Teledyne 200A 9 TROUBLESHOOTING, ADJUSTMENTS

Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247

9 TROUBLESHOOTING, ADJUSTMENTS

NOTE

The operations outlined in this chapter are to be

performed by qualified maintenance personnel only.

This section of the manual contains information on diagnosing and repairing instrument

performance problems. It contains information on how to use and interpret TEST and

DIAGNOSTIC data as well as WARNING messages the instrument generates. There is

information on how to troubleshoot the instrument subsystems. Finally there is information to

perform adjustments such as DAC calibration procedures.

This manual provides troubleshooting procedures that address problems to the board level. For

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

1. If the fault is light on and it stays on after you clear the warning messages, see Section

9.1.2.

2. Think of the analyzer as three sections:

Section 1: Pneumatics - Over 50% of all analyzer problems are traced to leaks in the pump

assembly, sample filter, instrument internal pneumatics, calibrator or external sample

handling equipment. Suspect a leak first, and check Section 9.2.

Section 2: Electronics - data processing section. This can be readily checked out using

Electric Test in Section 9.1.3.2.

Section 3: Optics - Optical section consisting of PMT, HVPS, Preamp, and signal

processing. Refer to Section 9.1.3.3 on use of Optical Test.

9-1

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Contents

Main INSTRUMENTS INSTRUCTION MANUAL Chemiluminescent NO/NO2/NOX ANALYZER Model 200A HIGHLIGHTS Page INSTRUCTION MANUAL MODEL 200A NITROGEN OXIDE ANALYZER Page SAFETY MESSAGES Page TABLE OF CONTENTS 3 SPECIFICATIONS, AGENCY APPROVALS, WARRANTY.............................. 3-1 6 OPTIONAL HARDWARE AND SOFTWARE....................................................... 6-1 7 CALIBRATION AND ZERO/SPAN CHECKS....................................................... 7-1 9 TROUBLESHOOTING, ADJUSTMENTS.............................................................. 9-1 Page Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 LIST OF FIGURES vii PRINTED DOCUMENTS ARE UNCONTROLLED Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 LIST OF TABLES Page Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 x PRINTED DOCUMENTS ARE UNCONTROLLED 1 HOW TO USE THIS MANUAL Page 2 GETTING STARTED 2.1 Unpacking 2.2 Electrical and Pneumatic Connections Page Page Page Page 2.3 Initial Operation Page Page Page Page Page Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 2-12 PRINTED DOCUMENTS ARE UNCONTROLLED Table 2-2-6: Final Test and Calibration Values (table continued) PROM # Serial # Date Technician 2-13 PRINTED DOCUMENTS ARE UNCONTROLLED Page Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 3 SPECIFICATIONS, AGENCY APPROVALS, WARRANTY 3.1 Specifications 3-1 PRINTED DOCUMENTS ARE UNCONTROLLED 3.2 EPA Equivalency Designation 3.3 Warranty Page 4 THE M200A NOX ANALYZER 4.1 Principle of Operation hv NO * NO Page 4.2 Operation Summary 4.2.1 Sensor Module, Reaction Cell, Detector 4.2.2 Pneumatic Sensor Board 4.2.3 Computer Hardware and Software 4.2.4 V/F Board 4.2.5 Front Panel Page 4.2.6 Power Supply Module 4.2.7 Pump, Valves, Pneumatic System Page Page 4.2.8 Ozone Generator 4.2.9 Molydbenum Converter Page 5 SOFTWARE FEATURES 5.1 Index To Front Panel Menus Page Page Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 5.1.1 Sample Menu Table 5-5-3: M200A Sample Menu Structure 9-1 5-4 PRINTED DOCUMENTS ARE UNCONTROLLED Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 5.1.2 Set-Up Menu Table 5-5-4: M200A Setup Menu Structure 5-5 PRINTED DOCUMENTS ARE UNCONTROLLED Table 5-5-6: M200A Menu Structure - Setup Menu #3 5-6 PRINTED DOCUMENTS ARE UNCONTROLLED Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 5-7 PRINTED DOCUMENTS ARE UNCONTROLLED 5.2 Sample Mode 5.2.1 Test Functions Page Page Page 5.2.2 CAL, CALS, CALZ, Calibration Functions Page 5.3 Set-Up Mode 5.3.1 Configuration Information (CFG) 5.3.2 Automatic Calibration (AutoCal) 5.3.3 Data Acquisition System (DAS) Page 5.3.4 Range Menu Page Page Page 5.3.5 Password Enable 5.3.6 Time of Day Clock 5.3.7 Diagnostic Mode 5.3.8 Communications Menu Page 5.4 Status Output 5.5 RS-232 Interface 5.5.1 Setting Up the RS-232 Interface Page Page Page 5.5.2 Command Summary 5-29 PRINTED DOCUMENTS ARE UNCONTROLLED Page Page Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 5.5.3 TEST Commands and Messages Table 5-5-17: RS-232 Test Messages 5-32 PRINTED DOCUMENTS ARE UNCONTROLLED 5.5.4 WARNING Commands and Messages 5.5.5 CALIBRATION Commands and Messages Page 5.5.6 DIAGNOSTIC Commands and Messages 5.5.7 DAS Commands and Message Page 5.5.8 Internal Variables Page 6 OPTIONAL HARDWARE AND SOFTWARE 6.1 Rack Mount Options 6.2 Zero/Span Valves Page 6.3 Internal Zero/Span (IZS) 6.4 Autocal - Setup of IZS and Zero/Span Valves Page 6.5 Permeation Tube Page Page 6.6 4-20 mA Current Loop Output 7 CALIBRATION AND ZERO/SPAN CHECKS 7-2 PRINTED DOCUMENTS ARE UNCONTROLLED Page 7.1 Manual Zero/Span Check or Cal With Zero/Span Gas in the Sample Port Page 7.2 Manual Zero/Span Check or Calibration with Zero/Span Valves Option 7.3 Manual Zero/Span Check with IZS Option 7.4 Automatic Zero/Span Check 7.5 Dynamic Zero/Span Calibration Page 7.6 Calibrate on NO2 Permeation Tube Page 7.7 Use of Zero/Span Valves or IZS with Remote Contact Closure 7.8 EPA Protocol Calibration 7.8.1 Calibration of Equipment Page 7.8.2 Calibration Gas and Zero Air Sources 7-14 PRINTED DOCUMENTS ARE UNCONTROLLED 7.8.3 Data Recording Device 7.8.4 Gas Phase Titration (GPT) System FT = analyzer flow demand (cm3/min) x 110/100 Equation 7-1 [NO]OUT = URL of analyzer (ppm) x 90/100 Equation 7-2 min2 FF V t Page min/ cm 24.5 ppm5.50 min/ cm 2750ppm45.0 = F = 80984 cm / - 24.5 cm / = 260 cm / 7.8.5 Dynamic Multipoint Calibration Procedure Page Page Page Page 7.8.6 Moly Converter Efficiency Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 7.8.6.1 Automatic Moly Converter Efficiency Compensation Table 7-7-17: Automatic Calculation of Converter Efficiency 7.8.7 Calibration Frequency 7.8.8 Other Quality Assurance Procedures Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 Table 7-7-18: Definition of Level 1 and Level 2 Zero and Span Checks (from Section 2.0.9 of Q.A. Handbook for Air Pollution Measurment Systems) 7.8.9 Summary of Quality Assurance Checks Table 7-7-19: Activity Matrix for Data Quality 7-29 PRINTED DOCUMENTS ARE UNCONTROLLED 7.8.10 ZERO and SPAN Checks 7.8.11 Recommended Standards for Establishing Traceability 7.8.12 Certification Procedures of Working Standards Page 7.9 Calibration of Independent Ranges or Autoranging 7.9.1 Zero Calibration with AutoRange or Independent Range 7.9.2 Span Calibration with AutoRange or Independent Range 7.10 Calibration Quality Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 Table 7-7-21: Calibration Quality Check After the above procedure is complete, the M200A is ready to measure sample gas. 7-36 PRINTED DOCUMENTS ARE UNCONTROLLED 7.11 References Page 8 MAINTENANCE 8.1 Maintenance Schedule Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 8-2 PRINTED DOCUMENTS ARE UNCONTROLLED Table 8-8-2: Preventative Maintenance Schedule 8.2 Replacing the Sample Particulate Filter Page 8.3 Replacing the Ozone Scrubber Charcoal 8.4 Replacing the Permeation 8.5 Replacing the IZS Zero Air Scrubber 8.6 Replacing the Molybdenum Converter Page 8.7 Cleaning the Reaction Cell Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 Table 8-8-5: Reaction Cell Assembly 8-10 PRINTED DOCUMENTS ARE UNCONTROLLED 8.8 Pneumatic Line Inspection Page Page Page 8.9 Leak Check Procedure 8.10 Light Leak Check Procedure 8.11 Prom Replacement Procedure 9 TROUBLESHOOTING, ADJUSTMENTS Page Page Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 Table 9-9-1: Test Functions Test Function Factory Set-Up Comment 9-4 PRINTED DOCUMENTS ARE UNCONTROLLED Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 Table 9-1: Test Functions (Continued) 9-5 PRINTED DOCUMENTS ARE UNCONTROLLED Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 Table 9-1: Test Functions (Continued) Test Function Factory Set-Up Comment 9-6 PRINTED DOCUMENTS ARE UNCONTROLLED Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 Table 9-1: Test Functions (Continued) Test Function Factory Set-Up Comment 9-7 PRINTED DOCUMENTS ARE UNCONTROLLED 9.1.2 Fault Diagnosis with WARNING Messages Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 Table 9-9-2: Front Panel Warning Messages 9-9 PRINTED DOCUMENTS ARE UNCONTROLLED Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 Table 9-2: Front Panel Warning Messages (Continued) 9-10 PRINTED DOCUMENTS ARE UNCONTROLLED 9.1.3 Fault Diagnosis Using DIAGNOSTIC Mode Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 Table 9-9-3: Summary of Diagnostic Modes 9-12 PRINTED DOCUMENTS ARE UNCONTROLLED Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 9.1.3.1 Signal I/O Diagnostic Table 9-9-4: Diagnostic Mode - Signal I/O 9-13 PRINTED DOCUMENTS ARE UNCONTROLLED Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 Table 9-4: Diagnostic Mode - Signal I/O (Continued) 9-14 PRINTED DOCUMENTS ARE UNCONTROLLED Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 Table 9-4: Diagnostic Mode - Signal I/O (Continued) 9-15 PRINTED DOCUMENTS ARE UNCONTROLLED Page Page 9.1.4 M200A Internal Variables Page Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 Table 9-9-5: Model 200A Internal Variables 9.1.5 Test Channel Analog Output 9-20 PRINTED DOCUMENTS ARE UNCONTROLLED Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 Table 9-9-6: Test Channel Readings 9-21 PRINTED DOCUMENTS ARE UNCONTROLLED Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 Table 9-6: Test Channel Readings (Continued) 9-22 PRINTED DOCUMENTS ARE UNCONTROLLED 9.1.6 Factory Calibration Procedure Page Page 9.2 Performance Problems 9.2.1 AC Power Check 9.2.2 Flow Check 9.2.3 No Response to Sample 9.2.4 Negative Output 9.2.5 Excessive Noise 9.2.6 Unstable Span 9.2.7 Unstable Zero 9.2.8 Inability to Span 9.2.9 Inability to Zero 9.2.10 Non-Linear Response 9.2.11 Slow Response 9.2.12 Analog Output Doesn't Agree with Display Concentration 9.3 Subsystem Troubleshooting and Adjustments 9.3.1 Computer, Display, Keyboard Page Page 9.3.2 RS-232 Communications Page Page 9.3.3 Voltage/Frequency (V/F) Board Page Page *Required settings Page Page 9.3.4 Status/Temp Board Page 9.3.5 Power Supply Module Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 Table 9-9-13: Power Supply Module Subassemblies 9-50 PRINTED DOCUMENTS ARE UNCONTROLLED Page Page Page 9.3.6 Ozone Generator Page Page 9.3.7 Flow/Pressure Sensor Page Page Page Page 9.3.8 NOx Sensor Module Page Page Page 9.3.9 Z/S Valves & IZS Permeation Tube Oven 9.3.10 Pneumatic System Page Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 10-1 PRINTED DOCUMENTS ARE UNCONTROLLED 10 M200A SPARE PARTS LIST Table 10-1: Teledyne API M200A Spare Parts List Part No. Description Includes: Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 10-2 PRINTED DOCUMENTS ARE UNCONTROLLED Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 10-3 PRINTED DOCUMENTS ARE UNCONTROLLED Page Page Page Page Page Teledyne API Model 200A NOX Analyzer Instruction Manual, 02246, Rev. G, DCN 5247 APPENDIX A ELECTRICAL SCHEMATICS Table A-1: Electrical Schematics A-1 PRINTED DOCUMENTS ARE UNCONTROLLED