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Teledyne M300E operation manual Teledyne Advanced Pollution Instrumentation, Operation Manual

Models: M300E M300EM

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Operation Manual

MODEL 300E FAMILY

CARBON MONOXIDE ANALYZERS

(Includes M300E, M300EM)

© TELEDYNE ADVANCED POLLUTION INSTRUMENTATION

9480 CARROLL PARK DRIVE SAN DIEGO, CA 92121-5201

USA

Toll-free Phone: 800-324-5190

Phone: 858-657-9800

Fax: 858-657-9816

Email: api-sales@teledyne.com

Website: http://www.teledyne-api.com/

Copyright 2008-2011	04288D DCN 5752
Teledyne Advanced Pollution Instrumentation	24 June 2011

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Teledyne M300EM operation manual Teledyne Advanced Pollution Instrumentation, Carroll Park Drive San Diego, Ca Usa

Contents

9480 CARROLL PARK DRIVE SAN DIEGO, CA USA TELEDYNE ADVANCED POLLUTION INSTRUMENTATIONMODEL 300E FAMILY CARBON MONOXIDE ANALYZERS Operation ManualPage SAFETY MESSAGES This page intentionally left blank Safety MessagesWARRANTY POLICY 02024D WARRANTYCAUTION – Avoid Warranty Invalidation COVERAGE04288D DCN5752 This page intentionally left blankinstrument ABOUT THIS MANUALPart No Name/Description2010 June REVISION HISTORYDocument Change SummaryRevision History This page intentionally left blank Revision Historyviii Table of Contents TABLE OF CONTENTS6. BASIC OPERATION PART II – OPERATING INSTRUCTIONS8. REMOTE OPERATION 7. ADVANCED FEATURES9. CALIBRATION PROCEDURES PART III – TECHNICAL INFORMATION 10. EPA CALIBRATION PROTOCOLxiii 11. THEORY OF OPERATION13. TROUBLESHOOTING & REPAIR 12. MAINTENANCE SCHEDULE & PROCEDURES14. A PRIMER ON ELECTRO-STATICDISCHARGE LIST OF FIGURES LIST OF APPENDICESTABLE OF CONTENTS xviii LIST OF TABLESTable This page intentionally left blank TABLE OF CONTENTSPart PART – GENERAL INFORMATIONGENERAL INFORMATION GENERAL INFORMATION PartThis page intentionally left blank 1.1.M300E FAMILY OVERVIEW 1.INTRODUCTION1.2.ADDITIONAL DOCUMENTATION TABLE OF CONTENTS 1.2.1.USING THIS MANUALPART I – GENERAL INFORMATION SPECIFICATIONS AND WARRANTYAPPENDICES PART III – TECHNICAL INFORMATIONADVANCED FEATURES OF THE M300E/EM ANALYZER MAINTENANCE SCHEDULE AND PROCEDURES2.1.SPECIFICATIONS 2.SPECIFICATIONS AND APPROVALSTable 2-1:M 300E/300EM Basic Unit Specifications 2.2.EPA EQUIVALENCY DESIGNATION 2.3.TUV DESIGNATION 2.4.2.SAFETY COMPLIANCE2.4.CE MARK COMPLIANCE 2.4.1.EMISSIONS COMPLIANCEThis page intentionally left blank Specifications and Approvals3.1.M300E/EM ANALYZER LAYOUT 3.GETTING STARTEDFigure Front Panel LayoutFigure Table 3-2:Inlet / Outlet Connector NomenclatureRear Panel Layout SAMPLEFigure 3-3:Internal Layout – M300E Getting StartedGetting Started Figure 3-5:Optical Bench Layout Figure 3-6:M300E/EM Internal Gas Flow Basic Configuration GENERAL SAFETY HAZARD 3.2.UNPACKING THE M300E/EM ANALYZERpower CAUTION – Avoid Warranty Invalidation ELECTRICAL SHOCK HAZARD3.3.ELECTRICAL CONNECTIONS 3.3.1.POWER CONNECTION3.2.1.VENTILATION CLEARANCE Do not defeat the ground wire on power plug3.3.2.ANALOG OUTPUT CONNECTIONS 3.3.3.CONNECTING THE STATUS OUTPUTSAnalog Output Connector FigureTable 3-5:Status Output Signals Figure 3-8:Status Output ConnectorSTATUS REAR PANELControl Input Connector 3.3.4.CONNECTING THE CONTROL INPUTSTable 3-6:Control Input Signals Figure3.3.6.CONNECTING TO A LAN OR THE INTERNET 3.3.5.CONNECTING THE SERIAL PORTS3.3.7.CONNECTING TO A MULTIDROP NETWORK 3.4.PNEUMATIC CONNECTIONS3.4.1.2.Span Gas exhaust and supply gas lines GENERAL SAFETY HAZARDglass, stainless steel or brass area or shelter surrounding the instrument3.4.2.2.Calibration Gas Sources 3.4.2.1.Sample Gas Sourceof the analyzer 3.4.2.3.Input Gas Venting 3.5.INITIAL OPERATION3.4.2.4.Exhaust Outlet using the procedures defined in Sectionconfiguration and calibration data 3.5.1.STARTUPSystem waits 3 seconds then automatically begins its initialization routine3.5.3.WARNING MESSAGES 3.5.2.WARM UPTable 3-9:Possible Warning Messages at Start-Up 3.5.4.FUNCTIONAL CHECK 3.6.1.INTERFERENTS FOR CO2 MEASUREMENTS 3.6.INITIAL CALIBRATION OF THE M300E/EMinstalled If it is not, press is set for SNGLSINGL ENTR3.6.2.2.Dilution Ratio Set Up 3.6.2.3.Set CO Span Gas Concentration STABIL= XXXX PPM 3.6.2.4.Zero/Span CalibrationSTABIL= XXXX PPM STABIL= XXXX PPM3.6.4.CO2 SENSOR CALIBRATION PROCEDURE 3.6.3.O2 SENSOR CALIBRATION PROCEDUREThe M300E/EM Analyzer is now ready for operation THANK YOU4.1.FAQ’S 4.FREQUENTLY ASKED QUESTIONSTerm 4.2.GLOSSARYDescription/Definition Description/Definition TermDescription/Definition Term5.1.EXTERNAL PUMPS OPTIONS 10A-10E,11, 5.OPTIONAL HARDWARE AND SOFTWARE5.2.RACK MOUNT KITS OPT 20 TO OPT 5.4.CURRENT LOOP ANALOG OUTPUTS OPTION 5.3.CARRYING STRAP/HANDLE OPTGENERAL SAFETY HAZARD Figure 5-2:Current Loop Option Installed on the Motherboard 5.6.CALIBRATION VALVES OPTIONS 50A, 50B, 50E, 50H 5.5.EXPENDABLES AND SPARES KITS OPTIONS 42A,5.6.2.ZERO/SPAN VALVE OPTION 50A 5.6.1.1.Gas Flow RateFigure 5.6.2.1.Internal Pneumatics OPT 50A5.6.2.3.Input Gas Venting 5.6.2.2.Pneumatic Set Up OPT 50A5.6.2.4.Exhaust Outlet SAMPLE GAS SOURCE5.6.3.1.Internal Pneumatics OPT 50B 5.6.3.ZERO/SPAN/SHUTOFF VALVE OPTION 50BFigure SAMPLE GAS SOURCE 5.6.3.2.Pneumatic Set Up OPT 50BCALIBRATION GAS SOURCES SPAN GAS ZERO AIR5.6.4.1.Internal Pneumatics OPT 50H SAMPLE GAS SOURCE 5.6.4.2.Pneumatic Set Up OPT 50HCALIBRATION GAS SOURCES SPAN GAS ZERO AIRScrubber 5.6.5.1.Internal Pneumatics OPT 50ESAMPLE GAS SOURCE 5.6.5.2.Pneumatic Set Up OPT 50ECALIBRATION GAS SOURCES SPAN GAS ZERO AIR5.7.1.RS-232MODEM CABLE OPTION 60A 5.7.COMMUNICATION OPTIONS5.7.2.RS-232MULTIDROP OPTION Table 5-5:M300E/EM Modem Cable OptionsFigure 5-12:M300E/EM Ethernet Card 5.7.3.ETHERNET OPTION 63A5.7.4.ETHERNET + MULTIDROP OPT 63C 5.8.SECOND GAS SENSORS5.8.1.OXYGEN SENSOR OPTION 65A 5.8.1.3.Pneumatic Operation of the O2 Sensor 5.8.1.2.Operation within the M300E/EM Analyzer5.9.CARBON DIOXIDE SENSOR OPTION 67A 5.9.1.CO2 SENSOR RANGES AND SPECIFICATIONS5.9.2.THEORY OF OPERATION 5.9.2.1.NDIR measurement of CO25.9.2.3.Pneumatic Operation of the CO2 Sensor 5.9.2.2.Operation within the M300E/EM AnalyzerFigure 5-16:CO2 sensor Theory of Operation 5.9.2.4.Electronic Operation of the CO2 Sensor Figure 5-19:Concentration Alarm Relay 5.10.CONCENTRATION ALARM RELAY OPTIONCO Alarm 1 = 20 PPM CO Alarm 2 = 100 PPM 5.11.2.MAINTENANCE MODE SWITCH 5.11.SPECIAL FEATURES5.11.3.SECOND LANGUAGE SWITCH 5.11.1.DILUTION RATIO OPTIONOPERATING INSTRUCTIONS PART – OPERATING INSTRUCTIONSThis page intentionally left blank OPERATING INSTRUCTIONS6.1.OVERVIEW OF OPERATING MODES 6.BASIC OPERATIONMODE EXPLANATIONanalyzer’s inability to calculate it 6.2.SAMPLE MODEFigure 6-2:Viewing M300E/EM Test Functions Test Functions Defined TableMEANING 6.3.WARNING MESSAGESThe IR source may be faulty Table 6-3:List of Warning Messagescurrently selected reporting range EXAMPLES 6.4.CALIBRATION MODEPrimary Setup Mode Features and Functions 6.5.SETUP MODESecondary Setup Mode Features and Functions instrument until the ENTR Key is pressed6.5.2.SETUP  ACAL: AUTOMATIC CALIBRATION 6.5.1.SETUP  CFG: CONFIGURATION INFORMATIONPassword Levels 6.5.3.SETUP  PASS: PASSWORD FEATURETable 04288D DCN5752 Basic Operationthe required number code 6.5.4.1.Setting the internal Clock’s Time and Day 6.5.4.2.Adjusting the Internal Clock’s Speed MODEL Table 6-7:M300E Family Physical range by ModelRANGE M300EFigure 6-4:Analog Output Connector Pin Out 6.6.2.ANALOG OUTPUT RANGES FOR CO CONCENTRATIONANALOG OUT SNGL 6.6.3.REPORTING RANGE MODESDUAL AUTOPage The two ranges must be independently calibrated concentrationsBasic Operation Toggle these keys to discards the new setting accepts the new settingselect the upper limit for the reporting range computing the CO concentrationreporting units Basic OperationPressure STP sufficientUsing the dilution ratio option is a 4-stepprocess This page intentionally left blank Basic Operation7.1.1.IDAS STATUS 7.ADVANCED FEATURESLED STATE IDAS STATUS7.1.2.1.iDAS Channels 7.1.2.IDAS STRUCTURETable 7-2:iDAS Data Channel Properties 7.1.3.DEFAULT IDAS CHANNELS Figure 7-1:Default iDAS Channel Setup Continue pressing to view remaining iDAS channels Channel No.: NAME: CONC TRIGGER EVENT: ATIMER 0 CONC: ATIMER, 1,7.1.5.1.Editing iDAS Data Channel Names 7.1.5.2.Editing iDAS Triggering Events found in Appendix A-5 7.1.5.3.Editing iDAS ParametersTable 7-3:iDAS Data Parameter Functions When the STORE NUM SAMPLES feature is turned on, the instrument will store how many 7.1.5.4.Editing Sample Period and Report Period In AVG, SDEV, MIN or MAX sample modes see Section 7.1.5.3, the settings for the Sample Period and the Report Period determine the number of data points used each time the parameter is calculated, stored and reported to the COMM ports 7.1.5.6.Editing the Number of Records 7.1.5.7.RS-232Report Function 7.1.5.8.Enabling/Disabling the HOLDOFF Feature 7.1.5.10.The Starting Date Feature 7.1.5.9.The Compact Report Feature7.1.6.DISABLING/ENABLING DATA CHANNELS 7.1.7.1.iDAS Configuration Using APICOM 7.1.7.REMOTE IDAS CONFIGURATIONattempting any iDAS changes DEFAULT 7.2.SETUP  MORE  VARS: INTERNAL VARIABLES VARSTable 7-4:Variable Names VARS ALLOWEDaccepts the new setting settingSETUP SETUPSIGNAL I/O Table 7-5:Diagnostic Mode DIAG FunctionsCONFIGURATION DIAG I/O7.3.1.ACCESSING THE DIAGNOSTIC FEATURES Table 7-6:DIAG - Analog I/O Functions 7.4.USING THE M300E/EM ANALYZER’S ANALOG OUTPUTSSUB MENU OUTPUTPage RANGE NAME Table 7-7:Analog Output Voltage Range Min/MaxRANGE SPAN MINIMUM OUTPUT04288D DCN5752 7.4.3.CALIBRATION OF THE ANALOG OUTPUTS See Section Manual calibration should be used for any analog output set for a 0.1V output range or in cases where Page The menu for manually adjusting the analog output signal level will only appear if the AUTO-CALfeature Advanced Features ground GENERAL SAFETY HAZARDAdvanced Features Voltage across % FSResistor for 2-20mA Resistor for 4-20mAPage Page DESCRIPTION TEST CHANNELZERO FULL SCALEnew setting settingSETUP SETUP7.4.7.AIN CALIBRATION STATUS ALARMLIMIT SET POINT1 This page intentionally left blank Advanced Features8.REMOTE OPERATION 8.1.2.COMM PORT DEFAULT SETTINGS8.1.1.RS-232DTE AND DCE COMMUNICATION Figure 8-1:Default Pin Assignments for Back Panel COMM Port connectors RS-232DCE & DTE 8.1.3.COMM PORT BAUD RATE 8192 8.1.4.COMM PORT COMMUNICATION MODES2048 1024Remote Operation 8.1.5.COMM PORT TESTING 8.1.6.MACHINE ID 8.1.7.TERMINAL OPERATING MODES 8.1.7.1.Help Commands in Terminal ModeTable 8-2:Terminal Mode Software Commands 8.1.7.3.Data Types 8.1.7.2.Command SyntaxX ID COMMAND <CR> Table 8-3:Teledyne API’s Serial I/O Command TypesX DDD:HH:MM Id MESSAGE<CRLF> 8.1.7.4.Status Reporting940331 is the default password 8.1.7.5.COMM Port Password SecurityLOGON V RS-232_PASS=NNNNNN8.2.MULTIDROP RS-232SET UP CALIBRATOR HostTAPI Analyzer Last INSTRUMENTFigure 8-5:CPU RS-485Setup 8.3.RS-485CONFIGURATION OF COM2Female DB-9COM2 The DCE/DTE switch has no effect on COM2RX/TX RX/TX+ Table 8-4:Ethernet Status Indicators 8.4.REMOTE ACCESS VIA THE ETHERNETDEFAULT STATE Table 8-5:LAN/Internet Configuration PropertiesSee your network administrator PROPERTYRemote Operation ∙Your LAN is not running a DHCP software package SETUP ON/OFFPRIMARY SETUP MENU SETUPMoves the cursor one character to the left or FUNCTIONright Inserts a character before the cursor locationFUNCTION 8.4.4.CHANGING THE ANALYZER’S HOSTNAMEENTR EXITMinimum Requirements 8.5.MODBUS SETUPActions 8.5.1.REMOTE ACCESS BY MODEM AT Y0 &D0 &H0 &I0 S0=2 &B0 &N6 &M0 E0 Q1 &W0 To initialize the modem press Remote Operation8.6.1.GENERAL OVERVIEW OF HESSEN PROTOCOL 8.6.2.HESSEN COMM PORT CONFIGURATIONProtocol network 8.6.3.ACTIVATING HESSEN PROTOCOL 8.6.4.SELECTING A HESSEN PROTOCOL TYPE MODE ID 8.6.5.SETTING THE HESSEN PROTOCOL RESPONSE MODEMODE DESCRIPTION TEXTGAS TYPE,RANGE,GAS ID,REPORTED 8.6.6.HESSEN PROTOCOL GAS LIST ENTRIESCO, 0, 310, REPORTED CO2, 0, 311, REPORTED O2, 0, 312, REPORTED8.6.6.2.Editing or Adding HESSEN Gas List Entries 8.6.6.3.Deleting HESSEN Gas List Entries Table 8-8:Default Hessen Status Flag Assignments 8.6.7.SETTING HESSEN PROTOCOL STATUS FLAGSDEFAULT BIT STATUS FLAG NAME8.6.8.INSTRUMENT ID CODE 8.7.APICOM REMOTE CONTROL PROGRAM Calibration Procedures 9.CALIBRATION PROCEDURESSECTION 9.1 – BEFORE CALIBRATION SECTION 9.5 – CO CALIBRATION QUALITY ANALYSIS9.1.2.CALIBRATION GASES 9.1.BEFORE CALIBRATION9.1.2.1.Zero Air troubleshooting tips9.1.2.2.Span Gas 9.1.3.DATA RECORDING DEVICES9.1.2.3.Traceability calibrationand alters the instrument’s Calibration Calibration Procedures See Section 12 for troubleshooting tips 9.2.2.PERFORMING A BASIC MANUAL CALIBRATION CHECKallowed for a reliable calibration the SPAN gas 9.2.3.PERFORMING A BASIC MANUAL CALIBRATIONthe bottle Calibration Procedures 9.2.3.2.Zero/Span Point Calibration Procedure9.3.MANUAL CALIBRATION WITH ZERO/SPAN VALVES 9.3.1.SETUP FOR CALIBRATION USING VALVE OPTIONSFigure 9-5:Pneumatic Connections – Option 51B: Zero/Span Calibration Valves Calibration Procedures the SPAN gas 9.3.3.MANUAL CALIBRATION USING VALVE OPTIONSthe bottle 9.3.3.2.Zero/Span Point Calibration Procedure Table 9-2:AUTOCAL Modes 9.4.AUTOMATIC ZERO/SPAN CAL/CHECK AUTOCALMODE NAME ACTIONTIMER ENABLED Table 9-3:AutoCal Attribute Setup ParametersATTRIBUTE ACTIONVALUE MODE ANDCOMMENT ZERO-SPANfrom the display SETUP X.X STARTING DATE: 04–SEP–08 for each Table 9-5:Calibration Data Quality Evaluation 9.5.CO CALIBRATION QUALITYFUNCTION MINIMUM VALUESETUP 9.6.1.DARK CALIBRATION TESTSETUP DAS RNGE PASS CLK MOREatmospheric pressure 9.6.2.PRESSURE CALIBRATION9.6.3.FLOW CALIBRATION 9.6.4.ELECTRICAL TEST CALIBRATION 9.7.1.1.O2 Calibration Setup 9.7.1.O2 SENSOR CALIBRATION PROCEDURE9.7.CALIBRATION OF OPTIONAL SENSORS Figure 9-7:O2 Sensor Calibration Set UpSet the expected O2 span gas concentration 9.7.1.2.Set O2 Span Gas Concentrationcomplete 9.7.1.3.Activate O2 Sensor Stability FunctionTo perform the zero/span calibration procedure 9.7.1.4.O2ZERO/SPAN CALIBRATION9.7.2.1.CO2 Calibration Setup 9.7.2.CO2 SENSOR CALIBRATION PROCEDURE9.7.2.2.Set CO2 Span Gas Concentration Figure 9-8:CO2 Sensor Calibration Set Upcomplete 9.7.2.3.Activate CO2 Sensor Stability FunctionCalibration Procedures 9.7.2.4.CO2 Zero/Span CalibrationThis page intentionally left blank Calibration Procedures10.1.CALIBRATION REQUIREMENTS 10.EPA CALIBRATION PROTOCOL10.1.2.2.Spare Parts and Expendable Supplies 10.1.2.1.Data Recording DevicePage 10.1.5.LEVEL 1 CALIBRATIONS VERSUS LEVEL 2 CHECKS 10.1.4.CALIBRATION FREQUENCYQ.A. Handbook1 Vol II, Part1, Section 12.3 & 10.2.ZERO AND SPAN CHECKS10.3.PRECISIONS CALIBRATION 10.2.1.ZERO/SPAN CHECK PROCEDURES10.2.2.PRECISION CHECK 10.3.1.PRECISION CALIBRATION PROCEDURES 10.4.AUDITING PROCEDURE10.4.1.CALIBRATION AUDIT 10.4.2.DATA REDUCTION AUDIT10.4.3.SYSTEM AUDIT/VALIDATION 10.5.DYNAMIC MULTIPOINT CALIBRATION PROCEDURE10.5.1.LINEARITY TEST ∙Leaks ∙Correct flow 10.6.REFERENCES PART PART – TECHNICAL INFORMATIONTECHNICAL INFORMATION This page intentionally left blank Technical information11.1.MEASUREMENT METHOD 11.THEORY OF OPERATION11.2.MEASUREMENT FUNDAMENTALS 11.1.1.BEER’S LAWFigure 11-1:Measurement Fundamentals 11.2.1.GAS FILTER CORRELATIONFigure 11-2:GFC Wheel 11.2.1.1.The GFC Wheel 11.2.1.2.The Measure Reference Ratio Figure 11-6:Chopped IR Signal 11.2.1.3.Summary Interference RejectionGENERAL SAFETY HAZARD 11.3.PNEUMATIC OPERATIONmaintenance schedule, Table over ambient pressure11.4.1.1.Critical Flow Orifice 11.4.FLOW RATE CONTROL11.4.3.PNEUMATIC SENSORS 11.4.2.PARTICULATE FILTER11.4.3.1.Sample Pressure Sensor 11.4.3.2.Sample Flow Sensor11.5.1.OVERVIEW 11.5.ELECTRONIC OPERATIONFigure 11-9:M300E/EM Electronic Block Diagram PC 104 BusMOTHER BOARDDISK-ON-MODULEDOM 11.5.2.CENTRAL PROCESSING UNIT CPUFLASH CHIP 11.5.3.OPTICAL BENCH & GFC WHEEL 11.5.3.1.Temperature Control11.5.3.2.IR Source 11.5.3.3.GFC WheelSEGMENT SENSOR Figure 11-10:GFC Light Mask M/R SENSORFigure 11-11:Segment Sensor and M/R Sensor Output SCHMIDT TRIGGERS11.5.4.1.Overview 11.5.3.4.IR Photo-DetectorM300E/EM Sync/Demod Block Diagram 11.5.4.2.Signal Synchronization and DemodulationFigure Table 11-2:Sync DEMOD Sample and Hold Circuits11.5.4.5.Dark Calibration Switch 11.5.4.4.Photo-DetectorTemperature Control11.5.4.3.Sync/Demod Status LED’s Figure 11-13:Sample & Hold Timing11.5.5.RELAY BOARD 11.5.4.6.Electric Test Switch11.5.5.1.Heater Control 11.5.5.2.GFC Wheel Motor ControlSTATUS LED’s RELAY PCA PN11.5.5.5.Status LED’s DC VOLTAGE TEST11.5.6.1.A to D Conversion 11.5.6.MOTHERBOARD11.5.6.2.Sensor Inputs 11.5.6.3.Thermistor Interface11.5.6.5.Internal Digital I/O 11.5.6.4.Analog Outputs11.5.6.6.External Digital I/O BENCH TEMPERATURE SENSOR11.5.7.I2C DATA BUS 11.5.8.POWER SUPPLY/ CIRCUIT BREAKERPOWER UP CIRCUIT GENERAL SAFETY HAZARDTheory of Operation Figure 11-15:Power Distribution Block DiagramFigure 11-16:Interface Block Diagram 11.5.9.COMMUNICATION INTERFACEMother Board11.5.10.1.Analyzer Status LED’s 11.5.10.FRONT PANEL INTERFACE11.5.10.2.Keyboard Figure 11-17:M300E/EM Front Panel Layout11.5.10.4.Keyboard/Display Interface Electronics 11.5.10.3.DisplayI2C Interface 2 x 40 CHAR. VACUUM FLUORESCENT DISPLAYKEY-DEPRESS-DETECTCIRCUIT KEYPAD DECODERI2C INTERFACE CHIP DISPLAY POWER WATCH DOGDISPLAY DATA DECODER DISPLAY CONTROLLER11.5.12.ADAPTIVE FILTER 11.5.11.SOFTWARE OPERATIONFigure 11-19:Basic Software Operation 11.5.13.CALIBRATION - SLOPE AND OFFSET 11.5.15.TEMPERATURE AND PRESSURE COMPENSATION11.5.14.MEASUREMENT ALGORITHM 11.5.16.INTERNAL DATA ACQUISITION SYSTEM IDASThis page intentionally left blank Theory of Operation12.1.MAINTENANCE SCHEDULE 12.MAINTENANCE SCHEDULE & PROCEDURESGENERAL SAFETY HAZARD QUALIFIED PERSONNELMaintenance Schedule & Procedures ACTION ITEMFREQ CAL CHECK MANUAL REQ’DMaintenance Schedule & Procedures Table 12-3:Predictive uses for Test Functions 12.2.PREDICTING FAILURES USING THE TEST FUNCTIONSFUNCTION CONDITION12.3.1.REPLACING THE SAMPLE PARTICULATE FILTER 12.3.MAINTENANCE PROCEDURES12.3.2.REBUILDING THE SAMPLE PUMP Figure 12-1:Sample Particulate Filter Assembly12.3.3.1.Vacuum Leak Check and Pump Check 12.3.3.PERFORMING LEAK CHECKS12.3.3.2.Pressure Leak Check GENERAL SAFETY HAZARD12.3.6.CLEANING EXTERIOR SURFACES OF THE M300E/EM 12.3.5.CLEANING THE OPTICAL BENCH12.3.4.PERFORMING A SAMPLE FLOW CHECK GENERAL SAFETY HAZARD13.1.GENERAL TROUBLESHOOTING 13.TROUBLESHOOTING & REPAIRGENERAL SAFETY HAZARD QUALIFIED PERSONNELCLR SETUP 13.1.1.FAULT DIAGNOSIS WITH WARNING MESSAGESSAMPLE BENCH TEMP WARNINGTable 13-1:Warning Messages - Indicated Failures 13.1.2.FAULT DIAGNOSIS WITH TEST FUNCTIONS PRES SAMPLE FL SAMP TEMP BENCH TEMP WHEEL TEMP INDICATED FAILURESBOX TEMP Table 13-2:Test Functions - Indicated FailuresPHT DRIVE SLOPE OFFSET INDICATED FAILURESFigure 13-2:Example of Signal I/O Function 13.1.4.INTERNAL ELECTRONIC STATUS LED’S 13.1.4.1.CPU Status IndicatorMotherboard P/N CPU Status LED Figure 13-3:CPU Status Indicator13.1.4.2.Sync Demodulator Status LED’s JP4 Connector to Opto-PickupD1 – M/R Sensor Status BoardSTATUS LED’s RELAY PCA PNDC VOLTAGE TEST POINTSRelay Board Status LED Failure Indications Table13.2.1.M300E/EM INTERNAL GAS FLOW DIAGRAMS 13.2.GAS FLOW PROBLEMSFigure 13-6:M300E/EM – Basic Internal Gas Flow Figure 13-7:Internal Pneumatic Flow OPT 50A – Zero/Span Valves OPT 50A & 50B Figure 13-9:Internal Pneumatic Flow OPT 51B – Zero/Span Valves with Internal Zero Air Scrubber Figure 13-11:M300E/EM – Internal Pneumatics with O2 Sensor Option 13.2.2.1.Flow is Zero 13.2.2.TYPICAL SAMPLE GAS FLOW PROBLEMS13.2.2.2.Low Flow 13.2.2.3.High Flow13.3.1.MISCALIBRATED 13.3.CALIBRATION PROBLEMS13.2.2.4.Displayed Flow = “Warnings” 13.2.2.6.Sample Pump13.3.3.INABILITY TO SPAN – NO SPAN KEY 13.3.2.NON-REPEATABLEZERO AND SPAN13.3.4.INABILITY TO ZERO – NO ZERO KEY 13.4.1.TEMPERATURE PROBLEMS 13.4.OTHER PERFORMANCE PROBLEMS13.4.1.1.Box or Sample Temperature 13.4.1.2.Bench Temperature13.4.1.4.IR Photo-DetectorTEC Temperature 13.4.1.3.GFC Wheel TemperatureELECTRICAL SHOCK HAZARD Hazardous Voltages are present during this test13.4.2.EXCESSIVE NOISE 13.5.2.DC POWER SUPPLY 13.5.1.AC MAINS CONFIGURATION13.5.SUBSYSTEM CHECKOUT DC Power Test Point and Wiring Color Codes13.5.4.KEYBOARD/DISPLAY INTERFACE 13.5.3.I2C BUSDC Power Supply Acceptable Levels TableTable 13-8:Relay Board Control Devices 13.5.5.RELAY BOARDFUNCTION CONTROL13.5.6.1.Sync/Demodulator Assembly 13.5.6.SENSOR ASSEMBLY13.5.6.2.Electrical Test 13.5.6.4.GFC Wheel Drive 13.5.6.3.Opto Pickup Assembly13.5.6.5.IR Source Table13.5.6.6.Pressure/Flow Sensor Assembly 13.5.7.1.A/D Functions 13.5.7.MOTHERBOARD13.5.7.2.Test Channel / Analog Outputs Voltage 13.5.7.3.Analog Outputs: Current Loop Table 13-12:Status Outputs Check 13.5.7.4.Status Outputs13.5.8.CPU 13.5.9.1.General RS-232Troubleshooting13.5.9.RS-232COMMUNICATIONS 13.5.7.5.Control Inputs – Remote Zero, Span13.5.10.THE OPTIONAL CO2 SENSOR 13.6.1.REPAIRING SAMPLE FLOW CONTROL ASSEMBLY 13.6.REPAIR PROCEDURESFigure 13-15:Opening the GFC Wheel Housing 13.6.2.REMOVING/REPLACING THE GFC WHEELFigure 13-17:Removing the GFC Wheel Housing Figure 13-16:Removing the Opto-PickupAssemblyOpto-Pickup Figure 13-18:Removing the GFC Wheel Housing Mounting Screws Sync/Demod PCA Housing VR1 Adjustment Made HereOptical Bench 13.7.TECHNICAL ASSISTANCE 13.6.4.DISK-ON-MODULEREPLACEMENT PROCEDURETeledyne API, Customer Service 9480 Carroll Park Drive14.1.HOW STATIC CHARGES ARE CREATED 14.A PRIMER ON ELECTRO-STATICDISCHARGEFigure 14-1:Triboelectric Charging 14.2.HOW ELECTRO-STATICCHARGES CAUSE DAMAGE 14.4.BASIC PRINCIPLES OF STATIC CONTROL 14.3.COMMON MYTHS ABOUT ESD DAMAGE14.4.1.GENERAL RULES Figure 14-2:Basic anti-ESDWorkbenchAlways wear an Anti-ESDwrist strap when working on the electronic assemblies of your analyzer. An anti-ESDwrist strap keeps the person wearing it at or near the same potential as other grounded objects in the work area and allows static charges to dissipate before they can build to dangerous levels. Anti-ESDwrist straps terminated with alligator clips are available for use in work areas where there is no available grounded plug 14.4.2.2.Working at an Anti-ESDWork Bench 14.4.2.1.Working at the Instrument Rack4.Place the item in the container CAUTION – Avoid Warranty Invalidation ESD Hazard∙DO NOT use pink-polybags This page intentionally left blank A Primer on Electro-StaticDischargePage Page Page Page Page Page Warnings, This page intentionally left blank Technical Manual - Model 300E Family CO AnalyzersAPPENDIX A-1:SOFTWARE MENU TREES, REVISION L.8 TEST1 SAMPLEMSG1 RNGE PASS SAMPLE SETUPCLK MORE <TST TST>APPENDIX A-1:Software Menu Trees, Revision L.8 Figure A-3:Primary Setup Menu  DAS SubmenuACAL1 APPENDIX A-1:Software Menu Trees, Revision L.8 CO, 310, REPORTED CO2, 311, REPORTED SAMPLESETUPO2, 312 REPORTED APPENDIX A-1:Software Menu Trees, Revision L.8 Figure A-6:DIAG Menu A-7Default Value Setup VariableNumeric Units Value RangeNumeric DefaultValue UnitsDefault Setup VariableAPPENDIX A-2:Setup Variables For Serial I/O NumericDefault Setup VariableNumeric ValueDefault Setup VariableAPPENDIX A-2:Setup Variables For Serial I/O NumericDefault Setup VariableNumeric ValueDefault Setup VariableSame settings as NumericDefault Setup VariableNumeric ValueDefault Setup VariableAPPENDIX A-2:Setup Variables For Serial I/O NumericDefault Setup VariableNumeric ValueDefault Setup VariableAPPENDIX A-2:Setup Variables For Serial I/O NumericDefault Setup VariableNumeric ValueDefault Setup VariableAPPENDIX A-2:Setup Variables For Serial I/O NumericMessage Text NameDescription APPENDIX A-3:Warnings and Test FunctionsMessage Text NameDescription A-22TEST FUNCTION NAME A-23MESSAGE TEXT DESCRIPTIONAPPENDIX A-3:Warnings and Test Functions A-24STABIL_SAMPLES TEST FUNCTION NAME A-25MESSAGE TEXT DESCRIPTIONBit or Channel Number Signal NameAPPENDIX A-4:Signal I/O Definitions APPENDIX A-4:Signal I/O DefinitionsBit or Channel Number Signal NameDescription A-27Number Bit or ChannelSignal Name DescriptionRear board temperature MUX analog inputs Signal NameBit or Channel Number DescriptionAPPENDIX A-4:Signal I/O Definitions Signal NameBit or Channel Number DescriptionDescription NameAPPENDIX A-5:DAS Triggers and Parameters A-31Description NameUnits A-32Description NameUnits A-33Table A-7:Terminal Command Designators APPENDIX A-6:Terminal Command DesignatorsAPPENDIX A-6:Terminal Command Designators COMMANDRegister Address MODBUSdec., 0-based MODBUS Floating Point Input RegistersMODBUS MODBUS Floating Point Holding RegistersDescription Unitssingle-bit; read-only MODBUS Discrete Input RegistersMODBUS Descriptionsingle-bit;read/write MODBUS Coil RegistersMODBUS Description04288D DCN5752 APPENDIX B - Spare PartsThis page intentionally left blank Part Number M300E Spare Parts ListDescription Reference: 05362J DCN5494 M300E Spare Parts ListPart Number DescriptionPart Number M300EM Spare Parts ListDescription Reference: 05424H DCN5494 M300EM Spare Parts ListPart Number Description6-10 M300EM Recommended Spare Parts Stocking Levels11-20 21-30Reference: 0096004C M300E/EX Expendables KitORIFICE, 13 MIL SAMPLE FLOW 000941000009550500 ASSY, SOURCE009560301 T300/T300M and M300E/EM APPENDIX C Warranty/Repair QuestionnaireEmail: api-customerservice@teledyne.com Please complete the following tableEmail: api-customerservice@teledyne.com APPENDIX C Warranty/Repair QuestionnaireT300/T300M and M300E/EM 2v/DIV04288D DCN5752 APPENDIX D – Wire List and Electronic Schematics04288D DCN5752 This page intentionally left blankInterconnect List, M300E/EU, SNs 100 and greater FROM FROM This page intentionally left blank Page Sync Demod Page 1 03297k_1.sch D C B ASync Demod Page 2 03297k_2.sch Sync Demod Page 3 03297k_3.schSchematics for PCA 03296, Sync Demod 1. This schematics is for PCASignal proper authorizationPREAMP_ENAB Schematics for PCA 03296, Sync DemodTV_ENAB SYNC_10proper authorization Schematics for PCA 03296, Sync DemodBIAS SUPPLY 17-Sep-200803632 PCA 03631, Isolated 0-20ma,E Series19-Jul-2002 1 ofNOTES 1. This schematic is based on thePWB PN, 03974 and applies to PCA PN,+15V +15V+15V +15VSchematic for E Series Motherboard PCA ADDR=0x360 DEFAULT05703 RX for Com2 TX for Com105703 +15V J109 +15V CONTROL INPUTS D2 D3 D4 D5 D6 D7 SHDN and PCA Schematics for PWBOPTO-INTERRUPTER BENCH Schematic, PCA 04135 Revision A, M300E Relay PCASPARE NOTE: 1. Use PWBNOTES 1. This schematic is based onapplies to PCA PN, the PWB PN, 03974 and04468 SCH, E-SeriesAnalog Output Isolator, PCA1 A B C D 1 Not Used