Teledyne 300M Instruction Manual Download Page 113

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Teledyne API Model 300M CO Analyzer Instruction Manual, 04033, Rev. A

11 ROUTINE MAINTENANCE

NOTE

The operations outlined in this chapter are to be

performed by qualified maintenance personnel only.

11.1 Model 300M Maintenance Schedule

The following are the recommended periodic maintenance items for the Teledyne API Model
300M CO Analyzer:

Table 11-1: Maintenance Schedule

Date Instrument Received _____________

Item

JAN

FEB MAR APR MAY JUN

JUL AUG

SEP

OCT NOV DEC

Recommended Action

Particulate
filter element

Replace weekly or as
needed

Pump
diaphragms

Replace every 12
months

Sample flow

Check for proper flow
(800cc/min

20%)

annually

Dark Cal

Perform annually as
needed, or after
adjusting R7 on Sync-
Demod board.

Pneumatic
lines

Examine and clean as
necessary

Leak Check

Leak Check after
maintenance or repair
and at least annually

Clean optical
bench

As needed

11-1

Summary of Contents for 300M

Page 1: ...RUMENTS ADVANCED POLLUTION INSTRUMENTATION DIVISION T API 6565 NANCY RIDGE DRIVE SAN DIEGO CA 92121 2251 TOLL FREE 800 324 5190 FAX 858 657 9816 TEL 858 657 9800 E MAIL api sales teledyne com WEB SITE www teledyne api com 04033 Revision A Copyright 2001 API Inc 1 15 01 ...

Page 2: ...n the manual and inside the instrument The definition of these symbols is described below GENERAL WARNING CAUTION Refer to the instructions for details on the specific danger CAUTION Hot Surface Warning CAUTION Electrical Shock Hazard TECHNICIAN SYMBOL All operations marked with this symbol are to be performed by qualified maintenance personnel only CAUTION The analyzer should only be used for the...

Page 3: ... Status Outputs Optional 1 11 1 6 4 RS 232 1 12 1 6 5 Pneumatic System 1 12 1 6 6 Sample Gas Connection 1 13 1 6 7 Zero Span Valve Connections 1 13 1 6 8 Exhaust Connections 1 13 1 7 OPERATION VERIFICATION 1 15 1 8 OPTIONS 1 17 1 8 1 Rack Mount With Slides 1 17 1 8 2 Span Valve 1 17 2 OPERATION 2 1 2 1 KEY FEATURES 2 1 2 1 1 CO Readout 2 1 2 1 2 CO Analog Output 2 1 2 1 3 E2 ROM Backup Of Software...

Page 4: ...E AND OFFSET 4 1 4 3 SETTING THE TIME OF DAY 4 2 4 4 SETTING THE DATE 4 2 4 5 ADJUSTING THE CLOCK SPEED 4 2 4 6 SETTING THE CO CONCENTRATION RANGE 4 3 4 6 1 Single Range Mode SNGL 4 3 4 6 2 Dual Range Mode DUAL 4 3 4 6 3 Auto Range Mode AUTO 4 3 4 7 SETTING THE ANALOG OUTPUT OFFSET 4 4 4 8 SETTING THE RS 232 BAUD RATE 4 4 4 9 SETTING THE ANALYZER I D 4 4 4 10 DISABLING THE CALIBRATION PASSWORD 4 4...

Page 5: ...2 10 2 2 Checking the CPU and Display 10 3 10 2 3 Checking the Keyboard 10 3 10 3 TROUBLESHOOTING USING WARNING MESSAGES 10 3 10 4 TROUBLESHOOTING USING TEST FUNCTION VALUES 10 5 10 5 TROUBLESHOOTING DYNAMIC PROBLEMS 10 7 10 5 1 Noisy or Unstable Readings at Zero 10 7 10 5 2 Noisy Unstable or Non Linear Span Readings 10 7 10 5 3 Slow Response to Changes in Concentration 10 7 10 5 4 Analog Outputs ...

Page 6: ...NG 11 2 11 3 1 Using a Leak Checker 11 2 11 3 2 Leak Self Test 11 3 12 SPARE PARTS LISTS 12 1 12 1 SPARE PARTS FOR CE MARK UNITS 12 1 12 2 MODEL 300M EXPENDABLES KIT 12 2 12 3 MODEL 300M SPARE PARTS KIT FOR ONE UNIT 12 2 12 4 MODEL 300M LEVEL 1 PARTS KIT FOR TEN UNITS 12 3 APPENDIX A TIPS ON CONNECTING THE TELEDYNE API ANALYZER RS 232 INTERFACE A 1 APPENDIX B ELECTRICAL DRAWING INDEX B 1 vi ...

Page 7: ...CAL PNEUMATIC CONNECTIONS 1 10 FIGURE 1 4 REAR PANEL 1 14 FIGURE 2 1 MODEL 300M FRONT PANEL 2 4 FIGURE 2 2 ILLUSTRATION OF NORMAL DISPLAY 2 8 FIGURE 8 1 GAS GENERATION SYSTEM 8 2 FIGURE 8 2 INLET VENTING RECOMMENDATIONS 8 2 FIGURE 9 1 M300M ELECTRICAL BLOCK DIAGRAM 9 2 FIGURE 10 1 OPTO PICKUP WAVEFORM 10 16 FIGURE 10 2 DETECTOR WAVEFORM 10 16 FIGURE A 1 RS 232 PIN ASSIGNMENTS A 1 vii ...

Page 8: ... CONTINUED 5 4 TABLE 5 2 I O SIGNALS CONTINUED 5 5 TABLE 5 2 I O SIGNALS CONTINUED 5 6 TABLE 5 3 M300M VARIABLES 5 7 TABLE 7 1 RS 232 PORT SETUP FRONT PANEL 7 1 TABLE 7 2 RS 232 MESSAGE TYPES 7 2 TABLE 7 3 RS 232 WARNING MESSAGE CLEAR COMMANDS 7 5 TABLE 7 4 STATUS REPORTS 7 6 TABLE 7 5 CONTROL COMMANDS 7 7 TABLE 7 6 DIAGNOSTIC COMMANDS 7 8 TABLE 7 7 DIAGNOSTIC REPORTS 7 8 TABLE 7 8 TEST MEASUREMEN...

Page 9: ...ailable COVERAGE After the warranty period and throughout the equipment lifetime Teledyne API stands ready to provide on site or in plant service at reasonable rates similar to those of other manufacturers in the industry All maintenance and the first level of field troubleshooting is to be performed by the customer NON TELEDYNE API MANUFACTURED EQUIPMENT Equipment provided but not manufactured by...

Page 10: ...IED WARRANTIES OF MERCHANTABILITY FITNESS FOR PARTICULAR PURPOSE OR OTHER WARRANTY OF QUALITY WHETHER EXPRESSED OR IMPLIED THE REMEDIES SET FORTH IN THIS SECTION ARE THE EXCLUSIVE REMEDIES FOR BREACH OF ANY WARRANTY CONTAINED HEREIN TELEDYNE API SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES ARISING OUT OF OR RELATED TO THIS AGREEMENT OF TELEDYNE API S PERFORMANCE HEREUNDER WHETHE...

Page 11: ... in a beam which is unaffected by any CO in the Sample Cell During the Measure pulse the Nitrogen in the filter wheel does not affect the beam which can subsequently be absorbed by any CO in the sample cell The Gas Filter wheel also incorporates an optical chopping mask which superimposes a 180 Cycles Second Light Dark modulation on the IR Beam This high frequency modulation is used to maximize de...

Page 12: ...Teledyne API Model 300M CO Analyzer Instruction Manual 04033 Rev A Figure 1 1 Pneumatic Diagram 1 4 ...

Page 13: ...ise Fall Time 95 60 sec to 95 Sample Flow Rate 800cc min 10 Temperature Range 5 40 C Humidity Range 0 95 RH non condensing Dust Sample must be dust free Temp Coefficient 0 5 PPM per C Voltage Coefficient 0 5 PPM per Volt Dimensions HxWxD 7 x 17 x 25 178 mm x 432 mm x 635 mm Weight 50 lbs 22 7 kg Power 100 50 60 Hz 115 60 Hz 220V 50 60 Hz 240 V 50 Hz 250 Watts Power CE 230 V 50 Hz 250 Watts Recorde...

Page 14: ... allow a minimum of 4 inches 10 cm of clearance at the back of the instrument and 1 inch 2 5 cm of clearance on each side for proper ventilation Also be sure that the clearance below the chassis is unobstructed by at least the height of the instrument feet 4 Connect sample inlet line to the sample port on rear panel NOTE See Figure 1 3 for rear panel pneumatic connections Sample gas should only co...

Page 15: ...se values to those noted during the final factory checkout listed in Table 1 2 The values observed should closely match the Table 1 2 values 9 Select the range on which the analyzer will be calibrated A From the SAMPLE menu press SETUP to enter the SETUP menu See Figure 2 2 for appearance of front panel B Enter the PASSWORD 818 C Press RNGE RANGE D Press SET E Enter the derived full scale range fo...

Page 16: ...nalyzer B Go to manual calibration by pressing the CAL button while in the sample mode C Enter the operator password 818 D The menu should now show SPAN CONC and EXIT Enter the concentration of the CO calibration gas by pressing CONC and entering the value from the keyboard E Wait 10 minutes for a stable reading to be attained and then press SPAN followed by ENTR If the SPAN button is not displaye...

Page 17: ...Teledyne API Model 300M CO Analyzer Instruction Manual 04033 Rev A Figure 1 2 Carbon Monoxide Analyzer 1 9 ...

Page 18: ...Teledyne API Model 300M CO Analyzer Instruction Manual 04033 Rev A Figure 1 3 Rear Panel Electrical Pneumatic Connections 1 10 ...

Page 19: ...teristics Output 3 is the same as 1 and 2 electrically but has analog TEST function signals routed to it See Diagnostics in Section 5 for details 1 6 2 Remote Contact Closures Zero Span Inputs Remote contact closures can be used to remotely energize the zero span valves to do a zero or span check The external contact closure should be capable of switching 12 VDC at 50 ma Refer to Figure 1 3 for co...

Page 20: ...nto high range 9 17 18 FLOW ALARM True if a flow warning exists 10 19 20 RESERVED 11 21 22 SOURCE WARNING True if the analyzer source intensity is out of limits 12 23 24 RESERVED 1 6 4 RS 232 The RS 232 connection is a male 9 pin D sub connector at the location shown in Figure 1 3 See also Appendix A for additional information 1 6 5 Pneumatic System The Model 300M is equipped with a vacuum pump ca...

Page 21: ... gas manifolds should supply their respective gases in excess of 800cc min demand of the analyzer The manifold should be vented to the outside atmosphere and be of sufficient length and diameter to prevent back diffusion and pressure effects See Figure 1 4 1 6 8 Exhaust Connections A single 1 4 O D tube should be connected from the analyzer sample exhaust to an area outside of the room the analyze...

Page 22: ...Teledyne API Model 300M CO Analyzer Instruction Manual 04033 Rev A Figure 1 4 Rear Panel Pneumatic Connections 1 14 ...

Page 23: ... button labeled TEST Not every TEST function is a diagnostic of correct analyzer operation therefore TEST functions not covered below can be ignored for now 4 CO REF CO MEAS TEST function values should be between 2500 mV and 4700 mV 5 Pressure 29 to 30 Inches Mercury Absolute at sea level Other values will be displayed depending on altitude of analyzer 6 Sample Flow 800 cc min 20 7 Sample Temp Amb...

Page 24: ...DC POWER SUPPLY mV 2500 200 SAMPLE TEMP C 45 50 BOX TEMP C 8 40 WHEEL TEMP C 68 2 Diagnostic Dark Ref mV 125 50 Dark Meas mV 125 50 Electrical test PPM 400 4 Span and CAL Values CO Span Conc PPM 400 CO Slope 1 0 0 3 CO Offset 0 1 to 0 1 Noise at Zero p p PPM 0 5 Noise at Span p p PPM 1 0 of reading Factory Installed Options Option Installed Factory Installed Options Option Installed Power Voltage ...

Page 25: ...e or by remote contact closure A span gas manifold should supply at least 1000 cc min The manifold should be vented to the outside atmosphere away from the personnel A span gas manifold can be connected to the analyzer in either of two ways 1 If it is desired to use span gas directly from a pressurized source e g a gas cylinder the connection can be made directly to the Pressure Span port on the a...

Page 26: ...Teledyne API Model 300M CO Analyzer Instruction Manual 04033 Rev A INTENTIONALLY BLANK 1 18 ...

Page 27: ...n addition TEST function values can be routed to a third analog output 2 1 3 E2 ROM Backup Of Software Configuration The Teledyne API CO Analyzer has a few jumpers that need to be set by the operator Configuration of the analyzer is done under software control and the configuration options are stored in electrically erasable E2 ROM Thus configuration options are saved even when the analyzer is pow...

Page 28: ...r computer to control the analyzer Refer to Appendix Figure A 1 or Appendix A for details on the RS 232 interface 2 1 7 Password Protection The M300M CO Analyzer provides password protection of the calibration and setup functions to prevent incorrect adjustments to the analyzer There are two levels of passwords which correspond to operator supervisor maintenance and analyzer configuration function...

Page 29: ...The front panel consists of a 2 line by 40 character alphanumeric display 8 push buttons and 3 status LED s Each of these features is described below 2 2 1 Front Panel Display The display is divided into 4 main fields the mode field in the upper left the message field in the top center the sample concentration field consisting of the most recent instantaneous Carbon Monoxide value field in the upp...

Page 30: ... only be performed by pressing the buttons on the front panel labeled CALZ CALS or CAL Automatic span check only occurs at the preset time Dynamic span adjust can be performed during automatic or remote span checks Remote span adjustment is performed via a command from the RS 232 or the external contact closure inputs Calibration and span adjustments are discussed in greater detail in Section 3 1 ...

Page 31: ...ition configuration DIAG I O 4 Test digital I O signals DIAG AOUT 4 Test analog output channels DIAG D A 4 Configure and Calibrate Digital to Analog converters DIAG TCHN 4 Configure Test Channel output 1 x A auto 2 x M manual A auto R remote 3 xxx software revision e g A 9 4 diagnostic test modes The message field shows test measurements or warning messages Table 2 3 and Table 2 4 summarize the te...

Page 32: ... mV MR RATIO X XXX Ratio of the Reference and Measure values AZERO OFFS x xxxxx Autozero offset PRES xxx IN HG A Absolute sample pressure inches Hg VAC xxx IN HG A Absolute vacuum pressure inches Hg SAMPLE FL xxx CC M Sample flow through analyzer cc min SAMPLE TEMP xxx C Temperature in the absorption cell BENCH TEP xxx C Optical Bench Temperature WHEEL TEP xxx C Filter Wheel Temperature BOX TEMP x...

Page 33: ...N ZERO CO offset 1500 or 1500 mV CANNOT DYN SPAN CO slope 0 5 or 2 0 V F NOT DETECTED A D I O card not installed or bad SYNC WARNING No modulation on detector output DCPS WARNING The menu field changes depending on the mode of the analyzer and the buttons that have been pressed It indicates the current function of each of the 8 push buttons below the display See Section 2 2 2 for information on us...

Page 34: ...r center display Pushing CLR will erase a message provided the condition causing the message has ceased Pushing SETUP changes the function of the push buttons and is used for setting basic parameters as described in Section 4 2 2 3 Status LED s The three status LED s to the right of the display indicate the general status of the Model 300M Analyzer The green SAMPLE LED indicates the sampling statu...

Page 35: ...inking Not monitoring DAS Disabled Monitoring normally taking DAS data Monitoring HOLD OFF mode on no data to DAS 1 Yellow Off On Blinking Auto Cal disabled Auto Cal enabled Calibrating Red Off Blinking No warnings exist Warnings exist 1 This occurs during calibration holdoff power up holdoff and when in Diagnostic mode 2 9 ...

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Page 37: ...an set points of the analyzer while in sample mode by allowing the instrument to sample calibration gas and pressing the CAL button This is also referred to as a multi point calibration 3 1 1 Zero Check Allow the analyzer to sample zero air through the sample port Press CAL button After a few minutes the CO reading should go to zero If it doesn t the operator may press the ZERO button followed by ...

Page 38: ...o read the correct value To do this press CONC and enter the expected concentration of the calibration gas The SPAN button should now be displayed on the front panel Pressing SPAN and ENTER will modify the internals formulas used to compute the CO reading If the SPAN button is not displayed this means that the span reading is too far out of adjustment to do a reliable calibration The reason for th...

Page 39: ...of how to calibrate the two ranges with calibration gas coming in through the sample port Step Action Comment 1 Press CAL Analyzer enters M P calibration mode Calibration gas source should be set to deliver zero gas to the sample port 2 Press LOW ENTR Select range to calibrate 3 Wait 15 min Wait for CO reading to stabilize at zero value 4 Press ZERO ENTR Changes calibration equations for Low range...

Page 40: ... may press the SPAN button followed by ENTR The expected span gas concentration may be changed by pressing the CONC button 3 3 Zero Span Valves Option If the Zero Span Valves option has been installed the operator can check the zero and span setpoints of the analyzer at any time by pressing the CALZ or CALS button Refer Figure 1 1 M300M flow diagram with Zero Span valves and AUTOZERO Note that bot...

Page 41: ...sired sequence and press the MODE button Use the PREV and NEXT buttons to select one of the modes shown below and press ENTR Mode 1 DISABLED Sequence is disabled 2 ZERO 3 SPAN 4 ZERO SPAN To change the setup parameters for a sequence press the SET button Pressing the SET and SET buttons allows you to scroll through the setup parameters and edit them by pressing the EDIT button The function of each...

Page 42: ...ime for the sequence by 15 minutes each day If you want to have the sequence run at the same time every day simply set the delta time to zero NOTE Avoid setting two or more sequences at the same time of the day Any new sequence which is initiated whether from a timer the RS 232 or the contact closure inputs will override any sequence which is in progress Duration The duration of each step of the s...

Page 43: ...TA TIME 00 00 7 DURATION 15 8 CALIBRATE OFF Example 2 To perform a 15 min zero span check once per day retarding 15 minutes everyday starting at 11 30 PM 12 20 93 1 MODE ZERO SPAN 2 TIMER ENABLED ON 3 STARTING DATE 12 20 93 4 STARTING TIME 23 30 5 DELTA DAYS 0 6 DELTA TIME 23 45 7 DURATION 15 8 CALIBRATE OFF Example 3 To perform span check once per week starting at 11 30 PM 12 20 93 1 MODE SPAN 2 ...

Page 44: ...ms of the button sequences used to access them Table 3 1 Calibration Controls Button Sequence Function Default Limits CALZ Begin zero check CALZ ZERO ENTR Adjust CO conc to zero CALZ EXIT Exit zero check CALS Begin span check CALS CONC ENTR Expected CO span value 400 PPM 1 20000 PPM CALS SPAN ENTR Adj CO conc to span val CALS EXIT Exit span check CAL Begin M P cal CAL ZERO ENTR Adj CO conc zero va...

Page 45: ... and a positive transition is detected on EXT_SPAN_CAL then the instrument will immediately go into span check To perform a zero check followed by a span check first generate a positive transition on EXT_ZERO_CAL and then when you want to do the span check generate a positive transition on EXT_SPAN_CAL The remote calibration signals may be activated in any sequence providing a virtually unlimited ...

Page 46: ... the analyzer See Section 7 for detailed information on using the RS 232 interface to do a remote Z S check 3 8 Power On Hold Off Whenever the Model 300M is powered on it will go through a HOLD OFF sequence see Section 3 9 like it does after a zero span check 3 9 Hold Off Every type of check or adjustment zero span manual remote etc is followed by a hold off period of from 1 to 20 minutes during w...

Page 47: ...are set only during zero and span calibration routines These parameters are used to adjust the span and zero values to their exact values The current value of the Carbon Monoxide reading that is displayed on the front panel and output on the D A terminals on the back panel is computed as follows 1 Every 160 msec the analyzer takes a CO MEAS reading i e a reading of the detector output with the IR ...

Page 48: ...the current date press SETUP CLK DATE The CPU will display the current date as DD MMM YY For example April 1 1999 would be displayed as 0 1 APR 9 9 Change the date by pressing the button under each field until the desired date is shown Then press ENTR to accept the new date or press EXIT to leave the date unchanged 4 5 Adjusting the Clock Speed In order to compensate for clock which run a little b...

Page 49: ...h range To set the ranges press SETUP RNGE SET and select which range you want to edit followed by ENTR The High and Low ranges have separate slopes and offsets for computing the Carbon Monoxide concentration Therefore the two ranges must be independently calibrated See Section 3 1 3 for details on calibrating the two ranges 4 6 3 Auto Range Mode AUTO In auto range mode the analyzer automatically ...

Page 50: ...rt recorder or other instrument 4 8 Setting the RS 232 Baud Rate To set the baud rate for the RS 232 channel press SETUP MORE COMM BAUD Press 300 1200 2400 4800 9600 or 19 2 followed by ENTR to accept the new baud rate or EXIT to leave the baud rate unchanged 4 9 Setting the Analyzer I D Each analyzer may be programmed with a unique I D number that appears on all RS 232 messages To set the analyze...

Page 51: ...tion can be requested from Teledyne API 4 11 1 Data Channels The function of the Data Channels is to store report and view data from the analyzer The data may consist of Carbon Monoxide concentration or may be diagnostic data such as the sample flow or detector output The M300M comes pre programmed with a set of useful Data Channels for logging Carbon Monoxide concentration and predictive diagnost...

Page 52: ...ed The last 360 daily averages about 1 year are stored CALDAT Logs new slope and offset every time a zero or span calibration is performed This Data Channel also records the instrument reading just prior to performing a calibration NOTE This Data Channel collects data based on an event a calibration rather than a timer This Data Channel will store data from the last 200 calibrations This does not ...

Page 53: ...lyzer is in the calibration mode Press CAL button prior to introducing span gas into the analyzer There are two types of alarms called Hi ALARM and HiHi ALARM The user can change the setting of each of the alarm concentration limit Press SETUP MORE ALRM then select either ALM1 or ALM2 and toggle ON OFF followed by ENTR When the concentration entry field is shown enter the desired limit concentrati...

Page 54: ... PPM SETUP RNGE UNIT Set Measurement Units PPM PPM mg m3 ug m3 SETUP PASS Password Enable ON OFF ON SETUP CLK TIME Set Time of Day 00 00 00 00 23 59 SETUP CLK DATE Set Current Date 01 JAN 00 31 DEC 99 SETUP MORE COMM BAUD RS 232 baud rate 2400 baud 300 1200 2400 4800 9600 19 2 SETUP MORE COMM ID Analyzer ID number 0000 0000 9999 SETUP MORE VARS DAS_HOLD_OFF Set Hold Off Interval 15 min 1 60 min SE...

Page 55: ...librate D A and A D Converters N A N A SETUP MORE DIAG ELECTRICAL TEST Generate Electrical Test Output N A N A SETUP MORE DIAG DARK CALIBRATION Adjust Dark Offset 125mV 75 175 mV SETUP MORE DIAG FLOW CALIBRATION Calibrate sample flowrate 800 cc m 800 cc m SETUP MORE DIAG TEST CHAN OUTPUT Select TEST to Analog Output None SETUP MORE DIAG RS 232 OUTPUT Generate RS 232 Output Test Pattern N A N A SET...

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Page 57: ...of the Model 300M or the Carbon Monoxide reading in any way so they may be viewed freely NOTE If the value of any test function is displayed as XXXX this indicates that the reading is off scale or otherwise non valid Additionally the values of most TEST functions can be output as an analog voltage at the instrument s rear panel see Figure 1 3 The TEST function to be output is selected by pressing ...

Page 58: ...f a diagnostic test The PREV button goes to the previous diagnostic test When pressed the CPU turns the current diagnostic test OFF if it is ON The NEXT button goes to the next diagnostic test When pressed the CPU turns the current diagnostic test OFF if it is ON The EXIT button exits the diagnostic mode and turns all the diagnostic tests OFF This ensures that a diagnostic test is not accidentally...

Page 59: ...WNOUT NO Display brownout is used to keep the display from getting corrupted during low line voltage conditions Circuitry on the Power Supply board 00015 senses low line voltage and sets this bit The CPU reads this and generates the BROWNOUT_RESET signal described below 1 EXT_ZERO_CAL NO Shows state of status input bit to cause the M300M to enter Zero Calibration mode Use to check external contact...

Page 60: ...gh M300M in alarm 1 mode Logic low Not in alarm 1 mode 13 ST_CONC_ALARM_2 YES Status Bit gas alarm 2 Logic high M300M in gas alarm 2 Logic low Not in alarm 2 mode 14 ST_FLOW_ALARM YES Status Bit Flow alarm Logic High Sample flow out of spec Logic Low Flows within spec 15 ST_TEMP_ALARM YES Status Bit Temperature alarm Logic High One or more temps out of spec Logic Low Temps within spec 16 ST_DIAG_M...

Page 61: ...ce Alarm Logic High IR Source output too low Logic Low IR Source output normal 23 ST_WHEEL_ALARM YES Status Bit Wheel Temperature Alarm Logic High Wheel Temp out of spec Logic Low Wheel Temp in spec 24 CO_MEASURE NO IR detector reading during measure phase Typically 2500 4500 mV 25 CO_REFERENCE NO IR detector reading during reference phase Typically 2500 4500 mV 26 SAMPLE_PRESURE NO Sample pressur...

Page 62: ... and displaying a 0 button Then every five seconds the output is increased 20 FS and the button is changed accordingly Thus the button and the analog outputs will cycle through the following value 0 20 40 60 80 100 0 To pause the output at the current voltage press the n button To resume automatic cycling press the n button again 5 2 3 Electric Test This test activates a diagnostic circuit located...

Page 63: ...ETUP VARS ENTR Use the PREV NEXT button to select the variable of interest and press EDIT to examine change the value then press ENTR to save the new value If no change is required press EXIT Table 5 3 M300M Variables No Name Units Default Value Value Range Description 0 DAS_HOLD_OFF MIN 15 0 20 DAS hold off duration after calibration or diagnostic 1 DYN_ZERO OFF OFF ON Enable to adjust zero calib...

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Page 65: ...if there are no more warning messages remaining the MSG and CLR buttons will disappear and the FAULT LED will be turned OFF If after pressing CLR warning messages still exist the FAULT LED will continue to blink and the MSG and CLR buttons will remain on the menu line If after clearing a message the warning condition for that message still exists the message will reappear after a period of time wh...

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Page 67: ...et the RS 232 mode bit field in the VARS menu To get to the variable press SETUP MORE VARS ENTR and scroll to RS232_MODE then press EDIT The possible values are Table 7 1 RS 232 Port Setup Front Panel Decimal Value Description 1 Turns on quiet mode messages suppressed 2 Places analyzer in computer mode no echo of chars 4 Enables Security Features Logon Logoff 8 Enables RS 232 menus display on M300...

Page 68: ...hich terminates the message and also makes the messages appear neatly on a printer Input messages to the Model 300M have a format which is similar to that for output messages X COMMAND CRLF The X indicates the message type as shown above in Table 7 2 and COMMAND is the command type each of which is described individually below The CRLF is used to terminate the command Typing CRLF a few times by it...

Page 69: ...th of the message only one data point may be printed per line Compact Data Report Format The compact format looks like the following D 31 10 06 0412 CONC 1 6 8 The fields up to the colon are the same as for the verbose format but the next fields are different The fields following the colon are the line number 1 in the example and the data point value 6 8 Presumably the user or remote computer know...

Page 70: ...ally valid The message format is W DDD HH MM IIII WARNING MESSAGE CRLF An example of an actual warning message is W 194 11 03 0000 SAMPLE FLOW WARN CRLF Warnings may be cleared via the RS 232 interface by issuing a command of the form W COMMAND CRLF Where COMMAND indicates which warning message to clear For example to clear the SAMPLE FLOW WARN message the host computer can issue the command W WSM...

Page 71: ...SOURCE WARNING W WSUTOZERO CRLF AUTOZERO WARNING W WBENCHTEMP CRLF BENCH TEMP WARNING W WWHEELTEMP CRLF WHEEL TEMP WARNING W WSAMPFLOW CRLF SAMPLE FLOW WARNING W WSAMPPRESS CRLF SAMPLE PRESSURE WARNING W WASMPTEMP CRLF SAMPLE TEMP WARNING W WBOXTEMP CRLF BOX TEMP WARNING W WSYNC CRLF SYNC WARNING W WDCPS CRLF DCPS WARNING W WDYNZERO CRLF CANNOT DYN ZERO W WDYNSPAN CRLF CANNOT DYN SPAN W WVFDET CRL...

Page 72: ...Table 7 4 Status Reports Report C DDD HH MM IIII START ZERO CALIBRATION C DDD HH MM IIII FINISH ZERO CALIBRATION C DDD HH MM IIII START SPAN CALIBRATION C DDD HH MM IIII FINISH SPAN CALIBRATION C DDD HH MM IIII START MULTI POINT CALIBRATION C DDD HH MM IIII FINISH MULTI POINT CALIBRATION C DDD HH MM IIII START CALIBRATION HOLD C DDD HH MM IIII FINISH CALIBRATION HOLD To do a remote adjustment via ...

Page 73: ...l only C EXIT CRLF Exit zero span or hold 1 Executed only if the instrument is in the proper calibration mode and concentration is within calibration limits This command adjusts slope and offset values 2 Initiated only If automatic calibration sequence setup is programmed and enabled NOTE The commands in Table 7 5 can only be entered via the RS 232 port when the analyzer is in the sample mode When...

Page 74: ...e D ENTER SIG before using this command NOTE The diagnostics mode may only be entered via the RS 232 port when the analyzer is in sample mode These commands may be used whether the diagnostics have been entered from the keyboard SETUP DIAG or the RS 232 D ENTER CRLF However when the diagnostics are entered via the keyboard no feedback is sent to the RS 232 channel This prevents the RS 232 output f...

Page 75: ...PU will send the current value of the test measurement to the RS 232 output The format of the test measurement message is T DDD HH MM IIII TEST MEASUREMENT CRLF For example the format of the DC Power Supply output in mV would be T 194 11 29 0000 DCPS 2500 MV CRLF To request a test measurement the host must issue a command of the form T MEASUREMENT CRLF For a summary of all test functions issue the...

Page 76: ...mV T COREF CRLF Current CO REF mV T MRRATIO CRLF Current MR RATIO T SAMPPRESS CRLF Sample pressure T VACUUM CRLF Vacuum pressure T SAMPFLOW CRLF Sample flow rate T SAMPTEMP CRLF Sample temperature T BENCHTEMP CRLF Optical Bench temperature T WHEELTEMP CRLF Filter Wheel temperature T BOXTEMP CRLF Internal box temperature T DCPS CRLF DC power supply output T COSLOPE CRLF Slope value T COOFFSET CRLF ...

Page 77: ...ome variables do not have warning limits DATALO and DATAHI are the low and high data entry limits respectively and are given for all variables The CPU will not set a variable s value or warning limits to values that are outside of the data entry limits For example to see the optical bench temperature set point the host computer would issue the command V BENCH_SET CRLF the CPU would respond with so...

Page 78: ...le to change the instrument ID the host computer would issue a command like this V MACHINE_ID 1234 CRLF and the CPU should respond with V DDD HH MM IIII MACHINE_ID 1234 0 9999 CRLF Table 7 9 lists the variable names that are variable through the RS 232 interface and their corresponding button sequences Table 7 9 RS 232 Variable Names Variable Name Button Sequence Legal Values MACHINE_ID SETUP MORE...

Page 79: ...nstable operation or at worst water contamination in the cell Calibration gas concentrations must be generated from an NIST traceable cylinder of CO in air Carrier air for transporting the CO must be the same as the zero air A suggested calibration gas generating system is shown in Figure 8 1 The materials in the calibration gas delivery system should be stainless steel TFE and FEP Teflon The syst...

Page 80: ...Teledyne API Model 300M CO Analyzer Instruction Manual 04033 Rev A Figure 8 1 Gas Generation System Figure 8 2 Inlet Venting Recommendations 8 2 ...

Page 81: ... min Qa of 800 cc min D of 188 inches L approximately 72 8 2 Multi Point Calibration Multi point calibration requires seven approximately equally spaced calibration points including zero using an NIST traceable CO source The calibration must be carried out 1 After maintenance 2 Every three months recommended CAUTION The test gas must be introduced into the analyzer through the sample inlet port Al...

Page 82: ...8 1 and Figure 8 2 for vent flow calculation 3 Pre calculate the calibrator flow to be sure that a CO concentration of 80 of URL upper range limit can be produced with enough surplus flow to provide an adequate vent flow 4 Connect the analyzer REC recorder terminals to a calibrated strip chart recorder For best accuracy connect a DVM to the same terminals or to the DAS Data Acquisition System term...

Page 83: ... evenly spaced CO concentrations into the manifold to complete the manual calibration 22 Record all calculated CO concentrations DVM reading and strip chart recorder readings or RS 232 output readings 23 Plot the calculated CO concentrations X axis versus output voltages and or percentage chart readings Y axis Calculate the curve equations CO PPM Volts b m where b is the offset should be within 0 ...

Page 84: ... 4 Dirt in the manifold 5 Proper manifold venting 6 Zero air system If none of these help see the TROUBLESHOOTING SECTION 10 Record all the analyzer setup data from the display Range DCPS Box Temp Wheel Temp Bench Temp Sample Temp Sample Flow Sample Pressure Vacuum Pressure MR ratio Measure reference ratio CO Reference CO Measure These data can be useful in future troubleshooting 8 6 ...

Page 85: ...00M daily zero and span checks are easy For Automatic Zero Span Check and Remote Zero Span Check to be effective it is necessary that the analyzer have the Zero Span valve option This option includes the two three way stainless steel valves and requires user supplied sources of zero air and span gas delivered at ambient pressure Operating instructions for Automatic Zero Span Check and Remote Zero ...

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Page 87: ...12 v and 5 v DC power to the analyzer Also four temperature linearization circuits for the bench temperature sample temperature box temperature and the gas wheel temperature are located on the power supply board Each circuit is a Whetstone bridge with the measuring thermistor being one leg A feedback circuit performs the required linearization Zero adjust pots have been factory set and no field ad...

Page 88: ...Teledyne API Model 300M CO Analyzer Instruction Manual 04033 Rev A Figure 9 1 M300M Electrical Block Diagram 9 2 ...

Page 89: ...ween TP3 AGND and TP9 DAC 0 on the top of the V F card See Drawing 00514 Appendix C 5 The value displayed by the voltmeter should be close 2 mV to the value on the M300M display If they are not close then the V F card has probably been configured improperly 6 Adjust the Zero pot R27 on the V F card until the value on the M300M display matches the value on the voltmeter to within 2 mV NOTE When adj...

Page 90: ...CFG and scroll by pressing NEXT to select current output channel 1 press SET CURR ENTR to define current output channel Press EXIT Now channel 1 is defined as current output 3 Press CAL to start the current output calibration The M300M display will read CAL CONC_OUT_1 CURR ZERO where CURR means current output and ZERO means zero analog output calibration Press UP UP10 U100 or DOWN DN10 D100 button...

Page 91: ...tput to the processing electronics to the processing electronics The average CO MEAS and CO REF dark reading are stored as offsets which are subtracted from all future CO detector readings Press SETUP MORE DARK VIEW to view the current dark offset Typical dark offset value is 125 50 mV Press EXIT when finished No password is required to view the dark offset only to change it 9 4 Output Voltage Ran...

Page 92: ...et B Check the readings of VAC or PRES of the TEST functions C Check if the pressure readings are close to the current absolute ambient pressure typical value at sea level is 29 9 in Hg Notice that it must be absolute pressure reading Check if both readings do not differ more than 2 from each other Replace the pressure flow sensor board if defective 2 Check Flow rate To check the sample flow proce...

Page 93: ...m the value recorded in Table 1 1 of this manual under Test Values the outputs of the individual regulators should be measured Test points 1 2 3 and 4 provide connection to the temperature outputs on drawing no 00016 in Appendix C 9 7 CPU If the display is operating and the green sample light is on the CPU should be operating If not check for 5 v to the CPU Refer to Section 10 6 4 Checking DC powe...

Page 94: ...Teledyne API Model 300M CO Analyzer Instruction Manual 04033 Rev A INTENTIONALLY BLANK 9 8 ...

Page 95: ...on and resolution of a problem A systematic approach to troubleshooting will generally consist of the following four steps performed in order 1 Confirm the proper operation of fundamental instrument sub systems Power Supplies CPU Display 2 Note any warning messages and take corrective action as required 3 Examine the values of all TEST functions and compare to factory values Note any major deviati...

Page 96: ...actions fail to occur power and or CPU operation should be checked as follows 10 2 1 Checking the Power Sub Systems WARNING Hazardous voltages exist within the instrument chassis use caution 1 Check incoming line power for proper Voltage and Frequency 2 Check the Circuit breaker on the analyzer s rear panel 3 Check the 3 wire safety power input plug on the analyzer s rear panel 4 Check for proper ...

Page 97: ...oard should cause a change of display modes If it does not check 1 Cable connections 2 CPU and Display operation see Section 10 2 2 If these checks are satisfactory it is probable that the keyboard is defective and should be replaced 10 3 Troubleshooting Using Warning Messages The most common and or serious instrument failures will result in a warning message or messages being displayed on the fro...

Page 98: ...LOW WARNING The sample flow is less than 500 cc min or greater than 1200 cc min Check for pneumatic system problems as described in Section 10 6 1 Check for flow transducer problems as described in Section 10 6 5 BOX TEMP WARNING The inside chassis temp is less than 10 C or is greater than 50 C See Section 10 6 2 SAMPLE TEMP WARNING The Sample Temperature is less than 10 C or is greater than 50 C ...

Page 99: ...ese Test Functions can be accessed by depressing the TEST Button on the instrument s front panel causing the next test function to be displayed By comparing the values of Test Functions to acceptable operating limits it is possible to quickly isolate and correct most problems Table 10 2 provides a list of available Test Functions along with their meaning their range of acceptable values and the re...

Page 100: ...S values as described above PRES The absolute pressure of the sample gas in the absorption cell 0 1 0 Hg below ambient pressure Check for pneumatic system problems See Section 10 6 1 Check for pressure transducer problems See Section 10 6 5 SAMPLE FLOW Sample flow rate 700 900 sec min Check for pneumatic system problems See Section 10 6 1 Check for flowmeter problems See Section 10 6 5 SAMPLE TEMP...

Page 101: ... 2 Confirm that the Zero gas is free of Carbon Monoxide 3 Check for a dirty particulate filter and replace as necessary as described in Section 11 2 10 5 2 Noisy Unstable or Non Linear Span Readings 1 Check for leaks in the pneumatic systems as described in Section 11 3 2 Check for a dirty particulate filter and replace as necessary see Section 11 2 3 Check for dirty pneumatic system components an...

Page 102: ...n or replace as necessary 4 Check for proper adjustment of DAC and ADC electronics by performing the adjustment procedure in Section 9 2 5 Confirm the sample temperature sample pressure and sample flow readings are correct Check and adjust as required 10 6 Troubleshooting Individual Sub Assemblies and Components The following sections provide troubleshooting check out methods for the specific sub ...

Page 103: ...o the pump If the pump does not operate with 115V present at its terminal replace the pump Check for plugged pneumatic lines filters or orifices 2 If the pump is over heated due to the line voltage exceeding 119 VAC etc or high ambient temperature it will run intermittently causing flow failure Low Flow 1 Check for leaks as described in Section 11 3 Repair and re check 2 Check for dirty sample fil...

Page 104: ...emperature readings appear to be incorrect check for proper thermistor operation by measuring the resistance of the thermistor s This resistance should be in the range of 7 6K ohms to 95 ohms If it is not the thermistor is defective and should be replaced Points for measuring thermistor resistance are as follows Sample Temperature Unplug the connector at Motherboard J2 and measure across the leads...

Page 105: ...hematic and physical diagram of the V F card are shown on Drawings 514 and 515 in Appendix C The V F is a multi function I O card that connects to the microprocessor via a STD Bus interface and acts as the primary I O interface between the microprocessor and the rest of the analyzer All functions of the board are performed under control of the microprocessor Proper operation of the V F board can b...

Page 106: ...10 V Full Scale S1 Recorder Output 1 6 1 5 1 4 1 3 S2 DAS Output 1 6 1 5 1 4 1 3 S3 Test Output 1 6 7 1 5 7 1 4 7 1 3 7 S4 Spare 1 6 7 1 5 7 1 4 7 1 3 7 3 If voltages and jumper settings are correct the V F card is faulty and should be replaced The primary functions of the board can be divided into three areas 1 Channels of Multiplexed Analog input to an Analog to Digital converter 2 Independent D...

Page 107: ...ed by the microprocessor using the clock oscillator U36 Jumper B15 allows the selection of either a 4 0 MHz or 4 8 MHz frequency to minimize electrical pickup at the operating line frequency Pots R27 and R31 provide offset and gain adjust respectively to the analog input of the V F converter allowing the A D section to be adjusted to match an external voltage standard 10 6 3 2 Digital to Analog Co...

Page 108: ...rs etc and to send and receive status conditions to from external equipment These lines are configured as 8 digital inputs and 24 digital outputs The convention for all Digital I O Lines is High 5V True Low 0V False 10 6 4 Checking the DC Power Supply Board A schematic and physical diagram of the DC Power Supply Board are shown on Drawings 015 and 016 in Appendix C The overall performance of the D...

Page 109: ...s is incorrect check thermistor operation as described in Section 10 6 2 If thermistors are operating correctly it is probable the DC Power Supply Board is defective and should be replaced 10 6 5 Checking the Synchronous Demodulator Board A schematic and physical diagrams of the Synchronous Demodulator Board are shown in drawings 798 and 799 in Appendix C Proper operation of the Synchronous Demodu...

Page 110: ...peration of the Opto Interrupter on the gas filter wheel can be confirmed by connecting an oscilloscope U6 Pin 11 on the Sync Demodulator board and comparing the waveform to Figure 10 1 The waveform should be symmetrical and 5 Volts peak to peak Figure 10 1 Opto Pickup Waveform Figure 10 2 Detector Waveform 10 16 ...

Page 111: ... assembly B Scroll to select VAC or PRES of the TEST functions D Check if the pressure readings are close to the current absolute ambient pressure typical value at sea level is 29 9 Hg In Notice that it must be absolute pressure reading Check if both readings do not differ more than 2 from each other Replace the pressure flow sensor board if defective C 2 Check Flow rate To calibrate the sample fl...

Page 112: ... SPAN _______ mV CO OFFSET _______ CO REF SPAN _______ mV MR RATIO SPAN _______ SAMPLE PRESS _______IN HG A VAC PRESS ________IN HG A SAMPLE FLOW _______SCC MIN SETUP VALUES SAMPLE TEMP _______ C BENCH TEMP _______ C ELECTRIC TEST _______PPM WHEEL TEMP _______ C BOX TEMP _______ C DARK MEAS _______mV DC POWER SUPPLY _______mV DARK REF _______mV TIME _______HH MM SS Has the unit been leak checked Y...

Page 113: ...alyzer Table 11 1 Maintenance Schedule Date Instrument Received _____________ Item JAN FEB MAR APR MAY JUN JUL AUG SEP OCT NOV DEC Recommended Action Particulate filter element Replace weekly or as needed Pump diaphragms Replace every 12 months Sample flow Check for proper flow 800cc min 20 annually Dark Cal Perform annually as needed or after adjusting R7 on Sync Demod board Pneumatic lines Exami...

Page 114: ...lement 7 Replace the filter top and re tighten 8 Leak check 9 Turn on the analyzer 11 3 Leak Checking There are two methods of leak checking 11 3 1 Using a Leak Checker Turn the power off Disconnect the fittings from the pump and bypass the pump Connect the leak checker to the sample inlet of the Model 300M Cap the exhaust of the analyzer Set the leak checker to pressure mode CAUTION Do not exceed...

Page 115: ...Test If only a Model 300M is available the following alternate method for leak checking can be used The power must be on and the pump must be in line Disconnect the power from the pump Check for the sample flow If the sample flow does not read zero record the reading Re connect the power to the pump Cap the sample inlet Check if the sample flow goes down to zero If not check the sample flow exceed...

Page 116: ...Teledyne API Model 300M CO Analyzer Instruction Manual 04033 Rev A INTENTIONALLY BLANK 11 4 ...

Page 117: ...LY MODULE UK 230V 50Hz 00611 04 ASSY STRIP HEATER 00611 05 ASSY HEATER WHEEL 01930 SAMPLE FILTER ASSY 00690 00 PADS 01930 KEYBOARD 00728 NEW DISPLAY 00798 SYNC DEMODULATOR BOARD 0261803 ASSY OPTICAL BENCH 00953 PREAMP DETECTOR ASSEMBLY 00956 0001 GAS FILTER WHEEL 00969 FILTER TFE 47 MM QTY 100 00969 01 FILTER TFE 47 MM QTY 25 00982 ASSY SYNCHRONOUS MOTOR 00987 OPTO INTERRUPTER ASSEMBLY 01037 CO CO...

Page 118: ...BING 6 1 8 BLK TU2 02475 TUBING 6 1 4 TYGON TU9 VA002 SOLENOID SS 3 WAY 24V VA004 SOLENOID SS 2 WAY 24V 12 2 Model 300M Expendables kit PART NO DESCRIPTION 009600400 300M 47 mm Filter Expendables Kit KNF Pump Model NO5ATI Includes 009690100 Filter TFE 47 mm 5 um Qty 25 FL0000001 Sintered Filter 002 024900 HW0000020 Spring Flow Control OR0000001 O Ring Flow Control PU0000022 Pump Rebuild Kit KNF Mo...

Page 119: ...ON 037610000 300M Level 1 Spare Parts Kit for 10 units Includes 000941000 Orifice 13 mil 800 cc Rx Cell 007930000 Assembly Fan PSM FA0000004 ASSY 009530000 Pre amplifier Detector Assembly 009820000 Motor Synchronous 015810000 Source Assembly with Adapter 019340200 Thermistor Assembly Sample TEE KIT000109 Replacement Opto Sensor 12 3 ...

Page 120: ... guidelines for connecting the Teledyne API analyzers to a variety of other equipment Connectors There are a wide variety of connectors and cables that are specified to operate with the RS 232 protocol This is because electronics have decreased in size over the years and connectors have been downsized to match the electronics Cables Adapters come in 4 general types 1 Cables cables are provided in ...

Page 121: ... As technology has progressed it has become more ambiguous who was DCE and DTE Teledyne API analyzers are wired as DTE i e like a printer As can be seen this presents difficulties if you a hook a printer to the instrument that is likewise wired as a printer To help understand the different problems 3 examples as shown below Example 1 Connecting the Teledyne API analyzer to an IBM PC AT compatible ...

Page 122: ...on the analyzer The signal will be between 5V and 15V with respect to signal ground pin 5 If not there is a problem with the CPU board or the cable This is the transmit TD signal out of the analyzer This should then be connected to TD input on the modem normally Pin 2 If the analyzer is equipped with a DTE DCE switch you may need to change its setting so the signal is on Pin 2 Second Go to the cab...

Page 123: ... Power Supply Module PCA 00551 Wiring Diagram Power Supply Module 00798 Assembly Sync Demodulator 00799 Schematic Sync Demodulator 00866 Assembly Mother Board 00867 Schematic Mother Board 00874 Assembly Pre Amp Bias 00875 Schematic Pre Amp Bias 01916 Assembly Rear Panel PCA CE Mark Units Only 01917 Schematic Rear Panel PCA CE Mark Units Only 01930 Assembly Keyboard PCA CE Mark Units Only 01931 Sch...

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Summary of Contents for 300M

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Summary of Contents for 300M

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