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Teledyne 400E 13.8. TROUBLE SHOOTING THE PHOTOMETER

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General Troubleshooting & Repair of the M400E Analyzer M400E Ozone Analyzer Operator’s Manual

13.8. TROUBLE SHOOTING THE PHOTOMETER

13.8.1. CHECKING MEASURE / REFERENCE VALVE

To check the function of the photometer’s measure / reference valve:

1. Set the analyzer’s front panel display to show the O3 REF test function (see Section 6.2.1).

2. Follow the instruction in Section 9.2.3 for performing a zero point calibration.

 Press

ZERO and allow the analyzer to stabilize.

3. Before completing the calibration by pressing the ENTR key, note of the displayed value.

4. Press the EXIT key to interrupt the zero point calibration process (DO NOT PRESS the ENTR key).

5. Follow the instruction in Sections Section 9.2.3 for performing a span point calibration of the

photometer.

 Press

SPAN and allow the analyzer to stabilize.

6. Before completing the calibration by pressing the ENTR key, note of the displayed value of O3 REF.

 If the

O3 REF value has decreased by more than 2 mV from its value with zero gas, then there is a

"cross-port" leak in the M/R valve or a bad O3 scrubber.

7. Press the EXIT key to interrupt the span point calibration process (DO NOT PRESS the ENTR key).

13.8.2. CHECKING THE PHOTOMETER UV LAMP POWER SUPPLY

NOTE

A schematic and physical diagram of the Lamp Power Supply can be found in Appendix D.

CAUTION

Electrical Shock Hazard

Hazardous voltage present - use caution.

It is not always possible to determine with certainty whether a problem is the result of the UV Lamp or the lamp

power supply, however, the following steps will provide a reasonable confidence test of the lamp power supply.

1. Unplug the cable connector at P1 on the lamp power supply and confirm that +15VDC is present

between Pins 1 and 2 on the cable connector.

2. If this voltage is incorrect, check the DC test points on the relay PCA as described in Section 13.7.2.

254 04315 Rev. C1

Contents

Main MODEL 400E PHOTOMETRIC OZONE ANALYZER Page TABLE OF CONTENTS Page Page Page Page Page LIST OF FIGURES LIST OF TABLES Page LIST OF APPENDICES Page Page 1. INTRODUCTION 1.1. SAFETY MESSAGES 1.2. M400E OVERVIEW CAUTION 1.3. USING THIS MANUAL TABLE OF CONTENTS: SECTION I GENERAL INFORMATION SECTION II OPERATING INSTRUCTIONS SECTION III TECHNICAL INFORMATION APPENDICES M400E Ozone Analyzer Operators Manual Specifications, Approvals and Warranty 2. SPECIFICATIONS, APPROVALS AND 04315 Rev. C1 7 WARRANTY 2.1. SPECIFICATIONS Table 2-1: Model 400E Basic Unit Specifications Page 2.2. EPA EQUIVALENCY DESIGNATION 2.3. CE MARK COMPLIANCE 2.4. WARRANTY 3. GETTING STARTED 3.1. MODEL 400E ANALYZER LAYOUT Page SAMPLE EXHAUST SPAN ZERO AIR DRY AIR Page 3.2. UNPACKING THE M400E ANALYZER 3.2.1.1. Ventilation Clearance 3.3. ELECTRICAL CONNECTIONS 3.3.1. POWER CONNECTION CAUTION 3.3.2. ANALOG OUTPUT CONNECTIONS A1 A2 A3 A4 + - + - + - + - 3.3.3. CONNECTING THE STATUS OUTPUTS 3.3.4. CONNECTING THE CONTROL INPUTS Input # Status Definition ON Condition - + 3.3.5. CONNECTING THE SERIAL PORTS 3.3.6. CONNECTING TO A LAN OR THE INTERNET 3.3.7. CONNECTING TO A MULTIDROP NETWORK 3.4. PNENUMATIC CONNECTIONS CAUTION SAMPLE AND CALIBRATION GASES SHOULD ONLY COME INTO CONTACT WITH PTFE, FEP OR GLASS. 3.4.1. ABOUT ZERO AIR AND CALIBRATION GAS 3.4.2. BASIC PNEUMATIC SETUP FOR THE M400E ANALYZER CAUTION 3.4.3. PNEUMATIC SETUP FOR THE M400E ANALYZER WITH INTERNAL ZERO/SPAN OPTION (IZS) Page 3.4.4.2. Pneumatic Set Up for M400Es Monitoring Remote Locations 3.5. INITIAL OPERATION 3.5.1. START UP 3.5.2. WARM UP 3.5.3. WARNING MESSAGES MESSAGE MEANING 28 04315 Rev. C1 3.5.4. FUNCTIONAL CHECK 3.6. INITIAL CALIBRATION OF THE M400E ANALYZER 3.6.1. INTERFERENTS FOR O3 MEASUREMENT 3.6.2. INITIAL CALIBRATION PROCEDURE FOR M400E ANALYZERS WITHOUT OPTIONS 3.6.2.1. Verifying the M400E Reporting Range Settings Page M400E Ozone Analyzer Operators Manual Getting Started 3.6.2.3. Initial Zero/Span Calibration Procedure: To perform an initial Calibration of the Model 400E photometric ozone analyzer, press: THE MODEL 400E ANALYZER IS NOW READY FOR OPERATION. 04315 Rev. C1 33 3.7. CONFIGURING THE INTERNAL ZERO/SPAN OPTION (IZS) 3.7.1. VERIFY THE O3 GENERATOR AND EXPECTED O3 SPAN CONCENTRATION SETTINGS: M400E Ozone Analyzer Operators Manual Getting Started 3.7.2. SETTING THE O3 GENERATOR LOW-SPAN (MID POINT) OUTPUT LEVEL 04315 Rev. C1 35 To set the ozone LO SPAN (Midpoint) concentration for the IZS O3 generator, press: setting ENTR accepts the new setting 3.7.3. TURNING ON THE REFERENCE DETECTOR OPTION EXIT discards the new setting ENTR accepts the new setting 3.7.4. INITIAL CALIBRATION AND CONDITIONING OF M400E ANALYZERS WITH THE IZS OPTION INSTALLED 3.7.4.1. Initial O3 Scrubber Conditioning 3.7.4.2. Verifying the M400E Reporting Range Settings 3.7.4.3. Initial Zero/Span Calibration Procedure: 3.7.4.4. Initiate Daily Zero-Point Auto-Cal of M400Es Monitoring Low Levels of O3 M400E Ozone Analyzer Operators Manual Getting Started 04315 Rev. C1 39 Page 4. FREQUENTLY ASKED QUESTIONS AND GLOSSARY 4.1. FAQS Page 4.2. GLOSSARY Page 5. OPTIONAL HARDWARE AND SOFTWARE 5.1. OPTIONAL PUMPS (OPT 10 THR OPT 13) 5.2. RACK MOUNT KITS (OPT 20 TO OPT 23) 5.3. CARRYING STRAP HANDLE (OPT 29) 5.4. CURRENT LOOP ANALOG OUTPUTS (OPT 41) 5.4.1. CONVERTING CURRENT LOOP ANALOG OUTPUTS TO STANDARD VOLTAGE OUTPUTS. 5.5. SPARE PARTS KITS 5.5.1. M400E EXPENDABLES KIT (OPT 42A) 5.5.2. M400E SPARE PARTS KIT FOR THE IZS OPTION (OPT 43) 5.6. CALIBRATION VALVE OPTIONS 5.6.1. ZERO/SPAN VALVES (OPT 50A) Page 5.6.1.1. Pneumatic Setup for the M400E Analyzer with Zero/Span Valve Option Page 5.6.2. INTERNAL ZERO SPAN (IZS) OPTION (OPT 51A) 51A 5.6.2.1. Disposable Charcoal O3 Filter 5.6.3. METAL WOOL SCRUBBER (OPT 68) 5.6.4. IZS DESICCANT (OPTION 56) 5.7. COMMUNICATION OPTIONS 5.7.1. EXTRA COMM CABLES 5.7.1.1. RS232 Modem Cables (OPTs 60A and 60B) 5.7.1.2. ETHERNET Cable (OPT 60C) 5.7.2. RS-232 MULTIDROP (OPT 62) 5.7.3. ETHERNET (OPT 63) 5.7.4. ETHERNET + MULTIDROP (OPT 63C) 5.8. ADDITIONAL MANUAL (OPT 70A & OPT 70B) Page Page 6. BASIC OPERATION OF THE M400E ANALYZER 6.1. OVERVIEW OF OPERATING MODES Mode Field 6.2. SAMPLE MODE 6.2.1. TEST FUNCTIONS DISPLAY PARAMETER UNITS DESCRIPTION 6.2.2. WARNING MESSAGE DISPLAY MESSAGE MEANING 62 04315 Rev. C1 See Section 13.1.1 for more information on using these messages to troubleshoot problems. 6.3. CALIBRATION MODE Basic Operation of the M400E Analyzer M400E Ozone Analyzer Operators Manual 6.4. SETUP MODE Table 6-5: Secondary Setup Mode Features and Functions 64 04315 Rev. C1 6.4.1. SETUP CFG: CONFIGURATION INFORMATION 6.4.2. SETUP PASS: ENABLING/DISABLING PASSWORDS 101 818 Page Page 6.4.3.2. Adjusting the internal Clocks speed 6.4.4. SETUP RNGE: ANALOG OUTPUT REPORTING RANGE CONFIGURATION 6.4.4.1. Physical Range versus Analog Output Reporting Ranges 6.4.4.2. Analog Output Ranges for O3 Concentration A NALOG OUT Page 6.4.4.3. RNGE MODE SNGL: Configuring the M400E analyzer for Single Range Mode 6.4.4.4. RNGE MODE DUAL: Configuring the M400E analyzer for Dual Range Mode 04315 Rev. C1 73 LOW range setting corresponds with the analog output labeled A1 on the rear panel of the HIGH range setting corresponds with the A2 output and is viewable via the test function RANGE2 6.4.4.5. RNGE MODE AUTO: Configuring the M400E analyzer for Auto Range Mode 6.4.4.6. SETUP RNGE UNIT: Setting the Reporting range Unit Type Page 7. ADVANCED FEATURES OF THE M400E ANALYZER 7.1. USING USING THE DATA ACQUISITION SYSTEM (IDAS) 7.1.1. IDAS STATUS 7.1.2. IDAS STRUCTURE TRIGGER 7.1.3. IDAS CHANNELS Table 7-2: iDAS Data Channel Properties 78 04315 Rev. C1 7.1.3.1. Default iDAS Channels Page Page 7.1.5. SETUP DAS EDIT: ACCESSING THE IDAS EDIT MODE KEY 82 04315 Rev. C1 FUNCTION iDAS EDIT Keypad Functions Page 7.1.5.2. Editing iDAS Triggering Events 7.1.5.3. Editing iDAS Parameters 04315 Rev. C1 85 Table 7-3: iDAS Data Parameter Functions Page 7.1.5.4. Editing Sample Period and Report Period 7.1.5.5. Report periods in Progress when Instrument Is Powered Off 7.1.5.6. Editing the Number of Records ENTR 04315 Rev. C1 89 7.1.5.7. RS-232 Report Function 7.1.5.8. Enabling / Disabling the HOLDOFF Feature 7.1.5.9. The Compact Report Feature 7.1.5.10. The Starting Date Feature 92 04315 Rev. C1 7.1.6. DISABLING/ENABLING DATA CHANNELS 7.1.7. REMOTE IDAS CONFIGURATION Figure 7-2: APICOMuser interface for configuring the iDAS. 04315 Rev. C1 93 94 04315 Rev. C1 7.2. SETUP MORE VARS: INTERNAL VARIABLES (VARS) 7 Table 7-4: Variable Names (VARS) NO. VARIABLE DESCRIPTION ALLOWED VALUES 6 Page 7.3. SETUP MORE DIAG :THE DIAGNOSTIC MENU Page 7.4. USING THE MODEL 400E ANALYZERS ANALOG OUTPUTS. 7.4.1. ADJUSTING & CALIBRATING THE ANALOG OUTPUT SIGNALS 7.4.2 7.4 7.4.6 Figure 7-4: Accessing the Analog I/O Configuration Submenus 04315 Rev. C1 99 7.4.2. CALIBRATION OF THE ANALOG OUTPUTS 7.4.2.1. Enabling or Disabling the AutoCal for an Individual Analog Output 7.4.2.2. Automatic Calibration of the Analog Outputs Page 7.4.2.3. Manual Calibration of the Analog Outputs configured for Voltage Ranges 104 04315 Rev. C1 These menus only appear if AUTO-CAL is turned OFF 7.4.2.4. Manual Adjustment of Current Loop Output Span and Offset 106 04315 Rev. C1 These menus only appear if AUTO-CAL is turned OFF V IN + V IN - V OUT + V OUT - 7.4.3. ANALOG OUTPUT VOLTAGE / CURRENT RANGE SELECTION Page 7.4.5. ADDING A RECORDER OFFSET TO AN ANALOG OUTPUT M400E Ozone Analyzer Operators Manual Advanced FEATURES of the M400E analyzer 7.4.6. SELECTING A TEST CHANNEL FUNCTION FOR OUTPUT A4 The test functions available to be reported are: 04315 Rev. C1 111 TEST setting ENTR accepts the new setting 112 04315 Rev. C1 M400E Ozone Analyzer Operators Manual Advanced FEATURES of the M400E analyzer 7.4.7. AIN CALIBRATION 04315 Rev. C1 113 Perform Troubleshooting or call Teledyne Customer Service Page 8. REMOTE OPERATION OF THE M400E 8.1. USING THE ANALYSERS COMMUNICATION PORTS 04315 Rev. C1 115 8.1.1. RS-232 DTE AND DCE COMMUNICATION 357BRemote Operation Of The M400E M400E Ozone Analyzer Operators Manual 8.1.2. COMM PORT DEFAULT SETTINGS AND CONNECTOR PIN ASSIGNMENTS RXD GND 116 04315 Rev. C1 CTS Figure 8-2: Defaul Pin Assignments for CPU COM Port connector (RS-232). 04315 Rev. C1 117 8.1.3. COMM PORT BAUD RATE M400E Ozone Analyzer Operators Manual 357BRemote Operation Of The M400E 8.1.4. COMM PORT COMMUNICATION MODES Table 8-1: COMM Port Communication Modes MODE1 ID DESCRIPTION Note Communication Modes for each COM port must be configured independently. 04315 Rev. C1 119 Page 8.1.5. COMM PORT TESTING Continue pressing <SET or SET> until ... 04315 Rev. C1 121 Test Runs Automatically 8.1.6. MACHINE ID 8.1.7. TERMINAL OPERATING MODES 8.1.7.1. Help Commands in Terminal Mode 04315 Rev. C1 123 Table 8-2: Terminal Mode Software Commands 8.1.7.2. Command Syntax Table 8-3: Teledyne Instruments Serial I/O Command Types 124 04315 Rev. C1 8.1.7.3. Data Types 8.1.7.4. Status Reporting 04315 Rev. C1 125 8.1.7.5. COMM Port Password Security 8.2. REMOTE ACCESS BY MODEM MODEM ENABLE communication mode is turned ON (Mode 64, see Section 8.1.4). 04315 Rev. C1 127 AT Y0 &D0 &H0 &I0 S0=2 &B0 &N6 &M0 E0 Q1 &W0 Page 8.2.1. MULTIDROP RS-232 SET UP COM2 04315 Rev. C1 129 Figure 8-3: Location of JP2 on RS232-Multidrop PCA (option 62) CALIBRATOR CALIBRATOR TAPI Analyzer Last INSTRUMENT Host RS-232 port Make Sure Jumper between JP2 pins 21 22 is installed. 8.3. RS-485 CONFIGURATION OF COM2 ( COM2 132 04315 Rev. C1 ) Figure 8-6: Back Panel connector Pin-Outs for COM2 in RS-485mode. 8.4. REMOTE ACCESS VIA THE ETHERNET 8.4.1. ETHERNET CARD COM2 COMMUNICATION MODES AND BAUD RATE 8.4.2. CONFIGURING THE ETHERNET INTERFACE OPTION USING DHCP Page 04315 Rev. C1 135 8.4.2.1. Manually Configuring the Network IP Addresses 04315 Rev. C1 137 From Step 1 above) Contact your IT Network Administrator 357BRemote Operation Of The M400E M400E Ozone Analyzer Operators Manual 8.4.3. CHANGING THE ANALYZERS HOSTNAME 138 04315 Rev. C1 Contact your IT Network Administrator the new setting EXIT ignores the new setting 8.5. USING THE M400E WITH A HESSEN PROTOCOL NETWORK 8.5.1. GENERAL OVERVIEW OF HESSEN PROTOCOL 8.5.2. HESSEN COMM PORT CONFIGURATION Page 8.5.4. SELECTING A HESSEN PROTOCOL TYPE 357BRemote Operation Of The M400E M400E Ozone Analyzer Operators Manual 8.5.5. SETTING THE HESSEN PROTOCOL RESPONSE MODE new setting 142 04315 Rev. C1 BCC MODE ID MODE DESCRIPTION CMD 8.5.6. HESSEN PROTOCOL GAS LIST ENTRIES 8.5.6.1. Gas List Entry Format and Definitions [GAS TYPE],[RANGE],[GAS ID],[REPORTED] O3, 0, 400, REPORTED 357BRemote Operation Of The M400E M400E Ozone Analyzer Operators Manual 8.5.6.2. Editing or Adding HESSEN Gas List Entries To add or edit an entry to the Hessen Gas List, press: 144 04315 Rev. C1 M400E Ozone Analyzer Operators Manual 357BRemote Operation Of The M400E 8.5.6.3. Deleting HESSEN Gas List Entries To delete an entry from the Hessen Gas list, press: 04315 Rev. C1 145 Continue pressing NEXT until ... There is only one GAS TYPE available on the M400E: O3 8.5.7. SETTING HESSEN PROTOCOL STATUS FLAGS 146 04315 Rev. C1 OPERATIONAL FLAGS SPARE/UNUSED BITS UNASSIGNED FLAGS (0000) 8.5.8. INSTRUMENT ID CODE 04315 Rev. C1 147 8.6. APICOM REMOTE CONTROL PROGRAM 9. M400E CALIBRATION PROCEDURES 9.1. BEFORE CALIBRATION 150 04315 Rev. C1 9.1.1. REQUIRED EQUIPMENT, SUPPLIES, AND EXPENDABLES 9.1.2. ZERO AIR AND SPAN GAS 9.2. BASIC MANUAL CALIBRATION CHECKS AND CALIBRATION OF THE M400E ANALYZER 9.2.1. SETUP FOR BASIC CALIBRATION CHECKS AND CALIBRATION OF THE M400E ANALYZER. Page 9.2.3. PERFORMING A BASIC MANUAL CALIBRATION 9.2.3.1. Setting the expected O3 Span Gas concentration 04315 Rev. C1 153 NOTE It is important to verify the PRECISE O3 Concentration Value of the SPAN gas independently. EXIT discards the new setting ENTR accepts the new setting Page 9.2.4. MANUAL CALIBRATION CHECKS AND CALIBRATIONS USING AUTO RANGE OR DUAL RANGE MODES Page Page MANUAL CALIBRATION CHECKS WITH VALVE OPTIONS INSTALLED 9.3.2. MANUAL CALIBRATION USING VALVE OPTIONS 9.3.2.1. Setting the Expected O3 Span Gas Concentration with the Z/S Option Installed M400E Ozone Analyzer Operators Manual M400E Calibration Procedures 9.3.2.2. Zero/Span Point Calibration Procedure the Z/S Option Installed 9.3.2.3. Use of Zero/Span Valve with Remote Contact Closure 9.4. AUTOMATIC ZERO/SPAN CAL/CHECK (AUTOCAL) Page M400E Calibration Procedures M400E Ozone Analyzer Operators Manual 9.4.1. SETUP ACAL: PROGRAMMING AND AUTO CAL SEQUENCE To program the example sequence shown in Table 9-3, press: 164 04315 Rev. C1 04315 Rev. C1 165 M400E Calibration Procedures M400E Ozone Analyzer Operators Manual 166 04315 Rev. C1 9.5. O3 PHOTOMETER ELECTRONIC CALIBRATION 9.5.1. PHOTOMETER DARK CALIBRATION 04315 Rev. C1 167 9.5.2. O3 PHOTOMETER GAS FLOW CALIBRATION M400E Ozone Analyzer Operators Manual M400E Calibration Procedures 9.6. CALIBRATION THE IZS OPTION O3 GENERATOR 04315 Rev. C1 169 To calibrate the O3 Generator press: Page 10. EPA PROTOCOL CALIBRATION 10.1.1. M400E CALIBRATION GENERAL GUIDELINES 04315 Rev. C1 171 10.1.2. CALIBRATION EQUIPMENT, SUPPLIES, AND EXPENDABLES Spare Parts and Expendable Supplies 172 04315 Rev. C1 10.1.3. CALIBRATION GAS AND ZERO AIR SOURCES Production of Zero Air 10.1.4. RECOMMENDED STANDARDS FOR ESTABLISHING TRACEABILITY 04315 Rev. C1 173 10.1.5. CALIBRATION FREQUENCY 10.1.6. DATA RECORDING DEVICE 174 04315 Rev. C1 10.1.7. RECORD KEEPING 10.2. LEVEL 1 CALIBRATIONS VERSUS LEVEL 2 CHECKS LEVEL 1 ZERO AND SPAN CALIBRATION 04315 Rev. C1 175 LEVEL 2 ZERO AND SPAN CHECK 10.3. MULTIPOINT CALIBRATION 10.3.2. MULTIPOINT CALIBRATION PROCEDURE 176 04315 Rev. C1 10.3.3. DYNAMIC MULTIPOINT CALIBRATION CHECK )FF( 04315 Rev. C1 177 10.3.4. LINEARITY TEST + Equation 10-1 100 A 178 04315 Rev. C1 )R/A(A E 21 = 10.3.5. O3 LOSS CORRECTION FACTOR 10.4. AUDITING PROCEDURES 10.4.1. MULTIPOINT CALIBRATION AUDIT Audit Procedure: 180 04315 Rev. C1 Results: d = [O3]R - [O3]A d 10.4.3. SYSTEM AUDIT 10.4.4. ASSESSMENT OF MONITORING DATA FOR PRECISION AND ACCURACY 04315 Rev. C1 181 10.5. SUMMARY OF QUALITY ASSURANCE CHECKS Page Table 10-1: Daily Activity Matrix CHARACTERISTIC ACCEPTANCE LIMITS FREQUENCY AND METHOD OF MEASUREMENT 04315 Rev. C1 183 AUDIT ACCEPTANCE LIMITS ACTION IF REQUIREMENTS ARE NOT MET OPERATING INSTRUCTIONS M400E Ozone Analyzer Operators Manual Table 10-3: Activity Matrix for Data Reduction, Validation and Reporting ACTIVITY ACCEPTANCE LIMITS 184 04315 Rev. C1 FREQUENCY AND METHOD OF MEASUREMENT 10.6. REFERENCES 04315 Rev. C1 185 Page Page Page 11. THEORY OF OPERATION 11.1. MEASUREMENT METHOD 11.1.1. CALCULATING O3 CONCENTRATION Equation 11-1 I=IO e-LC at STP Io is the intensity of the light if there was no absorption. I L C Equation 11-2 04315 Rev. C1 189 T P 190 04315 Rev. C1 Equation 11-4 11.1.2. THE PHOTOMETER UV ABSORPTION PATH ABSORPTION TUBE 04315 Rev. C1 191 Figure 11-1: O3 Absorption Path 11.1.3. THE REFERENCE / MEASUREMENT CYCLE 192 04315 Rev. C1 Measure Path ABSORPTION TUBE Flow / Pressure Sensor PCA 11.1.4. INTERFERENT REJECTION AROMATIC HYDROCARBONS 04315 Rev. C1 193 MERCURY VAPOR 11.2. PNEUMATIC OPERATION 11.2.1. SAMPLE GAS AIR FLOW 11.2.2. FLOW RATE CONTROL Figure 11-4: Flow Control Assembly & Critical Flow Orifice 04315 Rev. C1 195 11.2.2.1. Critical Flow Orifice 11.2.3. PARTICULATE FILTER 11.2.4. PNEUMATIC SENSORS 196 04315 Rev. C1 11.2.4.1. Sample Pressure Sensor 11.2.4.2. Sample Flow Sensor 11.3. ELECTRONIC OPERATION 11.3.1. OVERVIEW 04315 Rev. C1 197 I2C Bus MOTHERBOARD 11.3.2. CPU 11.3.3. MOTHERBOARD 198 04315 Rev. C1 11.3.3.1. A to D Conversion 11.3.3.2. Sensor Inputs 11.3.3.3. Thermistor Interface 04315 Rev. C1 199 11.3.3.4. Analog Outputs 11.3.3.5. External Digital I/O 11.3.4. RELAY PCA I2C Connector Figure 11-6: Relay PCA Layout (P/N 04523-0100) 04315 Rev. C1 201 AC Relay Safety Shield 11.3.4.1. Status LEDs 04315 Rev. C1 203 D6 (Green ) GPT Valve Table 11-1: Relay PCA Status LEDs LED Color Function Status When Lit Status When Unlit 11.3.4.3. Valve Control ZERO/SPAN valve selects which calibration gas inlet (the ZERO gas inlet or the SPAN Gas SAMPLE/CAL valve selects either the sample inlet when the analyzer is in SAMPLE mode or 11.3.4.4. Heater Control RELAY PCA TC1 5 15 Termination Selector IN = Isolate TC; OUT = Grounded TC TC2 TC2 Not Used 11.3.5. POWER SUPPLY/CIRCUIT BREAKER 11.3.5.1. Power Switch/Circuit Breaker 11.3.6. AC POWER CONFIGURATION JP6 04315 Rev. C1 207 JP7 RELAY PCA Page 11.3.6.2. AC Configuration Heaters for Option Packages (JP6) 04315 Rev. C1 209 Table 11-5: Power Configuration for Optional Metal Wool Scrubber Heater (JP6) 1 to 8 RED 11.3.7. PHOTOMETER LAYOUT AND OPERATION Figure 11-16: O3 Photometer Layout Top Cover Removed 210 04315 Rev. C1 11.3.7.1. Photometer Electronic Operation Figure 11-17: O3 Photometer Electronic Block Diagram 04315 Rev. C1 211 11.3.7.2. O3 Photometer UV Lamp Power Supply Figure 11-18: O3 Photometer UV Lamp Power Supply Block Diagram 212 04315 Rev. C1 11.3.7.3. Photometer Temperature 11.3.7.4. Photometer Gas Pressure and Flow Rate 11.4. INTERFACE GAS FILTER CORRELATION ANALYZER - MODEL 30 0E A4ST FRONT PANEL DISPLAY 11.4.1.1. Front Panel Display 11.4.1.2. Keypad 04315 Rev. C1 215 11.4.1.3. Front Panel States LEDs Table 11-6: Front Panel Status LEDs 11.5. SOFTWARE OPERATION ANALYZER HARDWARE 216 04315 Rev. C1 PC/104 BUS 11.5.2. CALIBRATION - SLOPE AND OFFSET 04315 Rev. C1 217 Page 12. MAINTENANCE SCHEDULE & PROCEDURES 12.1. PREDICTING FAILURES USING THE TEST FUNCTIONS 04315 Rev. C1 219 SAMP FL SAMPLE STABIL ZERO CAL 12.2. MAINTENANCE SCHEDULE Table 12-2: M400E Maintenance Schedule DATE PERFORMED ITEM ACTION FREQ CAL CHECK REQD.1 04315 Rev. C1 221 MANUAL SECTION 13.10.3 Page 12.3. MAINTENANCE PROCEDURES 12.3.1. REPLACING THE SAMPLE PARTICULATE FILTER 04315 Rev. C1 223 Figure 12-1 Replacing the Particulate Filter 12.3.2. REBUILDING THE SAMPLE PUMP IZS Zero Air Scrubber Figure 12-2 Replacing the IZS Zero Air Scrubber 224 04315 Rev. C1 12.3.4. PERFORMING LEAK CHECKS 12.3.4.1. Vacuum Leak Check and Pump Check 04315 Rev. C1 225 12.3.4.2. Pressure Leak Check CAUTION 12.3.5. PERFORMING A SAMPLE FLOW CHECK 12.3.6. MAINTENANCE OF THE PHOTOMETER ABSORPTION TUBE 12.3.6.1. Cleaning or Replacing the Absorption Tube 12.3.6.2. UV Lamp Adjustment 12.3.6.3. UV Lamp Replacement 12.3.7. ADJUSTMENT OR REPLACEMENT OF OPTIONAL IZS OZONE GENERATOR UV LAMP Page Page 13. GENERAL TROUBLESHOOTING & REPAIR OF THE M400E ANALYZER 13.1. GENERAL TROUBLESHOOTING 13.1.1. FAULT DIAGNOSIS WITH WARNING MESSAGES 234 04315 Rev. C1 Table 13-1: Front Panel Warning Messages WARNING FAULT CONDITION POSSIBLE CAUSES 04315 Rev. C1 235 SAMPLE PRES WARN RELAY BOARD WARN REAR BOARD NOT DET 13.1.2. FAULT DIAGNOSIS WITH TEST FUNCTIONS 13.1.3. DIAG SIGNAL I/O: USING THE DIAGNOSTIC SIGNAL I/O FUNCTION 04315 Rev. C1 237 Page 13.2. USING THE ANALOG OUTPUT TEST CHANNEL 04315 Rev. C1 239 TEMP Table 13-3: Test Channel Outputs as Diagnostic Tools TEST CHANNEL DESCRIPTION ZERO FULL SCALE 13.3. USING THE INTERNAL ELECTRONIC STATUS LEDS 13.3.1. CPU STATUS INDICATOR 240 04315 Rev. C1 Mother Board P/N 04069 Figure 13-2: CPU Status Indicator 13.3.2.2. O3 Option Status LED s D8 (Green) Photometer Meas/Ref Valve 04315 Rev. C1 241 O3_GEN_HEATER O3 GEN TEMP O3_SCRUB_HEATER O3 SCRUB 13.4. GAS FLOW PROBLEMS 13.4.1. TYPICAL FLOW PROBLEMS 242 04315 Rev. C1 13.4.1.1. Flow is Zero 13.4.1.2. Low Flow 13.5. CALIBRATION PROBLEMS 13.5.1. MIS-CALIBRATED 13.5.2. NON-REPEATABLE ZERO AND SPAN 13.5.3. INABILITY TO SPAN NO SPAN KEY (CALS) 13.5.4. INABILITY TO ZERO NO ZERO KEY (CALZ) 13.6. OTHER PERFORMANCE PROBLEMS 13.6.1. TEMPERATURE PROBLEMS 13.6.1.1. Box Temperature 13.6.1.2. Sample Temperature 13.6.1.3. UV Lamp Temperature PHOTO_LAMP_HEATER parameter under the SIGNAL I/O function of the DIAG menu, as 04315 Rev. C1 245 13.6.1.4. IZS Ozone Generator Temperature (Optional) O3_GEN_HEATER parameter under the SIGNAL I/O function of the DIAG menu, as 13.7. SUBSYSTEM CHECKOUT 13.7.1. AC MAIN POWER 13.7.2. DC POWER SUPPLY NAME TEST POINT# COLOR DEFINITION Figure 13-4: Location of DC Power Test Points on Relay PCA 13.7.3. I2C BUS 13.7.4. KEYBOARD/DISPLAY INTERFACE 13.7.5. RELAY PCA 13.7.6. PHOTOMETER PRESSURE /FLOW SENSOR ASSEMBLY BASIC PCA OPERATION: 04315 Rev. C1 249 PHOTOMETER PRESSURE SENSOR: PHOTOMETER FLOW SENSOR 13.7.7. MOTHERBOARD 13.7.7.1. Test Channel / Analog Outputs Voltage 13.7.7.2. A/D Functions 13.7.7.3. Status Outputs 04315 Rev. C1 251 DIAG SIGNAL I/O menu (See Section13.1.3), scroll through the inputs and outputs until Table 13-10: Status Outputs Check PIN (LEFT TO RIGHT) STATUS 13.7.8. CPU 13.7.9. RS-232 COMMUNICATIONS 13.7.9.1. General RS-232 Troubleshooting 04315 Rev. C1 253 13.7.9.2. Troubleshooting Analyzer/Modem or Terminal Operation 13.8. TROUBLE SHOOTING THE PHOTOMETER 13.8.1. CHECKING MEASURE / REFERENCE VALVE 13.8.2. CHECKING THE PHOTOMETER UV LAMP POWER SUPPLY CAUTION Hazardous voltage present - use caution. 13.9. TROUBLE SHOOTING THE IZS OPTIONS O3 GENERATOR 13.9.1. CHECKING THE O3 GENERATOR UV LAMP POWER SUPPLY 04315 Rev. C1 255 13.10. REPAIR PROCEDURES 13.10.1. REPAIRING SAMPLE FLOW CONTROL ASSEMBLY 256 04315 Rev. C1 Figure 13-5: Critical Flow Orifice Assembly (Instruments without IZS) 13.10.2. REPLACING THE STANDARD REFERENCE O3 SCRUBBER 13.10.3. REPLACING THE IZS O3 SCRUBBER IZ S Z ER O A IR SCRUBBER Figure 13-6: IZS O3 Generator Zero Air Scrubber Location 04315 Rev. C1 257 13.10.4. METAL WOOL SCRUBBER OPTION 13.11. TECHNICAL ASSISTANCE TELEDYNE-API, CUSTOMER SERVICE, 14. A PRIMER ON ELECTRO-STATIC DISCHARGE 14.1. HOW STATIC CHARGES ARE CREATED 04315 Rev. C1 259 Figure 14-1: Triboelectric Charging Table 14-1: Static Generation Voltages for Typical Activities 14.2. HOW ELECTRO-STATIC CHARGES CAUSE DAMAGE Table 14-2: Sensitivity of Electronic Devices to Damage by ESD. 260 04315 Rev. C1 14.3. COMMON MYTHS ABOUT ESD DAMAGE I didnt feel a shock so there was no electro-static discharge I didnt touch it so there was no electro-static discharge It still works so there was no damage Static Charges cant build up on a conductive surface Always wear an Anti-ESD wrist strap when working on the electronic assemblies of your analyzer Simply touching a grounded piece of metal is insufficient 262 04315 Rev. C1 Always store sensitive components and assemblies in anti-ESD storage bags or bins: Never use ordinary plastic adhesive tape near an ESD sensitive device or to close an anti-ESD bag. 14.4.2. BASIC ANTI-ESD PROCEDURES FOR ANALYZER REPAIR AND MAINTENANCE 14.4.2.1. Working at the Instrument Rack 04315 Rev. C1 263 14.4.2.2. Working at an Anti-ESD Work Bench. 14.4.2.3. Transferring Components from Rack to Bench and Back 14.4.2.4. Opening Shipments from Teledyne Instruments Customer Service 264 04315 Rev. C1 14.4.2.5. Packing Components for Return to Teledyne Instruments Customer Service ESD Hazard Page INDEX 1 04315 Rev. C1 267 2 5 D E 268 04315 Rev. C1 F G H I 04315 Rev. C1 269 K L P R 270 04315 Rev. C1 Recorder Offset S T U 04315 Rev. C1 271 V VARS Menu, 44, 64, 66, 67, 69, 78, 91, 94, 95 W Warning Messages, 27, 28, 61, 62, 234, 235, 236 272 04315 Rev. C1 Warranty, 5, 7, 10 Watchdog Circuit, 203, 240 Z Page Page APPENDIX A Software Version-Specific Documentation Page SAMPLE MSG1CLR1SETUP <TST TST> CALTEST1 modes. LOW2HIGH2 CONCZERO SPAN TEST FUNCTIONS Viewable by user while instrument is in SAMPLE Mode DIAGCOMM VARS Page Page Page Page Page Page Page APPENDIX A-2: Setup Variables, Revision D.4 Table A-1: M400E Setup Variables, Revision D.4 04402 Rev D.4 A-11 A-12 04402 Rev D.4 04402 Rev D.4 A-13 A-14 04402 Rev D.4 04402 Rev D.4 A-15 VALUE VALUE RANGE DESCRIPTION FACTORY_OPT 0 065535 A-16 04402 Rev D.4 04402 Rev D.4 A-17 Table A-3: M400E Test Functions, Revision D.4 NAME 1 MESSAGE TEXT DESCRIPTION A-18 04402 Rev D.4 04402 Rev D.4 A-19 SIGNAL NAME BIT OR CHANNEL NUMBER DESCRIPTION A-20 04402 Rev D.4 SIGNAL NAME BIT OR CHANNEL NUMBER DESCRIPTION 04402 Rev D.4 A-21 Page NAME DESCRIPTION Table A-6: M400E iDAS Functions, Revision D.4 NAME DESCRIPTION UNITS A-24 04402 Rev D.4 04402 Rev D.4 A-25 USER NOTES APPENDIX B M400E Spare Parts and Expendables Page Page M400E Spare Parts List Recommended Spare Parts Stocking Levels Model 400E Page M400E Expendables Kit Page Model M400E Manual Warranty/Repair Questionnaire TELEDYNE Appendix C PARAMETER RECORDED VALUE ACCEPTABLE VALUE Model M400E Manual Warranty/Repair Questionnaire TELEDYNE Appendix C APPENDIX D ELECTRONIC SCHEMATICS