for setting basic parameters as described in Section 4 0 2 2 3 Status LED s The three status LED s to the right of the display indicate the general status of the Model 300 Analyzer The green SAMPLE LED indicates the sampling status The yellow CAL LED indicates the calibration status The red FAULT LED indicates the fault status Table 2 5 summarizes the meanings of the status LED s P N 02163G1 Teledyne API
20. Instruction Manual Page 11 A critical flow orifice is used to control the sample flow The orifice is a precision drilled sapphire jewel protected by a 20 micron sintered filter The critical flow orifice never needs adjustment and maintains precise flow control as long as the ratio of the up stream to down stream pressures is greater than 53 sonic flow conditions 1 6 6 Sample gas connection see Figure 1 4 A 2 m section of 1 4 O D PTFE tubing is needed to connect the sample source to the Analyzer NOTE USE PTFE GLASS STAINLESS STEEL OR NON REACTIVE MATERIALS FOR SAMPLE GAS CONNECTIONS NOTE USE VENT LINE WHEN SAMPLING FROM PRESSURIZED MANIFOLDS SAMPLE PRESSURE SHOULD NOT EXCEED 1 H O 1 6 7 Zero span valve connections see Figure 1 4 Zero air and span gas manifolds should supply their respective gases in excess of 800cc min demand of the Analyzer The manifold should be vented to the outside atmosphere and be of sufficient length and diameter to prevent back diffusion and pressure effects Adequate zero air can be supplied by the M300 using the IZS option or by using a commercial calibrator P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 12 1 6 8 Exhaust connections see Figure 1 4 A single 1 4 O D tube should be connected from the Analyzer sample exhaust to an area outside of the room the Analyzer occupies The maximum length of the exhaust line should not exceed 30 feet
21. MAINTENANCE SCHEDUL EE 101 FIGURES FIGURE 1 1 CARBON MONOXIDE ANALYZER eerte 8 FIGURE 1 2 REAR PANEL ELECTRICAL CONNECTIONS 9 BLOW DIAGRAMA 14 FIGURE 1 4 REAR PANEL PHEUMATIC CONNECTIONS 15 REAR PANEL rei ee 16 FIGURE 1 6 MODEL 300 ASSEMBLY LAYOUT eese enne 17 FIGURE 2 1 MODEL 300 FRONT PANEL 25 FIGURE 2 2 ILLUSTRATION OF NORMAL DISPLAY 28 FIGURE 8 1 GAS GENERATION SYSTEM unseren ipsuin ito en de 72 FIGURE 8 2 INLET VENTING RECOMMENDATIONS 72 FIGURE 9 1 M300 ELECTRICAL BLOCK DIAGRAM m 78 FIGURE 9 2 FLOW AND PRESSURE READOUT ADJUSTMENT 81 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page v FIGURE 10 1 PICKUP WAVEFORM sea 97 FIGURE 10 2 DETECTOR WAVEFORM i ae 97 FIGURE RS 232 PIN ASSIGNMENTS its 111 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page vi 1 0 INTRODUCTION 1 1 Preface Teledyne API is pleased that you have purchased the Model 300 We at Teledyne API will be pleased to provide you with any support requir
22. N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 77 i M Le pu STD BUS re LO s i i M300 ELECTRICAL BLOCK DIAGRAM FIGURE 9 1 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 78 9 2 A D D A Calibration procedure Due to the stability of modern electronics this procedure should not have to be performed more than once a year or whenever a major sub assembly is exchanged or whenever analog output voltage range is changed To calibrate the ADC do the following 1 Press SETUP MORE DIAG 2 Enter Diagnostic password and press NEXT until D A CALIBRATION appears in the display and press ENTR 3 Press ADC to perform the A D Cal 4 The M300 display will read ADJUST ZERO A D xx x MV Put the probe of a voltmeter between TP3 AGND and TP9 DAC 0 on the top of the V F card See Drawing 00514 Appendix C 5 The value displayed by the voltmeter should be close 20 mV to the value on the M300 display If they are not close then the V F card has probably been configured improperly 6 Adjust the Zero pot R27 on the V F card until the value on the M300 display matches the value on the voltmeter to within 2 mV Note that when adjusting R27 the value on the M300 display will change the value on the voltmeter will remain constant 7 Press ENTR 8 The M300 display will now read ADJUST GAIN A D xx x MV 9 Adjust the Span pot R
23. SAMPLE FILTER O RING SCRUBBER O RING 2 141 V O RING INPUT OUTPUT MIRROR DETECTOR O RING WINDOW PUMP DIAPHRAM KNF MODEL MPUS27N79 PUMP 115V 50 60 Hz PUMP REBUILD KIT KNF MODEL NOSATI OVERHEAT SW CELL TUBING 6 1 8 CLR TUBING 6 1 8 BLK TUBING 6 1 4 TYGON SOLENOID SS 3 WAY 24V SOLENOID SS 2 WAY 24V P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 106 12 2 SPARE PARTS FOR NON CE MARK UNITS PART NO DESCRIPTION 00015 00094 10 00276 13 00329 00329 03 00329 06 00329 09 00369 00369 01 00402 05 00422 01 005 14 03 0055 1 02 0055 1 06 00551 10 00611 01 00611 02 00646 00690 01 00704 00728 00798 00864 00953 00956 0001 00958 01 00960 POWER SUPPLY BOARD ORIFICE 13 MIL CPU BOARD THERMISTOR ASSY 885 07 1600 THERMISTOR ASSY SAMPLE TEE THERMISTOR ASSY SAMPLE TEE THERMISTOR ASSY SAMPLE TEE FILTER TFE 37 MM QTY 100 872 006400 FILTER TFE 37 MM QTY 25 872 006300 PNEUMATIC SENSOR BOARD CO PROM W SOFTWARE V F BOARD POWER SUPPLY MODULE 115V 60Hz POWER SUPPLY MODULE 220V 50Hz POWER SUPPLY MODULE 240V 50Hz ASSY THERMISTOR ASSY HEATER THERMISTOR SAMPLE FILTER ASSY PADS KEYBOARD NEW DISPLAY SYNC DEMODULATOR BOARD ASSY OPTICAL BENCH PREAMP DETECTOR ASSEMBLY GAS FILTER WHEEL M300 LEVEL 1 SPARES KIT FOR S N ABOVE 320 M300 37 MM FILTER EXPENDABLES KIT KNF PUMP MODEL MPU527 N79 P N 02163G1 Teledyne API Model 300
24. TABLE OP CONTENTS een 111 TABLES sisas ra BIGURES3 LM E M M d 1 0 INTRODUCTION sacara 1 1l Preface la 1 CERE 2 1 3 Principle of Opera oma ae 3 4 1 5 Installation and overview s ee ehe 5 1 6 Electrical and pneumatic 10 177 Operation ee Eimer 18 150 Opel 20 ZOOM OPE RAMON cuotas aos 23 2217 AS 23 2 2 Front panel c a e b dat seu LOL ara 25 3 0 PERFORMANCE TESTING usina 31 3 1 Manual zero span check cue ea 31 3 2 IZS zero span check Option aneignen 32 HS LOS Pan valves cue e tr 33 3 4 Automatic zero span check 33 3 5 Summary of front panel check and calibration controls 36 3 6 Remote zero span check or adjustment contact closure 37 3 7 Remote zero span check or adjustment RS 232 seen 38 3 0 PO Wer On Bold ot ara Hr 38 39 Hold us M 38 40 SE TUR MODE A 39 4 1 Setup mode operazionale 39 4 2 Examining the carbon monoxide formula slope and offset 39 4 3 Setting the timie of day
25. Vent Span port at the rear panel should be vented to a suitable exhaust manifold at ambient atmosphere pressure The pressure regulator on the gas source cylinder should be sent to provide 30 35 PSI delivery pressure 2 If it is desired to use span gas from a source which delivers gas at atmosphere pressure e g a calibrator the span gas manifold should be connected at the Vent Span port at the Analyzer s rear panel and the Pressure Span port should be capped P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 20 1 8 3 Internal zero span The IZS option includes the valves and connection parts described above and in addition includes an internal zero air scrubber This scrubber operates by catalyticly converting CO in the gas stream to If the Analyzer is equipped with the IZS option Span gas connections should be made as described above and a source of clean air at ambient pressure should be connected to the IZS Zero Air Port on the Analyzer s rear panel P N 02163G1 Teledyne Model 300 CO Analyzer Instruction Manual Page 21 2 0 OPERATION 2 1 Key features The important features of the Teledyne API Model 300 CO Analyzer are listed below 2 1 1 CO readout The Teledyne API Model 300 CO Analyzer constantly displays the current Carbon Monoxide reading in PPM in the upper right hand corner of the alphanumeric display 2 1 2 CO analog output The Teledyne API CO Analyzer provides a buffe
26. and enter the password 818 Press ZERO It usually takes about 5 to 10 minutes for the reading to stabilize near zero After a stable reading has been obtained press ENTR The display should now read 0 0 ppm carbon monoxide er AR Rosgsme P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 6 NOTE REPEATEDLY PRESSING ENTR TO GET THE INSTRUMENT TO DISPLAY THE CORRECT SPAN ZERO VALVE DOES NOT IMPROVE THE ACCURACY OF THE CALIBRATION NOR DOES IT SPEED UP STABILIZATION THE REASON FOR WAITING 5 10 MIN IS THAT IT TAKES THE INSTRUMENT A PERIOD OF TIME TO ESTABLISH AN ACCURATE AVERAGE FOR THE SPAN ZERO READING 11 Adjust the Analyzer span point a Input span gas of approximately 80 of the related full scale range concentration from a known source through the sample port of the Analyzer Go to manual calibration by pressing the CAL button while in the sample mode Enter the operator password 512 The menu should now show SPAN CONC and EXIT Enter the concentration of the CO calibration gas by pressing CONC and entering the value from the keyboard Wait 10 minutes for a stable reading to be attained and then press SPAN followed by ENTR If the SPAN button is not displayed this means that the Analyzer is too far out of adjustment to do a reliable calibration and thus it is not permitted see Section 3 1 for information on the calibration limits The operator can exit the manual calibration
27. and enter the value from the keyboard Press ENTR to accept the change This variable is set to the number of seconds per day by which to speed up or slow down the clock It should only need to be set once for each Analyzer For example if the clock is running 10 seconds fast each day set the variable to 10 and press ENTR Note that 10 indicates that we want the clock to run 10 seconds slower each day If the clock is running 10 seconds slow each day set the variable to 10 indicating that we want the clock to run 10 seconds faster each day P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 40 If the clock speed adjust variable has already been set to a value other than 0 and the speed is still too fast or too slow ADD the required adjustment to the current value of the variable For example if the clock speed adjustment is already set to 10 and the clock is 5 seconds too slow per day add 5 to the current value yielding 15 as the new value 4 6 Setting the CO concentration range The CO concentration range is the concentration value that corresponds to the maximum voltage output at the rear panel usually 5 volts The M300 can operate in one of three analog output Range Modes The Range Mode can be changed through the SETUP RNGE MODE menu The modes are described below 4 6 1 Single range mode SNGL In this mode both analog outputs REC and DAS are set to the same range This range can be set to any va
28. enabled in the setup mode The Teledyne API Model 300 Carbon Monoxide Analyzer with IZS or Zero Span Valves option offers capability to check the zero and span point automatically on a timed basis or through remote RS 232 operation see Section 3 7 Under the SETUP ACAL menu there are three separate auto sequences called SEQI SEQ2 and SEQ3 Under each SEQ there are eight setup parameters that affect zero span checking the mode the starting date of the check the time of day for check the number of delay days time delay the duration of the check the range to check and whether to calibrate as well as check the range These are described individually below Use the PREV and NEXT buttons to scroll through the three sequences The mode for each sequence is displayed To change the mode for any of the sequences scroll to the desired sequence and press the MODE button Use the PREV and NEXT buttons to select one of the modes shown below and press ENTR Mode 1 DISABLED Sequence is disabled 2 ZERO 3 SPAN 4 ZERO SPAN To change the setup parameters for a sequence press the SET button Pressing the lt SET and SET gt buttons allows you to scroll through the setup parameters and edit them by pressing the EDIT button The function of each setup parameter is described below Timer Enabled When set to ON the sequence will be executed based on the internal timer as specified in the following parameters When set to OFF the sequence will b
29. gt W WSMPFLOW lt CRLF gt W WSMPRES lt CRLF gt W WSMPTEMP lt CRLF gt SAMPLE PRESSURE WARNING SAMPLE TEMP WARNING W WBOXTEMP lt CRLF gt W WBNCHTEMP lt CRLE gt W WDYNZERO lt CRLF gt W WDYNSPAN lt CRLF gt W WVFINS lt CRLF gt BOX TEMP WARNING BENCH TEMP WARNING CANNOT DYN ZERO CANNOT DYN SPAN V F NOT INSTALLED TABLE 7 2 7 3 Status control This subset of messages is concerned with reporting the status of the Analyzer and controlling the Analyzer remotely Whenever the Analyzer does a calibration it issues a report to the RS 232 output The table on the following page summarizes the status reports STATUS REPORTS C DDD HH MM START ZERO CALIBRATION C DDD HH MM FINISH ZERO CALIBRATION C DDD HH MM IIII START SPAN CALIBRATION C DDD HH MM IIII FINISH SPAN CALIBRATION C DDD HH MM IIII START MULTI POINT CALIBRATION C DDD HH MM IIII FINISH MULTI POINT CALIBRATION C DDD HH MM START CALIBRATION HOLD C DDD HH MM IIII FINISH CALIBRATION HOLD TABLE 7 3 To do a remote adjustment via the RS 232 interface the host computer should issue a message with the following format C COMMAND lt CRLF gt The commands are summarized in the table below P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 64 CONTROL COMMANDS C EXITS lt CRLF gt Exit span cal only Executed only if the instrument is in the proper calibration mode and concentration
30. procedure only by pressing the EXIT button P N 02163G1 Teledyne Model 300 CO Analyzer Instruction Manual Page 7 RESSUR CARBON MONOXIDE ANALYZER FIGURE 1 1 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 8 REAR PANEL ELECTRICAL CONNECTIONS FIGURE 1 2 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 9 1 6 Electrical and pneumatic connections 1 6 1 Electrical connections Output 1 Carbon Monoxide concentration Chart Recorder REC Output 2 Carbon Monoxide concentration Data Acquisition System DAS Output 3 Test function analog output Input 4 Zero valve request Input 5 Span valve request Input 6 Not Used There are 2 six pin connector strips on the rear panel shown in Figure 1 2 The pins are divided into 3 plus minus pairs and have the functions shown above Outputs 1 and 2 have identical signals and electrical characteristics Output 3 is the same as 1 and 2 electrically but has analog TEST function signals routed to it See Diagnostics in Section 5 for details 1 6 2 Remote contact closures zero span inputs and status outputs Remote contact closures can be used to remotely energize the zero span valves to do a zero or span check The external contact closure should be capable of switching 12 VDC at 50 ma Refer to Figure 1 2 for connection location See Sections 1 8 6 and 3 6 for further details NOTE ZERO OR SPAN CHECKS CAN BE PERFORMED IN A
31. receiving the transmission In the original spec modems communicated with terminals and were wired as Data Communications Equipment or DCE Terminals or printers received data from modems and thus were wired as Data Terminal Equipment or DTE As technology has progressed it has become more ambiguous who was DCE and DTE Teledyne API analyzers are wired as DTE i e like a printer As can be seen this presents difficulties if you a hook a printer to the instrument that is likewise wired as a printer To help understand the different problems 3 examples as shown below Example 1 Connecting the Teledyne API analyzer to an IBM PC AT compatible computer In this case the PC is wired as DCE and the analyzer is wired as DTE therefore a null modem is not needed The wiring is straight through i e pin 1 to pin 1 pin 2 to pin 2 etc Therefore all you have to do here is adapt the connector on the analyzer male DB 9 to whatever is on the PC Make sure none of the adapters have null modems in them Example 2 Connecting the Teledyne API analyzer to a serial printer In this case both the analyzer and the printer are wired as DTE so a Null Modem will have to be inserted in the line to change the wiring to make the analyzer look like a modem i e DCE Make sure in using your adapters that ONLY ONE null modem connector is used Null modems can be purchased in DB 9 and DB 25 connectors at each end Example 3 Connecting the Teledyne API a
32. reporting is initially set to OFF If this property is turned on the Data Channel will issue a report with a time and date stamp to the RS 232 port every time a data point is logged The report format is shown below D 31 10 06 0412 CONC AVG COCNC1 6 8 PPB The report consists of the letter D follow by a time date stamp 31 10 06 followed by the instrument ID number 0412 Next is the Data Channel and the sampling mode AVG indicates that the data point is an average of more than one sample as opposed to a instantaneous reading INST Finally the name of the parameter and its value COCNC1 6 8 PPB are printed For Data Channels that sample more than one parameter such as PNUMTC and CALDAT each parameter is printed on a separate line To enable RS 232 reporting for a specific Data Channel P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 49 1 Press SETUP DAS Enter DAS menu to edit Data EDIT Channels Press PREV NEXT Select Data Channel to edit Press EDIT Edit selected Data Channel BERGER RS 232 REPORT OFF is displayed 6 ToggleOFFto ON Change RS232 REPORT property 7 PresENTR Acceptschamge 8 PressEXIT 4times Exits back to sample menu See Section 7 3 1 for more information on DAS reporting through the RS 232 interface 4 12 Software configuration The software configuration can be displayed by e
33. 0 3 Troubleshooting using warning messages The most common and or serious instrument failures will result in a warning message or messages being displayed on the front panel Table 10 1 below lists the warning messages which the Analyzer may display along with their meaning and the recommended corrective action It should be noted that if multiple more than 2 or 3 warning messages occur at the same time it is often an indication that some fundamental analyzer sub system power supply V F board CPU has failed rather than an indication of the multiple failures referenced by the warnings In this situation it is recommended that proper operation of power supplies see Section 10 6 4 and the V F Board see Section 10 6 3 be confirmed before addressing the specific warning messages WARNING MESSAGES SOURCE WARNING The CO REF value is Check and adjust the greater than 5000 mV or Sync Demodulator and less than 2500 mV optical alignment as described in Section 10 6 6 and 10 6 8 SYNC ERROR No modulation is present Check IR source IR on the output of the IR detector pre amp and detector Opto interrupter P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 85 BENCH HEAT SHUTDOWN SAMPLE PRESSURE WARNING SAMPLE FLOW WARNING BOX TEMP WARNING SAMPLE TEMP WARNING CANNOT DYN ZERO CANNOT DYN SPAN V F NOT INSTALLED Temperature control of the Optical bench cannot be maintained at its 48
34. 31 on the V F card until the value on the M300 display matches the value on the voltmeter to within 2 mV 10 Press ENTR 11 The ADC is now calibrated and the M300 will automatically calibrate all the DAC s This process takes only a few seconds 12 Press EXIT 4 times to return to the sample menu 9 3 Dark current signal adjust procedure The detector dark current changes little as the detector ages Therefore this procedure should not need to be performed more than once per year or whenever a major sub assembly is changed To calibrate the dark current signal press SETUP MORE DIAG DARK CAL and the analyzer will automatically do the following 1 Disconnect the detector output from the processing electronics 2 Wait 2 minutes for electronics to stabilize at the dark value 3 Average CO MEAS and CO REF reading for 1 minute 4 Reconnect the detector output to the processing electronics to the processing electronics The average CO MEAS and CO REF dark reading are stored as offsets which are subtracted from all future CO detector readings P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 79 To view the current dark offset press SETUP MORE DARK VIEW Press EXIT when finished No password is required to view the dark offset only to change it 9 4 Output voltage range changes Output voltage ranges are set by DIP Switch settings on the V F board To change the range for the analog outputs 1 Turn off i
35. 6 and J13 7 If any of these voltages is incorrect it is probable that the DC Power Supply Board is faulty and should be replaced Four Temperature linearization circuits are contained on the DC Power Supply board The outputs of these circuits can be checked by measuring the voltages at test pointson the board as follows P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 95 TP1 Sample Temp 30 C 2 5 V 125 9 TP2 Optical Bench 50 C 2 5 V 125 9 TP3 Filter Wheel Temp 50 C 2 5 V 125 V 9C TP4 Chassis Temp 20 C 2 5 V 1 125 9 If any of these voltages is incorrect check thermistor operation as described in Section 10 6 2 If thermistors are operating correctly it is probable the DC Power Supply Board is defective and should be replaced 10 6 5 Checking the pneumatic sensor board A schematic and physical diagram of the Pneumatic Sensor Board are shown on Drawings 402 and 403 in Appendix C Proper operation of the pneumatic sensor board can best be determined by comparing the values of Flow and Pressure Test functions to measurements obtained with independent flow and pressure meters Flow and pressure readings can be adjusted as described in Section 9 5 If it is not possible to adjust the pneumatic sensor board to agree with independent flow and pressure measurements confirm the presence of 15V at connector J1 pin 6 If this voltage is not present check the DC Power Supply Board as describ
36. ABLE WILL NOT BE CHANGED AND THE ANALYZER WILL BEEP WHEN EXIT IS PRESSED 4 2 Examining the carbon monoxide formula slope and offset The slope and offset parameters can be examined by pressing the lt TST or TST gt buttons until the slope and offset test functions appear The slope and offset parameters are set only during zero and span calibration routines These parameters are used to adjust the span and zero values to their exact values The current value of the carbon monoxide reading that is displayed on the front panel and output on the D A terminals on the back panel is computed as follows 1 Every 160 msec the analyzer takes a CO MEAS reading i e a reading of the detector output with the IR beam passing through the N cell of the Gas Filter Wheel and a CO REF reading i e a reading of the detector output with the IR beam passing through the CO Cell of the Filter Wheel 2 raw uncorrected un linearized CO concentration value is calculated according to the following equation CONCENTRATION GAIN_CONST x 1 CO_MEAS CO_REF ZERO_CONST P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 39 3 Slope and offset corrections are made to the CO concentration according to the equation CORRECTED CONCENTRATION SLOPE x MEASURED CONCENTRATION OFFSET 4 The concentration value is linearized over the range of 0 to 1000 ppm by a multi point software look up table and corrected for temperature a
37. AVEFORM 10 6 8 Checking Optical Alignment The mirrors used in the optical system of the Model 300 are designed to have their alignment set permanently during the manufacturing process and no adjustment is normally needed If the optical system is disassembled or if failure of any of the optical components is suspected the instrument can be checked for proper optical alignment as follows 1 Connect a source of zero air to the analyzer 2 Allow the analyzer to warm up for 60 minutes 3 Confirm Optical System Energy through put by a Press the TST gt or TST lt button on the front panel until the CO MEAS value is displayed b Increase the gain of the Synchronous Demodulation by turning Pot R7 on the Sync Demodulator board clockwise Ifa CO MEAS value of 5000 mV can obtained energy throughput is acceptable c Re adjust Pot R7 on the Sync Demodulator Board to obtain a CO MEAS reading of 4200 mV 200 4 Connect an oscilloscope to U7 Pin 1 Sync the oscilloscope on this channel P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 97 5 Confirm the wave from of the optical signal by attaching an oscilloscope to the Sync Demodulator board a U2 Pin 7 The oscilloscope trace should appear like those shown in Figure 10 2 In particular the wave form should be symmetrical and should have distinct flat regions at the top and bottom of the pulses 6 If unable to achieve 4200 mV on CO MEAS then do the following
38. Assembly Sync Demodulator Schematic Sync Demodulator Assembly Mother Board Schematic Mother Board Assembly Pre Amp Bias Schematic Pre Amp Bias Assembly Rear Panel PCA CE Mark Units Only Schematic Rear Panel PCA CE Mark Units Only Assembly Keyboard PCA CE Mark Units Only Schematic Keyboard PCA CE Mark Units Only Assembly XFMR PTC CE Mark Units Only Schematic XFMR PTC CE Mark Units Only P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 115
39. C set point The Sample Pressure is less than 15 Hg or is greater than 35 Hg The sample flow is less than 500 cc min or greater than 1000 cc min The inside chassis temp is less than 10 C or is greater than 50 C The Sample Temperature is less than 10 C or is greater than 50 C An offset of more than 5 ppm would be required to Zero adjust the analyzer A slope of less than 0 5 or greater than 2 0 would be required to Span adjust the analyzer The CPU is unable to communicate with the V F Board Check Optical Bench heater and thermistor as described in Section 9 10 Check for pressure transducer problems as described in Sect 10 6 5 and Sect 10 6 1 Check for pneumatic system problems as described in Section 10 6 1 Check for flow transducer problems as described in Sect 10 6 5 See Section 10 6 2 See Section 10 6 2 See Section 10 5 5 See Section 10 5 6 Check and re seat CPU and V F board See Sect 10 6 3 SYSTEM RESET A power Off On cycle None required has occurred RAM INITIALIZED Dynamic memory has been re initialized in response to the installation of anew PROM or memory chip TABLE 10 1 None required P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 86 10 4 Troubleshooting using test function values The Model 300 provides the capability to display on operator demand the values of Test Functions which allow the observation of key analyzer operating parameters
40. DDD HH MM BENCH_SET 48 43 53 lt 0 100 gt lt CRLF gt indicating that the current set point is 40 degrees the warning limits are 43 to 53 degrees and the data entry limits are O to 100 degrees To modify a variable s value almost the same format of command is used V VARIABLE VALUE WARNLO WARNHI lt CRLF gt The VARIABLE field is the name of the variable being modified and the VALUE field is the new value WARNLO and WARNHI are the low and high warning limits respectively and may only be given if the variable uses warning limits They are optional for variables which use warning limits and if not given the warning limits are not changed After changing the variable s value the CPU will respond with P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 68 V VARIABLE VALUE WARNLO WARNHI DATALO DATAHI lt CRLF gt which should reflect the new value The values in square brackets are not required for all variables If needed the values are included on the command line separated by spaces For example to change the instrument ID the host computer would issue a command like this V MACHINE_ID 1234 lt CRLF gt and the CPU should respond with V DDD HH MM MACHINE ID 1234 0 9999 lt CRLF gt Table 7 9 lists the variable names which are variable through the RS 232 interface and their corresponding button sequences RS 232 VARIABLE NAMES TABLE 7 9 P N 02163G1 Teledyne AP
41. EF value described above P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 87 PRES The absolute 0 1 0 Hg below Check for pressure of the ambient pressure pneumatic system sample gas in the problems See Sect absorption cell 10 6 1 Check for pressure transducer problems See Sect 10 6 5 SAMPLE FLOW Sample mass flow 720 880 scc min Check for rate pneumatic system problems See Section 10 6 1 Check for flowmeter problems See Section 10 6 5 SAMPLE TEMP The temperature of 48 50 C After See Section 10 6 2 the sample gas in warm up the absorption cell BENCH TEMP The temperature of 48 C After warm See Section 10 6 2 the Optical Bench up WHEEL TEMP The temperature of _ See Section 10 6 2 BOX TEMP f The temperature 1 5 C above See Section 10 6 2 inside the analyzer ambient chassis DCPS DC Power Supply 2250 2750 mV See Section 10 6 4 reference A composite of all voltages provided by the DC Power Supply TABLE 10 2 10 5 Troubleshooting dynamic 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 Additionally analyzer behavior which appears to be a dynamic problem is often a symptom of a seemingly unrelated static problem For these reasons it recommended that dynamic problems not be addressed until all static problems and warning conditions
42. EST MSG CLR Operator 512 CALZ CALS CAL Setup 818 2 SETUP SETUP VARS SETUP DIAG 101 TABLE 2 1 NOTE THE OPERATOR AND SETUP PASSWORDS CAN BE DISABLED TO DO THIS ENTER SETUP PASSWORD AND TOGGLE ON TO OFF PUSH ENTR AND THE PASSWORDS WILL BE DISABLED P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 24 2 2 Front panel This section describes the operator interface from the point of view of the front panel The front panel consists of a 2 line by 40 character alphanumeric display 8 push buttons and 3 status LED s Each of these features is described below 2 2 1 Front panel display The display is divided into 4 main fields the mode field in the upper left the message field in the top center the sample concentration field consisting of the most recent instantaneous carbon monoxide value field in the upper right and the MENU field which occupies the entire bottom line of the display A typical display is shown in Figure 2 1 MODEL 300 FRONT PANEL FIGURE 2 1 The mode field indicates the current mode of the Analyzer Usually it shows SAMPLE A indicating that the instrument is in the sample mode and that automatic span checking is enabled Manual span checking or calibration can only be performed by pressing the buttons on the front panel labeled CALZ CALS or CAL Automatic span check only occurs at the preset time Dynamic span adjust can be perfo
43. I Model 300 CO Analyzer Instruction Manual Page 69 8 0 CALIBRATION This section describes a method of performing a multi point calibration of the Model 300 CO Analyzer and a method of performing a zero span check 8 1 REQUIRED EQUIPMENT AND GAS STANDARDS Zero air must be free of CO less than 0 1 ppm of CO CAUTION BE CAREFUL WHEN PULLING IN OUTSIDE AIR PARTICULARLY IF OUTSIDE HUMIDITY AND TEMPERATURE ARE HIGH CONDENSATION MAY RESULT WHICH CAN LEAD TO UNSTABLE OPERATION OR AT WORST WATER CONTAMINATION IN THE CELL Calibration gas concentrations must be generated from an NIST traceable cylinder of CO in air such as manufactured by Scott Marrin Carrier air for transporting the CO must be the same as the zero air A suggested calibration gas generating system is shown in Figure 8 1 The materials in the calibration gas delivery system should be stainless steel TFE and FEP Teflon The system must be clean The calibration gas delivery system or manifold must be properly vented near the Analyzer inlet to avoid imposing a pressure or vacuum at the inlet The recommended venting method is shown in Figure 8 2 P N 02163G1 Teledyne Model 300 CO Analyzer Instruction Manual Page 71 GAS GENERATION SYSTEM FIGURE 8 1 INLET VENTING RECOMMENDATIONS FIGURE 8 2 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 72 For minimum back diffusion through the vent and for minimum ba
44. INSTRUCTION MANUAL MODEL 300 CARBON MONOXIDE ANALYZER Teledyne Advanced Pollution Instrumentation T API 9480 Carroll Park Drive San Diego CA 92121 5201 Toll Free 800 324 5190 Telephone 858 657 9800 Fax 858 657 9816 Email api sales Oteledyne com Website www teledyne api com 02163 Rev G1 03 17 06 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 alerts you to potential hazards that could hurt you or others Each safety message is associated with a safety alert symbol These symbols are found in the manual and inside the instrument The definition of these symbols is described below GENERAL WARNING CAUTION Refer to the instructions for details on the specific danger CAUTION Hot Surface Warnin CAUTION Electrical Shock Hazard A N Technician Symbol All operations marked with this symbol are to be N performed by qualified maintenance personnel only Z AN 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 possibly hazardous consequences P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page ii TABLE OF CONTENTS SAFETY MESSAGES Maenner eo 11
45. Instruction Manual Page 108 APPENDIX A LISTOF AVAILABLE MODEL 300 OPTIONS RS 232 amp Status Outputs Internal Zero Span IZS with valves Rack Mount and Slides P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 109 APPENDIX B TIPS ON CONNECTING THE TELEDYNE API ANALYZER RS 232 INTERFACE Teledyne API analyzers use the RS 232 communications protocol to allow the instrument to be connected to a variety of computer based equipment RS 232 has been used for many years and as equipment has become more advanced connections between various types of hardware have become increasingly difficult Generally every manufacturer observes the signal and timing requirements of the protocol very carefully Problems arise when trying to specify connectors and wiring diagrams that attach the analyzer to various devices The problem centers around two areas First is the physical incompatibility of connectors Second is the wiring of the connectors This Note will attempt to provide some guidelines for connecting the Teledyne API analyzers to a variety of other equipment Connectors There is a wide variety of connectors NO uade S ee and cables that are specified to operate with the RS 232 protocol 9 52 This is because electronics have e ceo decreased in size over the years and j connectors have been downsized to match the electronics Pu Signal Cables amp Adapters come Not Used 2 T
46. MISTOR 00646 SAMPLE FILTER ASSY 00690 01 PADS 00728 NEW DISPLAY 00798 SYNC DEMODULATOR BOARD 00864 ASSY OPTICAL BENCH 00953 PREAMP DETECTOR ASSEMBLY 00956 GAS FILTER WHEEL 0001 00958 01 M300 LEVEL 1 SPARES KIT FOR S N ABOVE 320 00960 M300 37 MM FILTER EXPENDABLES KIT KNF PUMP MODEL MPU527 N79 00960 02 M300 47 MM FILTER EXPENDABLES KIT KNF PUMP MODEL MPU5247 N79 00960 03 M300 37 MM FILTER EXPENDABLES KIT KNF PUMP MODEL FNOSATI 00960 04 M300 47 MM FILTER EXPENDABLES KIT KNF PUMP MODEL FNOSATI 00969 FILTER TFE 47 MM QTY 100 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 105 00969 01 00982 00987 01037 01070 01077 01079 01080 01581 01595 01916 01 01930 01934 03 CB004 CH024 FA004 FLOO1 HEO17 HE018 HW020 HW036 HW037 OP009 OR001 OR018 OR021 OR030 OR034 OR039 PU010 PU020 PU022 SW006 TU001 TU002 TU009 VA002 VA004 FILTER TFE 47 MM QTY 25 ASSY SYNCHRONOUS MOTOR OPTO INTERRUPTER ASSEMBLY CO CO CONVERTER ASSEMBLY INSTRUCTION MANUAL FOR M300 FIELD MIRROR INPUT MIRROR OUTPUT MIRROR SOURCE ASSEMBLY WITH ADAPTOR OBJECTIVE MIRROR REAR PANEL BOARD CE KEYBOARD CE ASSY SAMPLE THERMISTOR FUSE 3 AG 3 AMP 250V CATALYST CONVERTER 1 OZ FAN SINTERED FILTER 002 024900 HEATER CO CO CONVERTER 12W HEATER 50W IZS SPRING FLOW CONTROL TFE THREAD TAPE 48 FT TIE CABLE WINDOW SAPPHIRE O RING FLOW CONTROL O RING
47. Model 300 CO Analyzer Instruction Manual Page 28 STATUS LED s Green Off Not monitoring DAS Disabled On Monitoring normally taking DAS data Blinking Monitoring HOLD OFF mode on no datato DAS 1 Yellow Off Auto Cal disabled On Auto Cal enabled Blinking Calibrating Red Off No warnings exist Blinking Warnings exist 1 This occurs during calibration holdoff power up holdoff and when in Diagnostic mode TABLE 2 5 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 29 3 0 PERFORMANCE TESTING Zero span checking and calibration of the Teledyne API CO Analyzer is divided into two sections Chapter 3 discusses the different methods by which the Analyzer s zero and span settings may be checked and adjusted The emphasis in Chapter 3 is on the operation of the buttons and the internal adjustments they make in the instrument 3 1 Manual zero span check Operators can manually check the zero and span setpoints of the Analyzer while in sample mode by allowing the instrument to sample calibration gas and pressing the CAL button This is also referred to as a multi point calibration NOTE ZERO OR SPAN CHECKS CAN BE PERFORMED IN ANY ORDER 3 1 1 Zero Check Allow the analyzer to sample zero air through the sample port Press CAL button After a few minutes the CO reading should go to zero If it doesn t the operator may press the ZERO button followed by ENTR This will force the CO reading to go
48. NY ORDER 1 6 3 Status Outputs Status outputs report analyzer conditions via contact closures located on the DB 50 connector on the rear panel The contacts are NPN transistors which can pass 50 mA of DC current The pin assignments are listed in Table 1 1 below P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 10 OUTPUT PIN PAIR STATUS CONDITION LOW HIGH 1 1 2 ZERO TRUE DURING ZERO CALIBRATION CALIBRATION WARNING EXISTS WARNING EXISTS DIAGNOSTIC MODE IS ON PRESSURE HIGH RANGE TRUE IF THE AUTO SELECTED RANGE FUNCTION HAS SWITCHED THE ANALYZER INTO HIGH RANGE 17 18 SYSTEM OK TRUE IFNO ALARM CONDITIONS EXIST 19 20 RESERVED 11 21 22 SOURCE TRUE IF THE WARNING ANALYZER SOURCE INTENSITY IS OUT OF LIMITS 23 24 RESERVED TABLE 1 1 STATUS OUTPUTS 1 6 4 RS 232 The RS 232 connection is a male 9 pin D sub connector at the location shown in Figure 1 2 1 6 5 Pneumatic system The Model 300 is equipped with a vacuum pump capable of pulling 800 cc min across a critical flow orifice This allows a smooth stable flow of sample through the Analyzer Sample enters the Analyzer through a 5 micron TFE particulate filter element 37 mm diameter mounted immediately behind the front panel The sample then enters directly into the sample cell Please see Figure 1 3 for a flow diagram and Figure 1 4 for pneumatic connections P N 02163G1 Teledyne API Model 300 CO Analyzer
49. PI Model 300 CO Analyzer Instruction Manual Page 42 4 11 1 Data Channels The function of the Data Channels is to store report and view data from the analyzer The data may consist of carbon monoxide concentration or may be diagnostic data such as the sample flow or detector output The M300 comes pre programmed with a set of useful Data Channels for logging carbon monoxide concentration and predictive diagnostic data The default Data Channels can be used as they are or they can be changed by the user to fit a specific application They can also be deleted to make room for custom user programmed Data Channels The data in the default Data Channels can be viewed through the SETUP DAS VIEW menu Use the PREV and NEXT buttons to scroll through the Data Channels and press VIEW to view the data The last record in the Data Channel is shown Pressing PREV and NEXT will scroll through the records one at a time Pressing NX10 and PV10 will move forward or backward 10 records For Data Channels that log more than one parameter such as PNUMTC buttons labeled lt PRM and PRM gt will appear These buttons are used to scroll through the parameters located in each record The function of each of the default Data Channels is described below CONC Samples carbon monoxide concentration Low Range at one minute intervals and stores an average every hour with a time and date stamp Readings during calibration and calibration hold off are not included
50. SETTING SLOPE DARK MEAS mV CO OFFSET DARK REF mV CONFIGURATION DATA PROM REV ANALYZER SERIAL TECHNICIAN DATE TABLE 1 1 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 19 1 8 Options 1 8 1 Rack mount with slides This option including slides and rack mounting ears permits the Analyzer to be mounted in a standard 19 wide x 30 deep RETMA rack NOTE A 1 MINIMUM SEPARATION BETWEEN EACH INSTRUMENT MUST BE MAINTAINED TO ALLOW FOR AIR CIRCULATION BLOCKING THE AIR INLET VENT ON THE BOTTOM OF THE ANALYZER WILL RESULT IN INTERNAL OVERHEATING 1 8 2 Zero span valves The Zero Span Valve option consists of three stainless steel solenoid valves mounted inside the Analyzer connected to admit sample gas or customer generated zero air or span gas The valves are controlled from the front panel push buttons the auto timer via the RS 232 interface or by remote contact closure A Zero air manifold should supply gas in excess of the 800 cc min 10 demand of the Analyzer The zero manifold should be connected at the IZS Zero Air fitting on the rear of the Analyze and should be vented to the outside atmosphere A Span gas manifold can be connected to the analyzer in either of two ways 1 If it is desired to use span gas directly from a pressurized source e g a gas cylinder the connection can be made directly to the Pressure Span port on the analyzer rear panel In this case the
51. Section 11 3 2 Check for pneumatic leaks as described in Section 11 2 3 Check for improper materials in the inlet manifold 10 5 4 Analog outputs do not agree with front panel readings 1 Confirm that the DAC offset SETUP MISC D A OFFS is set to zero 2 Perform a DAC ADC adjustment and Dark Signal adjustment by following the procedure described in Sections 9 2 and 9 3 10 5 5 Cannot zero or cannot dynamic zero 1 Check for leaks in the pneumatic system as described in Section 11 2 2 Confirm that the Zero gas is free of Carbon Monoxide 3 Check for a dirty particulate filter and replace as necessary as described in Section 11 1 10 5 6 Cannot span or cannot dynamic span 1 Check for leaks in the pneumatic systems as described in Section 11 2 Di Check for a dirty particulate filter and replace as necessary as described in Section 11 1 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 89 3 Check for dirty pneumatic system components and clean or replace as necessary as described in Section 11 3 4 Check for proper adjustment of DAC and ADC electronics by performing the adjustment procedure in Section 9 2 5 Confirm the Sample Temperature Sample Pressure and Sample Flow readings are correct Check and adjust as required 10 6 Troubleshooting individual sub assemblies and components The following sections provide troubleshootine check out methods for the specific sub assemblies and component
52. The verbose format looks like the following D 531510050 0412 CONC 2 AVE PEM This report uses the format of a leading first character D in this example a time stamp 31 10 06 and the instrument ID 0412 The other fields in the report are the data collector name CONC the sampling mode AVG the data point COCNCI the data point value 6 8 and the units PPM Due to the length of the message only one data point may be printed per line Compact Data Report Format The compact format looks like the following D 31210806 0412 CONC 6 28 The fields up to the colon are the same as for the verbose format but the next fields are different The fields following the colon are the line number 1 in the P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 62 example and the data point value 6 8 Presumably the user or remote computer knows all of the other information about the data point value This report format is particularly useful when you are sampling more than one data point because up to five data points may be printed per line The line number field is necessary because a single report may span multiple lines A compact report with two data points such as the PNUMTC Data Channel looks like this D 531810306 0412 1 800 0 2957 Example 1 To report the last 100 records from the CONC Data Channel in Ve
53. These Test Functions can be accessed by depressing the TEST Button on the instrument s front panel with each depression of the button causing the next test function to be displayed By comparing the values of Test Functions to acceptable operating limits it is possible to quickly isolate and correct most problems NOTE IF THE VALUE OF ANY TEST FUNCTION IS DISPLAYED AS XXXX THIS INDICATES THAT THE READING IS OFF SCALE OR OTHERWISE NON VALID Table 10 2 provides a list of available Test Functions along with their meaning their range of acceptable values and the recommended corrective actions if the value is not in the acceptable range Additionally Table 1 1 in this manual provides a list of the values of all Test Functions at the time the analyzer left the factory TEST FUNCTION VALUES Test Function Meaning Acceptable Values Corrective Action for Unacceptable Values RANGE The Current Full Any None required Scale Range Setting of the analyzer s analog outputs The most recent 2000 4800 CNTS Check and adjust IR detector reading source and Sync taken in Measure Demodulator and mode optical alignment as described in Sect 10 6 6 and 10 6 8 The most recent 2000 4800 mV Check and adjust IR detector reading source and Sync taken in Reference Demodulator and mode optical alignment as described in Sect 10 6 6 and 10 6 8 MR RATIO The ratio of the CO 1 00 1 25 Check CO REF and MEAS value to CO CO MEAS values as R
54. a constant stable output i e CO reading of about 40 ppm This test is particularly useful in isolating problems since it exercises essentially all electronic sub systems of the Analyzer but does not depend on the proper function of Optical or Pneumatic subsystems P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 57 6 0 HANDLING WARNINGS When a system warning occurs a warning message is displayed and the FAULT LED blinks A warning indicates that something in the system needs to be checked or adjusted Failure by the operator to respond to a warning may result in poor system performance and or less accurate data acquisition Warnings should be taken seriously When a warning is displayed the MSG and CLR buttons will appear on the menu line when not in setup mode Pressing MSG will scroll through the warning messages if there is more than one CLR will clear the currently displayed warning message and if there are no more warning messages remaining the MSG and CLR buttons will disappear and the FAULT LED will be turned OFF If after pressing CLR warning messages still exist the FAULT LED will continue to blink and the MSG and CLR buttons will remain on the menu line If after clearing a message the warning condition for that message still exists the message will reappear after a period of time which depends on how frequently the condition is checked by the CPU usually every few seconds If a warning messag
55. ands and the corresponding test measurements which will be returned TEST MEASUREMENT REQUEST COMMANDS TABLE 7 7 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 67 7 6 Viewing and modifying variables The most powerful feature of the RS 232 interface is the ability of a host computer to view and modify the Analyzer s internal variables Just as the operator modifies the variables by means of the setup mode the host computer modifies them by means of the RS 232 interface To view a variable s value the host computer issues a command of the following format V VARIABLE lt CRLF gt The CPU will respond by sending a message of the following format to the RS 232 output V VARIABLE VALUE WARNLO WARNHI lt DATALO DATAHI gt lt CRLF gt In both cases VARIABLE is the name of the variable that is being viewed VALUE is the current value of the variable WARNLO and WARNHI are the low and high warning limits respectively but may not appear for all variables since some variables do not have warning limits DATALO and DATAHI are the low and high data entry limits respectively and are given for all variables The CPU will not set a variable s value or warning limits to values which are outside of the data entry limits For example to see the optical bench temperature set point the host computer would issue the command V BENCH_SET lt CRLF gt and the CPU would respond with something like V
56. ation Category Overvoltage Category II Pollution Degree 2 100 mV 1 V 5 10 V Bi Polar 12 status outputs from opto isolators at constant temperature and voltage P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 4 1 5 Installation and overview The Model 300 is shipped with the following standard equipment 1 Power cord 2 Instruction manual CAUTION To avoid personal injury always use two persons to lift and carry the Model 300 Upon receiving the Model 300 please do the following 1 Verify no apparent shipping damage If damage has occurred please advise shipper first then Teledyne API 2 When installing the Model 300 allow a minimum of 4 inches 100mm of clearance at the back of the instrument and 1 inch 25mm of clearance on each side for proper ventilation Also be sure that the clearance below the chassis is unobstructed by at least the height of the instrument feet 3 Connect sample inlet line to the sample port on rear panel NOTE SEE FIGURE 1 4 FOR REAR PANEL PNEUMATIC CONNECTIONS SAMPLE GAS SHOULD ONLY COME INTO CONTACT WITH PTFE GLASS OR STAINLESS STEEL LEAK CHECK ALL FITTINGS WITH SOAP SOLUTION MAXIMUM PRESSURE FOR LEAK CHECK IS 5 PSI CAUTION Connect the exhaust fitting on the rear panel See Fig 1 4 to a suitable vent outside the analyzer area 4 Connect IZS inlet input if installed to a clean dry air supply 5 Connect a record
57. ators should be measured Test points 1 2 3 and 4 provide connection to the temperature outputs on drawing no 00016 in Appendix C 9 7 CPU If the display is operating and the green sample light is on the CPU should be operating If not check for 5v to the CPU P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 81 10 0 TROUBLESHOOTING NOTE THE OPERATIONS OUTLINED IN THIS CHAPTER ARE TO BE PERFORMED BY QUALIFIED MAINTENANCE PERSONNEL ONLY CAUTION DO NOT DISCONNECT CPU OR OTHER DIGITAL CARDS WHILE UNDER POWER 10 1 Overview The Model 300 has been designed to rapidly detect possible problems and allow their quick evaluation and repair During operation the analyzer continuously performs self check diagnostics and provides the ability to monitor the key operating parametersof the instrument without disturbing monitoring operations These capabilities will usually allow the quick isolation and resolution of a problem A systematic approach to troubleshooting will generally consist of the following four steps performed in order 1 Confirm the proper operation of Fundamental Instrument sub systems Power Supplies CPU Display 2 Note any warning messages and take corrective action as required 3 Examine the values of all TEST functions and compare to Factory values Note any major deviations from the factory values and take correction action as required 4 Address any Dynamic Sample re
58. cal mode 12 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 55 ST_FLOW_ALARM Status Bit Flow alarm Logic High Sample flow out of spec Logic Low Flows within spec ST_TEMP_ALARM Status Bit Temperature alarm Logic High One or more temps out of spec Logic Low Temps within spec ST_DIAG_MODE Status Bit In Diagnostic mode Logic High M100A in Diagnostic mode Logic Low Not in Diag mode Status Bit Power OK Logic High Instrument power is on Logic Low Instrument power is off Status Bit Flow alarm Logic High Sample pressure out of spec Logic Low pressure within spec ST_POWER_OK 17 ST_PRESS_ALARM YES 18 ST_HIGH_RANGE Status Bit Autorange High Range Logic High M300 in high range Logic Low M300 in low range 19 ST_SYSTEM_OK YES Status Bit System OK Logic High No instrument warning present Logic Low or more alarm present 20 ST_BENCH_ALARM YES Status Bit Bench Temperature Alarm Logic High Bench Temp out of spec Logic Low Bench Temp in spec 21 ST_SOURCE_ALARM YES Status Bit IR Source Alarm Logic High IR Source output too low Logic Low IR Source output normal 22 ST_WHEEL_ALARM YES Status Bit Wheel Temperature Alarm Logic High Wheel Temp out of spec Logic Low Wheel Temp in spec phase Typically 2500 4500 mV phase Typically 2500 4500 mV 25 SAMPLE_PRES NO Sample pressure in mV Typical sea level val
59. ciple of operation The detection and measurement of carbon monoxide in the Model 300 is based on the absorption of Infra Red IR radiation by CO molecules at wave lengths near 4 7 microns In practice the Model 300 uses a high energy heated element to generate broad band IR light This light is passed through a rotating Gas Filter Wheel which causes the beam to alternately pass through a gas cell filled with Nitrogen the Measure Cell and a cell filled with CO Nitrogen Mixture the Reference Cell This alternation occurs at a rate of 30 cycles second and causes the beam to be modulated into Reference and Measure pulses During a Reference pulse the CO in the gas filter wheel effectively strips the beam of all IR energy at wave lengths where CO can absorb This results in a beam which is unaffected by any CO in the Sample Cell During the Measure pulse the Nitrogen in the filter wheel does not effect the beam which can subsequently be alternated by any CO in the sample cell The Gas Filter wheel also incorporates an optical chopping mark which superimposes a 360 Cycles Second Light Dark modulation on the IR Beam This high frequency modulation is included to maximize detector signal to noise performance After the gas filter wheel the IR beam enters the multi pass sample cell This sample cell uses folding optics to generate a 16 meter absorption path length in order to achieve maximum sensitivity Upon exiting the sample cell the beam passes t
60. ck pressure in the manifold the following relationship should be met Q x L 500 Qax D Where Q is the vent flow in cc min For Q is the Analyzer flow in cc min L is the vent line length in inches D is the ID of the vent line in inches Q of 1000 cc min Q of 800 cc min D of 188 inches L approximately 72 8 2 MULTI POINT CALIBRATION Multi point calibration requires seven approximately equally spaced calibration points including zero using an NIST traceable CO source The calibration must be carried out Prior to field operation as an EPA DESIGNATED REFERENCE METHOD After maintenance Every three months recommended NOTE THE TEST GAS MUST BE INTRODUCED INTO THE ANALYZER THROUGH THE SAMPLE INLET PORT ALL FLOW MEASUREMENT DEVICES MUST BE CALIBRATED AGAINST AN NIST TRACEABLE STANDARD SUCH AS A BUBBLE FLOW METER WHICH HAS BEEN CALIBRATED AGAINST AN NIST TRACEABLE VOLUME STANDARD P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 73 There are two acceptable methods of generating accurate CO concentrations for calibrating the Model 300 One method uses a single cylinder of CO in air and a means of accurately diluting the cylinder gas with zero air This is illustrated in Figure 8 1 Alternatively several cylinders of CO in air of appropriate concentrations may be used without dilution The cylinder concentrations must be traceable to NIST standards Flow correction f
61. ct analyzer operation therefore TEST functions not covered below can be ignored for now CO REF CO MEAS TEST function values should be between 3200 mV and 4700 mV Pressure 29 to 30 Inches Mercury Absolute at sea level Other values will be displayed depending on altitude of Analyzer Sample Flow 800 cc min 10 96 Sample Temp Ambient temperature 10 C Optical Bench Temp 48 C 1 The computer drives the temp to this setpoint Filter Wheel Temp 68 C 2 The computer drives the temp to this setpoint Box Temp Ambient 10 C DC Power Supply 2500 mV 50 mV This is a composite of all of the DC voltages in the instrument The value is not important but it should be within the range indicated If the TEST functions are within the limits given above chances are very good the instrument will function correctly If there is a problem please read the manual and check your set up The Model 300 is now ready for calibration see Section 3 5 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 18 FINAL TEST AND CALIBRATION VALUES TEST VALUES INSTALLED OPTIONS RANGE PPM ZERO SPAN VALVES Ol CO MEAS mV RACK MOUNTS SLIDES CO REF mV POWER _ VOLTS Hz MR RATIO 4 20mA OUTPUT Ol SAMPLE PRESS IN HG A IZS L SAMPLE FLOW SCC MIN OTHER L SAMPLE TEMP Zo OPTICAL BENCH TEMP C WHEEL TEMP C BOX TEMP C DC POWER SUPPLY mV TIME HH MM SS CO SPAN SETTING ELECTRIC TEST CO ZERO
62. d of one year from the date of delivery If a Product fails to perform to its specifications Teledyne API shall correct such defect by in Teledyne API s 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 API 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 API SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF OR RELATED TO THIS AGREEMENT OF TELEDYNE API s PERFORMANCE HEREUNDER WHETHER FOR BREACH OF WARRANTY OR OTHERWISE TERMS AND CONDITIONS All units or components returned to Teledyne API 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 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 2 1 3 Prin
63. dicate that the diagnostic mode has been exited DIAGNOSTIC TESTS Nominal Value NONE CO MEASURE CO detector measure value 4500 mV CO REFERENCE CO detector reference 4200 mV value SAMP PRESS Sample pressure 125 mV SAMP FLOW Sample flow 3000 mV 6 SAMPTEMP Sampletemperatre 3000mW 8 WHEELTEMP Outputs filter wheel temp 3900 mV 9 CHASSIS TEMP OutputsChassistemp 2740 mV Any TABLE 5 1 5 2 1 Signal O The signal I O diagnostic mode gives the user access to the digital and analog inputs and outputs on the V F board The digital outputs can be controlled through the keyboard Any signals manually changed through the signal I O menu will remain in effect until you leave the signal I O menu At that time the analyzer will regain control of these signals To enter the signal I O test mode press SETUP MORE DIAG ENTR When the diagnostic mode is entered a message is sent to the RS 232 channel indicating entry into the diagnostic mode Use the PREV and NEXT buttons to scroll through the signals Edit buttons will appear for the signals that can be controlled by the user Press JUMP to skip to a specific I O Signal Table 5 2 below lists the I O signals available for the M300 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 54 l DISP_BROWNOUT NO Display brownout is used to keep the display from getting corrupted during low line voltage conditions Circuitry on the Power Supp
64. ds In the Model 300 an integrate period of 1 033 records is used for reading the photo detector outputs a 133 msec integrate period is used for all other signals Pots R27 and R31 provide offset and gain adjust respectively to the analog input of the V F converter allowing the A D section to be adjusted to match an external voltage standard 10 6 3 2 Digital to Analog Converters Four Independent Digital to Analog Converters DAC s are contained in IC s U10 and U11 and are used to generate the instrument s analog outputs These DAC s have 12 bit resolution and are fully buffered by OpAmps at U8 and U9 The outputs of the DAC s are jumper selectable for full scale range at jumpers B6 B7 B8 and B9 The Full Scale Ranges supported are 0 100 mV 0 1 V 0 5 V 0 10 V In the M300 the use of these four DAC s is DAC SIGNAL CHANNEL Strip Chart Analog Output 1 DAS Analog Output 1 2 Spare Test Function Analog Output The DAC s are operated in bipolar mode allowing a live zero on all output In addition DAC s 0 and 1 Strip Chart and DAS physically provide a Full Scale of 120 of the nominal selected value with the micro processor providing pre scaling to achieve the nominal value This combination provides 20 over range capability The P N 02163G1 Teledyne Model 300 CO Analyzer Instruction Manual Page 93 micro processor is also used to adjust for offset and gain needed to match DAC outputs to ex
65. e executed only upon an external RS 232 command Starting Date The starting date for the sequence is entered in the format of MM DD YY where MM is the month DD is the date and YY is the year Enter starting date and press ENTR or EXIT to leave the date unchanged Starting Time To set the time of day for the sequence enter in the format HH MM where HH is the hour in 24 hour format 1 e hours range from 00 to 23 and MM is the P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 33 minute 00 59 Enter the time of day for calibration check and then press ENTR to accept the new time or EXIT to leave the time unchanged NOTE THE PROGRAMMED START TIME MUST BE A MINIMUM OF 5 MINUTES LATER THAN THE REAL TIME CLOCK See Section 4 3 and 4 4 for setting real time clock Delta Days The number of delta days is the number of days between each auto sequence Enter desired number of delay days 0 365 and press ENTR Delta Time The delta time allows the automatic Z S check time of day to be delayed in the format of HH MM where HH is the hour from 00 to 23 and MM is the minutes 00 59 The delta days and delta time are added together to determine the total delay between sequences The delta time parameter allows you to advance or retard the starting time by a fixed amount each time the sequence is run For example Setting the delta days to 1 day and the delta time to 15 minutes will delay the starting time for th
66. e reappears every time after CLR is pressed the problem should be solved and the Analyzer restarted Some problems may be temporary and may not reappear after CLR 1s pressed e g temperature too high too low etc To ignore the warning messages and display the test measurement again simply press TEST The warning messages will remain active and may be viewed again by pressing MSG P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 59 7 0 RS 232 COMMUNICATIONS The Model 300 features a powerful RS 232 interface which is used both for reporting test results and for controlling the Analyzer from a host computer Because of the dual nature of the RS 232 interface the message format has been carefully designed to accommodate both printers and host computers All message outputs from the Model 300 have the following format X DDD HH MM MESSAGE lt CRLF gt The X is a character indicating the message type see table below RS 232 MESSAGE TYPES 1 Diagnostic Variable value HELP screen TABLE 7 1 The DDD HH MM is a time stamp indicating 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 The HII is a 4 digit Analyzer I D number The MESSAGE field contains variable information such as warning messages test measurements DAS reports etc The lt CRLF gt is a carriage return line f
67. e sequence by 15 minutes each day If you want to have the sequence run at the same time every day simply set the delta time to zero NOTE Avoid setting two or more sequences at the same time of the day Any new sequence which is initiated whether from a timer the RS 232 or the contact closure inputs will override any sequence which is in progress Duration The duration of each step of the sequence Enter the duration in minutes 1 60 and press ENTR Calibrate When set to ON the sequence will adjust the internal formulas slope and offset in the Analyzer to the value set in the span variable If this feature is enabled along with the automatic zero span check the Analyzer will re adjust its formulas to match the predetermined zero and span settings once each day P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 34 Range To Cal This setup parameter is enabled only if the range mode is set to Dual or Auto This parameter determines which range the sequence will check NOTE THE CALIBRATE FEATURE OF AUTO SEQUENCES ALTERS THE FORMULAS USED TO COMPUTE THE CARBON MONOXIDE READING THIS METHOD OF CALIBRATION IS NOT APPROVED BY USEPA AND IS NOT INTENDED TO REPLACE THE USEPA APPROVED CALIBRATION METHOD Examples of possible sequences are as following under any one of three available SEQx Example 1 to perform a 15 minute zero check once per day at 10 30 pm 12 20 93 gt
68. e CO readings and the last 100 averages This data is made available to other systems via the RS 232 interface The Analyzer can be programmed to automatically output a 1 minute to 60 minute average The last 100 averages can be called up through the remote RS 232 I O or viewed on the display through keyboard call up P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 23 2 1 6 RS 232 interface The Teledyne API CO Analyzer features an RS 232 interface which can output the instantaneous and or average CO data to another computer It can also be used as a command and status channel to allow another computer to control the Analyzer Refer to Figure 1 3 for details on using the RS 232 interface Tips on connecting the RS 232 port can be found in Appendix B 2 1 7 Password protection The Teledyne API CO Analyzer provides password protection of the calibration and setup functions to prevent incorrect adjustments to the Analyzer There are three levels of passwords which correspond to operator supervisor maintenance and analyzer configuration functions When prompted for a password any of the valid passwords can be entered but the CPU will limit access to the functions allowed for that password level Each level allows access to the functions of all the levels below plus some additional functions Table 2 1 lists the password levels and the functions allowed for each level PASSWORD LEVELS Functions Allowed No password T
69. e I D unchanged If changed the new I D number will appear on all RS 232 reports from this Analyzer 4 10 Disabling the calibration password Normally operators are required to enter the calibration password when doing a manual calibration via the CALZ CALS or CAL buttons To allow calibration without entering the password press SETUP PASS and set it to OFF and then press ENTR to accept the change or EXIT to leave it unchanged To enable the calibration password set the variable to ON 4 11 Data acquisition system DAS The Model 300 contains a flexible and powerful built in data acquisition system DAS that enables the analyzer to store concentration data as well as many diagnostic parameters in its battery backed memory This information can be viewed from the front panel or printed out through the RS 232 port The diagnostic data can be used for performing Predictive Diagnostics and trending to determine when maintenance and servicing will be required The logged parameters are stored in what are called Data Channels Each Data Channel can store multiple data parameters The Data Channels can be programmed and customized from the front panel A set of default Data Channels has been included in the Model 300 software These are described Section 4 11 1 For more information on programming custom Data Channels a supplementary document containing this information can be requested from Teledyne API P N 02163G1 Teledyne A
70. e independently calibrated When the analyzer is in Dual or Auto Range mode you will be prompted to enter the range to calibrate whenever you enter a calibration command from the front panel Press HIGH or LOW followed by the ENTR button to proceed with the calibration To calibrate the other range you must exit to the sample menu and restart the calibration See Section 4 6 for more information on the Range Modes The following procedure shows an example of how to calibrate the two ranges with calibration gas coming in through the sample port Analyzer enters M P calibration mode Calibration gas source should be set to deliver zero gas to the sample port L3 Wait 15 min Wait for CO reading to stabilize at zero value ______ Press ZERO ENTR Changes calibration equations for Low range so analyzer will read zero Press CONC Enter span gas concentration for Low range E men Enter span gas concentration for Low Range Set concentration calibration gas source to deliver span concentration 8 15 min Wait for CO reading to stabilize at span value Press SPAN ENTR Changes calibration equations for Low range so analyzer will read value Press EXIT Exits back to Exits back to sample menu Repeat steps 1 10 for High range 3 2 IZS zero span check Option If the IZS Internal Zero Scrubber option has been installed and a source of CO span gas has been connected the operator can check the zero and
71. e they won t be accessible from the RS 232 interface EVENT This property designates the event that will trigger data collection Since this could be a diagnostic tool it might be useful to read the parameter that is associated with the events such as the calibration A data channel can be triggered by only one event If you must trigger collection of the same data by multiple events then you can create multiple data channels and trigger each one with a different event The list of available triggering events is shown in following table P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 45 Triggering Events Name Description ATIMER REPORT PERIOD This property specifies the period between reports DAS entries Enter the number of days and press ENTR Then enter the number of hours the leftmost digits and minutes and press ENTR NUMBER OF RECORDS This property specifies how many records you want to store in this data channel Each record consists of a time stamp and the sampled measurements from each parameter The memory of the M300 has capacity for a total of about 8 000 records for all data channels When the specified number of records for a data channel has been reached the channel will wrap around with the oldest records being overwritten with the newest records NOTE Changing this property requires that any existing data records be deleted because memory must be re initialized
72. ed in Section 10 6 4 If 15V is present it is probable that the Pneumatic Sensor Board is defective and should be replaced 10 6 6 Checking the Synchronous Demodulator Board A schematic and physical diagrams of the Synchronous Demodulator Board are shown in drawings 798 and 799 in Appendix C Proper operation of the Synchronous Demodulator can best be confirmed by performing the Electric Test Diagnostic as described in Section 5 2 4 When activated the Electric Test Diagnostic should produce a constant stable analyzer output of approximately 50 ppm If this stable output is produced it is probably that the Synchronous Demodulator is functioning properly If Electric Test does not produce a stable output check the following 1 Confirm proper operation of the V F Board as described in Section 10 6 3 2 Confirm that during Electric Test the values of the CO MEAS and CO REF test functions are between 2500mV and 4500mV If they are not adjust the signal levels by turning Pot R7 on the Synchronous Demodulator Board P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 96 10 6 7 Checking the Opto Interrupter Correct operation of the Opto Interrupter on the gas filter wheel can be confirmed by connecting an oscilloscope U6 Pin 11 on the Sync Demodulator board and comparing the waveform to Figure 10 1 The waveform should be symmetrical and 5 Volts peak to peak FIGURE 10 1 OPTO PICKUP FIGURE 10 2 DETECTOR WAVEFORM W
73. ed so that you may utilize our equipment to the fullest extent The Teledyne API Model 300 keyboard operator interface makes the Teledyne API a very user friendly system We hope you will not experience any problems with the Model 300 but if you do the built in tests and diagnostics should allow you to quickly and easily find the problem In addition our customer service department is always available to answer your questions P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 1 1 2 Warranty WARRANTY POLICY Prior to shipment Teledyne API equipment is thoroughly inspected and tested Should equipment failure occur Teledyne API assures its customers that prompt service and support is available COVERAGE After the warranty period and throughout the equipment lifetime Teledyne API 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 API MANUFACTURED EQUIPMENT Equipment provided but not manufactured by Teledyne API is warranted and will be repaired to the extent and according to the current terms and conditions of the respective equipment manufacturer s warranty GENERAL Teledyne API warrants each Product manufactured by Teledyne API to be free from defects in material and workmanship under normal use and service for a perio
74. eed combination which terminates the message and also makes the messages appear neatly on a printer The uniform nature of the output messages makes it easy for a host computer to spare them Input messages to the Model 300 have a format which is similar to that for output messages X COMMAND lt CRLF gt P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 61 The X indicates the message type as shown above in Table 7 1 and COMMAND is the command type each of which is described individually below The lt CRLF gt is used to terminate the command Typing lt CRLF gt a few times by itself is agood way to clear the input buffer of any extraneous characters 7 1 DAS reporting Data from individual Data Channels in the DAS system can be retrieved through the RS 232 interface The command format for printing the data for a Data Channel is shown below D id REPORT name RECORDS number COMPACTIVERBOSE parameters in are optional id is the analyzers ID number SETUP MORE COMM ID name is the Data Channel name must be enclosed in quotes number is the number of records to print beginning with the most recent if this parameter is not specified then all available records for the Data Channel are printed COMPACTIVERBOSE refers to the report format Verbose Data Report Format There are two kinds of data reports verbose with a lot of detail and compact with just the data point values
75. ero check followed by a span check first generate a positive transition on EXT_ZERO_CAL and then when you want to do the span check generate a positive transition on EXT_SPAN_CAL The remote calibration signals may be activated in any sequence providing a virtually unlimited number of calibration types Remote adjustment is similar to automatic Z S checking in that if dynamic calibration is enabled the internal CO formulas will be modified following calibration To enable or disable adjustment press SETUP MORE VARS and press NEXT until the variable DYN_ZERO or DYN_SPAN is displayed To change the setting toggle the value between OFF ON and press ENTR to store the new value or EXIT to leave the value unchanged NOTE TELEDYNE API RECOMMENDS THAT CONTACT CLOSURES REMAIN CLOSED AT LEAST 10 MINUTES TO ALLOW FOR AN ACCURATE AVERAGE ZERO OR SPAN VALUE TO BE ESTABLISHED P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 37 NOTE REMOTE ZERO AND SPAN ADJUSTMENT ALTER THE FORMULAS USED TO COMPUTE THE CARBON MONOXIDE READINGS IF DYN_ZERO OR DYN_SPAN ARE ENABLED THIS METHOD OF CALIBRATION IS NOT APPROVED BY USEPA AND IS NOT INTENDED TO REPLACE THE USEPA APPROVED CALIBRATION 3 7 Remote zero span check or adjustment RS 232 Besides Z S checking from the front panel automatic Z S checking and remote Z S checking via the contact closure inputs the Analyzer can also be checked via the RS 232 interface
76. erve the front panel display As the analyzer goes through the setup the version number will be displayed on P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 103 the front panel It should read the same as the version number that was located on the top right corner of the label on the PROM Re enter any non default settings such as RANGE or ASEQ Re enter the CONC value in the CAL menu Check all settings to make sure that expected setup parameters are present Re calibrate the analyzer so that the default slope and intercept are overwritten with the correct values P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 104 12 0 SPARE PARTS LISTS 12 1 SPARE PARTS FOR CE MARK UNITS Note Use of replacement parts other than those supplied by Teledyne API may result in non compliance with European Standard EN 61010 1 PART NO DESCRIPTION 00015 POWER SUPPLY BOARD 00094 10 ORIFICE 13 MIL 00276 18 BOARD 00329 THERMISTOR ASSY 885 071600 00329 03 THERMISTOR ASSY SAMPLE TEE 00329 06 THERMISTOR ASSY SAMPLE TEE 00329 09 THERMISTOR ASSY SAMPLE TEE 00369 FILTER TFE 37 MM QTY 100 872 006400 00369 01 FILTER TFE 37 MM QTY 25 872 006300 00402 05 PNEUMATIC SENSOR BOARD 00422 01 W SOFTWARE 00514 03 V F BOARD 00551 14 POWER SUPPLY MODULE EU 230V 50Hz 00551 18 POWER SUPPLY MODULE UK 230V 50Hz 00611 01 ASSY THERMISTOR 00611 02 ASSY HEATER THER
77. f the analyzer All functions of the board are performed under control of the micro processor The primary functions of the board can be divided into three areas 16 Channels of Multiplexed Analog input to an Analog to Digital converter 4 independent Digital to Analog converters 32 Digital I O Lines configured as 24 outputs and 8 inputs The following sections describe each of these functional areas 10 6 3 1 Analog Inputs 16 Analog channels 0 5 VDC are multiplexed under micro processor control by IC U26 and transmitted via buffer amp U29 to the V F converter section of the board for A D conversion P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 92 Analog to Digital A D conversion is accomplished by performing a Voltage to Frequency V F conversion on the input signal at IC Ul7 and running the frequency output to a counter comprised of IC s U20 U21 U22 The full scale digital output of the counter section is 80 000 counts giving an A D resolution of 1 part in 80 000 The combination of V F converter and counter inherently provides an integrating Analog to Digital conversion The time base for this integration is controlled by the micro processor using the clock oscillator U36 Jumper B15 allows the selection of either a 4 0 MHz or 4 8 MHz frequency to minimize electrical pick up at the operating line frequency The time duration of integration is selectable over the range of 67 msec to 2 067 secon
78. hannels DEL EDIT PRNT Prints a summary of all of the data channel on the RS 232 port The creation or modification of data channel definitions is accomplished by modifying the properties of existing or default channel definitions The table below lists all ofthe properties defined for data channels P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 44 Data Channel Properties Property Description Initial Setting Setting Range NAME The data channel s NONE Up to 6 name primarily used letters or for RS 232 access and numbers reports EVENT The event which ATIMER Any ofthe triggers this data events listed channel to record a in the table sample or issue a of triggering report events shown above S parameters sampled REPORT The amount of time 000 01 00 000 00 01 to PERIOD between each report 366 23 59 Days Hours Minutes NUMBER OF How many reports 1 to 1000 RECORDS will be stored in the data file RS 232 Indicates whether or OFF OFF or ON REPORT not a report will be printed on the RS 232 channel ENABLED CAL HOLD ON or OFF OFF NAME This property is primarily for the user s convenience and the user should select meaningful names you can give a data channel any name you want up to six characters long When you edit this property you should see a display like the following Blank names all dashes or duplicate names should be avoided becaus
79. he following alternate method for leak checking can be used The power must be on and the pump must be in line Disconnect the power from the pump Check for the sample flow If the sample flow does not read zero record the reading Re connect the power to the pump Cap the sample inlet Check if the sample flow goes down to zero If not check the sample flow exceeds the prerecorded value when the pump was disconnected If the sample flow is above zero or higher than the prerecorded value the unit has the leak 11 4 Changing the prom 1 Locate the CPU card by referring to Figure 1 6 Remove the screws that hold the CPU card SBC40 printed on the lever top corner to the A D I O card then remove the card from the STD BUS backplane 3 Remove the two cables attached to the SBC40 taking note of the polarity 4 Remove the card laying it down on an insulating surface such that the card edge pins on the PCB are on the left The PROM chip should be at the top center The current chip should be labeled with something like API CO A 6 Gently pry the chip from its socket and replace it with the new chip Install the chip in the left end of the socket with the notch facing to the right Make sure that all of the legs insert into the socket correctly 5 Replace the CPU board and re attach the connectors making sure to observe the polarity 6 Re attach the CPU card to the STD BUS 7 Move the power switch to the ON position and obs
80. hrough a band pass interference filter to limit the light to wave length of interest Finally the beam strikes the detector which is a thermoelectricly cooled solid state photo conductor This detector along with its pre amplifier and bias voltage supply convert the light signal into a modulated voltage signal The detector output is electronically demodulated to generate two DC voltages CO MEAS and CO REF These voltages are proportional to the light intensity striking the detector during the Measure Pulse and Reference Pulse respectively P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 3 1 4 Specifications Ranges Zero Noise Span Noise Lower Detectable Limit Zero Drift 24 hours Zero Drift 7 days Span Drift 7 days Linearity Precision Lag Time Rise Fall Time 95 Sample Flow Rate Temperature Range Humidity Range Temp Coefficient Voltage Coefficient Dimensions HxWxD Weight Power Power CE Environmental Conditions Recorder Outputs Status User selectable to any full scale range from 1 ppm to 1 000 ppm lt 0 025 ppm rms lt 0 5 of reading rms lt 0 050 ppm lt 0 1 ppm 0 2 ppm 1 of reading 196 FS 0 596 of reading 10 sec 60 sec 800cc min 10 5 40 C 0 95 RH non condensing lt 0 05 per C lt 0 05 per V T x 17 x 25 178mm x 432mm x 660mm 50 lbs 22 7 kg 110V 60Hz 220V 50Hz 240V 50Hz 250 Watts 230V 50Hz 2 5 A Install
81. in the data The last 800 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 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 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 43 4 11 2 Setting up Data Channels To setup a new data channel or modify an existing data channel press SETUP DAS EDIT to get into the DAS edit mode Once in the DAS edit mode definitions of data channels may be created or modified by using the MENU buttons described in the following table Data Channel Edit Menu Button PREV NEXT one allowed up to 20 data c
82. ing device to the terminal strip connections on the rear panel See Figure 1 2 6 Connect the power cord to an appropriate power outlet see the serial number tag for correct voltage and frequency P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 5 gt gt 10 CAUTION CHECK THAT ANALYZER IS SET UP FOR PROPER VOLTAGE AND FREQUENCY CAUTION POWER PLUG MUST HAVE GROUND LUG Turn on the M300 by switching the switch on the lower right corner of the front panel See Figure 2 1 The front panel display should light with a sequence of messages API M300 software version number then a normal display as shown in Figure 2 2 Allow about 60 minutes for the temperatures to come up to their respective setpoints then press the left most button on the front keyboard to scroll through the TEST values Compare these values to those noted during the final factory checkout listed in Table 1 1 The values observed should closely match the Table 1 1 values Select the range on which the analyzer will be calibrated a From the SAMPLE menu press SETUP to enter the SETUP menu See Figure 2 2 for appearance of front panel Enter the PASSWORD 818 Press RNGE RANGE Press SET Enter the derived full scale range for analog outputs and press ENTR Press EXIT 2 times to return to the SAMPLE menu djust the analyzer zero point Input zero air into the sample port Press CAL from the SAMPLE menu
83. lated problems The following sections provide a guide for performing each of these steps Figure 1 6 in this manual shows the general layout of components and sub assemblies in the analyzer and can be referenced in performing the checks described in the following sections P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 83 10 2 Troubleshooting fundamental analyzer operation When the Analyzer is turned on several actions will normally occur which indicate the proper functioning of basic instrument sub systems These actions are 1 The sample pump should start The green sample light on the front panel should turn on 3 The Display should energize and display a log on message followed by a standard Sample display See Fig 2 2 for illustration of a normal display If these actions all occur it is probable that the Analyzer s Power Supplies CPU and Display are working properly If any of these actions fail to occur power and or CPU operation should be checked as follows 10 2 1 Checking the power sub systems WARNING HAZARDOUS VOLTAGES EXIST WITHIN THE INSTRUMENT CHASSIS USE CAUTION 1 Check incoming line power for proper Voltage and Frequency 2 Check the Circuit breaker on the Analyzer s rear panel 3 Check the 3 wire safety power input plug on the Analyzer s rear panel 4 Check for proper internal AC power by confirming that the Red right most LED on the Power Supply Mod
84. level on Pin 8 of the Analyzer is between 5V and 15V This pin should be connected through the cable to Pin 4 of the modem Now set the baud rate of the Analyzer to the speed required by the modem and it should work If you are still experiencing problems a cable adapter may be needed Please contact the factory for assistance Data Communications Software for a PC You will need to purchase a software package so your computer can transmit and receive on its serial port There are many such programs internally we use PROCOMM Once you set up the variables in PROCOMM and your wiring connections are correct you will be able to communicate with the analyzers Make sure the analyzer is set up for 2400 baud SETUP MORE COMM BAUD and that PROCOMM 15 set up as described in the RS 232 Pin Assignments Figure B 1 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 113 APPENDIX C ELECTRICAL DRAWING INDEX Drawing Number 00015 00016 00402 00403 00514 00515 00532 00533 00551 00704 00705 00798 00799 00866 00867 00874 00875 01916 01917 01930 01931 02035 02036 Title Assembly DC Power Supply PCA Schematic DC Power Supply PCA Assembly Pneumatic Sensor PCA Schematic Pneumatic Sensor PCA Assembly A D VO Card PCA Schematic A D I O Card PCA Assembly Power Supply Module PCA Schematic Power Supply Module PCA Wiring Diagram Power Supply Module Assembly Keyboard PCA Schematic Keyboard PCA
85. lue between 1 and 1 000 ppm and is accessed through the SETUP RNGE SET menu This is the default range mode for the analyzer 4 6 2 Dual range mode DUAL Selecting dual range mode will allow you to select different ranges for the REC and DAS analog outputs The two ranges are called Low and High The REC output at the rear panel is used for the Low range and the DAS output is used for the High range To set the ranges press SETUP RNGE SET and select which range you want to edit followed by ENTR The High and Low ranges have separate slopes and offsets for computing the carbon monoxide concentration Therefore the two ranges must be independently calibrated See Section 3 1 2 for details on calibrating the two ranges 4 6 3 Auto range mode AUTO In auto range mode the analyzer automatically switches between the Low and High range depending on the concentration When the CO concentration increases to 98 of the Low range value the analyzer will switch to the High range The analyzer will remain in the High range until the CO concentration drops to 75 of the Low range value It will then switch back to the Low range Auto ranging changes the range for the REC and DAS outputs simultaneously To set the ranges press SETUP RNGE SET and select which range you want to edit followed by ENTR The High and Low ranges have separate slopes and offsets for computing the carbon monoxide concentration Therefore the two ranges must be independently calibra
86. ly board 00015 senses low line voltage and sets this bit The CPU reads this and generates the BROWNOUT_RST signal described below EXT_ZERO_CAL NO Shows state of status input bit to cause the M300 to enter Zero Calibration mode Use to check external contact closure circuitry EXT_SPAN_CAL NO Shows state of status input bit to cause the M300 to enter the Span Calibration mode Use to check external contact closure circuitry SYNC_OK NO Indicates that demodulation circuitry on the Sync Demod Board 00798 is able to lock in on the detector signal SPAN_VALVE YES Switches the Zero Span valve Use this bit to test the valve function CAL_VALVE YES Switches the Sample Cal valve Use this bit to test the valve function BENCH_HTR YES Shows the status of the optical bench heater This has the same function as the LED in the power supply module WHEEL_HTR YES Shows the status of the filter wheel heater This has the same function as the LED in the power supply module DARK_CAL YES Turns off the detector input to the Sync Demod board for electronics calibration ELEC_TEST YES Activates the Electric Test diagnostic circuitry 0 BROWNOUT_RST YES Resets the DISP BROWNOUT circuitry described above ST_ZERO_CAL YES Status Bit Zero Calibration mode Logic high M300 in Zero cal mode Logic low Not in Zero cal mode ST_SPAN_CAL YES Status Bit Span Calibration mode Logic high M300 in Span cal mode Logic low Not in Span
87. nalyzer to a modem P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 112 The modem is configured as Data Communications Equipment DCE and may have additional signal requirements to enable transmission See modem troubleshooting section below NOTE Modems are especially difficult because they may have pins that need to be at certain EIA RS 232 levels before the modem will transmit data The most common requirement is the Ready to Send RTS signal must be at logic high 5V to 15V before the modem will transmit The Teledyne API analyzer sets pin 8 RTS to 10 volts to enable modem transmission Troubleshooting the modem connection First Disconnect the RS 232 cable from the Analyzer and verify use a DVM that you are getting a signal on Pin 2 of the RS232 port on the Analyzer The signal will be between 5V and 15V with respect to signal ground pin 5 If not there is a problem with the CPU board or the cable This is the transmit TD signal out of the Analyzer This should then be connected to TD input on the modem normally Pin 2 If the Analyzer is equipped with a DTE DCE switch you may need to change its setting so the signal is on Pin 2 Second Go to the cable connected to the modem terminal and verify use a DVM that you are getting a 5V to 15V signal on Pin 3 of the cable This pin should be connected to Pin 3 of the Teledyne API Analyzer Third for modems Check that the voltage
88. nd pressure 5 An average of the last 750 samples is computed and converted to the number displayed on the front panel This is the carbon monoxide concentration The number is also routed to the D A converter and the resulting voltage is output to the back panel 4 3 Setting the time of day To set the current time of day which is used for determining when to do an automatic calibration and for time stamping the RS 232 reports press SETUP CLK TIME The CPU will display the current time of day as four digits in the format HH MM where HH is the hour in 24 hour format i e hours range from 00 to 23 and MM the time of day and then press ENTR to accept the new time or press EXIT to leave the time unchanged 4 4 Setting the date To set the current date which is used for time stamping the RS 232 reports press SETUP CLK DATE The CPU will display the current date as DD MMM YY For example April 1 1990 would be displayed as 0 1 APR 9 0 Change the date by pressing the button under each field until the desired date is shown Then press ENTR to accept the new date or press EXIT to leave the date unchanged 4 5 Adjusting the clock speed In order to compensate for clocks which run a little bit fast or slow there is a variable to speed up or slow down the clock by a fixed amount every day To change this variable press SETUP MORE VARS Press NEXT until the CLOCK_ADJ variable is displayed To change the setting press the EDIT key
89. ng Remove the teflon hold down O ring Remove the old filter element and discard Install a new filter element in the filter cavity Be careful with the element it is fragile Replace the hold down O ring on top of the filter element Replace the filter top and re tighten Leak check Turn on the Analyzer 11 3 Leak checking There are two methods of leak checking OPO po 11 3 1 Using a leak checker Turn the power off Disconnect the fittings from the pump and bypass the pump Connect the leak checker to the sample inlet of the Model 300 Cap the exhaust of the analyzer Set the leak checker to pressure mode CAUTION DO NOT EXCEED 15 PSI OF PRESSURE Leave the checker on until 15 psi is achieved Close the valve and ensure the pressure remains at 15 psi for at least 5 minutes If pressure drops more than 1 psi there is a leak and it must be repaired If there is a leak present pressurize the Model 300 to 15 psi and put soap bubble solution on pneumatic assemblies until the leak is found P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 102 CAUTION BE CAREFUL USING THE BUBBLE SOLUTION IF THERE IS NO INTERNAL PRESSURE THE SOLUTION MAY ENTER AND CONTAMINATE THE CELL DO NOT ATTEMPT TO USE THE BUBBLE SOLUTION WHILE THE UNIT IS UNDER VACUUM THIS MAY CAUSE DAMAGE TO THE ANALYZER USE ONLY BUBBLES NOT LIQUID 11 3 2 leak self test If only a Model 300 is available t
90. nstrument power Remove the instrument cover Locate the V F board near the top of the drawing using Figure 1 6 2 Locate switches S1 S2 and S3 along the top edge of the card Select the desired range by setting the switches as shown in Table 9 1 below V F BOARD SWITCH SETTINGS RANGES FOR ANALOG OUTPUT Switch 100 mV 1V 5V 10 V Full Scale Full Scale Full Scale Full Scale 81 Recorder Output S2 DAS Output 53 Test Output TABLE 9 1 NOTE TO ADJUST ANALOG RECORDER OFFSET SEE SECTION 4 7 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 80 9 5 Flow readout adjustment The sensor module in the M300 consists of a flow sensor and a pressure sensor See Figure 9 2 for a LES diagram of this module From these three sensors two values are displayed on the front panel TEST lt lt function area These are SE ME Sample flow Sample cell pressure In order to adjust the flow or pressure read out select the desired test function on the front panel and adjust the appropriate pot for the desired value per Figure 9 2 FLOW AND PRESSURE READOUT ADJUSTMENT FIGURE 9 2 9 6 DC power supply Overall performance of the DC power supply may be checked by observing the value displayed during test DCPS If this value a composite of the five 5 regulator outputs deviates by more than 10 from the value recorded in Table 1 1 of this manual under Test Values the outputs of the individual regul
91. ntering the button sequence SETUP CFG LIST For example the M300 could display CO MACHINE SBC40 CPU Stating that the instrument was an Carbon Monoxide Analyzer using the SBC40 computer This feature is useful for showing any special features that are present in the currently installed PROM 4 13 Summary of setup functions The setup functions are summarized in Table 4 1 in terms of the button sequences used to access them SETUP FUNCTIONS SETUP CFG LIST List Software CO Mach N A ee AutoCal Sequences Zero Span SETUP DAS EDIT Define Change DAS Data Channels SETUP DAS VIEW View DAS Data SETUP RNGE MODE Set Range Mode Single Single Dual Auto SETUP RNGE SET Set D A output range 50 ppm 1 1000ppm P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 50 SETUP RNGE UNIT Set Measurement Units ppm ppb ppm mg m3 ug m3 SETUP PASS Password Enable OFF ON SETUP CLK TIME Set Time of Day 00 00 00 00 23 59 SETUP CLK DATE 01 JAN 00 31 DEC 99 SETUP MORE COMM BAUD RS 232 baud rate 2400 baud 300 1200 2400 4800 9600 19 2 SETUP MORE COMM ID Analyzer ID number 0000 0000 9999 DAS_HOLD_OFF SETUP MORE VARS Enable Remote OFF DYN_ZERO Dynamic Zero DYN_SPAN Dynamic Span Adjustment one RS232_MODE BE o A A CLOCK_ADJ Rate VIEW SIGNAL VO internal signals ANALOG OUTPUT Output Test Pattern D A CALIBRATION A D Converters ELECTRICAL TEST Test Output DARK CAL e
92. or standard temperature and pressure STP is not required with either method With dilution the correction is self canceling With the multi cylinder method the correction is not applicable 8 2 1 PROCEDURE 1 Set the Analyzer to the desired range The EPA approved ranges are any range between 0 10 ppm and 0 50 ppm 2 Set the calibration system to deliver a flow of at least 1500 cc min The Model 300 draws approximately 800 cc min See Section 8 1 and Figure 8 2 for vent flow calculation 3 Pre calculate the calibrator flow to be sure that a CO concentration of 80 of URL upper range limit can be produced with enough surplus flow to provide an adequate vent flow 4 Connect the Analyzer REC recorder terminals to a calibrated strip chart recorder For best accuracy connect a DVM to the same terminals or to the DAS Data Acquisition System terminals The standard output voltage of 0 5 0 VDC If in service data is to be collected from a device printer connected to the RS 232 port then the calibration data must be collected from the RS 232 pott Set the calibrator to deliver zero air to the manifold Push CAL on the Analyzer front panel Enter password If Enabled Wait 15 minutes for the Analyzer to stabilize Push ZERO and ENTR on the front panel The Analyzer is now zeroed 10 Push EXIT EXIT Return to sample mode 11 Record the DVM reading and the percentage chart
93. plays the analog voltage reading on the front panel as TEST XXXXX X MV When you exit the diagnostics this test measurement is removed 5 2 Diagnostic tests The diagnostic tests are used to help diagnose a problem in the Analyzer and should only be used by skilled maintenance people since they can potentially interfere with the carbon monoxide reading Table 5 1 below lists the low level diagnostic tests which are available To get into the diagnostic test mode press SETUP DIAG When the diagnostic mode is entered a message is sent to the RS 232 channel indicating entry into the diagnostic mode The buttons which are available to the operator are described below P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 53 The TEST button is used to scroll through the test measurements until the one of interest is displayed To turn the test on press the OFF ON button Viewing test measurements in the diagnostic mode is especially useful for viewing the results of a diagnostic test The PREV button goes to the previous diagnostic test When pressed the CPU turns the current diagnostic test OFF if it is ON The NEXT button goes to the next diagnostic test When pressed the CPU turns the current diagnostic test OFF if it is ON The EXIT button exits the diagnostic mode and turns all the diagnostic tests OFF This ensures that a diagnostic test is not accidentally left ON A message is also sent to the RS 232 channel to in
94. point and can use a different or the same sampling mode For instance you could create three parameters which all measure the CO concentration for range 1 the CONCI parameter but which use the MIN AVG and MAX sampling modes This permits you to record not only the average concentration during the reporting interval but the maximum excursions as well Like data channels parameters also have properties which are listed in the table below Parameter Properties Property Description Setting Range PARAMETER The parameter to sample CONCI Any of the parameters listed in the table of parameters shown above SAMPLE The sampling mode to use Any one of the INST MODE when reading this AVG MIN and MAX parameter PRECISION Number of decimal digits 0 3 The table below lists the data parameters initially defined The entries in the Name and Units columns are visible when editing and printing the data channel properties P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 47 Data Parameters Name Description Units NONE C CO Measure signal CO Reference signal Slope of Range 1 Slope of Range 2 Offset of Range 1 OFSET2 Offset of Range 2 AA x EA Rangel zero span measured concentration Range2 zero span measured concentration Concentration of Range 1 Concentration of Range 2 Stability Optical bench temperature Filter wheel temperature Sample flowrate Sample pressure
95. ransmit Data in4 g eneral types 3 Receive Data 1 Cables cables are provided in 4 Not Used various lengths from 6 to 50 feet In 5 Signal Ground most cases they have a male 6 Not Used connector at one end and a female at 7 Data Set Ready DSR the other Variations on this are 8 Request to Send RTS ones that provide both a cable and 9 Not Used adapter For example the cable RS 232 PIN ASSIGNMENTS provided with our analyzer adapts a FIGURE B 1 female DB 9 to a male DB 25 connector Most cables do not contain a Null modem 2 Gender changers convert a male connector to a female connector or vice versa They do so WITHOUT changing the pin to pin wiring 3 Adapters these change from one type plug DB 9 to another type plug DB 25 They do so WITHOUT changing the wiring P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 111 4 Null modems here the connector changes the internal wiring so that DTE devices can become DCE or vice versa The main internal change is swapping pin 2 and 3 so that data is transmitted and received on opposite pins NOTE Null modems can also combine gender changer or adapter features in the design When making up an adapter cable be careful to note what you are using especially with combination null modem adapter connectors Wiring The RS 232 is a point to point protocol and as such it specifies a two different wiring schemes depending on if you are originating the transmission or
96. rbose format type D REPORT CONC RECORDS 100 VERBOSE Example 2 To report all the records from the PNUMTC Data Channel in Compact format type D REPORT PNUMTC COMPACT 7 2 Warnings Whenever a warning message is displayed on the display it is also sent to the RS 232 output See Table 2 4 for a list of the warning messages These messages are very helpful when trying to track down a system problem and for determining whether or not DAS average data is actually valid The message format is W DDD HH MM WARNING MESSAGE lt CRLF gt An example of an actual warning message is W 194 11 03 0000 SAMPLE FLOW WARN lt CRLF gt Warnings may be cleared via the RS 232 interface by issuing a command of the form W COMMAND lt CRLF gt where COMMAND indicates which warning message to clear For example to clear the SAMPLE FLOW WARN message the host computer can issue the command W WSMPFLOW lt CRLF gt Attempting to clear a warning which is not active has no effect The table below lists the command to use to clear each possible warning message P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 63 WARNING MESSAGE CLEAR COMMANDS Command W WSYSRES lt CRLF gt W WRAMINIT lt CRLF gt W WSOURCE lt CRLF gt Warning Message Cleared SYSTEM RESET RAM INITIALIZED SOURCE WARNING BENCH HEAT SHUTDOWN WHEEL TEMP WARNING SAMPLE FLOW WARNING W WBHEAT lt CRLF gt W WWHLTEMP lt CRLE
97. rces of zero air and span gas Operating instructions for Automatic Zero Span Check and Remote Zero Span Check are described in Sections 3 4 through 3 7 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 76 9 0 ADJUSTMENTS NOTE THE OPERATIONS OUTLINED IN THIS CHAPTER ARE TO BE PERFORMED BY QUALIFIED MAINTENANCE PERSONNEL ONLY All adjustments to the Model 300 are easy to make Pots and test points are readily accessible without removing any components Figure 1 6 is a plan view of the Model 300 CO Analyzer showing all the major components Figure 9 1 is an electrical diagram of Model 300 CO Analyzer 9 1 Power supply board adjustment The power supply board provides 15v 12v and 5v DC power to the Analyzer Four temperature linearization circuits for the Analyzer main lamp Sample temp Box temp and IZS carbon monoxide generator are also located on the power supply board Each circuit is a whetstone bridge with the measuring thermistor being one leg A feedback circuit performs the required linearization Zero adjust pots have been factory set and no field adjustment should be required 9 1 1 Box temperature limits The box temperature is measured by a thermistor located on the motherboard The box temp is not controlled in the Model 300 The temperature is measured and displayed as a TEST function on the front panel see Section 5 1 The alarm limits can be set via an RS 232 port command P
98. rcle pertinent data Do Opto Interrupter and Detector wave forms match those shown in Figures 10 1 and 10 2 YES O NO Thank you for providing this information Your assistance enables Teledyne API to respond faster to the problem that you are encountering Teledyne API Customer Service Phone 858 657 9800 Toll Free 800 324 5190 FAX 858 657 9816 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 99 11 0 ROUTINE MAINTENANCE NOTE THE OPERATIONS OUTLINED IN THIS CHAPTER ARE TO BE PERFORMED BY QUALIFIED MAINTENANCE PERSONNEL ONLY 11 1 Model 300 maintenance schedule The following are the recommended periodic maintenance items for the Teledyne API Model 300 CO Analyzer Date Instrument Was Recieved J M J J O N D ITEM A U U RECOMMENDED ACTION umm HER filter element needed uA diaphragms months Sample flow Check for proper flow 800cc min 10 annually 25 lines necessary Leak Check Leak Check after maintenance and at least annually ST 08 bench TABLE 11 1 11 2 Replacement of sample filter a Turn off the Analyzer This will stop the pump and eliminate the possibility of sucking debris into the Analyzer while changing the filter element P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 101 b Open the front panel and remove the transparent filter cover and knurled retaining ri
99. reading or the RS 232 output e 225 Fn P N 02163G1 Teledyne Model 300 CO Analyzer Instruction Manual Page 74 12 13 14 15 16 17 18 19 20 2 22 23 Set the calibrator to produce 75 to 85 of the URL upper range limit This will be 40 ppm 2 5 ppm on the 50 ppm range Allow the Analyzer to sample the CO concentration Push CAL Enter password If enabled Push CONC Change the span value in the display to the calculated CO concentration in the manifold in ppm units and push ENTR Wait 15 minutes for the Analyzer to stabilize Push SPAN and ENTER The Analyzer is now spanned Record the calculated CO concentration the DVM reading and the percentage chart reading or the RS 232 output Push EXIT EXIT The Analyzer is now returned to the normal Sample mode Introduce at least five 5 more approximately evenly spaced CO concentrations into the manifold to complete the manual calibration Record all calculated CO concentrations DVM reading and strip chart recorder readings or RS 232 output readings Plot the calculated CO concentrations X axis versus output voltages and or percentage chart readings Y axis Calculate the curve equations CO ppm Volts b m where b is the offset should be within 0 05 volts of zero setting and m is the slope should be 098 to 102 based on 0 5V full scale or CO chart b m
100. red analog output of the current CO readings on each of two pairs of outputs on the rear panel see Figure 1 2 for DAS and recorder reporting The analog outputs provide for 20 overrange For example on the 50 ppm range the M300 will correctly report concentrations up to 60 ppm and output up to 6 00 volts to the DAS and recorder outputs In addition TEST function values can be routed to a third analog output 2 1 3 E ROM backup of software configuration The Teledyne API CO Analyzer has a few jumpers that need to be set by the operator Configuration of the Analyzer is done under software control and the configuration options are stored in electrically erasable E ROM Thus configuration options are saved even when the Analyzer is powered off There is one exception to this The analog output voltage ranges are set by jumpers on the A D V O board as shown in Section 10 6 3 2 1 4 Adaptive filter The Teledyne API CO Analyzer is able to provide a smooth stable output by means of an adaptive filter During conditions of constant or nearly constant concentration the filter is allowed to grow to 600 samples 2 minutes in length providing a smooth stable reading If a rapid change in concentration is detected the filter is cut to 50 samples to allow the Analyzer to quickly respond to rapidly varying signals 2 1 5 Data acquisition The Teledyne API CO Analyzer contains a built in data acquisition system which keeps track of the averag
101. rmed during automatic or remote span checks Remote span adjustment is performed via a command from the RS 232 or the external contact closure inputs Calibration and span adjustments are discussed in greater detail in Section 3 6 Table 2 2 below lists all the possible modes in the Analyzer and their meanings P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 25 SYSTEM MODES Doing a multi point calibration DIAGDAS 4 Data Acquisition configuration DIAG D A 4 Configure and Calibrate Digital to Analog converters 1 x A auto 2 x M manual A auto R remote 3 xxx software revision e g A 9 4 diagnostic test modes TABLE 2 2 The message field shows test measurements or warning messages Tables 2 3 and 2 4 summarize the test measurements and warning messages and their meanings Refer to Sections 4 0 and 5 0 for detailed information on viewing test measurements and warning messages and clearing warnings TEST MEASUREMENTS TABLE 2 3 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 26 WARNING MESSAGES TABLE 2 4 The menu field changes depending on the mode of the Analyzer and the buttons that have been pressed It indicates the current function of each of the 8 push buttons below the display See Section 2 2 2 for information on using the push buttons 2 2 2 Programmable push buttons The 8 push buttons below the display are programmable by the
102. s of the Analyzer 10 6 1 Troubleshooting flow problems When troubleshooting flow problems it is a good idea to first confirm that the actual flow and not the flow meter is in error If available use an independent flow meter rotameter or mass flow meter to measure flow s Sample flow can be measured at the sample inlet port at the instrument s rear panel If no independent flow meter is available placing a finger over an inlet port and feeling for a vacuum will at least give an indication whether flow is present If the independent flowmeter shows the flow to be correct check the Pneumatic Sensor Board as described in Section 10 6 5 In general flow problems can be divided into 3 categories Flow in zero no flow Flow is greater than zero but is too low and or unstable Flow is too high Figure 1 3 in this Manual provides a schematic diagram of the Flow in a Model 300 and its optional IZS subsystem Flow is zero WARNING HAZARDOUS VOLTAGES PRESENT USE CAUTION 1 Confirm that the sample pump sample flow and or IZS pump IZS flow is operating turning If not check the 115V power to the pump If the pump does not operate with 115V present at its terminal replace the pump Check for plugged pneumatic lines filters or orifices P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 90 Low Flow 1 Check for leaks as described in Section 11 2 Repair and re check 2 Check for dir
103. span setpoints of the analyzer at any time by pressing the CALZ or CALS button Pressing CALZ switches the Sample Cal valve and allows the analyzer to draw air through the zero air scrubber After a few minutes the CO reading should go to zero If it doesn t the operator may press the ZERO button followed by ENTR CALS works like CALZ except that externally supplied span gas is drawn through the analyzer After a few minutes the CO reading should approach the span level typically 40 PPM If it doesn t the operator may press the SPAN button followed by ENTR The expected span gas concentration may be changed by pressing the CONC button The operator can exit the IZS calibration only by pressing the EXIT button If either the ZERO or SPAN buttons were pressed and ENTR was not pressed the Analyzer will beep once to indicate that no changes have been made P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 32 3 3 Zero span valves Option If the Zero Span Valves option has been installed the operator can check the zero and span setpoints of the analyzer at any time by pressing the CALZ or CALS button Zero and Span checks using the Zero Span Valves option is identical to that described in Section 3 2 except that external zero and span gas is supplied to the analyzer through a zero span valve located on the rear panel of the instrument 3 4 Automatic zero span check Automatic zero span checking Z S check must be
104. ted See Section 3 1 2 for details on calibrating the two ranges 4 7 Setting the analog output offset In order to permit the Analyzer to connect to a wider variety of strip chart recorders and other instruments the analog output of the carbon monoxide readings can be adjusted by up to 500 mV for 0 5V range or 10 of current analog output range in software The default output offset is 0 mV To change it press SETUP MORE DIAG press P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 41 NEXT until D A CALIBRATION is displayed and press ENTR Press CFG to enter the D A configuration menu Use the NEXT and PREV buttons to select the desired analog output and press SET Enter a value of from 500 mV to 500 mV other ranges will ratio accordingly followed by ENTR to accept the change or EXIT to leave it unchanged The offset will be reflected immediately on the strip chart recorder or other instrument 4 8 Setting the RS 232 baud rate To set the baud rate for the RS 232 channel press SETUP MORE COMM BAUD Press 300 1200 2400 4800 9600 or 19 2 followed by ENTR to accept the new baud rate or EXIT to leave the baud rate unchanged 4 9 Setting the analyzer 1 D Each Analyzer may be programmed with a unique I D number which appears on all RS 232 messages To set the Analyzer I D press SETUP MORE COMM ID Enter a 4 digit number from 0000 to 9999 followed by ENTR to accept the new I D or EXIT to leave th
105. ternal voltage standards and no on board adjustments are needed or provided for this function The outputs of all DAC s are looped back to Analog input via the Mother Board channels This loop back allows for automatic micro processor checking of A D 10 6 3 3 Digital VO lines 32 Digital Lines are used to provide the primary means for the micro processor to control various analyzer functions valves heaters etc and to send and receive status conditions to from external equipment These lines are configured as 8 digital inputs and 24 digital outputs The convention for all Digital 1 O Lines is High 5V True Low 0V False 10 6 3 4 Proper operation of the V F board can be confirmed by performing an ADC calibration procedure as described in Section 9 2 If this calibration procedure can be performed correctly it is highly probable that the V F card is functioning properly If the V F does not function properly check the following 1 Confirm the presence of appropriate power by checking for 5V between TP 4 and TP 5 15V at TP 1 and TP 3 15V at TP 2 and TP 3 If any of these voltages are incorrect check the DC Power Supply as described in Section 10 6 4 2 Confirm that all jumpers and switches on the V F board are set properly as follows V F BOARD JUMPERS FACTORY SETTINGS Factory Set Jumpers Setting 3 4 ON Set to match input line frequenc TABLE 10 3 P N 02163G1 Teledyne API Model 300 CO
106. the connector at Motherboard J5 and measure across the leads Chassis Temperature Turn the analyzer off and remove the DC Power Supply Board Measure across Motherboard J21 pins A30 and C30 P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 91 If thermistor resistance s are within the proper range check the temperature linearzation circuits on the DC Power Supply Board as described in Section 10 6 4 If temperature sensor readings appear accurate but control temperatures are not being maintained at their proper value check the operation of the heaters as follows 1 Observe the indicator LED s on the Power Supply Module and confirm that the red right most LED is lit and that the CEL HTR LED is lit or cycling turningoff and on If these indicators are not correct it is probably that the Power Supply Module or the V F Board is at fault Check as described in Sections 10 2 and 10 6 3 2 Unplug the heater element from Power Supply Module and confirm that 115 VAC is present If 115 VAC is present the heater element has failed and should be replaced WARNING HAZARDOUS VOLTAGES PRESENT USE CAUTION 10 6 3 Checking the V F card A schematic and physical diagram of the V F card are shown on Drawings 514 and 515 in Appendix C The V F is a multi function VO card which connects to the micro processor via a STD Bus interface and acts as the primary VO interface between the micro processor and the rest o
107. to zero and modify the internal formulas used to compute the CO reading If the ZERO button is not displayed this means that the zero reading is too far out of adjustment to do a reliable calibration The reason for this must be determined before the analyzer can be calibrated See Section 10 5 for troubleshooting calibration problems Pressing EXIT will bring you back to the Sample menu or you can leave the instrument in CAL mode if you are also going to make a span check 3 1 2 Span Check Allow the analyzer to sample span gas through the sample port Press CAL button After a few minutes the CO reading should be at the expected concentration If the correct concentration is not reached then the instrument can be adjusted to read the correct value To do this press CONC and enter the expected concentration for calibration The SPAN button should now be displayed on the front panel Pressing SPAN and ENTER will modify the internals formulas used to compute the CO reading Ifthe SPAN button is not displayed this means that the span reading is too far out of adjustment to do a reliable calibration The reason for this must be determined before the analyzer can be calibrated See Section 10 5 for troubleshooting calibration problems P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 31 3 1 3 Dual Range Calibration If the analyzer is being operated in Dual Range mode or Auto Ranging mode then the High and Low ranges must b
108. ty sample filter or dirty orifice filter s 3 Check for partially plugged pneumatic lines orifices or valves High Flow 1 The most common cause of high flow is a leak around an orifice To correct remove the orifice as described in Section 11 5 replace O rings and re assemble 10 6 2 Troubleshooting temperature problems The Model 300 has been designed to operate at ambient temperatures between 5 C and 40 C As a first step in troubleshooting temperature problems confirm the ambient temperature is within this range and that the air inlet slots on the sides of the cover and the fan exhaust on the rear panel are not obstructed The instrument monitors four temperatures Sample Temperature Inside Chassis Temperature Optical Bench Temperature Gas Filter Wheel Temperature and controls the temperatures of two components by heating Optical Bench Gas Filter Wheel If any of the temperature readings appear to be incorrect check for proper thermistor operation by measuring the resistance of the thermistor s This resistance should be in the range of 7 6K ohms to 95 ohms If it is not the thermistor is defective and should be replaced Points for measuring thermistor resistance are as follows Sample Temperature Unplug the connector at Motherboard J2 and measure across the leads Optical Bench Temperature Unplug the connector at Motherboard J4 and measure across the leads Gas Filter Wheel Temperature Unplug
109. ue 4300mV for 29 9 HG A 26 SAMPLE_FLOW NO Sample flow in mV 27 SAMPLE TEMP NO Sample temp in mV P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 56 Optical Bench temp Typically 2270 mV for 48 C Filter Wheel temp Typically 4770 mV for 68 C 30 BOX_TEMP Internal analyzer temp in mV 31 DCPS_VOLTAGE DC power supply composite voltage output Typically 2500 mV 32 DAC_CHAN_0 Output of DAC O REC in mV 34 35 36 37 TABLE 5 2 VO SIGNALS Ar 32 1 in mV 34 in mV 35 in mV 36 37 5 2 3 D A output This test cycles 3 of the analog output channels from 0 to 100 of Full Scale in 20 FS steps It starts by outputting O volts to all four channels and displaying a 0 button Then every five seconds the output is increased 20 FS and the button is changed accordingly Thus the button and the analog outputs will cycle through the following value 0 20 40 60 80 100 0 To pause the output at the current voltage press the n button To resume automatic cycling press the n button again 5 2 4 Electric Test This test activates a diagnostic circuit located on the Synchronous Demodulator board which generates an artificial signal which simulates the output of the IR detector This signal is injected in place of the detector output When activated Electric Test will automatically switch the analyzer into a 50 ppm range and result in the Analyzer producing
110. ule is lit If this LED is not lit replace the fuse at the bottom center of the Power Supply Module 5 Check for proper DC Voltages by measuring for the following voltages on the V F Board 5V between TP4 and TP5 15V between TP1 and TP3 15V between TP2 and TP3 If any of these voltages are incorrect check the DC Power Supply as described in Section 10 6 4 10 2 2 Checking the CPU and display When the analyzer is turned on the front panel display should energize and the green Sample LED should light If proper DC power is present see Section 10 2 1 the P N 02163G1 Teledyne API Model 300 CO Analyzer Instruction Manual Page 84 absence of these actions will usually indicate either a CPU or Display failure To determine which module is defective perform the following procedure Turn off power Remove the ribbon cable from the CPU board to the Display Turn Power on A cursor character should appear in the upper left corner of the display If it does not the display is defective and should be replaced If the cursor does appear it is probable that the CPU is faulty 10 2 3 Checking the keyboard During normal Analyzer operation depressing the right most key of the keyboard should cause a change of display modes If it does not check Cable connections CPU and Display operation see Section 10 2 2 If these checks are satisfactory it is probable that the keyboard is defective and should be replaced 1

Teledyne Carbon Monoxide Analyzer 300 User's Manual

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