Teledyne 360E 9.2. Predicting Failures Using the Test Functions

MAINTENANCE SCHEDULE & PROCEDURES Model 360E Instruction Manual

9.2. Predicting Failures Using the Test Functions

The Test Functions can be used to predict failures by looking at how their values change over time. Initially it

may be useful to compare the state of these Test Functions to the values recorded on the printed record of the

final calibration performed on your instrument at the factory, p/n 04307. Table 9-3 can be used as a basis for

taking action as these values change with time. The internal data acquisition system (iDAS) is a convenient way

to record and track these changes. Use APICOM to download and review this data from a remote location.

Table 9-3: Predictive uses for Test Functions

FUNCTION CONDITION BEHAVIOR INTERPRETATION

STABILITY Zero Cal Increasing Pneumatic Leaks – instrument & sample system

Detector deteriorating

CO2 MEAS Zero Cal Decreasing

Source Aging

Detector deteriorating

Optics getting dirty or contaminated

Increasing

Source Aging

Detector deteriorating

Contaminated zero gas (H2O)

Zero Cal

Decreasing

Source Aging

Detector deteriorating

GFC Wheel Leaking

Pneumatic Leaks

Contaminated zero gas (CO2)

Increasing

Source Aging

Pneumatic Leaks – instrument & sample system

Calibration system deteriorating

MR RATIO

Span Cal

Decreasing

Source Aging

GFC Wheel Leaking

Calibration system deteriorating

Increasing > 1” Pneumatic Leak between sample inlet and Sample Cell

Change in sampling manifold

PRES Sample

Decreasing > 1”

Dirty particulate filter

Pneumatic obstruction between sample inlet and Sample

Cell

Obstruction in sampling manifold

PHT DRIVE Any, but with

Bench Temp at

48°C

Increasing

Mechanical Connection between IR-Detector and Sample

Cell deteriorating

IR-Photodetector deteriorating

Increasing See MR Ratio - Zero Cal Decreasing above

OFFSET Zero Cal Decreasing See MR Ratio - Zero Cal Increasing above

Increasing See MR Ratio - Span Cal Decreasing above

SLOPE Span Cal Decreasing See MR Ratio – Span Cal Increasing above

158 05232 Rev B3

Contents

Main INSTRUCTION MANUAL MODEL 360E CARBON DIOXIDE ANALYZER Page SAFETY MESSAGES Page TABLE OF CONTENTS Page Page Page Page LIST OF APPENDICES LIST OF FIGURES LIST OF TABLES Page 1. M360E DOCUMENTATION 1.1. Using This Manual Page Model 360E Instruction Manual Specifications, Approvals and Warranty 2. SPECIFICATIONS, APPROVALS AND WARRANTY 05232 Rev B3 3 2.1. Specifications Table 2-1: Model 360E Basic Unit Specifications 2.2. CE Mark Compliance 2.3. Warranty Page Page 3. GETTING STARTED 3.1. Unpacking and Initial Set Up Page 3.1.1. M360 Layout Getting Started Model 360E Instruction Manual Figure 3-3: Assembly Layout 10 05232 Rev B3 Page 3.1.2. Electrical Connections 3.1.2.1. Power Connection 3.1.2.2. Output Connections ANALOG A1 A2 A3 A 4 1 2 3 4 5 6 7 8 3.1.2.3. Connecting the Status Outputs 3.1.2.4. Connecting the Control Inputs - + 3.1.2.5. Connecting the Serial Ports 3.1.2.6. Connecting to a LAN or the Internet 3.1.3. Pneumatic Connections: 3.1.3.1. Basic Pneumatic Connections Page Page Page 3.1.3.2. Connections with Internal Valve Options Installed MODEL 360E MODEL X00E 3.1.3.3. Pneumatic Connections to M360E in Multipoint Calibration Applications 3.1.4. Setting the internal Purge Air Pressure. 3.2. Initial Operation 3.2.1. Startup 3.2.2. Warm Up 3.2.3. Warning Messages Page 3.2.4. Functional Check 3.3. Initial Calibration Procedure Page Model 360E Instruction Manual Getting Started 3. Perform the Zero/Span Calibration Procedure 05232 Rev B3 29 3.3.1. Initial O2 Sensor Calibration Procedure 3.3.1.1. O2 Calibration Setup 3.3.1.2. O2 Calibration Method Page Page Page Page 4. FREQUENTLY ASKED QUESTIONS 4.1. FAQs 4.2. Glossary Page Page 5. OPTIONAL HARDWARE AND SOFTWARE 5.1. Rack Mount Kits (Options 20a, 20b & 21) 5.2. Current Loop Analog Outputs (Option 41) 5.2.1. Converting Current Loop Analog Outputs to Standard Voltage Outputs. 5.3. Expendable Kits (Options 42C, 42D and 43) 5.4. Calibration Valves Options 5.4.1. Zero/Span/Shutoff Valve (Option 50) 5.4.2. Zero/Span/Shutoff with External CO2 Scrubber (Option 51) 5.4.3. Zero/Span Valve (Option 52) Page 5.4.4. Zero/Span Valve with External CO2 Scrubber (Option 53) 5.5. Communication Options 5.5.1. RS232 Modem Cable (Option 60) 5.5.2. RS-232 Multidrop (Option 62) 5.5.3. Ethernet (Option 63) 5.6. Oxygen Sensor (OPT 65) 5.6.1. Theory of Operation 5.6.1.1. Paramagnetic measurement of O2 5.6.1.2. Operation within the M360E Analyzer 5.6.1.3. Pneumatic Operation of the O2 Sensor 5.7. Additional Manuals 5.7.1. Printed Manuals (Option 70) 5.7.2. Manual on CD (Part number 045840200) 5.8. Extended Warranty (Options 92 & 93) 5.9. Special Software Features 5.9.2. Maintenance Mode Switch 5.9.3. Second Language Switch Page 6. OPERATING INSTRUCTIONS 6.1. Overview of Operating modes Mode Field 6.2. Sample Mode 6.2.1. Test Functions Page Page 6.2.2. Warning Messages 6.3. Calibration Mode 6.4. SETUP MODE 6.5. SETUP CFG: Viewing the Analyzers Configuration Information 6.6. SETUP ACAL: Automatic Calibration 6.7. SETUP DAS: Using the Data Acquisition System (iDAS) 6.7.1. iDAS Structure Operating Instructions Model 360E Instruction Manual 6.7.1.1. iDAS Channels 60 05232 Rev B3 6.7.1.2. iDAS Parameters 6.7.1.3. iDAS Triggering Events 6.7.2. Default iDAS Channels LIST OF CHANNELS LIST OF PARAMETERS LIST OF PARAMETERS Page Model 360E Instruction Manual Operating Instructions 6.7.2.1. Viewing iDAS Data and Settings 05232 Rev B3 65 iDAS data and settings can be viewed on the front panel through the following keystroke sequence. VIEW KEYPAD FUNCTIONS Operating Instructions Model 360E Instruction Manual 6.7.2.2. Editing iDAS Data Channels Model 360E Instruction Manual Operating Instructions From the end of the previous key sequence 05232 Rev B3 67 6.7.2.3. Trigger Events To edit the list of data parameters associated with a specific data channel, press: From the DATA ACQUISITION menu Press each key repeatedly to cycle through the list of available trigger events. 6.7.2.4. Editing iDAS Parameters 68 05232 Rev B3 Press SET> key until From the DATA ACQUISITION menu 05232 Rev B3 69 6.7.2.5. Sample Period and Report Period 05232 Rev B3 71 6.7.2.6. Number of Records 6.7.2.7. RS-232 Report Function 6.7.2.8. Compact Report 6.7.2.9. Starting Date Operating Instructions Model 360E Instruction Manual 6.7.2.10. Disabling/Enabling Data Channels Press SET> key until Press SET> key until From the DATA ACQUISITION menu 6.7.3. Remote iDAS Configuration Page 6.8. SETUP RNGE: Analog Output Reporting Range Configuration A NALOG OUT 6.8.1. Physical Range versus Analog Output Reporting Ranges 6.8.2. Reporting Range Modes 6.8.3. Single Range mode (SNGL) 6.8.4. Dual Range Mode (DUAL) 6.8.5. Auto Range Mode (AUTO) 6.8.6. Range Units 6.8.7. Dilution Ratio 6.9. SETUP PASS: Password Feature Model 360E Instruction Manual Operating Instructions 6.10. SETUP CLK: Setting the Internal Time-of-Day Clock Continue to press NEXT until 05232 Rev B3 85 6.11. SETUP MORE COMM: Using the Analysers Communication Ports 6.11.1. Analyzer ID 6.11.2. COMM Port Default Settings CN3 & CN4 RXD RTS TXD GND 246810 13579 6.11.3. RS-485 Configuration of COM2 ( COM2 ) 6.11.4. DTE and DCE Communication Model 360E Instruction Manual Operating Instructions 6.11.5. COMM Port Communication Modes 05232 Rev B3 91 92 05232 Rev B3 6.11.6. Ethernet Card Configuration 6.11.6.1. Ethernet Card COM2 Communication Modes and Baud Rate 6.11.6.2. Configuring the Ethernet Interface Option using DHCP Page Model 360E Instruction Manual Operating Instructions To view the above properties, press: 05232 Rev B3 95 6.11.6.3. Manually Configuring the Network IP Addresses From Step 1 above) 05232 Rev B3 97 Contact your IT Network Administrator Operating Instructions Model 360E Instruction Manual 6.11.6.4. Changing the Analyzers HOSTNAME 98 05232 Rev B3 SETUP X.X INITIALIZATION FAILED Contact your IT Network Administrator Use these keys (See Table 6-19) to edit HOSTNAME 6.11.7. Multidrop RS-232 Set Up Rear Panel Multidrop PCA JP2 Analyzer Analyzer Analyzer Last Analyzer 6.11.8. COM Port Baud Rate 05232 Rev B3 101 To select the baud rate of one of the COM Ports, press: 6.11.9. COM Port Testing 6.12. SETUP MORE VARS: Internal Variables (VARS) 104 05232 Rev B3 6.13. SETUP MORE DIAG: Using the Diagnostics Functions Operating Instructions Model 360E Instruction Manual 6.13.1. Accessing the Diagnostic Features 106 05232 Rev B3 To access the DIAG functions press the following keys: 6.13.2. Signal I/O 6.13.3. Analog Output Step Test SETUP X.X ENTER DIAG PASS: 818 8 1 8 ENTR EXIT 05232 Rev B3 107 6.13.4. Analog I/O Configuration Page 6.13.4.1. Analog Output Signal Type and Range Span Selection 6.13.4.2. Analog Output Calibration Mode 05232 Rev B3 111 6.13.4.3. Manual Analog Output Calibration and Voltage Adjustment Model 360E Instruction Manual Operating Instructions V +DC Gnd See Table 3-1 for pin assignments of Analog Out connector on the rear panel 05232 Rev B3 113 6.13.4.4. Current Loop Output Adjustment Model 360E Instruction Manual Operating Instructions 05232 Rev B3 115 Full scale Voltage for 2-20 mA (measured across resistor) Voltage for 4-20 mA (measured across resistor) 0% 0.5 V 1.0 V 100% 5.0 V 5.0 V 6.13.4.5. AIN Calibration 116 05232 Rev B3 Model 360E Instruction Manual Operating Instructions 6.13.5. Electric Test 05232 Rev B3 117 Repeat Pressing NEXT unti . . . SETUP X.X ENTER DIAG PASS: 818 8 1 8 ENTR EXIT 6.13.6. Dark Calibration Test 118 05232 Rev B3 SETUP X.X ENTER DIAG PASS: 818 8 1 8 ENTR EXIT Repeat Pressing NEXT until . . . 6.13.7. Pressure Calibration Operating Instructions Model 360E Instruction Manual 6.13.8. Flow Calibration 120 05232 Rev B3 Repeat Pressing NEXT until . . . 6.13.9. Test Channel Output SETUP X.X ENTER DIAG PASS: 818 8 1 8 ENTR EXIT Table 6-22: Test Parameters Available for Analog Output A4 TEST CHANNEL ZERO FULL SCALE 05232 Rev B3 121 Operating Instructions Model 360E Instruction Manual 6.14. SETUP MORE ALRM: Using the Gas Concentration Alarms 122 05232 Rev B3 ALARM STATUS LIMIT SET POINT ALM1 ALM2 analyzer will automatically scale the set points to match the new range unit setting. 6.14.1. Setting the Concentration Alarm Limits 6.15. Remote Operation of the Analyzer 6.15.1. Remote Operation Using the External Digital I/O 6.15.1.1. Status Outputs STATUS 1 2 3 4 5 6 7 8 D + 124 05232 Rev B3 Model 360E Instruction Manual Operating Instructions - 6.15.1.2. Control Inputs INPUT STATUS CONDITION WHEN ENABLED CAL Figure 6-18: Control Inputs 05232 Rev B3 125 6.15.2. Remote Operation Using the External Serial I/O 6.15.2.1. Terminal Operating Modes 6.15.2.2. Help Commands in Terminal Mode 6.15.2.3. Command Syntax 6.15.2.4. Data Types 6.15.2.5. Status Reporting Model 360E Instruction Manual Operating Instructions 6.15.2.6. Remote Access by Modem 05232 Rev B3 129 6.15.2.7. COM Port Password Security 6.15.2.8. APICOM Remote Control Program 6.15.3. Additional Communications Documentation 6.15.4. Using the M360E with a Hessen Protocol Network 6.15.4.1. General Overview of Hessen Protocol 6.15.4.2. Hessen COMM Port Configuration Model 360E Instruction Manual Operating Instructions 6.15.4.3. Activating Hessen Protocol 6.15.4.4. Selecting a Hessen Protocol Type 05232 Rev B3 133 6.15.4.5. Setting The Hessen Protocol Response Mode 6.15.4.6. Hessen Protocol Gas ID 6.15.4.7. Setting Hessen Protocol Status Flags 6.15.4.8. Instrument ID Code 136 05232 Rev B3 7. CALIBRATION PROCEDURES 7.1. Before Calibration 7.1.1. Zero Air and Span Gas 7.1.2. Calibration Gas Traceability 7.1.3. Data Recording Devices 7.2. Manual Calibration without Zero/Span Valves MODEL 360E Model 360E Instruction Manual Calibration Procedures 05232 Rev B3 139 140 05232 Rev B3 7.3. Manual Calibration Checks 7.4. Manual Calibration with Zero/Span Valves MODEL 360E Page 144 05232 Rev B3 05232 Rev B3 145 7.5. Manual Calibration Checks with Zero/Span Valves 7.5.1. Zero/Span Calibration on Auto Range or Dual Ranges 7.5.2. Use of Zero/Span Valves with Remote Contact Closure 7.6. Automatic Zero/Span Cal/Check (AutoCal) Page Calibration Procedures Model 360E Instruction Manual To program the Sequence: Default value is ON 150 05232 Rev B3 7.6.1. AutoCal with Auto or Dual Reporting Ranges Modes Selected 7.7. Calibration Quality Page Page Page 9. MAINTENANCE SCHEDULE & PROCEDURES 9.1. Maintenance Schedule MAINTENANCE SCHEDULE & PROCEDURES Model 360E Instruction Manual Table 9-1: M360E Maintenance Schedule 156 05232 Rev B3 CHECK ITEM ACTION FREQ CAL Page 9.2. Predicting Failures Using the Test Functions 9.3. Maintenance Procedures 9.3.1. Replacing the Sample Particulate Filter 9.3.2. Rebuilding the Sample Pump 9.3.3. Performing Leak Checks 9.3.3.1. Vacuum Leak Check and Pump Check 9.3.3.2. Pressure Leak Check 9.3.4. Performing a Sample Flow Check 9.3.5. Cleaning the Optical Bench 9.3.6. Cleaning Exterior Surfaces of the M360E Page 10. THEORY OF OPERATION 10.1. Measurement Method 10.1.1. Beers Law I = Io e-Lc I I L C 10.1.2. Measurement Fundamentals 10.1.3. Gas Filter Correlation 10.1.3.1. The GFC Wheel IR Source Photo-Detector GFC Wheel 10.1.3.2. The Measure Reference Ratio 10.1.4. Interference and Signal to Noise Rejection 10.1.4.1. Ambient CO2 Interference Rejection 10.2. Pneumatic Operation 10.2.1. Sample Gas Flow 10.2.2. Flow Rate Control 10.2.2.1. Critical Flow Orifice 10.2.3. Purge Gas Pressure Control 10.2.4. Particulate Filter 10.2.5. Pneumatic Sensors 10.2.5.1. Sample Pressure Sensor 10.2.5.2. Sample Flow Sensor 10.3. Electronic Operation 10.3.1. Overview THEORY OF OPERATION Model 360E Instruction Manual PC 104 CPU Card (optional) MOTHER BOARD PC 104 Bus Sensor Status & Control Optical Bench RELAY BOARD SYNC DEMOD 10.3.2. CPU 10.3.3. Optical Bench & GFC Wheel 10.3.3.1. Temperature Control 10.3.3.2. IR Source 10.3.3.3. GFC Wheel 10.3.3.4. IR Photo-Detector 10.3.4. Synchronous Demodulator (Sync/Demod) Assembly 10.3.4.1. Overview THEORY OF OPERATION Model 360E Instruction Manual Sample & Hold Circuits (x4) CO2 Reference 10.3.4.2. Signal Synchronization and Demodulation 176 05232 Rev B3 10.3.4.3. Sync/Demod Status LEDs 10.3.4.4. Photo-Detector Temperature Control 10.3.4.5. Dark Calibration Switch 10.3.4.6. Electric Test Switch 10.3.5. Relay Board 10.3.5.1. Status LEDs STATUS LEDs DC VOLTAGE TEST POINTS RELAY PCA PN 04135 10.3.5.2. I2C Watch Dog Circuitry 10.3.6. Mother Board 10.3.6.1. A to D Conversion 10.3.6.2. Sensor Inputs 10.3.6.3. Thermistor Interface 10.3.6.4. Analog Outputs 10.3.6.5. Internal Digital I/O 10.3.6.6. External Digital I/O 10.3.7. I2C Data Bus 10.3.8. Power Supply/ Circuit Breaker THEORY OF OPERATION Model 360E Instruction Manual 10.4. Interface GAS FILTER CORRELATION CO2 ANALYZER- MODEL 360E A4ST FRONT PANEL DISPLAY 10.4.1.1. Analyzer Status LEDs 10.4.1.2. Keyboard 10.4.1.3. Display 10.4.1.4. Keyboard/Display Interface Electronics Keypad Decoder 2 x 40 CHAR. VACUUM FLUORESCENT DISPLAY I2C Interface Page 10.5. Software Operation ANALYZER HARDWARE PC/104 BUS 10.5.1. Adaptive Filter 10.5.2. Calibration - Slope and Offset 10.5.3. Measurement Algorithm 10.5.4. Temperature and Pressure Compensation 10.5.5. Internal Data Acquisition System (iDAS) 11. TROUBLESHOOTING & REPAIR PROCEDURES 11.1. General Troubleshooting Hints 11.1.1. Interpreting WARNING Messages I 2 C CONC ALRM1 WARNING CONC ALRM2 WARNING I 2 C 05232 Rev B3 193 I 2 C 11.1.2. Fault Diagnosis with TEST Functions 05232 Rev B3 195 11.1.3. Using the Diagnostic Signal I/O Function 11.1.4. Internal Electronic Status LEDs 11.1.4.1. CPU Status Indicator Mother Board P/N 04069 11.1.4.2. Sync Demodulator Status LEDs 11.1.4.3. Relay Board Status LEDs RELAY PCA PN 04135 SIGNAL I/O PARAMETER LED FUNCTION ACTIVATED BY VIEW RESULT DIAGNOSTIC TECHNIQUE CAL_VALVE N/A 05232 Rev B3 199 11.2. Gas Flow Problems 11.2.1. M360E Internal Gas Flow Diagrams Page 11.2.2. Typical Sample Gas Flow Problems 11.2.2.1. Flow is Zero 11.2.2.2. Low Flow 11.2.2.3. High Flow 11.2.2.4. Displayed Flow = XXXX 11.2.2.5. Actual Flow Does Not Match Displayed Flow 11.2.2.6. Sample Pump 11.3. Calibration Problems 11.3.1. Miscalibrated 11.3.2. Non-Repeatable Zero and Span 11.3.3. Inability to Span No SPAN Key 11.3.4. Inability to Zero No ZERO Key 11.4. Other Performance Problems 11.4.1. Temperature Problems 11.4.1.1. Box or Sample Temperature 11.4.1.2. Bench Temperature 11.4.1.3. GFC Wheel Temperature 11.4.1.4. IR Photo-Detector TEC Temperature 11.4.2. Excessive Noise 11.5. Subsystem Checkout 11.5.1. AC Mains Configuration 11.5.2. DC Power Supply 11.5.3. I2C Bus 11.5.4. Keyboard/Display Interface 11.5.5. Relay Board 11.5.6. Sensor Assembly 11.5.6.1. Sync/Demodulator Assembly 11.5.6.2. Opto Pickup Assembly 11.5.6.3. GFC Wheel Drive 11.5.6.4. IR Source 11.5.6.5. Pressure/Flow Sensor Assembly 11.5.7. Motherboard 11.5.7.1. A/D Functions 11.5.7.2. Analog Outputs: Voltage 11.5.7.3. Analog Outputs: Current Loop 11.5.7.4. Status Outputs 11.5.7.5. Control Inputs Remote Zero, Span 11.5.8. CPU 11.5.9. RS-232 Communications 11.5.9.1. General RS-232 Troubleshooting 11.5.9.2. Troubleshooting Analyzer/Modem or Terminal Operation 11.6. Repair Procedures 11.6.1. Repairing Sample Flow Control Assembly 11.6.2. Removing/Replacing the GFC Wheel 11.6.3. Disk-On-Chip Replacement Procedure 12. A PRIMER ON ELECTRO-STATIC DISCHARGE 12.1. How Static Charges are Created 12.2. How Electro-Static Charges Cause Damage 12.3. Common Myths About ESD Damage 12.4. Basic Principles of Static Control 12.4.1. General Rules Page 12.4.2. Basic anti-ESD Procedures for Analyzer Repair and Maintenance 12.4.2.1. Working at the Instrument Rack 12.4.2.2. Working at an Anti-ESD Work Bench. 12.4.2.3. Transferring Components from Rack to Bench and Back 12.4.2.4. Opening Shipments from Teledyne Instruments Customer Service. 12.4.2.5. Packing Components for Return to Teledyne Instruments Customer Service. WARNING User Notes: Page Page Page Page Page Model 360E Instruction Manual APPENDIX A-1: M360E Software Menu Trees, Revision G.4 05233 Rev G.4 A-5 Figure A-4: Primary Setup Menu (iDAS) Page Page Figure A-7: Secondary Setup Menu (COMM Menu with HESSEN) A-8 05233 Rev G.4 odel 360E Instruction Manual APPENDIX A-1: M360E Software Menu Trees, Revision G.4 3 Rev G.4 A-9 A CFG PREV NEXT ENTR A-10 05233 Rev G.4 VALUE VALUE RANGE DESCRIPTION Low Access Level Setup Variables (818 password) Medium Access Level Setup Variables (929 password) Model 360E Instruction Manual 05233 Rev G.4 A-11 A-12 05233 Rev G.4 Model 360E Instruction Manual 05233 Rev G.4 A-13 A-14 05233 Rev G.4 Model 360E Instruction Manual 05233 Rev G.4 A-15 A-16 05233 Rev G.4 Model 360E Instruction Manual 05233 Rev G.4 A-17 A-18 05233 Rev G.4 Model 360E Instruction Manual 05233 Rev G.4 A-19 A-20 05233 Rev G.4 Model 360E Instruction Manual 05233 Rev G.4 A-21 VALUE VALUE RANGE DESCRIPTION A-22 05233 Rev G.4 05233 Rev G.4 A-23 Table A-3: M360E Test Functions, Revision G.4 TEST FUNCTION NAME A-24 05233 Rev G.4 05233 Rev G.4 A-25 A-26 05233 Rev G.4 Model 360E Instruction Manual 05233 Rev G.4 A-27 A-28 05233 Rev G.4 Model 360E Instruction Manual Table A-6: M360E iDAS Functions, Revision G.4 NAME DESCRIPTION UNITS 05233 Rev G.4 A-29 A-30 05233 Rev G.4 USER NOTES: Page APPENDIX B - M360E Spare Parts List Page Page M360E Spare Parts List Recommended Spare Parts Stocking Levels Model 360E * Page Model 360E Instruction Manual Questionnaire C-1 05235 Rev B Model 360E Instruction Manual Questionnaire APPENDIX D - ELECTRONIC SCHEMATICS User Notes: