Teledyne M102E/M501 TRS, Troubleshooting & Repair, Remove the reaction cell assembly, Rev A1

Page 66

3.Remove the reaction cell assembly.

TROUBLESHOOTING & REPAIR	M102E/M501 TRS
	(Addendum to M101E Manual - P/N 04740 Rev A)

3.Remove the reaction cell assembly.

4.Remove the two connectors on the PMT housing end plate facing towards the front panel.

5.Remove the end plate itself (4 screws with plastic washers). R

6.Remove all of the desiccant bags inside the PMT housing.

7.Along with the plate, slide out the OPTIC TEST LED and the thermistor that measures the PMT temperature.

•The thermistor will be coated with a white, thermal conducting paste. Do not contaminate the inside of the housing or the PMT tube with this grease.

8.Unscrew the PMT assembly. It is held to the cold block by two plastic screws.

•Because the threads of the plastic screws are easily damaged it is highly recommended to use new screws when reassembling the unit.

9.Carefully take out the assembly consisting of the HVPS, the gasket and the PMT.

10.Change the PMT or the HVPS or both, clean the PMT glass tube with a clean, anti-static wipe and do not touch it after cleaning.

11.If the cold block or TEC is to be changed disconnect the TEC driver board from the preamplifier board.

a.Remove the cooler fan duct (4 screws on its side) including the driver board.

b.Disconnect the driver board from the TEC and set the sub-assembly aside.

c.Remove the end plate with the cooling fins (4 screws) and slide out the PMT cold block assembly, which contains the TEC.

d.Unscrew the TEC from the cooling fins and the cold block and replace it with a new unit.

12.Re-assemble the TEC subassembly in reverse order.

CAUTION

The thermo-electric cooler needs to be mounted flat to the heat sink. If there is any significant gap, the TEC might burn out. Make sure to apply heat sink paste before mounting it and tighten the screws evenly and cross-wise.

a.Make sure to use thermal grease between the TEC and the cooling fins as well as between the TEC and the cold block.

b.Align the side opening in the cold block with the hole in the PMT housing where the sample Chamber attaches.

c.Evenly tighten the long mounting screws for good thermal conductivity.

13.Re-insert the TEC subassembly. Make sure that the O-ring is placed properly and the assembly is tightened evenly.

14.Insert the LED and thermistor into the cold bloc.

60	05514 Rev A1

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Contents ADDENDUM TO MODEL 101E OPERATORS MANUAL MODEL 102E TOTAL REDUCED SULFUR ANALYZERMODEL 501 TRS THERMAL CONVERTER withPage 05514 Rev A1 TABLE OF CONTENTSM102E/M501 TRS Addendum to M101E Manual - P/N 04740 Rev A10. TROUBLESHOOTING & REPAIR LIST OF APPENDICES8. INSTRUMENT MAINTENANCE 9. THEORY OF OPERATIONLIST OF FIGURES LIST OF TABLESPREFACE Page 1. PREFACE corner of the display any time the instrument is in SETUP modeUser Notes 1.1. Reference Numbering convention2.1.1. M501-TRS Specifications 2. SPECIFICATIONS, APPROVALS AND WARRANTY2.1. Specifications 2.2. EPA Equivalency Designation2.3. CE Mark Compliance 3.2. Unpacking the M501-TRS 3. GETTING STARTED3.1. Unpacking the M102E Never disconnect electronic circuit boards, wiring harnesses or3.2.1. M501-TRS Ventilation Clearance that the rack/enclosure itself is adequately ventilatedthe maximum operating temperature specification for the M102E 40C 3.3. Internal Layouts Figure 3-1 M102E Internal LayoutFigure 3-2 M501-TRS Internal Layout M102E INSTRUMENT CHASSIS 3.4. Internal Pneumatic Flow of the M102E & the M501-TRSTable 3-1 TRS - SO2 Switching Valve Operating Modes M501Figure 3-4 M102E Rear Panel Layout 3.5. Rear Panel Layout for the M102E & M501-TRSAlarm Output 5 Amp3.6.1.1. M102E Analog Output Connections 3.6. Initial Setup3.6.1. Electrical Connections Figure 3-6 Analog Output ConnectorM102E PNEMATIC CONNECTERS 3.6.1.2. M501-TRS Alarm Output Connections3.6.2. Pneumatic Connections M501-TRS PNEMATIC CONNECTERSMODEL 102EThe exhaust from the instrument needs to be vented outside the SPAN GAS3.6.2.1. Connections with Internal Valve Options Installed ZERO AIRGas Dilution Calibrator VENTVENT if input is pressurized Option Valve Option3.7.2. Functional Check of the M102E 3.7. Initial Operation3.7.1. Startup / Warm Up of the M102E Possible Warning Messages at Start-UpProcess Variable High Alarm LED Low Alarm LED3.7.3. Startup / Warm Up of the M501-TRS Display area3.8. Initial Calibration Page 4.2. Calibration Valves Options 4. OPTIONAL HARDWARE AND SOFTWARE4.1. Rack Mount Kits Options 20a, 20b, 21, 22 OPTIONAL HARDWARE AND SOFTWAREZero/Span Valve Operating States M102E INSTRUMENT CHASSIS Table 4-2 IZS Valve Operating States4.3. Additional Manuals 4.3.1. Printed Manuals P/N4.3.2. Addendum on CD Part number Figure 5-1 Analog Output Connector Key 5.1.1. M102E Analog Output Signals5. M102E OPERATING INSTRUCTIONS M102E OPERATING INSTRUCTIONS5.2.1. M102E Analog I/O Configuration 5.2. SETUP - DIAG Using the Diagnostics Functions5.1.2. Setting the M102E Gas Measurement Mode Table 5-1 M102E gas Measurement Modes5.3.1. M102E ID Code 5.3. SETUP - COMM Setting Up the M102E’s Communication Ports5.2.2. M102E Test Channel Output 5.3.2. M102E Ethernet Host NameCONTROL IN 5.4. Remote Operation of the Analyzer5.4.1. Control Inputs ZERO5.4.2.1. M102E Hessen Protocol Gas ID List 5.4.2. Using the M102E with a Hessen Protocol Network5 VDC Power Supply SPAN5.4.2.2. Setting Hessen Protocol Status Flags Table 5-6 Default Hessen Status Bit AssignmentsDO NOT OPERATE WITHOUT THE COVER OF THE M501TS CONVERTER INSTALLED 6. M501-TRS OPERATING INSTRUCTIONS6.1. Basic M501-TRS Controls Teledyne Instruments customer service6.2. To Display The Current Temperature Table 6-1 M501-TRS Temperature Controls and Definitions6.3. To Manually Adjust the Converter Oven Temperature DO NOT SET THE TEMPERATURE HIGHER THAN 1050OC6.4. Autotune the Temperature Controller 6.4.1. Initiating the Autotune Processhas reached a stable, constant temperature 6.5. M501TRS Alarm Relay Adjustment 6.4.2. Aborting the Autotune Processnecessary to repeat the autotune procedure Page 7.1. M102E Calibration 7. CALIBRATION PROCEDURESUSER NOTES 7.2. M501-TRS CalibrationPage 8. INSTRUMENT MAINTENANCE INSTRUMENT MAINTENANCE8.1. Additional and Updated Maintenance Procedures 8.1.1.1. Predicting When the SO2 Scrubber Should Be Replaced8.1.1. Maintaining the SO2 Scrubber 8.1.1.2. Checking the Function of the SO2 Scrubber 8.1.1.3. Changing the SO2 Scrubber MaterialPage 9.1.1. TRS Conversion 9. THEORY OF OPERATION9.1. Measurement Principle 9.1.2. SO2 Ultraviolet FluorescenceIa = I0 1 − exp− axSO2 SO2 + hv214nm ⎯⎯Ia⎯→ SO2SO2 * ⎯⎯→ SO2 + hv330nm Figure 9-1 UV Absorption in the M102E Reaction CellF = kSO2 kSO2 * ⎯⎯F⎯→ SO2 + hv330nmEquation9-6 9.2.1. UV Lamp Shutter & PMT Offset 9.2. The UV Light Path9.3. Pneumatic Operation 9.3.1. Sample gas Flow9.4.1. Sensor Module PMT HOUSING9.4. Electronic Operation SAMPLE CHAMBERUV LampSample Air Housing Outlet O-Ring O-Ring Seal Seal 9.4.1.1. Sample Chamber9.4.1.2. Sample Chamber Heating Circuit Sample AirHEATER 9.4.2.1. Thermal Switch9.4.2. M501-TRS electronics P-I-D CONTROLLER9.4.2.2. Temperature Alarms and Alarm Output 10.1.1.2. M501-TRS Error Codes 10. TROUBLESHOOTING & REPAIR10.1.1. Fault Diagnosis with Warning Messages 10.1.1.1. M102E Warning Messages10.1.2. Fault Diagnosis with Test Functions Table 10-2 Test Functions - Possible Causes for Out-Of-Range Valuesfunctioning 10.2.1. TRS Converter Not Heating 10.2. M501-TRS Trouble shooting10.3. Other Performance Problems 10.3.1. Excessive noise10.4. Subsystem Checkout 10.4.1. Checking the Efficiency of the M501-TRS SO2 Scrubber10.4.2. Checking the Efficiency of the M501-TRS TRS Æ SO2 Converter 10.5. Additional Repair Procedures 10.5.1. UV Lamp Adjustment and/or ReplacementLamp Assembly 10.5.1.1. Adjusting the UV Lamp Peaking the LampALWAYS wear UV-Protective, Safety Glasses when working with the UV Always grasp the main body of the lamp10.5.1.2. Replacing the UV Lamp Figure 10-1 Shutter Assembly - Exploded View10.5.2. Replacing the UV filter/lens Figure 10-2 Disassembling the Shutter Assembly10.5.3. Replacing the PMT, HVPS or TEC Figure 10-3 PMT Assembly - Exploded View3. Remove the reaction cell assembly 10.5.4. M102E PMT Hardware Calibration FACTORY CAL 6. Locate the Preamp board see Figure Figure 10-4 Pre-Amplifier Board LayoutAdjust the PMT until NORM PMT equals 1280 mV ± 10 mV 10.5.5. Replacing the TRS Converter Heating TubeIf a reporting range other than 500 ppb is used in this procedure NORM PMT value of twice the ppb value of the span gas EXAMPLEBe Careful 10.6. Manually Programming the M501-TRS Temperature ControllerThe ceramic bobbins at each end of the heater assembly are fragile element off10.6.1. Temperature Controller Primary Menu Parameters 115V/60Hz with a set value of 1000CTable 10-3 - Temperature Controller - Primary Parameter Settings 10.7. Technical Assistance Table 10-4 - Temperature Controller - Primary Parameter SettingsM102E/M501 TRS APPENDIX A-4 Model 102E Signal I/O Definitions APPENDIX A - Version Specific Software DocumentationAPPENDIX A-2 Model 102E Setup Variables Available Via Serial I/O M102E/M501 TRS APPENDIX A - Version Specific Software DocumentationAPPENDIX A-1 M102E Software Menu Trees, Revision A.2 SETUPENTER SETUP PASS APPENDIX A-1 M102E Software Menu Trees, Revision A.2 SAMPLEMSG 1,2 SAMPLETEST CLR 1,3ACAL1 SO2, 111, REPORTEDTR2, 112, REPORTED SAMPLE ENTER SETUP PASS Figure A-4 Secondary Setup Menu DIAGDIAG Table A-2 APPENDIX A-2 Setup Variables For Serial I/O, Revision A.2Deleted Setup Variables for M102E Software Revision A.2 MEASUREMODETable A-4 Warning Messages deleted from M102 Software Revision A.2 setting of STABILFREQ and STABILSAMPLESAPPENDIX A-3 Warnings and Test Functions, Revision A.2 Table A-6 Test Functions Deleted from M102 Software Revision A.2APPENDIX A-4 M102E Signal I/O Definitions, Revision A.2 APPENDIX A-4 M102E Signal I/O Definitions, Revision A.2M102E/M501 TRSRear board primary MUX analog inputs CTEMPW APPENDIX A-5 M102E iDAS Functions, Revision A.2Trigger Event FunctionA-10 APPENDIX A-5 M102E iDAS Functions, Revision A.2Table B-1 M102E Spare Parts List APPENDIX B - M102E Spare Parts ListAPPENDIX B - M102E Spare Parts List M101E Manual - P/N 04740120 Rev A05516 Rev A TELEDYNE Warranty/Repair Questionnaire Model 102EM102E/M501 TRS INSTRUMENTSTELEDYNE Table D-1 List of Included Electronic Schematics APPENDIX D - ELECTRONIC SCHEMATICSAPPENDIX D - ELECTRONIC SCHEMATICS Addendum to M101E Manual - P/N 04740 Rev AM102E/M501 TRS APPENDIX D - ELECTRONIC SCHEMATICSUser Notes 05518 Rev A