Calibration Procedures | Teledyne M300EM specification

Manual background

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

Calibration Procedures

9.3.2.MANUAL CALIBRATION CHECKS WITH VALVE OPTIONS INSTALLED

04288D DCN5752

195

Image 197

Teledyne M300EM operation manual Calibration Procedures

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 Messages WARRANTY POLICY 02024D WARRANTYCAUTION – Avoid Warranty Invalidation COVERAGE 04288D DCN5752 This page intentionally left blank instrument ABOUT THIS MANUALPart No Name/Description 2010 June REVISION HISTORYDocument Change Summary Revision History viii Revision HistoryThis page intentionally left blank Table of Contents TABLE OF CONTENTS 6. BASIC OPERATION PART II – OPERATING INSTRUCTIONS 8. REMOTE OPERATION 7. ADVANCED FEATURES 9. CALIBRATION PROCEDURES PART III – TECHNICAL INFORMATION 10. EPA CALIBRATION PROTOCOLxiii 11. THEORY OF OPERATION 13. TROUBLESHOOTING & REPAIR 12. MAINTENANCE SCHEDULE & PROCEDURES 14. A PRIMER ON ELECTRO-STATICDISCHARGE LIST OF FIGURES LIST OF APPENDICES TABLE OF CONTENTS xviii LIST OF TABLES Table This page intentionally left blank TABLE OF CONTENTS GENERAL INFORMATION PART - GENERAL INFORMATIONPart This page intentionally left blank PartGENERAL INFORMATION 1.1.M300E FAMILY OVERVIEW 1.INTRODUCTION 1.2.ADDITIONAL DOCUMENTATION TABLE OF CONTENTS 1.2.1.USING THIS MANUALPART I – GENERAL INFORMATION SPECIFICATIONS AND WARRANTY APPENDICES PART III – TECHNICAL INFORMATIONADVANCED FEATURES OF THE M300E/EM ANALYZER MAINTENANCE SCHEDULE AND PROCEDURES Table 2-1:M 300E/300EM Basic Unit Specifications 2.SPECIFICATIONS AND APPROVALS2.1.SPECIFICATIONS 2.2.EPA EQUIVALENCY DESIGNATION 2.3.TUV DESIGNATION 2.4.2.SAFETY COMPLIANCE2.4.CE MARK COMPLIANCE 2.4.1.EMISSIONS COMPLIANCE This page intentionally left blank Specifications and Approvals 3.1.M300E/EM ANALYZER LAYOUT 3.GETTING STARTEDFigure Front Panel Layout Figure Table 3-2:Inlet / Outlet Connector NomenclatureRear Panel Layout SAMPLE Figure 3-3:Internal Layout – M300E Getting Started Getting 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 HAZARD 3.3.ELECTRICAL CONNECTIONS 3.3.1.POWER CONNECTION3.2.1.VENTILATION CLEARANCE Do not defeat the ground wire on power plug 3.3.2.ANALOG OUTPUT CONNECTIONS 3.3.3.CONNECTING THE STATUS OUTPUTSAnalog Output Connector Figure Table 3-5:Status Output Signals Figure 3-8:Status Output ConnectorSTATUS REAR PANEL Control Input Connector 3.3.4.CONNECTING THE CONTROL INPUTSTable 3-6:Control Input Signals Figure 3.3.6.CONNECTING TO A LAN OR THE INTERNET 3.3.5.CONNECTING THE SERIAL PORTS3.3.7.CONNECTING TO A MULTIDROP NETWORK 3.4.PNEUMATIC CONNECTIONS 3.4.1.2.Span Gas exhaust and supply gas lines GENERAL SAFETY HAZARDglass, stainless steel or brass area or shelter surrounding the instrument of the analyzer 3.4.2.1.Sample Gas Source3.4.2.2.Calibration Gas Sources 3.4.2.3.Input Gas Venting 3.5.INITIAL OPERATION3.4.2.4.Exhaust Outlet using the procedures defined in Section configuration and calibration data 3.5.1.STARTUPSystem waits 3 seconds then automatically begins its initialization routine 3.5.3.WARNING MESSAGES 3.5.2.WARM UP Table 3-9:Possible Warning Messages at Start-Up 3.5.4.FUNCTIONAL CHECK installed 3.6.INITIAL CALIBRATION OF THE M300E/EM3.6.1.INTERFERENTS FOR CO2 MEASUREMENTS If it is not, press is set for SNGLSINGL ENTR 3.6.2.2.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 PPM 3.6.4.CO2 SENSOR CALIBRATION PROCEDURE 3.6.3.O2 SENSOR CALIBRATION PROCEDUREThe M300E/EM Analyzer is now ready for operation THANK YOU 4.1.FAQ’S 4.FREQUENTLY ASKED QUESTIONS Description/Definition 4.2.GLOSSARYTerm Description/Definition Term Description/Definition Term 5.2.RACK MOUNT KITS OPT 20 TO OPT 5.OPTIONAL HARDWARE AND SOFTWARE5.1.EXTERNAL PUMPS OPTIONS 10A-10E,11, GENERAL SAFETY HAZARD 5.3.CARRYING STRAP/HANDLE OPT5.4.CURRENT LOOP ANALOG OUTPUTS OPTION 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 Rate Figure 5.6.2.1.Internal Pneumatics OPT 50A 5.6.2.3.Input Gas Venting 5.6.2.2.Pneumatic Set Up OPT 50A5.6.2.4.Exhaust Outlet SAMPLE GAS SOURCE Figure 5.6.3.ZERO/SPAN/SHUTOFF VALVE OPTION 50B5.6.3.1.Internal Pneumatics OPT 50B SAMPLE GAS SOURCE 5.6.3.2.Pneumatic Set Up OPT 50BCALIBRATION GAS SOURCES SPAN GAS ZERO AIR 5.6.4.1.Internal Pneumatics OPT 50H SAMPLE GAS SOURCE 5.6.4.2.Pneumatic Set Up OPT 50HCALIBRATION GAS SOURCES SPAN GAS ZERO AIR Scrubber 5.6.5.1.Internal Pneumatics OPT 50E SAMPLE GAS SOURCE 5.6.5.2.Pneumatic Set Up OPT 50ECALIBRATION GAS SOURCES SPAN GAS ZERO AIR 5.7.1.RS-232MODEM CABLE OPTION 60A 5.7.COMMUNICATION OPTIONS5.7.2.RS-232MULTIDROP OPTION Table 5-5:M300E/EM Modem Cable Options Figure 5-12:M300E/EM Ethernet Card 5.7.3.ETHERNET OPTION 63A 5.8.1.OXYGEN SENSOR OPTION 65A 5.8.SECOND GAS SENSORS5.7.4.ETHERNET + MULTIDROP OPT 63C 5.8.1.3.Pneumatic Operation of the O2 Sensor 5.8.1.2.Operation within the M300E/EM Analyzer 5.9.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 CO2 Figure 5-16 CO2 sensor Theory of Operation 5.9.2.2.Operation within the M300E/EM Analyzer5.9.2.3.Pneumatic Operation of the CO2 Sensor 5.9.2.4.Electronic Operation of the CO2 Sensor Figure 5-19:Concentration Alarm Relay 5.10.CONCENTRATION ALARM RELAY OPTION CO 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 OPTION OPERATING INSTRUCTIONS PART – OPERATING INSTRUCTIONS This page intentionally left blank OPERATING INSTRUCTIONS 6.1.OVERVIEW OF OPERATING MODES 6.BASIC OPERATIONMODE EXPLANATION Figure 6-2:Viewing M300E/EM Test Functions 6.2.SAMPLE MODEanalyzer’s inability to calculate it Test Functions Defined Table MEANING 6.3.WARNING MESSAGESThe IR source may be faulty Table 6-3:List of Warning Messages currently selected reporting range EXAMPLES 6.4.CALIBRATION MODE Primary Setup Mode Features and Functions 6.5.SETUP MODESecondary Setup Mode Features and Functions instrument until the ENTR Key is pressed 6.5.2.SETUP  ACAL: AUTOMATIC CALIBRATION 6.5.1.SETUP  CFG: CONFIGURATION INFORMATION Table 6.5.3.SETUP  PASS: PASSWORD FEATUREPassword Levels 04288D DCN5752 Basic Operation the 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 M300E ANALOG OUT 6.6.2.ANALOG OUTPUT RANGES FOR CO CONCENTRATIONFigure 6-4:Analog Output Connector Pin Out SNGL 6.6.3.REPORTING RANGE MODESDUAL AUTOPage The two ranges must be independently calibrated concentrations Basic Operation Toggle these keys to discards the new setting accepts the new settingselect the upper limit for the reporting range computing the CO concentration reporting units Basic OperationPressure STP sufficient Using the dilution ratio option is a 4-stepprocess This page intentionally left blank Basic Operation 7.1.1.IDAS STATUS 7.ADVANCED FEATURESLED STATE IDAS STATUS Table 7-2:iDAS Data Channel Properties 7.1.2.IDAS STRUCTURE7.1.2.1.iDAS Channels 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 Table 7-3:iDAS Data Parameter Functions 7.1.5.3.Editing iDAS Parametersfound in Appendix A-5 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 7.1.6.DISABLING/ENABLING DATA CHANNELS 7.1.5.9.The Compact Report Feature7.1.5.10.The Starting Date Feature 7.1.7.1.iDAS Configuration Using APICOM 7.1.7.REMOTE IDAS CONFIGURATION attempting any iDAS changes DEFAULT 7.2.SETUP  MORE  VARS: INTERNAL VARIABLES VARSTable 7-4:Variable Names VARS ALLOWED accepts the new setting settingSETUP SETUP SIGNAL I/O Table 7-5:Diagnostic Mode DIAG FunctionsCONFIGURATION DIAG I/O 7.3.1.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 OUTPUT 04288D 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 HAZARD Advanced Features Voltage across % FSResistor for 2-20mA Resistor for 4-20mAPage Page DESCRIPTION TEST CHANNELZERO FULL SCALE new setting settingSETUP SETUP 7.4.7.AIN CALIBRATION LIMIT SET POINT1 ALARMSTATUS This page intentionally left blank Advanced Features 8.1.1.RS-232DTE AND DCE COMMUNICATION 8.1.2.COMM PORT DEFAULT SETTINGS8.REMOTE OPERATION 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 1024 Remote Operation 8.1.5.COMM PORT TESTING 8.1.6.MACHINE ID Table 8-2:Terminal Mode Software Commands 8.1.7.1.Help Commands in Terminal Mode8.1.7.TERMINAL OPERATING MODES 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 Types X DDD:HH:MM Id MESSAGE<CRLF> 8.1.7.4.Status Reporting 940331 is the default password 8.1.7.5.COMM Port Password SecurityLOGON V RS-232 PASS=NNNNNN 8.2.MULTIDROP RS-232SET UP CALIBRATOR HostTAPI Analyzer Last INSTRUMENT Figure 8-5:CPU RS-485Setup 8.3.RS-485CONFIGURATION OF COM2 RX/TX RX/TX+ The DCE/DTE switch has no effect on COM2Female DB-9COM2 Table 8-4:Ethernet Status Indicators 8.4.REMOTE ACCESS VIA THE ETHERNET DEFAULT STATE Table 8-5:LAN/Internet Configuration PropertiesSee your network administrator PROPERTY Remote Operation ∙Your LAN is not running a DHCP software package SETUP ON/OFFPRIMARY SETUP MENU SETUP Moves the cursor one character to the left or FUNCTIONright Inserts a character before the cursor location FUNCTION 8.4.4.CHANGING THE ANALYZER’S HOSTNAMEENTR EXIT Actions 8.5.MODBUS SETUPMinimum Requirements 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 Operation Protocol network 8.6.2.HESSEN COMM PORT CONFIGURATION8.6.1.GENERAL OVERVIEW OF HESSEN PROTOCOL 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 TEXT GAS TYPE,RANGE,GAS ID,REPORTED 8.6.6.HESSEN PROTOCOL GAS LIST ENTRIESCO, 0, 310, REPORTED CO2, 0, 311, REPORTED O2, 0, 312, REPORTED 8.6.6.2.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 NAME 8.6.8.INSTRUMENT ID CODE 8.7.APICOM REMOTE CONTROL PROGRAM Calibration Procedures 9.CALIBRATION PROCEDURESSECTION 9.1 – BEFORE CALIBRATION SECTION 9.5 – CO CALIBRATION QUALITY ANALYSIS 9.1.2.CALIBRATION GASES 9.1.BEFORE CALIBRATION9.1.2.1.Zero Air troubleshooting tips 9.1.2.2.Span Gas 9.1.3.DATA RECORDING DEVICES9.1.2.3.Traceability calibration and alters the instrument’s Calibration Calibration Procedures allowed for a reliable calibration 9.2.2.PERFORMING A BASIC MANUAL CALIBRATION CHECKSee Section 12 for troubleshooting tips the bottle 9.2.3.PERFORMING A BASIC MANUAL CALIBRATIONthe SPAN gas Calibration Procedures 9.2.3.2.Zero/Span Point Calibration Procedure 9.3.MANUAL CALIBRATION WITH ZERO/SPAN VALVES 9.3.1.SETUP FOR CALIBRATION USING VALVE OPTIONS Figure 9-5:Pneumatic Connections – Option 51B: Zero/Span Calibration Valves Calibration Procedures the bottle 9.3.3.MANUAL CALIBRATION USING VALVE OPTIONSthe SPAN gas 9.3.3.2.Zero/Span Point Calibration Procedure Table 9-2:AUTOCAL Modes 9.4.AUTOMATIC ZERO/SPAN CAL/CHECK AUTOCALMODE NAME ACTION TIMER ENABLED Table 9-3:AutoCal Attribute Setup ParametersATTRIBUTE ACTION VALUE MODE ANDCOMMENT ZERO-SPAN from 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 VALUE SETUP 9.6.1.DARK CALIBRATION TESTSETUP DAS RNGE PASS CLK MORE atmospheric pressure 9.6.2.PRESSURE CALIBRATION 9.6.3.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 Up Set the expected O2 span gas concentration 9.7.1.2.Set O2 Span Gas Concentration complete 9.7.1.3.Activate O2 Sensor Stability Function To perform the zero/span calibration procedure 9.7.1.4.O2ZERO/SPAN CALIBRATION 9.7.2.1.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 Up complete 9.7.2.3.Activate CO2 Sensor Stability Function Calibration Procedures 9.7.2.4.CO2 Zero/Span Calibration This page intentionally left blank Calibration Procedures 10.1.CALIBRATION REQUIREMENTS 10.EPA CALIBRATION PROTOCOL 10.1.2.2.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 FREQUENCY Q.A. Handbook1 Vol II, Part1, Section 12.3 & 10.2.ZERO AND SPAN CHECKS 10.2.2.PRECISION CHECK 10.2.1.ZERO/SPAN CHECK PROCEDURES10.3.PRECISIONS CALIBRATION 10.3.1.PRECISION CALIBRATION PROCEDURES 10.4.AUDITING PROCEDURE10.4.1.CALIBRATION AUDIT 10.4.2.DATA REDUCTION AUDIT 10.5.1.LINEARITY TEST 10.5.DYNAMIC MULTIPOINT CALIBRATION PROCEDURE10.4.3.SYSTEM AUDIT/VALIDATION ∙Leaks ∙Correct flow 10.6.REFERENCES TECHNICAL INFORMATION PART – TECHNICAL INFORMATIONPART This page intentionally left blank Technical information 11.1.MEASUREMENT METHOD 11.THEORY OF OPERATION11.2.MEASUREMENT FUNDAMENTALS 11.1.1.BEER’S LAW Figure 11-2:GFC Wheel 11.2.1.GAS FILTER CORRELATIONFigure 11-1:Measurement Fundamentals 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 Rejection GENERAL SAFETY HAZARD 11.3.PNEUMATIC OPERATIONmaintenance schedule, Table over ambient pressure 11.4.1.1.Critical Flow Orifice 11.4.FLOW RATE CONTROL 11.4.3.PNEUMATIC SENSORS 11.4.2.PARTICULATE FILTER11.4.3.1.Sample Pressure Sensor 11.4.3.2.Sample Flow Sensor 11.5.1.OVERVIEW 11.5.ELECTRONIC OPERATION Figure 11-9:M300E/EM Electronic Block Diagram PC 104 BusMOTHER BOARD FLASH CHIP 11.5.2.CENTRAL PROCESSING UNIT CPUDISK-ON-MODULEDOM 11.5.3.1.Temperature Control 11.5.3.OPTICAL BENCH & GFC WHEEL11.5.3.2.IR Source 11.5.3.3.GFC Wheel SEGMENT SENSOR Figure 11-10:GFC Light Mask M/R SENSORFigure 11-11:Segment Sensor and M/R Sensor Output SCHMIDT TRIGGERS 11.5.4.1.Overview 11.5.3.4.IR Photo-Detector M300E/EM Sync/Demod Block Diagram 11.5.4.2.Signal Synchronization and DemodulationFigure Table 11-2:Sync DEMOD Sample and Hold Circuits 11.5.4.3.Sync/Demod Status LED’s 11.5.4.5.Dark Calibration Switch11.5.4.4.Photo-DetectorTemperature Control Figure 11-13:Sample & Hold Timing 11.5.5.RELAY BOARD 11.5.4.6.Electric Test Switch11.5.5.1.Heater Control 11.5.5.2.GFC Wheel Motor Control STATUS LED’s RELAY PCA PN11.5.5.5.Status LED’s DC VOLTAGE TEST 11.5.6.1.A to D Conversion 11.5.6.MOTHERBOARD11.5.6.2.Sensor Inputs 11.5.6.3.Thermistor Interface 11.5.6.5.Internal Digital I/O 11.5.6.4.Analog Outputs11.5.6.6.External Digital I/O BENCH TEMPERATURE SENSOR 11.5.7.I2C DATA BUS 11.5.8.POWER SUPPLY/ CIRCUIT BREAKERPOWER UP CIRCUIT GENERAL SAFETY HAZARD Theory of Operation Figure 11-15:Power Distribution Block Diagram Figure 11-16:Interface Block Diagram 11.5.9.COMMUNICATION INTERFACEMother Board 11.5.10.1.Analyzer Status LED’s 11.5.10.FRONT PANEL INTERFACE11.5.10.2.Keyboard Figure 11-17:M300E/EM Front Panel Layout 11.5.10.4.Keyboard/Display Interface Electronics 11.5.10.3.DisplayI2C Interface 2 x 40 CHAR. VACUUM FLUORESCENT DISPLAY KEY-DEPRESS-DETECTCIRCUIT KEYPAD DECODER I2C INTERFACE CHIP DISPLAY POWER WATCH DOGDISPLAY DATA DECODER DISPLAY CONTROLLER Figure 11-19:Basic Software Operation 11.5.11.SOFTWARE OPERATION11.5.12.ADAPTIVE FILTER 11.5.14.MEASUREMENT ALGORITHM 11.5.13.CALIBRATION - SLOPE AND OFFSET11.5.15.TEMPERATURE AND PRESSURE COMPENSATION 11.5.16.INTERNAL DATA ACQUISITION SYSTEM IDAS This page intentionally left blank Theory of Operation 12.1.MAINTENANCE SCHEDULE 12.MAINTENANCE SCHEDULE & PROCEDURESGENERAL SAFETY HAZARD QUALIFIED PERSONNEL Maintenance Schedule & Procedures ACTION ITEMFREQ CAL CHECK MANUAL REQ’D Maintenance Schedule & Procedures Table 12-3:Predictive uses for Test Functions 12.2.PREDICTING FAILURES USING THE TEST FUNCTIONSFUNCTION CONDITION 12.3.1.REPLACING THE SAMPLE PARTICULATE FILTER 12.3.MAINTENANCE PROCEDURES12.3.2.REBUILDING THE SAMPLE PUMP Figure 12-1:Sample Particulate Filter Assembly 12.3.3.1.Vacuum Leak Check and Pump Check 12.3.3.PERFORMING LEAK CHECKS12.3.3.2.Pressure Leak Check GENERAL SAFETY HAZARD 12.3.6.CLEANING EXTERIOR SURFACES OF THE M300E/EM 12.3.5.CLEANING THE OPTICAL BENCH12.3.4.PERFORMING A SAMPLE FLOW CHECK GENERAL SAFETY HAZARD 13.1.GENERAL TROUBLESHOOTING 13.TROUBLESHOOTING & REPAIRGENERAL SAFETY HAZARD QUALIFIED PERSONNEL CLR SETUP 13.1.1.FAULT DIAGNOSIS WITH WARNING MESSAGESSAMPLE BENCH TEMP WARNING Table 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 Failures PHT DRIVE SLOPE OFFSET INDICATED FAILURES Figure 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 Indicator 13.1.4.2.Sync Demodulator Status LED’s JP4 Connector to Opto-PickupD1 – M/R Sensor Status Board STATUS LED’s RELAY PCA PNDC VOLTAGE TEST POINTS Relay Board Status LED Failure Indications Table Figure 13-6:M300E/EM – Basic Internal Gas Flow 13.2.GAS FLOW PROBLEMS13.2.1.M300E/EM INTERNAL GAS FLOW DIAGRAMS 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 Flow 13.3.1.MISCALIBRATED 13.3.CALIBRATION PROBLEMS13.2.2.4.Displayed Flow = “Warnings” 13.2.2.6.Sample Pump 13.3.4.INABILITY TO ZERO – NO ZERO KEY 13.3.2.NON-REPEATABLEZERO AND SPAN13.3.3.INABILITY TO SPAN – NO SPAN KEY 13.4.1.TEMPERATURE PROBLEMS 13.4.OTHER PERFORMANCE PROBLEMS13.4.1.1.Box or Sample Temperature 13.4.1.2.Bench Temperature 13.4.1.4.IR Photo-DetectorTEC Temperature 13.4.1.3.GFC Wheel TemperatureELECTRICAL SHOCK HAZARD Hazardous Voltages are present during this test 13.4.2.EXCESSIVE NOISE 13.5.2.DC POWER SUPPLY 13.5.1.AC MAINS CONFIGURATION13.5.SUBSYSTEM CHECKOUT DC Power Test Point and Wiring Color Codes 13.5.4.KEYBOARD/DISPLAY INTERFACE 13.5.3.I2C BUSDC Power Supply Acceptable Levels Table Table 13-8:Relay Board Control Devices 13.5.5.RELAY BOARDFUNCTION CONTROL 13.5.6.2.Electrical Test 13.5.6.SENSOR ASSEMBLY13.5.6.1.Sync/Demodulator Assembly 13.5.6.4.GFC Wheel Drive 13.5.6.3.Opto Pickup Assembly13.5.6.5.IR Source Table 13.5.6.6.Pressure/Flow Sensor Assembly 13.5.7.2.Test Channel / Analog Outputs Voltage 13.5.7.MOTHERBOARD13.5.7.1.A/D Functions 13.5.7.3.Analog Outputs: Current Loop Table 13-12:Status Outputs Check 13.5.7.4.Status Outputs 13.5.8.CPU 13.5.9.1.General RS-232Troubleshooting13.5.9.RS-232COMMUNICATIONS 13.5.7.5.Control Inputs – Remote Zero, Span 13.5.10.THE OPTIONAL CO2 SENSOR 13.6.1.REPAIRING SAMPLE FLOW CONTROL ASSEMBLY 13.6.REPAIR PROCEDURES Figure 13-15:Opening the GFC Wheel Housing 13.6.2.REMOVING/REPLACING THE GFC WHEEL Opto-Pickup Figure 13-16:Removing the Opto-PickupAssemblyFigure 13-17:Removing the GFC Wheel Housing Figure 13-18:Removing the GFC Wheel Optical Bench VR1 Adjustment Made HereHousing Mounting Screws Sync/Demod PCA Housing 13.7.TECHNICAL ASSISTANCE 13.6.4.DISK-ON-MODULEREPLACEMENT PROCEDURETeledyne API, Customer Service 9480 Carroll Park Drive Figure 14-1:Triboelectric Charging 14.A PRIMER ON ELECTRO-STATICDISCHARGE14.1.HOW STATIC CHARGES ARE CREATED 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-ESDWorkbench Always 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 Rack 4.Place the item in the container ∙DO NOT use pink-polybags ESD HazardCAUTION – Avoid Warranty Invalidation 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 Analyzers APPENDIX A-1:SOFTWARE MENU TREES, REVISION L.8 MSG1 SAMPLETEST1 RNGE PASS SAMPLE SETUPCLK MORE <TST TST> ACAL1 Figure A-3:Primary Setup Menu  DAS SubmenuAPPENDIX A-1:Software Menu Trees, Revision L.8 APPENDIX A-1:Software Menu Trees, Revision L.8 O2, 312 REPORTED SAMPLESETUPCO, 310, REPORTED CO2, 311, REPORTED APPENDIX A-1:Software Menu Trees, Revision L.8 Figure A-6:DIAG Menu A-7 Default Value Setup VariableNumeric Units Value Range Numeric DefaultValue Units Default Setup VariableAPPENDIX A-2:Setup Variables For Serial I/O Numeric Default Setup VariableNumeric Value Default Setup VariableAPPENDIX A-2:Setup Variables For Serial I/O Numeric Default Setup VariableNumeric Value Default Setup VariableSame settings as Numeric Default Setup VariableNumeric Value Default Setup VariableAPPENDIX A-2:Setup Variables For Serial I/O Numeric Default Setup VariableNumeric Value Default Setup VariableAPPENDIX A-2:Setup Variables For Serial I/O Numeric Default Setup VariableNumeric Value Default Setup VariableAPPENDIX A-2 Setup Variables For Serial I/O Numeric Message Text NameDescription APPENDIX A-3:Warnings and Test Functions Message Text NameDescription A-22 TEST FUNCTION NAME A-23MESSAGE TEXT DESCRIPTION STABIL_SAMPLES A-24APPENDIX A-3 Warnings and Test Functions TEST FUNCTION NAME A-25MESSAGE TEXT DESCRIPTION Bit or Channel Number Signal NameAPPENDIX A-4:Signal I/O Definitions APPENDIX A-4:Signal I/O Definitions Bit or Channel Number Signal NameDescription A-27 Number Bit or ChannelSignal Name Description Bit or Channel Number Signal NameDescription A-29 APPENDIX A-4:Signal I/O Definitions Signal NameBit or Channel Number Description Description NameAPPENDIX A-5:DAS Triggers and Parameters A-31 Description NameUnits A-32 Description NameUnits A-33 Table A-7:Terminal Command Designators APPENDIX A-6:Terminal Command DesignatorsAPPENDIX A-6:Terminal Command Designators COMMAND Register Address MODBUSdec., 0-based MODBUS Floating Point Input Registers MODBUS MODBUS Floating Point Holding RegistersDescription Units single-bit; read-only MODBUS Discrete Input RegistersMODBUS Description single-bit;read/write MODBUS Coil RegistersMODBUS Description 04288D DCN5752 APPENDIX B - Spare Parts This page intentionally left blank Description M300E Spare Parts ListPart Number Reference: 05362J DCN5494 M300E Spare Parts ListPart Number Description Description M300EM Spare Parts ListPart Number Reference: 05424H DCN5494 M300EM Spare Parts ListPart Number Description 6-10 M300EM Recommended Spare Parts Stocking Levels11-20 21-30 Reference: 0096004C M300E/EX Expendables Kit ORIFICE, 13 MIL SAMPLE FLOW 000941000009550500 ASSY, SOURCE 009560301 T300/T300M and M300E/EM APPENDIX C Warranty/Repair QuestionnaireEmail: api-customerservice@teledyne.com Please complete the following table Email: api-customerservice@teledyne.com APPENDIX C Warranty/Repair QuestionnaireT300/T300M and M300E/EM 2v/DIV 04288D DCN5752 APPENDIX D – Wire List and Electronic Schematics 04288D DCN5752 This page intentionally left blank Interconnect 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.sch Schematics for PCA 03296, Sync Demod 1. This schematics is for PCASignal proper authorization PREAMP_ENAB Schematics for PCA 03296, Sync DemodTV_ENAB SYNC_10 proper authorization Schematics for PCA 03296, Sync DemodBIAS SUPPLY 17-Sep-2008 03632 PCA 03631, Isolated 0-20ma,E Series19-Jul-2002 1 of NOTES 1. This schematic is based on thePWB PN, 03974 and applies to PCA PN, +15V +15V+15V +15V 05703 ADDR=0x360 DEFAULTSchematic for E Series Motherboard PCA 05703 TX for Com1RX for Com2 +15V J109 +15V CONTROL INPUTS D2 D3 D4 D5 D6 D7 SHDN OPTO-INTERRUPTER Schematics for PWBand PCA BENCH Schematic, PCA 04135 Revision A, M300E Relay PCASPARE NOTE: 1. Use PWB NOTES 1. This schematic is based onapplies to PCA PN, the PWB PN, 03974 and 04468 SCH, E-SeriesAnalog Output Isolator, PCA1 A B C D 1 Not Used