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INSTRUCTION MANUAL

MODEL 300

CARBON MONOXIDE ANALYZER

© Teledyne Instruments

Advanced Pollution Instrumentation Division

(T-API)

6565 Nancy Ridge Drive

San Diego, Ca 92121-2219

Toll Free: 800 324-5190

Telephone: 858 657-9800

Fax: 858 657-9816

Email:

[email protected]

Website: www.teledyne-api.com

02163

Rev. G

01/09/97

Summary of Contents for 300

Page 1: ...ledyne Instruments Advanced Pollution Instrumentation Division T API 6565 Nancy Ridge Drive San Diego Ca 92121 2219 Toll Free 800 324 5190 Telephone 858 657 9800 Fax 858 657 9816 Email api sales teledyne com Website www teledyne api com 02163 Rev G 01 09 97 ...

Page 2: ...und 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 Warning CAUTION Electrical Shock Hazard Technician Symbol All operations marked with this symbol are to be performed by qualified maintenance personnel only CAUTION The analyzer should only be used fo...

Page 3: ...ero span check 31 3 5 Summary of front panel check and calibration controls 34 3 6 Remote zero span check or adjustment contact closure 35 3 7 Remote zero span check or adjustment RS 232 36 3 8 Power on hold off 36 3 9 Hold off 36 4 0 SETUP MODE 37 4 1 Setup mode operation 37 4 2 Examining the carbon monoxide formula slope and offset 37 4 3 Setting the time of day 38 4 4 Setting the date 38 4 5 Ad...

Page 4: ...stment 75 9 6 DC power supply 75 9 7 CPU 75 10 0 TROUBLESHOOTING 76 10 1 Overview 76 10 2 Troubleshooting fundamental analyzer operation 77 10 3 Troubleshooting using warning messages 78 10 4 Troubleshooting using test function values 80 10 5 Troubleshooting dynamic problems 81 10 6 Troubleshooting individual sub assemblies and components 83 10 7 Warranty repair questionnaire 92 11 0 ROUTINE MAINT...

Page 5: ...TABLE 7 7 TEST MEASUREMENT REQUEST COMMANDS 62 TABLE 7 9 RS 232 VARIABLE NAMES 64 TABLE 9 1 V F BOARD SWITCH SETTINGS 74 TABLE 10 1 WARNING MESSAGES 79 TABLE 10 2 TEST FUNCTION VALUES 81 TABLE 10 3 V F BOARD JUMPERS FACTORY SETTINGS 87 TABLE 10 4 V F BOARD JUMPERS RANGES FOR ANALOG OUTPUT 88 TABLE 11 1 MAINTENANCE SCHEDULE 93 FIGURES FIGURE 1 1 CARBON MONOXIDE ANALYZER 8 FIGURE 1 2 REAR PANEL ELEC...

Page 6: ...P N 02163G Teledyne API Model 300 CO Analyzer Instruction Manual Page vi FIGURE 10 1 OPTO PICKUP WAVEFORM 90 FIGURE 10 2 DETECTOR WAVEFORM 90 FIGURE B 1 RS 232 PIN ASSIGNMENTS 102 ...

Page 7: ...required 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 av...

Page 8: ... 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 ...

Page 9: ...he 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...

Page 10: ... of reading Lag Time 10 sec Rise Fall Time 95 60 sec Sample Flow Rate 800cc min 10 Temperature Range 5 40 C Humidity Range 0 95 RH non condensing Temp Coefficient 0 05 per C Voltage Coefficient 0 05 per V Dimensions HxWxD 7 x 17 x 25 178mm x 432mm x 660mm Weight 50 lbs 22 7 kg Power 110V 60Hz 220V 50Hz 240V 50Hz 250 Watts Power CE 230V 50Hz 2 5 A Environmental Conditions Installation Category Over...

Page 11: ...by at least the height of the instrument feet 3 Connect sample inlet line to the sample port on rear panel 4 Connect IZS inlet input if installed to a clean dry air supply 5 Connect a recording 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 CAUTION To avoid...

Page 12: ...osely match the Table 1 1 values 9 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 b Enter the PASSWORD 818 c Press RNGE RANGE d Press SET e Enter the derived full scale range for analog outputs and press ENTR f Press EXIT 2 times to return to the SAMPLE menu 10 Adjust the analyzer zer...

Page 13: ...yboard e 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 procedure only by pressing the EXIT button NOTE...

Page 14: ...P N 02163G Teledyne API Model 300 CO Analyzer Instruction Manual Page 8 CARBON MONOXIDE ANALYZER FIGURE 1 1 ...

Page 15: ...P N 02163G Teledyne API Model 300 CO Analyzer Instruction Manual Page 9 REAR PANEL ELECTRICAL CONNECTIONS FIGURE 1 2 ...

Page 16: ...acteristics 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...

Page 17: ... OK TRUE IF NO ALARM CONDITIONS EXIST 10 19 20 RESERVED 11 21 22 SOURCE WARNING TRUE IF THE ANALYZER SOURCE INTENSITY IS OUT OF LIMITS 12 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 flo...

Page 18: ...4 O D PTFE tubing is needed to connect the sample source to the Analyzer 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 c...

Page 19: ...e 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 CAUTION Connect the exhaust fitting on the rear panel See Fig 1 4 to a suitable vent outside the analyzer area ...

Page 20: ...P N 02163G Teledyne API Model 300 CO Analyzer Instruction Manual Page 14 FLOW DIAGRAM FIGURE 1 3 ...

Page 21: ...P N 02163G Teledyne API Model 300 CO Analyzer Instruction Manual Page 15 REAR PANEL PNEUMATIC CONNECTIONS FIGURE 1 4 ...

Page 22: ...P N 02163G Teledyne API Model 300 CO Analyzer Instruction Manual Page 16 REAR PANEL FIGURE 1 5 ...

Page 23: ...P N 02163G Teledyne API Model 300 CO Analyzer Instruction Manual Page 17 MODEL 300 ASSEMBLY LAYOUT FIGURE 1 6 ...

Page 24: ...keyboard button labeled TEST Not every TEST function is a diagnostic of correct analyzer operation therefore TEST functions not covered below can be ignored for now 4 CO REF CO MEAS TEST function values should be between 3200 mV and 4700 mV 5 Pressure 29 to 30 Inches Mercury Absolute at sea level Other values will be displayed depending on altitude of Analyzer 6 Sample Flow 800 cc min 10 7 Sample ...

Page 25: ...N HG A IZS SAMPLE FLOW _______SCC MIN OTHER ____________ SAMPLE TEMP _______C OPTICAL BENCH TEMP_______C WHEEL TEMP _______C BOX TEMP _______C DC POWER SUPPLY _______mV TIME _______HH MM SS CALIBRATION VALUES SETUP VALUES CO SPAN SETTING _______PPM ELECTRIC TEST _______PPM CO ZERO SETTING _______PPM CO SLOPE _______ DARK MEAS _______mV CO OFFSET _______ DARK REF _______mV CONFIGURATION DATA PROM R...

Page 26: ...hould 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 Vent Span port at the rear panel should be vented to a suitable exhaust manifold at ambi...

Page 27: ...ed above and in addition includes an internal zero air scrubber This scrubber operates by catalyticly converting CO in the gas stream to CO2 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 ...

Page 28: ...alyzer is done under software control and the configuration options are stored in electrically erasable E 2 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 I 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 sta...

Page 29: ...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 ...

Page 30: ...pies 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 l...

Page 31: ... 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 Test Message Meaning TIME xx xx xx Current time of day HH MM SS RANGE xxxx PPM Analog output full scale range STABIL x xxx PPM Standard Deviation of CO readings CO MEAS x...

Page 32: ...l 63 C or 73 C CANNOT DYN ZERO CO offset 1500 or 1500 mV CANNOT DYN SPAN CO slope 0 5 or 2 0 V F NOT INSTALLED A D I O card not installed or bad SYNC ERROR No modulation on detector output 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 f...

Page 33: ...g 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 d...

Page 34: ...ring DAS Disabled On Monitoring normally taking DAS data Blinking Monitoring HOLD OFF mode on no data to 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 ...

Page 35: ...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...

Page 36: ...tion Enter span gas concentration for Low Range Set calibration gas source to deliver span concentration 7 Press ENTR 8 Wait 15 min Wait for CO reading to stabilize at span value 9 Press SPAN ENTR Changes calibration equations for Low range so analyzer will read span value 10 Press EXIT Exits back to sample menu Repeat steps 1 10 for High range 3 2 IZS zero span check Option If the IZS Internal Ze...

Page 37: ... 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 belo...

Page 38: ...day and the delta time to 15 minutes will delay the starting time for the 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 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...

Page 39: ...S 1 6 DELTA TIME 00 00 7 DURATION 15 8 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 1 MODE ZERO SPAN 2 TIMER ENABLED ON 3 STARTING DATE 12 20 93 4 STARTING TIME 23 30 5 DELTA DAYS 0 6 DELTA TIME 23 45 7 DURATION 15 8 CALIBRATE OFF Example 3 to perform span check once per week starting at 11 30 pm 12 20 93 1 MOD...

Page 40: ...e calibration controls are summarized below in terms of the button sequences used to access them CALIBRATION CONTROLS Button Sequence Function Default Limits CALZ Begin zero check CALZ ZERO ENTR Adjust CO conc to zero CALZ EXIT Exit zero check CALS Begin span check CALS CONC ENTR Expected CO span value 40 PPM 1 1000 PPM CALS SPAN ENTR Adj CO conc to span val CALS EXIT Exit span check CAL Begin M P...

Page 41: ...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 zero 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 ...

Page 42: ...old 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 h...

Page 43: ...hese 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 2 cell of the Gas Filter Whee...

Page 44: ...changed 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 unchan...

Page 45: ...nge 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 swit...

Page 46: ...bling 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 s...

Page 47: ...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 in the data The last 800 hourly averages are stored PNUMTC Collects sam...

Page 48: ...t Menu Button Description PREV Moves to the previous data channel NEXT Moves to the next data channel INS Inserts a new data channel in front of the current one allowed up to 20 data channels DEL Deletes the current data channel prompts first EDIT Edits the properties of the current data channel PRNT Prints a summary of all of the data channel on the RS 232 port The creation or modification of dat...

Page 49: ...S 232 channel OFF OFF or ON CHANNEL ENABLED ON ON or OFF CAL HOLD OFF ON ON or 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 because th...

Page 50: ...ing overwritten with the newest records 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 c...

Page 51: ...ich all measure the CO concentration for range 1 the CONC1 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 Initial Setting Setting Ra...

Page 52: ...ample flowrate cc min SMPPRS Sample pressure in Hg BOXTMP Box temperature o C DCPS DC power supply composite voltage mV 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 ...

Page 53: ...sabled for each Data Channel For all default data channels RS 232 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 followe...

Page 54: ...ration can be displayed by entering 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 ...

Page 55: ...FF ON SETUP MORE VARS DYN_SPAN Enable Remote Dynamic Span Adjustment OFF OFF ON SETUP MORE VARS RS232_MODE Set RS 232 Mode 8 SETUP MORE VARS CLOCK_ADJ Set Clock Adjustment Rate 0 15 to 15 SETUP MORE DIAG DARK VIEW View Dark Offset N A N A SETUP MORE DIAG SIGNAL I O View the state of internal signals N A N A SETUP MORE DIAG ANALOG OUTPUT Generate Analog Output Test Pattern N A N A SETUP MORE DIAG D...

Page 56: ...ssing 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 displays the analog voltage reading on the front panel as TEST XXXXX X MV When you exit the diag...

Page 57: ...CO detector reference value 4200 mV 4 SAMP PRESS Sample pressure 125 mV 5 SAMP FLOW Sample flow 3000 mV 6 SAMP TEMP Sample temperature 3000 mV 7 BENCH TEMP Optical bench temperature 3900 mV 8 WHEEL TEMP Outputs filter wheel temp 3900 mV 9 CHASSIS TEMP Outputs Chassis temp 2740 mV 10 DCPS VOLT Outputs DC power 2500 mV 11 DAS AVERAGE Current DAS average Any TABLE 5 1 5 2 1 Signal I O The signal I O ...

Page 58: ...mod Board 00798 is able to lock in on the detector signal 4 SPAN_VALVE YES Switches the Zero Span valve Use this bit to test the valve function 5 CAL_VALVE YES Switches the Sample Cal valve Use this bit to test the valve function 6 BENCH_HTR YES Shows the status of the optical bench heater This has the same function as the LED in the power supply module 7 WHEEL_HTR YES Shows the status of the filt...

Page 59: ...nge 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 1 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...

Page 60: ...l 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 ...

Page 61: ... 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 ...

Page 62: ...haracter Message Type W Warning C Control status D Diagnostic T Test measurement V 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 IIII is a 4 digit Analyzer I D number The MESSAGE field contains variable information such as wa...

Page 63: ...h the most recent if this parameter is not specified then all available records for the Data Channel are printed COMPACT VERBOSE 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 The verbose format looks like the following D 31 10 06 0412 CONC AVG COCNC1 6 8 PPM This report uses the fo...

Page 64: ...s 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...

Page 65: ... 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 Report C DDD HH MM IIII START ZERO CALIBRATION C DDD HH MM IIII FINISH ZERO CALIBRATION C DDD HH MM IIII START SPAN CALIBRATION C...

Page 66: ...he proper calibration mode and concentration is within calibration limits This command adjusts slope and offset values 2 Initiated only If automatic calibration sequence setup is programmed and enabled TABLE 7 4 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 CRLF to do a zero check the CPU will send the st...

Page 67: ...EPROM Erases all DAS data Resets all setup variables to factory 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 CRLF 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 cluttere...

Page 68: ...nt the host must issue a command of the form T MEASUREMENT CRLF For a summary of all test functions issue the command T LIST The table below lists the commands and the corresponding test measurements which will be returned TEST MEASUREMENT REQUEST COMMANDS Command Test measurement CRLF RS 232 HELP screen T LIST CRLF Summary of all TEST s T CO CRLF Current CO reading T COMEAS CRLF Current CO MEAS m...

Page 69: ...rning 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 CRLF and the CPU would respond with something like V DDD HH M...

Page 70: ... and the CPU should respond with V DDD HH MM IIII MACHINE_ID 1234 0 9999 CRLF Table 7 9 lists the variable names which are variable through the RS 232 interface and their corresponding button sequences RS 232 VARIABLE NAMES Var Name Button Sequence Legal Values CO_SPAN SETUP IZSC SPAN 0 1000 FILT_ADAPT SETUP MISC FILT ADAPT OFF ON REPORT_FREQ SETUP DAS FREQ 1 60 MACHINE_ID SETUP COMM ID 0000 9999 ...

Page 71: ...r 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 inl...

Page 72: ...P N 02163G Teledyne API Model 300 CO Analyzer Instruction Manual Page 66 GAS GENERATION SYSTEM FIGURE 8 1 INLET VENTING RECOMMENDATIONS FIGURE 8 2 ...

Page 73: ... 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 a Prior to field operation as an EPA DESIGNATED REFERENCE METHOD b After maintenance c Every three months recommended NOTE THE TEST GAS MUST BE INTRODUCED INTO THE ANALY...

Page 74: ...eliver 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 F...

Page 75: ...ons into the manifold to complete the manual calibration 22 Record all calculated CO concentrations DVM reading and strip chart recorder readings or RS 232 output readings 23 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 ...

Page 76: ...hecked 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 optio...

Page 77: ...ain 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 ...

Page 78: ...P N 02163G Teledyne API Model 300 CO Analyzer Instruction Manual Page 72 M300 ELECTRICAL BLOCK DIAGRAM FIGURE 9 1 ...

Page 79: ...he 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 R31 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 t...

Page 80: ...g outputs 1 Turn off instrument 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 Full Scale 1 V Full Scale 5 V Full Scale 10 V Full Scale S1 Reco...

Page 81: ...ppropriate 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 ...

Page 82: ... 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 related problems The following sections...

Page 83: ... the power sub systems 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 Module is lit If this LED is not lit replace the fuse at the bottom center of the Power ...

Page 84: ... 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 funda...

Page 85: ...blems as described in Sect 10 6 5 BOX TEMP WARNING The inside chassis temp is less than 10 o C or is greater than 50 o C See Section 10 6 2 SAMPLE TEMP WARNING The Sample Temperature is less than 10 o C or is greater than 50 o C See Section 10 6 2 CANNOT DYN ZERO An offset of more than 5 ppm would be required to Zero adjust the analyzer See Section 10 5 5 CANNOT DYN SPAN A slope of less than 0 5 o...

Page 86: ...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 Scale Range Setting of the analyzer s analog outputs Any None required CO MEAS The most recent detector reading taken ...

Page 87: ...TEMP The temperature of the Gas Filter Wheel 68 o C After warm up See Section 10 6 2 BOX TEMP The temperature inside the analyzer chassis 1 o 5 o C above ambient See Section 10 6 2 DCPS DC Power Supply reference A composite of all voltages provided by the DC Power Supply 2250 2750 mV See Section 10 6 4 TABLE 10 2 10 5 Troubleshooting dynamic problems Dynamic problems i e problems which only manife...

Page 88: ...ck 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 Section 11 3 2 Check for pneumatic leaks ...

Page 89: ...r 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 ...

Page 90: ...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 res...

Page 91: ...C is present the heater element has failed and should be replaced 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 I O card which connects to the micro processor via a STD Bus interface and acts as the primary I O interface between the micro processor and the rest of the analyzer All functions ...

Page 92: ...puts 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 inst...

Page 93: ...8 digital inputs and 24 digital outputs The convention for all Digital I 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 ...

Page 94: ...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 25VAC between J13 pins 4 and 5 15VAC between J13 pins 3 and 2 38VAC between J13 pins 6 and 7 If any of ...

Page 95: ...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 described 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 show...

Page 96: ...ng 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 or TST button on the front ...

Page 97: ...e to achieve 4200 mV on CO MEAS then do the following 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 z...

Page 98: ..._____ 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 NO What are failure symptoms _______________________...

Page 99: ...articulate filter element Repalce weekly or as needed Pump diaphragms Replace every 6 months Sample flow Check for proper flow 800cc min 10 annually Pneumatic lines Examine and clean as necessary Leak Check Leak Check after maintenance and at least annually Clean optical bench As needed TABLE 11 1 11 2 Replacement of sample filter a Turn off the Analyzer This will stop the pump and eliminate the p...

Page 100: ...11 3 Leak checking There are two methods of leak checking 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 Leave the checker on until 15 psi is achieved Close the valve and ensure the pressure remains at 15 psi f...

Page 101: ...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 t...

Page 102: ...was located on the top right corner of the label on the PROM 8 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 9 Re calibrate the analyzer so that the default slope and intercept are overwritten with the correct values ...

Page 103: ...7 MM QTY 25 872 006300 00402 05 PNEUMATIC SENSOR BOARD 00422 01 CO PROM 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 THERMISTOR 00646 SAMPLE FILTER ASSY 00690 01 PADS 00728 NEW DISPLAY 00798 SYNC DEMODULATOR BOARD 00864 ASSY OPTICAL BENCH 00953 PREAMP DETECTOR ASSEMBLY 00956 0001 GAS ...

Page 104: ...AMP 250V CH024 CATALYST CO CO2 CONVERTER 1 OZ FA004 FAN FL001 SINTERED FILTER 002 024900 HE017 HEATER CO CO2 CONVERTER 12W HE018 HEATER 50W IZS HW020 SPRING FLOW CONTROL HW036 TFE THREAD TAPE 48 FT HW037 TIE CABLE OP009 WINDOW SAPPHIRE OR001 O RING FLOW CONTROL OR018 O RING SAMPLE FILTER OR021 O RING SCRUBBER OR030 O RING 2 141 V OR034 O RING INPUT OUTPUT MIRROR DETECTOR OR039 O RING WINDOW PU010 ...

Page 105: ...1 FILTER TFE 37 MM QTY 25 872 006300 00402 05 PNEUMATIC SENSOR BOARD 00422 01 CO PROM W SOFTWARE 00514 03 V F BOARD 00551 02 POWER SUPPLY MODULE 115V 60Hz 00551 06 POWER SUPPLY MODULE 220V 50Hz 00551 10 POWER SUPPLY MODULE 240V 50Hz 00611 01 ASSY THERMISTOR 00611 02 ASSY HEATER THERMISTOR 00646 SAMPLE FILTER ASSY 00690 01 PADS 00704 KEYBOARD 00728 NEW DISPLAY 00798 SYNC DEMODULATOR BOARD 00864 ASS...

Page 106: ...EMBLY WITH ADAPTOR 01595 OBJECTIVE MIRROR 01934 03 ASSY SAMPLE THERMISTOR CB004 FUSE 3 AG 3 AMP 250V CH024 CATALYST CO CO2 CONVERTER 1 OZ FA004 FAN FL001 SINTERED FILTER 002 024900 HE001 HEATER CO CO2 CONVERTER 12W HE002 HEATER 50W IZS HW020 SPRING FLOW CONTROL HW036 TFE THREAD TAPE 48 FT HW037 TIE CABLE OP009 WINDOW SAPPHIRE OR001 O RING FLOW CONTROL OR018 O RING SAMPLE FILTER OR021 O RING SCRUBB...

Page 107: ...P N 02163G Teledyne API Model 300 CO Analyzer Instruction Manual Page 101 APPENDIX A LIST OF AVAILABLE MODEL 300 OPTIONS RS 232 Status Outputs Internal Zero Span IZS with valves Rack Mount and Slides ...

Page 108: ...ers to a variety of other equipment Connectors There is a wide variety of connectors and cables that are specified to operate with the RS 232 protocol This is because electronics have decreased in size over the years and connectors have been downsized to match the electronics Cables Adapters come in 4 general types 1 Cables cables are provided in various lengths from 6 to 50 feet In most cases the...

Page 109: ...elp 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 ...

Page 110: ... Third for modems Check that the voltage 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...

Page 111: ...hematic Power Supply Module PCA 00551 Wiring Diagram Power Supply Module 00704 Assembly Keyboard PCA 00705 Schematic Keyboard PCA 00798 Assembly Sync Demodulator 00799 Schematic Sync Demodulator 00866 Assembly Mother Board 00867 Schematic Mother Board 00874 Assembly Pre Amp Bias 00875 Schematic Pre Amp Bias 01916 Assembly Rear Panel PCA CE Mark Units Only 01917 Schematic Rear Panel PCA CE Mark Uni...

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Summary of Contents for 300

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