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TAI - Thermal Converter Operator Manual - Page 2

1.1 Claims for damaged shipments

All instruments should be thoroughly inspected immediately upon receipt. Material in the container
should be checked against the enclosed packing list. If the contents are damaged and/or the instrument
fails to operate properly, the carrier and TAI should be notified immediately.

The following documents are necessary to support claims:

•

Original freight bill and bill of lading

•

Original invoices or photocopy of original invoice

•

Copy of the packing list

•

Photographs of damaged equipment and container

1.2 Claims for shipping discrepancies

All containers should be checked against packing list immediately upon receipt. If a shortage occurs,
notify the carrier and TAI immediately. TAI will not be responsible for shortages against the packing list
unless they are reported immediately.

The following information is necessary to make a claim:

•

The instrument model number

•

Serial number

•

Sales order number or purchase order number

Upon receipt of a claim, TAI will advise disposition of the equipment for repair or replacement.

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Summary of Contents for 6200A

Page 1: ...MODEL 6200A TRS ANALYZER MANUAL ADDENDUM TELEDYNE ANALYTICAL INSTRUMENTS 03655 Rev A August 2000 ...

Page 2: ...ulfides Analyzer 4 2 3 Configurations 4 2 4 The TRS Total Reduced Sulfur Converter 8 2 5 Installation 10 2 6 Operation and Calibration 12 2 6 1 Calibration Theory 12 2 6 2 Zero and Span Calibration Procedure 13 2 7 M501TRS Temperature Controller 14 2 7 1 Changing the Temperature Set Point 14 2 7 2 Adjusting the P I D Parameters 15 3 0 TROUBLESHOOTNG 17 4 0 MAINTENANCE 19 4 1 SO2 Analyzer Maintenan...

Page 3: ...IGURES FIGURE 2 1 STANDARD CONFIGURATION 5 FIGURE 2 2 WITH IZS OPTION 6 FIGURE 2 3 WITH M702 CALIBRATOR OPTION 7 FIGURE 2 4 TRS CONVERTER LAYOUT 9 FIGURE 2 5 PNEUMATIC CONNECTIONS 11 FIGURE 3 1 TRS WIRING DIAGRAM 18 FIGURE 4 1 DILUTER FLOW BLOCK ASSEMBLY 21 ...

Page 4: ... i TABLE OF TABLES TABLE 2 1 TRS CONVERTER SPECIFICATIONS 3 TABLE 2 2 ZERO CALIBRATION PROCEDURE 13 TABLE 2 3 SPAN CALIBRATION PROCEDURE 14 TABLE 2 4 TEMPERATURE CONTROLLER INITIAL SETTINGS 16 TABLE 2 5 TEMPERATURE CONTROLLER SECONDARY MENU 16 ...

Page 5: ...scretion repairing or replacing such defective Product or refunding the purchase price of such Product The warranties set forth in this section shall be of no force or effect with respect to any Product i that has been altered or subjected to misuse negligence or accident or ii that has been used in any manner other than in accordance with the instruction provided by TAI or iii not properly mainta...

Page 6: ...lading Original invoices or photocopy of original invoice Copy of the packing list Photographs of damaged equipment and container 1 2 Claims for shipping discrepancies All containers should be checked against packing list immediately upon receipt If a shortage occurs notify the carrier and TAI immediately TAI will not be responsible for shortages against the packing list unless they are reported i...

Page 7: ... the SO2 analyzer are contained in the standard Model 6200A manual 2 1 2 M501TRS Converter Specifications TABLE 2 1 M501TRS Converter Specifications Specification Value Unit Flow Rate 1000 Cc min maximum TRS Concentration 20 ppm Converter Temperature 950 1050 o C Dilution Ratio 4 3 1 Number Conversion Eff H2S 98 Power 220 VAC 50 60 Hz 220 watts Weight 24 lbs 11 kg Dimensions 7 x 17 x 22 inches 178...

Page 8: ...ulting in about 4 oxygen in the sample The added oxygen allows the sulfur compounds to be oxidized to SO2 Any SO2 present in the sample is unaffected by the converter The sample gas then passes to a modified 6200A analyzer where the converted compounds are analyzed as SO2 2 3 Configurations There are three configurations available 1 The standard unit consisting of A modified 6200A Fluorescent SO2 ...

Page 9: ...TAI Thermal Converter Operator Manual Page 5 FIGURE 2 1 BASIC CONFIGURATION ...

Page 10: ...TAI Thermal Converter Operator Manual Page 6 FIGURE 2 2 WITH IZS OPTION ...

Page 11: ...TAI Thermal Converter Operator Manual Page 7 FIGURE 2 3 WITH M702 CALIBRATOR OPTION ...

Page 12: ...cated on the rear panel The alarm set point is adjustable in the temperature controller The heater temperature is sensed by a Type K chromel alumel thermocouple probe inserted in the bore alongside the quartz tube The quartz tube carrying the sample mixture runs through the core of the heater and is heated by radiation from electrical heating elements at the heater bore surface See Figure 2 4 for ...

Page 13: ...TAI Thermal Converter Operator Manual Page 9 FIGURE 2 4 TRS CONVERTER LAYOUT ...

Page 14: ... by an approved three wire grounded power cord The pneumatic connections are shown in Figure 2 5 Connection to the TRS analyzer must be made with Teflon or stainless steel tubing Connect the sample inlet to the labeled fitting The sample exhaust must be routed to a well ventilated area away from the air inlet for the zero air scrubber on the rear panel The overall pneumatic diagrams of the Model 6...

Page 15: ...TAI Thermal Converter Operator Manual Page 11 FIGURE 2 5 PNEUMATIC CONNECTIONS ...

Page 16: ...le to determine how well the charcoal will scrub compounds other than SO2 A 3 way valve is used to bypass the M501TRS converter so the sample gas now passes through a charcoal scrubber then directly to the reaction cell The instrument is allowed to collect data with the converter bypassed and this reading is stored as Z2 This is the actual instrument zero reading Span calibration uses span gas gen...

Page 17: ...omplete description of the calibration procedure Table 2 2 Zero Calibration Procedure Step Number Action Comment 1 Press CALZ With sample gas flowing into the sample inlet of the instrument press CALZ which routes sample air into the charcoal scrubber 2 Press ZERO ZERO starts Phase 1 of the zero calibration procedure allowing zero to be measured with the converter in the pneumatic pathway Allow 10...

Page 18: ...ature Controller The heater temperature is maintained by a front panel mounted programmable controller The Fuji Electric PXZ Series Operation Manual is included with the documentation for this instrument The controller has been set up at the factory Should further adjustments be necessary a brief summary of the operation of the controller is included By pressing the PV SV button in the lower left ...

Page 19: ...e function be used to set the control functions if reprogramming is necessary The following table is a guide to the approximate values for setting the parameters that will produce the initial settings for the autotune function Below is a summary of the autotune procedure refer to the Fuji Manual for more detailed information To perform Auto Tune function set the parameter A7 to 1 then press ENTER ...

Page 20: ...le 2 4 shows a Secondary Menu of parameters that set more basic parameters of the controller these include the thermocouple type the temperature units etc Table 2 5 Temperature Controller Secondary Menu PRESS DISPLAY PARAMETER VALUE SEL HOLD TILL p n1 SET TO 0 SEL p n2 SET TO 3 TYPE K THERMOCOUPLE SEL p dF DIGITAL FILTER SET TO 5 SEL P SL LOWER LIMIT SET TO 32 32C SEL P SU UPPER LIMIT SET TO 1050 ...

Page 21: ...on back of controller Check M501TRS wiring diagram Figure 3 1 TRS ANALYZER UNSTABLE Leak check Pressurize and see if pressure falls Use soap bubble to find leak EFFICIENCY 90 Leaking Leak check Plugged Compare flow through and bypassing converter Flow too high Set point temperature optimized Span gas correct Contaminated Check inside of Teflon tubing CONVERTER TEMP UNSTABLE Perform autotune proced...

Page 22: ...TAI Thermal Converter Operator Manual Page 18 FIGURE 3 1 TRS WIRING DIAGRAM ...

Page 23: ... create H2S span gas either permeation tube or tank with CO2 gas as the diluent Remember that rotameters and mass flow controllers are calibrated with air or nitrogen Using them with CO2 will produce large calibration errors Since CO2 gas has considerably different characteristics use flowmeters such as soap bubble or BIOS DryCal flowmeters that measure volume flow 2 Produce a calibration gas of 4...

Page 24: ...a small amount of ambient air into the sample stream to provide oxygen for the converter The diluter is located on the inside rear panel of the SO2 analyzer It consists of a stainless steel block and 2 orifices to control the amount of sample and air that is blended There should be no periodic maintenance required on this assembly but a diagram is included in case rebuilding of this assembly is re...

Page 25: ...TAI Thermal Converter Operator Manual Page 21 FIGURE 4 1 DILUTER FLOW BLOCK ASSEMBLY ...

Page 26: ... _______________ TELEDYNE ANALYTICAL INSTRUMENTS 16830 CHESTNUT STREET CITY OF INDUSTRY CA 91749 1020 TOLL FREE 888 789 8168 FAX 626 961 2538 TEL 626 934 1500 E MAIL tetci_customerservice teledyne com WEB SITE www teledyne ai com 02164 REV G Copyright 1994 12 12 98 ...

Page 27: ......

Page 28: ...Detector 4 4 4 2 2 Pneumatic Sensor Board 4 4 4 2 3 Computer Hardware and Software 4 4 4 2 4 V F Board 4 5 4 2 5 Front Panel 4 5 4 2 6 Power Supply Module 4 8 4 2 7 Pneumatic System 4 8 5 SOFTWARE FEATURES 5 1 5 1 INDEX TO FRONT PANEL MENUS 5 1 5 1 1 Sample Menu 5 3 5 1 2 Set Up Menu 5 4 5 2 SAMPLE MODE 5 7 5 2 1 Test Functions 5 7 5 2 2 CAL CALS CALZ Calibration Functions 5 10 5 3 SET UP MODE 5 1...

Page 29: ...RO SPAN CHECK OR CALIBRATION THROUGH THE SAMPLE PORT 7 4 7 2 MANUAL ZERO SPAN CHECK OR CALIBRATION WITH ZERO SPAN VALVES OPTION 7 6 7 3 MANUAL ZERO SPAN CHECK WITH IZS OPTION 7 7 7 4 AUTOMATIC ZERO SPAN CHECK 7 7 7 5 AUTOMATIC ZERO SPAN CALIBRATION 7 7 7 6 CALIBRATE ON SO2 PERMEATION TUBE 7 8 7 7 USE OF IZS OR ZERO SPAN VALVES WITH REMOTE CONTACT CLOSURE 7 8 7 8 EPA PROTOCOL CALIBRATION 7 9 7 8 1 ...

Page 30: ...nternal Variables 9 18 9 1 5 Test Channel Analog Output 9 20 9 1 6 Factory Calibration Procedure Quick Cal 9 21 9 2 PERFORMANCE PROBLEMS 9 23 9 2 1 AC Power Check 9 23 9 2 2 Flow Check 9 24 9 2 3 No Response to Sample Gas 9 24 9 2 4 Negative Concentration Display 9 25 9 2 5 Excessive Noise 9 25 9 2 6 Unstable Span 9 26 9 2 7 Unstable Zero 9 27 9 2 8 Inability to Span 9 27 9 2 9 Inability to Zero 9...

Page 31: ...r Replacement 9 58 9 4 3 UV Filter Replacement 9 59 9 4 4 Shutter System 9 59 9 5 PNEUMATIC SYSTEM TROUBLESHOOTING 9 60 9 5 1 Leak Check 9 60 9 5 2 Pump 9 60 9 5 3 Kicker 9 60 9 5 4 Z S Valves IZS Permeation Tube Oven 9 62 10 TAI 6200A SPARE PARTS LIST 10 1 APPENDIX A MAINTENANCE SCHEDULE FOR 6200A A 1 APPENDIX B ELECTRICAL SCHEMATICS B 1 iv ...

Page 32: ...IBRATION SETUP 7 3 FIGURE 7 2 DIAGRAM OF CALIBRATION SYSTEM 7 15 FIGURE 7 3 DIAGRAM F PERMEATION CALIBRATION SYSTEM 7 17 FIGURE 8 1 REPLACING THE PARTICULATE FILTER 8 3 FIGURE 8 2 REACTION CELL 8 7 FIGURE 8 3 PNEUMATIC DIAGRAM 8 8 FIGURE 9 1 CPU BOARD JUMPER SETTINGS 9 32 FIGURE 9 2 RS 232 PIN ASSIGNMENTS 9 34 FIGURE 9 3 V F BOARD DIP SWITCH SETTINGS 9 41 FIGURE 9 4 POWER SUPPLY MODULE LAYOUT 9 46...

Page 33: ...2 RS 232 CALIBRATION MESSAGES 6 19 TABLE 6 13 RS 232 CALIBRATION COMMANDS 6 20 TABLE 6 14 RS 232 DIAGNOSTIC COMMAND SUMMARY 6 21 TABLE 6 15 RS 232 DAS COMMANDS 6 21 TABLE 6 16 RS 232 OPERATING MODES 6 24 TABLE 7 1 TYPES OF ZERO SPAN CHECKS AND CALIBRATIONS 7 2 TABLE 7 2 MANUAL ZERO CALIBRATION PROCEDURE ZERO GAS THROUGH SAMPLE PORT 7 4 TABLE 7 3 ENTER EXPECTED SPAN GAS CONCENTRATIONS PROCEDURE 7 5...

Page 34: ... CHANNEL OUTPUT 9 20 TABLE 9 7 POWER SUPPLY MODULE SUBASSEMBLIES 9 45 TABLE 9 8 POWER SUPPLY MODULE LED OPERATION 9 48 TABLE 10 1 TAI 6200A SPARE PARTS LIST 10 1 TABLE 10 1 TAI 6200A SPARE PARTS LIST CONTINUED ERROR BOOKMARK NOT DEFINED TABLE 10 1 TAI 6200A SPARE PARTS LIST CONTINUED ERROR BOOKMARK NOT DEFINED TABLE 10 1 TAI 6200A SPARE PARTS LIST CONTINUED ERROR BOOKMARK NOT DEFINED TABLE 10 2 TA...

Page 35: ......

Page 36: ...bleshoot problems to assure maximum uptime and data integrity To address these needs we have created three indexes to the information inside They are Table of Contents Outlines the contents of the manual in the order the information is presented This is a good overview of the topics covered in the manual There is also a list of Tables and a list of Figures Index to 6200A Front Panel Menus The Menu...

Page 37: ...he 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 pu...

Page 38: ...over of the power supply module and compare that to your local power before plugging in the 6200A Check for internal shipping damage and generally inspect the interior of the instrument to make sure all circuit boards and other components are in good shape 3 Replace the instrument cover 4 When installing the 6200A allow at least 4 10 cm clearance at the back and at least 1 2 5 cm clearance at each...

Page 39: ...AT THE UV LAMP UV LIGHT COULD CASE EYE DAMAGE ALWAYS USE SAFETY GLASSES PLASTIC GLASSES WILL NOT DO Connect the exhaust fitting on the rear panel to a suitable vent outside of the room CAUTION DO NOT OPERATE WITH COVER OFF Before operation check for correct line voltage and frequency on Serial Number Sticker Do not plug in the power cord if the voltage or frequency is incorrect Do not operate with...

Page 40: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G Figure 2 1 Removal of Shipping Screws 2 3 ...

Page 41: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G Figure 2 2 Rear Panel 2 4 ...

Page 42: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G Figure 2 3 Rear Panel Pneumatic Recommendations 2 5 ...

Page 43: ... you can check for correct operation by using some of the 6200A s diagnostic and test features 3 Examine the TEST functions by comparing the values listed in Table 2 1 to those in the display Remember that as the instrument warms up the values may change until they reach their final values If you would like to know more about the meaning and utility of each TEST function refer to Table 9 1 Table 2...

Page 44: ...nt 1 Press CAL CONC This key sequence causes the 6200A to prompt for the expected SO2 concentration Enter the SO2 span concentration value by pressing the key under each digit until the expected value is set 2 Press ENTR ENTR stores the expected SO2 span value This value will be used in the internal formulas to compute subsequent SO2 concentration values 3 Press EXIT Returns instrument to SAMPLE m...

Page 45: ... and zeroes the instrument 6 Press EXIT 6200A returns to the CAL menu Now switch gas streams to span gas 7 Wait 10 min Wait for reading to stabilize at the span value If you wait less than 10 minutes the final span value may drift 8 Press SPAN The SPAN button should be displayed If it is not check the Troubleshooting Section 9 2 8 for instructions on how to proceed In certain circumstances at low ...

Page 46: ...the value is not in this range check Section 7 10 or 9 If the SLOPE value is in the acceptable range the instrument will perform optimally 2 Scroll the TEST function menu until the SO2 OFFSET is displayed The 6200A will display the OFFSET parameter for the SO2 equation A value between 50mV to 250mV indicates calibration in the optimal range If the OFFSET value is outside this range check Section 7...

Page 47: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G Figure 2 4 Front Panel 2 10 ...

Page 48: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G Figure 2 5 Assembly Layout 2 11 ...

Page 49: ... mV 0 5000 9 4 1 UV LAMP mV 2000 4000 typical 9 4 2 STR LGT PPB 100 Table 9 1 DRK PMT mV 50 200 9 4 3 Table 9 1 DRK LMP mV 50 200 Table 9 1 SLOPE 1 0 0 3 7 10 OFFSET mV 250 7 10 HVPS V 550 900 constant 9 3 10 DCPS mV 2500 200 9 3 5 RCELL TEMP o C 50 1 9 3 7 BOX TEMP o C 8 50 9 3 4 1 PMT TEMP o C 7 1 9 3 9 IZS TEMP o C 50 0 3 9 5 4 Electric Test Optic Test Electric Test PMT Volts mV 2000 1000 9 1 3...

Page 50: ...n rms PPB 0 5 of reading above 50 ppb Table 9 1 Measured Flows Parameter Observed Value Units Nominal Range Reference Section Sample Flow cc min 700 10 9 2 2 9 3 6 Figure 9 6 IZS Purge Flow cc min 50 10 6 3 Factory Installed Options Option Installed Power Voltage Frequency Rack Mount w Slides Rack Mount w Ears Only Fluorocarbon Zero Span Valves Internal Zero Span IZS Permeation Tube Output Specifi...

Page 51: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G INTENTIONALLY BLANK 2 14 ...

Page 52: ...rature Range 5 40o C Temp Coefficient 0 1 per o C Humidity 0 95 RH non condensing Voltage Coefficient 0 05 per V Dimensions HxWxD 7 x17 x 23 6 18cm x 43cm x 61cm Weight Analyzer 45 lbs 20 5 kg w internal pump Power Analyzer 110v 60Hz 220v 50Hz 240v 50Hz 250 watts Power Analyzer4 230v 50Hz 2 5A Environmental Conditions Installation Category Overvoltage Category II Pollution Degree 2 Recorder Output...

Page 53: ...solute pressure 1 slpm or better 6 Software settings A Dynamic span OFF B Dynamic zero ON or OFF C AutoCal ON or OFF D Dual range ON or OFF E Autorange ON or OFF F Temp Pressure compensation ON Under the designation the Analyzer may be operated with or without the following options 1 Rack mount with chassis slides P N 01469A 2 Rack mount without slides ears only P N 01470A 3 Fluorocarbon zero span...

Page 54: ... date of shipment All replacement parts and repairs are warranted for 90 days after the purchase If a Product fails to conform to its specifications within the warranty period TAI shall correct such defect by in TAI 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 ...

Page 55: ...2164 Rev G TERMS AND CONDITIONS All units or components returned to TAI should be properly packed for handling and returned freight prepaid to the nearest designated Service Center After the repair the equipment will be returned freight prepaid 3 4 ...

Page 56: ...ter The equations describing the above reactions are as follows 2 SO hv SO Ia 1 2 1 The excitation ultraviolet light at any point in the system is given by 2 0 SO ax exp 1 I Ia 2 Where I0 is the UV light intensity a is the absorption coefficient of SO2 x the path length and SO2 the concentration of SO2 The excited SO2 decays back to the ground state emitting a characteristic fluorescence 2 2 KF 2 ...

Page 57: ...al to the light energy in the sample stream being analyzed The preamp board converts this signal into a voltage which is further conditioned by the signal processing electronics The UV light source is measured by a UV detector Software calculates the ratio of the PMT output and the UV detector in order to compensate for variations in the UV light energy Stray light is the background light produced...

Page 58: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G Figure 4 1 6200A Sulfur Dioxide Analyzer 4 3 ...

Page 59: ...sensor and a flow sensor The pressure sensor measures the sample pressure at the reaction cell which is near ambient pressure This sample pressure is displayed in the test menu A solid state flow sensor measures the sample flow Likewise it is displayed as a TEST function The 6200A displays pressure in inches of mercury absolute in Hg A and flow in cc min 4 2 3 Computer Hardware and Software The 62...

Page 60: ... preserved 4 2 4 V F Board Computer communication is done via 2 major hardware assemblies These are the V F board and the front panel display keyboard The V F board is multifunctional consisting of A D input channels digital I O channels and analog output channels Communication with the computer is via a STD bus interface The computer receives all of the instrument data and provides all control fu...

Page 61: ...tic test Elec Electrical test RS232 RS 232 test LAMP Lamp cal TCHN Test channel The mode field indicates the current mode of the Analyzer Usually it shows SAMPLE indicating that the instrument is in sample mode The center field displays TEST values The TEST functions allow you to quickly access many important internal operating parameters of the 6200A This provides a quick check on the internal he...

Page 62: ...he LED s are given in Table 4 2 Table 4 2 Front Panel Status LED s LED State Meaning Green Off On Blinking NOT monitoring DAS Disabled or inactive Monitoring normally taking DAS data Monitoring DAS in HOLDOFF mode 1 Yellow Off On Blinking Auto cal disabled Autocal Enabled Calibrating Red Off Blinking Warnings exist No warnings exist 1 This occurs during Calibration DAS holdoff Power up Holdoff and...

Page 63: ...ER and the reaction cell The internal external optional pump is supplied as standard equipment with the 6200A When the zero span valve option is included the sample passes through the TFE zero valve and then enters the sample filter See Section 6 By having the sample gas zero air and span gas all pass through the sample filter the effects of the filter are common to all gases Sample flow is contro...

Page 64: ...the Setup mode offering advanced instrument control capabilities for optimum operation of the instrument For installation and initial operation please see Section 2 Getting Started 5 1 Index To Front Panel Menus The next several pages contain two different styles of indexes that will allow you to navigate the 6200A software menus The first two pages show a tree menu structure to let you see at a g...

Page 65: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G Figure 5 2 Setup Menu Tree 5 2 ...

Page 66: ...ro Span calibration w gas through sample port 5 2 2 1 7 1 CALZ Zero calibration w zero gas from zero valve option or IZS option 5 2 2 2 7 2 7 3 CALS Span calibration w span gas from span valve option or IZS option tube 5 2 2 3 7 2 7 3 ZERO Press ZERO then ENTR will zero analyzer 5 2 2 2 SPAN Press SPAN then ENTR will span analyzer 5 2 2 3 CONC Expected SO2 span concentration SETUP The SETUP Menu S...

Page 67: ...ically scrolls the list 5 3 1 AUTOCAL Automatic zero span check or calibration 5 3 2 6 2 SEQx Select SEQUENCE 1 thru 3 5 3 2 6 2 MODE Disable or enable zero and or span mode 5 3 2 6 2 SET SETUP automatic zero sapn calibration sequence 5 3 2 6 2 DAS Data Acquisition System DAS 5 3 3 EDIT SETUP Data Acquisition System DAS 5 3 3 VIEW PREV Examine the DAS data buffer display previous average 5 3 3 PV1...

Page 68: ...NGLE Single range for both REC and DAS outputs 5 3 4 SET Sets range if mode is Single range 5 3 4 1 LO Sets low range value if Autorange enabled 5 3 4 2 HI Sets high range value if Autorange enabled 5 3 4 2 UNITS Unit selection menu 5 3 4 5 PPB PPM UGM MGM Select units that instrument uses 5 3 4 5 PASS Password enable disable menu 5 3 5 ON OFF Enable disable password checking 5 3 5 CLOCK TIME Adju...

Page 69: ...0 9600 19 2K 5 3 8 6 8 ID Sets the instrument ID included on all RS 232 messages 5 3 8 6 8 VARS Internal variables 5 3 9 9 1 4 PREV NEXT JUMP EDIT PREV NEXT scroll up and down through the VARS menu Jump will go to variable number selected EDIT will allow editing of the selected variable 5 3 9 9 1 4 DIAG Diagnostic menu 5 3 7 9 1 3 PREV NEXT PREV NEXT scroll up and down through the DIAG menu SIGNAL...

Page 70: ...values require The TEST values will show the range the instrument is currently operating in and will dynamically display the alternate range as the range changes occur Stability The instrument stability is used to indicate the stability of measurement of analyzer It is computed as the standard deviation of 25 samples of a moving window with interval of 10 seconds between each sample Typical value ...

Page 71: ...c Dark PMT This dark current of the PMT is measured periodically to compensate any PMT dark current drift Typical value is near 50 200 mV Dark Lamp This is the dark current of the UV reference detector which is used to compensate any dark current drift This measurement is synchronized to the Dark PMT measurement period Typical value is near 50 200 mV Slope The coefficient of straight line equation...

Page 72: ...t over 5 to 40o C ambient temperature range PMT Temperature The temperature of the PMT is closely controlled by a dedicated proportional temperature controller The nominal set point is 7 1o C Readings outside this range will cause instrument drift due to gain changes in the PMT detector IZS Temperature The IZS option has an oven for SO2 permeation tubes The oven temperature is nominally 50C The ac...

Page 73: ...ment with span gas in the reaction cell If the ZERO key does not come on as expected check Section 9 2 9 5 2 2 3 Span Pressing the SPAN key along with ENTR will cause the instrument to adjust the SLOPE value of the internal formula so the instrument displays the span value The expected SO2 span concentration must be entered before doing a SPAN calibration See Table 7 3 Like the Zero calibration th...

Page 74: ... analog analyzer there is only a limited range of adjustment allowed for either term and there are consequences of having the values near the high or low limits of their respective ranges The x term is the conditioned PMT signal PMT signal is adjusted for the lamp ratio background range temperature and pressure The offset b term is the total background light with the zero term subtracted out The z...

Page 75: ...hannels Each Data Channel can store multiple data parameters The Data Channels can be programmed and customized from the front panel A set of default Data Channels has been included in the Model 6200A software These are described Section 5 3 3 1 For more information on programming custom Data Channels a supplementary document containing this information can be requested from TAI 5 3 3 1 Data Chann...

Page 76: ...his Data Channel will store data from the last 200 calibrations This does not represent any specific length of time since it is dependent on how often calibrations are performed As with all Data Channels a time and date stamp is recorded for every data point logged 5 3 4 Range Menu The instrument operates on any full scale range from 50 to 20 000 ppb The range is the concentration value that equal...

Page 77: ...e instrument output increases to 98 of the low range value it will Auto Range into Hi range In Hi range when the output decreases to 75 of low range it will change to the lower range This is only one low range and one high range for all outputs The Hi range mode is signaled by a bit on the STATUS option see Table 6 3 If you select a Hi range that is less than Low range the 6200A will remain locked...

Page 78: ...the test measurement parameters for RANGE1 are used throughout the 6200A When initiating calibration remotely via the contact closures the RS 232 or automatically via the timer the 6200A will calibrate RANGE 1 5 3 4 4 Dilution Ratio The dilution feature allows the 6200A to be used with a stack dilution probe With the Dilution feature you can select the range and display the concentration at the va...

Page 79: ...to read the correct concentration at the conditions being used This adjustment is not needed if units are within the same type To change the current units press SETUP RNGE UNIT from the SAMPLE mode and select the desired units Example If the current units are in ppb and the span value is 400 ppb and the units are changed to ug m3 the span value is NOT re calculated to the equivalent value in ug m3...

Page 80: ... entered by pressing SETUP CLOCK DATE and entering the date in a dd mmm yy format If you are having trouble with the clock running slow or fast the speed of the clock can be adjusted by selecting the CLOCK_ADJ variable in the SETUP MORE VARS menu See Section 9 1 4 5 3 7 Diagnostic Mode The 6200A Diagnostic Mode allows additional tests and calibrations of the instrument These features are separate ...

Page 81: ...ternal variables The VARS Table 9 5 is located in the Troubleshooting Section 9 1 4 NOTE Before changing the settings on any variables please make sure you understand the consequences of the change The variables should only be changed by skilled maintenance people since they can potentially interfere with the performance of the analyzer 5 18 ...

Page 82: ...A rack Can also be ordered without slides for applications requiring the instrument to be rigidly mounted in a RETMA rack 6 2 Zero Span Valves The Zero Span Valve option consists of two fluorocarbon solenoid valves See Figure 2 5 for valve location Connections are provided on the rear panel for span gas and zero gas inputs to the valves See Figure 2 2 These valves can be actuated by several method...

Page 83: ...alysis 2 Zero mode The sample cal valve is energized to the cal mode The zero span valve is un energized in the zero mode thus allowing zero gas to be admitted through the rear panel bulkhead fitting into the analyzer 3 Span mode The sample cal valve is energized and in the cal mode The zero span valve is energized in the span mode With both valves on span gas is admitted through a rear panel bulk...

Page 84: ... be set up to operate automatically on a timed basis The TAI model 6200A with IZS option offers capability to check any combination of zero and span points automatically on a timed basis through remote RS 232 operation see Section 6 8 5 or external contact closure see Section 7 7 There are three auto calibration sequences called SEQ1 SEQ2 and SEQ3 Under each SEQ there are five parameters that affe...

Page 85: ...e the automatic calibration timer while the remote RS 232 calibration of specific sequence can be initiated 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 The programmed start time must be a minimum of 5 minutes later than the real ...

Page 86: ... 15 0 MINUTES 8 CALIBRATE ON Example 3 to perform zero span calibration check once per day at 10 30 pm and zero calibration adjust once per week starting at 11 30 PM 12 20 98 1 Select any one of SEQx and program as example 1 2 Select any other SEQx and program as following Always avoid setting two or more sequences at the same time of the day 1 MODE ZERO 2 TIMER ENABLE ON 3 STARTING DATE 12 20 98 ...

Page 87: ...tput is a fixed function of the permeation tube and is noted on shipping container The temperature is set at 50 0o C Check SETUP MORE VARS and scroll to the IZS_SET variable to verify that the temperature is properly set It should be set to 50o C with over and under temperature warnings set at 49o C and 51o C There is a 50 cc min purge flow across the permeation tube at all times to prevent build ...

Page 88: ...b at 0 7 liter minute This will give you a IZS Span response of 80 to 90 of full scale in the 500 ppb range Refer to the above equation for calculating other concentrations and instrument flow rates Once the Analyzer has stabilized the response to the permeation tube is not expected to change more than 5 If during a periodic span check the response varies by more than 5 or more importantly shows d...

Page 89: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G Figure 6 1 Permeation Tube Installation 6 8 ...

Page 90: ...nel The closures are available on a 50 pin connector on the rear panel The contacts are NPN transistors which can pass 50 ma of direct current The pin assignments are listed in Table 6 3 below Table 6 3 Status Output Pin Assignments OUTPUT PIN DEFINITION CONDITION 1 1 2 ZERO CAL CLOSED IN ZERO CAL 2 3 4 SPAN CAL CLOSED IN SPAN CAL 3 5 6 FLOW ALARM CLOSED IF FLOW WARNING 4 7 8 TEMP ALARM CLOSED IF ...

Page 91: ...19 2K It is important to note that the other device must have identical settings in order for the communications to work correctly Second is physical wiring of the analyzer to the other unit We have incorporated into the Analyzer LED s that signal the presence of data on the communications lines and also jumper blocks to easily re configure the analyzer from DCE to DTE if necessary see drawing 011...

Page 92: ...ld be 4 8 12 Security Feature The RS 232 port is often connected to a public telephone line which could compromise instrument security If the LOGON feature is implemented the port has the following attributes 1 A password is required before the port will operate 2 If the port is inactive for 1 hour it will automatically LOGOUT 3 If not logged on the only command that is active is the If this comma...

Page 93: ...a host computer or data logger is connected to the analyzer it should be placed into COMPUTER MODE which does not echo characters received or allow the special editing keys See Table 6 5 for relevant commands Table 6 5 RS 232 Switching From Terminal Mode to Computer Mode Key Function Control T ASCII 20 decimal Switch to terminal mode echo edit Control C ASCII 3 decimal Switch to computer mode no e...

Page 94: ... are shown on the help screen in uppercase but they are not case sensitive You must type the entire keyword abbreviations are not accepted OBTAINING HELP Typing followed by Return or Enter will cause a help screen to be displayed 6 8 2 Command Summary The information contained in the rest of this section covers all of the normal commands that are required to operate the instrument from a remote te...

Page 95: ... CLEAR ALL Disable W LIST use with W SET C command Execute calibration command from Table 6 12 D LIST Prints all I O signal values D name Prints single I O signal value state D name value Sets variable to new value D LIST NAMES Lists diagnostic test names D ENTER name Enters and starts name diagnostic test D EXIT Exits diagnostic mode D RESET Resets analyzer same as power on D RESET RAM System res...

Page 96: ...one of the two principal uses for the RS 232 interface You can effectively disable the asynchronous reporting feature by setting the interface to quiet mode All messages output from the analyzer including those output in response to a command line request have the format X DDD HH MM IIII MESSAGE X is a character indicating the message type as shown in the table below DDD HH MM is a time stamp indi...

Page 97: ...nt V Variable W Warning There are 6 different types of messages output by the 6200A They are grouped below by type in Table 6 9 Table 6 14 The meanings of the various messages are discussed elsewhere in the manual The TEST DIAGNOSTIC and WARNING messages are discussed in Section 9 1 9 2 9 3 DAS and VARIABLES are discussed in Section 5 3 3 and 5 3 9 CALIBRATE is discussed in Section 7 6 16 ...

Page 98: ...DRK PMT xx x MV PMT dark current in MV DARKLAMP DRK LMP xx x MV UV detector dark current in MV SLOPE SLOPE x xxx Calibration slope parameter OFFSET OFFSET xxx x MV Calibration offset parameter HVPS HVPS xxxxx V High voltage power supply DCPS DCPS xxxxxx MV DC power supply RCELLTEMP RCELL TEMP xxx C Reaction cell temperature BOXTEMP BOX TEMP xxx C Internal box temperature PMTTEMP PMT TEMP xxx C PMT...

Page 99: ...Sample flow out of spec WSAMPPRESS SAMPLE PRESSURE WARNING Sample pressure below 15 Hg or above 35 Hg WUVLAMP UV LAMP WARNING UV lamp output is below 600mV or above 4995mV or PMT above 4995mV WPMTTEMP PMT TEMP WARNING PMT temperature too high or too low WSHUTTTER SHUTTER WARNING Shutter not functioning WRCELLTEMP RCELL TEMP WARNING Reaction cell temp out of spec WBOXTEMP BOX TEMP WARNING Box tempe...

Page 100: ...erface To clear the sample flow warning shown above the command would be W WSAMPFLOW 6 8 5 CALIBRATION Commands and Messages Table 6 12 RS 232 Calibration Messages Message Description START ZERO CALIBRATION Beginning IZS zero calibration FINISH ZERO CALIBRATION SO2 1 xxxxx PPB Finished IZS zero calibration START SPAN CALIBRATION Beginning IZS span calibration FINISH SPAN CALIBRATION SO2 1 xxxxx PP...

Page 101: ...d Description C LIST List calibration commands C ZERO Start remote zero calibration C SPAN Start remote span calibration C COMPUTE ZERO Adjust remote zero calibration C COMPUTE SPAN Adjust remote span calibration C EXIT Terminate remote zero or span calibration C ABORT Abort calibration sequence C ASEQ X Initiate automatic sequence X if previously setup 6 8 6 DIAGNOSTIC Commands and Messages When ...

Page 102: ...this command to exit SIG ET or OT Diagnostic modes D RESET Resets analyzer software Same as power on D RESET RAM Resets analyzer software and erases RAM Erases SO2 conc values Keeps setup variables and calibration Same as installing new software version D RESET EEPROM Resets analyzer software and erases RAM and EEPROM Returns all setup variables to factory defaults resets calibration value 6 8 7 D...

Page 103: ...nel summary report and data reports Data Channel Summary Format When you press the PRNT button in the data channel edit menu a report like the following is printed on the RS 232 channel SETUP PROPERTIES FOR CONC NAME CONC EVENT ATIMER STARTING DATE 25 JUL 96 SAMPLE PERIOD 000 00 01 REPORT PERIOD 000 00 05 NUMBER OF RECORDS 800 RS 232 REPORT ON COMPACT REPORT OFF CHANNEL ENABLED ON CAL HOLD OFF ON ...

Page 104: ...at of a leading first character D in this example a time stamp 31 10 06 and the instrument ID 0412 The other fields in the report are the data channel name CONC the sampling mode AVG the parameter CONC1 the parameter value 6 8 and the units PPB If the RS 232 interface is in the quiet mode then these reports are not printed although they can be requested by a user or host computer at a later time 6...

Page 105: ...gnostic test DIAG Main diagnostic menu DIAG I O Signal I O diagnostic DIAG RS232 RS232 output diagnostic DIAG ERASE Memory erase diagnostic SETUP x x Setup mode x x is software version SAMPLE A Sampling automatic cal enabled SAMPLE Sampling automatic cal disabled The 6200A operational modes are listed above To list the analyzer s current mode type V MODE Lists 6200A current operational mode See Ta...

Page 106: ... values data_hi upper limit of allowable values Variables can be changed Before changing the settings on any variables please make sure you understand the consequences of the change We recommend you call the factory before changing the settings on any variables The general format for changing the settings on a variable is V LIST name value warn_lo warn_hi For example to change the warning limits o...

Page 107: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G INTENTIONALLY BLANK 6 26 ...

Page 108: ... be initiated and controlled via the RS 232 port see Section 6 8 for details NOTE If you are using the 6200A for EPA monitoring it is recommended to follow the calibration method described in Section 7 8 All other calibration methods except in Section 7 6 are also applicable to EPA SLAMS if calibrated under the proper conditions as explained in Section 7 8 NOTE If there are any problems completing...

Page 109: ... 5 Dynamic Z S Calibration with Z S Valves or IZS Option Operates Z S valves or IZS once per day and adjusts the calibration 7 6 Calibrate using SO2 Permeation Tube Allows calibration using SO2 gas from the IZS permeation tube 7 7 Use of Z S Valve or IZS with Remote Contact Closure Operates Z S valves or IZS with rear panel contact closures Without valves or IZS can be used to switch instrument in...

Page 110: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G Figure 7 1 Model 6200A Calibration Setup 7 3 ...

Page 111: ...s not necessary to enter the expected zero value Table 7 2 details the zero calibrate procedure with zero gas coming in through the sample port Table 7 2 Manual Zero Calibration Procedure Zero Gas Through Sample Port Step Number Action Comment 1 Press CAL The 6200A enters the calibrate mode from sample mode The zero gas must come in through the sample port 2 Wait 10 min Wait for reading to stabili...

Page 112: ...pan value 3 Press EXIT Returns instrument to SAMPLE mode Table 7 4 Manual Span Calibration Procedure Span Gas Through Sample Port Step Number Action Comment 1 Press CAL The 6200A enters the calibrate mode External span gas should be fed to the sample port 2 Wait 10 min Wait for reading to stabilize at span value 3 Press SPAN If you change your mind after pressing SPAN you can still press EXIT here...

Page 113: ... press EXIT here without zeroing the instrument 4 Press ENTR Pressing ENTR actually changes the calculation equations forcing the reading to zero 5 Press EXIT The 6200A returns to sample mode Immediately after calibration readings do not go into the DAS averages Table 7 6 Manual Span Calibration Procedure Z S Valves Step Number Action Comment 1 Press CALS The 6200A enters the calibrate mode from s...

Page 114: ...utomatically check AUTOCAL its calibration each day If provided with the proper options the 6200A provides this capability by using the time of day clock to signal the computer system to check operations When enabled the instrument software will automatically check zero and span AUTOCAL on a timed basis Optionally the Z S cycle can be moved backwards or forwards a fixed time each day to avoid miss...

Page 115: ...alves with Remote Contact Closure The Zero Span valve or IZS options can be operated using Remote Contact Closures provided on the rear panel See Figure 2 2 for connector location and pinout When the contacts are closed the analyzer will switch to zero or span mode The contacts must remain closed for at least 1 second and the Analyzer will remain in zero or span mode as long as the contacts are cl...

Page 116: ...ir Pollution Measurement Systems abbreviated Q A Handbook be purchased from the NTIS phone 703 605 6000 Special attention should be paid to Section 2 9 which deals with fluorescence based SO2 analyzers and upon which most of this section is based Specific regulations regarding the use and operation of ambient sulfur dioxide analyzers can be found in 40 CFR 50 and 40 CFR 58 Both publications are av...

Page 117: ...ed on more than one range it should be calibrated separately on each applicable range see Section 7 9 Calibration documentation should be maintained with each analyzer and also in a central backup file 7 8 2 Calibration Gas Sources Compressed SO2 in nitrogen The NIST SRM s provide references against which all calibration gas mixtures must be compared Section 2 0 7 Q A Handbook The procedure requir...

Page 118: ...Handbook Return equipment supplies to supplier or take corrective action Working standard SO2 cylinder gas or SO2 permeation tube Traceable to NIST SRM meets limits in traceability protocol for accuracy and stability Section 2 0 7 Q A Handbook Analyzed against NIST SRM see protocol in Section 2 0 7 Q A Handbook Obtain new working standard and check for traceability Zero air Clean dry ambient air f...

Page 119: ...ffect the calibration Subsec 2 5 Q A Handbook Repeat the calibration 7 8 3 Data Recording Device Either a strip chart recorder data acquisition system digital data acquisition system should be used to record the data from the 6200A RS 232 port or analog outputs If analog readings are being used the response of that system should be checked against a NIST referenced voltage source or meter Data rec...

Page 120: ...f the instrument will be used more than one range it should be calibrated separately on each applicable range 2 Automatic temperature pressure compensation See Table 9 5 3 Alternate units make sure ppb units are selected for EPA monitoring See Section 5 3 4 2 The analyzer should be calibrated on the same range for monitoring If autoranging option is selected the highest of the ranges will result i...

Page 121: ...e CAL menu 1 Adjust the SO2 concentration to approximately 80 of the URL of the range The expected SO2 span concentration can be determined by measuring the cylinder and diluent flows and computing the resulting concentration Calculate the expected concentration as follows SO F F SO gas total ga 2 s Equation 7 1 2 where SO2 gas cylinder gas concentration ppm Fgas SO2 gas flow rate cc min Ftotal to...

Page 122: ...key sequence causes the 6200A to prompt for the expected SO2 concentration Enter the SO2 span concentration value by pressing the key under each digit until the expected value is set 2 Press ENTR ENTR stores the expected SO2 span value 3 Press EXIT Returns instrument to SAMPLE mode Sample the generated concentration until the SO2 response is stabilized Span the instrument by the following procedur...

Page 123: ...the corresponding calculated concentrations to obtain the calibration relationships Determine the straight line of best fit y mx b determined by the method of least squares After the best fit line has been drawn for the SO2 calibration determine whether the analyzer response is linear To be considered linear no calibration point should differ from the best fit line by more than 2 of full scale 7 8...

Page 124: ... the URL of the range Calculate the expected concentration as follows SO P F F c 2 3 4 4 10 382 10 Equation 7 2 SO2 SO2 gas concentration ppm P permeation flow rate at the specific temperature ug SO2 min Fc carrier flow rate over the permeation tube SLPM 25o C 760 mmHg Fd diluent air flow rate SLPM 25o C 760 mmHg Figure 7 3 Diagram F Permeation Calibration System 7 17 ...

Page 125: ... to the expected SO2 concentration entered in the procedure given in step 3 above See the Troubleshooting Section 9 2 8 if there are problems Also see the Calibration Quality Check procedure Section 7 10 After the zero and the 80 URL points have been set determine five approximately evenly spaced points between zero and 80 URL without further adjustment to the instrument And allow the instrument t...

Page 126: ...lished calibration units or the calibration limits in Section 2 0 9 Subsection 9 1 3 Q A Handbook a calibration should be performed 7 8 7 Other Quality Assurance Procedures Essential to quality assurance are scheduled checks for verifying the operational status of the monitoring system The operator should visit the site at least once each week It is recommended Level 1 zero and span check conducte...

Page 127: ...ed to any changes drifts in the analyzer response LEVEL 2 ZERO AND SPAN CHECK A Level 2 zero and span check is an unofficial check of an analyzer s response It may include dynamic checks made with uncertified test concentrations artificial stimulation of the analyzer s detector electronic or other types of checks of a portion of the analyzer etc Level 2 zero and span checks are not to be used as a...

Page 128: ... No moisture foreign material leaks obstructions sample line connected to manifold Weekly visual inspection Clean repair or replace as needed Recorder 1 Adequate ink paper 2 Legible ink traces 3 Correct chart speed and range 4 Correct time Weekly visual inspection 1 Replenish ink and paper supply 2 Adjust time to agree with clock note on chart Analyzer operational settings 1 TEST measurements at n...

Page 129: ...s 1 and 2 are described in detail in Subsection 9 1 3 of Section 2 0 9 Q A Handbook Item 3 is described in Subsection 9 1 4 of the same section Refer to the Troubleshooting Section 9 of this manual if the instrument is not within the allowed variations 7 8 9 1 Zero Span Check Procedures The Zero and Span calibration can be checked a variety of different ways They include 1 Manual Zero Span Check Z...

Page 130: ...o sample the precision gas until a stable trace is obtained 3 Record this value Information from the check procedure is used to assess the precision of the monitoring data see 40 CFR 58 for procedures for calculating and reporting precision 7 8 10 Recommended Standards for Establishing Traceability To assure data of desired quality two considerations are essential 1 the measurement process must be...

Page 131: ...h Range1 and Range2 separately Pressing CAL key will prompt 1 and 2 keys for Range1 Low Range or Range2 Hi Range calibration selection Select desired range number and press ENTR to proceed to the calibration Once Range is selected the display will show Test Measurements and SO2 concentration for the corresponding Range You must enter expected SO2 gas concentrations separately per Table 7 3 procedu...

Page 132: ...xplanation of the use of these terms in the concentration calculation see Section 5 2 2 5 The slope and offset parameters are similar to the span and zero pots on an analog instrument Just as in the analog instrument if the slope or offset get outside of a certain range the instrument will not perform as well The offset value gives information about the background signal level Check the observed o...

Page 133: ... for Air Pollution Measurement Systems Volume II Ambient Air Specific Methods EPA 600 4 77 027a 1977 Catalog of NBS Standard Reference Materials NBS Special Publication 260 1975 76 Edition U S Department of Commerce NBS Washington D C June 1975 Tel 301 975 6776 for ordering the catalog 3 Quality Assurance Handbook for Air Pollution Measurement Systems Volume I Principles EPA 600 9 76 005 March 197...

Page 134: ...eeded Section 7 Zero Span checks Daily Section 7 Table 6 2 Particulate Filter Weekly as needed Figure 8 1 Zero air canister Refill every 3 months Section 8 4 Zero Air DFU filter Change every 12 months Section 8 4 Reaction cell cleaning Clean annually and clean as necessary Section 8 6 Figure 8 3 Sample Flow Check every 6 months Figure 8 3 Section 9 2 2 Pneumatic Lines Examine every 12 months clean...

Page 135: ...ate filter should be changed at a minimum every 2 weeks If instrument is operated under high dust environment then should replace filter more frequently To check and change the filter refer Figure 8 1 1 Fold down the 6200A front panel 2 Locate the filter on the left side of the analyzer front panel and visually inspect the filter through the glass window 3 If the filter appears dirty unscrew the h...

Page 136: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G Figure 8 1 Replacing the Particulate Filter 8 3 ...

Page 137: ...garding permeation tube output concentration CAUTION Avoid turning off the analyzer with perm tube inside of the analyzer for more than an hour This will cause to contaminate the analyzer with saturated perm tube gas When transporting the analyzer remove the perm tube from the oven and store it inside of the shipping container in safe cool place 8 4 Replacing the IZS Zero Air Scrubber option The I...

Page 138: ... far left and far right only from the vacuum manifold assembly 3 With a toothpick or paper clip remove the spring filter o ring orifice and the o ring from each port 4 Discard the filter 5 Check the orifice by looking it at the light to see that the orifice itself is open If it is not open try cleaning the orifice with a strand of fine wire or immersing in a solvent such as methyl alcohol or both ...

Page 139: ... 5 Wipe out the reaction cell with a de ionized water wetted lintless wipe Dry with another lintless wipe 6 Be sure that all lint particles are removed particularly from the UV lens and PMT filter 7 Install the cell cover 8 Install the shock absorber mount screws 9 Leak check per Section 8 8 8 7 Pneumatic Line Inspection Particulate matter and contamination in the pneumatic lines will affect the r...

Page 140: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G Figure 8 2 Reaction Cell 8 7 ...

Page 141: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G Figure 8 3 Pneumatic Diagram 8 8 ...

Page 142: ...eck the sample flow reading It should be close 20 CC min to the previous reading in step 4 After step 1 of above pull the vacuum for about 15 in Hg and close the shut off valve of the leak checker If the pressure changes more than 1 in Hg within 5 minutes there is a leak It is not possible by the vacuum method to tell where the leak is located See the pressure method below to locate the leak Press...

Page 143: ...rboard Gently lift the assembly far enough out of the instrument to remove the connector from the display and the RS 232 connector 3 The CPU board is attached to the larger V F board 4 Remove the board laying it down on an insulating surface such that the board edge pins on the PCB are on the left The EPROM chip should be at the top center See Figure 9 1 for location of prom on CPU card Gently pry...

Page 144: ...or component level troubleshooting consult the schematics for the appropriate board in Appendix A 1 NOTE The values of the readings shown on the front panel of the instrument may at times read XXXXXX This means that the reading is off scale and therefore meaningless General Troubleshooting Hints 1 Is the fault light on If it stays on after you clear the warning messages see Section 9 1 2 2 Think o...

Page 145: ... lines kicker reaction cell etc d UV lamp not calibrated 2 Possible causes for the drift or change of offset are a Pneumatic leak b Light leak c UV filter damaged d Incorrect zero gas Incorrect span gas concentration this could come either from the calibrator or entering the expected span gas concentration in the 6200A incorrectly see Table 7 3 4 If the instrument does not respond to span gas chec...

Page 146: ... and range 2 Auto range option allows 2 different ranges for each channel and will automatically switch to the other range dynamically as concentration values require The TEST values will show the range the instrument is currently operating in and will dynamically display the alternate range as the range changes occur STABIL The instrument stability is computed for 25 samples with 10 seconds defau...

Page 147: ...ured by the solid state flow meter Incorrect flow can be caused by the plugged orifice pneumatic leak or the flow meter itself A rTAId method of determining if the orifice is plugged is to disconnect the sample tube from the reaction cell then briefly put your finger over the fittings on the cell You should feel the vacuum build up Another reliable method is to attach a rotameter or soap bubble fl...

Page 148: ...n 450mV and relatively constant High or noisy readings could be due to Pneumatic leak Excessive background light which is caused by a possible aging UV filter Low UV lamp output PMT recently exposed to room light It takes 24 48 hours for the PMT to adapt to dim light Light leak in reaction cell Reaction cell contaminated UV LAMP 1000 4800 mV This is the instantaneous reading of the UV lamp intensi...

Page 149: ...light causing complete darkness inside of the reaction cell This darkness reading by the PMT is monitored and compensated for any PMT dark current drift High dark PMT reading could be due to Light leak Shutter not closing completely High PMT temperature High electronic offset DRK LMP 50 200 mV This is the reading of the UV reference detector without the UV lamp When the shutter blocks the UV light...

Page 150: ...igh offset could be due to Light leak Aging UV filter Contaminated reaction cell Pneumatic leak Poor calibration quality HVPS 550 900 V This represents the scaled up HVPS programming voltage to the HVPS The design of the HVPS precludes taking a single reading that indicates the health of the supply Refer to the HVPS Troubleshooting Section 9 3 10 for a procedure for testing the HVPS This TEST func...

Page 151: ...52o C PMT TEMP 7 1o C The PMT detector is very temperature sensitive The PMT temperature should always be 7o C except at power up Temperatures more than 1o C from the set point indicate problems with the cooler circuit See Section 9 3 9 for PMT cooler diagnostic and troubleshooting Warning limits are 0o C and 15o C IZS TEMP 50 0 3o C The IZS temperature is the temperature of the permeation tube ov...

Page 152: ...d in the RAM UV LAMP WARNING UV lamp output is below 1000mV or above 4995mV or PMT output above 4995 mV UV lamp could be aging or need to peak output by adjusting the position Also dirty optical system will cause to read lower SHUTTER WARNING Shutter system is not functioning properly Either it is not energized electrically or has mechanical problem Strong light leak could cause false shutter alar...

Page 153: ...DYN ZERO Dynamic zero cal out of spec The reading of the PMT was too high for the ZERO button to appear Make sure the instrument is receiving zero gas Check for dirty reaction cell Do the factory calibration procedure located in Section 9 1 6 CANNOT DYN SPAN Dynamic span cal out of spec The reading of the PMT was too high or low for the SPAN button to appear Make sure the instrument is receiving c...

Page 154: ...To enter DIAG mode press SETUP MORE DIAG The diagnostic modes are summarized in Table 9 3 To access these functions after you have pressed SETUP MORE DIAG then press NEXT PREV to select the desired mode then press ENTR to select that mode Table 9 3 below contains a summary of the diagnostic modes and their operation This section is a detailed description of the test and suggestions for its use 9 1...

Page 155: ... buffer amplifiers DAC CALIBRATION The analog output is created by 4 digital to analog converters This selection starts a procedure to calibrate these outputs Refer to Section 9 3 3 1 for a detailed procedure OPTICAL TEST Sets the 6200A into a known state and turns on an LED near the PMT to test the instrument signal path See Section 9 1 3 3 for details on using this test ELECTRICAL TEST Tests jus...

Page 156: ...Span valve Use this bit to test the valve function 4 CAL_VALVE YES Switches the IZS Sample Cal valve Use this bit to test the valve function 5 DARK_SHUTTER YES Energizes the shutter Use this bit to test the shutter function which will block mechanically the UV lamp light source 6 RCELL_ HEATER NO Shows the status of the reaction cell heater This has the same function as the LED in the power supply...

Page 157: ...s Bit Shutter alarm Logic High Shutter not working Logic Low Shutter working properly 14 PRMP_RNG_HI YES Switches the preamp 01105A hardware range Standard ranges are 2000 and 20 000 ppb Logic high 20 000 ppb logic low 2000 ppb 6200A will reset range to correct value based on user set range value 15 ST_ZERO_CAL YES Status Bit Zero Calibration mode Logic high 6200A in Zero cal mode Logic low Not in...

Page 158: ... as PMT voltage in TEST menu Bi polar typically in 0 5000mV range A constant value of 5000mV indicates offscale 24 RCELL_TEMP NO Reaction Cell temperature 3500 mV for 50o C 25 BOX_TEMP NO Box Temperature Typically 1800 mV for 25o C 26 IZS_TEMP NO IZS permeation tube oven temp Typically 3500 mV for 50o C 27 PMT_TEMP NO PMT cold block temperature Typically 4300 mV for 7o C 28 DCPS_VOLTAG NO DC power...

Page 159: ...puter for proper functioning The result of electric test should be a smooth quiet signal as shown by constant values for the SO2 concentration Likewise the analog outputs should produce a smooth quiet trace on a strip chart analog output range is set to 2000ppb and auto ranging is disabled Procedure 1 Scroll the TEST function to PMT 2 Press SETUP MORE DIAG scroll to ELECT TEST by pressing the NEXT...

Page 160: ...o select the optic test and push ENTR button 4 The PMT reading in TEST functions should be 2000 1000mV If the HVPS or the span gain adjust on the preamp card has been changed without doing a FACTORY CALIBRATE the reading in step 4 may be different than 2000 mV since the overall calibration affects OPTIC TEST Also if the SO2 concentration display is not within the nominal range of 1000 500 ppb then...

Page 161: ... manufacture and do not need to be adjusted for the lifetime of the instrument It is possible to change these variables either through the RS 232 port or the front panel Altering the values of many of the variables especially those not listed on Table 9 5 will adversely affect the performance of the instrument and could possibly affect the EPA equivalency designation Therefore it is recommended th...

Page 162: ...C 50 30 70 Reaction cell temperature set point 3 IZS_SET C 50 30 70 IZS temperature set point 4 DYN_ZERO OFF OFF ON Enable to adjust zero calibration through remote contact closure 5 DYN_SPAN OFF OFF ON Enable to adjust span calibration through remote contact closure 6 RS232_MODE Bit Field 8 0 99999 Value is SUM of following decimal numbers 1 enable quiet mode 2 enable computer mode 3 enable secur...

Page 163: ...0 5000mV 2 UV READING UV lamp output 0 5000mV 3 SAMPLE PRESS Sample pressure sensor 0 40 in Hg 4 SAMPLE FLOW Sample flow rate 0 1000 cc min 5 RCELL TEMP Reaction cell temp sensor 0 70o C 6 BOX TEMP Box temp sensor 0 70o C 7 IZS TEMP IZS temp sensor 0 70o C 8 PMT TEMP PMT temp sensor 0 20o C 9 CONV TEMP H2S converter temperature H2S version only 0 500o C 10 DCPS VOLTAGE DC power supply 0 5000mV 11 ...

Page 164: ...n label inside of the Preamp cover 2 Adjust the UV lamp per Section 9 4 2 and reset the Lamp Cal value by selecting SETUP MORE DIAG and scroll to select LAMP CALIBRATION Reset the LAMP CAL value by pressing ENTR Value displayed is the current UV lamp intensity and pressing ENTR will update the value 3 Set RANGE MODE to SING by SETUP RNGE MODE to select single range operation 4 Set the RANGE to 500...

Page 165: ...ove procedure do the following to re adjust the ET signal 2 To re adjust ET press SETUP MORE DIAG then scroll to ELEC TEST and press ENTR 3 Scroll the TEST functions until PMT is displayed 4 Adjust R27 until 2000mV 1000 is displayed 5 Press EXIT to return to SAMPLE mode 9 1 6 2 Optic Test OT Procedure 1 Any time the PMT buffer amplifier circuit R19 gain and or the PMT high voltage setting is chang...

Page 166: ...ning SO2 leaking into zero air line B Saturation of charcoal scrubber C Cracked DFU filter 4 Change in span gas concentration A Zero air or ambient air leaking into span gas line B Permeation tube or cal gas tank exhaustion C Dirty particulate filter 9 2 1 AC Power Check 1 Check that power is present at main line power input Verify that correct voltage and frequency is present 2 Check that the uni...

Page 167: ... Check instrument inlet flow using separate flow meter and compare the flow rate to the SAMP FLOW reading If the flow is lower than expected flow then leak check the analyzer as described in Section 8 8 6 If there is no leak and all above procedures can not correct flow rate reading then replace the flow meter see Figure 9 6 9 2 3 No Response to Sample Gas Confirm general operation of analyzer A C...

Page 168: ... new reaction cell may take a week or longer of conditioning time to reach low steady state condition 9 2 5 Excessive Noise Common reasons for excessive noise are 1 Leak in pneumatic system 2 Light leak check the sensor module with strong light 3 HVPS noisy see HVPS test procedure See Section 9 3 10 4 Defective electronic components on preamp board use optic test and electric test to check electro...

Page 169: ...unctions Check diagnostic LED in Power Supply Module for normal cycling 8 PMT temperature not stable observe warning messages or PMT TEMP in TEST functions 9 Sample vent line too short allowing room air to mix with span gas line should be a minimum of 15 long 10 Calibration gas source unstable if equipped with IZS option permeation tube could be nearing exhaustion or IZS oven temperature is unstab...

Page 170: ...n an analog instrument it would be the equivalent to the span pot hitting the maximum Here are some things to check 1 Check the expected span concentration value in CAL CONC and compare this to the value of the calibrator span gas being input They should be close 2 Check the PMT TEST function The value there should be about 2 x the expected span concentration in step 1 above for range settings up ...

Page 171: ...h reading the probable reasons are A Leak that admits gas containing SO2 B Contaminated reaction cell Remove and clean cell C Light leak D Zero gas that isn t really zero Make sure you re not trying to zero the machine with ambient air or span gas E Bad UV filter 9 2 10 Non Linear Response Common causes are 1 Leak in pneumatic system 2 Calibration device in error re check flowrate and concentratio...

Page 172: ...Teflon 3 Insufficient time allowed for purging of lines upstream of analyzer 4 Insufficient time allowed for SO2 cal gas source to become stable or cal gas flow is too low 9 2 12 Analog Output Doesn t Agree With Display Concentration 1 V F board DAC s out of calibration Do DAC calibration and Factory Calibration 2 Analog outputs electrically loaded down causing voltage to sag Could be due to input...

Page 173: ...on self test it will display a single underline character _ in the left most character of the top line of the display If this character is present the display is working properly 6 Turn off the power of the analyzer and re attach the 24 line cable to J2 and proceed to the next test 9 3 1 2 Single Board Computer The SBC40 is a full function computer designed for instrument control applications It c...

Page 174: ...Figure 2 5 2 Power the instrument on 3 Locate the red LED at the top left edge of the board 4 It should be flashing at a frequency of about once per second 5 This flashing indicates the board is powered up and is executing instructions RS 232 diagnostic procedures are described in Section 9 3 2 2 It is possible for the UART driver chip to malfunction in either or both of the input or output ports ...

Page 175: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G Figure 9 1 CPU Board Jumper Settings 9 32 ...

Page 176: ...8 is defined as the SETUP key Pressing key 8 should cause the SETUP menu to be displayed Example 3 If the 5 character field above any key is blank the key is not defined pressing the key has no effect The 3 status LED s indicate several functional states of the instrument such as calibration fault and sample modes The state of the LED s is controlled by 3 lines on the parallel port of the SBC40 Fu...

Page 177: ... DB 25 Adapter In this case the PC is wired as DTE and the analyzer s jumpers are set as DCE therefore a null modem is not needed The wiring is straight through i e pin 1 to pin 1 pin 2 to pin 2 etc Therefore all you have to do here is adapt the connector on the analyzer cable male DB 25 to the DB 25 male on the PC A female to female DB 25 gender changer cable or adapter will complete the connecti...

Page 178: ... the jumpers of the analyzer to DTE mode Refer to drawing 01115 Example 3 Connecting the TAI analyzer to a modem The modem is always configured as DCE Therefore setting jumpers as the DTE will be required to connect the analyzer to the modem Refer to drawing 01115 Data Communications Software for a PC You will need to purchase a software package so your computer can transmit and receive on its ser...

Page 179: ... that there is a grounding problem Check the relative ground levels of pin 5 on the DB 9 9 3 3 Voltage Frequency V F Board The V F Board consists of 16 analog input channels each software addressable 8 digital inputs and 24 digital outputs each line independently addressable and 4 independent analog output channels The analog input channels are connected to V F converter capable of 80 000 counts w...

Page 180: ...3 3 1 for information on how to calibrate the V F board 3 Digital input channel test The digital I O section of the V F board has 8 input bits and 24 output bits Two of the 8 input bits are assigned as calibration controls See Section 7 7 for information on calibration using external contact closures To test the digital inputs A Turn the 6200A power on B Connect a jumper wire across REMOTE IN term...

Page 181: ...DAC 0 Put the probe of a voltmeter recommend to use 4 1 2 digits meter on the recorder output terminals 1 and 2 on the 6200A rear panel The value displayed on the front panel and the voltmeter reading should be the same 3 mV If they are not adjust the zero pot R27 on the V F board until the two values are the same 1 mV Note that the voltmeter reading does not change while adjusting the zero pot R2...

Page 182: ...ORE DIAG ENTR and scroll down to the D A CALIBRATION diagnostic mode press ENTR to start the procedure Press CFG and scroll by pressing NEXT to select desired current output channel press SET CURR ENTR to define current output channel 3 Press CAL to start the calibration The 6200A display will read x CONC_OUT_X CURR ZERO where X the output channel number Press the up down buttons on the front pane...

Page 183: ...anges Several different output voltage ranges can be selected by DIP switch setting on the V F board See Figure 9 3 for the DIP switch settings If you change the analog output voltage range then you must reset the power of the instrument and do a ADC DAC calibration per Section 9 3 3 1 9 40 ...

Page 184: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G Figure 9 3 V F Board Dip Switch Settings 9 41 ...

Page 185: ...emperature Amplifier Section The Status Temp board is a multifunction board consisting of 4 thermistor amplifiers that monitor 1 IZS temperature 2 Reaction Cell temperature 3 Box temperature 4 Spare The voltages of the thermistor and thermocouple amplifier outputs are brought out to test points on the edge of the board The voltages can also be read using the DIAGNOSTIC SIGNAL I O feature see Table...

Page 186: ... inputs and outputs are terminated at the rear panel see schematic diagram 01114 The output lines are opto coupled NPN transistors which can pass 50 ma max of direct current with a voltage of 30 VDC max see Schematic 01087 The input lines are optically coupled with inputs pulled up to 5VDC External contacts can be contact closures or open channel transistor contacts DO NOT apply any voltage since ...

Page 187: ...greater The total load resistance should be between a 200ohm min to 1000 max precision load resistor of 1 tolerance or better is recommended 2 Current method Although current is constant in a series circuit accuracy in this type of measurement is usually less precise than with the voltage method due to the type of circuitry used in digital multi meters Connect a load resistance between 200 1000ohm...

Page 188: ...rent is required from the supply Switch Board The Switch Board has many different functions It takes logic signals from the V F board and uses them to switch 4 115 VAC and 4 12VDC loads The board also contains the instrument central grounding tie point It routes unswitched AC and DC power as needed Connector J2 programs the power transformers to take 115 220 or 240 VAC inputs Power Transformers Th...

Page 189: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G Figure 9 4 Power Supply Module Layout 9 46 ...

Page 190: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G Figure 9 5 Electrical Block Diagram 9 47 ...

Page 191: ... be tested by observing the diagnostic LEDS along the top edge of the board The following Table 9 8 describes the typical operation of each LED Table 9 8 Power Supply Module LED Operation No Function Description 1 Shutter Should energize once every 30 minutes for about 15 sec On shutter closed mode Off shutter open mode The shutter can be energized manually under SIGNAL I O of Diagnostic mode See ...

Page 192: ...ding if observing the TEST functions To adjust the sample flow proceed as followings 1 Remove the 1 8 fitting from the reaction cell 2 Scroll to select SFLOW of the TEST functions 3 Using independent flow meter verify the flow rate into the reaction cell 4 Adjust R3 of the flow pressure board to match the front panel display to the flow rate of independent flow meter 5 If not able to adjust then r...

Page 193: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G Figure 9 6 Flow Pressure Sensor 9 50 ...

Page 194: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G Figure 9 7 SO2 Sensor Module 9 51 ...

Page 195: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G Figure 9 8 SO2 Sensor Module 9 52 ...

Page 196: ...ee Section 9 3 9 is not adjustable 9 3 9 PMT Cooler The PMT cooler uses a Thermal Electric Cooler TEC supplied with DC current from the switching power supply in the Power Supply Module An overall view is shown in Figure 9 9 The temperature is controlled by a temperature controller circuit located on the Preamp board Voltages applied to the cooler element vary from 0 1 to 12VDC The input voltage f...

Page 197: ...the fan duct and unplug cable plugs from the fan duct assembly 3 Remove four screws holding the heatsink assembly from the PMT housing assembly and separate these two assembly carefully by pulling heatsink assembly slowly out of the PMT housing until HVPS module is completely out of the PMT housing refer to Figure 9 8 4 Remove two screws from the HVPS module to separate HVPS module from the cooler...

Page 198: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G Figure 9 9 PMT Cooler Subsystem 9 55 ...

Page 199: ...red in the Factory Calibration Procedure in Section 9 1 6 To troubleshoot the HVPS 1 While sampling stable SO2 gas record PMT reading and HVPS reading of the TEST function 2 Change HVPS voltage about 50V lower than the current setting by adjusting S2 and S1 on the preamp board If PMT reading on the display drops about 40 10 from the previous reading then HVPS is working properly 3 If PMT reading d...

Page 200: ...t each pin of the supply and the overall voltage 10 Turn off the instrument power and re connect the PMT tube then re assemble the sensor If any faults are found in the test you must obtain a new HVPS as there are no user serviceable parts inside the supply Figure 9 10 High Voltage Power Supply 9 57 ...

Page 201: ... voltage Lamp short term drift Over a period of hours the UV emitted from the lamp may increase or decrease slightly 2 Lamp aging Over a period of months the UV energy will show a downward trend usually 30 in the first 90 days and then a slower rate until the end of useful life of the lamp 2 3 years nominally 3 Lamp positioning The physical alignment of the lamp in its holder which is optimized by...

Page 202: ...emove 4 screws from the shutter cover refer to Figure 9 7 and remove the cover 4 Remove 4 screws from the UV filter retainer 5 Carefully remove the UV filter 6 Install the UV filter Handle carefully and never touch the filter s surface UV filter s wider ring side should be facing out 7 Install UV filter retainer and tighten screws 8 Install the shutter cover and minifit connector Tighten 4 screws ...

Page 203: ...e noted the pump may need servicing Pneumatic leak also can cause higher pressure 9 5 3 Kicker The Kicker assembly consists of the membrane tube and Teflon tube The pump creates the vacuum between the membrane and the Teflon tube causing a differential pressure Poly nuclear Hydrocarbon in the sample is removed while passing through membrane tube by this differential pressure Leak check as Section ...

Page 204: ...TAI Model 6200A SO2 Analyzer Operator Manual 02164 Rev G Figure 9 11 Kicker Leak Check 9 61 ...

Page 205: ...splay CALS and CALZ buttons on the second line of the display The presence of the buttons indicates that the option has been enabled in software Troubleshooting the Z S valves It is possible to manually toggle each of the valves in the DIAGNOSTIC mode Refer to Section 9 1 3 for information on using the DIAG mode Also refer to Figure 8 3 for a pneumatic diagram of the system Check for the IZS optio...

Page 206: ... Parts List PART NO DESCRIPTION QTY F1548 Filter TFE 47 mm 25 per packet 2 F1549 Sintered Filter 002 024900 5 S1282 Spring Flow Control 1 O305 O Ring Flow Control 2 P1094 Pump Rebuild Kit KNF model NO5ATI 1 F1550 Filter DFU 4 T1307 Converter Tube 1 F1551 Furnace 1 IZS Option CP2106 Activated Charcoal 6 pounds 1 F1549 Sintered Filter 002 024900 2 F1550 Filter DFU 036 040180 1 O305 O Ring Flow Contr...

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