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Model 300E Carbon Monoxide Analyzer 
Instruction Manual 

TROUBLESHOOTING & REPAIR PROCEDURES 

 

P/N 04288 REV: A 

 

205 

 

2.  Assuming that the I

2

C bus is working and that there is no other failure with 

the Relay board, the solid-state relay (K1) on the Relay Board (see Figure 
10-2) may have failed.  Using the WHEEL_HEATER parameter under the 

Signal I/O function, as described above, turn on and off K1 (D2 on the relay 
board should illuminate as the heater is turned on). Check the AC voltage 

present between pin 1 and 4.  

 

WARNING:  Hazardous Voltages are present during this test

  

 
If the relay has failed there should be no change in the voltage across pins 1 

and 4.  Note, K1 is socketed for easy replacement.  

3.  If K1 checks out OK, the thermistor temperature sensor located at the front 

of the filter wheel assembly may have failed. Unplug the connector labeled 

“Wheel”, and measure the resistance of the thermistor.  The resistance near 
the 68

o

C setpoint is ~5.7k ohms.  

11.4.1.4. IR Photo-Detector TEC Temperature

 

If the 

PHT DRIVE

 test parameter described above in Table 10-2 is out of range 

there are two four possible causes of failure.   

1.  The screws retaining the IR photo detector to the Absorption Bench have 

become loose.  Carefully tighten the screws, hand-tight and note whether, 

after the analyzer has come up to operating temperature, whether the PHT 

DRIVE

 voltage has returned to an acceptable level.  

2.  The two large transistor-type devices mounted to the side of the Absorption 

Bench have come loose from the bench.  Tighten the retaining screws and 

note whether there is an improvement in the 

PHT DRIVE

 voltage. 

3.  The photo-detector has failed.  Contact the factory for instructions. 

4.  The Sync Demodulator circuit board has failed.  Contact the factor for 

instructions. 

11.4.2. 

Excessive Noise 

Noise is continuously monitored in the TEST functions as the

 STABIL

 reading and 

only becomes meaningful after sampling a constant gas concentration for at least 
10 minutes.  Compare the current 

STABIL

 reading with that recorded at the time 

of manufacture (included in the M300E Final Test and Validation Data sheet-p/n 
04271 shipped with the unit from T-API).   

1. 

The most common cause of excessive noise is leaks.  Leak check and flow 

check the instrument described in Section 9.5.   

Summary of Contents for 300E

Page 1: ...TRUMENTS ADVANCED POLLUTION INSTRUMENTATION DIVISION T API 6565 NANCY RIDGE DRIVE SAN DIEGO CA 92121 2251 TOLL FREE 800 324 5190 TEL 858 657 9800 FAX 858 657 9816 E MAIL api sales teledyne com WEB SITE www teledyne api com 04288 REV A Copyright 2001 T API Inc May 2002 ...

Page 2: ...s 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 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...

Page 3: ...ning Messages 33 3 2 4 Functional Check 34 3 3 INITIAL CALIBRATION PROCEDURE 35 4 FREQUENTLY ASKED QUESTIONS 41 5 OPTIONAL HARDWARE AND SOFTWARE 43 5 1 RACK MOUNT OPTION 43 5 2 ZERO SPAN SHUTOFF VALVE OPTIONS 43 5 2 1 Zero Span Shutoff Valve Option 50 44 5 2 2 Zero Span Valve Option 51 45 5 2 3 Zero Span Valve Option 52 45 5 2 4 Zero Span Valve Option 53 46 5 3 CURRENT LOOP OPTION 48 5 4 MULTIDROP...

Page 4: ...Offset Adjustment 75 6 6 DIAGNOSTIC MODE DIAG 77 6 6 1 Signal I O Diagnostic Functions 79 6 6 2 Analog Output Step Test 80 6 6 3 Analog I O Configuration 81 6 6 4 Electric Test 84 6 6 5 Dark Calibration Test 85 6 6 6 Flow Calibration 86 6 7 EXTERNAL DIGITAL I O 86 6 7 1 Status Outputs 86 6 7 2 Control Inputs 87 6 8 SERIAL INTERFACES 89 6 8 1 Serial I O Default Settings 89 6 8 2 Serial I O Physical...

Page 5: ...2 Interface to the iDAS 121 7 CALIBRATION PROCEDURES 123 7 1 BEFORE CALIBRATION 123 7 1 1 Zero Air and Span Gas 124 7 2 MANUAL CALIBRATION WITHOUT ZERO SPAN VALVES 125 7 3 MANUAL CALIBRATION WITH ZERO SPAN VALVES 128 7 3 1 Zero Span Calibration on Auto Range or Dual Ranges 131 7 3 2 Use of Zero Span Valves with Remote Contact Closure 131 7 4 AUTOMATIC ZERO SPAN CAL CHECK AUTOCAL 132 8 EPA PROTOCOL...

Page 6: ... GFC Wheel 166 10 3 4 Synchronous Demodulator Sync Demod Assembly 169 10 3 5 Relay Board 173 10 3 6 Mother Board 175 10 3 7 Power Supply Circuit Breaker 178 10 4 INTERFACE 179 10 5 SOFTWARE OPERATION 182 10 5 1 Adaptive Filter 183 10 5 2 Calibration Slope and Offset 184 10 5 3 Measurement Algorithm 184 10 5 4 Internal Data Acquisition System iDAS 185 11 TROUBLESHOOTING REPAIR PROCEDURES 187 11 1 G...

Page 7: ...n 206 11 5 2 DC Power Supply 207 11 5 3 I2 C Bus 208 11 5 4 Keyboard Display Interface 208 11 5 5 Relay Board 208 11 5 6 Sensor Assembly 209 11 5 7 Motherboard 212 11 5 8 CPU 214 11 5 9 RS 232 Communications 215 11 6 REPAIR PROCEDURES 216 11 6 1 Repairing Sample Flow Control Assembly 217 11 6 2 Removing Replacing the GFC Wheel 218 11 6 3 Disk On Chip Replacement Procedure 221 ...

Page 8: ...u Trees and Index APPENDIX A 2 Setup Variables Available Via Serial I O APPENDIX A 3 Warning Messages and Test Measurements Available Via Serial I O APPENDIX A 4 Signal I O Definitions APPENDIX A 5 iDAS Functions APPENDIX B M300E Spare Parts List APPENDIX C Test Functions and Repair Questionnaire for M300E APPENDIX D ELECTRONIC SCHEMATICS INTERCONNECTION DRAWING AND INTERCONNECTION LIST ...

Page 9: ...gure 6 1 Front Panel Display 51 Figure 6 2 Analog Output Pin Assignments 74 Figure 6 3 Setup for Checking Current Output Signal Levels 75 Figure 6 4 Status Output Connector 86 Figure 6 5 Control Inputs 88 Figure 6 6 Default iDAS Channels Setup 109 Figure 7 1 Pneumatic Connections for Manual Calibration w o Z S Valves 125 Figure 7 2 Pneumatic connections for Manual Calibration With Z S Valves 128 F...

Page 10: ...Operation 183 Figure 11 1 Viewing and Clearing Warning Messages 189 Figure 11 2 Example of Signal I O Function 194 Figure 11 3 CPU Status Indicator 195 Figure 11 4 Sync Demod Board Status LED Locations 196 Figure 11 5 Relay Board Status LEDs 197 Figure 11 6 Critical Flow Restrictor Assembly Disassembly 218 Figure 11 7 Removing the GFC Sensor Heater Cover 219 Figure 11 8 Removing the Opto Pickup As...

Page 11: ...in Assignments 87 Table 6 13 Control Input Pin Assignments 88 Table 6 14 COM A and COM B Default Pin Assignments 91 Table 6 15 COMM Port Communication Modes 92 Table 6 16 Basic Terminal Mode Software Commands 96 Table 6 17 Terminal Mode Help Commands 97 Table 6 18 Serial I O Command Designations 97 Table 6 19 Serial Interface Documents 103 Table 6 20 iDAS Data Channel Properties 106 Table 6 21 iDA...

Page 12: ...odes 207 Table 11 5 DC Power Supply Acceptable Levels 207 Table 11 6 Relay Board Control Devices 209 Table 11 7 Opto Pickup Board Nominal Output Frequencies 210 Table 11 8 Analog Output Test Function Nominal Values Voltage Outputs 212 Table 11 9 Analog Output Test Function Nominal Values Current Outputs 213 Table 11 10 Status Outputs Check 214 ...

Page 13: ...eyword and phrase search feature q Figures and Tables are linked so that clicking on the Figure number will display the associated graphic q A list of Chapters and Sections are displayed at the left of the text q Entries in the Table of Contents are linked to the corresponding locations in the manual q Links embedded in the manual will take you to the corresponding location on the Internet if the ...

Page 14: ...ty statement 3 0 Getting Started A concise set of instructions for unpacking your analyzer installing it and running it for the first time 4 0 FAQ Answers to the most frequently asked questions about operating the analyzer 5 0 Optional Hardware Software A description of the various options available that add functionality to your analyzer 6 0 Operation Instructions This section includes step by st...

Page 15: ...t work and interact with each other A close reading of this section is invaluable for learning how to identify the source of problems with the instrument should they occur 11 0 Troubleshooting Section This section includes pointers and instructions for diagnosing problems with the instrument such as excessive noise or drift It also includes instructions on performing certain simple repairs of the ...

Page 16: ...M300E DOCUMENTATION Model 300E Carbon Monoxide Analyzer Instruction Manual 16 P N 04288 Rev A INTENTIONALLY BLANK ...

Page 17: ...5 RH Non Condensing Temp Coefficient 0 05 per C Voltage Coefficient 0 05 per V Dimensions HxWxD 7 x 17 x 23 5 178 mm x 432 mm x 597 mm Weight 50 lb 22 7 kg AC Power 100V 50 60 Hz 3 25A 115 V 60 Hz 3 0A 220 240 V 50 60 Hz 2 5A Environmental Conditions Installation Category Over voltage Category II Pollution Degree 2 Analog Outputs Three 3 Outputs Analog Output Ranges 100 mV 1 V 5 V 10 V 2 20 or 4 2...

Page 18: ...5 micron TFE filter element installed in the internal filter assembly 5 Sample flow of 800 80 cc min at sea level 6 Internal sample pump 7 Software settings Dilution factor 1 0 AutoCal ON or OFF Dynamic Zero ON or OFF Dynamic Span OFF Dual range ON or OFF Auto range ON or OFF Temp Pres compensation ON Under the designation the Analyzer may be operated with or without the following options 1 Rack m...

Page 19: ...after the purchase If a Product fails to conform to its specifications within the warranty period T API shall correct such defect by in T 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 negl...

Page 20: ...Specifications Agency Approvals and Warranty Model 300E Carbon Monoxide Analyzer Instruction Manual 20 P N 04288 REV A INTENTIONALLY BLANK ...

Page 21: ...ity records file for this instrument 3 Carefully remove the top cover of the analyzer and check for internal shipping damage q Remove the set screw located in the top center of the rear panel q Remove the four screws fastening the top cover to the unit two per side q Lift the cover straight up Do not slide backwards NOTE Some versions of the 300E CO Analyzer may have a spring loaded fastener at th...

Page 22: ... firmly and properly seated 6 Verify that all of the optional hardware ordered with the unit has been installed These are listed on the paperwork accompanying the analyzer 7 Once you have determined that no shipping damage exists and the unit includes all expected hardware options remove all red colored shipping screws from the bottom of the chassis as shown in Figure 3 1 Figure 3 1 Removal of Shi...

Page 23: ...s CAUTION Check the voltage and frequency label on the rear panel of the instrument See Figure 3 2 for compatibility with the local power before plugging the M300E into line power CAUTION Power connection MUST have functioning ground connection 1 Refer to Figure 3 2 for the location of the rear panel electrical connections 2 Attach a strip chart recorder and or data logger to the appropriate analo...

Page 24: ...el of the instrument are PIN Analog Output VDC Signal mADC Signal 1 V Out I Out 2 A1 Ground I Out 3 V Out I Out 4 A2 Ground I Out 5 V Out I Out 6 A3 Ground I Out 7 V Out Not Available 8 A4 Spare Ground Not Available q The default analog output voltage setting of the 300E CO Analyzer is 0 5 VDC with a range of 0 50 ppm q TO change these settings see Sections 6 4 and 6 5 3 If you wish utilize the an...

Page 25: ...ors on pins 1 8 are bussed together DC POWER 5 VDC Digital Ground The ground level from the analyzer s internal DC Power Supplies NOTE Most PLC s have internal provisions for limiting the current that the input will draw from an external device When connecting to a unit that does not have this feature an external dropping resistor must be used to limit the current through the transistor output to ...

Page 26: ...r is placed in Span Calibration mode The mode field of the display will read SPAN CAL R C SPARE D SPARE E SPARE F SPARE Digital Ground May be connected to the ground of the datalogger recorder U Pullup supply for inputs Input pin for 5 VDC required to activate pins A F This can be from an external source or from the pin of the instruments STATUS connector Internal 5V Supply Internal source of 5V w...

Page 27: ...Teflon FEP glass stainless steel or brass IZS Inlet Pressure Span Inlet Vent Span Outlet Status Outputs Serial I O LED s Control Inputs Analog Outputs COM B Connector RS 232 or RS 485 Exhaust Outlet Sample Inlet Cooling Fan Power Receptacle COM A Connector RS232 Only DCE DTE Switch Volt Freq Information Figure 3 2 Rear Panel Connectors CAUTION In order to prevent dust from getting into the gas flo...

Page 28: ...off Valve Options installed but NO internal Zero Air Scrubber attach a gas line to the source of Zero Air here 2 Attach a sample inlet line to the sample inlet port Ideally the pressure of the sample gas should be at ambient pressure 0 psig q The SAMPLE input line should not be more than 2 meters long q Figure 3 3 depicts the pneumatic flow for this analyzer in its basic configuration q Figure 3 4...

Page 29: ...as Removed during Calibration Valve OR Needle Valve to control Flow Figure 3 3 Basic Pneumatic Connections Flow Diagram NOTE The Inlet Outlet labels appearing in the various pneumatic diagrams found in this manual such as Figure 3 3 The order in which they appear in the illustrations IS NOT necessarily the same order in which they are arranged on the rear panel of the instrument CAUTION Sample Gas...

Page 30: ...ENT if input is pressurized Option 50 Needle Valve to control Flow MODEL 300E Sample Exhaust Pressure Span Vent Span IZS Certified CO Gas Source of SAMPLE Gas VENT if input is pressurized Option 53 MODEL 300E Sample Exhaust Pressure Span Vent Span IZS MODEL 701 Zero Air Generator Source of SAMPLE Gas Certified CO Gas Source of SAMPLE Gas VENT if input is pressurized Option 52 Needle Valve to contr...

Page 31: ...s means that both the source of Zero Air and Span Gas must be connected to the calibrator whose output is then connected to the Pressure Span inlet on the Rear Panel of the instrument Figure 3 5 depicts the pneumatic set up in this sort of application of a Model 300E CO Analyzer with Zero Span Valve Option 50 installed Gas Pressure should be regulated at 30 35 PSIG MODEL 300E Sample Exhaust Pressu...

Page 32: ...diately display a single horizontal dash at the far left of the display This will last for approximately 20 30 seconds as the microprocessor that is the heart of the analyzer loads its basic operating system Once the CPU has completed this activity it will begin loading the analyzer firmware and factory calibration data During this process several progress messages similar to the following will ap...

Page 33: ...the 30 minutes warm up period is over investigate their cause using the troubleshooting guidelines in Section 11 of this manual The following table includes a brief description of the various warning messages that may appear Message Meaning SYSTEM RESET The computer has rebooted SOURCE The IR source may be faulty SYNC The instrument is not properly tracking the rotation of the Gas Filter Correlati...

Page 34: ...indication of a legitimate problem and not an artifact of the Warm Up period 3 2 4 Functional Check After the unit has thoroughly warmed up verify that the software supporting any hardware options with which the analyzer was shipped have been properly set up For information on navigating through the analyzer s software menus see the menu trees described in Appendix A Check to make sure that the an...

Page 35: ...s to measure between 0 ppm and 50 ppm an appropriate Span Gas would be 40 ppm If the application is to measure between 0 ppm and 100 ppm an appropriate Span Gas would be 80 ppm Span Gas can be purchased in pressurized canisters or created using a Dynamic Dilution Calibrator such as the T TAPI Model 700 Zero Air is similar in chemical composition to the earths atmosphere but scrubbed of all compone...

Page 36: ... 3 RANGE CONTROL MENU MODE SET UNIT EXIT SETUP C 3 RANGE MODE SNGL SNGL DUAL AUTO ENTR EXIT SETUP C 3 RANGE 50 0 Conc 0 0 0 5 0 0 ENTR EXIT SETUP C 3 CONC UNITS PPM PPB PPM UGM MGM ENTR EXIT Press EXIT 2x s to Return to the Main SAMPLE Display To change the value of the Range Setting enter the number sequence by pressing the key under each digit until the expected value is set SETUP C 3 RANGE 50 0...

Page 37: ...the M300E to prompt for the expected CO span concentration The CO span concentration value automatically defaults to 40 0 Conc Make sure that you input the ACTUAL concentration value of the SPAN Gas To change this value to meet the actual concentration of the SPAN Gas enter the number sequence by pressing the key under each digit until the expected value is set NOTE For this Initial Calibration it...

Page 38: ...witch gas streams to span gas M P CAL RANGE 50 0 PPM CO TST TST SPAN CONC M P CAL RANGE 50 0 PPM CO TST TST ENTR CONC EXIT M P CAL RANGE 50 0 PPM CO TST TST ENTR CONC EXIT This operation changes the calculation equations and zeroes the instrument WAIT 10 MINUTES Or until the reading stabilizes and the ZERO button is displayed This operation changes the calculation equations and sets the Span of th...

Page 39: ... vital to our efforts in continuously improving our service and our products THANK YOU Particulate Filter Sync Demod Board GFC Wheel Motor Assy ON OFF SWITCH PS1 5 VDC 15VDC PS2 12 VDC Pump Assy Relay Board Optional Zero Span Valve Sample Chamber Optical Bench Critical Flow Orifice Front Panel Rear Panel CPU Card Mother Board Power Receptacle Optional Sample Cal Valve Optional Shutoff Valve Gas Fl...

Page 40: ...Getting Started Model 300E Carbon Monoxide Analyzer Instruction Manual 40 P N 04288 REV A INTENTIONALLY BLANK ...

Page 41: ...than 20 minutes Once you adjust the setting in question to an allowable value the ENTR key will re appear 4 Is there an optional midpoint calibration There is an optional mid point linearity adjustment however midpoint adjustment is applicable only to applications where CO measurements are expected above 100 ppm Call T API s Service Department for more information on this topic 5 How do I make the...

Page 42: ...trol Assembly that is attached to the inlet side of the sample pump see Figure 3 6 See Section 11 6 1 for instructions on disassembly and replacement 10 How do I set up a SEQUENCE to run a nightly calibration check The setup of this option is located in Section 7 4 11 How do I set the analog output signal range and offset Instructions for this can be found in Section 6 5 12 What is the averaging t...

Page 43: ... Option Number Description OPT 20A Rack mount with Chassis Slides 26 in OPT 20B Rack mount with Chassis Slides 24 in STD OPT 21 Rack mount WITHOUT Chassis Slides Each of these options permits the Analyzer to be mounted in a standard 19 wide x 30 deep RETMA rack 5 2 Zero Span Shutoff Valve Options There are four available options involving Zero Span Shutoff valves From an operational and software s...

Page 44: ...nternal vent line isolated by a shutoff valve ensures that the gas pressure of the SPAN gas is reduced to ambient atmospheric pressure Normally Zero Air would be supplied from Zero Air Module such as a T API model 701 In order to ensure that SPAN gas does not migrate backwards through the vent line and alter the concentration of the SPAN Gas a gas line not less than 2 meters in length should be at...

Page 45: ...y an internal Zero Air Scrubber This means that the IZS inlet can simply be left open to ambient air Like Option 50 Option 51 requires an external gas line greater than 2 meters but less than 10 meters in length be attached to the Span Vent outlet on the Rear Panel of the instrument Span gas must to be supplied at a minimum of 800 cc min preferably 1600 cc min Table 5 1 lists the Open Closed state...

Page 46: ...in preferably 1600 cc min Table 5 1 lists the Open Closed state of each valve during the analyzers various operational modes 5 2 4 Zero Span Valve Option 53 Option 53 is a variant of Option 52 with the addition of an internal Zero Air Scrubber Filter Pump Sample Chamber Sample Exhaust Pressure Span Vent Span IZS Vent as shown if Inputs are Pressurized Zero Span Valve Zero Air Scrubber Sample Cal V...

Page 47: ...RO AIR SCRUBBER SAMPLE Shutoff Closed Sample Cal Open to ZERO SPAN Valve Zero Span Open to ZERO AIR SCRUBBER ZERO CAL Shutoff Closed Sample Cal Open to ZERO SPAN Valve Zero Span Open to SHUTOFF Valve 51 SPAN CAL Shutoff Open to PRESSURE SPAN Inlet Sample Cal Open to SAMPLE inlet SAMPLE Zero Span Open to IZS inlet Sample Cal Open to ZERO SPAN Valve ZERO CAL Zero Span Open to IZS inlet Sample Cal Op...

Page 48: ...is option may be ordered separately for each Analog Output It can be installed at the factory or added later Call the factory for price and availability The Current Loop Option can be configured for any output range between 0 and 20 mADC Most current loop applications require either 2 20 mA or 4 20 mA spans Information on calibrating or adjusting these outputs can be found in Section 6 5 2 Current...

Page 49: ...nload data from an M300E over either an intranet or the public Internet using APIcom or certain other specialized software products The setup and instructions for using this option are provided as a separate document 5 6 Dilution Ratio Option The Dilution Ration Option is a software option that is designed for applications where the Sample gas is diluted before being analyzed by the Model 300E Typ...

Page 50: ...Optional Hardware and Software Model 300E Carbon Monoxide Analyzer Instruction Manual 50 P N 04288 REV A INTENTIONALLY BLANK ...

Page 51: ...rations such as for the iDAS system the Analog Output ranges or the serial RS 232 RS 485 Ethernet communication channels The Set up mode is also used for performing various diagnostic tests during troubleshooting POWER FAULT CAL SAMPLE GAS FILTER CORRELATION ANALYZER MODEL 300E ADVANCED POLLUTION INSTRUMENTATION INC SAMPLE A RANGE 50 PPM CO 40 0 TST TST CAL CALZ CALS SETUP MODE FIELD KEY DEFINITIO...

Page 52: ...AN CAL R Unit is performing SPAN Cal procedure initiated remotely via the RS 232 RS 4485 or Digital I O Control Inputs M P CAL This is the basic Calibration Mode of the instrument and is activated by pressing the CAL key SETUP1 SETUP mode is being used to configure the analyzer CO sampling will continue during this process DIAG One of the analyzer s Diagnostic Modes is being utilized see Section 6...

Page 53: ...ure of the sample gas is outside the specified limits See Section 11 1 1 for more information on using these messages to troubleshoot problems To View and Clear the various warning messages press SAMPLE WHEEL TEMP WARNING CO XX XX TEST CAL MSG CLR SETUP Make SURE warning messages are NOT due to LEGITIMATE PROBLEMS Press CLR to clear the message currently being Displayed If more than one warning is...

Page 54: ...the Sample Chamber Sample Flow SAMPLE FLOW cc min Sample mass flow rate This is computed from the differential between the pressures measured up stream and down stream of the Sample Critical Flow Orifice pressures Sample Temperature SAMPLE TEMP C The Temperature of the gas inside the Sample Chamber Bench Temperature BENCH TEMP C Optical Bench Temperature Wheel Temperature WHEEL TEMP C Filter wheel...

Page 55: ...unctions indicates an OUT OF RANGE reading NOTE Sample Pressure are represented in terms of ABSOLUTE pressure because this is the least ambiguous method reporting gas pressure Absolute atmospheric pressure is about 29 92 in Hg A at sea level It decreases about 1 in Hg per 1000 ft gain in altitude A variety of factors such as air conditioning systems passing storms and air temperature can also caus...

Page 56: ...ure the analyzer s various hardware and software features and to read data from the internal data acquisition system iDAS NOTE Any changes made to a variable during one of the following procedures is not acknowledged by the instrument until the ENTR Key is pressed If the EXIT key is pressed before the ENTR key the analyzer will beep alerting the user that the newly entered value has been lost 6 3 ...

Page 57: ...s Allowed No password Operator TEST MSG CLR 101 Maintenance CALZ CALS CAL 818 Configuration SETUP SETUP VARS SETUP DIAG To enable the various password levels press the following keystroke sequence s SAMPLE RANGE 50 0 PPM CO TST TST CAL SETUP SETUP C 3 CFG DAS RNGE PASS CLK MORE EXIT SETUP C 3 PASSWORD ENABLE OFF OFF ENTR EXIT SETUP C 3 PASSWORD ENABLE ON ON ENTR EXIT SETUP C 3 PASSWORD ENABLE ON O...

Page 58: ... 4 Configuration Information CFG CFG key allows the user to review certain software configuration information This feature is useful for showing any special features that are present in the currently installed Disk on Chip It can be displayed by entering the key sequence Press NEXT of PREV to move back and forth through the following list of Configuration information SERIAL NUMBER SOFTWARE REVISIO...

Page 59: ...ay press SETUP C 3 CFG DAS RNGE PASS CLK MORE EXIT SETUP C 3 TIME OF DAY CLOCK TIME DATE EXIT SETUP C 3 CFG DAS RNGE PASS CLK MORE EXIT Exit to Return to the Sample Menu Enter Current Date of Year SETUP C 3 DATE 01 JAN 02 0 1 JAN 0 2 ENTR EXIT SETUP C 3 DATE 01 JAN 02 0 1 JAN 0 2 ENTR EXIT SETUP C 3 TIME OF DAY CLOCK TIME DATE EXIT Enter Current Time of Day SETUP C 3 TIME 12 00 1 2 0 0 ENTR EXIT S...

Page 60: ...RNGE PASS CLK MORE EXIT SETUP C 3 COMM VARS DIAG HALT EXIT Exit Returns to main Sample Display SETUP C 3 0 DAS_HOLD_OFF 15 0 Minutes NEXT JUMP EDIT PRNT EXIT Enter Number of Seconds per day the clock gains or loses SETUP C 3 1 DYN_ZERO OFF PREV NEXT JUMP EDIT PRNT EXIT SETUP C 3 3 CLOCK_ADJ 0 Sec Day PREV JUMP EDIT PRNT EXIT SETUP C 3 CLOCK_ADJ 0 Sec Day 0 0 ENTR EXIT SETUP C 3 3 CLOCK_ADJ 0 Sec D...

Page 61: ... data is stored in the iDAS channels during situations when the software considers the data to be questionable such as during warm up of just after the instrument returns from one of its Calibration mode to SAMPLE Mode May be set for intervals between 0 5 20 min DYN_ZERO When ON this function causes the analyzer to automatically adjust the SLOPE and OFFSET of its measurement calculation as the las...

Page 62: ...SS CLK MORE EXIT SETUP C 3 COMM VARS DIAG HALT EXIT Exit at Any Time to Return to main the Sample Display SETUP C 3 0 DAS_HOLD_OFF 15 0 Minutes NEXT JUMP EDIT PRNT EXIT SETUP C 3 1 DYN_ZERO OFF PREV NEXT JUMP EDIT PRNT EXIT SETUP C 3 3 CLOCK_ADJ 0 Sec Day PREV JUMP EDIT PRNT EXIT SETUP C 3 CLOCK_ADJ 0 Sec Day 0 0 ENTR EXIT SETUP C 3 ENTER VARS PASS 818 8 1 8 ENTR EXIT SETUP C 3 2 DYN_SPAN OFF PREV...

Page 63: ...that configures and scales a Measurement Range to allow the user to optimize the analyzer s operation for their specific application The span of the instrument s Measurement Range is also used during calibration procedures This ensures that the portion of the hardware Physical Range being recorded is calibrated as accurately as possible Additionally the scale and limits selected for the Measuremen...

Page 64: ...ent ranges e g 0 10 VDC vs 0 1 VDC See Section 6 5 2 Dual range allows the A1 and A2 outputs to be configured for separate and independent units of measure and measurement spans as well as separate electronic signal levels 3 Auto range mode gives the analyzer the ability to automatically switch the A1 and A2 analog outputs between two ranges low and high dynamically as the concentration value fluc...

Page 65: ...MODE SET UNIT EXIT EXIT Returns to the Main SAMPLE Display Go To Section 6 4 3 Go To Section 6 4 4 Go To Section 6 4 5 SETUP C 3 RANGE MODE SNGL SNGL DUAL AUTO ENTR EXIT 6 4 3 A1 A2 Single Range Mode This is the default Measurement Range mode for the analyzer In this mode both analog outputs A1 and A2 are set to the same range This Measurement Range can be set to any value between 1 0 and 1 000 pp...

Page 66: ... and 1 000 ppm Range mode Defaults to SNGL Remember while both A1 and A2 are reporting the same data within the same Measurement Range span their respective electronic signal levels can still be configured differently see Section 6 5 to meet the input requirements of different recording devices 6 4 4 A1 A2 Dual Range Mode Selecting Dual Range mode allows the A1 and A2 outputs to be configured with...

Page 67: ... A1 and C2 High or A2 To set the ranges press following keystroke sequence SAMPLE RANGE 50 0 PPM CO TST TST CAL SETUP SETUP C 3 CFG DAS RNGE PASS CLK MORE EXIT SETUP C 3 RANGE CONTROL MENU MODE SET UNIT EXIT SETUP C 3 RANGE MODE SNGL SNGL DUAL AUTO ENTR EXIT EXIT Returns to the Main SAMPLE Display SETUP C 3 RANGE MODE DUAL SNGL DUAL AUTO ENTR EXIT SETUP C 3 RANGE CONTROL MENU MODE SET UNIT EXIT SE...

Page 68: ...w Range once the CO concentration falls below 75 of the Low Range span To set the ranges press following keystroke sequence SAMPLE RANGE 50 0 PPM CO TST TST CAL SETUP SETUP C 3 CFG DAS RNGE PASS CLK MORE EXIT SETUP C 3 RANGE CONTROL MENU MODE SET UNIT EXIT SETUP C 3 RANGE MODE SNGL SNGL DUAL AUTO ENTR EXIT EXIT Returns to the Main SAMPLE Display SETUP C 3 RANGE MODE AUTO SNGL DUAL AUTO ENTR EXIT S...

Page 69: ...units of measure EXAMPLE Switching from PPM to UGM SETUP C 3 CONC UNITS UGM PPM PPB UGM MGM ENTER EXIT EXIT Returns to the Main SAMPLE Display EXIT Returns to the SETUP Menu NOTE Concentrations displayed in mg m3 and ug m3 use 0 C 760 mmHg for Standard Temperature and Pressure STP Consult your local regulations for the STP used by your agency CAUTION Once the units of Measurement have been changed...

Page 70: ...MM VARS DIAG HALT EXIT Press Exit at Any Time to Return to DIAG Menu DIAG SIGNAL I O NEXT ENTR EXIT DIAG ANALOG OUTPUT PREV NEXT ENTR EXIT DIAG TEST CHANNEL NONE NEXT ENTR EXIT DIAG TEST CHAN OUTPUT PREV NEXT ENTR EXIT Press Exit at Any Time to Return to SETUP Menu Press Exit at Any Time to Return to Main SAMPLE Display Continue pressin NEXT until DIAG TEST CHANNEL CO MEASURE PREV NEXT ENTR EXIT P...

Page 71: ...a signal on the A3 Analog Output but a TEST parameter is added to the list of Test Functions viewable via the Front Panel Display To activate the TEST channel and select a Test Function press 6 4 8 Using the Dilution Option The Dilution Ration Option is a software option that allows the user to compensate for any dilution of the Sample Gas before it arrives at the Sample Inlet on the Rear Panel of...

Page 72: ...the Dilution Ratio Factor If for instance the sample gas is being diluted by a factor of 20 1 entering a Dilution Ration Factor of 20 would provide the proper compensation STEP 4 CALIBRATE THE ANALYZER Once the above settings have been entered calibrate the instrument using one of the methods discussed in Section 7 of this manual 6 5 Analog Outputs Electronic Configuration The final step in config...

Page 73: ...Current output options are also available from the factory Table 6 7 Analog Output Current Loop Min Max Range Span Minimum Output Maximum Output 2 20 mADC 1 mADC 21 mADC 4 20 mADC 3 mADC 21 mADC The default offset for all ranges is 0 mADC Pin outs for the Analog Output connector at the rear panel of the instrument are Table 6 8 Analog Output Pin Assignments PIN Analog Output VDC Signal mADC Signal...

Page 74: ...these Keys to set the DC Offset of the selected channel Exit to Return to the I O Configuration Menu DIAG AIO CONC_OUT_2 RANGE 5V SET EDIT EXIT DIAG AIO OUTPUT RANGE 5V 0 1V 1V 5V 10V CURR ENTR EXIT DIAG AIO CONC_OUT_2 REC OFS 0 mV SET SET EDIT EXIT DIAG AIO RECORD OFFSET 0 MV 0 0 0 0 ENTR EXIT DIAG AIO CONC_OUT_2 CALIBRATED NO SET CAL EXIT DIAG AIO CONC_OUT_2 CALIBRATED YES SET CAL EXIT These Key...

Page 75: ...e signal zero and span levels of the current loop output is done by raising or lowering the voltage output of the D to A converter circuitry on the analyzer s Mother Board This raises or lowers the signal level produced by the Current Loop Option circuitry The software allows this adjustment to be made in 100 10 or 1 count increments Since the exact amount by which the current signal is changed pe...

Page 76: ...nnel to be configured DISPLAYED AS CHANNEL CONC_OUT_1 A1 CONC_OUT_2 A2 TEST OUTPUT A3 Then Press EDIT to continue DIAG AIO AIN CALIBRATED NO SET EDIT EXIT ENTR returns to the previous menu These keys increment decrement the ZERO SPAN D to A converter output by 100 10 or 1 counts respectively The resulting change in output voltage is dispalyed on the TOP Line Continue adjustments until the correct ...

Page 77: ...IAG Functions Display Mode Meaning Manual Section DIAG I O SIGNAL I O Allows observation of all digital and analog signals present in the instrument Allows certain digital signals to be toggled between ON and OFF states 6 6 1 DIAG AOUT ANALOG I O The analyzer is performing an Analog output Step Test This calibrates the Analog output channels 6 6 2 DIAG AIO ANALOG I O CONFIGURATION Analog I O param...

Page 78: ...UP C 3 COMM VARS DIAG HALT EXIT Press Exit at Any Time to Return to DIAG Menu DIAG SIGNAL I O NEXT ENTR EXIT DIAG ANALOG OUTPUT PREV NEXT ENTR EXIT DIAG ANALOG I O CONFIGURATION PREV NEXT ENTR EXIT DIAG ELECTRICAL TEST PREV NEXT ENTR EXIT DIAG DARK CALIBRATION PREV NEXT ENTR EXIT DIAG FLOW CALIBRATION PREV NEXT ENTR EXIT DIAG TEST CHAN OUTPUT PREV NEXT ENTR EXIT Press Exit at Any Time to Return to...

Page 79: ... TST TST CAL SETUP EXAMPLE SETUP C 3 CFG DAS RNGE PASS CLK MORE EXIT SETUP C 3 COMM VARS DIAG HALT EXIT DIAG SIGNAL I O PREV NEXT JUMP ENTR EXIT DIAG I O Test Signals Displayed Here PREV NEXT JUMP PRNT EXIT See Appendix D for a complete list of available SIGNALS DIAG I O JUMP TO 5 0 5 ENTR EXIT To Jump to Signal no 5 SAMPLE_LED DIAG I O SAMPLE_LED ON PREV NEXT JUMP ON PRNT EXIT Exit to Return to t...

Page 80: ...ices attached to the analyzer To begin the Analog Output Step Test press SAMPLE RANGE 50 0 PPM CO TST TST CAL SETUP SETUP C 3 CFG DAS RNGE PASS CLK MORE EXIT SETUP C 3 COMM VARS DIAG HALT EXIT Exit at Any Time to Return to main the Sample Display DIAG SIGNAL I O NEXT ENTR EXIT Exit 2X s to Return to the Diag Menu SETUP C 3 ENTER DIAG PASS 818 8 1 8 ENTR EXIT DIAG ANALOG OUTPUT PREV NEXT ENTR EXIT ...

Page 81: ...s them input of a DC Voltage to let the user manually offset the output level CALIBRATED Performs the same calibration as AOUT CALIBRATED but on this one channel only NOTE Any change to RANGE or A1 OFS requires recalibration of this output 6 4 6 5 1 6 5 1 N A CONC_OUT_2 Sets the basic electronic configuration of the A2 output There are three options RANGE Selects the signal type and level of the o...

Page 82: ...AIN A C FREQUENCY 50 HZ SET EDIT EXIT STARTING FROM DIAGNOSTIC MENU see Section 6 6 Select the AC frequency of the Line Power being Supplied to the analyzer 6 6 3 2 AIN Calibration Exit at Any Time to Return to the main DIAG Menu DIAG ANALOG I O CONFIGURATION PREV NEXT ENTR EXIT DIAG AIO AIN A C FREQUENCY 60 HZ SET EDIT EXIT DIAG AIO AIN CALIBRATED NO SET SET CAL EXIT DIAG AIO CALIBRATING A D ZERO...

Page 83: ... CALIBRATING TEST_OUTPUT Exit at Any Time to Return to the main DIAG Menu DIAG ANALOG I O CONFIGURATION PREV NEXT ENTR EXIT DIAG AIO AIN A C FREQUENCY 60 HZ SET EDIT EXIT DIAG AIO AOUT CALIBRATED NO SET SET CAL EXIT DIAG AIO AOUT CALIBRATED YES SET SET CAL EXIT Calibrates Automatically Exit to Return to the I O Configuration Menu STARTING FROM DIAGNOSTIC MENU see Section 6 6 ...

Page 84: ... panel display should be 40 0 ppm To activate the Electric Test press SAMPLE RANGE 50 0 PPM CO TST TST CAL SETUP SETUP C 3 CFG DAS RNGE PASS CLK MORE EXIT SETUP C 3 COMM VARS DIAG HALT EXIT Exit at Any Time to Return to main the Sample Display DIAG SIGNAL I O NEXT ENTR EXIT Exit returns to the Diag Menu SETUP C 3 ENTER DIAG PASS 818 8 1 8 ENTR EXIT Repeat Pressing NEXT unti DIAG ELECTRIC TEST PREV...

Page 85: ...may be reviewed by the user via the front panel display To activate the Dark Calibration procedure or review the results of a previous calibration press Calibration runs automaitcally Electric offset for Measurement signal Electric offset for Reference signal SAMPLE RANGE 50 0 PPM CO TST TST CAL SETUP SETUP C 3 CFG DAS RNGE PASS CLK MORE EXIT SETUP C 3 COMM VARS DIAG HALT EXIT Exit at Any Time to ...

Page 86: ...pt logic level digital inputs such as Programmable Logic Controllers PLC s Each Status bit is an open collector output that can withstand up to 40 VDC All of the emitters of these transistors are tied together and available at D NOTE Most PLC s have internal provisions for limiting the current that the input will draw from an external device When connecting to a unit that does not have this featur...

Page 87: ... point is being calibrated 6 DIAG MODE On whenever the instrument is in DIAGNOSTIC mode 7 SPARE 8 SPARE D EMITER BUSS The emitters of the transistors on pins 1 8 are bussed together DC POWER 5 VDC Digital Ground The ground level from the analyzer s internal DC Power Supplies 6 7 2 Control Inputs Several Control Inputs are provided via an 10 pin connector labeled CONTROL IN on the analyzer s rear p...

Page 88: ...ay will read SPAN CAL R C SPARE D SPARE E SPARE F SPARE Digital Ground May be connected to the ground of the datalogger recorder U DC power for Input pull ups Input pin for 5 VDC required to activate pins A F This can be from an external source or from the pin of the instruments STATUS connector Internal 5V Supply Internal source of 5V which can be used to actuate control inputs when jumpered to t...

Page 89: ...nal RS 232 multidrop assembly contact T API sales for price and availability or alternatively up to 8 analyzers can be multidropped together with no adapters by connecting using COM B configured for RS 485 operation contact the factory for further information Ethernet Communications When equipped with the optional Ethernet interface assembly contact T API sales for price and availability the analy...

Page 90: ...CPU or the wiring between the CPU and the motherboard Once a cable is connected between the analyzer and a computer or modem both the red and green LED s should be ON If not for COM A switch the DTE DCE switch on the rear panel to exchange the receive transmit lines If both LED s are still not illuminated check the cable to make sure it is constructed properly For COM B it may be necessary to inst...

Page 91: ...anel using the DTE DCE switch 6 8 4 DTE versus DCE Communication RS 232 was developed for allowing communications between Data Terminal Equipment DTE and Data Communication Equipment DCE Dumb Terminals always fall into the DTE category while modems are always considered DCE s The difference between the two is which pin is assigned the Data Receive function that is assigned the Data Transmit functi...

Page 92: ...ta from the M300E RS 485 MODE 1024 Configures the Com Port for RS 485 style communication RS 485 mode has precedence over Multidrop mode if both are enabled MULTIDROP PROTOCOL 32 Multidrop protocol modifies the default T API protocol to allow the use of an ID number in every command used in multi instrument configurations with a single serial communications link ENABLE MODEM 64 Enables the sending...

Page 93: ... COM1 COM2 EXIT Select which Com Port is to be configured SETUP C 4 COM1 MODE 0 SET EDIT EXIT EXIT returns to the previous Menu SETUP C 4 COM1 QUIET MODE OFF NEXT OFF ENTR EXIT SETUP C 4 COM1 COMPUTER MODE OFF PREV NEXT OFF ENTR EXIT SETUP C 4 COM1 QUIET MODE ON NEXT ON ENTR EXIT Use PREV and NEXT keys to move up and down the list of available Modes See Table 6 17 for a list of available modes EXI...

Page 94: ...CFG DAS RNGE PASS CLK MORE EXIT SETUP C 4 COMM VARS DIAG HALT EXIT SAMPLE RANGE 50 0 PPM CO TST TST CAL SETUP SETUP C 4 COMMUNICATIONS MENU ID COM1 COM2 EXIT Select which COMM Port is to be configured SETUP C 4 COM1 MODE 0 SET EDIT EXIT EXIT returns to the previous Menu SETUP C 4 COM1 BAUD RATE 19200 SET SET EDIT EXIT EXIT key ignores the new setting ENTR key accepts the new setting Use PREV and N...

Page 95: ... the analyzer should flicker To initiate the test press SETUP C 4 COM1 TEST PORT SET TEST EXIT SETUP C 4 TRANSMITTING TO COM1 SET TEST EXIT SETUP C 4 CFG DAS RNGE PASS CLK MORE EXIT SETUP C 4 COMM VARS DIAG HALT EXIT SAMPLE RANGE 50 0 PPM CO TST TST CAL SETUP SETUP C 4 COMMUNICATIONS MENU ID COM1 COM2 EXIT Select which COMM Port is to be tested SETUP C 4 COM1 MODE 0 SET EDIT EXIT EXIT returns to t...

Page 96: ...vices COMPUTER MODE Used when the analyzer is being exercised from a computer a dedicated interface program such as APIcom More information regarding APIcom can be found on in Section 7 10 or on T API s website at http www Teledyne api com INTERACTIVE MODE Used with a terminal emulation programs such as Hyperterm or a dumb terminal The following commands are used to operate the analyzer in this mo...

Page 97: ...ments of a command i e keywords data values etc with a space character All Commands follow the syntax X ID COMMAND CR WHERE X à Command Type Designator A one letter designator that defines what type of command is being issued Legal designators are Table 6 18 Serial I O Command Designations Designator Command Type C Calibration D Diagnostic L Logon T Test measurement V Variable W Warning ID à Multi...

Page 98: ...ign is permitted For example 0x1 0x12 0x1234abcd are all valid hexadecimal integers Floating Point Numbers Floating point numbers are used to specify continuously variable values such as temperature set points time intervals warning limits millivolts etc They consist of an optional plus or minus sign followed by zero or more digits an optional decimal point and zero or more digits At least one dig...

Page 99: ...r controlling the instrument You can effectively disable the asynchronous reporting feature by setting the interface to quiet mode see Section 6 8 4 Asynchronous reports include A2 reports warning messages calibration and diagnostic status messages Refer to Appendix A for a list of the messages and Section 6 9 2 for information on controlling the instrument via the RS 232 interface 6 9 4 1 General...

Page 100: ... requires a db 9 female to db 25pin male cable available from T API as p n WR0000024 Once the cable has been connected check to make sure the DTE DCE is in the correct position Also make sure the model 300E COM port s are set for a Baud Rate see Section 6 8 5 that is compatible with your device and that your device operates with an 8 bit word length wit one stop bit The first step is to turn on th...

Page 101: ...BAUD RATE 19200 SET SET EDIT EXIT ENTR accepts the new string and returns to the previous menu EXIT ignores the new string and returns to the previous menu The CH and CH Keys move the cursor left and right along the text string The INS Key inserts a character at the cursor location Press the Key repeatedly to cycle through the entire available character se A Z 0 9 space Ó _ The DEL Key deletes a c...

Page 102: ...e port will operate 14 If the port is inactive for 1 hour it will automatically LOGOFF 15 Repeated attempts at logging on with incorrect passwords will cause subsequent logins even with the correct password to be disabled for 1 hour 16 If not logged on the only command that is active is the 17 The following messages will be given at logon LOG ON SUCCESSFUL Correct password given LOG ON FAILED Pass...

Page 103: ...ssed when standing in front of the instrument Remotely edit system parameters and set points View graph save and download data View retrieve edit save and upload data acquisition scripts or calibrator sequence scripts Check on system parameters for trouble shooting or quality control 6 9 8 Serial I O Reference Documents Table 6 19 Serial Interface Documents Interface Tool Manual Title Part No Avai...

Page 104: ...r to automatically download the stored data for further processing One of the best uses of the iDAS is to log and trend certain predictive diagnostic data that can assist the user in identifying possible problems with the analyzer BEFORE they each a point where the functionality of the instrument is affected A separate Built In iDAS Manual is available form T API describing the full functionality ...

Page 105: ... Channels relate Triggering Events to Data Parameters and define certain operational functions related to the recording and reporting of the data 6 10 3 1 Data Channels The key to the iDAS flexibility is its ability to allow the user to create a vast number of combinations of Triggering Events and Data Parameters in the form of Data Channels Users may create as many separate Data Channels as is al...

Page 106: ...of reports that will be stored in the data file 100 1 to 999 999 limited by available storage space RS 232 REPORT Indicates whether or not a report will be printed automatically to the RS 232 channel OFF OFF or ON CHANNEL ENABLED Provides a convenient means to temporarily disable a data channel ON OFF or ON CAL HOLD OFF Disables sampling of data parameters while instrument is in calibration mode O...

Page 107: ...he samples accumulated so far for that time period are lost If the instrument is powered back on during the same averaging interval the iDAS begin averaging samples from that point onward until the scheduled end of the averaging period Example A data channel is configured to make one measurement every minute and to record the average of these measurements in 1 hour increments If the instrument is ...

Page 108: ... the analyzer s software for logging carbon monoxide concentration and certain predictive diagnostic data These default channels include but are not limited to CONC Samples carbon monoxide concentration 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 By default the last 800 hourly ...

Page 109: ...L HOLD OFF OFF PARAMETER O3CNC1 MODE AVG PRECISION 1 STORE NUM SAMPLES ON PARAMETER SMPFLW MODE AVG PRECISION 1 STORE NUM SAMPLES OFF PARAMETER SMPPRS MODE AVG PRECISION 1 STORE NUM SAMPLES ON PARAMETER SLOPE1 MODE INST PRECISION 3 STORE NUM SAMPLES OFF PARAMETER OFSET1 MODE INST PRECISION 1 STORE NUM SAMPLES OFF PARAMETER ZSCNC1 MODE INST PRECISION 1 STORE NUM SAMPLES OFF LIST OF DATA CHANNELS LI...

Page 110: ...PE1 0 000 PV10 PREV PRM PRM EXIT SETUP C 3 00 00 00 CONC1 0 0 PPM PV10 PREV NEXT NX10 EXIT SETUP C 3 00 00 00 SMPFLW 000 0 cc m PRM PRM EXIT SETUP C 3 DATA ACQUISITION VIEW EDIT EXIT SETUP C 3 CFG DAS RNGE PASS CLK MORE EXIT VIEW KEYPAD FUNCTIONS KEY FUNCTION PRM Moves to the next Data Parameter PRM Moves to the previous Data Parameter NX10 Moves to view pointer forward 10 data points channels NEX...

Page 111: ...ing to the main SAMPLE Display SETUP C 3 ENTER DAS PASS 818 8 1 8 ENTR EXIT Moves the display up down the list of Data Channels Inserts a new Data Channel into the list BEFORE the Channel currently being displayed Deletes The Data Channel currently being displayed Exports the configuration of all data channels to RS 232 interface Exits to the Main Data Acquisition Menu SETUP C 3 NAME CONC SET SET ...

Page 112: ...ee parameters are included in this Channel EVENT This Channel is set up to record 900 events 6 11 2 Editing the Data Channel Name To edit the name of a specific Data Channel press Edit Data Channel Menu SETUP C 3 0 CONC ATIMER 2 900 PREV NEXT INS DEL EDIT PRNT EXIT FROM THE DATA CHANNEL PASSWORD MENU Exits to the Main Data Acquisition Menu SETUP C 3 NAME CONC C O N C ENTR EXIT ENTR accepts the new...

Page 113: ... Channel Menu SETUP C 3 0 CONC ATIMER 2 900 PREV NEXT INS DEL EDIT PRNT EXIT FROM THE DATA CHANNEL PASSWORD MENU Exits to the Main Data Acquisition Menu Press each Key repeatedly to cycle through the list of available Trigger Events see Appendix A for a complete list SETUP C 3 NAME CONC SET SET EDIT PRINT EXIT SETUP C 3 EVENT ATIMER SET SET EDIT PRINT EXIT ENTR accepts the new string and returns t...

Page 114: ...enu SETUP C 3 NAME CONC SET SET EDIT PRINT EXIT SETUP C 3 PARAMETERS 2 SET SET EDIT PRINT EXIT SETUP C 3 0 PARAM DETREP MODE INST PREV NEXT INS DEL EDIT EXIT Press SET key until SETUP C 3 EDIT PARAMS DELETE DATA YES NO NO returns to the previous menu Moves the display up down the list of Parameters Inserts a new Data Parameter into the list BEFORE the one currently being displayed Deletes The Data...

Page 115: ...PARAMETERS DETREF PREV NEXT ENTR EXIT PREV NEXT Cycle through list of available Data Parameters CHANGING THE PARAMETER TYPE DELETES ALL RECORDED DATA ENTR accepts the new setting and returns to the previous menu EXIT ignores the new setting and returns to the previous menu SETUP C 3 SAMPLE MODE INST INST AVG MIN MAX EXIT Press the key for the desired Mode SETUP C 3 PRECISION 1 SET SET EDIT EXIT SE...

Page 116: ...IOD 000 01 00 SET SET EDIT PRINT EXIT Press SET key until SETUP C 3 REPORT PERIODD DAYS 0 0 0 0 ENTR EXIT ENTR accepts the new string and returns to the previous menu EXIT ignores the new string and returns to the previous menu Toggle keys to set hours between reports Format HH MM This is a 24 hr clock PM hours are 13 thru 24 Example 2 15 PM 14 15 Toggle keys to set number of days between reports ...

Page 117: ...SWORD MENU Exits to the Main Data Acquisition Menu SETUP C 3 NAME CONC SET SET EDIT PRINT EXIT SETUP C 3 NUMBER OF RECORDS 000 SET SET EDIT PRINT EXIT Press SET key until SETUP C 3 REPORT PERIODD DAYS 0 0 0 0 0 ENTR EXIT ENTR accepts the new setting and returns to the previous menu EXIT ignores the new setting and returns to the previous menu Toggle keys to set number of records 1 99999 SETUP C 3 ...

Page 118: ...XT INS DEL EDIT PRNT EXIT FROM THE DATA CHANNEL PASSWORD MENU Exits to the Main Data Acquisition Menu SETUP C 3 NAME CONC SET SET EDIT PRINT EXIT SETUP C 3 RS 232 REPORT OFF SET SET EDIT PRINT EXIT Press SET key until ENTR accepts the new setting and returns to the previous menu EXIT ignores the new setting and returns to the previous menu SETUP C 3 RS 232 REPORT OFF OFF ENTR EXIT Toggle key to Tu...

Page 119: ...INS DEL EDIT PRNT EXIT FROM THE DATA CHANNEL PASSWORD MENU Exits to the Main Data Acquisition Menu SETUP C 3 NAME CONC SET SET EDIT PRINT EXIT SETUP C 3 CHANNEL ENABLE ON SET SET EDIT PRINT EXIT Press SET key until ENTR accepts the new setting and returns to the previous menu EXIT ignores the new setting and returns to the previous menu SETUP C 3 CHANNEL ENABLE ON OFF ENTR EXIT Toggle key to Turn ...

Page 120: ...el Menu SETUP C 3 0 CONC ATIMER 2 900 PREV NEXT INS DEL EDIT PRNT EXIT FROM THE DATA CHANNEL PASSWORD MENU Exits to the Main Data Acquisition Menu SETUP C 3 NAME CONC SET SET EDIT PRINT EXIT SETUP C 3 CAL HOLD OFF ON SET EDIT PRINT EXIT Press SET key until ENTR accepts the new setting and returns to the previous menu EXIT ignores the new setting and returns to the previous menu SETUP C 3 CAL HOLD ...

Page 121: ...ng sampled by a channel A detailed method of calculating required memory space for iDAS channels is described in the T API APIcom Users Manual which can be downloaded from T API s website at http www teledyne api com When programming the iDAS from the users front panel the ENTR key will disappear when the maximum storage capacity of the analyzer is reached preventing additional channels or paramet...

Page 122: ...Operating Instructions Model 300E Carbon Monoxide Analyzer Instruction Manual 122 P N 04288 REV A INTENTIONALLY BLANK ...

Page 123: ...edure for checking or calibrating the instrument with Zero Span Valves installed and operating but controlled manually through the keypad on the Front Panel of the instrument This section also includes a section on activating the Zero Span Valves via the Control In contact closures of the analyzers External Digital I O SECTION 7 4 AUTOMATIC ZERO SPAN CHECK WITH ZERO SPAN VALVES OPTIONS INSTALLED T...

Page 124: ...full scale of the desired measurement range It is recommended that the span gas used have a concentration equal to 80 of the full measurement range If Span Gas is sourced directly from a calibrated pressurized tank the gas mixture should be CO mixed with Zero Air or N2 at the required ratio NOTE ALL calibration gasses should be EPA Protocol gasses or NIST traceable standards Table 7 1 NIST Standar...

Page 125: ...pan Valves This is the basic method for manually calibrating the Model 300E CO Analyzer without functioning Zero Span Valve options It is identical to the method described in the GETTING STARTED section of this manual and is repeated her for you convenience STEP ONE Connect the Sources of Zero Air and Span Gas as shown below No Valve Options Installed MODEL 300E Sample Exhaust Pressure Span Vent S...

Page 126: ... causes the M300E to prompt for the expected CO span concentration The CO span concentration value automatically defaults to 40 0 Conc Make sure that you input the ACTUAL concentration value of the SPAN Gas To change this value to meet the actual concentration of the SPAN Gas enter the number sequence by pressing the key under each digit until the expected value is set NOTE For this Initial Calibr...

Page 127: ...quations and zeroes the instrument WARNING If you are performing a ZERO CHECK DO NOT press ENTR If performing a CHECK press EXIT now WAIT 10 MINUTES Or until the reading stabilizes and the ZERO button is displayed This operation changes the calculation equations and sets the Span of the instrument NOTE In certain instances where low Span gas concentrations are present 10 ppm both the Zero SPAN but...

Page 128: ...300E Sample Exhaust Pressure Span Vent Span IZS Source of SAMPLE Gas VENT MODEL 701 Zero Air Generator VENT Certified CO Gas Source of SAMPLE Gas VENT if input is pressurized Option 50 Needle Valve to control Flow MODEL 300E Sample Exhaust Pressure Span Vent Span IZS Certified CO Gas Source of SAMPLE Gas VENT if input is pressurized Option 53 MODEL 300E Sample Exhaust Pressure Span Vent Span IZS M...

Page 129: ... of the SPAN Gas To change this value to meet the actual concentration of the SPAN Gas enter the number sequence by pressing the key under each digit until the expected value is set NOTE For this Initial Calibration it is important to independently verify the PRECISE CO Concentration Value of the SPAN gas If the source of the Span Gas is from a Calibrated Bottle use the exact concentration value p...

Page 130: ...ear see Section 9 for troubleshooting tips Analyzer enters ZERO CAL Mode See Table 5 1 for Z S Valve States during this operating mode EXIT halts the calibration process and returns the unit to SAMPLE Mode If performing a CHECK press EXIT ZERO CAL M RANGE 50 0 PP CO 0 00 TST TST ZERO CONC EXIT SAMPLE RANGE 50 0 PPM CO 40 58 TST TST CAL CALZ CALS SETUP ZERO CAL M RANGE 50 0 PP CO 40 58 TST TST SPAN...

Page 131: ...PLE RANGE TO CAL HIGH LOW HIGH ENTR SETUP Continue Calibration as per Standard Procedure Once this selection is made the calibration procedure continues as previously described in Section 7 2 The other range may be calibrated by starting over from the main SAMPLE display 7 3 2 Use of Zero Span Valves with Remote Contact Closure Contact closures for controlling calibration are located on the rear p...

Page 132: ...TION Disabled Disables the Sequence Zero Causes the Sequence to perform a Zero calibration check Zero Span Causes the Sequence to perform a Zero and Span concentration calibration check Span Causes the Sequence to perform a Span concentration calibration check For each mode there are seven parameters that control operational details of the SEQUENCE They are Table 7 3 AutoCal Attribute Setup Parame...

Page 133: ...arting Date Sept 4 2001 Start after Sept 4 2001 Starting Time 01 00 First Span starts at 1 00AM Delta Days 2 Do Sequence 2 every other day Delta Time 00 30 Do Sequence 2 hr later each day Duration 15 0 Operate Span valve for 15 min Calibrate NO Do not calibrate at end of Sequence NOTE The programmed STARTING_TIME must be a minimum of 5 minutes later than the real time clock See Section 6 3 5 for s...

Page 134: ...NEXT MODE EXIT SETUP C 4 MODE DISABLED NEXT ENTR EXIT SETUP C 4 MODE ZERO PREV NEXT ENTR EXIT SETUP C 4 MODE ZERO SPAN PREV NEXT ENTR EXIT SETUP C 4 SEQ 2 ZERO SPAN 1 00 00 PREV NEXT MODE SET EXIT SETUP C 4 TIMER ENABLE ON SET EDIT EXIT SETUP C 4 STARTING DATE 01 JAN 02 SET SET EDIT EXIT SETUP C 4 STARTING DATE 01 JAN 02 0 4 SEP 0 3 ENTR EXIT Toggle keys to set Day Month Year Format DD MON YY SETU...

Page 135: ... MM This is a 24 hr clock PM hours are 13 24 Example 2 15 PM 14 15 CONTINUED FROM PREVIOUS PAGE STARTING DATE CONTINUE NEXT PAGE With DURATION TIME SETUP C 4 STARTING TIME 14 15 SET SET EDIT EXIT SETUP C 4 DELTA DAYS 1 SET SET EDIT EXIT SETUP C 4 DELTA DAYS 1 0 0 2 ENTR EXIT Toggle keys to set number of days between procedures 1 367 SETUP C 4 DELTA DAYS 2 SET SET EDIT EXIT SETUP C 4 DELTA TIME00 0...

Page 136: ...r each iteration of the sequence Set in Decimal minutes from 0 1 60 0 SETUP C 4 CALIBRATE OFF SET SET EDIT EXIT SETUP C 4 CALIBRATE OFF ON ENTR EXIT SETUP C 4 CALIBRATE ON SET SET EDIT EXIT Toggle key Between Off and ON SETUP C 4 SEQ 2 ZERO SPAN 2 00 30 PREV NEXT MODE SET EXIT Display show SEQ 2 ZERO SPAN 2 00 30 Sequence Delta Time MODE Delta Days CONTINUED FROM PREVIOUS PAGE DELTA TIME NOTE If a...

Page 137: ...ntal Research Information or the U S Government Printing Office at http www gpo gov The Handbook can also be located on line by searching for the title at http www usepa gov Special attention should be paid to Section 2 6 which covers CO analyzers of this type Specific regulations regarding the use and operation of ambient CO analyzers can be found in Reference 1 at the end of this Section A bibli...

Page 138: ...mbient air requires a certain amount of basic sampling equipment and supplemental supplies the Quality Assurance Handbook Section 2 6 contains information about setting up the appropriate systems Spare Parts and Expendable Supplies In addition to the basic equipment described in the Q A Handbook it is necessary to maintain an inventory of spare parts and expendable supplies Section 9 describes the...

Page 139: ...onse LEVEL 2 ZERO AND SPAN CHECK Section 12 of Q A Handbook 5 A Level 2 zero and span check is an unofficial check of an analyzer s response It may include dynamic checks made with uncertified test concentrations artificial stimulation of the analyzer s detector electronic or other types of checks of a portion of the analyzer etc Level 2 zero and span checks are not to be used as a basis for analy...

Page 140: ...ail to appear see Section 9 for troubleshooting tips Analyzer enters ZERO CAL Mode and switches the Z S valves to supply Zero Air See Table 5 1 for Z S Valve States during this operating mode EXIT halts the calibration process and returns the unit to SAMPLE Mode SAMPLE RANGE 50 0 PPM CO 40 58 TST TST CAL CALZ CALS SETUP ZERO CAL M RANGE 50 0 PP CO 40 58 TST TST SPAN CONC EXIT M P CAL RANGE 50 0 PP...

Page 141: ...mmended once per quarter but frequency may be determined by applicable regulations and end use of the data Refer to The Q A Handbook Volume II Section 2 6 65 Reference 5 for a more detailed description 8 1 6 1 Calibration Audit A calibration audit consists of challenging the M300E with known concentrations of CO The difference between the known concentration and the analyzer response is obtained a...

Page 142: ...d periodically as appropriate as significant changes in system operations occur 8 1 7 Calibration Frequency To ensure accurate measurements of the ambient CO concentrations calibrate the M300E at the time of installation and recalibrate it 1 No later than 3 months after the most recent calibration or performance audit which indicated the M300E response to be acceptable or 2 Following any one of th...

Page 143: ...ion points between zero and 80 URL without further adjustment to the instrument Allow the instrument to sample these intermediate concentrations for about 10 minutes each and record the instrument responses Plot the analyzer responses versus the corresponding calculated concentrations to obtain a calibration relationship Determine the best fit straight line y mx b determined by the method of least...

Page 144: ...Quality Surveillance Code of Federal Regulations Title 40 Part 58 3 Appendix A Quality Assurance Requirements for State and Local Air Monitoring Stations SLAMS Code of Federal Regulations Title 40 Part 58 4 Appendix B Quality Assurance Requirements for Prevention of Significant Deterioration PSD Air Monitoring Code of Federal Regulations Title 40 Part 50 Appendix D 5 Quality Assurance Handbook for...

Page 145: ...more often than shown NOTE A Span and Zero Calibration Check see CAL CHECK REQ D Column of Table 0 1 must be performed following certain of the maintenance procedure listed below A check involves applying zero and span gas to the analyzer and noting the result but not changing the instrument s offset and slope factors To perform a CHECK of the instrument s Zero or Span Calibration follow the same ...

Page 146: ...ticulate Filter Replace Weekly or as needed Yes Verify Test Functions Record and analyze Weekly or after any Maintenance or Repair No Pump Diaphragm Replace Every 2 years Yes Perform Flow Check Check Flow Every 6 Months No Perform Leak Check Verify Leak Tight Annually or after any Maintenance or Repair Yes Pneumatic lines Examine and clean As needed Yes if cleaned Cleaning Clean As needed Only if ...

Page 147: ... Analyzer Instruction Manual P N 04288 REV A 147 Table 9 2 M300E Test Function Record Date Recorded Function Operating Mode STABILITY ZERO CAL CO MEAS ZERO CAL Zero CAL MR RATIO SPAN CAL PRES SAMPLE PHT DRIVE SAMPLE After Warn up SLOPE SPAN CAL OFFSET ZERO CAL ...

Page 148: ... Cal Decreasing Source Aging Detector deteriorating Optics getting dirty or contaminated Increasing Source Aging Detector deteriorating Contaminated zero gas H2O CO2 Zero Cal Decreasing Source Aging Detector deteriorating GFC Wheel Leaking Pneumatic Leaks Contaminated zero gas CO Increasing Source Aging Pneumatic Leaks instrument sample system Calibration system deteriorating MR Ratio Span Cal Dec...

Page 149: ...g or contamination We recommend that when you change the filter handle it and the wetted surfaces of the filter housing as little as possible Do not touch any part of the housing filter element PTFE retaining ring glass cover and the o ring To change the filter 1 Turn OFF the analyzer to prevent drawing debris into the instrument 2 Open the M300E s hinged front panel and unscrew the knurled retain...

Page 150: ...uctions and diagrams are included with the kit Always perform a Flow and Leak Check after rebuilding the Sample Pump 9 3 3 Performing Leak Checks Leaks are the most common cause of analyzer malfunction Section 9 3 3 1 presents a simple leak check procedure Section 9 3 3 2 details a more thorough procedure 9 3 3 1 Vacuum Leak Check and Pump Check This method is easy and fast It detects but does not...

Page 151: ...ove on the sample inlet at the rear panel 3 Remove the instrument cover and locate the inlet side of the sample pump Remove the flow assembly from the pump and plug it with the appropriate gas tight fitting 4 Pressurize the instrument with the leak checker allowing enough time to fully pressurize the instrument through the critical flow orifice Check each fitting with soap bubble solution looking ...

Page 152: ...ent viewable from the Front Panel of the instrument This measurement is only for detecting major flow interruptions such as clogged or plugged gas lines See Figure 3 2 for sample port location 1 Turn off power 2 Attach the Flow Meter to the sample inlet port on the rear panel Ensure that the inlet to the Flow Meter is at atmospheric pressure 3 Turn on instrument power 4 Sample flow should be 800 c...

Page 153: ...AG HALT EXIT Exit at Any Time to Return to main the SETUP Menu DIAG SIGNAL I O NEXT ENTR EXIT EXIT returns to the previous menu SETUP C 3 ENTER DIAG PASS 818 8 1 8 ENTR EXIT Repeat Pressing NEXT until DIAG FLOW CALIBRATION PREV NEXT ENTR EXIT DIAG FCAL ACTUAL FLOW 751 CC M 0 7 5 1 ENTR EXIT DIAGFCAL ACTUAL FLOW 853 CC M 0 8 5 3 ENTR EXIT DIAG FLOW CALIBRATION PREV NEXT ENTR EXIT EXIT ignores the n...

Page 154: ...bly and optical bench is complex and delicate Disassembly and cleaning is not recommended Please check with the factory before disassembling the optical bench 9 3 7 Cleaning Exterior Surfaces of the M300E If necessary the exterior surfaces of the M300E can be cleaned with a clean damp cloth Do not submerge any part of the instrument in water or cleaning solution ...

Page 155: ...ument is performed in software and does not require physical adjustments to the instrument During calibration the microprocessor measures the current state of the IR Sensor output and various other physical parameters of the instrument and stores them in memory The microprocessor uses these calibration values the IR absorption measurements made on the Sample Gas along with data regarding the curre...

Page 156: ...s as it is being absorbed C is the concentration of the absorbing gas In the case of the Model 300E carbon monoxide CO α is the absorption coefficient that tells how well CO absorbs light at the specific wavelength of interest 10 1 2 Measurement Fundamentals In the most basic terms the Model 300E uses a high energy heated element to generate a beam of broad band IR light with a known intensity mea...

Page 157: ...hoto detector that converts the light signal into a modulated voltage signal representing the attenuated intensity of the beam 10 1 3 Gas Filter Correlation Unfortunately several gases also absorb light at 4 7µm Among these are water and carbon dioxide both of which are much more common gases compared to CO To overcome the interfering effects of these as well as other gases the Model 300E adds ano...

Page 158: ...IR IS affected by CO in Reference Cell H Figure 10 3 Measurement Fundamentals with GFC Wheel As the GFC wheel spins the IR light alternately passes through the two cavities When the beam is exposed to the Reference Cell the CO in the gas filter wheel strips the beam of most of the IR at 4 7µm When the light beam is exposed to the Measurement Cell the N2 in the filter wheel does not absorb IR light...

Page 159: ...e gas mixture of the Reference Cell will attenuate the intensity of the IR Beam by 20 giving a M R Ratio 0f 1 2 1 Adding CO to the Sample Chamber causes the peaks corresponding to both cells to be attenuated by a further percentage Since the intensity of the light passing through the Measurement Cell is greater the effect of this additional attenuation is greater This causes CO MEAS to be more sen...

Page 160: ...hts remains the same Thus the difference in the peak heights and the resulting M R ratio is only due to CO and not to interfering gases In this way Gas Filter Correlation rejects the effects of interfering gases and so that the analyzer responds only to the presence of CO To improve the signal to noise performance of the IR Photo Detector the GFC wheel also incorporates an optical mask that chops ...

Page 161: ...k checks can be found in Section 9 5 10 2 1 Sample Gas Flow Sample Chamber Filter From Sample Port Pressure Sensor Sample Pressure Flow Sensor Sample Flow PUMP Critical Flow Orifice To Exhaust Port Figure 10 7 Model 300E Pneumatic Operation An internal pump evacuates the sample chamber creating a small vacuum that draws sample gas into the analyzer Normally the analyzer is operated with its inlet ...

Page 162: ...ifice directly upstream of the pump but down stream from the Sample Chamber As the pump pulls against the restricted airway of the orifice a pressure differential is created By keeping a sufficiently large the pressure differential across the orifice approximately 2 1 a simple and effective control mechanism is established for maintaining an even flow rate This has several other benefits q Fluctua...

Page 163: ...ng the analyzer s accuracy The filter is accessible through the front panel which folds down to allow access and should be changed according to the suggested maintenance schedule described in Table 9 1 10 2 6 Valve Options A variety of optional valve sets can be purchased for the analyzer which allow the user to more easily supply and manipulate various calibration gases such as Zero Air and Span ...

Page 164: ...ital I O I2 C Bus Sensor Inputs Box Temp Thermistor Interface SAMPLE TEMP BENCH TEMP WHEEL TEMP A1 A2 A3 Optional 4 20 mA MOTHER BOARD A D Converter V F PC 104 Bus External Digital I O Back Panel Connectors Analog Outputs D A TEC Control PHT Drive Detector Output Segment Sensor M R Sensor GFC Wheel GFC Motor Zero Span Valve Options Wheel Heater Bench Heater Keyboard Display Sensor Status Control O...

Page 165: ...uit assembly CO MEAS and CO REF are converted into digital data by a unipolar Analog to Digital Converter located on the Mother Board A variety of sensors report the physical and operational status of the analyzer s major components again through the signal processing capabilities of the Mother Board These status reports are used as data for the CO concentration calculation and as trigger events f...

Page 166: ...tore critical calibration and configuration data Segregating this data on a separate less heavily accessed chip significantly decreases the chance of this key data being corrupted 10 3 3 Optical Bench GFC Wheel Electronically the Model 300E s optical bench GFC wheel and associated components do more than simply measure the amount of CO is present in the Sample Chamber A variety of other critical f...

Page 167: ... across a broad band This radiation is optically filtered after it has passed through the GFC Wheel and the Sample Chamber and just before it reaches the photo detector to eliminate all black body radiation and other extraneous IR emitted by the various components of those components GFC Wheel A synchronous AC motor turns the GFC Wheel motor For analyzers operating on 60Hz line power this motor tu...

Page 168: ...f a full revolution of the wheel The resulting light signal tells the analyzer whether the IR beam is shining through the Measurement or the Reference side of the GFC Wheel Segment Sensor This emitter detector shines through a portion of the mask that is divided into the same number of segments as the portion of the mask through which the IR beam passes It is used by the Synchronous Demodulation c...

Page 169: ...orrespondingly low and the its output voltage output is high During those times when the IR beam intensity is low or completely blocked by the GFC Wheel mask the temperature of the detector is lowered by the two stage thermo electric cooler increasing the detectors resistance and lowering the output voltage 10 3 4 Synchronous Demodulator Sync Demod Assembly Overview While the Photo Detector conver...

Page 170: ... Dark Gate CO Measure CO Reference 56V Bias Variable Gain Amp From GFC Wheel From CPU via Mother Board Signal Conditioner Signal Conditioner 10 x10 TEC Control PHT DRIVE Figure 10 11 300E Sync Demod Block Diagram Signal Synchronization and Demodulation The signal emitted by the IR Photo Detector goes through several stages of amplification before it can be accurately demodulated The first is a pre...

Page 171: ...n IR Beam Passing Through Segment Sensor Pulse is Measure Gate MEASUREMENT cell of GFC Wheel HIGH Measure Dark Gate MEASUREMENT Cell of GFC Wheel LOW Reference Gate REFERENCE cell of GFC Wheel HIGH Reference Dark Gate REFERENCE cell of GFC Wheel LOW Timing for activating the Sample and Hold circuits is provided by a Phase Lock Loop circuit PLL Using the Segment Sensor output as a reference signal ...

Page 172: ...l diagnostic tools for checking the GFC Wheel rotation LED Function Status OK Fault Status D1 M R Sensor Status LED flashes approximately 2 second LED is stuck ON or OFF D2 Segment Sensor Status LED flashes approximately 6 second LED is stuck ON or OFF See Section 11 1 3 for more information Photo Detector Temperature Control The Synch Demod Board also contains circuitry that controls the IR Photo...

Page 173: ...nch Heater also includes circuitry that selects which one of its two separate heating elements is activated depending on whether the instrument is running on 100 VAC 115 VAC or 230 VAC line power GFC Wheel Motor Control The GFC Wheel operates from a AC voltage supplied by a multi input transformer located on the Relay Board The step down ratio of this transformer is controlled by factory installed...

Page 174: ...s On Off Every 3 Seconds under direct control of the analyzer s CPU D2 YELLOW Wheel Heater HEATING NOT HEATING D3 YELLOW Bench Heater HEATING NOT HEATING D4 YELLOW Spare N A N A D5 GREEN Sample Cal Gas Valve Option Valve Open to CAL GAS FLOW Valve Open to SAMPLE GAS FLOW D6 GREEN Zero Span Gas Valve Option Valve Open to SPAN GAS FLOW Valve Open to ZERO GAS FLOW D7 GREEN Shutoff Valve Option Valve ...

Page 175: ...gital word The A D consists of a Voltage to Frequency V F converter a programmable logic device PLD three multiplexers several amplifiers and some other associated devices The V F converter produces a frequency proportional to its input voltage The PLD counts the output of the V F during a specified time period and sends the result of that count in the form of a binary number to the CPU The A D ca...

Page 176: ...temperature of the Sample Gas in the chamber This data is used to during the calculation of the CO concentration value BENCH TEMPERATURE SENSOR This thermistor attached to the Sample Chamber housing reports the current temperature of the chamber housing to the CPU as part of the Bench Heater control loop WHEEL TEMPERATURE SENSOR This thermistor attached a the heat sync on the GFC Wheel Motor assem...

Page 177: ...nalog outputs are connected back to the A D converter through a Loopback circuit This permits the voltage outputs to be calibrated by the CPU without need for any additional tools or fixtures Internal Digital I O This channel is used to communicate digital status and control signals about the operation of key components of the Optical Bench The CPU sends signals to the Synch Demod Board that initi...

Page 178: ...CPU boots and the instrument software can establish control 10 3 7 Power Supply Circuit Breaker The analyzer operates on 100 VAC 115 VAC or 230 VAC power at either 50Hz or 60Hz Individual units are set up at the factory to accept any combination of these five attributes As illustrated in Figure 10 14 power enters the analyzer through a standard IEC 320 power receptacle located on the rear panel of...

Page 179: ...BOARD Figure 10 14 Power Distribution Block Diagram 10 4 Interface The analyzer has several ways to communicate the outside world see Figure 10 15 Users can input data and receive information directly via the Front Panel keypad and display Direct communication with the CPU is also available by way of the analyzers RS232 RS485 I O ports or an optional Ethernet port The analyzer can also send and re...

Page 180: ...YBOARD RELAY BOARD PC 104 BUS DISPLAY I2 C BUS I2 C BUS Optional Ethernet Interface COM A COM B Figure 10 15 Interface Block Diagram Front Panel The Front panel of the analyzer is hinged at the bottom and may be opened to gain access to various components mounted on the panel itself or located near the front of the instrument such as the GFC Wheel assembly Two fasteners located in the upper right ...

Page 181: ...e of text displays a variety of informational messages Warning messages are displayed here as are responses by the analyzer to queries for operation data about the instrument During interactive tasks such as instrument calibration or certain diagnostic procedures the instrument s response messages are also displayed here Concentration Field The far right portion of the top line of text displays th...

Page 182: ...AS is disabled On Unit is operating in Sample Mode Front Panel Display being updated iDAS data being stored SAMPLE Green Blinking Unit is operating in Sample Mode Front Panel Display being updated iDAS Hold Off mode is ON iDAS disabled CAL Yellow Off On Blinking Auto Cal disabled Auto Cal enabled Unit is in calibration mode FAULT Red Off Blinking No warnings exist Warnings exist 10 5 Software Oper...

Page 183: ...the software automatically switches between two different length filters based on the conditions at hand Once triggered the short filter remains engaged for a fixed time period to prevent chattering During conditions of constant or nearly constant concentration the software by default computes an average of the last 750 samples or approximately 150 seconds This provides the calculation portion of ...

Page 184: ...calibration can be viewed by pressing the following keystroke sequence SAMPLE RANGE 50 0 MGM CO XX XX TST TST CAL SETUP SAMPLE TIME 16 23 34 CO XX XX TST TST CAL SETUP SAMPLE OFFSET 0 000 CO XX XX TST TST CAL SETUP SAMPLE SLOPE 1 000 CO XX XX TST TST CAL SETUP 10 5 3 Measurement Algorithm Once the IR Photo Detector is signal is demodulated into CO MEAS and CO REF by the Sync Demod Board and conver...

Page 185: ... differences are accommodated New data parameters and triggering events can be added to the instrument firmware as needed Users have full control over which data is stored and when it s stored The iDAS is designed to store a large amount of data Depending on the sampling frequency and the number of data parameters the iDAS can store more than a year s worth of data The data is stored in non volati...

Page 186: ...THEORY OF OPERATION Model 300E Carbon Monoxide Analyzer Instruction Manual 186 P N 04288 Rev A INTENTIONALLY BLANK ...

Page 187: ...t disturbing monitoring operations A systematic approach to troubleshooting will generally consist of the following four steps 1 Note any WARNING MESSAGES and take corrective action as required 2 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 3 Use the Internal Electronic Status LED s t...

Page 188: ...11 1 lists warning messages along with their meaning and recommended corrective action It should be noted that if more than two or three warning messages occur at the same time it is often an indication that some fundamental analyzer sub system power supply Relay Board Motherboard has failed rather than indication of the of the specific failures referenced by the warnings In this case it is recomm...

Page 189: ...analyzer s CPU or Mother Board can result in any or ALL of the following messages Table 11 1 Warning Messages Warning Message Fault Condition Possible Causes BENCH TEMP WARNING The optical bench temp is controlled at 48 5 C Bench Heater Bench Temperature Sensor Relay controlling the Bench Heater Entire Relay Board I2 C Bus BOX TEMP WARNING Box Temp is 5 C or 48 C Box Temperature typically runs 7o ...

Page 190: ...Sensor Circuitry SAMPLE PRES WARN Sample Pressure is 15 in Hg or 35 in Hg Normally 29 92 in Hg at sea level decreasing at 1 in Hg per 1000 ft of altitude with no flow pump disconnected If Sample Pressure is 15 in HG Blocked Particulate Filter Blocked Sample Inlet Gas Line Failed Pressure Sensor circuitry If Sample Pressure is 35 in HG Blocked Vent line on pressurized Sample Zero Span gas supply Ba...

Page 191: ...ng useful as predictive diagnostic tools the Test Functions viewable from the Front Panel can be used to isolate and identify many operational problems when combined with a thorough understanding of the analyzers Theory of Operation see Section 10 The acceptable ranges for these Test Functions are listed in the Nominal Range column of the analyzer Final Test and Validation Data Sheet p n 04307 shi...

Page 192: ...also BAD GFC Wheel stopped or rotation is too slow Failed Sync Demod Board IR Source Failed IR Source Failed Relay Board Failed I2 C Bus Failed IR Photo Detector MR Ratio When the analyzer is sampling Zero Air and the ratio is too low The Reference Cell of the GFC Wheel is contaminated or leaking The alignment between the GFC Wheel and the Segment Sensor the M R Sensor or both is incorrect Failed ...

Page 193: ...ure Sensor P1 or circuitry Invalid M R ratio see above Bad incorrect Span Gas concentration due OFFSET Values outside range indicate Contamination of the Zero Air supply Contaminated or leaking GFC Wheel either chamber Faulty IR Photo Detector 11 1 3 Using the Diagnostic Signal I O Function The Signal I O parameters found under the DIAG Menu see Section 7 4 1 and Appendix A combined with a thoroug...

Page 194: ...urn to software control DIAG SIGNAL I O PREV NEXT ENTR EXIT If Parameter is an Input Signal DIAG I O 0 EXT_ZERO_CAL ON PREV NEXT JUMP PRNT EXIT DIAG I O 18 WHEEL_HTR ON PREV NEXT JUMP ON PRNT EXIT SETUP ENTER DIAG PASS 818 8 1 8 ENTR EXIT DIAG I O 25 SAMPLE_PRESSURE 2540 MV PREV NEXT JUMP PRNT EXIT DIAG I O 18 WHEEL_HTR OFF PREV NEXT JUMP OFF PRNT EXIT If Parameter is an Output Signal or Control T...

Page 195: ...f the motherboard just to the right of the CPU board flashes when the CPU is running the main program loop After power up approximately 30 60 seconds DS5 should flash on and off If characters are written to the front panel display but DS5 does not flash then the program files have become corrupted contact customer service because it may be possible to recover operation of the analyzer If after 30 ...

Page 196: ...Fault Status Indicated Failure s D1 M R Sensor Status LED is stuck ON or OFF GFC Wheel is not turning M R Sensor on Opto Pickup Board failed Sync Demod Board failed JP 4 Connector Wiring faulty Failed Faulty 5 VDC Power Supply PS1 D2 Segment Sensor Status LED is stuck ON or OFF GFC Wheel is not turning Segment Sensor on Opto Pickup Board failed Sync Demod Board failed JP 4 Connector Wiring faulty ...

Page 197: ...ates the health of the I2 C bus LED Function Fault Status Indicated Failure s D1 RED I2 C bus Health Watchdog Circuit Continuously ON or Continuously OFF Failed Halted CPU Faulty Mother Board Keyboard or Relay Board Faulty Connectors Wiring between Mother Board Keyboard or Relay Board Failed Faulty 5 VDC Power Supply PS1 If D1 is blinking the other faults following LED s can be used in conjunction...

Page 198: ...CAL_VALVE N A Sample Cal Valve should audibly change states If not Failed Valve Failed Relay Drive IC on Relay Board Failed Relay Board Faulty 12 VDC Supply PS2 Faulty Connectors Wiring D6 Green Zero Span Gas Valve Option SPAN_VALVE N A Zero Span Valve should audibly change states If not Failed Valve Failed Relay Drive IC on Relay Board Failed Relay Board Faulty 12 VDC Supply PS2 Faulty Connectors...

Page 199: ... 2 1 1 Flow is Zero The unit displays a SAMPLE FLOW warning message on the Front Panel Display or the SAMPLE FLOW Test Function reports a zero or very low flow rate Confirm that the sample pump is operating turning If not use an AC Voltmeter to make sure that power is being supplied to the pump If no power is present at the electrical leads of the pump see Section 11 5 If AC power is being supplie...

Page 200: ... Check for the sample filter and the orifice filter for dirt Replace filters see Sections 9 2 and 9 4 1 respectively 4 Check for partially plugged pneumatic lines orifices or valves Clean or replace them 5 If an IZS option is installed in the instrument press CALZ and CALS If the flow increases then suspect a bad Sample Cal valve The valve 11 2 1 3 High Flow The most common cause of high flow is a...

Page 201: ...mple pump should start immediately after the front panel power switch is turned ON The TEST variable VACUUM should read about 10 Hg for a pump in good condition Readings above 15 Hg indicate that the pump needs rebuilding or the instrument has a leak 11 3 Calibration Problems 11 3 1 Miss Calibrated There are several symptoms that can be caused by the analyzer being miss calibrated This condition i...

Page 202: ...te sample is being delivered to the sensor assembly 3 A failing IR Photo Detector may be at fault Check the CO MEAS and CO REF Test Functions via the Front Panel Display to make sure the signal levels are in the normal range See Appendix A and are quiet 4 Confirm the Sample Pressure Wheel Temperature Bench Temperature and Sample Flow readings are correct and have steady readings 5 Disconnect the e...

Page 203: ...Valve Options 51 or 53 installed this 4 Check to make sure that there is no ambient air leaking into Zero Air line 11 4 Other Performance Problems Dynamic problems i e problems which only manifest themselves when the analyzer is monitoring sample gas can be the most difficult and time consuming to isolate and resolve The following section provides an itemized list of the most common dynamic proble...

Page 204: ...elay K2 on the Relay Board see Figure 10 2 may have failed Using the BENCH_HEATER parameter under the Signal I O function as described above turn on and off K2 D3 on the relay board should illuminate as the heater is turned on Check the AC voltage present between pin 2 and 4 for a 100 or 115 VAC model and pins 3 and 4 for a 220 240 VAC model WARNING Hazardous Voltages are present during this test ...

Page 205: ...cribed above in Table 10 2 is out of range there are two four possible causes of failure 1 The screws retaining the IR photo detector to the Absorption Bench have become loose Carefully tighten the screws hand tight and note whether after the analyzer has come up to operating temperature whether the PHT DRIVE voltage has returned to an acceptable level 2 The two large transistor type devices mount...

Page 206: ...e M300E are provided by switching power supplies Switch mode supplies create DC outputs by switching the input AC waveform at high frequencies As the components in the switcher age and degrade the main problem observed is increased noise on the DC outputs If a noisy switcher power supply is suspected attach an oscilloscope to the DC output test points located on the top right hand edge of the Rela...

Page 207: ...iring used to connect the various printed circuit assemblies and DC Powered components and the associated test points on the Relay Board 03134 follow a standard color coding scheme as defined in Table 11 4 Table 11 4 DC Power Test Point and Wiring Color Codes Name Test Point TP and Wire Color Dgnd 1 Black 5V 2 Red Agnd 3 Green 15V 4 Blue 15V 5 Yellow 12V 6 Purple 12R 7 Orange A Voltmeter should be...

Page 208: ...sed on the front panel Assuming that there are no wiring problems and that the DC power supplies are operating properly The vacuum fluorescent display is good if on power up a character is visible on the upper left hand corner of the display The CPU Status LED DS5 is flashing see Section 11 1 4 1 If there is a character on the display at power up and D1 on the Relay Board is flashing then the Keyb...

Page 209: ...es Function Control Device In Socket Wheel Heater K1 Yes Bench Heater K2 Yes Spare AC Control K3 Yes IZS Valves U4 Yes IR Source Drive U5 No The IR Source drive output can be verified by measuring the Voltage at J16 with the IR Source disconnected It should be 11 5 0 5 VDC 11 5 6 Sensor Assembly 11 5 6 1 Sync Demodulator Assembly To verify that the Sync Demodulator Assembly is working follow the p...

Page 210: ...ing properly can be obtained by measuring the frequency at TP1 and TP2 using a frequency counter a Digital Volt Meter with a frequency counter or an oscilloscope per the table below Table 11 7 Opto Pickup Board Nominal Output Frequencies Nominal Measured Frequency AC Mains Freq TP1 TP2 50 Hz 25 300 60 Hz 30 360 11 5 6 3 GFC Wheel Drive If the D1 and D2 on the Sync Demodulator board are not flashin...

Page 211: ... bad 11 5 6 5 Pressure Flow Sensor Assembly The pressure flow sensor PCA 04003 located on the top of the absorption bench can be checked with a Voltmeter using the following procedure which assumes that the wiring is intact and that the Motherboard and the power supplies are operating properly 1 For Pressure related problems Measure the voltage across C1 it should be 5 0 25 VDC If not then the boa...

Page 212: ...tage displayed through the Signal I O function If the wiring is intact but there is a large difference between the measured and displayed Voltage 10 mV then the Motherboard is bad 11 5 7 2 Analog Outputs Voltage To verify that the Analog outputs are working properly connect a voltmeter to the output in question and perform an Analog Output Step Test as described in Section 6 6 2 For each of the st...

Page 213: ... Nominal Output Values Step Current V 250 Ohms Current V 250 Ohms 1 0 2 mA 0 5V 4 1 2 20 5 6 1 4 7 2 1 8 3 40 9 2 2 3 10 4 2 6 4 60 12 8 3 2 13 6 3 4 5 80 16 4 4 1 16 8 4 2 6 100 20 5 20 5 11 5 7 4 Status Outputs The procedure below can be used to test the Status outputs 18 Connect a jumper between the D pin and the s pin on the status output connector 19 Connect a 1000 ohm resistor between the pi...

Page 214: ...witch from SAMPLE mode to ZERO CAL R mode 24 Connect a second jumper from the pin on the Status connector to the B pin on the Control In connector The instrument should switch from SAMPLE mode to SPAN CAL R mode In each case the M300E should return to SAMPLE mode when the jumper is removed 11 5 8 CPU There are two major types of failures associated with the CPU board complete failure and a failure...

Page 215: ... T 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 ...

Page 216: ...enable modem transmission Make sure the BAUD rate word length and stop bit settings between modem and analyzer match see Section 7 7 Use the RS 232 test function to send w characters to the modem terminal or computer See Section 7 7 7 Get your terminal modem or computer to transmit data to the analyzer holding down the space bar is one way the green LED should flicker as the instrument is receivin...

Page 217: ...t in Appendix B for part numbers and kits 1 Turn off Power to the analyzer 2 Locate the assembly attached to the sample pump see Figure 3 5 3 Disconnect the pneumatic connection from the flow assembly and the assembly from the pump 4 Remove the fitting and the components as shown in the exploded view in Figure 11 5 5 Replace the o rings p n OR_01 and the sintered filter p n FL_01 6 If replacing th...

Page 218: ... Housing P N 000850000 Figure 11 6 Critical Flow Restrictor Assembly Disassembly 11 6 2 Removing Replacing the GFC Wheel When Removing or replacing the GFC Wheel it is important to perform the disassembly in the following order to avoid damaging the components 25 Turn off the analyzer 26 Remove the top cover as described in Getting Started Section 3 1 27 Open the Instruments hinged front panel 28 ...

Page 219: ... 30 Carefully remove the cover and the stand offs located between the cover ands the GFC Wheel Housing SAFETY SHIELD SYNCHRONOUS MOTOR SOURCE ASSEMBLY THERMISTOR HEATER Figure 11 7 Removing the GFC Sensor Heater Cover 31 Remove the TWO 2 screws holding protective metal cover over the Opto Pickup printed circuit assembly to the GFC Wheel housing 32 Carefully remove the cover from the Opto Pickup pr...

Page 220: ...truction Manual 220 P N 04288 Rev A Opto Pickup Figure 11 8 Removing the Opto Pickup Assembly 33 Remove the THREE 3 screws holding the GFC Wheel Housing to the GFC Motor Heatsink 34 Carefully remove the GFC housing GFC WHEEL HOUSING Figure 11 9 Removing the GFC Wheel Housing ...

Page 221: ...instrument software This will cause all of the instrument configuration parameters and iDAS data to be lost However a backup copy of the operating parameters are stored in a second non volatile memory and will be loaded into the new the Disk on Chip on power up To change the Disk on Chip follow this procedure 1 Turn off power to the instrument 2 Fold down the rear panel by loosening the thumbscrew...

Page 222: ...TROUBLESHOOTING REPAIR PROCEDURES Model 300E Carbon Monoxide Analyzer Instruction Manual 222 P N 04288 Rev A INTENTIONALLY BLANK ...

Page 223: ...PENDIX A Software Version Specific Documentation APPENDIX A 1 Software Menu Trees and Index APPENDIX A 2 Setup Variables Available Via Serial I O APPENDIX A 3 Warning Messages and Test Measurements Available Via Serial I O APPENDIX A 4 Signal I O Definitions APPENDIX A 5 iDAS Functions ...

Page 224: ...Model 300E Carbon Monoxide Analyzer Instruction Manual Appendix A P N 04288 REV A INTENTIONALLY BLANK ...

Page 225: ...d by API may result in non compliance with European standard EN 61010 1 Part or List Description 040340100 Model 300E Spare Parts 009600400 Model 300 320 47MM Filter Expendables Kit KNF Pump Model NO5ATI 040350100 Model 300E Level 1 Spare Parts Kit for 10 Units 040360100 Model 300E Spares Kit for 1 Unit 043020000 Model 300E SNs 99 Recommended Spare Part Stocking Levels ...

Page 226: ...Model 300E Carbon Monoxide Analyzer Instruction Manual Appendix B P N 04288 REV A INTENTIONALLY BLANK ...

Page 227: ... Carbon Monoxide Analyzer Instruction Manual P N 04288 REV A Appendix C APPENDIX C Test Functions and Repair Questionnaire for M300E Document Title 04305 Test Functions and Repair Questionnaire for M300E SNs 100 ...

Page 228: ...Model 300E Carbon Monoxide Analyzer Instruction Manual Appendix C P N 04288 REV A INTENTIONALLY BLANK ...

Page 229: ...nect List M300E SNs 100 04216 Interconnect Drawing M300E SNs 100 04136 PCA 04135 Relay Driver Source Supply 03297 PCA 03296 IR Photodetector Preamp and Sync Demodulator 04070 PCA 04069 Motherboard E series 03632 PCA 03631 0 20mA driver 03976 PCA 03975 Keyboard Display Driver 04259 PCA 04258 Keyboard Display Driver 04003 PCA 04003 Pressure Flow Transducer Interface 04089 PCA 04088 Opto Pickup Inter...

Page 230: ...Model 300E Carbon Monoxide Analyzer Instruction Manual Appendix D P N 04288 REV A INTENTIONALLY BLANK ...

Page 231: ...play DS_9 CN1 11 Keyboard Interface 03975 or 04258 J3 11 DISP_BUSY Display DS_9 CN1 12 Keyboard Interface 03975 or 04258 J3 12 DISP_RETURN Display DS_9 CN1 13 Keyboard Interface 03975 or 04258 J3 13 DISP_RETURN Display DS_9 CN1 14 Keyboard Interface 03975 or 04258 J3 14 DISP_PWR Display DS_9 CN1 15 Keyboard Interface 03975 or 04258 J3 15 DISP_PWR Display DS_9 CN1 16 Keyboard Interface 03975 or 042...

Page 232: ... Heater Wiring harness 03799 P1 1 Wheel Heater 006110200 P1 1 AC Return Wiring harness 03799 P1 4 Wheel Heater 006110200 P1 2 Bench Htr 115V Wiring harness 03799 P1 2 Bench Htr 037250000 P1 1 Bench Htr 230V Wiring harness 03799 P1 3 Bench Htr 037250000 P1 2 AC Return Wiring harness 03799 P1 4 Bench Htr 037250000 P1 3 Chassis Gnd Wiring harness 03799 P1 5 03789 15 PS1 SK1 1 Relay 04135 J13 4 5 PS1 ...

Page 233: ...5 J16 1 IR Source 009550400 P1 1 IR Source Drv Relay 04135 J16 2 IR Source 009550400 P1 2 03995 GFC Drive A Relay 04135 J6 1 GFC Motor 009820200 P1 1 GFC Drive B Relay 04135 J6 2 GFC Motor 009820200 P1 2 Motor Return Relay 04135 J6 3 GFC Motor 009820200 P1 3 Chassis Gnd Relay 04135 J6 4 GFC Motor 009820200 P1 4 04103 5V Ref Mother Board 040690100 J27 6 Bench Temp Snsr 003290500 P1 1 Bench Temp Mot...

Page 234: ...J1 2 Motherboard 040690100 J109 6 Sample Flow Flow Module 04002 J1 5 Motherboard 040690100 J109 2 AGND Flow Module 04002 J1 Shld Motherboard 040690100 J109 9 Measure Sync Demod 03296 J3 1 Motherboard 040690100 J109 4 PD Temp Sync Demod 03296 J3 2 Motherboard 040690100 J109 1 Reference Sync Demod 03296 J3 5 Motherboard 040690100 J109 3 AGND Sync Demod 03296 J3 6 Shld Dark Switch Sync Demod 03296 J3...

Page 235: ...26 CN3 6 Motherboard 040690100 J12 11 GND 0 CPU CP_26 CN3 9 Motherboard 040690100 J12 10 RXD 1 CPU CP_26 CN4 3 Motherboard 040690100 J12 9 RTS 1 CPU CP_26 CN4 4 Motherboard 040690100 J12 8 TXD 1 CPU CP_26 CN4 5 Motherboard 040690100 J12 7 CTS 1 CPU CP_26 CN4 6 Motherboard 040690100 J12 6 GND 1 CPU CP_26 CN4 9 Motherboard 040690100 J12 5 NET CPU CP_26 CN5 2 Motherboard 040690100 J12 7 NET CPU CP_26...

Page 236: ......

Page 237: ...J13 CON10THROUGH 1 1 2 3 4 5 6 7 8 9 10 J14 CON10THROUGH DGND 5V AGND 15V AGND 15V 12RET 12V EGND CHS_GND AC_Line AC_Neutral I2C_Vcc 1 2 JP5 HEADER 1X2 DC PWR IN KEYBRD MTHR BRD SYNC DEMOD SPARE 5V 5V 1 2 3 4 K1 SLD RLY 1 2 3 4 K2 SLD RLY 1 2 3 4 K3 SLD RLY I2C_Vcc 1 2 3 JP8 WTCDG OVR C8 10 16 C6 10 16 C1 0 1 R2 20K BENCH HTR SPARE GFC MOTOR 1 2 3 4 J1 CON4 1 2 3 4 5 J3 WHEEL HTR 1 1 2 3 4 5 6 7 8...

Page 238: ...TEST SYNC ERROR PDETTEMP M R_DET SEGMENT_DET 1 2 3 4 5 6 7 8 JP3 MICROFIT 8 pin DIGITAL GND Analog GND TP3 TP TP4 TP NC 4 GND 2 IN 8 NC 5 GND 6 GND 3 OUT 1 GND 7 U15 LM78L05ACM 8 15V_A 5VREF C14 0 68uf 25V Ceram C15 0 68uf 25V Ceram R4 499K VIN 3 VOUT 2 ADJ 1 U14 LT1084CT C1 100UF 25V C2 100UF 25V C3 100UF 25V DGND TP AGND TP VCC TP 1 2 3 4 5 6 JP6 BM06B SRSS TB mfg JST TDIN TCK TMS TDOUT VCC 15V_...

Page 239: ... LF444 9 10 8 U4C LF444 15V_A COREF TO A D COMEAS TO A D SYNC ERROR R65 16 9K R66 75K R67 80 6K C39 0 1 Poly C25 1 0 Poly 2 3 1 4 11 U4A LF444 R60 200 15V_A D1 2 S1 3 IN1 1 4 13 12 5 U10A DG444 D2 15 S2 14 IN2 16 U10B DG444 D3 10 S3 11 IN3 9 U10C DG444 D4 7 S4 6 IN4 8 U10D DG444 D3 10 S3 11 IN3 9 U8C DG444 D4 7 S4 6 IN4 8 U8D DG444 IO GCK3 1 IO 2 IO 3 GND 4 IO 5 IO 6 IO 7 IO 8 TD IN 9 TMS 10 TCK 1...

Page 240: ...9 0 1 Ceram C52 0 1 Ceram C53 0 1 Ceram C54 0 1 Ceram C55 0 1 Ceram C57 0 1 Ceram C59 0 1 Ceram C60 0 1 Ceram 15V_A 15V_A VCC U2 U4 U4 U2 U5 U5 U7 U8 U8 U8 U10 U10 U10 U12 14 13 12 U4D LF444 C5 10 35V tantalum 3 2 6 1 5 7 4 U9 LF351 R3 39 2k R33 20K R52 100K C65 330PF Ceram 0603 Chip 15V_B 15V_B C66 0 01 100V CERAMIC C38 0 01 100V CERAMIC C51 100 100V ELECTROLYTIC 15V_B F 19 27 Khz V 27 2 VOLTS BI...

Page 241: ...5 uF ceramic 9 10 8 U6C 74HC32 1 TP56 A 23 B 22 C 21 D 20 G1 18 G2 19 Y0 1 Y1 2 Y2 3 Y3 4 Y4 5 Y5 6 Y6 7 Y7 8 Y8 9 Y9 10 Y10 11 Y11 13 Y12 14 Y13 15 Y14 16 Y15 17 U2 74HC154 4 5 6 U50B 74HC08 12 13 11 U50D 74HC08 9 10 8 U50C 74HC08 1 2 JP1 IDC HEADER C3 0 15 uF ceramic 1 2 3 U51A 74HC08 D 2 CLK 3 Q 5 Q 6 PRE 4 CLR 1 U5A 74HC74 12 13 11 U6D 74HC32 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 ...

Page 242: ... 5 NC 6 RTS 7 CTS 8 NC 9 J1013 DB9M 2 1 DS2 LED GRN smt 1206 R10 NOT INSTALLED 2 1 DS1 LED RED smt 1206 R111 10k 1 1 TP14 1 TP18 R12 4 9K 5 1 TP15 R13 NOT INSTALLED R14 NOT INSTALLED 1 TP16 1 TP17 15V 15V VCC 12VRET 12V 15V Com1 RS232 A Com2 RS232 B RS485 AUX DC POWER IN 1 2 3 4 5 6 7 8 9 J1010 DB9 FEMALE TX1 CTS1 2 1 DS4 LED GRN smt 1206 2 1 DS3 LED RED smt 1206 RS GND1 RX0 TX0 RTS0 CTS0 RS GND0 ...

Page 243: ...D2 3 D3 4 D4 5 D5 6 D6 7 D7 8 D8 9 CLK 11 OC 1 Q1 19 Q2 18 Q3 17 Q4 16 Q5 15 Q6 14 Q7 13 Q8 12 U30 74HC574 R16 18 7K C17 0 15 uF ceramic 2 3 1 4 11 U36A OP AMP PRECISION QUAD R63 10k 1 R15 40K 2 2 4 4 6 6 8 8 1 1 3 3 5 5 7 7 J19 IDC 8 C18 0 15 uF ceramic 13 12 14 4 11 U35D OP AMP PRECISION QUAD 2 2 4 4 6 6 8 8 1 1 3 3 5 5 7 7 J21 IDC 8 9 10 8 U20C 74HC32 9 10 8 4 11 U36C OP AMP PRECISION QUAD 2 2 ...

Page 244: ...TER D1 2 D2 3 D3 4 D4 5 D5 6 D6 7 D7 8 D8 9 CLK 11 OE 1 Q1 19 Q2 18 Q3 17 Q4 16 Q5 15 Q6 14 Q7 13 Q8 12 U60 74HC574 1 TP54 R43 100 R47 100 7 2 3 4 6 U53 OP AMP PRECISION 1 TP49 1 2 3 4 5 6 7 8 9 10 11 12 J109 MICROFIT 12 R48 200 4 5 8 1 X1 MB100H 4 8MHZ C45 10 uF 35V TANTALUM R45 1M 1 1206 CHIP C46 0 15 uF ceramic GND 40 GND 39 GND 38 GND 37 GND 36 FREQ 35 VCC 34 VCC 12 GND 10 GND 11 GND 13 GND 14...

Page 245: ...0 A1 17 RS 18 U48 MAX382CWN D1 2 S1 3 VS 4 GND 5 S4 6 D4 7 IN4 8 IN3 9 S3 11 IN1 1 IN2 16 D2 15 S2 14 VS 13 VCC 12 D3 10 U49 DG444DY 1 2 3 4 5 6 7 8 9 10 11 12 13 14 J27 MICROFIT 14 XT1 THERMISTER TEMPMUX DACMUX TEMP IOW DAC1 DAC2 DAC3 D 0 7 DAC0V DAC0 DAC1V DAC3V DAC2V SHDN 15V 15V 5VANA VCC VCC 15V 5VANA 15V 1 2 3 4 5 6 7 8 RN21 10Kx4 R34 10K THERMISTER1 THERMISTER2 THERMISTER3 THERMISTER4 THERM...

Page 246: ... 74HC541 16 14 12 10 15 13 11 9 8 7 6 5 4 3 2 1 U13 PS2702 4 16 14 12 10 15 13 11 9 8 7 6 5 4 3 2 1 U12 PS2702 4 D 0 7 DIGIO4 IOR DIGIO0 VCC VCC CONTROL INPUTS EXTERNAL CONTROL IN A EXTERNAL CONTROL IN B EXT_ 5V_OUT EXT_ 5V_OUT L19 L20 L22 FE BEAD L21 L23 L24 L25FE BEAD L26 L28 L29 L27 FE BEAD L30 C35 10000 pF C56 C57 C34 10000 pF C59 10000 pF C61 C62 C58 10000 pF C64 10000 pF C65 C66 C63 10000 pF...

Page 247: ... 74HC574 D1 2 D2 3 D3 4 D4 5 D5 6 D6 7 D7 8 D8 9 CLK 11 OE 1 Q1 19 Q2 18 Q3 17 Q4 16 Q5 15 Q6 14 Q7 13 Q8 12 U24 74HC574 16 14 12 10 15 13 11 9 8 7 6 5 4 3 2 1 U22 PS2702 4 1 2 3 4 5 6 7 8 9 10 11 12 J1017 TERMBLOCK 12 12 13 11 U20D 74HC32 16 14 12 10 15 13 11 9 8 7 6 5 4 3 2 1 U26 PS2702 4 SHDN D 0 7 IOW DIGIO2 DIGIO3 VCC VCC B STATUS OUTPUTS DIGITAL OUTPUTS A STATUS OUTPUTS VCC D6 DIODE SCHOTTKY...

Page 248: ... 4 3 2 1 U19 PS2702 4 R7 2 2K 5 1 4 3 2 5 K3 RELAY SPDT Q1 SO2222 16 14 12 10 15 13 11 9 8 7 6 5 4 3 2 1 U18 PS2702 4 D1 2 D2 3 D3 4 D4 5 D5 6 D6 7 D7 8 D8 9 CLK 11 OE 1 Q1 19 Q2 18 Q3 17 Q4 16 Q5 15 Q6 14 Q7 13 Q8 12 U17 74HC574 1 2 3 4 5 6 7 8 9 10 11 12 13 14 J1008 TERMBLOCK 14 16 14 12 10 15 13 11 9 8 7 6 5 4 3 2 1 U16 PS2702 4 SHDN DIGIO0 D 0 7 IOW DIGIO4 VCC VCC 12V 12V 12V 12V 12VRET DIGITA...

Page 249: ...3 4 5 6 7 8 J1 HEADER 4X2 15V 15V IOUT IOUT VIN VIN 15 7 9 1 2 16 10 8 VS1 VS1 GND1 VS2 GND2 VS2 VIN VOUT U4 ISO124 VIN JP1 JUMPER2 12V 12V 12V 12V VS 1 0V 2 0V 5 VOUT 6 VOUT 7 SOUT 8 SIN 14 U1 DCP010515 C1 0 47 C2 0 47 C3 0 47 ISO_ 15V ISO_GND ISO_ 15V ISO_ 15V ISO_ 15V R1 4 75K R2 9 76K 3 2 6 1 8 7 4 U2 OPA277 C4 1000PF C5 220PF D1 1N914 ISO_ 15V ISO_ 15V VREF 15 SENSE 12 VRADJ 11 VIN 10 4 VREFI...

Page 250: ...WITCH TP2 VCC TP3 5_DISP TP6 DISP_PWR TP7 DISP_RET TP1 GND TP8 BUSY DISP_RET 5_DISP VCC DISP_BUSY DISP_PWR C2 1uF C13 10uF C3 1uF C8 220pF C9 220pF 5_DISP C4 1uF C14 100uF DISP_RET C10 220pF U1 C11 220pF C12 220pF DISP_RET C5 1uF U2 1 2 JP5 DISP_PWR_OVR DISP_PWR_EN must be high for display to be powered KBD_A0 KBD_A1 KBD_A2 DISP_DA_A0 DISP_DA_A1 DISP_DA_A2 DISP_CN_A0 DISP_CN_A1 DISP_CN_A2 SCL SDA ...

Page 251: ...SP_PWR TP7 DISP_RET TP1 GND TP8 BUSY DISP_RET 5_DISP VCC DISP_BUSY DISP_PWR C2 1uF C13 10uF C3 1uF C8 220pF C9 220pF 5_DISP C4 1uF C14 100uF DISP_RET C10 220pF U1 C11 220pF C12 220pF DISP_RET C5 1uF U2 1 2 JP5 DISP_PWR_OVR DISP_PWR_EN must be high for display to be powered KBD_A0 KBD_A1 KBD_A2 DISP_DA_A0 DISP_DA_A1 DISP_DA_A2 DISP_CN_A0 DISP_CN_A1 DISP_CN_A2 SCL SDA SCL SDA SCL SDA SPR_I O_1 SPR_I...

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Page 253: ...ohibited This document or any information contained in it may not be duplicated without proper authorization Schematics for PWB 04087 A 1 1 2 Apr 2002 LAST MOD B of CAC 4 30 01 04089 1 2 3 4 5 6 J2 R1 357 R4 2K R2 2K C1 1 0uF 5V TP1 TP2 R3 1 K R7 151K R8 150K R5 150K R6 150K 5V 5V 1 2 3 14 7 U1A MC74HC132A 4 5 6 14 7 U1B MC74HC132A 9 10 8 14 7 U1C MC74HC132A 12 13 11 14 7 U1D MC74HC132A O2 OPB804 ...

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