Main
INSTRUCTION MANUAL
MODEL 360E CARBON DIOXIDE ANALYZER
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SAFETY MESSAGES
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TABLE OF CONTENTS
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LIST OF APPENDICES
LIST OF FIGURES
LIST OF TABLES
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1. M360E DOCUMENTATION
1.1. Using This Manual
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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
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3. GETTING STARTED
3.1. Unpacking and Initial Set Up
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3.1.1. M360 Layout
Getting Started Model 360E Instruction Manual
Figure 3-3: Assembly Layout
10 05232 Rev B3
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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
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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
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3.2.4. Functional Check
3.3. Initial Calibration Procedure
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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
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4. FREQUENTLY ASKED QUESTIONS
4.1. FAQs
4.2. Glossary
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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)
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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
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6. OPERATING INSTRUCTIONS
6.1. Overview of Operating modes
Mode Field
6.2. Sample Mode
6.2.1. Test Functions
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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
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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
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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
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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
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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)
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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
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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
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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
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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:
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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:
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APPENDIX B - M360E Spare Parts List
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M360E Spare Parts List
Recommended Spare Parts Stocking Levels Model 360E
*
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Model 360E Instruction Manual
Questionnaire
C-1 05235 Rev B
Model 360E Instruction Manual
Questionnaire
APPENDIX D - ELECTRONIC SCHEMATICS
User Notes:
Model 360E Instruction Manual Operating Instructions Note The CALDAT, STBZRO and STBSPN channels collect data based on events (e.g. a calibration operation) rather than a timed interval. This does not represent any specific length of time since it is dependent on how often calibrations are performed. Triggering Events and Data Parameters/Functions for these default channels are: