M102E/M501 TRS, Troubleshooting & Repair, Be Careful | Teledyne

Be Careful!

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

2.Allow it to cool to room temperature. This may take up to 30 minutes.

3.Remove the instruments top cover (see Section 3.2 of this addendum)

4.Remove the four screws holding the converter cover in place.

5.Carefully lift the converter cover away.

6.Loosen front and rear pneumatic fittings at each end of the tube and remove the gas lines from the converter tube.

7.Remove the front ceramic bobbin from the converter tube. The thermistor assembly will come with it.

NOTE:

Be Careful!

The ceramic bobbins at each end of the heater assembly are fragile.

8.Slide a new tube into the heater coil assembly.

9.Make sure that the thermistor is threaded through its notch on the center hole of the front converter bobbin and properly seated in the corresponding indentation in the body of the quartz heater tube.

10.Reattach the front bobbin onto the converter tube.

11.Reattach the gas lines and retighten the pneumatic fittings.

12.Reassemble the converter cover and reattach the M501-TRS top cover.

NOTE

The M501-TRS will not operate properly with the top cover removed.

The air cooling required to stabilize the temperature of the converter tube is dependent

on air flow patterns that only exist with the top cover in place.

Without the top cover in place, the thermal cutout may overheat, and shut the heating

element off.

13.Restart the M501-TRS.

14.Check the converter efficiency. See Section 10.4.2 of this addendum.

10.6.Manually Programming the M501-TRS Temperature Controller

NOTE

The temperature controller has been programmed at the factory and should not be

altered, (except for temperature set point).

64	05514 Rev A1

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Teledyne Manually Programming the M501-TRS Temperature Controller, M102E/M501 TRS, Troubleshooting & Repair, Be Careful

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 A 10. TROUBLESHOOTING & REPAIR LIST OF APPENDICES8. INSTRUMENT MAINTENANCE 9. THEORY OF OPERATION LIST OF TABLES LIST OF FIGURESPREFACE Page 1. PREFACE corner of the display any time the instrument is in SETUP mode User Notes 1.1. Reference Numbering convention 2.1.1. M501-TRS Specifications 2. SPECIFICATIONS, APPROVALS AND WARRANTY2.1. Specifications 2.2. EPA Equivalency Designation 2.3. CE Mark Compliance 3.2. Unpacking the M501-TRS 3. GETTING STARTED3.1. Unpacking the M102E Never disconnect electronic circuit boards, wiring harnesses or that the rack/enclosure itself is adequately ventilated 3.2.1. M501-TRS Ventilation Clearancethe maximum operating temperature specification for the M102E 40C Figure 3-1 M102E Internal Layout 3.3. Internal LayoutsFigure 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 M501 Figure 3-4 M102E Rear Panel Layout 3.5. Rear Panel Layout for the M102E & M501-TRSAlarm Output 5 Amp 3.6.1.1. M102E Analog Output Connections 3.6. Initial Setup3.6.1. Electrical Connections Figure 3-6 Analog Output Connector M102E PNEMATIC CONNECTERS 3.6.1.2. M501-TRS Alarm Output Connections3.6.2. Pneumatic Connections M501-TRS PNEMATIC CONNECTERS MODEL 102E The exhaust from the instrument needs to be vented outside the SPAN GAS 3.6.2.1. Connections with Internal Valve Options Installed ZERO AIR VENT Gas Dilution CalibratorVENT if input is pressurized Option Valve Option 3.7.2. Functional Check of the M102E 3.7. Initial Operation3.7.1. Startup / Warm Up of the M102E Possible Warning Messages at Start-Up Process Variable High Alarm LED Low Alarm LED3.7.3. Startup / Warm Up of the M501-TRS Display area 3.8. 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 SOFTWARE Zero/Span Valve Operating States M102E INSTRUMENT CHASSIS Table 4-2 IZS Valve Operating States 4.3.1. Printed Manuals P/N 4.3. Additional Manuals4.3.2. Addendum on CD Part number Figure 5-1 Analog Output Connector Key 5.1.1. M102E Analog Output Signals5. M102E OPERATING INSTRUCTIONS M102E OPERATING INSTRUCTIONS 5.2.1. 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 Modes 5.3.1. 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 Name CONTROL IN 5.4. Remote Operation of the Analyzer5.4.1. Control Inputs ZERO 5.4.2.1. M102E Hessen Protocol Gas ID List 5.4.2. Using the M102E with a Hessen Protocol Network5 VDC Power Supply SPAN 5.4.2.2. Setting Hessen Protocol Status Flags Table 5-6 Default Hessen Status Bit Assignments DO NOT OPERATE WITHOUT THE COVER OF THE M501TS CONVERTER INSTALLED 6. M501-TRS OPERATING INSTRUCTIONS6.1. Basic M501-TRS Controls Teledyne Instruments customer service 6.2. To Display The Current Temperature Table 6-1 M501-TRS Temperature Controls and Definitions 6.3. To Manually Adjust the Converter Oven Temperature DO NOT SET THE TEMPERATURE HIGHER THAN 1050OC 6.4.1. Initiating the Autotune Process 6.4. Autotune the Temperature Controllerhas reached a stable, constant temperature 6.4.2. Aborting the Autotune Process 6.5. M501TRS Alarm Relay Adjustmentnecessary to repeat the autotune procedure Page 7.1. M102E Calibration 7. CALIBRATION PROCEDURESUSER NOTES 7.2. M501-TRS CalibrationPage 8. INSTRUMENT MAINTENANCE INSTRUMENT MAINTENANCE 8.1.1.1. Predicting When the SO2 Scrubber Should Be Replaced 8.1. Additional and Updated Maintenance Procedures8.1.1. 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 Fluorescence Ia = I0 1 − exp− axSO2 SO2 + hv214nm ⎯⎯Ia⎯→ SO2SO2 * ⎯⎯→ SO2 + hv330nm Figure 9-1 UV Absorption in the M102E Reaction Cell kSO2 * ⎯⎯F⎯→ SO2 + hv330nm F = kSO2Equation9-6 9.2.1. UV Lamp Shutter & PMT Offset 9.2. The UV Light Path9.3. Pneumatic Operation 9.3.1. Sample gas Flow 9.4.1. Sensor Module PMT HOUSING9.4. Electronic Operation SAMPLE CHAMBERUV Lamp Sample Air Housing Outlet O-Ring O-Ring Seal Seal 9.4.1.1. Sample Chamber9.4.1.2. Sample Chamber Heating Circuit Sample Air HEATER 9.4.2.1. Thermal Switch9.4.2. M501-TRS electronics P-I-D CONTROLLER 9.4.2.2. 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 Messages Table 10-2 Test Functions - Possible Causes for Out-Of-Range Values 10.1.2. Fault Diagnosis with Test Functionsfunctioning 10.2.1. TRS Converter Not Heating 10.2. M501-TRS Trouble shooting10.3. Other Performance Problems 10.3.1. Excessive noise 10.4.1. Checking the Efficiency of the M501-TRS SO2 Scrubber 10.4. Subsystem Checkout10.4.2. Checking the Efficiency of the M501-TRS TRS Æ SO2 Converter 10.5. Additional Repair Procedures 10.5.1. UV Lamp Adjustment and/or Replacement Lamp 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 lamp 10.5.1.2. Replacing the UV Lamp Figure 10-1 Shutter Assembly - Exploded View 10.5.2. Replacing the UV filter/lens Figure 10-2 Disassembling the Shutter Assembly 10.5.3. Replacing the PMT, HVPS or TEC Figure 10-3 PMT Assembly - Exploded View 3. 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 Layout Adjust 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 EXAMPLE Be Careful 10.6. Manually Programming the M501-TRS Temperature ControllerThe ceramic bobbins at each end of the heater assembly are fragile element off 10.6.1. Temperature Controller Primary Menu Parameters 115V/60Hz with a set value of 1000C Table 10-3 - Temperature Controller - Primary Parameter Settings 10.7. Technical Assistance Table 10-4 - Temperature Controller - Primary Parameter Settings M102E/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 Documentation APPENDIX A-1 M102E Software Menu Trees, Revision A.2 SETUPENTER SETUP PASS APPENDIX A-1 M102E Software Menu Trees, Revision A.2 SAMPLE MSG 1,2 SAMPLETEST CLR 1,3 SO2, 111, REPORTED ACAL1TR2, 112, REPORTED Figure A-4 Secondary Setup Menu DIAG SAMPLE ENTER SETUP PASSDIAG Table A-2 APPENDIX A-2 Setup Variables For Serial I/O, Revision A.2Deleted Setup Variables for M102E Software Revision A.2 MEASUREMODE Table 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.2 APPENDIX A-4 M102E Signal I/O Definitions, Revision A.2M102E/M501 TRS APPENDIX A-4 M102E Signal I/O Definitions, Revision A.2Rear board primary MUX analog inputs CTEMPW APPENDIX A-5 M102E iDAS Functions, Revision A.2Trigger Event Function A-10 APPENDIX A-5 M102E iDAS Functions, Revision A.2 Table B-1 M102E Spare Parts List APPENDIX B - M102E Spare Parts ListAPPENDIX B - M102E Spare Parts List M101E Manual - P/N 04740120 Rev A 05516 Rev A TELEDYNE Warranty/Repair Questionnaire Model 102EM102E/M501 TRS INSTRUMENTS TELEDYNE Table D-1 List of Included Electronic Schematics APPENDIX D - ELECTRONIC SCHEMATICSAPPENDIX D - ELECTRONIC SCHEMATICS Addendum to M101E Manual - P/N 04740 Rev A M102E/M501 TRS APPENDIX D - ELECTRONIC SCHEMATICSUser Notes 05518 Rev A