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Teledyne M300EM operation manual Ain Calibration

Models: M300E M300EM

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7.4.7.AIN CALIBRATION

Advanced Features

Teledyne API – Technical Manual - Model 300E Family CO Analyzers

7.4.7.AIN CALIBRATION

This is the submenu to conduct a calibration of the M300E/EM Analyzer’s analog inputs. This calibration should only be necessary after major repair such as a replacement of CPU, motherboard or power supplies.

To perform an analog input calibration, select the ANALOG I/O CONFIGURATION submenu (see Figure 7-4)then press:

146	04288D DCN5752

Image 148

Teledyne M300EM operation manual Ain Calibration

Contents

TELEDYNE ADVANCED POLLUTION INSTRUMENTATION 9480 CARROLL PARK DRIVE SAN DIEGO, CA USAMODEL 300E FAMILY CARBON MONOXIDE ANALYZERS Operation ManualPage SAFETY MESSAGES Safety Messages This page intentionally left blankWARRANTY WARRANTY POLICY 02024DCAUTION – Avoid Warranty Invalidation COVERAGEThis page intentionally left blank 04288D DCN5752ABOUT THIS MANUAL instrumentPart No Name/DescriptionREVISION HISTORY 2010 JuneDocument Change SummaryRevision History This page intentionally left blank Revision Historyviii TABLE OF CONTENTS Table of ContentsPART II – OPERATING INSTRUCTIONS 6. BASIC OPERATION7. ADVANCED FEATURES 8. REMOTE OPERATION9. CALIBRATION PROCEDURES 10. EPA CALIBRATION PROTOCOL PART III – TECHNICAL INFORMATIONxiii 11. THEORY OF OPERATION12. MAINTENANCE SCHEDULE & PROCEDURES 13. TROUBLESHOOTING & REPAIR14. A PRIMER ON ELECTRO-STATICDISCHARGE LIST OF APPENDICES LIST OF FIGURESTABLE OF CONTENTS LIST OF TABLES xviiiTable TABLE OF CONTENTS This page intentionally left blankPart PART – GENERAL INFORMATIONGENERAL INFORMATION GENERAL INFORMATION PartThis page intentionally left blank 1.INTRODUCTION 1.1.M300E FAMILY OVERVIEW1.2.ADDITIONAL DOCUMENTATION 1.2.1.USING THIS MANUAL TABLE OF CONTENTSPART I – GENERAL INFORMATION SPECIFICATIONS AND WARRANTYPART III – TECHNICAL INFORMATION APPENDICESADVANCED 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 2.4.2.SAFETY COMPLIANCE 2.3.TUV DESIGNATION2.4.CE MARK COMPLIANCE 2.4.1.EMISSIONS COMPLIANCESpecifications and Approvals This page intentionally left blank3.GETTING STARTED 3.1.M300E/EM ANALYZER LAYOUTFigure Front Panel LayoutTable 3-2:Inlet / Outlet Connector Nomenclature FigureRear Panel Layout SAMPLEGetting Started Figure 3-3:Internal Layout – M300EGetting Started Figure 3-5:Optical Bench Layout Figure 3-6:M300E/EM Internal Gas Flow Basic Configuration 3.2.UNPACKING THE M300E/EM ANALYZER GENERAL SAFETY HAZARDpower CAUTION – Avoid Warranty Invalidation ELECTRICAL SHOCK HAZARD3.3.1.POWER CONNECTION 3.3.ELECTRICAL CONNECTIONS3.2.1.VENTILATION CLEARANCE Do not defeat the ground wire on power plug3.3.3.CONNECTING THE STATUS OUTPUTS 3.3.2.ANALOG OUTPUT CONNECTIONSAnalog Output Connector FigureFigure 3-8:Status Output Connector Table 3-5:Status Output SignalsSTATUS REAR PANEL3.3.4.CONNECTING THE CONTROL INPUTS Control Input ConnectorTable 3-6:Control Input Signals Figure3.3.5.CONNECTING THE SERIAL PORTS 3.3.6.CONNECTING TO A LAN OR THE INTERNET3.3.7.CONNECTING TO A MULTIDROP NETWORK 3.4.PNEUMATIC CONNECTIONS3.4.1.2.Span Gas GENERAL SAFETY HAZARD exhaust and supply gas linesglass, 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 3.5.INITIAL OPERATION 3.4.2.3.Input Gas Venting3.4.2.4.Exhaust Outlet using the procedures defined in Section3.5.1.STARTUP configuration and calibration dataSystem waits 3 seconds then automatically begins its initialization routine3.5.2.WARM UP 3.5.3.WARNING MESSAGESTable 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 is set for SNGL If it is not, pressSINGL ENTR3.6.2.2.Dilution Ratio Set Up 3.6.2.3.Set CO Span Gas Concentration 3.6.2.4.Zero/Span Calibration STABIL= XXXX PPMSTABIL= XXXX PPM STABIL= XXXX PPM3.6.3.O2 SENSOR CALIBRATION PROCEDURE 3.6.4.CO2 SENSOR CALIBRATION PROCEDUREThe M300E/EM Analyzer is now ready for operation THANK YOU4.FREQUENTLY ASKED QUESTIONS 4.1.FAQ’STerm 4.2.GLOSSARYDescription/Definition Term Description/DefinitionTerm Description/Definition5.1.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 5.5.EXPENDABLES AND SPARES KITS OPTIONS 42A, 5.6.CALIBRATION VALVES OPTIONS 50A, 50B, 50E, 50H5.6.2.ZERO/SPAN VALVE OPTION 50A 5.6.1.1.Gas Flow Rate5.6.2.1.Internal Pneumatics OPT 50A Figure5.6.2.2.Pneumatic Set Up OPT 50A 5.6.2.3.Input Gas Venting5.6.2.4.Exhaust Outlet SAMPLE GAS SOURCE5.6.3.1.Internal Pneumatics OPT 50B 5.6.3.ZERO/SPAN/SHUTOFF VALVE OPTION 50BFigure 5.6.3.2.Pneumatic Set Up OPT 50B SAMPLE GAS SOURCECALIBRATION GAS SOURCES SPAN GAS ZERO AIR5.6.4.1.Internal Pneumatics OPT 50H 5.6.4.2.Pneumatic Set Up OPT 50H SAMPLE GAS SOURCECALIBRATION GAS SOURCES SPAN GAS ZERO AIR5.6.5.1.Internal Pneumatics OPT 50E Scrubber5.6.5.2.Pneumatic Set Up OPT 50E SAMPLE GAS SOURCECALIBRATION GAS SOURCES SPAN GAS ZERO AIR5.7.COMMUNICATION OPTIONS 5.7.1.RS-232MODEM CABLE OPTION 60A5.7.2.RS-232MULTIDROP OPTION Table 5-5:M300E/EM Modem Cable Options5.7.3.ETHERNET OPTION 63A Figure 5-12:M300E/EM Ethernet Card5.7.4.ETHERNET + MULTIDROP OPT 63C 5.8.SECOND GAS SENSORS5.8.1.OXYGEN SENSOR OPTION 65A 5.8.1.2.Operation within the M300E/EM Analyzer 5.8.1.3.Pneumatic Operation of the O2 Sensor5.9.1.CO2 SENSOR RANGES AND SPECIFICATIONS 5.9.CARBON DIOXIDE SENSOR OPTION 67A5.9.2.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 5.10.CONCENTRATION ALARM RELAY OPTION Figure 5-19:Concentration Alarm RelayCO Alarm 1 = 20 PPM CO Alarm 2 = 100 PPM 5.11.SPECIAL FEATURES 5.11.2.MAINTENANCE MODE SWITCH5.11.3.SECOND LANGUAGE SWITCH 5.11.1.DILUTION RATIO OPTIONPART – OPERATING INSTRUCTIONS OPERATING INSTRUCTIONSOPERATING INSTRUCTIONS This page intentionally left blank6.BASIC OPERATION 6.1.OVERVIEW OF OPERATING MODESMODE EXPLANATIONanalyzer’s inability to calculate it 6.2.SAMPLE MODEFigure 6-2:Viewing M300E/EM Test Functions Table Test Functions Defined6.3.WARNING MESSAGES MEANINGThe IR source may be faulty Table 6-3:List of Warning Messages6.4.CALIBRATION MODE currently selected reporting range EXAMPLES6.5.SETUP MODE Primary Setup Mode Features and FunctionsSecondary Setup Mode Features and Functions instrument until the ENTR Key is pressed6.5.1.SETUP  CFG: CONFIGURATION INFORMATION 6.5.2.SETUP  ACAL: AUTOMATIC CALIBRATIONPassword Levels 6.5.3.SETUP  PASS: PASSWORD FEATURETable Basic Operation 04288D DCN5752the 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 Table 6-7:M300E Family Physical range by Model MODELRANGE M300EFigure 6-4:Analog Output Connector Pin Out 6.6.2.ANALOG OUTPUT RANGES FOR CO CONCENTRATIONANALOG OUT 6.6.3.REPORTING RANGE MODES SNGLDUAL AUTOPage concentrations The two ranges must be independently calibratedBasic Operation discards the new setting accepts the new setting Toggle these keys toselect the upper limit for the reporting range computing the CO concentrationBasic Operation reporting unitsPressure STP sufficientUsing the dilution ratio option is a 4-stepprocess Basic Operation This page intentionally left blank7.ADVANCED FEATURES 7.1.1.IDAS STATUSLED 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 0 CONC: ATIMER, 1, Channel No.: NAME: CONC TRIGGER EVENT: ATIMER7.1.5.1.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.REMOTE IDAS CONFIGURATION 7.1.7.1.iDAS Configuration Using APICOMattempting any iDAS changes 7.2.SETUP  MORE  VARS: INTERNAL VARIABLES VARS DEFAULTTable 7-4:Variable Names VARS ALLOWEDsetting accepts the new settingSETUP SETUPTable 7-5:Diagnostic Mode DIAG Functions SIGNAL I/OCONFIGURATION DIAG I/O7.3.1.ACCESSING THE DIAGNOSTIC FEATURES 7.4.USING THE M300E/EM ANALYZER’S ANALOG OUTPUTS Table 7-6:DIAG - Analog I/O FunctionsSUB MENU OUTPUTPage Table 7-7:Analog Output Voltage Range Min/Max RANGE NAMERANGE 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 GENERAL SAFETY HAZARD groundAdvanced Features % FS Voltage acrossResistor for 2-20mA Resistor for 4-20mAPage Page TEST CHANNEL DESCRIPTIONZERO FULL SCALEsetting new settingSETUP SETUP7.4.7.AIN CALIBRATION STATUS ALARMLIMIT SET POINT1 Advanced Features This page intentionally left blank8.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 8.1.4.COMM PORT COMMUNICATION MODES 81922048 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 8.1.7.2.Command Syntax 8.1.7.3.Data TypesX ID COMMAND <CR> Table 8-3:Teledyne API’s Serial I/O Command Types8.1.7.4.Status Reporting X DDD:HH:MM Id MESSAGE<CRLF>8.1.7.5.COMM Port Password Security 940331 is the default passwordLOGON V RS-232_PASS=NNNNNN8.2.MULTIDROP RS-232SET UP Host CALIBRATORTAPI Analyzer Last INSTRUMENT8.3.RS-485CONFIGURATION OF COM2 Figure 8-5:CPU RS-485SetupFemale DB-9COM2 The DCE/DTE switch has no effect on COM2RX/TX RX/TX+ 8.4.REMOTE ACCESS VIA THE ETHERNET Table 8-4:Ethernet Status IndicatorsTable 8-5:LAN/Internet Configuration Properties DEFAULT STATESee your network administrator PROPERTYRemote Operation ∙Your LAN is not running a DHCP software package ON/OFF SETUPPRIMARY SETUP MENU SETUPFUNCTION Moves the cursor one character to the left orright Inserts a character before the cursor location8.4.4.CHANGING THE ANALYZER’S HOSTNAME FUNCTIONENTR 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 Remote Operation To initialize the modem press8.6.1.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 8.6.5.SETTING THE HESSEN PROTOCOL RESPONSE MODE MODE IDMODE DESCRIPTION TEXT8.6.6.HESSEN PROTOCOL GAS LIST ENTRIES GAS TYPE,RANGE,GAS ID,REPORTEDCO, 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 8.6.7.SETTING HESSEN PROTOCOL STATUS FLAGS Table 8-8:Default Hessen Status Flag AssignmentsDEFAULT BIT STATUS FLAG NAME8.6.8.INSTRUMENT ID CODE 8.7.APICOM REMOTE CONTROL PROGRAM 9.CALIBRATION PROCEDURES Calibration ProceduresSECTION 9.1 – BEFORE CALIBRATION SECTION 9.5 – CO CALIBRATION QUALITY ANALYSIS9.1.BEFORE CALIBRATION 9.1.2.CALIBRATION GASES9.1.2.1.Zero Air troubleshooting tips9.1.3.DATA RECORDING DEVICES 9.1.2.2.Span Gas9.1.2.3.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 9.2.3.2.Zero/Span Point Calibration Procedure Calibration Procedures9.3.1.SETUP FOR CALIBRATION USING VALVE OPTIONS 9.3.MANUAL CALIBRATION WITH ZERO/SPAN VALVESFigure 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 9.4.AUTOMATIC ZERO/SPAN CAL/CHECK AUTOCAL Table 9-2:AUTOCAL ModesMODE NAME ACTIONTable 9-3:AutoCal Attribute Setup Parameters TIMER ENABLEDATTRIBUTE ACTIONMODE AND VALUECOMMENT ZERO-SPANfrom the display SETUP X.X STARTING DATE: 04–SEP–08 for each 9.5.CO CALIBRATION QUALITY Table 9-5:Calibration Data Quality EvaluationFUNCTION MINIMUM VALUE9.6.1.DARK CALIBRATION TEST SETUPSETUP DAS RNGE PASS CLK MORE9.6.2.PRESSURE CALIBRATION atmospheric pressure9.6.3.FLOW CALIBRATION 9.6.4.ELECTRICAL TEST CALIBRATION 9.7.1.O2 SENSOR CALIBRATION PROCEDURE 9.7.1.1.O2 Calibration Setup9.7.CALIBRATION OF OPTIONAL SENSORS Figure 9-7:O2 Sensor Calibration Set Up9.7.1.2.Set O2 Span Gas Concentration Set the expected O2 span gas concentration9.7.1.3.Activate O2 Sensor Stability Function complete9.7.1.4.O2ZERO/SPAN CALIBRATION To perform the zero/span calibration procedure9.7.2.CO2 SENSOR CALIBRATION PROCEDURE 9.7.2.1.CO2 Calibration Setup9.7.2.2.Set CO2 Span Gas Concentration Figure 9-8:CO2 Sensor Calibration Set Up9.7.2.3.Activate CO2 Sensor Stability Function complete9.7.2.4.CO2 Zero/Span Calibration Calibration ProceduresCalibration Procedures This page intentionally left blank10.EPA CALIBRATION PROTOCOL 10.1.CALIBRATION REQUIREMENTS10.1.2.1.Data Recording Device 10.1.2.2.Spare Parts and Expendable SuppliesPage 10.1.4.CALIBRATION FREQUENCY 10.1.5.LEVEL 1 CALIBRATIONS VERSUS LEVEL 2 CHECKS10.2.ZERO AND SPAN CHECKS Q.A. Handbook1 Vol II, Part1, Section 12.3 &10.3.PRECISIONS CALIBRATION 10.2.1.ZERO/SPAN CHECK PROCEDURES10.2.2.PRECISION CHECK 10.4.AUDITING PROCEDURE 10.3.1.PRECISION CALIBRATION PROCEDURES10.4.1.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 Technical information This page intentionally left blank11.THEORY OF OPERATION 11.1.MEASUREMENT METHOD11.2.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 11.2.1.3.Summary Interference Rejection Figure 11-6:Chopped IR Signal11.3.PNEUMATIC OPERATION GENERAL SAFETY HAZARDmaintenance schedule, Table over ambient pressure11.4.FLOW RATE CONTROL 11.4.1.1.Critical Flow Orifice11.4.2.PARTICULATE FILTER 11.4.3.PNEUMATIC SENSORS11.4.3.1.Sample Pressure Sensor 11.4.3.2.Sample Flow Sensor11.5.ELECTRONIC OPERATION 11.5.1.OVERVIEWPC 104 Bus Figure 11-9:M300E/EM Electronic Block DiagramMOTHER BOARDDISK-ON-MODULEDOM 11.5.2.CENTRAL PROCESSING UNIT CPUFLASH CHIP 11.5.3.1.Temperature Control 11.5.3.OPTICAL BENCH & GFC WHEEL11.5.3.2.IR Source 11.5.3.3.GFC WheelFigure 11-10:GFC Light Mask M/R SENSOR SEGMENT SENSORFigure 11-11:Segment Sensor and M/R Sensor Output SCHMIDT TRIGGERS11.5.3.4.IR Photo-Detector 11.5.4.1.Overview11.5.4.2.Signal Synchronization and Demodulation M300E/EM Sync/Demod Block DiagramFigure Table 11-2:Sync DEMOD Sample and Hold Circuits11.5.4.4.Photo-DetectorTemperature Control 11.5.4.5.Dark Calibration Switch11.5.4.3.Sync/Demod Status LED’s Figure 11-13:Sample & Hold Timing11.5.4.6.Electric Test Switch 11.5.5.RELAY BOARD11.5.5.1.Heater Control 11.5.5.2.GFC Wheel Motor ControlRELAY PCA PN STATUS LED’s11.5.5.5.Status LED’s DC VOLTAGE TEST11.5.6.MOTHERBOARD 11.5.6.1.A to D Conversion11.5.6.2.Sensor Inputs 11.5.6.3.Thermistor Interface11.5.6.4.Analog Outputs 11.5.6.5.Internal Digital I/O11.5.6.6.External Digital I/O BENCH TEMPERATURE SENSOR11.5.8.POWER SUPPLY/ CIRCUIT BREAKER 11.5.7.I2C DATA BUSPOWER UP CIRCUIT GENERAL SAFETY HAZARDFigure 11-15:Power Distribution Block Diagram Theory of Operation11.5.9.COMMUNICATION INTERFACE Figure 11-16:Interface Block DiagramMother Board11.5.10.FRONT PANEL INTERFACE 11.5.10.1.Analyzer Status LED’s11.5.10.2.Keyboard Figure 11-17:M300E/EM Front Panel Layout11.5.10.3.Display 11.5.10.4.Keyboard/Display Interface ElectronicsI2C Interface 2 x 40 CHAR. VACUUM FLUORESCENT DISPLAYKEYPAD DECODER KEY-DEPRESS-DETECTCIRCUITDISPLAY POWER WATCH DOG I2C INTERFACE CHIPDISPLAY DATA DECODER DISPLAY CONTROLLER11.5.12.ADAPTIVE FILTER 11.5.11.SOFTWARE OPERATIONFigure 11-19:Basic Software Operation 11.5.15.TEMPERATURE AND PRESSURE COMPENSATION 11.5.13.CALIBRATION - SLOPE AND OFFSET11.5.14.MEASUREMENT ALGORITHM 11.5.16.INTERNAL DATA ACQUISITION SYSTEM IDASTheory of Operation This page intentionally left blank12.MAINTENANCE SCHEDULE & PROCEDURES 12.1.MAINTENANCE SCHEDULEGENERAL SAFETY HAZARD QUALIFIED PERSONNELMaintenance Schedule & Procedures ITEM ACTIONFREQ CAL CHECK MANUAL REQ’DMaintenance Schedule & Procedures 12.2.PREDICTING FAILURES USING THE TEST FUNCTIONS Table 12-3:Predictive uses for Test FunctionsFUNCTION CONDITION12.3.MAINTENANCE PROCEDURES 12.3.1.REPLACING THE SAMPLE PARTICULATE FILTER12.3.2.REBUILDING THE SAMPLE PUMP Figure 12-1:Sample Particulate Filter Assembly12.3.3.PERFORMING LEAK CHECKS 12.3.3.1.Vacuum Leak Check and Pump Check12.3.3.2.Pressure Leak Check GENERAL SAFETY HAZARD12.3.5.CLEANING THE OPTICAL BENCH 12.3.6.CLEANING EXTERIOR SURFACES OF THE M300E/EM12.3.4.PERFORMING A SAMPLE FLOW CHECK GENERAL SAFETY HAZARD13.TROUBLESHOOTING & REPAIR 13.1.GENERAL TROUBLESHOOTINGGENERAL SAFETY HAZARD QUALIFIED PERSONNEL13.1.1.FAULT DIAGNOSIS WITH WARNING MESSAGES CLR SETUPSAMPLE BENCH TEMP WARNINGTable 13-1:Warning Messages - Indicated Failures 13.1.2.FAULT DIAGNOSIS WITH TEST FUNCTIONS INDICATED FAILURES PRES SAMPLE FL SAMP TEMP BENCH TEMP WHEEL TEMPBOX TEMP Table 13-2:Test Functions - Indicated FailuresINDICATED FAILURES PHT DRIVE SLOPE OFFSETFigure 13-2:Example of Signal I/O Function 13.1.4.1.CPU Status Indicator 13.1.4.INTERNAL ELECTRONIC STATUS LED’SMotherboard P/N CPU Status LED Figure 13-3:CPU Status IndicatorJP4 Connector to Opto-Pickup 13.1.4.2.Sync Demodulator Status LED’sD1 – M/R Sensor Status BoardRELAY PCA PN STATUS LED’sDC VOLTAGE TEST POINTSTable Relay Board Status LED Failure Indications13.2.1.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.TYPICAL SAMPLE GAS FLOW PROBLEMS 13.2.2.1.Flow is Zero13.2.2.2.Low Flow 13.2.2.3.High Flow13.3.CALIBRATION PROBLEMS 13.3.1.MISCALIBRATED13.2.2.4.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.OTHER PERFORMANCE PROBLEMS 13.4.1.TEMPERATURE PROBLEMS13.4.1.1.Box or Sample Temperature 13.4.1.2.Bench Temperature13.4.1.3.GFC Wheel Temperature 13.4.1.4.IR Photo-DetectorTEC TemperatureELECTRICAL SHOCK HAZARD Hazardous Voltages are present during this test13.4.2.EXCESSIVE NOISE 13.5.1.AC MAINS CONFIGURATION 13.5.2.DC POWER SUPPLY13.5.SUBSYSTEM CHECKOUT DC Power Test Point and Wiring Color Codes13.5.3.I2C BUS 13.5.4.KEYBOARD/DISPLAY INTERFACEDC Power Supply Acceptable Levels Table13.5.5.RELAY BOARD Table 13-8:Relay Board Control DevicesFUNCTION CONTROL13.5.6.1.Sync/Demodulator Assembly 13.5.6.SENSOR ASSEMBLY13.5.6.2.Electrical Test 13.5.6.3.Opto Pickup Assembly 13.5.6.4.GFC Wheel Drive13.5.6.5.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 13.5.7.4.Status Outputs Table 13-12:Status Outputs Check13.5.9.1.General RS-232Troubleshooting 13.5.8.CPU13.5.9.RS-232COMMUNICATIONS 13.5.7.5.Control Inputs – Remote Zero, Span13.5.10.THE OPTIONAL CO2 SENSOR 13.6.REPAIR PROCEDURES 13.6.1.REPAIRING SAMPLE FLOW CONTROL ASSEMBLY13.6.2.REMOVING/REPLACING THE GFC WHEEL Figure 13-15:Opening the GFC Wheel HousingFigure 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 13.6.4.DISK-ON-MODULEREPLACEMENT PROCEDURE 13.7.TECHNICAL ASSISTANCETeledyne 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 14.3.COMMON MYTHS ABOUT ESD DAMAGE 14.4.BASIC PRINCIPLES OF STATIC CONTROL14.4.1.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 14.4.2.1.Working at the Instrument Rack 14.4.2.2.Working at an Anti-ESDWork Bench4.Place the item in the container CAUTION – Avoid Warranty Invalidation ESD Hazard∙DO NOT use pink-polybags A Primer on Electro-StaticDischarge This page intentionally left blankPage Page Page Page Page Page Warnings, Technical Manual - Model 300E Family CO Analyzers This page intentionally left blankAPPENDIX A-1:SOFTWARE MENU TREES, REVISION L.8 TEST1 SAMPLEMSG1 SAMPLE SETUP RNGE PASSCLK 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 Figure A-6:DIAG Menu A-7 APPENDIX A-1:Software Menu Trees, Revision L.8Setup Variable Default ValueNumeric Units Value RangeDefault NumericValue UnitsSetup Variable DefaultAPPENDIX A-2:Setup Variables For Serial I/O NumericSetup Variable DefaultNumeric ValueSetup Variable DefaultAPPENDIX A-2:Setup Variables For Serial I/O NumericSetup Variable DefaultNumeric ValueSetup Variable DefaultSame settings as NumericSetup Variable DefaultNumeric ValueSetup Variable DefaultAPPENDIX A-2:Setup Variables For Serial I/O NumericSetup Variable DefaultNumeric ValueSetup Variable DefaultAPPENDIX A-2:Setup Variables For Serial I/O NumericSetup Variable DefaultNumeric ValueSetup Variable DefaultAPPENDIX A-2:Setup Variables For Serial I/O NumericName Message TextDescription APPENDIX A-3:Warnings and Test FunctionsName Message TextDescription A-22A-23 TEST FUNCTION NAMEMESSAGE TEXT DESCRIPTIONAPPENDIX A-3:Warnings and Test Functions A-24STABIL_SAMPLES A-25 TEST FUNCTION NAMEMESSAGE TEXT DESCRIPTIONSignal Name Bit or Channel NumberAPPENDIX A-4:Signal I/O Definitions APPENDIX A-4:Signal I/O DefinitionsSignal Name Bit or Channel NumberDescription A-27Bit or Channel NumberSignal Name DescriptionSignal Name Rear board temperature MUX analog inputsBit or Channel Number DescriptionSignal Name APPENDIX A-4:Signal I/O DefinitionsBit or Channel Number DescriptionName DescriptionAPPENDIX A-5:DAS Triggers and Parameters A-31Name DescriptionUnits A-32Name DescriptionUnits A-33APPENDIX A-6:Terminal Command Designators Table A-7:Terminal Command DesignatorsAPPENDIX A-6:Terminal Command Designators COMMANDMODBUS Register Addressdec., 0-based MODBUS Floating Point Input RegistersMODBUS Floating Point Holding Registers MODBUSDescription UnitsMODBUS Discrete Input Registers single-bit; read-onlyMODBUS DescriptionMODBUS Coil Registers single-bit;read/writeMODBUS DescriptionAPPENDIX B - Spare Parts 04288D DCN5752This page intentionally left blank Part Number M300E Spare Parts ListDescription M300E Spare Parts List Reference: 05362J DCN5494Part Number DescriptionPart Number M300EM Spare Parts ListDescription M300EM Spare Parts List Reference: 05424H DCN5494Part Number DescriptionM300EM Recommended Spare Parts Stocking Levels 6-1011-20 21-30M300E/EX Expendables Kit Reference: 0096004C000941000 ORIFICE, 13 MIL SAMPLE FLOW009550500 ASSY, SOURCE009560301 APPENDIX C Warranty/Repair Questionnaire T300/T300M and M300E/EMEmail: api-customerservice@teledyne.com Please complete the following tableAPPENDIX C Warranty/Repair Questionnaire Email: api-customerservice@teledyne.comT300/T300M and M300E/EM 2v/DIVAPPENDIX D – Wire List and Electronic Schematics 04288D DCN5752This page intentionally left blank 04288D DCN5752Interconnect List, M300E/EU, SNs 100 and greater FROM FROM This page intentionally left blank Page D C B A Sync Demod Page 1 03297k_1.schSync Demod Page 2 03297k_2.sch Sync Demod Page 3 03297k_3.sch1. This schematics is for PCA Schematics for PCA 03296, Sync DemodSignal proper authorizationSchematics for PCA 03296, Sync Demod PREAMP_ENABTV_ENAB SYNC_10Schematics for PCA 03296, Sync Demod proper authorizationBIAS SUPPLY 17-Sep-2008PCA 03631, Isolated 0-20ma,E Series 0363219-Jul-2002 1 of1. This schematic is based on the NOTESPWB 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 Schematic, PCA 04135 Revision A, M300E Relay PCA BENCHSPARE NOTE: 1. Use PWB1. This schematic is based on NOTESapplies to PCA PN, the PWB PN, 03974 andSCH, E-SeriesAnalog Output Isolator, PCA 044681 A B C D 1 Not Used